PROJECT TITLE

HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 1/22 REV. A

Procedure for Insulation work at Hawiyah Gas Plant

CONTRACT NO.: 6600041164 (IK)

BI/JO NO.: 10-02145
CONSTRUCTION CONTRACTOR: SNAMPROGETTI SAUDI ARABIA CO. LTD. (SAIPEM)

1: Approved 4: Not Applicable

CONTRACTOR
2: Approved with comments 4:
Review result by
3: Rejected
Department Date Name Designation Signature

Technical Discipline 1 2 3 4

Field Engineering Dept. 1 2 3 4

HSE Dept. 1 2 3 4

QA/QC Dept. 1 2 3 4

1: Approved 4: Not Applicable

2: Approved with comments 5: Revise & Re-submit
COMPANY 3: Rejected
Review result by Date Name Signature
1 2 3 4 5

Alwin Joy Nabil Balbale Faisal B /

D IFA 01-06-20 IFA Vikash K

Designation
QA/QC QHSE/Projects
QC Engineer
Manager Manager
Revision
REV Status Date Issued By Checked By Approved by
Memo
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 2/22 REV. A

TABLE OF CONTENTS

1.0 SCOPE OF WORK………………………………………………………………. 3

2.0 DEFINATION……………………………………………………..………………. 3
..
REFERENCES……………………………………………………………………
3.0 3
.
4.0 DESIGN…………………………………………………………………………… 5
5.0 RESPONSIBILITIES…………………………………………………………… 7
6.0 GENERAL REQUIREMENTS………………………………………………. 7
7.0 INSULATION APPLICATION……………………….................................. 8
7.1 HOT INSULATION APPLICATION………………………………………….. 8
7.2 JACKETING APPLICATION (HOT INSULATION) …..…………………... 9
7.3 COLD INSULATION APPLICATION………………………………………… 11
7.4 CONTRACTION JOINTS……………………………………………………... 12
7.5 VAPOR BARRIER APPLICATION…………………………………………... 12
7.6 JACKETING APPLICATION (COLD INSULATION) ……………………… 12
7.7 PERSONNEL PROTECTION INSULATION APPLICATION…………….. 14
7.8 INSPECTION PLUG REQUIREMENTS……………………………………. 14
7.9 COLD CONSERVATION & ACOUSTIC CONTROL INSULATION……... 15
7.10 ACOUSTIC CONTROL INSULATION………………………………………. 16
7.11 ACOUSTIC INSULATION JACKETING…………………………………….. 16
8.0 INSULATION DETAILS……………………………….................................. 18
9.0 INSULATION INSTALLATION REQUIREMENTS…………...................... 18
10.0 INSULATION MATERIAL.……………………………………...................... 18
11.0 MATERIAL HANDLING & STORAGE………………………....................... 21
12.0 ADDITIONAL REQUREMENTS………………………………..................... 21
13.0 PROTECTION OF INSTALLED INSULATION………….…....................... 22
14.0 DAMAGE CONSIDERATIONS…………………………….…...................... 22
15.0 GENERAL HOUSEKEEPING…………………………………..................... 22
16.0 ATTACHMENTS………………………………………………........................ 22
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 3/22 REV. A

1.0 SCOPE OF WORK

This specification covers the minimum mandatory requirement governing the design and
insulation of industrial insulation activity for piping and equipment for HAWIYAH GAS
PLANT EXPANSION PROJECT

2.0 DEFINATION:
Company Saudi Aramco
Contractor The agreement entered between Saipem and RBH for the project
Subcontractor Altrad RB Hilton SA ltd

IH Hot Insulation
PP Personnel protection
IC Cold Insulation
ET Electrical Tracing
ST Steam Tracing
SJ Steam Jacketed
AI Acoustic Insulation

3.0 REFERENCES:
The following reference specifications and standards are to be regarded as integral part of this
project specification:

BE-744722 - Project Specification for Industrial Insulation

3.1 Saudi Aramco Engineering Standards

SAES-A-105 Noise Control (Edition 7 April 2015)

SAES-N-001 Basic criteria, Industrial Insulation (Edition 16 January 2014).

AA-036911-000 Standard Details of Insulation for Hot Lines.

AA-036912-001 Insulation Details for Hot Vessel (for Vertical Vessels).

AA-036913-001 Insulation Details for Cold Piping.

AA-036913-002 Insulation Details for Cold Vessels.

