Professional Documents
Culture Documents
CONTENT
1. CONTENT 1
2. DISTRIBUTION LIST 2
3. GENERAL
3.1 Introduction 3
3.2 Scope 3
3.3 Definitions 4
5 APPLICATION PROCEDURE
5.1 Standard procedure for 17
installation of insulation
5.2 Insulation procedure for 20
specific cases
5.3 Insulation procedure for Austenitic 24
stainless steel surfaces
5.4 Application of Calcium Silicate 25
Insulation
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SECTION - 2
DISTRIBUTION LIST
COPY NO ISSUED TO
1. DGM (MAINTENANCE)
2. DGM (PROJECTS)
3. DGM (TECH)
4. DGM (E&C)
5. DGM (CPO)
6. DGM (MANUFACTURING)
7. GM (OPS)
8. GM (TECH)
9. CHIEF MANAGER - ADVISORY SERVICES
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SECTION - 3
GENERAL
3.1 INTRODUCTION
The need for efficient thermal insulation has become more important with
increasing energy costs & higher operating temperatures. Liquids lose their
heat energy through metal surfaces in which they are contained or flowing.
As this heat loss amounts to the loss of energy, methods to minimise
these losses need attention. The prevention of heat leakage/loss can be
achieved by judicious application and maintenance of thermal insulation.
3.2 SCOPE
This Engineering Manual covers the Design and Material requirements for
above ground , external insulation for Piping, Equipment and Storage Tanks
operating between ambient temperature and 760 0C in normal process plant
atmosphere in BPCL / NRL / BORL. It also describes the methods of
Application of insulation on Piping, Equipment & Storage Tanks. In this
manual , unless otherwise stated the term insulation shall mean hot
insulation.
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Cold insulation and insulation by refractories have not been covered in this
manual .
BPCL specification no. AE-S-3611 Rev.3 and AE-S-3613 Rev. 4 shall be used
for procurement of insulation at BPCL / NRL / BORL, and shall continue to
be guiding factor. This Engineering manual is intended to cover all technical
aspects of standard as an explanation and reference only.
3.3 DEFINITIONS :
v. Vapour barrier :
Material used to restrict the transmission of vapour, generally water
vapour.
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vi. Thermal conductivity :
The quantity of heat flow per unit time (in the steady state) through
one square centimetre cross-section of an infinite piece of material, when
the temperature difference between two planes normal to thermal flux
and one centimetre apart is one degree unit.
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SECTION - 4
Out of the above four areas, the first three areas are discussed in this section
while Application Technique has been discussed in Section - 5.
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For application at location with service temperature below 125 0C,
chemically treated water repellent category insulation must only be used.
Calcium Silicate
Calcium Silicate is good for high temperature service , for fire protection and
in areas of high maintenance traffic. Calcium Silicate shall be used for
temperatures above 125 0C to ensure that it remains moisture free. In any
isolated case of application at location with service temperature below 125
0C, chemically treated water repellent category insulation must only be
used.
The main advantages of Calcium Silicate Blocks are longer life due to high
mechanical strength and resistance to vibrations. Presently these are used in
a limited way as Refractory Material (rather than Insulation) in Furnaces and
Boilers due to difficulty in handling and site erection.
Ceramic Fibres
Ceramic fibres are made by spinning or blown process by making fibres out
of molten Aluminium Oxide and Silica (Ceramic). They can be pressed into
a blanket. They are suitable for use at comparatively higher temperatures.
The maximum operating temperature depends on density and composition
of the fibres. They are suitable for the intended operational temperature
range from 551 to 760 0C. Ceramic fibres have excellent heat resistance
upto this temperature. Also the thermal conductivity is lower than
mineral wool at higher temperatures. They have better integrity and
enhanced life compared to mineral wools.
Asbestos
1. The figures in Table- 1 are based on data collected from vendors for the
materials currently available in the market. The figures are indicative and
shall not be taken as standard figures.
2. The figures for maximum operating temperatures listed below are indicative
and the same may be reduced based on the density and composition of the
Insulation material. Also the same may be reduced due to chemicals in the
insulation environment. e.g. ceramic fibre may be affected by some alkalis.
