Section: Civil Page 1 of 27

Approved: Head of Section Date: 2/04/2005

Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

(1) PURPOSE
This manual covers the minimum requirements for material and applications to
be used in the thermal insulation of Company’s vessels, equipment and pipe
works. The aim is also to ensure that the performance and application of the
work is in accordance with the commonly used standards for good workmanship
in the country where the plant is to be constructed. The recommendations and
standards listed in this manual are to be observed carefully.

(2) SCOPE
This manual covers all applications operating between -268 oC and 650oC. This
manual does not incorporate the REFRACTORY insulation of Furnaces,
Reformers or Fired heaters etc..

(3) RESPONSIBILITIES
The Head of Civil Section is responsible to monitor that this manual is adhered
to. The Corrosion Protection Engineer shall be responsible for ensuring that this
manual is followed. The Mechanical Field Engineers are responsible for the
integrity of Insulation. All Project Coordinators are responsible for ensuring that
all Insulation works that may be carried out in lump sum projects etc. are
according to this manual, and shall submit the Fmt-Ci-009, Rev.0,
23/2/06 - Notification of Insulation Request Form for Inspection
(Available Online under controlled documents) to the Corrosion Protection
Engineer at least 24 hours prior to insulation works commencing. Any
deviations from the Company manual shall be approved in writing from the
Head of Civil Section prior to works commencing.

(4) DESCRIPTION

4.1 GENERAL
4.2 COLD INSULATION
4.3 HOT INSULATION
4.4 PERSONNEL PROTECTION
4.5 ACCOUSTIC INSULATION
4.6 MATERIALS
4.7 STORAGE/HANDLING
4.8 COLD INSULATION THICKNESS
4.9 HOT INSULATION THICKNESS
4.10 ACOUSTIC INSULATION THICKNESS
(5) REFERENCE
Section: Civil Page 2 of 27
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THERMAL INSULATION MANUAL

(6) DEFINITIONS
(7) LIST OF DRAWINGS
(8) APPENDIX OF DRAWINGS

4.1 GENERAL

The contractor has the following responsibilities in the performance of the work
under the contract:-
 To familiarize himself with the type and extent of the work to be provided
under the contract.

 To assign experienced tradesmen to the project working under the direct

supervision of a competent authorized Qafco representative. This
representative must be solely responsible for the coordination of the work
and for promoting cooperation with the Qafco Representative.

 To provide the scope, latest "Qafco-approved" drawings, project

specifications, and applicable QAFCO Standards to his authorized
representative for use at the work site.

 To provide a high quality, workmanlike installation and respect Qafco and its
Contract Coordinator’s responsibility for reviewing workmanship and
materials at any stage after the award of the contract.

 To order quality materials meeting the approved Materials standards, and to

obtain Manufacturer’s certifications for these products where required.

 Products equivalent to the Qafco manual there under shall be accepted after
the physical properties are reported to and approved in writing by the
Company.

 Plant equipment and piping with a surface temperature below 60 oC during

normal operating remains un-insulated, if not otherwise specified by
individual equipment specification or drawings.

 The insulation work should not be started until the pressure test of
equipment and pipelines has been completed. All joints (bolted, flanged,
welded, laminated) shall only be insulated after the pressure test. Valves
and flanged joints which were provided with line blinds shall only be
insulated after the leakage test. Pipes without welds may be insulated prior
to the pressure test. For the leakage test of cold-insulated pipelines with
process fluids at operating temperatures, valves and flanges shall be
temporarily insulated (e.g. by means of mineral fiber mats) to prevent the
formation of ice)
Section: Civil Page 3 of 27
Approved: Head of Section Date: 2/04/2005
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THERMAL INSULATION MANUAL
 This recommendation applies to the thermal insulation of equipment,
vessels, machinery and pipelines. It contains generally applicable
requirements for insulation materials (type of insulation materials, sheet-
metal, hardware) and the performance of insulation work. This
recommendation will be supplemented by special instructions, if necessary.
Deviations from this recommendation shall be agreed upon in writing.

General Insulation Application Requirements for piping &

equipments are as follows:

 All surfaces to be insulated shall be clean, dry and free from coarse rust and
scale. Painted surfaces shall be insulated only after the paint has dried
thoroughly.

 All piping and equipment within this manual shall be completely insulated
including all hand hole covers, manholes, flanges, fittings and valves etc..

 Insulation pipe sections shall be secured with S.S. banding of 25mm over the
pipe covering at about 500 mm centers. All insulation boards shall be
butted tightly together with S.S. Banding of 25mm.
 Insulating materials, unless otherwise stated, shall have a PH value of
between 7 and 10 in order that the possibility of corrosion of insulated
equipment or piping is negated. Insulation materials with a leach able
chloride iron content of <6 mg. /kg. Shall be used.

 Nameplates, code inspection plates and directional arrows on vessels and

machinery shall not be covered. Insulation shall be beveled off from such
parts and sealed thoroughly with suitable sealant as per this manual against
entry of moisture.

 All insulated attachments and appurtenances on piping and equipment that

protrude through the Insulation, shall be insulated to the same thickness as
the piping or equipment over a length of at least four times the thickness or
300 mm whichever is the greater. After this process the insulation thickness
is reduced to the thickness required on the attachments and appurtenances,
if not indicated otherwise.

 Insulation thickness shall be the nominal thickness of the basic insulating

medium and shall not include the finishing or weather proofing materials.

 Ceramic Fiber wool blankets shall be used especially for Reformer and
Instrument tubing due to high temperature limits.

 To avoid corrosion, insulation materials composed of dissimilar metals

subject to galvanic action shall not brought in contact with each other.

 Insulation material shall be protected against inclement conditions (e.g.

moisture, rain). Damp insulation materials shall not be used. If work is
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THERMAL INSULATION MANUAL
interrupted for any genuine reason, unfinished areas shall be covered with
fire retardant tarpaulin or plastic sheet according to the plant requirements.

 Adjoining sections of all preformed material shall be closely butted, leaving

no gaps or voids. On pipes up to 150mm diameter the insulation shall be
secured with wire at a maximum pitch of 450mm and with not less than two
attachments per section.

 Boards shall be used for flat walls. These should be held in place by the use
of insulation pins or suitable approved fixings.

Allowable load per pin : 25 Kg.

Minimum number of pins per square meter is : 9 for vertical walls
4 for floors
12 for ceilings.

 The Contractor may choose welding of pins of suitable metal on high

temperature vessels or equipments after getting the line approval from
Qafco Inspection Group.