3.2 Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering
Requirement (Edition 15 February 2016).
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HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 4/22 REV. A

3.3 Saudi Aramco Typical Inspection Plan

SATIP-N-001-01 - Cold Service Insulation

SATIP-N-001-02 - Hot Service Insulation

3.4 Process Industry Practice

PIP INEG 1000 Insulation Design and Guide

PIP INEG 2000 Guidelines for Use of Insulation Practices

PIP INIC 1000 Cold Insulation Installation Details

PIP INIH 1000 Hot Insulation Installation Details

PIP INSC 1000 Cold Service Insulation Materials and Installation Specification

PIP INSC2000 Installation of Cold Service Insulation Systems

PIP INSH 1000 Hot Service Insulation Materials and Installation Specification

PIP INSH 2000 Installation of Hot Service Insulation Systems

PIP INSR 1000 Installation of Flexible, Removable/Reusable Insulation Covers for Hot Insulation
Service

PIP INTG 1000 Insulation Inspection Checklist

3.5 International Organization for Standardization (ISO)

ISO 15665 Acoustics – Acoustic Insulation for Pipes, Valves and Flanges (First Edition-2003)

3.6 American Society of Testing and Materials (ASTM)

ASTM A167 Specification for Stainless and Heat Resisting Chromium Nickel Steel Plate, Sheet
and Strip

ASTM B209 Specification for Aluminium and Aluminium-Alloy Sheet and Plate

ASTM A463M Specification for Aluminized Sheet and Plate

ASTM C195 Specification for Mineral Fiber Thermal Insulating Cement

ASTM C449 Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating Cement

ASTM C450 Fabrication of Thermal Insulating Fitting Covers for NPS Piping, and Vessel
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 5/22 REV. A

Lagging

ASTM C534 Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in
Sheet and Tubular Form

ASTM C547 Specification for Mineral Fiber Pipe Insulation

ASTM C552 Specification of Cellular Glass Block and Pipe Thermal Insulation

ASTM C592 Specification for Mineral Fiber Block and Blanket-Type Pipe Insulation

ASTM C612 Specification for Mineral Fiber Block and Board Thermal Insulation

ASTM C692 Method for Evaluating the Influence of Thermal Insulations on the External Stress
Corrosion Cracking Tendency of Austenitic Stainless Steel

ASTM C764 Specification for Mineral Fiber Loose Fill Thermal Insulation

ASTM C795 Specification for Thermal Insulation for Use in Contact with Austenitic Stainless
Steel

ASTM C871 Methods for Chemical Analysis of Thermal Insulation Materials for Leachable
Chloride, Fluoride, Silicate and Sodium Ions

ASTM C929 Practice for Handling, Transporting, Shipping, Storage, Receiving, and Application
of Thermal Insulating Materials to be used over Austenitic Stainless Steel

ASTM E84 Test Method for Surface Burning Characteristics of Building Materials

ASTM E96 Test Method for Water Vapor Transmission of Materials

4.0 DESIGN

Insulation codes and classification

Insulation codes shall be used on P&ID, data sheets, piping isometrics, and other project
documents the following codes shall apply

4.1 Hot Insulation

Piping and equipment shall be insulated for energy conservation, in hot service, when the
normal operating fluid temperature is above average annual temperature and heat loss
limitation is required.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 6/22 REV. A

4.2 Cold Insulation

Piping and equipment shall be insulated for cold conservation (CC) when the normal
operating fluid temperature is below than yearly average daily max. temperature (99°F /
37.2°C) and heat gain limitation is needed. Insulation systems that operate below the
ambient dew-point temperature must be protected from the inward permeation of moisture.

The control of moisture penetration in low-temperature systems is required to prevent

condensation or the formation of ice inside the insulation or on the surface of insulated item.
This control is accomplished by designing an insulation system that includes a closed cells
insulation material (e.g. cellular glass), a vapor barrier with a low permeation rating and an
appropriate jacket with moisture resistant caulking at all joints and penetrations.

4.3 Acoustic Insulation

The symbols used on drawings and P&IDs to indicate the class of acoustic insulation
required shall be comprehensive of the code AC (Acoustic Control) insulation followed by
the second character to identify the class of sound absorption defined by ISO 15665:2003,
namely AC1 (Acoustic Control Class A), AC2 (Acoustic Control Class B) or AC3 (Acoustic
Control Class C). In case of class C, acoustic insulation shall cover all piping components
(valve and flanges included).

Acoustic insulation shall be comply with noise control level requirements mentioned in
SAES-A-105 and SAEP-371.

Acoustic insulation shall be designed in accordance with the criteria and material
characteristics prescribed by ISO 15665:2003 reference standard.

4.4 Personnel Protection (PP & MS)

All accessible piping and equipment operating at temperature above 60°C / 140°F (PP) not
provided with other type of insulation, shall be guarded for personnel protection purpose.
Personnel Protection in hot service with service temperature between 60°C / 140°F and
175°C / 347°F shall be covered by Guard Mesh and all details are described.

Insulation (or guard mesh) for personnel protection shall extend within 910mm horizontally
and to a height of 2133mm above any area that is routinely used as work space or access
way by operational personnel.

Personnel protection in hot service is provided by means of metal shields (or metal guards)
and it shall be designated with the insulation code (class) MS. Metal shields (or guards) for
personnel protection will be selected only for piping in intermittent service and designated
equipment, when thermal or acoustic insulation would not otherwise be required.

