RFCC-T-PCGC-0155 Method Statement For Work of Insulation Rev.1 PDF

Cilacap Resid Fluid Catalytic
Cracking (RFCC) Project

PT. PERTAMINA (Persero)
Doc. No. : RFCC-G-CS-PR-010

Rev. No. : 1
Page No. : 2 / 47
METHOD STATEMENT FOR

WORK OF INSULATION
REVISION HISTORICAL SHEET
Rev.
Page /
Paragraph
Item
P6 / 7.1.1
7.1.2.2
Revised phrase as per Doc No. RFCC-C-CS-SP-002.

Added phrase
P7 / 7.1.2
71.2.3
7.1.2.6
7.1.2.7
P7
7.1.3
P8
8.5
P6 / 7.1.2
9.2.6
9.2.12
9.2.14
9.2.15
9.5
9.6
9.7
Description of Change
Revised Phrase as per Doc No. RFCC-C-CS-SP-002.

Revised Phrase as per MOM No. RFCC-M-GC/PC-0108
P9 / 9.2
P9
P10
9.3.3
Added phrase horizontal and vertical equipment
P10
9.3.8
Added phrase
P11
9.3.13
P12
9.5
9.6
9.7
P14
Added phrase
Added phrase
Added JSA for Insulation Work Using Man Basket
CONSORTIUM ADHI GS E&C


WORK OF INSULATION
TABLE OF CONTENTS
1.
PURPOSE
2.
SCOPE
3.
REFERENCES
4.
DEFINITIONS
5.
RESPONSIBILITIES
6.
INSULATION CODES, TYPE & THICKNESS
7.
INSULATION MATERIALS
8.
EXTENT OF INSULATION
9.
APPLICATION PROCEDURE FOR INSULATION
10. INSPECTION AND REPORTING PROCEDURE

11. QA/ QC RESPONSIBILITY
12. HSE
13. JOB SAFETY ANALYSIS FOR INSULATION WORK
14. ATTACHMENTS

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WORK OF INSULATION
1. PURPOSE
The purpose of this method statement is to ensure the insulation is carried out as per project
specification and to facilitate to the execution team that they are using specified materials as it is
required places.
2. SCOPE
The scope of this method statement is to define the guidelines/ procedures to carry out supply and
application of Thermal Insulation and Cold Insulation works. Thermal Insulation works includes Hot
Insulation works, Personnel Protection works, Electric Tracing and Steam Tracing works on various
piping and equipment. All the insulation works shall be done in plant under construction or
commissioning at Pertamina Resid Fluid Catalytic Cracking (RFCC) Project in Cilacap, Central Java,
Indonesia.
3. REFERENCES
This method statement based on the following:
3.1 Project Specification No: RFCC-C-CS-SP-002.
3.2 Inspection and Test Plan No: RFCC-ITP-PA-0001.
4. DEFINITIONS
4.1
Owner
The Owner means Indonesia PT. PERTAMINA (Persero), who is the owner of this project.
4.2. Contractor
The Contractor is the employer for whom the sub-contractor is working in the case: ADHI-GS
E&C CONSORTIUM.
4.3. Sub Contractor
The Sub Contractor is the organization who is performing Insulation Works on this project for
Contractor, in this case Sub Contractor is PT. KRAZU NUSANTARA.


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WORK OF INSULATION
5. RESPONSIBILITIES
5.1 Site Manager
He will be responsible for overall control of work according to this approved method statement
in line with requirement of Health, Safety and Environment. He will coordinate with client for
the scheduling and progress of work. He will assist his site team for completing the scope as
per project requirement.
5.2 Construction Manager
He will be responsible for coordinate with the concerned supervisor and inspectors and to
carry out the job as per schedule.
5.3 HSE Manager
He will responsible for safe implementation of this method statement for completing the scope
as per project Health, Safety and Security, environment requirement.
5.4 QA/QC Inspector
He will be responsible for maintaining the quality of work as per project specification, for the
implementation of quality plan and the project requirement, and for the management of nonconformance and quality audit. As per Project Doc. No. RFCC-ITP-PA-0001.
5.5 Supervisor
He will be responsible for day to day activity as per planning and instruction of Site Manager.
Manpower and equipment planning, daily progress of work shall be his main responsibilities.
6. INSULATION CODES, TYPE & THICKNESS

Category
Hot service
insulation
Cold service
insulation
Other service
insulation
Insulation Codes
Ih
ST
TW
TO
JW
SJ
ET
C
JC
A
P / Is
M
Insulation Type
Normal heat conservation insulation
Steam tracing insulation
Hot water tracing insulation
Hot medium tracing insulation
Hot water jacketing insulation
Steam jacketing insulation
Electric tracing insulation
Normal cold insulation
Cold medium jacketing insulation
Anti-sweat insulation
Personal protection insulation
Dual temperature Service
Following insulation codes based on Project Spec. No. RFCC-C-CS-SP-002. Section 2.1.1


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WORK OF INSULATION
6.1
Thickness In Drawing
The insulation thickness as given in the isometrics drawing shall be considered as final and with
cross reference with table 2 and 3 and based on this thickness, the work will be executed.
7. INSULATION MATERIALS
All the insulation materials following ref. Project Spec. No: RFCC-C-CS-SP-002. Section 3, insulation
materials shall be part of material submittal and is to be approved by owner. The insulation materials
delivered at site shall be inspected by QA/QC for it is package and damage conditions, batch no.,
manufactures certificate, storage and expiry, etc. and recorded in ITP for verification of owner. The
materials to be used shall be follows:
7.1
HOT AND PERSONNEL PROTECTION INSULATION
7.1.1
7.1.2
Insulation Material
7.1.1.1 Calcium silicate pipe section having density of 220 kg/m, shall be used for piping
NPS 2 and above refer Project Spec. No: RFCC-C-CS-SP-002 (ASTM C533, Type
I).
7.1.1.2 Mineral wool blanket backed one side with galvanized mesh having density of min.
93 kg/m and max. 128 kg/m (ASTM C592, Type I, II & III) shall be used for
equipment insulation with operation temperature up to 370C and mineral wool
blanket backed one side with stainless steel wire mesh shall be used above 370C
operating temperature and on austenitic stainless steel surfaces.
7.1.1.3 Mineral wool pipe section having density of min. 100 kg/m, shall be used for piping
size NPS 1.5 and below and for socket type (ASTM C547, Type II & III).
7.1.1.4 Ceramic fibre blanket having density 128 kg/m (ASTM C892, Type III Grade 8) shall
be used for pipe and equipment with temperature above 700C.
7.1.1.5 Mineral wool blanket loose (ASTM C553 type VII).
Jacketing Material
The sheet metal jacketing shall be aluminum alloy sheet with moisture retarder which consist
of polyethylene or polysurlyn. 1060 Al 99.5 with manganese composition limits max. 0.03. Or
AA 3003 with manganese composition limits min. 1.0 and max.1.5 (per cent), and as per
ASTM B209M and C1729 (refer Project Spec. No: RFCC-C-CS-SP-002, section 3.6).
7.1.2.1 Flat sheet with a minimum thickness of 0.3mm for insulation below NPS 30 (ASTM
B209M).
7.1.2.2 Flat sheet with a minimum thickness of 0.4mm for insulation NPS 30 and above, and
for equipment insulation with equipment OD below 760mm (ASTM B209M).
7.1.2.3 Flat sheet with a minimum thickness of 0.6mm for horizontal equipment insulation
with equipment OD 760mm and above (ASTM B209M).
7.1.2.4 Flat sheet with a minimum thickness 0.8mm for valve and flange boxes NPS 10 and
below (ASTM B209M).
7.1.2.5 Flat sheet with a minimum thickness of 1.0mm for valve and flange boxes NPS 12
and above (ASTM B209M).
7.1.2.6 Corrugated sheet with a minimum thickness of 0.6mm for vertical equipment
insulation with equipment OD 760mm and above. (ASTM C1729).


