Doc No : SOP/ENG/01 Effect date :

Rev : Page : 1 of 10

STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

HOT INSULATION

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PREPARED BY CHECKED BY APPOVED BY

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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

1. SCOPE
This procedure covers the installation quality of the external thermal insulation applied to Piping
and Equipment in hot service for Project
The intent of this document is to develop the detailed quality procedure based upon the project
specification, and the related technical clarification.
2. REFERENCE
ISO 9001:2008 clause 7.1 clause 7.2.1 clause 7.2.2 clause 7.5.1 clause 7.5.2 clause 8.1 clause
8.2.3 clause 8.2.4.
2.1 Project Specification
- General Specification Hot Insulation
- Specification Project
3. GENERAL REQUIREMENTS
3.1 Definition
The following words and phrases as used in this specification shall be defined as follows:
 Piping – shall include all components in the piping system except as noted. The
piping line numbering system, including insulation designation, is included in the
specification, “piping Design”
 Equipment – shall include vessels, towers, exchangers, tanks, turbines, pumps,
filters etc.
 Normal temperature – shall be the normal operating temperature, as shown in the
line designation tables of the appropriate project data book.
 Maximum Temperature – shall be the highest/lowest temperature reached during
operation, system out, process update, regeneration, cool down, depressurization,
as shown in the designation tables of the appropriate project data book.
 Upset Temperature – shall be the highest/lower temperature reached and
sustained for 30 minutes or longer during emergency or upset conditions, as shown
in the line designation tables of the appropriate project data book.
 Insulation Design Temperature- shall be the normal operating temperature, but the
insulation itself shall be able to withstand the maximum and upset temperature.
3.2 Criteria
3.2.1 The following selection criteria are used to established when insulation is require :
 Piping having normal operating temperature between 60◦ F and 150◦ F will
not be insulated for heat conservation. No valves or flanges shall be
insulated for heat conservation, except not heat traced piping or tubing.
 Conservation of Heat for economy (HC) – Cold or Hot Insulation is required
if the heat saved is economically justified.
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

 Personnel Protection (PP) – Insulation is required or guards must be

provided if the normal operating temperature is above 60◦ C (or under -
10◦ C in upset temperature ) and the exposed surfaces are located withi
0.375 m horizontally and 2.1 m vertically above grade, or normal access,
walkway, platform or work area.
 Pumps and Turbines - Pumps and Turbines operating between 29◦ C and
121◦ C shall not be insulated for economy, unless specified, otherwise all
pumps shall be insulated for hot or cold service as appropriate.
3.2.2 The installed insulation system shall meet the following installation criteria :
 Allow equipment, pipe expansion joints and loops to contract or expand
during startup and operation without damage to the insulation system.
 Maintain complete weather coating integrity and vapor barrier integrity
where applicable during all contraction or expansion to prevent eventual
failure of the system.
 System shall be designed as single-layered or multi-layers are required to
avoid excessive thermal stress throughout the specified temperature range.
3.3 Omitted Insulation
Insulation shall be specified to be omitted on piping components and sections of equipment
where a heat loss is desired as compressor discharge line upstream of the discharge cooler if
such line are located where they do not constitute a personnel hazard.
3.4 Clearance
The clearance between the outside surface of any insulated and adjacent equipment or
structural members (including stairways) shall be not less than 25 mm
3.5 Insulation window.
An insulation window shall be provided for wall thickness measurement using ultrasonic
equipment.
3.5.1 Cutting the insulation in cylindrical shape shall make the Insulation window. A with
self-drill screws, as shown on the attached figure.
3.5.2 The equipment which need to be provided with inspection holes and quantity of
inspection holes required.
4. MATERIAL.
Material and their usage are summarized as follows. The detailed information of each material
together with product data sheet, and Material Data Sheet (MSDS).
4.1 Hot Insulation Material
4.1.1 Calcium Silicate Insulation.
Usage : Insulation material for Piping up to 30◦ NPS
Standard : ASTM C533-85 Type 1
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

Density : Normal 170 kg/ m3 and maximum 240 kg/ m3

4.1.2 Mineral Fiber Blanket

Usage : Insulation material for box insulation such as valves, flanges,

nozzle, manhole.

