DOCUMENT NO.

PT Caltex Pacific Indonesia

REV.

SP-PI-PP-005
DATE :

1
SHEET :

SEPT 26, 2001

Nurhasan Nurhasan Shawn

OF

12

SPECIFICATION

PREPARED BY CHECKED BY APPROVED BY

NHS NHS SPD

HOT INSULATION

PT. CALTEX PACIFIC INDONESIA

REV

DATE

PAGES

DESCRIPTION

PREPD

CHKD

APPD

0 1

9/26/01 1/7/02

ALL ALL

ISSUED FOR IMPLEMENTION CPI SPEC REVIEW TEAM (TRB, ANDR, TOTO, KWK)

NHS Team

NHS Team

SPD Team

TABLE OF CONTENT 1. GENERAL .......................................................................................................................... 2 1.1. 1.2. 1.3. 1.4. 2. 3. Scope........................................................................................................................ 2 References................................................................................................................. 2 Terminology.............................................................................................................. 3 Definition.................................................................................................................. 3

DESIGN REQUIREMENTS ............................................................................................... 4 MATERIALS ...................................................................................................................... 5 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. Acceptable Basic Materials - Piping........................................................................... 5 Permissible Insulation Materials ................................................................................ 6 Insulating and Finishing Cements............................................................................... 7 Jacketing Materials ................................................................................................... 7 Plastic Weatherproofing ............................................................................................ 7 Sealers...................................................................................................................... 8 Standard Accessory Material...................................................................................... 8

4.

APPLICATION................................................................................................................... 8 4.1. 4.2. 4.3. General..................................................................................................................... 8 Application of Insulation............................................................................................ 9 Removable and Reusable Insulation Covers .............................................................. 10

5.

ATTACHMENTS.............................................................................................................. 11

OPTIONAL ATTACHEMENTS FOR THIS SPECIFICATION:

ADDENDUM 1: Project Specific Clarifications & Requirements

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Hot Insulation SP-PI-PP-005 Rev. 1

1.

GENERAL 1.1. Scope This specification prescribes the procedures for the selection, applications of field applied, external, thermal insulation and weatherproofing for equipment and piping operating at higher than ambient temperature. Wherever a difference exists between this specification and the drawings, the drawings shall govern. However, no deviations shall be made from this specification without written authorization from COMPANY. 1.2. References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect at the time of Contract issue and this specification unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, work included in this specification shall conform to the applicable provisions of these publications. 1.2.1. Related Specifications Work prescribed by this specification is to be coordinated with Work prescribed in other specifications in this package. 1.2.2. Code and Standards
? ? ASTM (American Society for Testing and Materials)

C195 C449 C450 C533 C547 C552 C585 C591 C592 C610 C612

Specification for Mineral Fiber Thermal Insulating Cement Specification for Mineral Fiber Hydraulic Setting Thermal Insulating and Finishing Cement Recommended Practice for Fabrication of Thermal Insulating Fitting Covers Calcium Silicate Block and Pipe Thermal Insulation Specification for Mineral Fiber / Fibergla ss Preformed Pipe Insulation Cellular Glass Thermal Insulation Recommended Practice for Inner and Outer of Rigid Thermal Insulation for Nominal Sizes of Pipe and Tubing Unfaced Preformed Rigid Cellular Polyurethane Thermal Insulation Specification for Mineral Fiber / Fiberglass Blanket Insulation (Metal Mesh Covered) Expanded Perlite Block and Pipe Thermal Insulation Specification for Mineral Fiber Block and Board Thermal Insulation
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C892 C1094 E84 E96 1.3. Terminology

High Temperature Fiber Blanket Thermal Insulation Specification for Removable Covers Surface Burning Characteristics of Building Materials Water Vapour Transmission of Materials in Sheet Form

In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise. 1.3.1. COMPANY Refers to PT. CALTEX PACIFIC INDONESIA, as the ultimate user and owner, the authorized representative of COMPANY or COMPANY third party inspection. CONTRACTOR Refers to company selected by COMPANY, which may be responsible for the detailed engineering design, material and equipment procurement, and construction as specified in Contract, Scope of Work, or Work Order. Vendor Refers to the company selected by COMPANY or CONTRACTOR, which i s responsible for the purchase agreement or purchase order of the goods/services specified in this specification Note:
? ? For EPC (Engineering, Procurement and Construction) project purposes:

1.3.2.

