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HINDUSTAN PETROLEUM CORPORATION LTD.


MUMBAI

DIESEL HYDROTREATER PROJECT

TITLE

STANDARD SPECIFICATION FOR HOT INSULATION

DOCUMENT NO.

44LK-5100-00-V.02-0003-A4

REV
NO.

ISSUE
DATE

PAGES

REV DESCRIPTION

PREPARED

CHECKED

APPROVED

BY

BY

BY

29.07.2008

38

Issued for Clients approval

MVS

CR

HSC

09.09.2008

38

Issued as general specification

SNK

CR

HSC

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

TABLE OF CONTENTS

1.0

SCOPE

2.0

DESIGN BASIS

3.0

EXTENT OF INSULATION

4.0

MATERIALS

5.0

WEATHER PROOFING

6.0

ANCILLIARY MATERIALS

7.0

APPLICATION

8.0

INSPECTION, TESTING & MEASUREMENT OF WORK

9.0

CONTRACTORS OBLIGATIONS

Attachments:
Insulation sketches : 18 nos.

A.2 Hot Insulation

Page 2 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

Page 3 of 38
Rev. 0
Date: 09.09.2008

1.0

SCOPE

1.1

This specification covers minimum technical requirements for the design, material
procurement, supply, storage & application of all types of external, above ground
insulation of piping and equipment operating between ambient temperature & 5500C for
the purpose of heat conservation, maintenance of operating temperature, process
stabilisation & personnel protection.

1.2

This specification does not cover insulation for boilers, fired heaters, furnaces, and cold
services.

1.3

All the codes/standards mentioned in this specification shall be of latest issue.

2.0

DESIGN BASIS

2.1

Heat conservation insulation is designed to limit the cold face temperatures below 550C if
economically justified with 350C ambient temperature in still air condition limiting the heat
loss at 150 kcal/hr m2 on insulation outside surface basis. Emisivity for aluminium
cladding shall be 0.3.

2.2

The design temperature used for calculation of insulation thickness shall be the normal
operating temperature of the contained fluid. However the insulation material shall be
suitable for the design temperature of piping and equipment for which it is used.

2.3

Insulation shall be applied for the following purpose:


Heat Conservation
Process stabilisation
Steam, hot water, hot oil or liquid jacketing
Steam, hot oil or electric tracing
Personnel protection

2.4

Insulation for Personnel protection is applicable where exposed surface temperatures


exceed 65 0C in normal or short-term operating conditions. Over internally insulated
piping and equipments, provide open mesh metal guards and for surfaces which are not
internally insulated, provide insulation on those parts of surfaces with which operating
and maintenance personnel may come in contact while performing routine duties. The
actual extent of insulation shall be determined by Field Construction Personnel and/or
operating personnel using the criteria that the exposed surfaces located within 600mm
horizontally or 2100mm vertically of a normal access, walkway or work area are to be
insulated.

2.5

Insulation is not desired for piping and equipment for which heat loss is desired
excepting for personnel protection or to avoid thermal stress problems.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

3.0

EXTENT OF INSULATION:

3.1

ON PIPING :

Page 4 of 38
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Date: 09.09.2008

Insulated nozzles, flanges, valves, fittings & piping speciality items shall be considered a
part of the piping & shall have the same insulation requirements as the attached piping.
3.1.1

Insulated piping systems shall have straight pipe, bends, tees and pipe fittings completely
insulated.

3.1.2

All valves and flanged joints shall be completely insulated only in steam, condensate
service, hot oil lines and in lines which are trace heated or jacketed to maintain
temperatures.

3.1.3

For bucket and float type traps the inlet piping and trap shall be insulated.

3.1.4

Insulation on inlet piping to thermostatic and thermodynamic steam traps shall terminate
at approximately 500 mm before the trap.

3.1.5

Steam trap outlet piping other than closed condensate recovery system shall not be
insulated except for personnel protection reasons.

3.1.6

Instrumentation to be insulated, such as level gages, level controllers, level switches, dp


cells, shall have their fluid containing sections and the associated piping completely
insulated, including pipes, valves and fittings.

3.1.7

Insulation shall be designed to provide an absolute minimum clearance of 25 mm


between the outside surface of any insulation finishing material and adjacent surfaces.

3.1.8

Where insulated horizontal piping is supported on steel shoes, the height of the shoe
shall be such that the underside of the insulation finishing material is clear of the
supporting structures upon which the shoe rests by 25mm minimum.

3.1.9

Insulation shall not be applied to the following unless otherwise specified.


1.
2.
3.
4.

5.
6.
7.
8.