General Cladding Application Requirements for piping &

equipments are as follows :

 Weatherproofing jacket shall be applied for all insulation and overlaps at

either 10 or 2 O’clock
positions. The overlapping shall have a crimp. Insulation shall be protected
from weather, oil
spillage, mechanical wear, damage etc., by the installation of a weather
proofing aluminum jacket as
per Qafco Manual.

 The liner extension of equipment and pipelines with operating temperatures

of >150oC shall be considered by “expansion joints” properly arranged.

 On horizontal pipes subject to foot traffic, the cladding material on the top
quadrant only shall be 2mm thick. (This may be applied in two separate
layers). Particular care and attention shall be exercised in the fabrication,
fitting and sealing of insulation, vapour barriers and cladding around
supports, brackets, nozzles etc. Where possible these shall be insulated to
the same thickness as the piping or equipment, over a length of at least four
times the thickness or 300mm, whichever is the greater.

 Cladding for the straight shell shall be installed in the form of

circumferential strakes working upwards, vertical support being afforded by
‘S’ Clips at a pitch of 610mm incorporated in the circumferential joint.
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 In the case of straight runs of pipe work, cladding shall be fitted to ensure a
longitudinal overlap of not less than 50mm. Each rolled casing shall be ball-
swaged at least 50mm from the leading end so as to provide a
circumferential seal to adjoining casing. The outer longitudinal edge shall
be crimped over its full length.

 In the case of Vertical vessels and other equipment, the appropriate type of
metal sheet- Flat or corrugated – (according to Qafco manual) shall be cut to
size and shape, fabricated and assembled to fit to the contour of the vessel
allowing a minimum overlap on longitudinal seams of 75mm and of 100 mm
on circumferential seams.

 Corrugated Sheet shall be used for vertical Vessels or Equipments

>10,000mm insulation circumference with overlaps on longitudinal of 75mm
and 100mm on circumferential.

 On completion, cladding of the straight shell shall be restrained by machine-

tensioned circumferential bands at a pitch of approximately 500mm. Sheets
shall be tightened with SS screws / aluminum rivets as per this manual.

 Roof slope bottom and side ends shall be jointed with the vertical wall
sheets by 1mm thick flat aluminum sheet Flashings. Armaflex or equivalent
materials shall be used to block wall sheet corrugation troughs.

 The longitudinal junction between opposite roof slopes is covered by flat

ridge sheet of the same thickness as the corrugated roof sheets and 150mm
wide at the least.

 All overlap joints in the cladding shall be sealed with suitable joint sealant as
per Qafco manual.

Valve & Flanges

The Cladding of valves and flanges shall be tapered to allow removal of the
bolts without damage to the insulation. The taper shall be thoroughly sealed
with mastic. At Interruptions in the line, the cladding shall be terminated in
such a manner so as not to impede the withdrawal of stud bolts. In the case of
horizontal pipe run the cladding shall be fitted with end caps of lock form
construction. In case of vertical pipe runs the upper end cap shall be of conical
construction to provide a watershed.

4.2 COLD INSULATION (-100oC to <140oC)

Cold Insulation shall be carried out as per the following

methods:
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THERMAL INSULATION MANUAL
 "Classic Method" By means of Pre-formed Polyurethane Foam, Poly-
isocyanurate Foam or Foam Glass shells and slabs.
 "In-Situ Method" By Injecting / pouring Polyurethane Foam (Component A
& B mixed together) between equipment, pipes or accessories and metallic
jackets.

 FOR EQUIPMENT: (Vessels and Heat Exchangers)

Shells and heads : by the " Classic Method "
Flanges, nozzles manholes : by the " In-Situ Method "

 FOR PIPING:
Straight parts, elbows, reducers, tees : by the "Classic Method" or "In-
Situ Method"
Flanged components : by the "Classic Method" or "In-Situ
Method"

 Insulation must not be applied to surface that are covered with ice or water.
This is best achieved by restricting the application of cold insulation to plant
shutdown periods. Where it is essential to insulate pipe work, equipment,
fittings on pipe work etc., during maintenance jobs, every effort must be
made to remove ice, either physically or using methanol and drying the
surface as much as possible prior to insulation.

METHODS OF COLD SERVICES APPLICATIONS

Foam Injected Material for Cold Insulation (In-SITU Method)

 Polyol and Isocyanate mixed and injected materials shall be from the same
manufacturer.

 Existing polyurethane foam or poly-isocyanurate insulation shall be replaced

or repaired with polyurethane foam or poly-isocyanurate based material
except where specifically authorized by Qafco Representative

 The foam shall be in the form of two components froth foam, produced with
the aid of proprietary ‘insta-foam’ portable pressurized dispenser and
chemical components supplied in the disposable pack form and shall be
introduced through appropriate sited injection holes which have a diameter
of no more than 5.5mm.

 Foaming may be performed in closed (chamber method) or in open system

(Visible foaming). In the case of the chamber method, the volume of the
chambers and the amount of the foam mix to be filled in shall exactly be
adapted to each other.

 In the case of foaming in closed system, at least one opening for filling and
one opening for inspection shall be provided at the uppermost point of the
respective chamber.
Section: Civil Page 7 of 27
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 Visible foaming (e.g. in the case of vertical equipment) shall be performed

after each course of sheet metal has been installed.

 Prior the foaming, the ends of the cladding (e.g. at flanges) shall be sealed
against the foaming pressure (e.g. by means of shaped parts of foam).

 The manufacturers’ instructions for mixing the foam components shall be

observed. Foaming may only be commenced at ambient temperatures of
>10oC. The temperature of the surface to be insulated and the cladding
shall be >15 oC and shall not exceed 40 oC. The foam components should
have a temperature of about 20 oC during the mixing procedure. Foaming is
not permitted at a relative air humidity of >90%. The system to be foamed
up shall be protected against solar radiation.
 For valve / Flanges and manholes the whole of the interior surface shall be
covered with suitable plastic sheet prior being fitted, following which the
cover shall be in filled with a two component polyurethane foam in froth
form, injected through suitably sized and located holes.

 After foaming, the openings for filling shall be sealed by means of covers made of sheet metal or
plastics. The opening for inspection shall be sealed by means of self-tapping screws and seal
washers made of plastics as soon as the foam overflows. Extra foam spread on the cladding shall
be cleaned.

 Since the process is sensitive to climatic conditions, it is essential to store

the components in a controlled environment at minimum of 24 OC for at least
48 hours prior to use.

