Document
CERIPL/QAQC/SOP/HT
QA/QC No
Issue No: 01
Revision
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SOP For Hot No.
Insulation Effective
01-10-2024
Date:
STANDARD OPERATING
PROCEDURE FOR
HOT INSULATION
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CERIPL/QAQC/SOP/HT
QA/QC No
Issue No: 01
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SOP For Hot No.
Insulation Effective
01-10-2024
Date:
INDEX
NO. OF CLAUSE NAME OF CLAUSE
General
1
Reference/ Abbreviations
2
Hot Insulation
3
Insulation Thickness
4
Weather Protection Jacket (Cladding)
5
Ancillary Materials
6
Application
7
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CERIPL/QAQC/SOP/HT
QA/QC No
Issue No: 01
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SOP For Hot No.
Insulation Effective
01-10-2024
Date:
1. GENERAL
This procedure covers minimum requirements for material, fabrication, installation
and application of insulation on piping and equipment to be used for “Hot and Cold
Service”
2. Reference/ Abbreviations
IS 14164 : Code of Practice for Industrial Application and finishing of thermal insulation
material at temperature -800 C and up to 7500 C.
ASTM C 547 : Mineral Fiber preformed pipe insulation
ASTM C 553 : Mineral Fiber blanket thermal insulation
TS 6701 : Thermal Insulation – Hot service
IS 1254 : Specification for corrugated aluminium sheet
3. HOT INSULATION
o This consist of insulation for heat conservation, process stabilization,
temperature maintenance (Ih), insulation for steam traced lined (It), insulation for
electrical traced lines (Ie), Insulation for fire protection for operating
temperatures above ambient temperature (If) for all sizes of lines.
o Wherever insulation for personnel protection (Is) is mentioned, the same shall be
applied as per insulation specifications.
o All the valves and flanges etc. in high temperature service (>3000C) should be
insulated with a fire-resistant material like calcium silicate.
o The insulation of piping, equipment’s and vessels shall be carried out with the
following insulating materials, and the thickness of insulation shall be chosen
from the tables enclosed and refer clause 4. of the specification.
o Bonded mineral wool shall be used from ambient to 550˚c.
o Hot Insulation material
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3.1 Bonded Mineral wool. (Ih, Ie, Is, except valves and flanges above 3000C)
Lightly resin bonded Rockwool insulation shall conform to ASTM C592 class II for
blankets and ASTM C547 class III for preformed pipe section. Rockwool insulation as per
IS 8183 and IS 9842 are also acceptable. The material shall be suitable for intended
operational temperature range from ambient to 5500C.
The physical requirement of bulk density and chloride content, thermal conductivity and
PH valve of the material shall be as follows :
Bulk density : 140kg\m3 For resin bonded pipe section
128kg\m3 resin bonded LRB blankets
Chloride Content : 20 ppm (max.) for other materials
10 ppm (max.) S.S surfaces with inhibitors.
Thermal Conductivity : 0.43m W/cm0C for mean temp 500C
0.52m W/cm0C for mean temp 1000C
0.62m W/cm0C for mean temp 1500C
0.68m W/cm0C for mean temp 2000C
0.80m W/cm0C for mean temp 2500C
0.90m W/cm0C for mean temp 3000C
PH Valve : 7.0 To 10.0
Resin bonded pipe sections of glass wool may be used upto 3500C. Density shall not be
less than 80Kg./m3
3.2 Calcium Silicate (If or valves and flanges above 3000C)
Calcium Silicate block and pipe thermal insulation shall be composed principally of
hydrous calcium silicate reinforced with mineral Fibers (except slag wool)
The physical requirement of bulk density, chloride content, thermal conductivity and ph
value of the material shall be as follows.
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Bulk density : 200 to 280 kg/m3
Chloride Content : 50 ppm (max.)for carbon steel
50 ppm(max.) used over stainless steel.
Thermal Conductivity :
Mean Temp ⁰C Thermal Conductivity (W/mK)
200 0.080
250 0.088
300 0.097
350 0.110
400 0.121
450 0.135
500 0.148
PH Valve : 7 to 10
a) Polyisocyanurate (PIR) / Polyurethane (PUR)
Rigid polyisocyanurate / polyurethane foam block, pipe and fitting insulation shall be
manufacture with polyester or polyether resins, flammability retarding agents, special
catalysts and a blowing agent. This can be used upto a temperature of 125 deg C.