1.3.3.

The terminology shall have the meanings as above.

? ? For Direct Proc urement by COMPANY purposes:

Vendor shall also be responsible as CONTRACTOR. 1.4. Conflicting Requirements 1.4.1. In case of conflict between this Specification and its associated Specifications and the above Codes and Standards, the Vendor shall bring the matter to the COMPANYs attention for resolution and approval in writing. However, the most stringent requirement shall apply. Should conflicts exist between this specification and other documents, the following order of precedence shall govern: ? ? Scope of Work ? ? Data Sheets. ? ? This Specification ? ? Other COMPANY Specifications ? ? Other Referenced Publications ? ? Approved for Construction Drawings
? ? Vendors Code

1.4.2.

1.5.

Definition

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Hot Insulation SP-PI-PP-005 Rev. 1

1.5.1. 1.5.2. 1.5.3. 1.5.4. 1.5.5.

Thermal Insulation Materials that retard the flow of heat energy. Personnel Protection Controls surfaces temperatures for safety and comfort. Temperature Control Facilitates the control of a process temperature Condensation Control Prevents vapour flow and water condensation on cold surfaces. Mechanical Damage and Corrosion Protection Prevents or reduces damage to piping and equipment from exposure to fire and corrosive atmosphere.

1.5.6.

Exposed Area An area normally exposed to viewing by persons performing daily tasks in a building.

2.

DESIGN REQUIREMENTS 2.1. 2.2. 2.3. Thickness of insulation for piping, vessels, and equipment shall be determined by operating temperatures and the applicable Insulation Thickness Charts included in attachments. Painting of piping systems shall be prior to the application of insulation. Insulation for personnel protection shall be applied to hot pipes and surfaces not normally insulated whose temperature may exceed 1400 F and where otherwise designated. Personnel protection shall be applied to surfaces within a vertical distance of 7 feet and a horizontal distance of 3 feet from the edge of any normal walking or working platform level or to surfaces that are in such a position where accidental contact may be possible. Pressure tests shall be completed before insulation is installed. If insulation is applied before testing, welds, threads, and bolted connections shall be left uninsulated and exposed until completion of testing. Insulation supports on piping shall be supplied and installed by the fabricator. Field welding of any insulation supports to piping is not allowed without prior written authorisation from COMPANY. Equipment nozzles, flanges, valves, fittings, and piping specialty items shall be considered a part of the piping and shall have the same insulation requirements as the attached piping. The word "fitting" shall designate elbows, tees, caps, mitters, reducers, and stub-in connections. Preformed insulation shall be used at fittings whenever commercially available, provided the material satisfies the specifications of the insulation for straight pipe. All size of fittings may be insulated with pieces of mitered pipe or block insulation wired in place. Use single layer insulation if commercially available for thickness less than 3 inches.
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2.4.

2.5.

2.6.
2.7.

2.8.
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2.9. 2.10. 2.11.

Pipe insulation shall be preformed in sections with dimensions conforming to ASTM-C585. Insulation thickness over 3 inches shall be installed in multiple layers unless the insulation thickness is available for one layer only. Equipment with irregular or complex surfaces such as valves and flanges that require regular inspection and maintenance shall be insulated with removable and reusable covers or pads. Removable covers shall be designed to provide for the following qualities :
? ? Suitable insulation integrity ? ? Accuracy of fit ? ? Ease in removing and replacing

2.12.