 Prefabricated wooden support according to the pipe diameter and insulation

thickness shall be installed for all the adjustable saddle clamp supports.

Classic Method Insulation Boards, Formed Slabs & Pipe

covers

Mastic & Vapour Barrier for Cold Insulation

 Boards, formed slabs and pipe covers shall be laid on clean surface with
closely butted joints. The joints may be glued with joint sealer. Adhesives
shall not adversely affect the foam and coatings.

 Adjoining sections of all preformed material shall be closely butted, leaving

no gaps or voids. On pipes up to 150mm diameter the insulation shall be
secured with wire or S.S. Banding at a maximum pitch of 450mm and with
not less than two attachments per section. All insulation boards shall be
butted tightly together with joint sealer.

 All insulation boards having been applied in a day shall be covered with the
vapour barrier at least single layer within the same day.
Section: Civil Page 8 of 27
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 Vapour seal should be applied over the banding clip area to fully seal and
avoid any damaged.

 Vapour seal is applied in minimum of 2 layers, second layer must be applied

after a drying period of at least 16 hours of first layer with reinforced 10x10
glass cloth (Scrim cloth #10 or equivalent) overlapped at least 50mm.
Mastic Material shall be emulsion pre-mixed. Two coats shall be applied. The
initial tack coat shall be applied at a uniform rate of not less than 1 litre/m 2
to provide a film thickness of 1mm. A layer of SCRIM CLOTH (No. 10 or
equivalent) shall be used on wet 1st layer coating of vapour barrier by the
application of slight pressure working from the centre to the edge, all
adjoining edges, protrusions and terminal points having a 50mm overlap.

 At the terminations of insulation it is imperative that the vapour barrier is

continued over the end of the insulation and lapped onto the pipe wall.
After a drying period of at least 16 hours, the second coat shall be applied at
a uniform rate not less than 2.5 liter/m 2 affording a wet film thickness of 2
mm.

 Final drying shall extend over three days, before the application of any
metal cladding. It is not permitted to use screws as fixings, metal
cladding shall be secured with S.S. banding at the pitch of 150mm.

 Prefabricated wooden support according to the pipe diameter and insulation

thickness shall be installed for all the adjustable saddle clamp supports.

 Valve, Flanged joints, etc., should also be insulated with shells. Cavities and
gaps shall be carefully filled with the same type of foam.

Application of Cladding – Cold - Pipe work

 All joints shall than be secured with self-tapping screws only in case “SITU
Method” at
Maximum pitch of 150mm.

 No screws or rivets are allowed in “Classic Method”. S.S. banding of given

size only to be fixed to secure the Cladding.

 Cladding Requirement in “Classic Method” is optional and shall be decided

by Qafco authorized Representative according to technical requirements.

Cold – Equipments, Vessels and Exchangers

Shells of ID above 450 mm. shall be insulated by block insulation (The classic
method).

Size of shell Type of block insulation

Shell inside diameter from 450 up to 900 Formed blocks
Section: Civil Page 9 of 27
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THERMAL INSULATION MANUAL
mm
Shell inside diameter above 900 mm. Standard flat block trimmed to
fit.

 Shells of ID up to 450 mm shall be insulated in the same manner as

described for piping in this Manual.
 Each layer of insulation board thickness shall not be greater than 50 mm.

 Insulation board shall be held at first by means of adhesive on equipment

with the joints staggered and then secured by S.S banding of 25mm.

CRYOGENIC INSULATION - CELLULAR FOAM GLASS (-268oC to

427oC)

METHODS OF APPLICATIONS

 Existing Cellular foam glass insulation shall be replaced or repaired with

foam glass materials on low temperature Chemical processing system,
Cryogenic and low temperature pipe work, equipment, tanks, vessels,
medium and high temperature etc. and where specifically authorized by
Qafco Representative.

 All insulation pipe covers / boards shall be butted tightly together with
vapour sealer.

 All insulation pipe covers / boards having been applied in a day shall be
covered with the vapour barrier at lest single layer within the same day.

 Vapour seal should be applied with gloved hand, trowel or float over the
banding clip area to fully seal any damaged.

 Prefabricated wooden support according to the pipe diameter and insulation

thickness shall be installed for all the adjustable saddle clamp supports.

 Foam Glass shells and slabs shall have small and mainly closed cells. To
avoid cracks caused by internal stresses (e.g. because of changes in
temperature), the size of the shells or slabs shall be selected accordingly.

 For single layer applications a staggered joint (>150mm) should be cut from
one half of the insulation, the remaining section should have a bead of joint
sealer fitted to the circumferential and longitudinal joints

 Mastic Material shall be emulsion pre-mixed. Two coats shall be applied. The
initial tack coat shall be applied to provide a film thickness of 1mm. A layer
of 10x10 glass cloth Scrim cloth #10 overlapped at least 50mm shall be
used on wet first layer coating of vapour barrier by the application of slight
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pressure working from the centre to the edge, all adjoining edges,
protrusions and terminal points having a 75mm overlap.

 At the terminations of insulation it is imperative that the vapour barrier is

continued over the end of the insulation and lapped onto the pipe wall.

 The second coat of 1mm thickness vapour barrier to be applied not less than
6-8 hours after the first coat and smoothed to uniform finish to provide a
continuous seal ensuring that the reinforcing membrane is completely
covered.
 For the Multi-layer applications the inner layer shall be applied dry and
secured by tape of 25mm wide (glass reinforced polyester self adhesive
tape at 100mm center). Oversized sections or radiuses and beveled lags
shall be fitted with a staggered joint, jointing compound, vapour sealer and
scrim cloth which are to be applied in the same manner for the application
of a single layer (On no account should wood or metal skewers be used that
will penetrate of the insulation as this may cause a cold path.)
Metal Cladding.
 Cladding Requirement in “Cryogenic” is optional and shall be decided by
Qafco authorized
Representative according to technical requirements.

 It is not permitted to use screws as fixings on metal cladding on “Cryogenic

Service” as they will
Penetrate the vapour barrier. Metal cladding shall be secured with S.S.
banding at the pitch
of 150mm.

ELASTROMERIC DUAL TEMPRATURE INSULATION (ARMAFLEX)

(-40oC to 150oC)
METHODS OF APPLICATIONS

 Thermal insulation for pipe work, valves etc., operating at high or low
temperatures.

 Thermal Insulation material should have a particular operating

temperature range which can be from -40oC to 150oC to use on low
temperature refrigeration installation or hot surface up to given
temperatures limit.