Bulk density: 40 to 64 kg/m3
Thermal Conductivity:
Mean temp ⁰C Thermal Conductivity (Max) mW/cm deg
10 0.238
24 0.245
38 0.252
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4. INSULATION THICKNESS
4.1 The insulation thickness and type of insulation (Ih, It, Is, Ic, and acoustics ) to be applied on
piping, equipment & vessels shall be as per data sheet.
4.2 Rigid preformed pipe sections and lags shall be used. Unbonded fibrous material shall not
be used.
5. Weather Protection jacket (Cladding)– Hot Insulation
5.1 Aluminium jacketing shall be used as weather protection over insulation unless other wise
specified and shall be as per ASTM B209 alloy 3003 h16 or IS :737 designation 31000 (old
NS3) condition H3 for flat sheets and designation 31500\51300 condition H4 for corrugated
sheets. Cladding shall be coated on the side in contact with insulation with bitumen
anticorrosive paint. The thickness of jacket shall be as follows :
For all materials except For Calcium Silicate Calcium Silicate
For shell of vertical(24 SWG) 0.71 mm (22 SWG) 0.56mm
Vessels, columns etc. corrugated corrugated
Storage tanks & Tank Roofs 1.22mm (18 SWG) 0.56mm (20 SWG)
For all piping, other than 0.71mm (22 SWG) 0.56mm
(24 SWG)
For Horton sphere & 0.71mm (22 SWG) 0.56mm
(24 SWG)
For Removable covers 1.22mm (18 SWG) 1.22 mm (18 SWG)
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5.2 Rigid material (Calcium silicate, moulded expanded perlite, polyisocyanurate, polyurethane
foam (PUR) blocks, cast-in-situ polyurethane foam and cellular glass
Application Thickness for Aluminium Thickness for stainless steel
jacket / cladding / Aluminized steel
jacket/cladding
Piping, horizontal vessel 0.56 mm (24 SWG) flat 0.46 mm (26 SWG) flat
head & tanks roof
Vertical vessel shells & 0.56 mm (24 swg) 0.46 mm (26
vertical portion of storage corrugated. The circular SWG)corrugated. The
tank profile of corrugated sheet circular profile of corrugated
shall be 32 mm 5mm sheet shall be 32mm 5 mm
Removable Cover 1.22 mm (18 SWG) flat 1.22 mm(18 SWG) flat
6. ANCILLIARY MATERIALS
6.1 If material is Aluminium, then specification shall be ASTM B209 Alloy 3003 H16 or IS:737
designation 31000 ( Old NS3 ) condition H3; If Stainless Steel , It shall be 18/8.
6.2 For securing fibrous insulation on piping, 24 SWG X 12 wide, stainless steel
bands shall be used.
For securing fibrous insulation on equipment’s, 24 SWG x 20 wide, stainless steel bands
shall be used.
For securing fibrous material on vertical storage tank, stainless steel 25 mm wide X 24 SWG
thick flat shall be used.
For securing fibrous material on spheres, stainless steel bands of 25 mm wide X 0.8mm (
min. ) thick flat shall be used & 16 SWG SS Wire and bend.
6.3 For securing rigid insulation on pipe upto 16” O.D., stainless steel wire of 16 SWG shall be
used.
For securing rigid insulation on pipe upto 18” O.D., and above, steel band 20mm wide X 24
SWG shall be used.
For securing rigid insulation on vertical and horizontal vessels, steel band 20mm wide X 24
SWG shall be used.
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6.4 For securing cladding on insulation on piping, stainless steel bands 12mm (min) X
24 SWG thick shall be used.
For securing cladding on insulation on equipment, stainless steel bands 20mm (min) X 24
SWG thick shall be used.
For securing cladding on insulation on vertical storage tank stainless steel bands 25mm
wide X 24 SWG thick shall be used.
For securing cladding on insulation for spheres stainless steel bands 25mm wide X 24 SWG
shall be used.