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WORK OF INSULATION
7.1.2.7
1
7.1.3
7.2
Weather proofing mastic, for bottom head of small equipment, body of insulated
valve 20 and above (Ih type only) and for unfitted metal jacketing portion.
Auxiliary Materials
7.1.3.1 Galvanized tie wire swg #20 for fastening of insulation material NPS up to 12, and
galvanized tie wire swg #18 for fastening of insulation material NPS 14 up to 18,
with interval max. 300mm, for tacking of circumferential and horizontal of wire mesh
blanket, and shall be used for floating ring of insulation. Stainless steel wire shall be
used for fastening insulation material to austenitic stainless piping and equipment.
7.1.3.2 Galvanized strapping band 13 X 0.4mm and wing seal for fastening of insulation
material for NPS 20 and above, and for cylindrical equipment with OD below 760mm.
Galvanized strapping band 19 X 0.5mm and wing seal for fastening of insulation
material for cylindrical equipment with OD 760mm and above.
7.1.3.3 S/s strapping band 13 X 0.4mm and wing seal for fastening jacketing material for all
piping, and equipment OD below 760mm. S/s strapping band 19 X 0.5mm for
fastening jacketing equipment with OD 760mm and above.
7.1.3.4 S/s self tapping screws as per ASTM A167, 4.8 X 13mm and 4.8 X 19mm for fittings
area and equipment jacketing securing.
7.1.3.5 C/s flat bar 30 X 3mm for insulation support ring of vertical pipe and equipment.
7.1.3.6 Blind rivets aluminum 2 X 10mm.
7.1.3.7 Silicone sealant for metal jacketing
7.1.3.8 G/i and s/s bolts and nuts M8.
7.1.3.9 Glass cloth (10 X 10 mesh) for application weather proofing mastic.
7.1.3.10 Glass fiber tape/ ceramic rope (for loop of tracer lines and Instrument tubing
insulation).
7.1.3.11 Aluminum foil sheet 20 and aluminum foil tape (Jacketing of instrument tubing
insulation).
7.1.3.12 S/s toggle clips shall be used for valve and flange removable boxes according to size.
7.1.3.13 S/s 304 welded wire mesh 25 X 25 X 3mm for wire mesh barrier of personnel
protection on austenitic stainless steel surface.
7.1.3.14 S/s 304 flat bar 30 X 3mm for support ring wire mesh barrier of personnel protection
on austenitic s/s stainless steel surface.
7.1.3.15 Insulating cement for filling gap of calcium silicate (gap above 3mm shall be filled by
insulating cement)
COLD INSULATION & ANTI-SWEAT INSULATION
7.2.1
Insulation Material
7.2.1.1 PIR (Polyisocyanurate) performed pipe section in green & or natural color with
density min. 40 kg/m3.
7.2.1.2 Rigid preformed cellular urethane with density min. 40 kg/m3.
7.2.1.3 Mineral wool blanket loose (ASTM C553 type VII).
7.2.2
Auxiliary Material
7.2.2.1 S/s strapping band 13 X 0.4mm and 19 X 0.5mm.


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WORK OF INSULATION
7.2.2.2
7.2.2.3
7.2.2.4
7.2.2.5
7.2.2.6
7.2.2.7
7.2.2.8
7.2.2.9
Joint sealant.
Vapor stop (mastic, foam seal, bond)
Glass cloth (10 X 10 mesh)
Multi flex foil 50. (vapor barrier)
Multi flex tape 50mm wide.
Butyl rubber sheet 1mm.
Butyl rubber gum tape 1mm.
Filament tape wide 25mm
8. EXTENT OF INSULATION
Extent of insulation following ref. Project Spec. No: RFCC-C-CS-SP-002. Section 2:

8.1
Name plates and stamping shall be left clear of insulation or shall be fitted on outside of the
jacketing.
8.2
Expansions/ construction joints.
8.3
Pumps area.
8.4
Compressors and auxiliary boilers
8.5
Insulation of valves and flanges box cover in insulated piping for steam lines service and steam
tracing lines service (ST). For valves of insulated line (Ih) 20 and above, body of valve shall be
insulated with mineral wool blanket with galvanized mesh, covered with glass cloth and weather
proofing mastic.
9. APPLICATION PROCEDURE FOR INSULATION

9.1
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
9.1.6
9.1.7
9.1.8
General Application Procedure

Check that the surface to be insulated are clean, dry and free from dust, dirt, grease and oil.
The surround area is free from obstacles and debris.
Verify insulation system is defined on the work release and attached working isometric or
drawing and suitable against the referred temperatures and process class.
Check the insulation materials are of the correct type and size for application as per project
specification.
All calcium silicate and mineral wool pipe section shall be visually checked to ensure edges
are not damaged. Damaged area shall be cut back neatly prior to use, wherever practical.
Where insulation is secured using wire, the cut ends shall be twisted and turned into the
insulation.
Fabrication of insulation and jacketing materials shall take place under controlled conditions in
suitably equipped workshop situated on the project.
Without exception, activities in the field shall commence only after the issue of necessary work
permit and TBM.
Insulation works shall not be started until it has been ascertained that all appropriate testing
has been completed and application of the specified protective coating system is completed
and that any damaged areas have been properly repaired.