Standard : ASTM 553

Density : Normal 80 Kg/m3
Lamination : Galvanized steel hexagonal wire stitched on one side.
4.2 Coating Material and their accessory.
4.2.1 Hard Cement
Usage : Trowel over insulation surface to provide hard smooth surface
allows for the application of Water Proofing Wastic
4.2.2 Hexagonal Wire Mesh
Usage : Reinforcement for Hard Cement
Description : 25 mm hex mesh 3 twits of 20 BWG, soft Type 304 S/S
4.3 Fastening Material
4.3.1 S/S Self Tapping Screw
Usage : Fastening of metal cladding
Description : 4,2 mm OD X 12 mm long alumunium pop rivet
4.3.2 S/S Steel Wire
Usage : fastening material for pipe insulation up to 16” NPS
Material : S/S wire OD 1.6” mm
4.3.3 Stainless Steel Band and Seal
Usage : fastening material for insulation and metal Cladding
Dimension : 13 mm X 0.5 mm (up to 18” NPS0, 19 mm X 0.5 mm (above 18”
NPS)
Specification : Type 304 Stainless steel
4.3.4 Expansion Spring
Usage : install together with band insulation and metal cladding for
each 7.6 m of band.
Material : Stainless Steel 4” length
4.4 Metal Cladding
Usage : weather Jacket for insulation
Material : Alumunium with factory applied polykraft moisture barrier.
Standard : ASTM B209 Alloy 3003
Thickness : 0.4 mm & 0.5 mm
Shape :
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

- 0.4 mm Flat sheet for piping and exchanger head

- 0.5 mm Flat sheet for fitting, flange and valve
- 0.5 mm X 5 mm corr for horizontal equipment and vertical
equipment 30” ⱷ or less
- 0.5 mm X 32 mm corr for equipment vertical 30 ⱷ and over.
4.5 Other
4.5.1 Metal Sealant
Usage : water sealing of metal cladding where water may Ingress
5. APPLICATION
5.1.1 The thickness of piping insulation shall be as specified in the line designation Tables
and/or ISO drawing. Where smaller diameter piping is included in a line, such as
drain or control valve, stations, proportionately thinner insulation may attached
insulation thickness tables.
5.1.2 The thickness of equipment insulation shall be as specified in Equipment Insulation
Schedule. For any unspecified the thickness shall be selected from the insulation
thickness.
5.2 Surface Preparation
All insulated components shall have their surface prepared in accordance with the following:
All items to be insulated shall be cleaned of oil, grease, loose scale and foreign matter.
Surface shall be dry and clean prior to application of insulation.
5.3 Application of Insulation
5.3.1 Straight Piping
Straight Piping shall be covered with Calcium Silicate pipe section held in place with
S/S wire at approximately 225 mm centers.
a) S/S wire of No. 16 gauge shall be used for pipe diameter up to 16”. The ends of
wire loops shall be firmly twisted together, bent over, and embedded into the
surface of the insulation
b) Single layer shall be applied for the insulation thickness of up to 75mm, multiple
layers shall be applied for insulation thickness of above 75 mm. in the multiple
layers insulation, joints between layers shall be staggered.
c) Straight Piping insulation material shall be Calcium Silicate.
d) Insulation of vertical piping, which is 4 inch nominal diameter and larger, and
has uninterrupted vertical straight runs over 3.7 m long shall be supported by
the insulation support ring. Such support is not required where intermediate
branch connections provided equivalent support. Insulation subcontractor shall
do the supply and installation of insulation support ring.
e) Expansion joints shall be provided in all insulation straight over 12.2 m long.
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