 Material should have a high resistance to oil and in standard fire test to
minimized smoke development and water vapour transmission combined
with low thermal conductivity and fire performance.
 Material should be self-extinguishing. Should not generate burning
droplets.

 Insulation to be used on all Cold or moderate piping temperature range

from –400C to 1500C.
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 Insulation thickness shall be the nominal thickness of 3/8” (10mm), ½”

(13mm), ¾” (19mm) & 1” (25mm) in popular sizes up to 2 – 1/8” ID.

 All insulated attachments and appurtenances on piping and equipment

that protrude through the Insulation, shall be insulated to the same
thickness as the piping or equipment over a length of at least four times
the thickness or 300 mm whichever is the greater. After this process the
insulation thickness is reduced to the thickness required on the
attachments and appurtenances, if not indicated otherwise.

 To facilitate sweating of joints, insulation should be able to pulled back

temporarily on either side of the connections, then released to extend
over the joint before sealing.

 To avoid corrosion, insulation materials composed of dissimilar metals

subject to galvanic action shall not brought in contact with each other.
 Contact adhesive is to be applied to both surface of longitudinal and butt
joints, or self-adhering system.
 No cladding is required over the insulation. Additional securements or
finishes can be provided with self-adhesive aluminium foil tape OR re-
enforced duct tape of 50mm wide for indoors and outdoor applications.

 Vapour barrier coating or Cladding can be applied for outdoor applications

as per cold insulation procedure in this manual after authorization.

(4.3) HOT INSULATION (0oC to 650oC)

METHODS OF APPLICATIONS

 Mattress shall be cut to suit the outer diameter of the insulation. Each layer
of mattress on vertical equipment and vertical pipes with diameter of
>1mtr. Shall be additionally secured against sliding off by means of S.S.
banding of 25mm.

 Insulation up to and including 80mm thickness shall be applied as a single

layer. For greater thickness multiple layer shall be used. Where two or
more layers of insulation are used the joints shall be staggered relative to
those in the underlying layer. The offset shall be approximately 50% of the
relevant dimension of the section.

 When G.I. wire is used to tighten insulation board, knots or twisted ends
shall be bent down into the boards.

 Mattresses shall be seamed using G.I. wire at the rate of 15 stitches

minimum per meter at all circumferential and longitudinal joints. Sealing
washers or equivalent can be used to lock the insulation mattress and board
where required.
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 Where pipe work is fitted with heat tracing, for better heat transfer, a
thermal shield or a thermal foil shall be placed between the insulation
material and the tracing. The shield or foil shall prevent the insulation
material from penetrating between the tracing and the surface to be
insulated.

 In the case of plastic pipes, an aluminum foil may be placed between the
surface to be heated and the tracing cable for better heat distribution. This
foil shall be placed as smooth as possible. The tracing cables as well as the
sensing elements of temperature measuring and control instruments shall
not be damaged and their position not to be changed.

 If insulation with mineral fibre mattress, shells of slabs is impossible, elbows,

inaccessible area and cavities may be packed with loose mineral fibres if
approved by the Qafco representative.

(4.4) PERSONNEL PROTECTION

 Steam vents and drains shall be heat insulated when accessible to

personnel from a normal access way. No cold temperature limitation is
given since it is considered that equipment operating below freezing point
will be insulated to prevent condensation and ice formation thus
eliminating the need for personnel protection.

 Thickness of insulation shall be as per schedule, to reach a maximum

surface temperature of the sheathing of >600C at 300C ambient
temperature. At a height of less than 2.5m above personnel walking level
(ground, platform, walkways and stairways etc. At a distance of less than
1.2m from any device limiting personnel movement (hand rail, end of any
equipment and so on.
 Access to pipe work or devices which by their shape cannot be easily
insulated, may be prevented by means of a protective insulated metal
plates, if there is any risk for the operating personal.

Hot oil lines

Flanges and valves on hot oil lines are usually left bare in case the insulation
material becomes saturated in the event of a flange leak. This may not be
readily seen and could result in spontaneous combustion. If the un-insulated
valve or flange presents a hazard to plant personnel, a simple box prefabricated
from aluminium cladding with no insulation infill can afford protection.

Metal-to-Metal contact

It is a requirement of this manual that wherever the possibility of metal to metal

contact exists between cladding and pipe work, supports, valve, vessel,
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exchanger, particularly at end caps and terminations etc., ceramic ladder tape
minimum 5mm thickness or equivalent of a suitable width shall be placed
around the object being insulated to prevent such contact.

Reformer & Instruments Tubing

Ceramic Glass Fibre Blankets shall be used for Reformer pigtails, doglegs,
flexible Instrument tubing & steam tracing lines. Ceramic Re-enforced
Aluminised Glass Fabric Cloth (used internal application where proper water
shed is provided) & Ceramic Re-enforced glass fabric with water proof coating
(used for external application) shall be used as wrapping material for Ceramic
Glass Fibre blankets.

Thickness of Ceramic Glass Fibre Blanket : 25mm & 38mm

Aluminised Glass Fabric : (Type EKA 622)
0.70mm nominal x 1000MM wide x
50M length rolls.

Vessels and Heat Exchangers

 Shells of inside diameter above 450 mm. shall be insulated by block

insulation.

Size of shell Type of block insulation

Shell inside diameter from 450 up to 900 Formed blocks
mm
Shell inside diameter above 900 mm. Standard flat block
trimmed to fit.

 Shells of ID up to 450 mm. shall be insulated in the same manner as

described for piping.

 Each layer of insulation board thickness shall not be greater than 50mm.

 Insulation boards shall be secured by S.S. banding of 25mm on the

equipment with the joints staggered.

(4.5) ACOUSTIC INSULATION

(Hot & Cold Sound Insulation)

 This recommendation applies to sound insulation heat/sound insulation

and cold/sound insulation of equipment and pipelines. It contains
generally applicable requirements for insulation materials and the
performance of sound insulation work.
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 Insulation materials of mineral fibers shall preferably be used for sound
absorption or deducing the sound level. The gross density of the
insulation material in installed state shall not exceed 140 kg/m 3.

 Special soundproofing measures (e.g. by sound-proof cabins, sound-

absorbing casings for machinery, sound absorbing screens, sound
absorbers and sound absorption hoods) are not covered by this
recommendation.

 All insulation boards shall be butted tightly together. Webs of pre-pressed

mineral-fiber blocks may be used for horizontal surfaces if this produces
better results for the sound insulation from the technical or economic
points of view. The mineral-fiber blocks shall have a gross density of
>150 kg/ m3 . They shall be arranged at equal distances are only
permitted if approved by Qafco.