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4.3 CORROSION CONSIDERATIONS
Corrosion under wet thermal insulation is a serious and costly problem and
hence it needs specific attention . The corrosion of carbon steel under wet
thermal insulation is non uniform general attack or highly localised pitting
or both. On austenitic stainless steel , it is pitting or the more serious
Chloride Stress Corrosion Cracking . The problem can be controlled by use
of suitable Insulation Materials confirming to BPCL specification no.
AE-S-3611 Rev. 3 and AE-S-3613 Rev. 4 . The parameters viz. Shot content,
Moisture content and Moisture absorption, Chloride content and Sulphur
content are particularly important. Following are the recommendations to
minimise the corrosion problem -
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18 SWG soft annealed galvanised steel. For rigid insulation such as
Calcium Silicate blocks 16 SWG annealed galvanised steel wire shall
be used.
A For Piping Band 24 SWG thick stainless steel x 12mm (min) wide.
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galvanised steel) shall be coated on the side in contact with the
insulation with a Bitumen anti-corrosive paint. Thickness of the
cladding shall be as mentioned below;
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Application Thickness for Thickness of
Aluminium cladding Stainless steel /
Aluminized steel
cladding
Removable covers 1.22mm (18 SWG) 1.22mm (18 SWG)
Flat Flat
OSBL (Outside 0.56mm (24 SWG) 0.46mm (26 SWG)
Battery Limit) and Flat Flat
Offsite piping.
Self Tapping screws are used for fixing outer Aluminium sheets and
joining two Aluminium sheets. These shall be Parker screws with no.
8 or no. 10 with length 1/2 or 3/4 (depending on application)
Exchangers All the heads shall be provided with one inspection window
each. Minimum two inspection windows shall be provided on the shell.
Columns & Vessels Heads shall be provided with one inspection window
each. One inspection window shall be provided at every platform. Minimum
two inspection windows shall be provided on shell portion.
Tanks One inspection window shall be provided at each course of the tank
and also at the top.
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4.5 CALCULATION OF HEAT LOSS AND ECONOMIC THICKNESS.
As these two factors are having reversing effect on each other, a break
even thickness has to be found, below which heat losses will be higher and
above which savings on heat loss may be offset by higher insulation cost.
This break even thickness is called "Optimum Economic Thickness".
Th - Tc
Q = ------------------------------------- -----------------------(I)
(d/2k) * log (d1/d) + (d/fd1)
Where
With the assumed value of Tc , the Heat Loss (Q) is calculated. Tc is then
calculated using following formula -
Q * d
Tc = Ta + --------------- ----------------------------------(II)
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f * d1
b) Based on the above quantities and latest price lists from manufacturers,
the cost of materials may be calculated.
The cost of providing insulation per mtr length as above may then be calculated
for different thickness of a given Insulation material and plotted against thickness
values.
The summation of Cost of Heat Loss and Cost of providing Insulation is the Total
Cost. The Total cost values can be tabulated and plotted for different thickness
for given Insulation material . The Thickness at which Total Cost in minimum is
the Economic Thickness.
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For given values of Th and Ta the same calculations for Total Cost can be repeated
for different Insulation materials and Economic thickness obtained for various
materials. The comparison of Total Cost figures will dictate the selection of
materials, if Economics is the sole consideration.
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TABLE -2
50 (2) 25 25 50 50 75 75
75 (3) 25 50 50 75 75 75
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SECTION 5
APPLICATION PROCEDURES
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For vertical pipelines, support rings shall be provided at 3.0 m spacing.
Support rings shall be provided only when the vertical height exceeds
3.0 m. For vertical pipes since support rings is being provided at interval of
every 3.0 m, hence only two spacer rings shall be provided in between the
support rings mainly at ends of elbow / flanges etc.
ii. All the joints (longitudinal & circumferential) shall have minimum 50
mm overlap after wrapping of outer cover sheet.
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iii. Sheet shall be fixed using self taping screws (also known as Parker
Screws). The Pitch between two screws on longitudinal joints of outer
cover sheet shall not exceed 150 mm and on circumferential joints shall
not exceed 200 mm. Parker screws may be locked against vibration
using synthetic resins.
viii. For tall columns and vertical pipelines, where extra strengthening to
outer cover sheets is required, SS bands shall be provided.