A.2 Hot Insulation

Piping which becomes hot intermittently, such as relief valves, vents, steam-out
and snuffing steam systems flare and blow-down systems.
Supports for piping, excluding pipe hangers to the extent covered by insulation.
Steam Traps (except as noted in paragraph 3.1.3).
Valves, including control valves and flanges in process piping systems (except as
noted in 3.1.2 and 3.1.7). However, personnel protection insulation for these
items shall be applied, as required
Pipe Union fittings.
Thermowell bosses and pressure tappings
Expansion joints, hinged joints and hose assemblies.
Sight flow indicators.

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

Page 5 of 38
Rev. 0
Date: 09.09.2008

3.1.10 Valves and flanges in services below 300 C are usually not insulated unless other
requirements are overruling.
3.1.11 Flanges for hydrogen service shall never be insulated.
0

3.1.12 Flanges in services of 300 C and above which are not insulated, e.g. hydrogen service
and equipment nozzles, shall be provided with a weather protection cover.
3.1.13 Steam traps and the downstream lines of them shall not be insulated, except when heat
of the drain is to be recovered.
3.2

ON EQUIPMENT:

3.2.1

Support skirts of insulated vertical vessel greater than 1200 mm diameter shall be
insulated both internally and externally for a minimum distance of 600 mm below the
bottom tangent line. The insulation shall terminate not less than 300 mm above the
support concrete or steelwork.

3.2.2

Support skirts of insulated vertical vessels of 1200 mm and less shall be insulated
externally only, as described in para 3.2.1 above. The insulation thickness shall be 50%
of that provided for the main equipment.

3.2.3

Bottom heads of insulated vertical vessels enclosed by a support skirt shall be insulated
without finishing material and shall be insulated only when the vessel outside diameter is
greater than 1200 mm. The insulation thickness shall be same as that provided for the
main equipment.

3.2.4

Turbine and steam ends of reciprocating pump shall be insulated for heat conservation.

3.2.5

Liquid ends of pumps shall be insulated when heat traced or jacketed.

3.2.6

Items and equipment for which heat loss is essential or those which are refractory lined
from inside shall not be insulated.

3.2.7

Rotating equipment
Pumps and compressors are normally not insulated. Protective fencing may be
considered.
If insulation is necessary, e.g. for steam and gas turbines, boiler feed water pumps, it
shall be done by one of the following methods:
-

Insulating blankets shall be applied over the housing, stitched together with
binding wire and covered with aluminium cladding.
A metal box, reinforced with insulation material, shall not be applied when
pumping flammable liquids at high temperature, since if these liquids are
absorbed by the insulation it can catch fire.

3.2.8

Nameplates, stampings, thermowell bosses and pressure tapping shall be left clear of
insulation.

3.2.9

Flare line for hydrocarbon gas and liquid shall not be insulated.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

Page 6 of 38
Rev. 0
Date: 09.09.2008

4.0

MATERIALS

4.1

General

4.1.1

All insulation, fixing, sealing & weatherproofing materials shall be new undamaged and of
good quality and appearance. They shall be of a normally available commercial grade.

4.1.2

Insulation material shall be chemically inert of low chloride content, non sulphurous, nonhygroscopic, impervious to hot water and steam, rot, fungus and vermin proof. It shall be
non-injurious to health and shall not exert a corrosive effect on the surfaces to be
insulated and on the finishing materials even if soaked in water at ambient temperatures
for extended periods. It shall be unaffected by acidic & saline atmospheric conditions.

4.1.3

Insulation and finishing materials shall not contain ASBESTOS in any form.

4.1.4

All insulation materials and accessories shall conform to local health and safety
regulations. Contractor shall determine applicability of regulatory requirements prior to
use.

4.1.5

Insulation support lugs or other support attachments shall not be field welded without
written authorization.

4.1.6

Insulation material for austenitic stainless steel piping and equipment shall comply with
ASTM C795. Leachable chloride content shall be less than 50ppm.

4.1.7

Insulation or jacketing material used shall not be backed with any flammable material.

4.1.8

For Insulation Cladding, Moisture retarder shall be used. Moisture retarder is a liner
underneath the Cladding. Dupont make liner can be used, if same is available.
Alternatively, ITW make of Insulation cladding with moisture retarder liner can be
used.