Metal shields (or guards) for personnel protection should be selected for piping and
equipment in continuous service temperatures between 60 and 175°C, or in cyclic service
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 7/22 REV. A

crossing such service temperature range, on metal substrates subjected to high risk of CUI
(Corrosion Under Insulation), when thermal or acoustic insulation would not be required.

Metal shields (or guards) will be selected on items where personnel protection is to be
provided but the items is designated to dissipate heat.

Metal shields (or metal guards) for personnel protection purpose shall be provided to
910mm horizontally and to a height of 2.13m above any area that is routinely used as
workspace or access way (e.g. from periphery of platforms, walkways or ladders, etc.).

4.5 Insulation for Traced Line

Lines that are identified Electrical Traced (ET) or Steam Traced (ST) on drawings and on
P&IDs shall be insulated to minimize heat loss and to avoid process disruption or
solidification.

5.0 REPONSIBILITIES
5.1 Insulation Superintendent/Supervisor

Ensure full compliance by all insulation foremen, insulation erectors, and labors regarding
the execution of the work in accordance with manufacturer recommendation and project
requirements and specifications. Confirm the availability of all material, tools, equipment and
competent persons to perform the work. Ensure compliance by all labors, equipment
operators and craftsmen associated with the execution of insulation works to the
requirements of this procedure, project quality control procedure, relevant drawings, safety
procedure, and project specifications Secure all necessary work permits.

5.2 Quality control inspector

Conduct inspection in accordance with procedure and QCIP. Monitor daily insulating
activities and verify strict compliance to the project requirements, specifications, and
manufacturer recommendations. Prepare daily observation records and final acceptance
documentation where required.

5.3 Safety Supervisor

Monitor the work areas of unsafe conditions. Ensure that all safety requirements are
adequately addressed, and the work is being carried out safely in accordance with HSSE
safety procedures. Ensure that material safety data sheets are available at site.

6.0 GENERAL REQUIREMENTS

6.1 All materials shall be stored, mixed, thinned, and applied in accordance with the
manufacturer's printed instructions. All conflicts between this specification and the
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 8/22 REV. A

manufacturer's instructions shall be brought to the attention of the Purchaser for resolution.
6.2 Authorization to proceed with application of insulation shall be obtained in writing from the
Purchaser.
6.3 Unless otherwise specified, insulation shall not be applied until completion of the following
has been verified:
6.3.1 Required hydrostatic and/or pneumatic pressure testing
6.3.2 Application of required substrate protective coating systems, including touch-up of
previously applied coatings
6.3.3 Installation and testing of required tracing systems
6.3.4 Cleaning of surfaces that are to receive insulation
6.4 If required by the Purchaser, application of insulation may proceed before pressure testing
is complete, provided that all welds and flanged and threaded connections are left
exposed until the pressure testing is complete. Temporary terminations of installed
insulation shall be adequately protected at all times.
6.5 Where insulation has been specified on piping or equipment flanges that are to be hot
bolted, the insulation shall not be installed until hot bolting has been accomplished and the
flange determined to be leak-free.
6.6 Unless otherwise specified, all insulation materials shall be installed in a single layer when
the total thickness does not exceed 3 in. (75 mm).
6.7 When applying single layer insulation, other than hinged pipe covering, the circumferential
butt joints of each half section shall be staggered.
6.8 Thicknesses 3-1/2 in. (90 mm) and greater shall be applied in multi-layers with staggered
joints. Consideration shall be given to multi-layer insulation for operating temperatures
over 600°F (316°C).
6.9 When applying double or multi-layer insulation all longitudinal and circumferential joints
shall be staggered.
6.10 Each layer of double layer or multi-layer insulation shall be held in place separately.
6.11 At final inspection, all insulation is smooth and free from cracks, voids, gaps and
depression greater than 3mm should be refitted.

7.0 INSULATION APPLICATION

7.1 Hot Insulation Application

• Mineral wool pipe section (ASTM C547), Density = 128 Kg/m3 and Mineral wool blanket
with GI wire mesh (ASTM C592) type II or III, Density = 128 Kg/m3 shall be used for hot
insulation.

• Insulation thickness for piping and equipment in hot service shall be as specified in
specification BE744722 or the applicable isometric drawing.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 9/22 REV. A

• Insulation on piping up to NPS 6” shall be insulated with preformed pipe cover and piping
with NPS > 6” shall be insulated with Mineral wool blanket with wire mesh.

• Insulation layering, unless otherwise specified by the Purchaser, for piping and equipment
shall be applied as a multiple layer for operating temperature above 300°C.

• Circumferential butt joints of each half section shall be staggered in single layer insulation
and all longitudinal and circumferential joints shall be staggered in multi-layer insulation.