Vertical lines shall be fully covered with moisture barrier. For other
equipment the requirement of moisture barrier shall be decided on case to
case basis by the concerned Inspection Engineer.
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At junctions in the glass cloth , the overlap shall not be less than 75 mm. A
second coat of 3 mm mastic shall be applied after approximately 12 hrs. On
drying the coating shall be a minimum of 1.5 mm thick. Care must be taken
however to ensure that the individual coats are greater than 3 mm
(especially corners) otherwise some cracking of dried coat may result. The
mastic shall not be applied over wet insulation or until the adhesive is dry.
During the drying time , the Insulation shall be protected from the weather
by Alkathene film type tarpaulin or similar materials.
3. Thermowell bosses and pressure tappings shall not be insulated but left
accessible.
5. Equipment name plates shall remain visible after insulation has been
applied by bevelling back the insulating material and carefully sealing
the exposed edges to prevent ingress of moisture.
All the circumferential joints shall be closely fitted and the gap, if any, shall
be filled with insulating material.
All the vertical pipelines of 4 inch and above, shall have support ring
welded before hydrotesting of the line at every 3 metres and at the lowest
horizontal weld seam and above each flange . The ring on the pipe shall be
50 mm away from flange to pipe joint.
The insulation shall be fastened using 16 SWG galvanised steel wire and/or
strapping bands at intervals of 500 mm . The ends of the binding wire shall
be tightly twisted together, bent under and pressed into the surface of
insulation. Strapping bands shall be crimped suitably.
The blankets, cut to adequate size, shall be applied with the galvanised
chicken wire netting on the outside and be fastened into position with
strapping band as mentioned earlier or galvanised wire of 18 SWG at 250mm
interval or may be fastened helically. The chicken wire mesh shall be
stitched on to one side of insulation blankets with 22 SWG annealed
galvanised wire.
All the vertical pipelines of 4 inch and above, shall have support ring
welded before hydrotesting on the line at every 3 metres as described in
5.2.1.
On horizontal lines, loose support rings with stays of carbon steel shall be
attached to the pipe at intervals of about 900 mm to support the
aluminium sheets and to prevent sagging of the insulation.
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The Insulation shall be covered with aluminium sheeting as detailed in 5.1.4
In case of valves, the stuffing box shall be kept outside to replace the
packing without damaging insulation.
Pipeline used for gases and steam service shall have 1 no. 1/2 Inch NB vent
and drain at the flanged joints in insulation. Vent shall be fitted with elbow
to avoid ingress of rain water.
The steam tracing that are used with main lines shall be held in position
using galvanised steel strap bands of size 25 mm x 18 SWG at 600 mm pitch.
The pipe and steam tracer shall then be wrapped with a galvanised hex
chicken wire mesh 20mm / 25mm x 22 SWG and bound with 18 SWG GI
wire at 300 mm pitch.
The insulating material, cut to adequate size, shall be provided with the
galvanised chicken wire netting on the outside. An outer insulating cover
shall be then provided and suitably fastened.
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Special care shall be taken to ensure that insulation material do not get
embedded between the pipe and steam tracing . The section of the steam
tracer that is not required to be in touch with main line shall be wrapped
using 25 mm dia. asbestos rope. The winding shall be tight with no gap.
The grooves and notches shall be filled with quick setting plaster. After
drying of plaster, bituminous weather proofing coat shall be applied. It is
recommended that complete steam tracing line shall be insulated using glass
wool if it is open to severe weather conditions.
The insulation blankets, cut to adequate size, shall be applied with the
galvanised chicken wire netting on the outside. The chicken wire mesh shall
be stitched on to one side of insulation blankets with 18 SWG
annealed galvanised wire. Each layer of insulation on shell of equipment
shall be secured by bands .
The insulation shall be applied on the shell, top and bottom in similar
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manner as described for horizontal equipment.
Support skirt of insulated vertical vessel greater than 1200 mm dia shall be
insulated both internally and externally for a minimum distance of 600 mm
below the tangent line . The insulation shall terminate not less than 300 mm
above support concrete or steel work.