4.2

Insulation Materials

4.2.1

Rock wool / Mineral wool


0
0
(Warning: This specification shall not be used below - 30 C and above 550 C)

4.2.1.1 The material shall be lightly resin bonded; processed into long fibres from molten state
0
0
and suitable for the intended operational temperature range from 60 C to 550 C. Fibres
shall be of high tensile strength, tough, non hygroscopic & of diameter varying between 3
& 5 microns. There shall be no settling of fibres over an extended period of use or under
vibration.
4.2.1.2 Glass wool / slag wool shall not be used.
4.2.1.3 Lightly bonded mineral wool & slabs shall generally meet all the requirements of IS:
8183. Only machine made & machine stitched mattresses having uniform density &
thickness shall be used.
4.2.1.4 Preformed Snap-On rigid pipe sections conforming to IS 9842 shall be used for sizes
upto 350 NB. The density of these pipe sections shall be 140 kg/m3 minimum.
A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 7 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

4.2.1.5 Properties & specifications


Unless specifically mentioned otherwise all properties shall be tested per IS-3144.
3

1)

Bulk Density () - 120 kg/m upto 300 C for LRB mattresses.


140 kg/m3 above 3000C & for all preformed pipe sections

2)

Thermal Conductivity, k (IS - 3346)


Mean Temperature (0C)

50
100
150
200
250
300

4.2.2

k (mW / cm 0C)
= 120 kg/m3
0.43
0.52
0.62
0.73
0.84
0.95

= 140 kg/m3
0.43
0.52
0.62
0.70
0.85
1.00

3)

Sulphur content

0.6%

4)

Moisture content & Moisture Absorption -

2.0%

5)

6)

Shot Content :
500 microns size
250 microns size
Resin content

5% maximum
5% maximum
3.0%

7)
8)

Chloride content
Incombustibility

9)

Linear Shrinkage

< 20ppm
Incombustible with weight loss
of 5%.
2%.

10)

Recovery after Compression

Recovery shall be 90% after


compression of the material
upto75%.

Performed pipe sections


Curved Segments

200NB
> 200NB

Calcium Silicate:
Calcium Silicate block and pipe thermal insulation shall be composed principally of
hydrous Calcium Silicate reinforced with mineral fibres (except slagwool). The
specification shall conform to ASTM C533 type I upto 649 oC & type II above 649 oC to
871 oC.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 8 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

The physical requirement of bulk density, chloride content, thermal conductivity and pH
value of the material shall be as follows.
: 200 to 280 kg/m3
: 20ppm
: 10 ppm if used over stainless steel
: As per Code
: 7 to 10

Bulk density
Chloride content
Thermal conductivity
pH Value
5.0

WEATHER PROOFING

5.1

FOR FIBROUS MATERIAL (MINERAL WOOL)


Minimum cladding thickness (mm)
Type of eqpt.
Vertical storage tank &
vessel shells
Tank roofs & removable
covers
Sphere, Horizontal
vessel shell & heads,
vertical vessel heads
All piping

Aluminium

Stainless steel

Flat

Corrugated

Flat

Flat

Corrugated

0.71

0.8

0.6

0.4

1.22

0.8

0.6

0.4

0.71

0.8

0.6

0.4

0.71

0.8

0.5

0.4

0.56

Piping in Off sites

5.2

Galvanised steel

FOR CALCIUM SILICATE


For Calcium Silicate
For shell of vertical vessels, columns etc

0.56mm (24SWG) corrugated

Storage tanks & tank roofs

0.56mm (24SWG) corrugated

For all piping other than grade piping in offsite

0.56 mm (24SWG) flat

For Horton sphere & horizontal vessels shell &


heads, vertical vessel heads

0.56 mm (24SWG) flat

For removable covers

1.22 mm (18SWG) flat

For grade piping in offsite

0.56 mm (24SWG) flat

5.3

Unless otherwise specifically mentioned aluminium jacketing shall be used as


weatherproofing material. Aluminium material shall be with low copper content & shall
conform to ASTM B209 alloy 3003 H16 or IS:737 designation 31000 H3 for flat sheets &
H4 for corrugated sheets. Finishing material shall be coated on the inside surface (i.e.
the surface in contact with insulation material) with bitumen anticorrosive paint.

5.4

Stainless steel material (if required to be applied) shall be of SS-304 grade.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 9 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

6.0

ANCILLIARY MATERIALS

6.1

Insulation on stainless steel surfaces:


All insulated stainless steel surfaces shall be given following coating before insulation.

6.1.1

Stainless steel surfaces at temperature to 120O C


Primer
Finish coat

6.1.2

High build coal tar epoxy, polyamide cured 100-150 microns DFT
High build coal tar epoxy, polyamide cured 100-150 microns DFT

Stainless steel surfaces at temperature to 149O C


Primer
Finish coat

6.1.3

:
:

:
:

Phenolic epoxy, polyamide cured 100-150 microns DFT


Phenolic epoxy, polyamide cured 100-150 microns DFT

Aluminium foil for protection of stainless steel surfaces.