Insulated steam line shall not be buried. Bridges and sleeved insulated line shall be used for road crossings. This dry road crossing design shall get COMPANY approval.

3.

MATERIALS 3.1. Acceptable Basic Materials - Piping 3.1.1. Insulation materials and accessories shall conform to the regulations of the OSHA (Occupational Safety and Health Administration). MSDS (Material Safety Data Sheet) is required for insulation product system or accessory, including adhesives. CONTRACTOR shall provide and appropriate current information regarding known problems associated with the recommended use of the company's products, and shall also recommend protective measures to be employed in their safe utilisation. CONTRACTOR shall establish appropriate safety and health practices and determine the applicability of regulatory requirements prior to use. Insulation and accessory materials shall not contain asbestos in any form. This requirement shall be maintained without exceptions. The basic insulating materials for piping NPS 4 and under can be formed in cylindrical sections, 1 (one) piece or half sections, depending upon pipe size and commercial availability. The term "block", as used in this specification refers to rigid insulation having compressive strength of at least 100 psi at 5 percent deformation. Preformed insulation shall be used at fittings whenever commercially available, provided the material that satisfy the specifications of the insulation for straight pipe. All size of fittings may be insulated with pieces of mitter pipe or block insulation. Insulating cement is used when pie ces of mitter pipe or block insulation can not be installed for insulation. The basic insulating material for piping greater than 4 inch OD, and equipment operating at temperatures to 12000 F can be blankets on the horizontal piping subject to human foot traffic, then rigid insulation shall be installed. The blanket shall have metal mesh.

3.1.2.

3.1.3. 3.1.4.

3.1.5. 3.1.6.

3.1.7.

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3.2.

Permissible Insulation Materials The following is a general inventory of the characteristics and properties of accepted insulating materials. 3.2.1. Calcium silicate block and preformed pipe covering. This shall meet ASTM C533 requirements for face temperatures up to 650?C (1200?F) for type I or 816?C (1500?F) for type II and be asbestos-free. Mineral wool blankets, precut and preformed pipe covering, block, board, and loose fill. These shall have a neutral pH, a nominal density of not less than 128 kg/m3 (8 lb/ft3 ), and be suitable for face temperatures of 650?C (1200?F), except as noted. Additional requirements are:
? ? Blankets shall conform to ASTM C592 and be faced with wire mesh on both

3.2.2.

sides, wire mesh inside and expanded metal lath outside or only glass mat outside.
? ? Precut single -layer pipe insulation shall conform to ASTM C592 and be

faced with lath strips or wire mesh inside and wire mesh or lath outside or only glass mat outside.
? ? Mineral woll blocks and boards shall conform to ASTM C612. Minimum

nominal density shall be 144 kg/m3 (9 lb/ft3 ) for face temperatures up to 650?C (1200?F) and 208 kg/m3 (13 lb/ft3 ) up to 982?C (1800?F).
? ? Preformed pipe insulation shall conform to ASTM C547 and have a

minimum nominal density of 144 kg/m3 (9 lb/ft3 ).

? ? Metal facings shall not be galvanized for use on austenitic steel surfaces.

3.2.3.

Glass fiber block, board, blankets, preformed pipe covering and removable and reusable covers. The density of 64 to 96 kg/m3 (4 to 6 lb/ft3 ) shall be suitable for indicated maximum temperature. Additional requirements are:
? ? Preformed pipe insulation shall be suitable for a face temperature up to

232?C (450?F) and conform to ASTM C547. Pipe insulation for higher temperatures must have COMPANY approval. mechanically bonded.

? ? Glass fiber insulation for flexible covers shall either have binders or be ? ? Fibrous glass board or block shall be suitable for a face temperature up to

232?C (450?F) and conform to ASTM C612. High-temperature block or board suitable for a face temperature up to 454?C (850?F) may be used only with COMPANY Approval.

3.2.4. 3.2.5.