 Hot & Cold Acoustic materials must be replaced with same materials as
existing.

 Acoustic insulation shall be applied to piping, especially pipes in which

gases, fluids or particles solids are transported at high velocities.
 Application of the acoustic insulation will be the same as for heat
conservation. The choice of insulation in nearly all cases will be mineral
wool in the form of mattress, pipe cover and slabs.

 Existing Acoustic insulation material shall be replaced with the same

material and thickness. The thickness of insulation will depend upon the
db (Decibel) rating.

 Metal cladding shall be used for the protection of an acoustic system (see
section 4.6). The Sound deadening coating shall have a thickness of
>2mm. (preferably Terophone -112 DB) shall be applied to the internal
portion of cladding and caps. The gross density of the sound-deadening
compound should be approx. 1400 kg/m3. The product of the reducing
factor and the modulus of elasticity (N/cm2) shall be >10 N/cm2 in the
temperature range of 0 to 60oC.

 The sound deadening coating shall have a thickness of >2 mm. The
gross density of the sound-deadening compound should be approximate
1400 kg/m3. The sound deadening coating shall be applied to the inside of
claddings and caps. The overlapping areas of the longitudinal and
circumferential seams including the crimps may be left uncoated.
Permanent adhesion between the sound deadening coating and the
cladding must be ensured.

 Cladding must be installed prior to foaming in cold Acoustic same as

“SITU METHOD” or “CLASSIC METHOD” and mineral wool
Section: Civil Page 15 of 27
Approved: Head of Section Date: 2/04/2005
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THERMAL INSULATION MANUAL
blanket/slabs or pipe sections should be applied as second layer over the
cladding.
 Webs of pre-pressed mineral fiber blocks may be used for horizontal
surface if this produces better result for the sound insulation from the
technical or economic point of view. The mineral fiber shall have a gross
density of > 150 kg/m3. They shall be arranged at equal distances at
the circumference of the item to be insulated and pressed to the item by
means of banding.

Valves, Flange & Acoustic Covers (Applicable for Hot and Hot
Acoustic Insulation)

 The Cladding of valves and flanges shall be tapered to allow removal of

the bolts without damage to the insulation. The taper shall be thoroughly
sealed with mastic.
 Acoustic Cover for equipments shall be removable
 At interruptions in the line, the cladding shall be terminated in such a
manner so as not to impede the withdrawal of stud bolts. In the case of
horizontal pipe run the cladding shall be fitted with end caps of lock form
construction. In case of vertical pipe runs the upper end cap shall be of
conical construction to provide a watershed.

4.6 MATERIALS

General

 All insulation materials including cements, vapour barriers, Mastics etc.,

shall be asbestos-free.

 The insulation materials shall be chemically neutral, tear resistant, rot

proof, vermin proof, flame resistant, dimensionally stable and free from
impurities.

 In the plants in which nitric acid or ammonium nitrate are produced or

used, insulation materials containing organic binding agents (e.g. phenolic
resin) shall not be used. In plants in which the formation of volatile
flammable vapours and gases is possible, only insulation with a closed
surface (e.g. foam glass) shall be used. Foam components shall be
supplied in unmixed state to the site.

 Thermal conductivity (in relation to the reference temperature) and gross

density of the insulation shall be demonstrated to the Company if so
requested. For the testing methods and tolerances, the specified
standards (e.g. DIN 52612, ASTM C 177, ASTM C 236 ) shall apply. In
addition to the thermal conductivity and gross density, the following
properties of foam shall be demonstrated to the Company if so requested:
Section: Civil Page 16 of 27
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THERMAL INSULATION MANUAL
 Water vapour permeability
 Dimensional stability
 Cellular structure
 Coefficient of thermal expansion
 Water absorption

Metal Jacket

The sheeting shall be plain aluminium, semi hard Type AA 3105 H-14 plain,
or corrugated aluminum sheet to DIN-EN 573 / ASTM B-209 or equivalent
standard. The alloying components shall be 0.3 - 0.8% Mn., and 0.2 – 0.8%
Mg.

The thickness of aluminum sheet shall be as follows depending on

insulation circumference :

* 0.8mm thickness of plain sheet for piping & vessels circumference under 450
mm
* 1.0mm thickness of plain sheet for piping & vessels circumference over 450
mm.
* 1.0mm Aluminum Corrugated sheet shall be used for all vertical equipments
circumference
>10,000mm

FASTENING MATERIALS:

Bands:
Bands shall be stainless steel, AISI 304. Application methods of banding are
shown on the attached standard drawings in this manual. Banding shall be
secured as follows :

Material Pitch Required Application

S.S. Banding 500mm Piping and equipment up to

25mm X 0.8 mm 950mm diameter over
the cladding.

S.S. Banding 500mm Piping and equipment above

50mm X 0.8mm 950mm diameter over the
cladding

Stainless Steel banding shall be used on all diameter pipe work, vessel,
Equipment & Exchangers.

Wires:
Wire shall be G.I. The minimum thickness shall be 0.8mm thick.
Section: Civil Page 17 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

Screws & Rivets:

Sheet metal self-tapping type screws shall be stainless steel AISI 304 and blind
rivets shall be aluminum equivalent standard. Screws & blind rivets shall be
fixed at maximum pitch of 150mm.

Sealing Materials

Silicon based metal seal (Silicon Sealant 1200 Or Equivalent).

Netting:

Net for reinforced mineral wool and mastics shall be used as follows :
For mineral wool : Mesh size 20 mm. hexagonal
Diameter of wire : 0.7mm

COLD SERVICES MATERIALS

Polyurethane & Poly-isocyanurate Foam

Rigid Polyurethane or Poly-isocyanurate foam shall be used and conform to the

requirements of DIN 52612, ASTM C-177 & ASTM C-236. Slab insulation is
required in excess of 50mm thickness, multi layers shall be used and none shall
exceed 50mm.
Material : Polyurethane foam / Poly-isocyanurate
foam
Gross density : >45 kg/m3
Temperature resistance : from -500C up to 1100C
Tolerance of thermal conduct : +0/ -5%
Compressive strength : 20 N/cm3 (ASTM D-1621)
Water vapour absorption : 0.0042 g/m2/s
Determination of thermal conductivity : ASTM C-177
Thermal conductivity at mean temperature (MT)
MT -500C -200C 00C +500C
W/mk 0.028 0.031 0.033 0.039

SEALING MATERIALS FOR PIR/PUF PIPE SECTIONS / SLABS

Foster FIRE-RESISTIVE ADHESIVE 81-33 or equivalent standard.