For stainless steel surfaces at temperature above 149O C a layer of 0.19mm (36 SWG)
thick aluminium foil shall be applied first on stainless steel surfaces to avoid direct
contact of insulation material with hot surface. Aluminium foil shall be as per ASTM B209
alloy 3003 H16 or IS:737 designation 31000, H3.Aluminium foil protection can also be
given in lieu of painting as described above . However vendor has to indicate clearly his
plans regarding the protection of SS surfaces at offer stage.

6.2

Securing Bands:

6.2.1

For securing fibrous insulation


Equipment type
Piping
Equipment
Vertical storage tanks
Horton spheres

6.2.2

Band size width x thickness


Aluminium
12 x 22 SWG
20 x 24 SWG
-

Stainless Steel
25 x 0.8mm

Galvanized steel
40 x 3mm
-

For securing cladding on fibrous insulation


Equipment type
Piping
Equipment
Vertical storage tanks
Spheres

A.2 Hot Insulation

Band size width x thickness


Aluminium
Stainless Steel
Galvanized steel
12 Wide x 24 SWG
20 Wide x 24 SWG
25 Wide x 24 SWG
25 Wide x 24 SWG

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

6.3

Page 10 of 38
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Self tapping screws:


Self tapping screws with aluminium sheeting shall be No. 8, 12mm long cadmium plated,
flat or pan headed complete with neoprene washers under the head.

6.4

Clips:
Valves, strainers & flanged joints requiring frequent removal shall be provided with
removable box type insulation cladding with snap on type quick release clips.

6.5

Hardware:
All steel nuts, bolts, screws, washers etc. shall be of commercial quality, hot dip or
electro galvanized.

6.6

Wire netting, Lacing & stitching wire:


Wire netting shall be 20mm mesh x 20 SWG galvanised steel wire.
Lacing & stitching wire shall be 20 SWG galvanised steel per IS-3150 or equivalent.

6.7

Overlap & Sealer:


Metal cladding overlap shall be 50mm on Longitudinal & circumferential joints conforming
to IS:14164.
Sealer is to be applied for scaling the overlapped joints. Sealing strips should be of
bituminised felt conforming to IS: 1322 grade 1 of minimum 25mm width.

6.8

Spacer Rings:
Spacer rings as per following specifications shall be supplied by the insulation contractor.

6.8.1

Spacers are used for providing framework on which metal sheeting used for protecting
the insulation is cladded. These rings shall be fabricated from 25 x 3mm MS flats. The
outside diameter of these rings shall be equivalent to the diameter of the pipes measured
over the insulation.

6.8.2

Spacer rings shall not be used for pipe sizes 80NB & below except where the insulation
thickness exceeds 50mm.

6.8.3

Spacers shall be provided with L shaped stays fabricated from same size of MS flats at
an interval of not more than 300mm along the circumference with a minimum of 3nos. &
at a pitch of not more than 1200mm along the length.6.8.4 Spacers shall be painted with
one coat of red oxide zinc chromate primer or heat resistant aluminium paint.

6.8.5

To minimize direct conduction of heat packing of 5mm thick asbestos mill board shall be
provided at the joints of stays & pipes and between stays & outer MS rings.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

7.0

Page 11 of 38
Rev. 0
Date: 09.09.2008

APPLICATION
The application methods given in this standard are general in nature. The contractor is
responsible for applying an insulation system, (strictly following the safety norms of site)
that will give satisfactory operational performance & the requirements given herein shall
be regarded as the acceptable minimum. The contractor shall carryout the work in
accordance with the best practice of insulation application, with minimum of waste &
debris and the final job shall have a neat & workmanlike appearance.

7.1

For fibrous material (Mineral wool):


Surface preparation
Prior to installing insulation/heat transfer putty, the contractor must remove all oil and dirt
from the surfaces to be insulated. Any occurrence of rust must be removed through wire
brushing.

