NNPC

ESCRAVOS GAS TO LIQUIDS PROJECT ESCRAVOS, NIGERIA

FLEXIBLE, REMOVABLE AND REUSABLE INSULATION COVERS FOR HOT SERVICE INSULATION

Technology contained on this document is exported from the U.S. in accordance with U.S. export regulations. These regulations prohibit the reexport or further distribution of the document, and the technology set forth therein, to certain foreign countries or transmittal to certain entities. See U.S. Code of Federal Regulations [CFR] (15 CFR 744 and 15 CFR 746). This document contains confidential information belonging to or licensed to Chevron Nigeria Limited (CNL), and is not intended for publication. This information shall not be furnished in whole or part to others except in accordance with the terms of the agreement under which it was supplied or with the prior written consent of CNL and, where applicable, Licensors respectively, and shall be returned upon request. The copyright in this document is owned by Chevron Nigeria Limited, and any reproduction or adaptation thereof requires CNL's express approval.

Rev.

Description

Date ddMMMyy

Contractor Originator

Contractor Reviewer

Contractor Approver

Company Reviewed

Company Approver

C1 D1

IFC Initial Issue

12FEB07 10AUG06

EES EES

RR RR

RR DM PAGE 1 OF 9 REV. C1

INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EGTL DOCUMENT NUMBER EGTL1-MGN-CIF-SP-000013

Escravos Gas to Liquids Project Chevron Nigeria Limited Delta State, Nigeria

EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 2 of 9

Revision Description Page

Section Number ALL ALL 12FEB07 EES RR Date

Contractor
Originator EES

Contractor
Reviewer RR

Rev. D1

Description INITIAL ISSUE Issued for Construction, after CNL approval (ref. EGTL1-CNL-MGNHOC-TRN-000405)

ddMMMyy
10AUG06

COMPANY Approver

COMPANY Approver

C1

Escravos Gas to Liquids Project Chevron Nigeria Limited Delta State, Nigeria

EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 3 of 9

TABLE OF CONTENTS 2.0 3.0 4.0

4.1 4.2

SCOPE.............................................................................................................................. 4 ABBREVIATIONS AND DEFINITIONS............................................................................ 4 REFERENCES.................................................................................................................. 4

ESCRAVOS PROJECT DOCUMENTS ....................................................................................................4 MISCELLANEOUS STANDARDS .............................................................................................................4

5.0
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9

MATERIALS ..................................................................................................................... 4
GENERAL ......................................................................................................................................................4 TESTING........................................................................................................................................................5 INSULATION MATERIAL ............................................................................................................................5 INNER LINER ................................................................................................................................................5 OUTER JACKET...........................................................................................................................................5 TIE-DOWN STRAPS ....................................................................................................................................5 DRAWSTRINGS ...........................................................................................................................................6 THREAD ........................................................................................................................................................6 HARDWARE..................................................................................................................................................6

6.0
6.1 6.2 6.3 6.4 6.5

DESIGN AND FABRICATION.......................................................................................... 6

PIPING AND EQUIPMENT COVERS .......................................................................................................6 JACKET FABRIC SEAM CONSTRUCTION.............................................................................................6 TIE-DOWN/ANCHOR STRAP CONSTRUCTION ...................................................................................7 VALVE COVERS ..........................................................................................................................................8 IDENTIFICATION TAGS .............................................................................................................................8

7.0 8.0 9.0 10.0

INSTALLATION REQUIREMENTS.................................................................................. 8 INSPECTION .................................................................................................................... 8 EXTENT OF INSULATION ............................................................................................... 9 THICKNESS TABLE ........................................................................................................ 9

Escravos Gas to Liquids Project Chevron Nigeria Limited Delta State, Nigeria

EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 4 of 9

1.0

PURPOSE This specification provides requirements for flexible, removable/reusable insulation covers for hot service insulation systems.

2.0

SCOPE This specification describes the minimum requirements for materials, fabrication, and installation of flexible, removable/reusable hot service insulation covers, ambient to 450C.

3.0

ABBREVIATIONS AND DEFINITIONS Refer to Engineering Standard EGTL-00-40, Abbreviations & Definitions.

4.0 4.1

REFERENCES ESCRAVOS PROJECT DOCUMENTS EGTL1-MGN-ENG-SP-000040, Abbreviations and Definitions EGTL1-MGN-CIF-SP-000004, Hot Service Insulation

4.2

MISCELLANEOUS STANDARDS ASTM C692, Standard Test Method for Evaluating the Influence of Thermal Insulations on External Stress Corrosion Cracking Tendency of Austenitic Stainless Steel ASTM C795, Thermal Insulation for Use in Contact with Austenitic Stainless Steel ASTM C871, Standard Test Methods for Chemical Analysis of Thermal Insulation Materials for Leachable Chloride, Fluoride, Silicate, and Sodium Ions ASTM C1086, Standard Specification for Glass Fiber Felt Thermal Insulation ASTM D3776, Standard Test for Methods for Mass per Unit Area (Weight) of Woven Fabric

5.0 5.1 5.1.1

MATERIALS GENERAL Insulation and accessory materials shall be furnished in accordance with the requirements of this specification, including the specific grade or type. Insulation and accessory materials shall be formulated without asbestos. Materials shall be new and shall be used prior to the expiration date. Use of materials other than those specified herein shall require prior written approval of the COMPANY. Requests for substitutions shall be included as an alternate in the CONTRACTORS proposal.