Cellular glass block and performed pipe covering. This shall conform to ASTM C552, with a maximum face temperature of 232?C (450?F) Perlite block and preformed coverings. This shall be suitable for face temperatures up to 816?C (1500?F) and shall conform to ASTM C610, except that organic reinforcing fibers and organic binders may be used in addition to the inorganic binders.

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3.2.6.

Plastic foam block and preformed pipe covering of polyurethane or isocyanurate. This shall conform to ASTM C591, Type II, with a flame spread rating not exceeding 25 according to ASTM E84. Higher density and higher strength foam such as Type III may be used where higher load bearing properties are required. Face temperatures are limited to 107?C (225?F) for polyurethane and 149?C (300?F) for isocyanurate. Alumina silica fiber blanket conforming to ASTM C892, with density of 96 to 128 kg/m3 (6 to 8 lb/ft3 ) and a maximum use temperature of 1260?C (2300?F). This may be used as the first layer or layers, where the maximum use temperature of the outer insulation would otherwise be exceeded, or as the sole insulation.

3.2.7.

3.3.

Insulating and Finishing Cements 3.3.1. 3.3.2. Mineral fiber insulating cement shall meet the requirements of ASTM C195 and be suitable for a temperature rating of 871?C (1600?F). Finishing cement shall be asbestos-free, meet the requirements of ASTM C449 and be suitable for temperatures up to 538?C (1000?F). It shall be a fast drying cement that provides a smooth, hard surface when dry. One-coat combined insulating and finishing cement shall conform to ASTM C449 for temperatures up to 650?C (1200?F). It shall be suitable for application to the required dry thickness in one operation and, when troweled, shall produce a smooth surface after drying. Insulating and combined insulating and finishing cements shall contain a rust inhibitor to protect the substrate.

3.3.3.

3.3.4. 3.4.

Jacketing Materials 3.4.1. Jacketing material selection shall be based on temperature requirements, code requirements, environmental considerations, maintenance requirements. (Refer to Attachment 04.) Galvanized steel jackets have a higher fire resistance than aluminium or stainless steel jackets. Galvanized steel jackets are prefered to be used instead of aluminium jackets to prevent theft. High temperature steam conditions require jackets with high mechanical strength and temperature ranges. Metal jacketing systems shall have a moisture barrier to prevent galvanic corrosion at the metal-to-insulation interface of the jacket and the pipe. Moisture barriers are factory applied or field applied to the underside of the metal jacket; common types are Kraft paper with polyethylene film, polysurlyn, and epoxy coating, as per attachment 04.

3.4.2.

3.4.3. 3.4.4.

3.5.

Plastic Weatherproofing Plastic weatherproofing shall be capable of being applied by trowel, glove, or brush and shall be suitable for application of paint with an aluminum or asphalt base. It shall be a noncorrosive, heat resistant, fire-retardant plastic capable of withstanding continuous

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exposure to 93?C (200?F). The material shall have an ASTM E84 flame spread classification not exceeding 60. Plastic that contains a flammable, toxic, or volatile solvent shall not be used. The material shall also be resistant to cracking at the lowest temperature for the site. Membrane reinforcement for weatherproofing plastic shall be 10 mesh polyester cloth with a minimum mass per area of 0.092 kg/m2 (2.7 oz/yd2 ). 3.6. Sealers Flashing compounds and joint sealers shall be a minimum of 94 percent nonvolatile, permanently flexible through a temperature range from 50 to 204?C (-58 to 400?F), and capable of withstanding repeated expansion and contraction without cracking and with minimum shrinkage. Water vapor permeance shall not exceed 4.6 x 10-9 g/Pa-s-m2 (0.08 perm) for the thickness to be used or a lesser thickness.

3.7.