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WORK OF INSULATION
9.1.9 The insulation shall only be started from mechanical and piping team.
9.2
Insulation for Hot Insulation and Personnel Protection Codes Ih, ST, JW, SJ, ET, P / Is
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
9.2.6
1
9.2.7
9.2.8
9.2.9
9.2.10
9.2.11
9.2.12
1
9.2.13
9.2.14
1
9.2.15
The insulation code and thickness shall be verified from isometric drawing or from project
specification No. RFCC-C-CS-SP-002.
For pipe NPS 1.5 and below, insulation shall be used mineral wool pipe section, and NPS 2
and above insulation shall be used calcium silicate pipe section.
On vertical pipe length approximately 4000mm shall be fixed with one support ring for
insulation material and fabricated with c/s flat bar 30 X 3mm. And expansion joint with mineral
lose wool shall be located under support ring.
Support rings shall be isolated with direct contact of pipe or equipment by means glass fiber
tape to prevent damage on pipe surface.
Piping at slope between 45o and 90o shall be considered as vertical.
Mineral wool pipe section for NPS 1.5 and below (socket type) and calcium silicate pipe sectio
n for NPS 2 up to 12 shall be secured with galvanized tie wire swg #20. For 14 up to 18
shall be secured with galvanized tie wire swg #18. Galvanized strapping band 13 X 0.4mm for
pipe NPS 20 and above. wire and bands shall be located approximately 50 mm from the end
of each section and at center interval of max. 300 mm. Bands shall be machine tensioned, tig
htened and sealed.
Longitudinal and circumferential joints in outer layers of multiple layer installations shall be sta
ggered from those in adjacent inner layer.
The insulation for calcium silicate shall include contraction joints as per project specification wi
th max. 5700mm spacing for horizontal straight pipe or centre between two pipe shoe or as sp
ecified by the vendor design on calculation. Construction joint space is 25mm and filling with
mineral loose wool.
In case of exposed area in tracer pipe it shall be wrapped with 30 X 3mm glass fiber tape or
rope and covering with aluminum foil sheet and foil tape.
Insulation on steam traced lines shall be oversized preformed calcium silicate pipe sections
arranged to enclose both the line and its accompanying tracer.
Bolt clearance shall be maintained on both side of flange, and minimum clearance shall be
bolt + 50mm at least one side as per site condition.
For equipment insulation shall be used by mineral wool blanket with galvanized wired mesh as
per ASTM C592 Type I, II & III for temperature up to 370oC, and mineral wool blanket with s/s
wired mesh for equipment temperature above 370oC and on austenitic stainless steel surfaces.
For alternate insulation material is mineral wool board as per ASTM C612 type II and IV
(Project Specification No. RFCC-C-CS-SP-002)
In case of equipment Four Stage Cyclone Separator (101-V-511) with temperature 709oC,
insulation shall be covered with ceramic fiber blanket with density 128 kg/m as per ASTM
C892 Type3 Grade 8. Insulation thickness 150mm with 6 layers of 25mm thickness ceramic
fiber blanket, for 1st, 2nd, 4th, 5th layer shall be secured with s/s 304 tie wire and for 3rd and 6th
layer shall be secured with s/s strapping band 19 X 0.5mm.
Equipment insulation shall be secured with galvanized band 13 X 0.4mm for OD below
760mm, and galvanized band 19 X 0.5mm for OD 760mm and above , machine tensioned and
sealed. Band shall be positioned at max. 300mm spacing centre on vertical equipment and
horizontal equipment to avoid loosening of blanket.
The adjacent joints of blankets shall be tack stitched with galvanized wire swg #18 or #20.


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WORK OF INSULATION
9.2.16 Insulation at equipment flanges shall be stopped short of the bolts. The bolt removal clearance
left for all flanged equipment connections. The clearance at equipment shall be nut length plus
50mm.
9.2.17 Where the bending radius is too small to be neatly segmented, insulation shall be fitted in Tee
piece form to receive metal jacketing.
9.2.18 Equipment insulation work shall start after completion of external mechanical work done.
9.2.19 Installation insulation shall be done before equipment installation if required.
9.2.20 Instrument tube shall be insulated with glass fiber tape or ceramic rope as per thickness
requirement and shall be covered with aluminum foil sheet and shall be fastened with
aluminum tape.
9.2.21 All insulation activities shall be completed in one day, if this is impossible, the insulation shall
be covered temporarily with water proof film/ plastic, to be sealed at the outer ends of water
resistance.
9.3
9.3.1
9.3.2
9.3.3
1
9.3.4
9.3.5
9.3.6
9.3.7
9.3.8
1
Jacketing Procedure of Piping & Equipment

The metal jacketing to be used over insulated piping, fittings and equipment shall be aluminum
alloy sheet with moisture retarder which consist of polyethylene or polysurlyn 1060 Al 99.5
with manganese composition limits max. 0.03. Or 3003 with manganese composition limits
min. 1.0 and max.1.5 (per cent ) and as per ASTM B209 and ASTM C1729.
For pipe jacketing with flat sheet with moisture retarder which consist of polyethylene or
polysurlyn 1060 Al 99.5 with manganese composition limits max. 0.03. Or 3003 with
manganese composition limits min. 1.0 and max.1.5 (per cent ) and minimum thickness
0.3mm for pipe below NPS 30, and minimum thickness 0.4 for NPS 30 and above.
For vertical equipment jacketing with corrugated sheet with moisture retarder which consist of
polyethylene or polysurlyn. 1060 Al 99.5 with manganese composition limits max. 0.03. Or AA
3003 with manganese composition limits min. 1.0 and max.1.5 (per cent ) with deep
corrugated dimension 1-x (32mmX6.3mm) and minimum and minimum thickness 0.6mm
for OD 760mm and above. And OD below 760mm jacketing material shall be used flat sheet
with minimum thickness 0.4mm.
Overlaps of minimum 50mm shall be provided on circumferential and longitudinal joints. All
jacketing shall be installed in watershed manner.
Longitudinal seams of horizontal piping shall be staggered at 3 Oclock and 5 Oclock.
Horizontal seams shall be concealed from view from the sides of pipe rack or pipe track.
Longitudinal seams on vertical pipe jacketing shall be staggered and placed away from the
prevailing wind direction.
On piping jacketing circumferential lap joints shall not be screw fastened, piping shall be
secured with s/s bands only, with 13 X 0.4mm for all piping, and shall be positioned at each
overlap and at max. 300 mm centers interval. S/s self tapping screw shall be applied only for
fittings area.
S/s strapping band shall be applied on circumferential equipment jacketing with max. 300mm
centers interval, on vertical equipment s/s strapping band shall be secured with J clips to
prevent loosing on circumferential. S/s 304 self tapping screws shall be used for securing the
equipment jacketing at max. 150mm centers for equipment, every longitudinal and
circumferential overlap.