5.1.2 5.1.3 5.1.4

Escravos Gas to Liquids Project Chevron Nigeria Limited Delta State, Nigeria

EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 5 of 9

5.2 5.2.1

TESTING All materials shall be qualified for use on austenitic stainless steel in accordance with ASTM C795. If requested, test reports shall be furnished. Material manufacturer shall also furnish a chemical analysis in accordance with ASTM C871 for materials. This chemical analysis shall not vary by more than 50% from the chemical analysis of the production lot tested under ASTM C692. Unless otherwise specified in the purchase order, certification of chemical analysis is not required for each production lot from which material is furnished for this project. However, the manufacturer shall state that the chemical analysis will not vary by more than 50% from those done during the production lot tested under ASTM C795. Testing shall be conducted by a laboratory accredited by the National Institute of Standards and Technologys National Voluntary Laboratory Accreditation Program (NVLAB). INSULATION MATERIAL Insulation material shall be composed of 100% selected-grade Type E glass fibers fabricated in mat form without the addition of resinous or organic binders in accordance with ASTM C1086. Insulation shall be suitable for hot face temperatures to 538C. Insulation shall have a nominal density of 128 kg/m. INNER LINER Inner liner for operating temperatures to 260C shall be a fiberglass fabric impregnated with PTFE, having a minimum weight of 542 g/m in accordance with ASTM D3776, and grey in color. Inner liner for operating temperatures 261C to 538C shall be a four-ply laminate, consisting of two layers of fiberglass cloth and two layers of 25m thick aluminum foil, with a minimum weight of 610 g/m. OUTER JACKET Outer jacket shall be a fiberglass fabric impregnated with PTFE, having a minimum weight of 542 g/m in accordance with ASTM D3776, and grey in color.

5.2.2

5.2.3

5.2.4

5.3 5.3.1

5.3.2 5.3.3 5.4 5.4.1

5.4.2

5.5

5.6 5.6.1 5.6.2

TIE-DOWN STRAPS Tie-down straps shall be constructed of the same material as the outer jacket. Tie-down straps shall be fabricated using a double thickness of the fabric, with edge trim sewn in place along both edges. Edge trim shall be applied to not leave exposed fabric edges. Ends of the straps shall be turned under 6 to 12 mm and double-stitched to prevent unraveling.

5.6.3 5.6.4

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EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 6 of 9

5.7

DRAWSTRINGS Drawstrings shall be made from 100% textured fiberglass sleeving with plain weave, 10 mm inside diameter, 0.8 mm wall thickness, and shall be suitable for 538C service.

5.8 5.8.1 5.8.2 5.8.3 5.8.4

THREAD PTFE-coated fiberglass thread shall be used for service temperatures to 260C. Fiberglass thread shall be 0.53 mm diameter, minimum 9 kg tensile strength. Kevlar-coated stainless steel thread shall be used for service temperatures above 260C. Stainless steel thread shall be minimum 0.38 mm diameter and minimum 8.2 kg tensile strength. HARDWARE All hardware such as D-rings, buckles, tags, etc., shall be type 304 stainless steel.

5.9

6.0 6.1 6.1.1

DESIGN AND FABRICATION PIPING AND EQUIPMENT COVERS Insulated items shall be pre-measured to assure a tight fit. Allowances for valve bonnet height, gland openings, protrusions, etc shall be included. Allowances for steam tracing penetrations shall also be included. Force-folding or bending of covers shall not be permitted. Covers shall be fabricated with a minimum 50 mm of overlap at the end flap over adjacent insulation. Covers shall be fabricated to allow easy access to valve packing glands and flange bolts without having to completely remove the cover. If possible, covers shall be fabricated with parting faces at the cover low point to facilitate drainage. Otherwise, drainage grommets shall be installed at the cover low point. Any single cover or cover piece shall not exceed 21 kg. Covers with a finished weight of 21 kg. or less shall be fabricated in one piece. JACKET FABRIC SEAM CONSTRUCTION All fabric seams shall be sewn. Machine stitching shall be used wherever practical. Hand stitching shall be kept to an absolute minimum. All cover seams shall be turned in or under and sewn to prevent any raw edges from being exposed on any surface. Gusset-type construction shall be utilized for all cover thicknesses greater than 25 mm.