• Each layer of double-layer or multiple-layer insulation shall be held in place separately.

• Insulation on piping with 12” NPS shall be secured with 1.3mm Type SS304 tie wire, cut
ends of tie wire shall be embedded into the insulation.

• Insulation on piping and equipment diameter above 12” NPS and up to 24” NPS shall be
secured with 13mm wide by 0.5mm thick 304 type stainless steel bands and wing seals.

• Insulation for piping and equipment above 24” NPS shall be secured with 19mm wide by
0.5mm thick 304 type stainless steel bands and wing seals.

• Bands shall be tensioned and secured with wing-type seal fasteners.

• Insulation on pipes and equipment shall be banded at approximately 300mm maximum

spaced centers.

• Vertical pipe insulation shall be supported by a pipe insulation support located directly
above all elbow, flanges or flanged valves

• Maximum support ring spacing shall be 5m. for piping with temperatures below 315 deg C
and 3.65m above 315 deg C.

• Insulation on fittings, flange and valves shall be pre-fabricated.

• Flange and Valves shall be insulated with removable / reusable insulation covers.

• Clearance (Bolt length + 25MM) must be made for removal of flange bolt without disturbing
the fixed insulation.

• Code or nameplates on equipment shall not be covered by insulation and shall be

attached with extended brackets to give adequate clearance for full insulation thickness.

7.2 Jacketing Application (Hot insulation)

• Aluminum jacketing ASTM B209, ALLOY 3003M H-14 with polysurlyn moisture barrier
should be used as jacketing material in non-fire hazardous area.

• Except in Fire Classified Areas for which cladding shall be aluminized steel only.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 10/22 REV. A

• 0.6mm thk stucco embossed sheet with 1 1/4" corrugation for vertical equipment 48" and
larger diameter.

• 0.6mm thk stucco embossed sheet for horizontal equipment 48" and larger diameter.

• 0.5mm thk stucco embossed sheet for vessel less than 48" and all piping

• 0.5mm thk smooth and plain sheet for head segment, fittings and valve covers

• Aluminized Steel jacketing ASTM A463 Type 1 should be used as jacketing material for Fire
hazardous area.

• 0.45mm thk Aluminised jacket shall be used for piping & equipment upto 36” and 0.6mm thk
jacketing shall be used for equipment above 36”

• Corrugated aluminised jacketing shall be used for vertical equipment’s with diameter 48”
and above.

• Metal jacketing for equipment shall be overlapped by 50mm both longitudinally and
circumferentially.

• Metal jacketing for outer diameter up to 24” NPS shall be secured with 13mm wide by
0.5mm thick 304 type stainless steel bands and wing seals.

• Metal jacketing above 24” NPS shall be secured with 19mm wide by 0.5mm thick 304 type
stainless steel bands and wing seals.

• Jacketing on piping shall be banded at approximately 300mm maximum spaced centers.

• Jacketing on equipment shall be banded at approximately 450mm maximum spaced

centers.

• Securement of insulation over the heads of horizontal equipment and top head heads of
vertical equipment, using a floating ring made from 6mm diameter stainless steel rod. The
floating ring shall be placed in the center of the head and the girth rings made from two
bands shall be installed on the shell at approximately 150 mm from the tangent line of the
head. Band shall be run radially from the floating ring to the girth rings. The bands shall be
spaced at 300 mm maximum centers. Band shall be stainless steel type 304, 19 mm wide x
0.5 mm thick with matching seals.

• Metal jacketing over vertical pipe and vertical equipment shall be supported by S-clips
spaced at approximately 24" (610mm) or minimum of two (2) S-clips per sheet. These S & J
clips fabricated from 19 mm banding.

• The metal jacketing shall be secured with stainless steel bands using J-clips at 6ft (1.8m)
centers to prevent the bands from sliding down.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 11/22 REV. A

• Bands securing equipment insulation weather jacketing shall incorporate 4-inch (100-mm)
long, compression spring in accordance with Table 2 of PIP INSH 1000.

• All metal joints and protrusion must be caulked and or sealed for possible ingress of
moisture or water. For vertical vessel sealant, shall be applied only for longitudinal overlap
of metal cladding.

• Exposed edges of metal jacketing shall be bent or rolled to eliminate sharp edges.

7.3 Cold Insulation Application

• Cellular glass having density 115 kg/m3 shall be as base insulation material for cold
insulation.

• Piping and equipment, which is subject to either hydrostatic test or alternative tests shall not
be insulated until such tests, have been successfully completed.

• Contractor shall identify the areas to be insulated by issuing work release document.

• Insulation thickness for piping and equipment in cold service shall be as specified in
specification BE-744722 or the applicable isometric drawing.

• The insulation material on piping / equipment shall be applied in single layer for insulation
thickness upto 75mm. insulation thickness greater than 90mm shall be in multi-layer.