Standard Accessory Material 3.7.1. 3.7.2. 3.7.3. Securements Bands shall be 18-8 Cr-Ni stainless steel, AISI Type 302 or 304, annealed temper, 1/2 inches wide by 0.015 inches thick. Seals for bands shall be 18-8 CR-Ni stainless steel, AISI Type 302 or 304, T-5005 hard temper, wing type, 0.032 inches thick. Wire shall be 0.051 inches (16 gage) diameter, 18-8 Cr-Ni stainless steel, AISI Typed 302 or 304, annealed temper, to secure pipe insulation, and for lacing of blanket insulation. Screws, self-tapping, slotted hex head, sheet metal, 18-8 Cr-Ni stainless steel, AISI Type 302 or 304, Number 8 by inch long. S-Clips shall be fabricated form, 3/4 inch by 0.020 inches thick, with a 2 -inch minimum length, AISI Type 304 stainless steel banding. Band Loops to be fabricated from 1/2 inch by 0.015 inches thick, AISI Type 304 stainless steel banding

3.7.4. 3.7.5. 3.7.6.

4.

APPLICATION 4.1. General 4.1.1. Insulation applications shall be in accordance with the specifications or Vendors recommendations. CONTRACTOR shall submit to COMPANY for approval, materials, insulation details, or intended practices of insulation application not covered in these specifications. Materials shall be new, the best quality of the respective types, and suitable for the intended service. Craftsmen regularly engaged in the insulation industry shall install the insulation. Installation procedures shall follow good and acceptable insulation practices for the particular service and temperature involved.

4.1.2. 4.1.3.

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4.1.4.

Surfaces to be insulated shall be clean and dry. Painted surfaces shall be insulated only after the paint has dried. Austenitic stainless steel surfaces shall be washed with potable water (with less than 50 ppm chlorides) and dried just pr ior to insulation. Insulation shall not be applied to any piping or equipment that is to be hydrostatically tested, until such tests have been successfully completed and released for insulation. Insulation materials shall be protected against the elements at all times. Every precaution should be taken to ensure that each day's work is weatherproofed during erection and before leaving for the night. Insulation shall be kept dry before and during application. If applied insulation has become wet before it is properly finished, it shall be replaced before a vapour barrier and sealed or weatherproofing is applied. CONTRACTOR shall not remove or modify COMPANY supplied insulation supports (if applicable) without prior notification and approval of COMPANY. Code inspection plates or stamping, nameplate, data-plate, test plugs, and system components on equipment shall be left permanently visible by cutting back the insulation where necessary, and properly sealing it against moisture penetration (but insulation shall be applied behind the bracket, where feasible). Directional arrow which must be covered shall be marked so that they are conspicuous.

4.1.5.

4.1.6.

4.1.7. 4.1.8.

4.2.

Application of Insulation 4.2.1. Piping Insulation 4.2.1.1 The following items shall not be insulated unless otherwise noted on the drawings : ? ? Drains ? ? Unions ? ? Vents 4.2.1.2 Steam traps shall not be insulated, except when specified in the project specification. 4.2.1.3 Spectacle blinds must not be totally enclosed by insulation boxes but must be left visible 4.2.1.4 Insulation on expansion joint shall permit free operation of the joint without insulation damage. 4.2.1.5 Valves or flanges in steam service shall be insulated. 4.2.1.6 When insulation is specified for flanges and flanged valves, reusable thermal insulation covers as specified in the Products section shall be used. Refer to Section 4.3. Removable and Reusable Pads. 4.2.2. Insulation Application
? ? Single thickness sectional pipe insulation shall be applied with longitudinal

joints staggered. Multilayer sectional pipe insulation shall be applied with joints staggered.

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? ? Insulation supports shall be installed on vertical lines. Supports are not

required on vertical rises less than 10 feet.