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WORK OF INSULATION
9.3.9
9.3.10
9.3.11
9.3.12
9.3.13
1
9.3.14
9.3.15
9.3.16
9.3.17
9.3.18
9.3.19
9.3.20
9.3.21
9.4
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
Fabrication of elbows/ bends shall be swage in swage for OD up to 600mm, and for above OD
600mm with overlap, each segment shall be secured by s/s 304 self tapping screws with
minimum two screws per segment along the longitudinal seam.
Caps end shall be installed at insulation terminations. These shall be by disc and swage up to
OD 200mm over insulation, and lock formed for insulation OD above 200mm. cap ends on
vertical pipe shall be lock formed and conical to provide watershed.
S clips fabricated from s/s 304 13 X 0.4mm or 19 X 0.5mm strapping band shall be
introduced between individual length of metal jacketing on vertical pipe and vertical equipment
to prevent telescoping.
Metal jacketing shall be installed in watershed manner at all times. The cutted side shall be
sealed by the application of a metal silicone sealant.
Removable Metal box insulation shall be used for valves and flanges for steam lines service
and steam tracing lines service. For valve size 20 and above shall be insulated on body valve
only with mineral wool blanket with galvanized mesh, covered with glass cloth and weather
proofing mastic (Ih code only)
Removable Box shall be fabricated with thickness 1.0mm flat aluminum sheet for NPS 12 and
above, thickness 0.8mm flat aluminum sheet for NPS 10 and below, box shall be riveted to
the inside of the boxes with pop rivets and screws, and shall be incorporated circumferential
and longitudinal lock seams.
Removable type metal box shall be pre insulated inside with mineral wool blanket secured with
pins or clips and the thickness insulation shall be same of pipe or equipment.
Boxes shall be fastened by s/s 304 type quick release toggle fasteners. Toggle shall be
minimum two numbers on each side of over laps, additional toggles shall be installed where
necessary to neatly and firmly close the box with good seal.
Personnel protection with steel welded wire mesh barrier shall consist of physical barriers shall
extend to a height of 2000mm and 600mm either side of working platform or walking level.
Spacing requirements for shields and cages shall be 50mm minimum, but shall not be less
than the heat conservation insulation thickness.
Gusset plate and steel ring shall be fabricated of cs or s/s 304 size 30 X 3mm and 25 X 25 X
3mm s/s welded wire mesh shall be installed.
Gusset plate shall be isolated with direct contact of pipe or equipment by means of glass fiber
tape to prevent damage to pipe surface.
For jacketing at small bottom head equipment shall be wrapped with weather proofing mastic.
Insulation for Cold Insulation and Anti-Sweat Insulation Codes C, JC and A

Piping and equipment shall have all welding completed and shall be hydrostatically or
pneumatically tested prior to application of insulation.
For cold insulation it is essential that no water or water vapour penetrates in to the insulation.
For cold insulation preformed PIR section shall be used according to table 3 of Spec
No.RFCC-C-CS-SP-002.
For piping and large cylindrical surfaces insulation preformed cylindrical section or segments
shall be used.
Vapor stop shall be installed at all pipe supports locations and applied between the pipe and
insulation termination. Application shall be extended over the roughened pipe surface for


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WORK OF INSULATION
9.4.6
9.4.7
9.4.8
9.4.9
9.5
9.5.1
9.5.2
9.6
50mm. All vapor stops shall start from pipe or equipment surface and to step upward to outer
surface to insulation with reinforcing membrane with a minimum overall DFT of 2mm. No
reinforcement is required on underside of insulation to a depth of 50mm. Insulation shall be
installed after vapor stops becomes dry to touch. Adhesive shall be coated on the dried vapor
stop coating for the adjacent outer most layer joint of PIR.
In multilayer system, in addition to the primary vapor barrier a secondary vapour barrier shall
be applied between the outermost layer and the next insulation layer.
The insulation system shall include contraction joints as per project specification.
All insulation materials applied in one day shall have the vapor barrier applied the same day.
If it is found impracticable to apply the vapor barrier, exposed insulation shall be temporarily
protected with a black polyethylene sheet.
For jacketing on cold insulation shall be done same system with hot insulation jacketing.
Insulation Application for Piping
Piping insulation shall be done before pressure test except the welding joints on safe working
condition.
Welding joints in insulation application will be done after pressure test with safe working
conditions (i.e. scaffolding, man lift, man basket with approval safety)
Insulation Application for All Equipment
9.6.1
9.6.2
9.7
9.7.1
9.7.2
Equipment insulation work shall be done after completion of external mechanical work done.
Insulation shall be done before equipment installation on ground if required.
Rework on Damage or Open Portion for Piping and Equipment
Damaged insulation and open portion will be checked for extent of damage or open portion
and shall be re-insulated with the same specification as required for the piping and equipment.
Insulation will be done using scaffolding, man lift or man basket with safety approval.
10. INSPECTION AND REPORTING PROCEDURE

The QA/QC operative on site will carry out periodic and stage wise inspection. Once QA/QC operative
is satisfied in all respects with the work, he shall offer the area to Contractor/ Owner for inspection.
Inspection will be carried out as per the Inspection and Test Plan. The inspection report with all the
finding shall be recorded and signed with all parties in the reporting formats in ITP (Project Doc. No.
RFCC-ITP-PA-0001).
11. QA/QC RESPONSIBILITIES
All the insulation works on the project will be under QA/QC operative and main contractor inspection
department. The QA/QC operative will be responsible for overall quantity of the work according
attached ITP (Doc No. RFCC-ITP-PA-0001) and will fill all the relevant inspection forms which shall be
signed off by each party. His specific responsibilities will include:


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WORK OF INSULATION
11.1
11.2
11.3
11.4
11.5
11.6
Ensure all the materials for the project are strictly in accordance with the specifications &
WMS.
Ensure correct materials are used for application. Delivery notes & test certificates/
certificate of compliance shall be reviewed during material inspection.
inspected materials shall be used for site work.
Inspect workmanship of work in progress, ensure all tools and equipments are in good
condition.
Responsible for recording on inspection findings and maintaining them for each
item
to
obtain final completion certificate.
Strictly follow ITP of the work and report management for any shortfall and non conformance
report.
12. HSE
Full care and precaution shall be given by the field management for the safety and sanitation of the
manpower in the field to prevent accident during the execution of works. Refer to the site safety for
general site control. One of the main aspects of this procedure is Safety and Health Control. This is to
control the prevention of incidents, personal injuries as well as damage to equipment and properties
during the entire construction period. In order to ensure a safe working environment during the entire
construction period, the following safety measures shall be implemented as follows:
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
All personnel involved in the insulation and other related activities should be inducted as per
contractor/ owner safety requirement.
Administrative control shall be applied for use to reduce the potential summer season.
Provision of rest shelters/ recovery area or stand by vehicle for each group.
Each worker shall be provided with drinking water during hot weather conditions during
working hours. Toilet with urinal and wash area shall be provided. Drinking water station shall
be in place with cold water.
All workers shall be provided with and wear Personnel Protective Equipment ie. safety helmet,
safety glasses (clear & dark), safety shoes/ boots and wear long sleeve shirt/ jacket or
coveralls. Additional PPE requirements shall be provided to workers as work scope dictates ie.
face shield (welding/ grinding/ fabrication), respiratory protection (dust mask/ respirator), full
body harness (FBH) when working at height and as per MSDS requirements.
All waste material will be collected on regular basis to be stacked in a designated location at
site, this material should be removed periodically from site.
Sufficient number of toilet units provided for workers in line with project regulations and units
maintained in hygienic condition.
All equipment should be inspected and approved by HSE officer of GS E&C.
Tool box meeting shall be arranged before work activity and the same should be recorded.
The work site should always be maintained clean and tidy.
13. JOB SAFETY ANALYSIS FOR INSULATION WORK