COATING MATERIALS FOR PIR / PUF PIPE SECTIONS / SLABS

Foster SEALFAS COATING – 30 – 36 Class 1, Grade-A or Equivalent statndard.

ELASTOMERIC SERVICES MATERIALS

Section: Civil Page 18 of 27
Approved: Head of Section Date: 2/04/2005
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THERMAL INSULATION MANUAL

Sealing material for Armaflex shall be ARMAFLEX 520 Adhesive or equivalent.

FINISHING MATERIALS FOR ARMAFLEX

Self-adhesive aluminium foil tape, 50mm wide for indoor applications. Vapour
barrier coating for outdoor applications according to Cold Insulation applications
(Optional)

Material : Elastomeric Thermal Insulation (ARMAFLEX)

Thermal Conductivity : ASTM C 177 or C 518
Permeability : Water vapour diffusion
resistance factor : µ >3.000
Density : 3.0 – 6.0 lbs./ft (ASTM D 1662 or D1667)
Operating temperature limits : –400C to 150 0C
Water absorption, % by volume : 0.02 (ASTM C209)

HOT SERVICES/PERSONNEL PROTECTION MATERIALS

Mineral Wool : Consisting of siliceous fibres with an aspect of cottony wool. In

order to avoid any risk of corrosion its chemical composition shall be checked in
particular:

Alkaline oxide content : 0.3% maximum

Sulphur, in soluble salt form : 0.0% maximum
Sulphur in insoluble salt form : 0.5% maximum
Chlorides iron contents : <6 mg./kg.
Fibre must be non-degradable, undergo no alteration in the presence of water or
vapour, be non- flammable, and stand up to a temperature of 650 0C without any
apparent alteration.

Form :

Mineral Wool shall be used solely in mattresses, pipe cover or slab form, the use
of packing materials is prohibited and the mattresses shall not get out of shape
particularly under their own weight.
Characteristics of wool most currently used with application range:

Materials : Mineral Wool Fiber blankets / Blocks &

Slabs
Gross density : 100 kg/m3 (Blankets) 140 kg/ m3 (Blocks
& Slabs)
Tolerance : 10 %
Temperature resistance : up to 6500C
Tolerance of thermal conduct : +0/ -5%
Type of Mesh : Hexagonal
Mesh Size : 20mm
Section: Civil Page 19 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL
Diameter of wire : 0.7mm
Determination of thermal conductivity : ASTM C-177

Thermal conductivity at mean temperature (MT)

MT 1000C 1500C 2000C 3000C
W/mk 0.047 0.055 0.067 0.096
Density : 80 Kg/m3 - temperature up to 1500C inclusive
:100 Kg/ m3 - temperature from 1500C to 3000C inclusive

Thickness : Up to insulation thickness of 80mm. Mattresses and slabs shall

be applied as
a single layer. Above this thickness they shall consist of two
layers (or more).

In order to avoid any risk of corrosion its chemical composition shall be checked
in particular:
Alkaline oxide content : 0.3% maximum
Sulphur, in soluble salt form : 0.0% maximum
Sulphur in insoluble salt form : 0.5% maximum
Chlorides iron Contents : <6 mg./kg.

Fibre must be non-degradable, undergo no alteration in the presence of water or

vapour, be non- flammable, and stand up to a temperature of 650 0 C without
any apparent alteration.

HOT ACOUSTIC SERVICES MATERIALS

Form :

Mineral Wool shall be used solely in mattresses, pipe cover or slab form. The
use of packing materials is prohibited, and the mattresses shall not get out of
shape particularly under their own weight. The following are the characteristics
of wool most currently used with application range :

Materials : Mineral Wool Fiber blankets / Blocks &

Slabs
Gross density : 140 kg/m3 (Blanknes) 150kg/ m3
(Slabs/Blocks)
Tolerance : 10%
Temperature resistance : up to 6500C
Tolerance of thermal conduct : +0/ -5%
Type of Mesh : Hexagonal
Mesh Size : 20mm
Diameter of wire : 0.7mm
Determination of thermal conductivity : ASTM C-177

Thermal Conductivity :
Section: Civil Page 20 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL
MT 1000C 1500C 2000C 3000C
W/mk 0.047 0.055 0.067 0.096
Density : 80 Kg/m3 - temperature up to 1500C inclusive
: 100 Kg/ m3 - temperature from 1500C to 3000C inclusive

COLD ACOUSTIC SERVICES MATERIALS

Same as Cold Insulation “IN-SITU METHOD” or “ CLASSIC METHOD” as First

Layer and Mineral Fibre blankets /pipe covers or Slabs of suitable thickness as
Second Layer over the Cladding.

4.7STORAGE/HANDLING

 Handling of insulation materials shall be performed carefully so that they

will not be damaged.

 All Insulation materials shall be packaged to prevent ingress of moisture

both during shipment and subsequent storage at site. Standard cardboard
cartons are not acceptable without a stout polythene liner.

 All insulation materials shall be dry and shall be placed into dry storage
facilities allocated for this purpose. The Insulation Contractor shall
provide site materials facility/ies.

 Where ingress of moisture is possible (e.g. rain, condensation, spillage,

humidity etc.) insulation shall be transferred to the worksite by covered
transport. Only material for one shift’s work shall be transported to the
worksite. All material transferred to the worksite shall be stored under
cover at all times.

 Where weatherproof enclosures are not provided, the Insulation

Contractor shall ensure that insulation materials are protected against
ingress of water by encapsulating any areas of exposed insulation
material with heavy-duty polythene sheeting. Such instances should be
kept to a minimum.

 Jointing compounds, mastics etc. should be stored in accordance with the

manufacturer’s recommendations, which is typically at a temperature not
less than 50C.

4.8 COLD INSULATION THICKNESS SCHEDULE

Insulation thickness shall be in accordance with " SCHEDULE OF INSULATION

THICKNESS", below. Insulation thickness for fittings, valves and flanges shall be
the same as for pipes.
Section: Civil Page 21 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL
NOTE :- Schedule of Cold insulation thickness is based on original
engineering Specifications of each plant.
QAFCO – I & II

Polyurethane ASTM C 591 or better (Units: mm.)

Nom. Pipe Size
1/2" up to 2" 2 1/2" - 12" 14" and above &
Operating Temp. Plane surfaces
Above 10 0 C 20 20 25
Above 50C 20 25 30
Above 0 0C 25 30 35
Above -10 0 C 30 40 45

QAFCO – III
Polyurethane ASTM C 591 or better (Units:
mm.)