6.5 Rivets used for securement of metal jacket shall be expanding aluminum “POP” blind eye
type, 9.5mm long X 5mm diameter.
6.6 Screw : As per client specification
6.7 `S` & `J ` clits
7. Application
7.1 All insulation work shall commence only after successful completion of hydro testing of
piping and equipment’s including steam tracing systems.
7.2 Surface to be insulated shall be thoroughly cleaned, dried and made free from loose scale,
oil or grease.
7.3 No welding or drilling of equipment’s and piping shall be permitted for insulation application.
7.4 Wet or damaged insulation shall not be used under any circumstances.
Insulation material to be applied shall not be kept over bare ground to avoid water
absorption. Installed material awaiting its protective cover shall be adequately protected
from damage, rain and contamination and shall be covered with cladding at a minimum loss
of time. Insulation on vertical piping shall be supported by bolted on metal collar shall be
extended to provide for each layer.
7.5 Insulation for impulse piping shall be taken care of all projections, such as lifting lugs,
trunnion, support lugs, support cleats shall be insulated to the same extent that of
equipment of piping.
7.6 Insulation windows : As per specification to be provided
Insulation windows for inspection thickness survey are to be provided for insulated
equipment and piping (piping more than 4” dia meter) for 20% of bend locations. However for
transfer lines the insulation windows should be provided at 100% bend locations.
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7.7 Cleats used for supports of insulation shall not project outside insulation.
7.8 Extent of insulation shall be as per P&ID, Line list, General arrangement drawings, Isometrics
and vessel and equipment data sheets.
7.9 In case of hot insulation system, insulation shall not be applied to the following unless
specifically asked otherwise.
a) Valves, including control valves, flanges in process lines below 3000C (Safety insulation
shall be provided wherein required)
b) Pipe union fittings.
c) Steam Traps, sight flow indicators.
d) Pumps with operating temp below 2000C
e) Fans, compressors, blower or other rotating or reciprocating equipment’s.
f) Internally insulated or refractory lined equipment.
g) Turbine seal caps, shaft bearing housing, throttle valves, governors and supports.
h) Exchanger channel and covers, shall and channel flanges and expansion joints.
i) Nozzles, manholes and handholds and flanges of equipment.
j) Surfaces of coolers and condensers.
k) Thermo well bosses and pressure tapings.
l) Piping which becomes hot intermittently, such as relief valves, vents, steam-out and
snuffing steam systems flare and blowdown system.
7.10 Instrumentation to be insulated, such 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.
7.11 For all cold lines, all steam and condensate lines, all hot oil lines, all jacketed lines, the
extent of insulation shall include valves, flange joints, instruments and control valves.
7.12 To ensure perfect water proofing, all cladding joints shall be packed with sealing
materials which may either be in the form of a elastomeric sealing compound or fibre based
bituminous felt strips. Minimum overlap in sheet metal at joints shall be 100mm.
7.13 Support skirts of vertical vessels and columns shall be insulated both from inside and
outside to a minimum distance of 600mm from bottom tangent line. The insulations must
terminate at minimum 300mm above support concrete or steel work.
7.14 Tank shell insulation should have continuity in insulation cladding even at stiffener
retainer ring location on shell.
7.15 Proper expansion/contraction joints shall be provided to allow movement of pipe or
vessel without producing random cracking of all the insulation.
7.16 Vapour barrier shall be applied on all the vessels and equipment’s in cold services and
also for services upto 1250C
7.17 Hot insulation over stainless steel surfaces shall be inhibited by sodium silicate.
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Inhibition of hot insulation over austenitic stainless steel surfaces with sodium silicate as
per ASTM C-795 and testing of inhibited insulation material as per ASTM C-692.
Restriction of leachable chloride shall be 10ppm (max) as per the test method ASTM C-871.
Insulation to be put on Austenitic SS surfaces only if it is a process requirement. Insulation
for the purpose of human safety, if not process requirement, shall be substituted by
alternate protection like safety guard wire mesh caging weather protection etc.
7.19 All insulated austenitic stainless steel piping and equipment insulated with rock wool or
calcium silicate shall be protected against chloride attack.
7.20 Name plates should be visible after insulation.
7.21 Guarantee & test certificates as per client specification
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