As per attachment #1


Rev. No. : 1
Page No. : 14 / 47

WORK OF INSULATION
14. ATTACHMENTS
No.
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Description
Job Safety Analysis for Insulation
Job Safety Analysis for Insulation Work Using Man Basket
Insulation Thickness for Hot Service (Mineral Wool)
Insulation Thickness for Hot Service (Calcium Silicate)
Insulation Thickness for Hot Service (Ceramic Fiber + Calcium Silicate)
Insulation Thickness for Personnel Protection (Mineral Wool)
Insulation Thickness for Personnel Protection (Calcium Silicate)
Insulation Thickness for Cold and Anti-Sweat Insulation
Inspection and Test Plan
Inspection Format Forms
Typical Details For Piping Insulation
Typical Details For Valve Insulation
Flange Insulation And Insulation Support Ring Details
Insulation Details at Pipe Support
Vertical Vessel Insulation (Blanket Insulation)
Vertical Vessel Insulation (Block Insulation)
Horizontal Vessel Insulation (Blanket Insulation)
Horizontal Vessel Insulation (Block Insulation)
Heat Exchanger Insulation
Insulation Details For Vertical Vessel Head
Flashing Details At Nozzle And S And J-Clip Details
Wire Mesh Barrier for Personnel Protection Details
Removable Insulation Cover for Pumps (Hot Insulation)
Insulation for Body of Valve 20 and Above (Ih Insulation only)
Reference
Attachment #1
Attachment #2
Table 2 (1)
Table 2 (2)
Table 2 (3)
Table 2 (4)
Table 2 (5)
Table 3
Attachment #3
Attachment #4
Attachment #5
Attachment #6
Attachment #7
Attachment #8
Attachment #9
Attachment #10
Attachment #11
Attachment #12
Attachment #13
Attachment #14
Attachment #15
Attachment #16
Attachment #17
Attachment #18

Rev. No. : 1
Page No. : 15 / 47

WORK OF INSULATION
Attachment #1.
Prepared by:
Reviewed by:
Step
No.
1
JOB SAFETY ANALYSIS FOR INSULATION

Afendi Muslim
Yanam
Approved by:
Date
:
Description of Task Step

Insulation Fixing & Removal
Fabrication Shop
Control Measures/
Preventive Measures
Hazard
Calcium Silicate, Glass wool.

Sharp Objects.
Dust.
Skin Irritation.
Cho In Seok
20 August 2013
Falling object.
Flammable gasses
Inadequate access
Working at height
Proper PPE as per MSDS.

Wear proper hand gloves, proper manual handling.
Wear proper dust mask, good housekeeping.
Agreed Lay down area for storage, proper PPE as
per MSDS.
Secure all loose insulation at storage area from high
wind, secure all tools during working at height.
Gas testing to be done at the start of insulation work
on any line containing flammable gasses.
Make sure that adequate access is available.
If scaffold is used for access it should be inspected
by a certified scaffolding inspector & scaff-tag
should be installed
100% tied off full body harness.
Wear proper hand gloves

Proper manual handling, wear proper hand gloves
Isolate power cable, secure with Lock Out Tag Out.
Proper material arranging and good housekeeping.
Equipment certification and Fire Extinguisher
Pinch point
Sharp object
Electrical tools
Slip, trip and fall
Machinery equipment
Responsible Person
Worker
Worker
Worker
Worker
Worker
Authorized gas tester
Worker
Scaffolding Inspector
Worker
Worker
Worker
Worker
Worker
Safety Officer


Rev. No. : 1
Page No. : 16 / 47

WORK OF INSULATION
Step
No.
3

Using Foam Spray for
Insulation
Control Measures/
Preventive Measures
Hazard
Chemical
(Polyol + Iso-cyanide,
Polyurethane)
Pressured Injection gun
Foaming machine
Wasting Insulation Material

(Hazardous Substances)
Health Impairment
Fire / Explosion
Environmental Impact
Proper Gun maintenance

Fire Extinguisher
Wear proper PPE as per the MSDS (mater
Workers should not play around with the tools
Only competent workers are allowed to use the
pressurized injection gun
Operators must read the manufacturers for using the
foaming machine
Assessment on the hazards and risk to health by
potentially harmful substances shall be carried out.
Shall detail the control measures that will be taken
to reduce risk to health.
MSDS and assessment of the risk and necessary
control measure shall be in place prior to the work
being carried out.
Personnel shall be instructed to take appropriate
precautions to protect their health from the hazards.
Training shall be given in the correct use and
maintenance of PPE.
Hazardous substances shall be stored in a safe
manner. Materials shall be segregated in
accordance with good practice, e.g. Keeping
oxidizing and reducing agent apart.
Contingency arrangements shall be in place to
initiate the spillage of any hazardous substances.
Responsible Person
Worker
Safety Officer
Worker
Worker
Worker
Worker
Worker & Safety Officer



Rev. No. : 1
Page No. : 17 / 47

WORK OF INSULATION
Step
No.
5

House Keeping
Hazard
Can occur when particles

of dust, debris or grit,
etc. Are blown around
the workplace or when
particles
are
such
dislodged
from
work
areas above. I.e. from
scaffolding
Control Measures/
Preventive Measures
Personnel shall ensure that the highest levels of
housekeeping are maintained at all times.
The company operates a mandatory Eye
Protection policy on all project locations. Personnel
shall adhere to this strict policy at all times.
Supervisors shall monitor the standards of
housekeeping on a daily basis to ensure that they
are acceptable and implement routine Clean Ups
where necessary.
Responsible Person
Worker
Worker
Supervisor

Rev. No. : 1
Page No. : 18 / 47

WORK OF INSULATION
1
Attachment #2.
Prepared by:
Reviewed by:
Step
No.
1.
JOB SAFETY ANALYSIS FOR INSULATION WORK USING MAN BASKET

Afendi Muslim
Yanam

Insulation Fixing & Removal
Approved by:
Date
:
Hazard
Cho In Seok
11 January 2014
Control Measures/
Preventive Measures
Responsible Person
Inexperienced or incompetent
operator/ riggers
Crane Operators and Riggers shall be certified by HSE Officer

Third Party Inspection and competent enough to
perform Lifting Operations.
Other personnel may assist in rigging operations (if Crane Operator/ Rigger
experienced) however a Rigger shall examine all
rigging prior to commencing a lift.
Toolbox talks shall be held prior to all major or unusual HSE Officer
lifts to ensure that all personnel are aware of the
operations.
Faulty lifting equipment
Visually inspect all equipment priors to use to ensure it

is free from any defects / Leaks and or damage.
Color Coding and all test certificates by Third Party
Inspection on Man-basket / Equipment shall be
checked to ensure they are current.
Ensure that the number of Person(s) allowed in Manbasket is stenciled on its side.
All equipment shall be of adequate rating to perform
operations.
Any damaged equipment shall be quarantined and
Crane Operator/ Rigger

HSE Officer


Rev. No. : 1
Page No. : 19 / 47

WORK OF INSULATION
Step
No.
Hazard
Control Measures/
Preventive Measures
Responsible Person
reported to your Supervisor immediately.