Temprature
Limits ( 0C )
- 40 or Less

-29 TO -20

-19 TO -10
-39 TO -30

TO 0

0 TO 20
Nominal
Size
(inches)
-9

½ - 3
/4 50 50 40 40 40 40

1 50 50 40 40 40 40
1 1/4 - 11/2
50 50 50 40 40 40
2 - 2 1/2 50 50 50 40 40 40
3 60 60 50 40 40 40
4 60 60 50 40 40 40
6 - 8 80 80 60 50 40 40
10 80 80 60 50 40 40
12 80 80 60 50 40 40
14 80 80 60 50 40 40
16 80 80 60 50 40 40
18 80 80 60 50 40 40
20 80 80 60 50 40 40
24 80 80 80 60 50 40
Above 24” 80 80 80 60 50 40
QAFCO - IV

Polyurethane ASTM C 591 or better (Units:

mm.)
Section: Civil Page 22 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

Temprature
Limits ( 0C )

- 40 or Less

-29 TO -20

-19 TO -10
-39 TO -30

TO 0

0 TO 10
Nominal
Size
(inches)

-9
½ - 3
/4 50 50 40 40 40 40

1 50 50 40 40 40 40
1 /4 - 1 /2
1 1
50 50 50 40 40 40
2 - 2 1/2 50 50 50 40 40 40
3 60 60 50 40 40 40
4 60 60 50 40 40 40
6 - 8 80 80 60 50 40 40
10 80 80 60 50 40 40
12 80 80 60 50 40 40
14 80 80 60 50 40 40
16 80 80 60 50 40 40
18 80 80 60 50 40 40
20 80 80 60 50 40 40
24 80 80 80 60 50 40
Above 24” 80 80 80 60 50 40

4.9 HOT - INSULATION THICKNESS

Section: Civil Page 23 of 27
Approved: Head of Section Date: 2/04/2005
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THERMAL INSULATION MANUAL
Insulation thickness shall be in accordance with " SCHEDULE OF HOT
INSULATION THICKNESS", attached hereto. Insulation thickness for fittings,
valves and flanges shall be the same as for pipes.

SCHEDULE OF HOT INSULATION THICKNESS

NOTE: - Schedule of hot insulation thickness is based on original
engineering Specifications of each plant.

QAFCO I & II
(Unit : mm)

Tempratur
From 60 - 150

e Limits ( 151 – 230

0
C)

231 - 300

201 - 400

401 - 600
Nominal
Size
(inches)

½ 30 30 40 50 80
3
/4 30 30 40 50 80
1
30 30 40 50 80
11/2 QAFCO 30
– III
30 40 50 80
2 30 30 40 80 100
3 30 40 50 80 100
4 30 40 50 80 100
6 40 40 80 80 100
8 40 40 80 80 100
10 40 40 80 100 150
12 40 50 80 100 150
14 40 50 80 100 150
Above
14” &
Shell, 40 50 80 100 150
Equip.
Etc.
Section: Civil Page 24 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

QAFCO III

(Unit : mm)

Temprature
Limits ( 0C )

176 - 230

231 - 290

291 - 340

341 - 400

401 - 455

456 - 510
Upto 120

121 – 175
Nominal
Size
(inches)

½ - 3
/4 30 40 50 50 80 80 80 80

1 30 40 50 80 80 80 80 80
1 /4 - 1 /2
1 1
30 40 80 80 80 80 80 80
2 - 2½ 40 50 80 80 80 80 80 80
3 50 80 80 80 80 80 80 100
4 50 80 80 80 80 100 100 100
6 - 8 60 80 80 80 100 100 100 100
10 80 80 80 100 100 100 100 100
12 80 100 100 100 100 100 100 150
14 80 100 100 100 100 100 100 150
16 80 100 100 100 100 100 150 150
18 80 100 100 100 100 150 150 150
20 80 100 100 100 100 150 150 150
24 80 100 100 100 150 150 150 150
Above 24” 80 100 100 100 150 150 150 150
Personal
Protection 30 40 50 50 50 80 100 100
(PP)
Section: Civil Page 25 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

QAFCO – IV
(Unit : mm)

Temprature
Limits ( 0C ) 176 - 230

231 - 290

291 - 340

341 - 400

401 - 455

456 - 510

511 - 600
Upto 120

121 – 175

Nominal
Size
(inches)

½ - 3
/4 30 50 50 50 80 80 80 80 100

1 30 40 50 80 80 80 80 80 100
1 1/4 - 11/2
30 40 80 80 80 80 80 80 100
2 - 2 1/2 50 50 80 80 80 80 80 80 100
3 50 80 80 80 80 80 80 100 100
4 50 80 80 80 100 100 100 100 100
6 - 8 80 80 80 80 100 100 100 100 150
10 80 80 80 100 100 100 100 100 150
12 80 80 100 100 100 100 100 100 150
14 80 80 100 100 100 100 100 150 150
16 80 80 100 100 100 100 150 150 150
18 80 80 100 100 100 150 150 150 150
20 80 80 100 100 100 150 150 150 150
24 80 80 100 100 150 150 150 150 150
Above 24” 80 80 100 100 150 150 150 150 150
Personal
Protection 30 30 30 30 50 80 80 100 150
(PP)

Schedule of Hot Insulation Thickness for Desalination Units in

Qafco :
&

Manways & Hand

etc.
Evaporator, heat

with

with

Equipment to
Steam Tracing.
(Desalination

(Desalination

(Desalination

(Desalination

be insulated
compressors.

Steam Chest
exchangers
condensers

Operating
Ejectors,

Ejectors

Ejectors

Temperatures
Units)
Unit)

holes

(0C)

60 – 150 50 100 60 60 50
151 – 250 -- 100 70 70 50
251 – 350 -- -- 80 80 80
351 – 450 -- -- -- -- 100
451 – 600 -- -- -- -- 130
Section: Civil Page 26 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

4.10 ACOUSTIC INSULATION THICKNESS SCHEDULE

 Insulation thickness shall be in accordance with " SCHEDULE OF ACOUSTIC
INSULATION THICKNESS", attached hereto.
 Acoustic Insulation thickness for fittings, valves and flanges shall be same
as for pipes.

NOTE :- Schedule of Acoustic insulation thickness is based on original engineering Specifications of each plant.

QAFCO – III
(Units
: mm.)