3. For operating temperatures above 450 0C , the stainless steel surfaces shall
be painted with 2 coats of heat resistant silicone based aluminium paint
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with DFT of 20 microns minimum per coat.
Calcium Silicate may be applied in the form of flat blocks, bevelled lags, pipe
sections or curved segments depending on the Piping or Equipment to be
insulated. The standard sizes, thickness and dimensional tolerance of
preformed blocks shall be in accordance with IS 8154/ IS 9428 . Curved
segments shall be used for curved surface having external radius greater than
110 mm. Hollow cylindrical shapes split in half lengthwise in a plane including
the cylindrical axis shall be used for pipes upto 14 inch size. Pieces of Insulation
with crushed or damaged ends shall not be used. Pipe sections bored or
machined out shall not be used .
For vessels installed with Calcium Silicate insulation and operating at high
temperature special care shall be taken. Calcium Silicate insulation shall be
installed in bevelled or curved segments only , to avoid voids and provide an
efficient insulation system. For equipment upto 3000 mm in diameter and
200 0C , to take care of equipment circumferential expansion , the
circumferential block is cut and fitted to be 13 mm greater in circumference
than the equipment and secured so that tension of the bands produces
compression on the butt edges rather than on the surface towards the vessel .
The little annular space and the compressiveness of the blocks would suffice to
take care of circumferential expansion of equipment.
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SECTION - 6
Inspection of insulation plays a vital role to obtain desired results out of it.
Inspection will guarantee that the work is carried out according to laid
down norms/procedures and desired quality obtained.
All the materials used for insulation shall be inspected and checked for their
conformance to the above requirements by the manufacturers.
Manufacturers Quality Assurance Certificate must be submitted to BPCL
Inspection for every batch of insulation material received at site. BPCL
Inspection department shall review the test certificates before acceptance of
materials. If need is felt by BPCL inspection , BPCL shall have a right to
inspect any or all the tests conducted on insulation material by
manufacturer at his shop or any laboratory.
Only qualified welders and approved welding procedures shall be used for
welding of lugs. Care shall be taken not to induce any injurious defects on
the equipment during welding. Welding shall be offered to BPCL for visual
inspection.
Inspection of outer Aluminium cover shall be carried out after fixing of the
same on the insulated material. Following shall be checked :
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Sealing of Joint / Nozzles
All the seal joints as well as the sealing around nozzles and locations
where insulation ends shall be inspected and ensured that proper sealing is
achieved.
a. If insulation has been provided with inspection windows the cover from
inspection windows shall be opened, insulation material removed and the
surface underneath inspected for paint failure, corrosion, etc. In case of
continuous insulation outer aluminium cover sheets shall be removed at
random locations which are prone to deterioration/corrosion. The
insulation material shall be removed and the surface underneath shall be
inspected for paint failure or corrosion.
At few locations, insulation thickness may have come down due to service
over the years. In such cases, insulation thickness could be built up using
fresh required extra thickness insulation material.
OR
Zinc Dust Graphite Paint (Temperature 2 x 30 Brush
Resistance : 450 0C )
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B) Painting Systems Using Manual Cleaning To St 2 OR Power Tool Cleaning
To St 3 As Surface Preparation.
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Recoatability : 24 hours.
Full cure : 5 days.
Shelf life : 12 months
dry heat : up to 200deg c
Colour : Black
Finish : Matt
Type : Single pack
Application : Brush
Volume solids : 40 2 %
DFT : 30-40 microns
Area Coverage (Theoretical) : 11-14 sq.m / litre
Surface dry : 4 hrs.
Hard dry : 48 hrs.
Recoatability : 24 hrs.
Full cure : 48 hrs
Shelf life : 12 months
Temperature Resistance : 200 0C
Colour : Grey
Finish : Matt
Application : Brush / Spray
Zinc dust : 31 2 % by wt.
Graphite : 24 2 %
Volume Solids : 40 2 %
DFT : 40-45 microns
Area Coverage (Theoretical) : 10-11 sq.m /litre
Surface dry : 12 hrs.
Hard dry : 12-14 hrs.
Recoatability : after 12 hrs. before 16 hrs.
Full cure : 18 hrs
Shelf life : 6 months.
Temperature Resistance : 450 0C
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