Outriggers shall be properly extended, set and locked Crane Operator/ Rigger
where locking devices are provided.
All equipment shall be properly maintained and HSE Officer/ Inspector
inspected on a weekly basis.
Personnel injuries
Uncontrolled lifts
Leather Hand Gloves shall be worn at all times to

protect the hands during lifting operations
Workers shall wear Full Body Harness, which is
connected to the lifeline that is attached to the Crane
hook prior to lift.
Loads or Man-basket shall not be moved or swing on
top of workers.
Workers shall use Grab Bar and keep all parts of their
body inside the man-basket during Hoisting, Lowering
and Positioning.
The Crane Operator shall never leave the crane
controls unattended while personnel are still working
or the man-basket is suspended.
Worker
Worker
Worker
Single point lifting shall be avoided wherever possible

If direct lifting is not possible, use of Taglines shall be Crane Operator/ Rigger
utilized to avoid the load from swinging.
Lifting/ rigging operations shall be carried out from Crane Operator/ Rigger
approve codes of practice.
Short cuts causes accidents, do not take risks
Worker


Rev. No. : 1
Page No. : 20 / 47

WORK OF INSULATION
Step
No.
Hazard
Control Measures/
Preventive Measures
Responsible Person
Barricade the area prior to commencing operations.

A qualified signal person must be in the basket at all Crane Operator/ Rigger
times when transporting personnel
Where applicable, Method Statement shall be read to All parties
establish specific precautions necessary to the
operations
High winds
Maximum Wind velocity (25 Knots) must be

considered during lifting operations.
Check approved Anemometer wind velocity reading
from the client.
Slings and other lifting materials shall be inspected
regularly from defects and properly tagged for colorcoded.
Lifting operations shall be closely monitored and
supervised by trained and competent Riggers

HSE Officer/ Inspector

Rev. No. : 1
Page No. : 21 / 47

WORK OF INSULATION
Table 2 (1) Insulation Thickness for Hot Service (Mineral Wool)
Unit: mm
SIZE
1/2
3/4
1.1/2
2.1/2 3
10
12
14
16
18
20
22
24 PLANE
100
25
25
25
25
25
25
25
25
30
30
30
30
30
40
40
40
40
40
40
150
25
25
25
25
25
30
30
30
40
40
40
40
40
40
40
50
50
50
50
200
25
25
25
30
250
25
30
30
40
30
40
40
40
40
50
50
50
50
50
50
50
50
50
65
40
40
40
50
50
50
50
65
65
65
65
65
65
65
75
300
30
30
40
40
40
50
50
50
65
65
65
65
65
65
75
75
75
75
90
350
30
40
400
40
40
40
50
50
50
50
65
65
65
75
75
75
75
75
75
75
75
90
50
50
50
65
65
65
75
75
75
75
75
90
90
90
90
90
100
450
40
50
50
50
65
65
65
75
75
90
90
90
90
90
100 100 100 100
115
500
so
50
50
65
65
75
75
75
90
90
100 100
90
100 100 100 100 115
125
550
50
50
65
6S
75
75
75
90
100 100 100 100 100 115 115 115 115 115
140
600
50
65
65
75
75
75
90
90
100 100 115 115 100 125 125 125 125 125
150
650
65
65
65
75
75
90
90 100 100 115 115 115 125 125 125 140 140 140
150
TEMP.
Notes : Density : As per ASTM Code.

128kg/m3 Max. - 93kg/m3 Min. (blanket ) ASTM C592 Type III
128kg/m3 Min.(board/slab) ASTM C612 Class II & IV
100kg/m3 Min. (pipe cover) ASTM C547 Class II & III

Rev. No. : 1
Page No. : 22 / 47

WORK OF INSULATION
Table 2 (2) Insulation Thickness for Hot Service (Calcium Silicate)
Unit: mm
SIZE
1/2
3/4
1.1/2
2.1/2
10
12
14
16
18
20
22
24 PLANE
100
25
25
25
25
25
25
25
25
30
30
30
30
30
40
40
40
40
40
40
150
25
25
25
25
25
30
30
30
40
40
40
40
40
40
50
50
50
50
50
200
25
25
25
30
30
40
40
40
40
50
50
50
50
50
50
50
50
50
65
250
30
30
30
30
40
40
40
50
50
50
50
50
65
65
65
65
65
65
75
300
30
30
30
40
40
50
50
50
50
65
65
65
65
65
65
65
65
75
75
350
30
30
40
40
50
50
50
50
65
65
65
75
75
75
75
75
75
75
90
400
40
40
40
50
50
50
50
65
65
75
75
75
75
75
75
75
90
90
100
450
40
'40
50
50
50
65
65
65
75
75
75
75
90
90
90
90
90
90
100
500
40
40
50
50
65
65
65
75
75
75
90
90
90
90
90
100 100 100
115
550
50
50
50
65
65
65
65
75
75
90
90
90
100 100 100 100 100 100
125
600
50
50
50
65
65
75
75
75
90
90
100
100 100 100 100 100 115 115
125
650
50
50
65
65
65
75
75
75
90
100 100
100 100 115 115 115 115 115
140
TEMP.
Notes : Density : As per ASTM C533 type I

220 kg/m
Table 2 (3) Insulation Thickness for Hot Service (Ceramic Fiber + Calcium Silicate)
(Temp. maximum 750 C)
PIPE SIZE
1st layer
2nd layer
(inch)
Ceramic Fiber
Calcium Silicate
1"
25mm
40mm
1.5"
25mm
50mm
3"
25mm
50mm
30"
50mm
50mm
Plane
150mm
Remarks
For 4TH
Stage Cyclone Separator
(1) Ceramic fiber Use of Density 128 kg/m (ASTM C892 Type3 Grade 8).
(2) Maximum Thickness of Ceramic Fiber Blanket 25mm.
(3) If the thickness required to 50mm, use of Two layer.

Rev. No. : 1
Page No. : 23 / 47

WORK OF INSULATION
Table 2 (4) Insulation Thickness for Personnel Protection (Mineral Wool)
Unit mm
SIZE
1/2
3/4
1.1/2
2.1/2
10
12
14
16
18
20
22
24 PLANE
100
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
150
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
200
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
250
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
300
25
25
25
25
30
30
30
30
30
30
40
40
40
40
40
40
40
40
40
350
30
30
30
40
40
40
40
40
40
40
40
50
50
50
50
50
50
50
50
400
40
40
40
40
40
50
50
50
50
50
50
65
65
65
65
65
65
65
65
450
40
40
50
50
50
50
65
65
65
65
65
65
65
65
65
65
65
75
75
500
50
50
50
65
65
65
65
65
75
75
75
75
75
90
90
90
90
90
90
550
65
65
65
65
65
75
75
75
90
90
90
90
90
90
100 100 100 100
115
600
65
65
65
75
90
90
90
90
100 100 115 115 115 115 115 115 115 115
140
650
75
75
75
90
90
90
100 100 115 115 115 125 125 125 125 140 140 140
165
TEMP.
Notes :Density :As per ASTM code

128kg/m3 Max. - 93kg/m3 Min. (blanket ) ASTM C592 Type III
128kg/m3 Min.(board) ASTM C612 Class II & IV
100kg/m3 Min. (pipe cover) ASTM C547 Class II & III