• Single layer insulation, the circumferential butt joints of each section shall be staggered.

• All insulation shall be smooth and free from cracks, voids, gaps and depressions greater
than 3mm. all crack, voids, gaps and depression in the insulation greater than 3mm shall be
refitted not filled.

• The circumferential and longitudinal joints of each section when applying insulation shall be
butted and staggered.

• Insulation on piping with 12” NPS shall be secured with 25mm filament tape.

• Insulation on piping and equipment diameter above 12” NPS and upto 24” NPS shall be
secured with 13mm wide by 0.5mm thick 304 type stainless steel bands and wing seals.

• Insulation for piping and equipment above 24” NPS shall be secured with 19mm wide by
0.5mm thick 304 type stainless steel bands and wing seals.

• Insulation on pipes and equipment shall be banded at approximately 300mm maximum

spaced centers.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

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• All circumferential and longitudinal insulation joints shall be sealed with sealant. Inner layer
shall be installed without any joint sealer. All joints of single layer and only outer layer of
multi-layer insulation shall be applied with joint sealer.

• Vapor stops that seal the insulation to the pipe or equipment shall be installed at all
insulation terminations. (applicable for Cold insulation CODE: CC)

• Installed insulation shall be applied with temporary protection at the end of shift if rain or
other forms of atmospheric moisture can damage the insulation.

7.4 Contraction Joints

• Contraction joints shall also be provided in uninterrupted straight pipe insulation when the
run length is equal to or greater than half of the following maximum allowed distance.

Operating Temperature (0C) Maximum Contraction Joints Spacing (m)

Carbon steel Stainless steel
0 to -18 89 67
-19 to -46 52 40
-47 to -73 n/a 28
-74 to -101 n/a 22
-102 to -129 n/a 18
-130 to -157 n/a 15
-158 to -184 n/a 13

• Insulation contraction joints shall be installed in all layers of multiple layer insulation and
shall be staggered between layers. Outer contraction joint shall be covered with a flexible
vapor seal / butyl tape.

• Contraction joints shall be filled with fiberglass blanket.

7.5 Vapor Barrier Application

• Before the application of weatherproof jacketing, all surfaces of installed insulation shall be
vapor sealed with membrane type vapor barrier sheet.

• Membrane type vapor barrier sheet shall be installed for strainght and shell sections without
fish mouthing gaps or folds and shall have a minimum 50-mm (2-in) overlap at all joints.

• Vapor barrier mastic and reinforcing fabric shall be applied as vapor barrier for compound
shape (e.g. flanges, valves, head etc)

7.6 Jacketing Application (Cold insulation)

• Aluminium jacketing ASTM B209, ALLOY 3003M H-14 with polysurlyn moisture barrier
should be used as jacketing material in non-fire hazardous area.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

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• 0.6mm thk stucco embossed sheet for horizontal equipment 48" and larger diameter.

• 0.5mm thk stucco embossed sheet for vessel less than 48" and all piping

• 0.5mm thk smooth and plain sheet for head segment, fittings and valve covers

• Aluminized Steel jacketing ASTM A463 Type 1 should be used as jacketing material for fire
hazardous area.

• 0.45mm thk Aluminised jacket shall be used for piping & equipment upto 36” and 0.6mm thk
jacketing shall be used for equipment above 36”

• The weather proof jacketing shall be applied over the vapor barrier.

• Corrugated metal jacketing shall not be used on Cold insulation

• The jacketing on piping and equipment shall be applied with a minimum 50mm overlap on
both longitudinally and circumferentially.

• The weatherproof jacketing for OD up to 24” NPS shall be held in place with 13mm x 0.5mm
thick SS 304 type bands. For OD larger than 24” NPS shall be held in place with 19mm x
0.5mm thick band. The spacing between bands shall be 300mm.

• Jacket bandings on vessels over 8ft (2.4m) in diameter shall have 4-inch (100mm) stainless
steel compression spring. Spring shall be located every 30ft (9.1m) of band length.

• Exposed edges of metal jacketing shall be machine-bent or rolled to eliminate sharp edges.

• Metal jacketing over vertical pipe and vertical equipment shall be supported by S-clips
spaced at approximately 24" (610mm) or minimum of two (2) S-clips per sheet.

• The metal jacketing shall be secured with stainless steel bands using J-clips at 6ft (1.8m)
centers fastened to the jacket to prevent the bands from sliding down.

• Securement of insulation over the heads of horizontal equipment and top head heads of
vertical equipment, using a floating ring made from 6mm diameter stainless steel rod. The
floating ring shall be placed in the center of the head and the girth rings made from two
bands shall be installed on the shell at approximately 150 mm from the tangent line of the
head. Band shall be run radially from the floating ring to the girth rings. The bands shall be
spaced at 300 mm maximum centers. Band shall be stainless steel type 304, 19 mm wide x
0.5 mm thick with matching seals.