6.1.2 6.1.3

6.1.4

6.1.5

6.1.6

6.2 6.2.1

6.2.2

6.2.3

Escravos Gas to Liquids Project Chevron Nigeria Limited Delta State, Nigeria

EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 7 of 9

6.2.4

Sewing shall be double straight stitched with minimum 7 stitches per 25 mm. Each row shall be parallel and spaced a minimum of 3 mm to a maximum of 12 mm inch apart. Fabric seams shall be inside seams, except that the final closing seam may be an outside seam. Insulation within the jacketing shall be secured with lacing hooks or insulation anchors to prevent insulation from settling within the cover. These supports shall penetrate the cold face jacketing and the insulation core, but not the hot face jacketing. Point protectors shall be used to prevent penetration of the hot face jacketing. TIE-DOWN/ANCHOR STRAP CONSTRUCTION The terminal ends of splits in covers shall be constructed with flaps or drawcord/flaps to seal the covers from wind and water. Flaps shall have no gaps where they contact adjacent insulation. D-ring type buckles and/or hook-and-loop tie-down/anchor straps shall be used. Lacing Hooks 1. 2. Lacing hooks and wire shall not be used unless approved by the COMPANY. If COMPANY approves the use of lacing hooks and wires, the lacing hooks shall be tufted to the cold face jacketing. If lacing hooks penetrate the hot face, the hooks shall be secured by self-locking washers with a patch of the hot face jacketing material sewn over the washer. A silicone rubber patch shall be placed between the washer and the cover.

6.2.5

6.2.6

6.3 6.3.1

6.3.2 6.3.3

3.

4. 6.3.4

Ends of straps shall be turned under 6 mm to 12 mm and double stitched to prevent unraveling. Strap length and number of straps for covers shall be sufficient to ensure a snug and proper fit without gaps or sagging of the cover. Tie-down strap length shall have a minimum of 150 mm excess length for pulling and securing. Drawcords 1. Drawcords shall be used if terminal ends of covers need to be drawn down around adjacent insulation, valve bonnets, nozzles, etc., to seal the covers from wind and water. Covers shall incorporate flaps at the terminal ends. Drawcord shall be located within this flap. Tie-down/anchor straps adjacent to the covers terminal ends shall be spaced a minimum of 50 mm back from the drawcord flaps.

6.3.5

6.3.6

6.3.7

2.

3.

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EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 8 of 9

4.

Cord length shall be sufficient to allow a minimum of 150 mm of cord to protrude from each end of the flap when it is drawn down. Cut ends of braided sleeving cord shall be turned back inside the sleeving a minimum of 25 mm and double-stitched to prevent fraying. A double stitch shall be located at the middle of the flap to secure the cord and prevent it from pulling out.

5.

6.

6.4 6.4.1

VALVE COVERS Valve covers shall be designed to permit full function of the valves and shall not obscure the valves position indicator. Any leak from the packing gland or flanges must be channeled out of the cover to prevent soaking the insulation. IDENTIFICATION TAGS Stainless steel identification tags shall be permanently attached to the outside of the cover. The identification legend shall be mechanically embossed on the tag. Information contained on each tag shall be specified by the COMPANY. Tags shall not be riveted directly to the cold face jacketing. Tags shall be riveted to straps that are similar to tie-down/anchor straps. These straps shall be secured to the cold face jacketing to allow the straps to double as handles or lifting loops. Covers utilizing multi-piece construction shall be appropriately tagged for assembly. INSTALLATION REQUIREMENTS All surfaces to be insulated shall be clean and dry. Before insulating, any steel requiring coating shall be coated in accordance with applicable specifications. Insulation shall not be installed until completion of stress relieving, chemical cleaning, pressure testing, installation of heat tracing, and authorization in writing by COMPANY. The fit of the covers shall be in accordance with the design requirements of this specification and any referencing project specification. INSPECTION The COMPANY reserves the right to inspect the covers during manufacture. Any materials or installations that do not meet the requirements of this specification shall be replaced or corrected.

6.4.2

6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5

6.5.6 7.0 7.1 7.2

7.3

7.4

8.0 8.1 8.2

Escravos Gas to Liquids Project Chevron Nigeria Limited Delta State, Nigeria

EGTL1-MGN-CIF-SP-000013 Rev. C1 Page 9 of 9

9.0

EXTENT OF INSULATION The extent of insulation shall be in accordance with the project specification EGTL1-MGNCIF-SP-000004.

10.0

THICKNESS TABLE Insulation thicknesses for flexible, removable/reusable covers shall be as shown in Table 1.

Table 1: Insulation Thickness for Flexible Removable/Reusable Covers Nominal Pipe Size (inches) 1 & below 1.5 2 3 4 6 8 10 12 14 16 18 20 24 26 28 34 Over 34 & flat Normal Operating Temperature (C) 61 To 100 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 101 to 150 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 151 to 200 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 201 to 250 30 30 30 30 40 40 40 40 40 40 40 40 40 40 40 40 40 40 251 To 300 40 40 40 40 40 40 50 50 50 50 50 50 50 50 50 50 50 50 301 to 350 40 40 50 50 50 50 50 60 60 60 60 60 60 60 60 60 60 60 351 to 400 50 50 50 60 60 60 60 70 70 70 70 70 70 70 70 70 70 80 401 to 450 50 60 60 60 70 70 70 70 80 80 80 80 80 80 80 80 80 80