Rev. No. : 1
Page No. : 24 / 47

WORK OF INSULATION
Table 2 (5) Insulation Thickness for Personnel Protection (Calcium Silicate)
Unit mm
SIZE
1/2
3/4
1.1/2
2.1/2
10
12
14
16
18
20
22
24
PLANE
100
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
150
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
200
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
250
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
300
25
25
25
25
25
25
30
.30
30
30
30
30
30
30
30
30
30
30
40
350
25
25
30
30
30
40
40
40
40
40
40
40
40
40
40
40
40
40
40
400
30
30
40
40
40
40
40
40
50
50
50
50
50
50
50
50
50
50
50
450
40
40
40
40
40
50
50
50
50
50
65
65
65
65
65
65
65
65
65
500
40
40
50
50
50
50
50
65
65
65
65
65
65
65
65
65
65
65
75
550
50
50
50
50
65
65
65
65
65
65
75
75
75
75
75
75
75
75
90
600
50
50
65
65
65
65
65
65
75
75
75
75
75
90
90
90
90
90
100
650
50
65
65
65
65
75
75
75
90
90
90
90
90
90
90
100 100 100
115
TEMP.
Notes : Density : As per ASTM C533 type I

220 kg/m

Rev. No. : 1
Page No. : 25 / 47

WORK OF INSULATION
Table 3. Insulation Thickness for Cold and Anti-Sweat Insulation
Unit mm
PLANE
1/2
3/4
1. 1/2
2. 1/2
10
12
14
16
18
20
24
26
30
36
42
48
10
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
30
25
25
25
25
25
25
25
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
35
-5
25
25
25
30
30
30
30
30
35
35
35
35
35
35
35
35
35
35
35
35
35
35
40
-10
25
30
30
30
30
35
35
35
35
40
40
40
40
40
40
40
40
40
40
40
40
40
45
-15
30
30
30
35
35
35
40
40
40
40
45
45
45
45
45
45
45
45
45
45
45
45
50
-20
30
35
35
35
40
40
40
40
45
45
45
50
50
50
50
50
50
50
50
50
50
50
55
-25
35
35
35
40
40
45
45
45
50
50
50
50
55
55
55
55
55
55
55
55
55
55
60
-30
35
40
40
40
45
45
45
50
50
55
55
55
55
60
60
60
60
60
60
60
60
60
65
-35
40
40
40
45
45
50
50
55
55
60
60
60
60
60
65
65
65
65
65
65
65
65
70
-40
40
40
45
50
50
50
55
55
60
60
65
65
65
65
70
70
70
70
70
70
70
70
75
-45
45
45
45
50
55
55
55
60
65
65
70
70
70
70
70
75
75
75
75
75
75
75
80
-50
45
45
50
55
55
60
60
65
65
70
70
75
75
75
75
75
80
80
80
80
80
85
90
-55
45
50
50
55
60
60
65
65
70
75
75
80
80
80
80
80
85
85
85
85
85
90
95
-60
50
50
55
60
60
65
65
70
75
80
80
80
85
85
85
85
90
90
90
90
90
95
100
-65
50
55
55
60
65
65
70
75
80
80
85
85
85
90
90
90
95
95
95
95
95
100
105
-70
55
55
60
65
65
70
70
75
80
85
90
90
90
95
95
95
95
100
100
100
100
105
110
-75
55
60
60
65
70
70
75
80
85
90
90
95
95
95
100
100
100
100
105
105
105
110
115
-80
55
60
65
70
70
75
80
80
90
90
95
100
100
100
100
105
105
105
110
110
110
110
120
-85
60
60
65
70
75
75
80
85
90
95
100
100
105
105
105
110
110
110
110
115
115
115
125
-90
60
65
65
75
75
80
85
85
95
100
100
105
105
110
110
110
115
115
115
120
120
120
130
-95
65
65
70
75
80
80
85
90
95
100
105
110
110
110
115
115
120
120
120
125
125
125
135
-100
65
70
70
75
80
85
90
95
100
105
110
110
115
115
115
120
120
120
125
125
130
130
140
-105
65
70
75
80
85
85
90
95
105
110
110
115
115
120
120
120
125
125
130
130
130
135
145
-110
70
70
75
80
85
90
95
95
105
110
115
120
120
120
125
125
130
130
130
135
135
135
150
SIZE
TEMP

Rev. No. : 1
Page No. : 26 / 47

WORK OF INSULATION
-115
70
75
75
85
85
90
95
100
110
115
115
120
120
125
125
130
130
135
135
140
140
140
155
-120
70
75
80
85
90
95
95
100
110
115
120
125
125
130
130
130
135
135
140
140
145
145
160
-125
70
75
80
85
90
95
100
105
110
120
125
125
130
130
135
135
140
140
140
145
145
150
165
-130
75
75
80
90
95
95
100
105
115
120
125
130
130
135
135
140
140
145
145
150
150
150
170
-135
75
80
85
90
95
100
105
110
115
125
130
130
135
135
140
140
145
145
150
150
155
155
175
-140
75
80
85
90
95
100
105
110
120
125
130
135
135
140
140
145
145
150
150
155
155
160
0.2
-145
75
80
85
95
95
100
105
110
120
125
130
135
140
140
145
145
150
150
155
155
160
160
180
-150
80
85
85
95
100
105
110
115
125
130
135
140
140
145
145
150
150
155
155
160
160
165
185
-155
80
85
90
95
100
105
110
115
125
130
135
140
145
145
150
150
155
155
160
165
165
165
190
-160
80
85
90
95
100
105
110
115
125
135
140
145
145
150
150
155
155
160
160
165
170
170
190
-165
80
85
90
100
105
110
110
120
130
135
140
145
145
150
155
155
160
160
165
170
170
175
195
-170
85
85
90
100
105
110
115
120
130
135
140
145
150
150
155
160
160
165
165
170
175
175
200
-175
85
90
95
100
105
110
115
120
130
140
145
150
150
155
155
160
165
165
170
170
175
180
200
-180
85
90
95
100
105
110
115
125
135
140
145
150
155
155
160
160
165
170
170
175
180
180
205
Notes:
1. Table is based on thickness required to prevent condensation on surfaces with following design
conditions:
Ambient temperature
: 30 C
Relative humidity
: 85 percent
2
Surface heat transfer coefficient: 8 W/(m2K) [6.88 kcal/(m hC)]
2. Where other design conditions are used, thickness should be adapted to meet job requirements.
3. Bulk density : Min. 40kg/m

Rev. No. : 1
Page No. : 27 / 47

WORK OF INSULATION
Attachment #3.
INSPECTION & TEST PLAN FOR

INSULATION
No.
Reference
(Code/Std/Spec./Proc.)
Description of Inspection
Doc No : RFCC-ITP-PA-0001
Rev. No : 3
Date
Page
Inspection for
Report Form. No.
Remarks
C
Owner
a) Check the completion of welding, hydro testing and assembly
b) Surface cleaning and touch up painting
c) Insulation material form & thickness
d) Extend of Insulation
e) Insulation support ring (Vertical Only)
f) Cool down system installation (Fiber optic Cable-by instrument)
Sc
A
INSULATION
Material Verification
Project Specification
P.O.Spec. / Vendor Documents Field
Material Control Procedure
a) Verify the material/ Size/ Quantity & Physical Properties

b) Check the damage
2
2-1
Piping Insulation
Pre-Insulation Check
Applicable drawing & Specification
Sc : Sub-Contractor;
C : Contractor;
M : Execution;
W : Witness;
I : Spot Witness
R : Review Inspection
Manufacturer's
Certificate and Field
Receiving Report
ITP-IN(CP)-001
H : Hold
MIGAS