• Metal joints and protrusions shall be caulked with sealant wherever there is chance of water
ingress.
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7.7 Personnel protection Insulation Application (PP & MS)

• All accessible piping and equipment operating at temperature above 60°C / 140°F (PP) not
provided with other type of insulation, shall be guarded for personnel protection purpose.

• Personnel Protection in hot service with service temperature between 60°C / 140°F and
175°C / 347°F shall be covered by Guard Mesh.

• Personnel protection shall be provided within normal working areas or access ways in an
extent of 0.9m horizontally from periphery of platform, walkway or platforms and a height of
2.1m above the grade or platform.

• Metal shields/guards should be as follow:

➢ Stand-off distances (from guarded surfaces) up to 100mm:
o SS 304 grade perforated (square holes) sheets, holes size 10mm x holes pitch 12mm,
sheet thickness 1.0mm OR
o SS 304 grade welded wire mesh sheets/rolls, mesh size = 1/2”x1/2” (13mmx13mm),
wire diameter 16 gauge (1.6mm)

➢ Stand-off distances (from guarded surfaces) above 100mm:

o SS 304 grade perforated (square holes) sheets, holes size 10mm x holes pitch 12mm,
sheet thickness 1.5mm OR
o SS 304 grade welded wire mesh sheets/rolls, mesh size = 1”x1” (25mmx25mm), wire
diameter 12 gauge (2.5mm)

• Metal shields shall meet the following stand-off distance:

NPS Operating Temperature, °C Guard Standoff Distance (mm)

< 1 ½” 30
2” to 6” 60 to 80 40
>6” 50
Equipment 50
< 1 ½” 40
2” to 6” 80 to 100 50
>6” 60

7.8 Inspection plug requirements

• Removable insulation plugs shall be provided to permit on-stream ultrasonic inspection
when required by the operating proponent. Plugs shall be vapor tight, ultra violet resistant
and be such that they can be opened and reclosed without disturbing the adjacent
insulation.

• Removable plugs, collars and inspection windows shall be provided to permit “on-site”
nondestructive ultrasonic thickness inspections. Number, location and dimensions for
inspection windows shall comply with Company standard requirements.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 15/22 REV. A

• Plugs, collars and windows shall be vapor tight, UV resistant and such that they can be
operated and reclosed.

• Plugs, collars and inspection windows shall not be located in flat areas subject to standing
water.

• Inspection plugs size detail:

➢ - 1.5” (38mm diameter) inspection plugs to be installed on <= 10” Diameter Piping
➢ - 2.5” (64mm diameter) inspection plugs to be installed on >= 12” Diameter Piping
➢ - 2.5” inspection plugs to be installed on Vessels and Equipment (shell, heads)
➢ - Inspection plugs on equipment nozzles shall be as per piping requirements.

7.9 Cold conservation & Acoustic control Insulation (CCA)

Material Layer
Armacell Arma-check R Flexible polymeric barrier, 2mm thick
Armacell Armafoam Barrier Mass loaded vinyl acoustic barrier.
Armacell Armafoam Sound 240 Open cell FEF insulation.
Armacell LT/Armaflex Closed cell FEF insulation.
Armacheck Mastic Sealant for armacheck R
Armaflex HT 625 Adhesive to bond FEF insulation
Cellular glass ASTM C552

• All joints in FEF insulation layers shall be adhesive bonded/sealed. Joints between layers
shall be staggered.

• Insulation termination, including those at flanges and valves, shall be sealed with a layer
(disc) of closed cell (thermal) FEF between the pipe and inside surface of closed cell
(thermal) FEF outer layer.

• All FEF insulation shall be finished with flexible polymeric barrier.

• On all lines designated to receive sound and thermal control insulation, the piping
expansion joints (bellows) if a part of the line, shall also be insulated for sound and thermal
control.

• Sound and thermal control insulation shall completely cover Pipe trunnions.

• Insulation layering shall be as indicated in Insulation thickness Table 5,6 & 7 of spec
BE744722.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 16/22 REV. A

7.10 Acoustic Control Insulation (AC1, AC2 & AC3)

• Insulation materials, weatherproofing, and accessories shall be in accordance with project
approved data sheet and client specifications.

• Client shall identify the areas to be insulated by issuing work release document with
applicable drawings.

• Piping erection drawings or assembly drawings will define the limit for extension of acoustic
insulation.

• Valve and flanges installed online caded AC1 and AC2 are not to be insulated.

• Pipe support clamps that extends outside the pipe insulation shall be fully insulated,
including insulation terminated on the hanger rod.

• Insulation shall be applied with tightly butted joints, using contact adhesive on all butt joint
surfaces.

• Insulation installed in two or more layers shall be staggered.

7.11 Acoustic Insulation Jacketing (AC1, AC2 & AC3)

• Projections through the jacketing shall be caulked with a liberal application of silicone
sealant, jacketing shall not make direct contact with projections.