7.1.1

Single Layer Insulation

7.1.1.1 Single layer Insulation shall be used up to 75mm thickness. For insulation, thickness over
75 mm, the insulation shall be applied in multiple layers.
7.1.1.2 Lightly resin bonded mineral wool mattresses shall be machine made, machine stitched
at shop (to a suitable size) and shall have galvanized wire netting on one side.
7.1.1.3 The stitched mattresses shall be wrapped over the surface to be insulated and ends
knitted with GI wire or wire hooks. The successive mattresses shall be applied over the
surface such that the joints are staggered and also the gap between the joints is kept as
small as possible.
7.1.1.4 The mounted mattresses shall be held in position by metal bands.
7.1.1.5 Finally the insulation shall be covered by metal weather- proofing of aluminium sheets.
The type and thickness of aluminium sheets shall be as per 5.1.
7.1.1.6 Metal weatherproofing shall be provided over the insulation with an overlap of 50mm
(minimum) at all lap joints.
7.1.1.7 All the overlap joints shall be sealed and secured with self tapping screws.
7.1.1.8 Metal weatherproofing applied to irregular surfaces shall be shaped to fit the contour of
insulation.
7.1.2

Double or Multilayer Insulation

7.1.2.1 The first layer shall be applied in the same manner as for single layer insulation.
7.1.2.2 After the installation of first layer, the second layer of stitched mattresses with joints
staggered shall be placed and ends knitted together. Care has to be taken that there are
minimum gaps. The second layer shall be held in position on the previous layer by metal
bands. This has to be continued (application of successive layers) till required thickness
is achieved.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

Page 12 of 38
Rev. 0
Date: 09.09.2008

7.1.2.3 Over the final layer of insulation weather protection of aluminium sheet shall be provided.
7.1.3

Pipes Bends, Elbows, Fittings, Flanges

7.1.3.1 Elbows, Bends and fittings:


The insulation to be built up on elbows and all other fittings shall be the same as for
adjoining pipe. Machine stitched mattresses from resin bonded mineral wool in suitable
sizes shall be fitted properly around the pipe fittings. These then will be held in position
by tie wire and steel bands, one at the centre and one at each end. Finally weather
protection of aluminium sheets shall be provided as described in 5.1.
7.1.3.2 Flanges
At flanges in pipelines, the normal run insulation shall be terminated such that the gap
between the flanges and insulation is equal to length of bolt plus 20mm. So that the
flange can be disconnected without damaging the insulation
The gap shall be packed with loose mineral wool and then the flange shall be insulated
with resin bonded machine stitched mattresses of same thickness as the adjoining pipe
and held in position by tie wire and metal bands. Finally, weather protection of aluminium
sheets shall be provided. The insulation of flange shall form a box structure (removable
type).
7.1.4

Mineral Wool Pipe Sections Insulation.

7.1.4.1 Performed pipe sections shall be installed in the same manner as the blanket insulation
except as follows:
Sectional pipe insulation shall be applied with all the joints butted together and shall
be secured with the bands.
7.1.5

Pumps and Compressors:


In general, pumps and compressors that require insulation shall be insulated with
removable metal boxes lined with flexible mineral wool mattresses, soundly adhered to
the metal body by an approved method. The thickness of insulation shall be as specified
for the connecting pipe work. The metal box shall be made in at least two pieces, no
piece weighing more than 30 kg secured by quick release toggle clips.

7.1.6

Man-way etc.

7.1.6.1 Man-way covers shall generally be insulated with removable metal boxes lined with
flexible mattress, soundly adhered to the metal box by an approved method. The
thickness of insulation shall be as required for the vessel. The metal box shall be made in
at least two pieces, no piece weighing more than 30 kg secured by quick release toggle
clips.
7.1.6.2 Where tell-tale holes are provided in branch reinforcement rings, a small weep pipe
should be fitted projecting clear of the insulation.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

7.1.7

Page 13 of 38
Rev. 0
Date: 09.09.2008

HOT PIPE INSULATION

7.1.7.1 Piping and equipment which is heat traced and insulated shall be covered with oversized
pipe insulation to include the tracer with a suitable heat transfer compound. The
standard grade heat transfer compound shall be soft, smooth, heavy mastic consisting of
graphite, selected filters, inhibitors and bonding vehicle. Heat transfer compound shall
have a proven performance record of at least five (5) years in local weather conditions.
8.0

INSPECTION, TESTING & MEASUREMENT OF WORK

8.1

Test certificates
Along with quotation contractor shall submit recent test certificates from recognised
laboratories for all the insulation material proposed to be used by him. The test
certificates shall cover all the properties given in the relevant IS Specifications or
applicable international standards, including the properties given below. Any quotation
without test certificates shall be liable for rejection.
a)
b)
c)
d)
e)
f)
g)
h)
I)
j)

8.2

K value at different temperatures up to 500 0C. for hot insulation material.