? ? On vertical pipes insulated by single layer construction, insulation expansion

joints shall be located at each insulation support. On horizontal pip ing insulated by single layer construction, insulation expansion joints shall be located according to the last item of Section 4.2.2, support and expansion joint location, below.
? ? Fittings, except valves body, shall be insulated with prefabricated fitting

covers or mittered sectional pipe insulation, securely wired in place. All size of Fittings may be insulated with pieces of mitter pipe or block insulation, if possible. Insulating cement is used when pieces of mitter pipe or block insulation can not be installed for insulation
? ? Insulation shall be stopped at flange or union connections to permit removal

of bolts without damage to the insulation. Each end shall be square cut and weatherproofed with a metal bevel cup. Clearance shall be stud length plus 1 inch.
? ? Horizontal piping elevated on shoes shall have continuous insulation.

Vertical and horizontal piping without shoes shall have the insulation cut away and weatherproofed on each side of the support. 4.2.3. Weatherproofing Application
? ? Straight portions of insula ted lines shall have the basic insulation jacketed

with metal jacket, and shall have joints lapped and arranged to shed water. The jacketing shall be secured with bands. A band shall be applied over each circumferential lap joint.
? ? Fittings shall be weatherproofed with prefabricated metal covers with

weatherproof seams.
? ? A watertight metal flashing ring shall be installed where pipe insulation

terminates.
? ? Heavy fillets of flashing compound shall be applied at all possible sources of

moisture penetration.
? ? Irregularly shaped surfaces that cannot be suitably weatherproofed with

metal jacketing shall be finished with a 3/8 inch thick layer of insulating and finishing cement. A 1/16 inch thick tack coat of mastic shall then be applied over the dry cement, followed by a layer of reinforcing fabric installed wrinkle-free. Over the reinforcing fabric, a 1/8 inch thick dry coat of mastic weathercoat shall be applied with a smooth finish. This finish shall extend approximately 2 inches under the adjacent pipe jacketing. No porosity shall exist in mastic weathercoating when dry. 4.3. Removable and Reusable Insulation Covers
? ? Density and thickness of insulation material shall conform to applicable insulation

material (refer to attachment 01 & 02 and Section 2.1 Part B Recommended Insulation Materials).

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? ? The weather barrier for the outer surface shall be silicone rubber impregnated glass

cloth; Alpha-Maritex 3259-2-SS or Teflon coated cloth; Alpha-Maritex Style TC-114, or an approved equal.
? ? Cloth cover surfaces shall be covered with a layer of Maritex Type 304 stainless steel

wire, 0.011 inches in diameter, with a density of 60.

? ? Covers shall be designed with a minimum number of pieces with joints located to

provide flashing against weather. Covers shall overlap adjacent insulation and must be designed to prevent air movement behind the insulating covers.
? ? Where a joint cannot be located at the 6 o'clock position, NPS 1/2 inch nipples must be

installed in the downward position to detect flange leakage.

? ? Covers shall be designed either from drawings or actual field measurements to ensure

proper fit and design. Covers for valves shall be designed and applied so that the packing and stem remain uninsulated.
? ? Covers for valves and flanges shall have their maximum use temperature stencilled on

the outside of the cover. 5. Requirements for Personnel Protection 5.1. All personnel working with Synthetic Vitreous Fibers shall wear the following Equipment:
? ? Respiratory protection: Half-Mask air purifying respirator with high efficiency filters. ? ? Eye Protection: Safety Glasses shall be the minimum protection and worn at all times

for any personnel working in the general area. Personnel working with, and handling, fibrous insulation shall wear eye protection Goggles.
? ? Skin Protection: Gloves, steel-toe boots, loose clothing with long-sleeves shall be worn

at all times. Head and neck covering shall be worn by personnel directly handling Fibrous insulation 6. ATTACHMENTS Attachment 01 : Attachment 02 : Attachment 03 : Attachment 04 : Attachment 05 : Attachment 06 : Thickness Table For Fiberglass Thickness Table For Mineral Fiber Personnel Protection Insulation Thickness (Inches) Jacketing - Covers and Finishes Fasteners for Insulation and Jacketing Size, Material and Spacing Fasteners for Removable and Reusable Flexible Type Covers

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