• Jacketing and film barrier shall be retained by stainless steel bands. Screws shall not be
used as jacketing securement.

• Silicone sealant shall be applied between overlapped jacketing and film barrier surfaces to
provide continuous seal between laps.

• Example of minimum unitary mass (kg/m2) for jacketing to comply with class A, B or C shall
be as indicated below.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 17/22 REV. A

 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 18/22 REV. A

8.0 INSULATION DETAILS

8.1 Preformed insulation joints shall be in staggered arrangement. Multiple layer insulation
shall be in staggered arrangement at both the longitudinal and circumferential joints. Each
layer shall be secured.
8.2 Vessels and tanks shall be insulated with blanket or foam insulation.
8.3 Removable or flexible type insulation shall be used in areas where access for frequent
maintenance is necessary. The insulation shall be bonded to the removable cover.
8.4 All metallic protrusions through insulation systems shall be caulked with a sealant.

9.0 INSULATION INSTALLATION REQUIREMENT

9.1 Insulation support rings, pins, clips, studs, and accessories shall be of materials
compatible with the components to which they are attached, and if welded, shall be
installed by the fabricator prior to post-weld heat treatment unless specifically permitted
otherwise by the Saudi Aramco Engineer.
9.2 All equipment, vessels, and piping shall have been tested and inspected as required by
the relevant specification prior to the installation of insulation.
9.3 Nameplates shall not be insulated and shall be attached with extended brackets to give
adequate clearance for full insulation thickness.
9.4 Manufacturers' instructions and recommendations of insulation and vapor barrier
manufacturers shall be followed.

10.0 INSULATION MATERIALS

10.1 General

• Materials approved by Client shall be used for this project.

• The assistance of heavy equipment for loading and unloading of insulation material /
accessories on site shall be taken care by Client.

• When potential exposure to moisture or water is identified, insulations shall be covered

with polythene sheets tied with G.I. wire to protect from getting wet.

• Insulation material shall be 100% asbestos free.

10.2 Hot insulation materials

• Mineral Fibre preformed pipe sections in accordance with ASTM C547, type II, Density:
128kg/m3.

• Mineral Fibre blanket as per ASTM C592, type II, Density: 128kg/m3.
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 19/22 REV. A

• Metal sealant: All metal joints and protrusions must be caulked and sealed for possible
ingress of moisture or water. RTV silicone sealant, aluminum or grey color to be used as
metal sealant.

• Weatherproof Jacketing (Applicable for Hot & Cold Insulation as ARAMCO standard
drawing)

• 0.6 mm thick stucco Embossed jacketing with 1 ¼” Corrugation ASTM B209, Alloy 3003
H-14, with polysurlyn moisture barrier should be used as jacketing material for vertical
equipment’s.

• 0.6 mm thick stucco Embossed jacketing ASTM B209, Alloy 3003 H-14, with polysurlyn
moisture barrier should be used as jacketing material for horizontal equipment’s.

• 0.5 mm thick stucco Embossed jacketing ASTM B209, Alloy 3003 H-14, with polysurlyn
moisture barrier should be used as jacketing material for Vessel less than 48” and all
piping.

• 0.5mm thk smooth and plain sheet ASTM B209, Alloy 3003 H-14, with polysurlyn moisture
barrier for head segment, fittings and valve covers

• 0.45mm thk Aluminised jacket ASTM A463 Type 1 shall be used for piping & equipment
upto 36” and 0.6mm thk jacketing shall be used for equipment above 36”

• Stainless Steel Screws for hot insulation.

• Expansion Springs on external jacketing shall be compression type spring, 100mm long.

• Stainless Steel Bands and Wing Seals, Type 304

13mm x 0.5mm thk

19mm x 0.5mm thk

• Tie Wire, 1.6mm, Type 304 Stainless Steel

• Toggle Clips 2"

• Float ring shall be made from 6mm diameter Carbon steel rod.

• Support ring shall be fabricated from 30x3mm thk GI & SS flat bar.

10.3 Cold insulation materials

• The main insulation materials Cellular glass to be used for cold insulation in accordance
with ASTM C552 (Density 115 kg/m3).
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 20/22 REV. A

• Joint Sealant

Sealant to be applied on jacketing joint having possibility water ingress.

Properties:

Service Temperature: -171°C to 93°C

Single component off-white color.

• Vapor Stop

Vapor stops that seal the insulation to the pipe or equipment shall be installed at all
insulation terminations.

Properties:

Service Temperature : -196°C to 121°C

• Glass cloth:

Reinforcing membrane, leno weave synthetic fabric.

• Vapor barrier:

Self-adhesive membranes with a glassfibre reinforcement which is impregnated and

coated on both sides with elastomeric, thermo plastic rubber which provides high
adhesive properties.