Max. temp. up to which the material can be used.
Sintering temperature.
Sulphur content.
Chloride content.
Shot content.
Fibre diameter
Water absorption & tendency to corrode metals.
Density of material.
Resin properties (chemical)

Inspection and Testing

8.2.1. The contractor shall carry out various tests as listed in technical specifications mentioned
herein but shall not be limited to this. All the tests either on the field or at outside
the
laboratories concerning the execution of work and supply of materials by the contractor
shall be carried by the contractor at his own cost. The owner / consultant shall have free
access to the manufacturing facility of the contractor for inspection / testing of material as
and when required.
8.2.2. The work is subject to inspection at all times by the Engineer-in-charge. The contractor
shall carry out all instruction given during inspection and shall ensure that the work is
being carried out according to the technical specification of this specification.
8.2.3. The contractor shall provide for purpose of inspection access ladders, lighting and
necessary instruments at his own cost.
8.2.4. Every batch of material supplied should be backed by test certificates for any or all of the
requirements specified. Results of inspection and tests shall be recorded by the
Contractor in the inspection reports, proforma of which shall be approved by the
Engineer-in-Charge. These reports as well as test certificates shall be submitted as part
of completion certificates.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

Page 14 of 38
Rev. 0
Date: 09.09.2008

8.2.5. Inspection and acceptance of the work shall not relieve the Contractor from any of his
responsibilities under this contract.
8.3

Measurement of work:

8.3.1. The Measurement of Insulation work shall be in general as per IS: 14164 except
otherwise specified.
8.3.2. Insulation over Tanks/Columns/Vessels/heat Exchangers and Equipments.
8.3.2.1 Measurements shall be taken in m2 over finished insulation surfaces in all cases.
8.3.2.2 No deduction shall be made for any area required to be left un-insulated the area of
which is equivalent to a circle of 600 mm in diameter or less.
8.3.2.3 Dished ends of vessels shall be considered as twice the projected circular area of the
dished end for the purpose of measurement.
8.4

Insulation over Piping

8.4.1

All measurements for piping shall be taken over the finished insulated surface in meters
(except for providing aluminium foil over SS/alloy steel piping), corrected to nearest
centimetres along the centre line of piping, through all fittings, insulated or otherwise,
such as valves, flanges, elbows, tees and reducers.

8.4.2

If the valves, flanges or other fittings are also insulated then, in addition to the lengths
being already covered under piping and ducting insulation as stipulated in 8.4.1, extra
measurement as prescribed below shall be allowed in linear meter of the connected
piping or ducting :
INSULATED FITTING

FOR SHEET METAL


FINISH

FOR OTHER
FINISHES

Valve/venturi/steam traps/strainers
including flanges and body (upto
300mm size)
Valve/venturi/steam traps/strainers
including flanges and body (for sizes
larger than 300mm)
Pair of flanges including orifice plate
and flanges

1.50m

1.40m

2.00m

1.90m

0.80m

0.60m

Bends and elbows

Twice the actual length, as measured along


the centre line of the piping or ducting.
Actual length of larger size (along the centre
line of piping)
2 (D1 + D2) where D1 & D2 are insulated
diameters of the two pipelines forming the tee

Reducer
Tees

A.2 Hot Insulation

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

Page 15 of 38
Rev. 0
Date: 09.09.2008

Note:
Measurements of all valves, flanges and other fittings shall be based on actual count and
then converted into equivalent lengths of connected piping, to arrive at the total
equivalent lengths of piping or ducting of various diameters. Fittings that connect two or
more different sizes of piping/ducting shall be counted as part of the larger size.
8.4.3

Steam traced and non-steam traced pipelines shall be normally specified and measured
separately. Steam traced pipelines with single or multiple traces shall also be normally
specified and measured separately, according to the number of tracers.

8.4.4

For steam traced pipe lines, which are specified and measured separately, only the dia.
of the main pipeline(s) shall be reckoned for measurement of insulation. No separate
measurement shall be made for insulation of the steam-traced line(s), which shall be
deemed to have been covered under the insulation of main pipe line.

8.4.5

In case of any special treatment to steam traced pipe lines, other than wrapping with wire
netting and/or lacing with GI/black annealed wire, to be carried out, such as application of
special heat conducting compounds or wrapping with aluminium foil, such special
treatment shall be measured separately.

8.4.6

For application of aluminium foil over SS piping and equipment prior to application of
insulation, the measurement shall be taken over finished aluminium foiled surface on
overall area basis.

8.5

Insulation of instruments shall be measured separately and the length covered by such
instruments which are not axial with the pipeline shall not be considered in the
measurement of the concerned piping insulation.

8.6

Inspection plugs, if any provided, in the insulation of pipeline or any equipment shall be
measured separately on number basis and no deduction shall be made on this account
from the overall measurement of insulation of concerned equipment or pipeline.

8.7

Measurement for removal of hot/cold insulation shall be on actual area basis without any
addition.