Temprature
Limits ( 0C )
176 - 230

231 - 290

291 - 340

341 - 400

401 - 455

456 - 510
Upto 120

121 – 175

Nominal
Size
(inches)

½ - 3
/4 80 80 80 80 100 100 100 100

1 80 80 80 80 100 100 100 100

1 1/4 - 11/2
80 80 100 100 100 100 100 100
2 - 2 1/2 80 80 100 100 100 100 100 100
3 80 80 100 100 100 100 100 100
4 100 100 100 100 100 100 100 100
6 - 8 100 100 100 100 100 100 100 100
10 100 100 100 100 100 100 100 100
12 100 100 100 100 100 100 100 150
14 100 100 100 100 100 100 100 150
16 100 100 100 100 100 100 150 150
18 100 100 100 100 100 150 150 150
20 100 100 100 100 100 150 150 150
24 100 100 100 100 150 150 150 150
Above 24” 10
100 100 100 150 150 150 150
0
Section: Civil Page 27 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

QAFCO – IV
(Units:
mm.)

Temprature
Limits ( 0C )
176 - 230

231 - 290

291 - 340

341 - 400

401 - 455

456 - 510

511 - 600
Upto 120

121 – 175

Nominal
Size
(inches)

½ - 3
/4 80 80 80 80 100 100 100 100 100

1 80 80 80 80 100 100 100 100 100

1 1/4 - 11/2
80 80 100 100 100 100 100 100 100
2 - 2 1/2 80 80 100 100 100 100 100 100 100
3 80 80 100 100 100 100 100 100 100
4 100 100 100 100 100 100 100 100 100
6 - 8 100 100 100 100 100 100 100 100 100
10 100 100 100 100 100 100 100 100 150
12 100 100 100 100 100 100 100 150 150
14 100 100 100 100 100 100 100 150 150
16 100 100 100 100 100 100 150 150 150
18 100 100 100 100 100 150 150 150 150
20 100 100 100 100 100 150 150 150 150
24 100 100 100 100 100 150 150 150 150
Above 24” 10
100 100 100 150 150 150 150 150
0

5. REFERENCE

QAFCO P&ID standard

BS En 12241 : 1998.
DIN – EN 573 / ASTM B-209 or Equivalent
AISI 304
ASTM C 518
Section: Civil Page 28 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL
ASTM C 591
DIN 52612
ASTM C 177
ASTM C 209
ASTM C 236
ASTM D 1662
ASTM D1667

6. DEFINITIONS

Insulation is defined as those materials or combinations of materials, which

retard the flow of heat energy by performing one or more of the following
functions:
 Conserve energy by reducing heat loss or gain.
 Control surface temperatures for personnel protection and comfort.
 Facilitate temperature control of a process.
 Prevent vapor flow and water condensation on cold surfaces.
 Increase operating efficiency of heating/ventilating/cooling, plumbing,
steam, process and power systems.
 Prevent or reduce damage to equipment from exposure to fire or corrosive
atmospheres.

Applications in the temperature range are between -268oC and 650oC termed
“Thermal Insulation”. Thermal Insulation is further split into 3 categories.

Low Temperature Thermal Insulation

1. 15.6ºC through 0ºC (60ºF through 32ºF) -- i.e. Cold or chilled water.
2. -0.6ºC through -39.4ºC (31ºF through -39ºF) -- i.e. Refrigeration or glycol.
3. -40.0ºC through -73.3ºC (-40ºF through -100ºF) -- i.e. Refrigeration or brine.

Intermediate Temperature Thermal Insulation

1. 16.1ºC through 99.4ºC (61ºF through 211ºF) -- i.e. Hot water and s
team condensate.
2. 100.0ºC through 315.6ºC (212ºF through 600ºF) -- i.e. Steam, high
temperature hot water.

High Temperature Thermal Insulation

316.1ºC through 815.6ºC (601ºF through 1500ºF) -- i.e. Turbines, expansion
joints, stacks, exhausts, incinerators, boilers.

All applications below -73.3ºC (-100ºF) are termed “Cryogenic”, and those above
815.6ºC (1500ºF) are termed “Refractory”.
Section: Civil Page 29 of 27
Approved: Head of Section Date: 2/04/2005
Signature: Replaced: SMt-Ci-004, Rev: 0, 01/03/1996
THERMAL INSULATION MANUAL

7. LIST OF DRAWINGS :
COLD INSULATION
S. Drawing Description
No. No.
1 C-1 Application Method Of Banding
2 C-2 Heads Insulation
3 C-3 Insulation For Straight Pipes
4 C-4 ( 1/2 ) Insulation For Flanges Of
Equipment
5 C-4 ( 2/2 ) Insulation For Pipe Flanges
6 C-5 Insulation For Valves & Flanges
7 C-6 Insulation For Tees And Elbows
8 C-7 Insulation For Hangers &
Supports
9 C-8 Insulation Support For Pipes
10 C-9 ( 1/4 ) Insulation for Expansion Joints
( Typical )
11 C-9 ( 2/4 ) Insulation for Expansion Joints
( Typical )
12 C-9 ( 3/4 ) Insulation for Expansion Joints
( Typical )
13 C-9 ( 4/4 ) Insulation for Expansion Joints
( Typical )
14 C-10 Flexible Elastomeric Pipe
Insulation
15 C-11 Elastomeric Sheets

HOT INSULATION
S. Drawing N. Description
No.
1 H-1 Application Method Of Banding
2 H-2 Head Insulation
3 H-3 Expansion Joint For Towers &
Vertical Drums
Section: Civil Page 30 of 27
Approved: Head of Section Date: 2/04/2005
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THERMAL INSULATION MANUAL
4 H-4 Insulation For Piping
5 H-5 (1/2) Insulation For Flanges Of
Equipment
6 H-5 (1/2) Insulation For Pipe Flanges
7 H-6 Insulation For Valves & Flanges
8 H-7 Insulation For Trace Piping
9 H-8 Insulation For Hangers &
Supports
10 H-9 Insulation Support For Pipes
11 H-10 Insulation Of Tanks
12 H-11 Steam Tracing Arrangement
13 H-12 Typical Arrangements For
Cladding

ACOUSTIC INSULATION

S. No. Drawing Description

No.
1 A-1 Spacers For Pipes And
Equipment
2 A-2 Overlapping Of Cladding Joints
3 A-3 Insulation For Flange Caps
4 A-4 Insulation For Valve Caps
8. APPENDIX OF DRAWINGS

This is provided as a separate document, titled:

THERMAL INSULATION – APPENDIX OF DRAWINGS