Rev. No. : 1
Page No. : 28 / 47

WORK OF INSULATION
INSULATION
No.
2-2
Reference
Verifying
Document
Rev. No : 3
Date
Page
Intervention
Sc
Owner
a) Anti-abrasive coating
b) Joint staggered & fit up
c) Insulation Segments
(Approx 8" for 2' Long, Approx 12" for 3' Long)
d) SUS band interval for outer layer

(SUS 304, min. 0.4mm t x 13 mm w, max 225 mm centers)
e) Joint Sealant
(Outer layer only, wet film thickness App 3.5mm)
f) Expansion/ Construction Joint
g) Primary vapor barrier w/ Glass cloth

(Dry film thickness 3.0mm)
h) Vapor stop ( Pipe Suports, Valves & Flanges)
Insulation
Appicable drawing & Specification
C : Contractor;
M : Execution;
W : Witness;
I : Spot Witness
ITC-IN(CP)-001
H : Hold
Remarks
MIGAS

Rev. No. : 1
Page No. : 29 / 47

WORK OF INSULATION
INSULATION
2-3
2-4
3
3-1
Reference
No.
Rev. No : 3
Date
Page
Inspection for
Report Form. No.
Sc
Owner
a) Jacketing installation
(Longitudinal overlaps min. 50mm & 90 or 150 positions)
(Circumferential overlaps min. 50mm)
b) Jacket band interval

( 0,4mm t x 13mm w for NPS 24", max. 300mm centers)
( 0,5mm t x 19mm w for NPS > 24", max. 300mm centers)
c) Metal Sealant
(white color/ min. 4mm dry thickness)
d) Flange & Valve Box Installation
Final Inspection
a) Surface cleaning and touch up painting
b) Check the completion of installation,

Assembly and final inspection
c) Insulation material form & thickness
d) Extend of Insulation
e) Insulation support ring
Jacketing
Equipment Insulation
ITP-IN(CP)-001
ITP-IN (CE)-002
Pre-insulation check
C : Contractor;
M : Execution;
W : Witness;
I : Spot Witness
H : Hold
MIGAS
Remarks

Rev. No. : 1
Page No. : 30 / 47

WORK OF INSULATION
INSULATION
No.
Reference
Rev. No : 3
Date
Page
Inspection for
Report Form. No.
Sc
Owner
a) Anti-Abrasive coating
b) Joint staggered & fit up
c) Insulation Segments
(Approx8" for 2' Long, Approx,12" for 3' Long)
d) SUS band interval for outer layer

(SUS 304, 0.5mm t x 19mm w, max. 300mm centers)
e) Joint sealant
(Outer layer only, wet film thickness App 3.5mm)
f) Expansion/ Construction Joint
g) Primary vapor barrier w/ Glass cloth

(Dry film thickness 3.0mm)
h) Vapor stop (Supports, Valves & Flanges)
f) Cool down system installation

(Fiber optic cable-by instrument)
3-2
Insulation
C : Contractor;
M : Execution;
W : Witness;
I : Spot Witness
ITP-IN(CE)-002
H : Hold
MIGAS
Remarks

Rev. No. : 1
Page No. : 31 / 47

WORK OF INSULATION
INSULATION
No.
3-3
3-4
Reference
Rev. No : 3
Date
Page
Inspection for
Report Form. No.
Sc
Owner
a) Jacketing Installation
(Laps-min. 50mm for flat jacketing)
b) Jacket band interval (max. 300mm centers)

(0.5mm t x 19mm w )
c) Metal Sealant
(white color/ min. 4mm dry thickness)
d) Manhole box installation
Final Inspection
Jacketing
C : Contractor;
M : Execution;
W : Witness;
I : Spot Witness
ITP-IN(CE)-002
H : Hold
MIGAS
Remarks


WORK OF INSULATION
Attachment #4.

Rev. No. : 1
Page No. : 32 / 47


WORK OF INSULATION

Rev. No. : 1
Page No. : 33 / 47


WORK OF INSULATION
Attachment #5.
Typical Details For Piping Insulation
COATED WITH MOISTURE BARRIER
Note : All Dimensions are in mm.

Rev. No. : 1
Page No. : 34 / 47


Rev. No. : 1
Page No. : 35 / 47

WORK OF INSULATION
Attachment #6.
Typical Details For Valve Insulation
FLANGED VALVES
VALVE OTHER THAN FLANGED


Rev. No. : 1
Page No. : 36 / 47

WORK OF INSULATION
Attachment #7.
Flange Insulation And Insulation Support Ring Details
FLANGE INSULATION
INSULATION SUPPORT RING FOR PIPING


WORK OF INSULATION
Attachment #8.

Rev. No. : 1
Page No. : 37 / 47


Rev. No. : 1
Page No. : 38 / 47

WORK OF INSULATION
Attachment #9.


Rev. No. : 1
Page No. : 39 / 47

WORK OF INSULATION
Attachment #10.


WORK OF INSULATION
Attachment #11.

Rev. No. : 1
Page No. : 40 / 47


WORK OF INSULATION
Attachment #12.

Rev. No. : 1
Page No. : 41 / 47


WORK OF INSULATION
Attachment #13.
Heat Exchanger Insulation
TYPICAL DETAIL AT PIPING HANGER
DOUBLE PIPE HEAT EXCHANGER

Rev. No. : 1
Page No. : 42 / 47

Rev. No. : 1
Page No. : 43 / 47

WORK OF INSULATION
Attachment #14.
Insulation Details For Vertical Vessel Head

max interval 150 mm
WATERSHED MANNER
OVERLAP


Rev. No. : 1
Page No. : 44 / 47

WORK OF INSULATION
Attachment #15.
Flashing Details At Nozzle And S And J-Clip Details
FLASHING DETAIL AT NOZZLE
S AND :J CLIP DETAILS


Rev. No. : 1
Page No. : 45 / 47

WORK OF INSULATION
Attachment #16.
Wire Mesh Barrier for Personnel Protection Details
steel welded wire mesh
* use s/s components on s/s pipe


Rev. No. : 1
Page No. : 46 / 47

WORK OF INSULATION
Attachment #17.
Removable Insulation Cover for Pumps (Hot Insulation)
Filling with mineral wool
50mm


Rev. No. : 1
Page No. : 47 / 47

WORK OF INSULATION
Attachment #18.
Insulation for Body of Valve 20 and Above (Ih Insulation only)
MINERAL WOOL BLANKET WITH METAL MESH

JACKETING (GLASS CLOTH WITH WEATHER PROOF MASTIC

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Cilacap Resid Fluid Catalytic

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METHOD STATEMENT FOR

Revised phrase as per Doc No. RFCC-C-CS-SP-002.

Revised Phrase as per Doc No. RFCC-C-CS-SP-002.

Added phrase horizontal and vertical equipment

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