8.8

The mode of measurement for insulation work for piping above 20 dia shall be on overall
area basis based on actual measurement on finished insulated surface, without addition
of extra measurement in lieu of any fittings such as valves, flanges, tees, etc. This shall
also be applicable to all sizes and shapes of insulated ducts.

8.9

Guarantee
Contractor shall guarantee for the quality of Insulation material and other ancillary and
weather protection material. Contractor shall also guarantee for the service and
workmanship of application of insulation.

A.2 Hot Insulation

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

9.0

Page 16 of 38
Rev. 0
Date: 09.09.2008

CONTRACTORS OBLIGATIONS
Definition
For the purpose of this specification the Consultant shall refer to Jacobs and the
contractor shall refer to insulation contractor selected by the Client/Consultant to supply
and fix the Plant insulation.

9.1

The Contractor shall work in accordance with this specification, the Consultants
Insulation Purchase Specification (enquiry and/or order) and the Consultants site
regulations (sent with the insulation contract order) and any clients site rules as may be
applicable.

9.2

The contractor shall provide all materials, tools, site accommodation, transport service
and supervision necessary for the satisfactory completion of the insulation contract.

9.3

The contractor shall provide storage sheds to protect materials from the weather.

9.4

Special treatment coatings etc. shall be applied strictly in accordance with the procedure
laid down herein, and with the manufacturers (suppliers) instructions. Where the
manufacturers instructions conflict with this specification, the former shall take
precedence.

9.5

The contractor shall remove all oil, grease, loose scales and dirt from surfaces to be
insulated and shall ensure that all surfaces requiring insulation are clean and thoroughly
dry before applying any insulation.

9.6

The contractor shall cover all openings in vessels, towers and any other equipment to
prevent the entry of insulating materials and shall daily remove from job site all cartons,
wrappers and other debris.

9.7

Each days application of insulation is to be weather-proofed over night by either the final
protective coating or some form of temporary weather-proof covering.

9.8

Before starting site work the contractor and the Consultants site supervisor shall agree to
a detailed programme of work. Before the application of insulation, the contractor shall
check with the consultants site supervisor that the equipment or pipeline to be insulated
is available, i.e. all testing is completed.

9.9

Insulation of all flanges, valves etc., where required shall be left off until authorisation is
given by the Consultants site supervisor to carry out this work. In general this will be
done after lines or equipment has reached operating conditions and all joints have been
proven tight.

9.10

The contractor shall provide facilities to ensure that the materials can also be fitted under
bad weather conditions. Prior to fitting the finishing material, the contractor shall remove
and replace any wet insulation material.

9.11

Contractor shall specify make and type of all insulation sealing and coating materials to
be used. No insulating or ancillary material shall be used beyond its recommended
temperature usage range.

A.2 Hot Insulation

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 17 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

HEAT CONSERVATION INSULATION THICKNESS


INSULATION MATERIAL : RESIN BONDED MINERAL WOOL

OPERATING TEMPERATURE (0 C)
60
Pipe 
Size, in
NB
NB
1 NB
1 NB
1 NB
2 NB
2 NB
3 NB
4 NB
5 NB
6 NB
8 NB
10 NB
12 NB
14 NB
16 NB
18 NB
20 NB
24 NB
Flat
surface

A.2 Hot Insulation

25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25

100

25
25
25
25
25
25
25
25
25
30
30
30
30
30
30
30
30
30
30
30

150

30
30
30
30
40
40
40
40
40
40
40
50
50
50
50
50
50
50
50
50

200
250
300
350
400
INSULATION THICKNESS (mm)
50
50
50
50
50
50
60
60
60
60
60
70
70
80
80
80
80
80
80
80

60
60
60
60
70
70
80
80
80
90
90
100
100
100
100
100
100
100
100
100

80
80
90
90
90
90
100
100
110
110
110
120
120
140
140
140
140
140
140
140

90
90
90
100
100
100
120
120
120
140
140
140
140
160
160
160
160
160
160
160

100
100
100
110
110
120
140
140
140
140
140
160
160
160
180
180
180
180
180
180

450

110
110
110
120
120
140
140
140
160
160
160
180
180
180
180
200
200
200
200
200

500

120
120
120
140
140
140
160
160
160
180
180
180
200
200
200
200
220
220
220
220

550

120
120
140
140
140
160
160
160
180
200
200
200
220
220
220
220
240
240
240
240

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 18 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