• Metal sealant: All metal joints and protrusions must be caulked and sealed for possible
ingress of moisture or water. RTV silicone sealant, aluminum or grey color to be used as
metal sealant.

• Expansion Springs: Flat spring for insulation & compression type spring for jacketing,
100mm long.

• Stainless Steel Bands and Wing Seals, Type 304

13mm x 0.5mm thk

19mm x 0.5mm thk

• Glass filament tape: 25mm wide pressure sensitive tape.

• Float ring shall be made from 6mm diameter Carbon steel rod.

• SS Rivets 3.8mmx15.9mm Long

 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 21/22 REV. A

11.0 MATERIAL HANDLING & STORAGE

• Handling & Storage of material shall be in accordance with the requirements of the project
specification.

• All the materials shall be stored at locations designated by Client

• Materials shall be stored in a way that it is protected from exposure to extreme weather
e.g. Heat, rain, dirt, etc.

• All material shall also be protected from getting wet and getting in contact with chemicals
or any other flammable substances during storage.

• The insulation materials shall be kept on pallet / off the ground surface (direct contact of
insulation material to ground surface shall be avoided).

12.0 ADDITIONAL REQUIREMENTS

12.1 Piping Insulation
12.1.1 Flanges and valves shall be insulated only in a piping system insulated to conserve
energy. Where there is a need for access for frequent maintenance, the insulation
shall be of the removable type. Allowance must be made for the removal of flange bolts
without disturbing the fixed insulation and permanent vapor barrier. Packing glands
shall be left exposed.
12.1.2 Flanges shall not be insulated in hydrogen service, or in toxic service such as phenol
or hydrogen sulfide.
12.1.3 For hydrogen service or where heat conservation insulation is not required for flanges,
a sheet-metal shroud should be installed over flanges for personnel protection.
12.1.4 Spectacle blinds shall be left visible for easy accessibility and not totally enclosed by
insulation boxes.
12.2 Equipment Insulation
12.2.1 Removable insulated covers shall be provided for manways and designed so that their
removal shall not disturb the surrounding permanently fixed insulation.
12.2.2 Removable insulation plugs shall be provided to permit on-stream ultrasonic inspection
when required by the company Plugs shall be vapor tight, and ultraviolet resistant such
that they can be opened and closed without disturbing the adjacent insulation.
12.2.3 Insulation and metal jacketing shall be fastened with stainless steel bands at
approximately 12 in (305mm). Longitudinal joints of metal jacketing shall be fastened
with screw at 6 in (150mm) maximum centers.
12.2.4 Insulation systems must be caulked and/or sealed at all possible points of moisture
entry. Do not feather edge of caulk.
12.2.5 Installed insulation shall have the required permanent protection or temporary
 PROJECT TITLE
HAWIYAH GAS PLAN (HGP) EXPANSION PROJECT

SUBCONTRACTOR NO. 1312808 JOB H02755 UNIT 00

CUSTOMER: SAUDI ARAMCO OIL COMPANY – SAUDI ARAMCO (IK) DOC NO. H99-ZA-E-0002711

PLANT LOCATION: HAWIYAH – SAUDI ARABIA Page 22/22 REV. A

protection applied before the conclusion of that day's work.

12.2.6 Installed insulation shall have temporary protection applied if the insulation can be
damaged by rain or other forms of atmospheric moisture

13.0 PROTECTION OF INSTALLED INSULATION

13.1 Insulation systems must be caulked and/or sealed at all possible points of moisture entry.
Do not feather edge of caulk.
13.2 Installed insulation shall have the required permanent protection or temporary protection
applied before the conclusion of that day's work.
13.3 Installed insulation shall have temporary protection applied if the insulation can be
damaged by rain or other forms of atmospheric moisture.

14.0 DAMAGE CONSIDERATIONS

14.1 Unless otherwise specified, insulation that becomes wet shall be removed and replaced
with dry insulation, and the wet insulation shall be discarded.
14.2 Damaged insulation shall be replaced if the nature of the damage will adversely affect
the thermal performance of the system. Any disputes regarding the need for replacement of
insulation shall be referred to the Purchaser for resolution.

15.0 GENERAL HOUSEKEEPING

15.1 Insulation materials shall be handled and disposed of in accordance with applicable
federal, state, and local laws and regulations.
15.2 Insulation-related materials, such as mastics, shall be handled and applied with care to
prevent splattering on adjacent facilities, such as concrete foundations, paving, structural
steel, equipment, piping, gauge glasses, instruments, machined surfaces, valve stems,
and packing.
15.3 All mastic over-spray and splatter shall be cleaned up as soon as it occurs.
15.4 Flammable materials shall be stored away from ignition sources such as welding
operations.
15.5 Debris resulting from insulation application work shall be removed from the work
area on a regular basis and placed in containers at the end of the workday.

16.0 ATTACHMENTS

16.1 Toolbox Talk CMS GF 013