HEAT CONSERVATION INSULATION THICKNESS


0

INSULATION MATERIAL : CALCIUM SILICATE WITH AMBIENT TEMPERATURE 35 C AND NO WIND


0

A.2 Hot Insulation

650-704

705-760

761-815

594-649

539-593

428-538

316-427

205-315

40

40

50

80

90

90

100

100

115

115

40
40
40
50
50
50
50
50
50
65
65
65
65
65
65

40
50
50
50
65
65
65
65
65
80
80
80
80
80
80

50
65
65
80
80
80
90
90
90
90
90
90
90
90
100

80
90
90
90
100
100
100
115
115
115
115
115
115
115
130

90
90
100
100
115
115
130
130
130
140
140
140
140
140
150

90
100
100
115
115
130
140
140
140
140
140
150
150
150
165

100
100
115
115
130
130
140
150
150
150
150
150
150
150
180

100
115
130
130
140
140
150
150
150
150
150
165
165
165
180

115
130
140
140
150
150
165
165
165
180
180
180
180
190
200

130
140
150
150
165
180
180
180
190
190
190
200
200
200
200

20-149
Pipe  Size,
in
1 &
SMALLER
2 NB
3 NB
4 NB
6 NB
8 NB
10 NB
12 NB
14 NB
16 NB
18 NB
20 NB
24 NB
30 NB
36 NB
> 36 to FLAT

150-204

OPERATING TEMPERATURE ( C)

INSULATION THICKNESS (mm)

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 19 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

PERSONNEL PROTECTION INSULATION THICKNESS


INSULATION MATERIAL : RESIN BONDED MINERAL WOOL

OPERATING TEMPERATURE (0 C)
80
to
93
Pipe

Size, in
1 NB
1 NB
2 NB
3 NB
4 NB
6 NB
8 NB
10 NB
12 NB
14 NB
16 NB
18 NB
20 NB
22 NB
24 NB
Flat surface

A.2 Hot Insulation

25
25
25
25
25
25
25
25
25
25
25
25
25
25
40
40

94
to
149

25
25
25
25
25
25
25
25
25
25
25
25
25
25
40
40

159
205
261
317
372 to
to
to
to
to
427
204
260
316
371
INSULATION THICKNESS (mm)
25
25
25
25
25
25
25
25
25
25
25
25
25
25
40
40

25
25
25
25
25
25
25
40
40
40
40
40
40
40
40
40

25
40
40
40
40
40
40
40
40
40
40
40
40
50
50
50

40
40
40
40
40
50
50
50
50
50
50
50
50
50
65
65

40
50
50
50
50
50
50
65
65
65
65
65
65
80
80
80

428 to
482

50
50
50
65
65
65
65
80
80
80
80
80
80
95
95
95

483 to
530

50
65
65
65
65
80
80
95
95
95
95
95
95
95
100
100

HPCL-MUMBAI

STANDARD SPECIFICATION FOR

44LK-5100

Page 20 of 38
Rev. 0
Date: 09.09.2008

HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

PERSONNEL PROTECTION INSULATION THICKNESS


0

INSULATION MATERIAL : CALCIUM SILICATE WITH AMBIENT TEMPERATURE 35 C AND NO WIND


0

A.2 Hot Insulation

705-760

761-815

594-649

539-593

428-538

316-427

205-315

650-704

Pipe  Size,
in
1 & Smaller
2 NB
3 NB
4 NB
6 NB
8 NB
10 NB
12 NB
14 NB
16 NB
18 NB
20 NB
24 NB
30 NB
36 NB
> 36 to FLAT

150-204

20-149

OPERATING TEMPERATURE ( C)

100
100
115
130
130
140
140
150
150
150
150
150
165
165
165
165

115
115
130
130
140
150
150
165
165
165
165
180
180
180
190
190

115
130
130
150
165
180
180
180
190
190
190
200
200
200
200
200

INSULATION THICKNESS (mm)


25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25

25
25
40
40
40
40
40
40
40
40
40
40
40
40
40
40

40
50
50
50
50
50
50
50
50
50
65
65
65
65
65
65

65
65
65
65
80
80
80
80
80
80
80
90
90
90
90
90

80
80
90
90
90
100
100
100
100
100
115
115
115
115
115
115

90
90
90
100
100
115
115
115
115
130
130
130
130
130
140
140

90
100
100
115
115
130
130
130
140
140
140
140
140
150
150
150

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 21 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 22 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 23 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 24 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 25 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 26 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 27 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 28 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 29 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 30 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 31 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 32 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 33 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 34 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 35 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 36 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 37 of 38
Rev. 0
Date: 09.09.2008

HPCL-MUMBAI
44LK-5100

STANDARD SPECIFICATION FOR


HOT INSULATION
DOC.NO. 44LK-5100-00-V.02-0003-A4

A.2 Hot Insulation

Page 38 of 38
Rev. 0
Date: 09.09.2008