f) The weatherproof jacket shall be install the same day as the insulation,
otherwise, exposed insulation shall be covered with temporary from rainwater.
5.3.2 Elbows and Band
a) Elbows and bands 2 inch diameter and larger shall be covered with miters cut
from section of Calcium Silicate pipe section.
b) Elbows and Bands up to 1 inch diameter may be covered with “Stove-pipe”
(single mitre) elbow.
5.3.3 Valves, Flanges, Nozzles
a) Valves, Flanges, Nozzles shall be covered with Mineral Wool Blanket held in
place by galvanized steel wire.
b) Sufficient clearance shall be left on at least one side of flanged connections for
bolt removal without damage to adjacent insulation .
c) The thickness of Mineral wool Blanket shall be equal to adjacent Calcium Silicate
insulation of straight piping.
5.3.4 Branch Connections
Branch Connections, such as tees and nozzle – welds shall have the insulation on the
main run notched in the shape of “V” at the point of intersection on the insulation
for the branch shall have the end cut to a match the “V” on the main run. The two
parts shall be pressed together as firmly as possible.
5.3.5 Equipment
Not hot insulation shall be installed on equipment nameplates, manway, shall and
channel flanges of heat exchangers, nozzle flanges, lifting lugs, clip for pipe support
or platforms, support saddles or flanges on pump and turbine casing, unless that
insulation is required for personnel protection. All insulated equipment shall be in
accordance with the procedures described below.
5.3.6 Vessel shall
a) Vessel shall be insulated with Calcium Silicate held in place with stainless steel
bands at approximately 300 mm centers. The side of blocks shall be beveled so
as to provide 100% contact with adjoining blocks. End joints of adjacent blocks
shall be staggered and butted closely. Shall insulation shall extend over the
insulation on the heads.
b) Vessel outer diameter up to 22 inch shall be secured with stainless steel band of
13 mm wide X0.5 mm thickness, above 22 inch diameter shall be that of 19 mm
wide X 0.5 mm thickness.
c) The circumferential bands on equipment 3.5 mm diameter and larger shall have
expansions springs installed at maximum intervals of 7.6 m.
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

d) Vertical vessel having insulation support ring and/or stiffer rings shall have 25
mm expansion space between the under side of the ring and the insulation
below. The 25 mm void shall be packed with loose mineral wool.
e) Stainless steel bands applied to the conical section shall be installed with
adequate support to prevent circumferential bands from coming loose.
f) Vessel stiffer rings shall be boxed-in so as to provided the full depth of
insulation over the ring.
5.3.7 Vessel Heads.
a) Vessel Heads shall be insulated with Calcium Silicate fitted in tapered segments
as required to follow the contour. The stainless steel bands shall radiate from
the floating ring around center nozzle. The maximum spacing of the bands shall
be 300 mm or one block width ever is the least.
b) Insulation for horizontal vessel heads up to 700 mm outside diameter may be in
the form of circular discs fabricated from Calcium silicate. Voids formed local to
the knuckle radius of the heads inside shall be packed with loose mineral wool.
c) Insulation of bottom heads inside skirt surface of vessel over 1. 000 mm outside
diameter shall be either curved or standard flat Calcium silicate block secured by
stainless steel bands to insulation rods provide be vessel fabricator. The
insulation shall be covered with galvanized hexagonal wire mesh, and finished
with hard cement applied over wire mesh. Thickness of hard cement shall be
adequate to fill in any key into the wire mesh.
5.3.8 Pumps and Turbines
Irregular shape items, such as pumps and turbines, shall be covered with a pieced of
Material Wool Block fitted to the contour and impaled on weld-pins and secured
with “speed” washers.
Galvanized hexagonal wire mesh shall be fitted closely over the blocks and secured
with separate “speed” washer on the same weld-pins.
When no weld pins is provided, mineral wool block shall be istalled with galvanized
steel wire.
Hard cement shall be trowelled on approximately 13 mm thick over wire mesh.
After hard cement becomes dry, waterproofing mastic shall be coated over the hard
cement (no metal cladding is installed).
5.4 Application of Metal Clading
5.4.1 Straight Piping
a) Straight Piping insulation shall be weatherproof with 0.4 mm thickness,
alumunium cladding. All metal cladding shall ve overlapped a minimum of 50
mm, with laps placed so as to shed water.
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

b) Stainless steel bands shall be tightened around alumunium cladding at intervals

of approximately 288 mm so that the cladding is held snugly in intervals of
approximately 288 mm so that the cladding is held snugly in contact with the
insulation. Bands shall be located at the center of each overlap of the
alumunium cladding.
c) Vessel outer diameter up to 22 inch shall be secured with stainless steel bands
of 13 mm wide X 0,4 mm thickness, above 22 inch diameter shall be that of 19
mm wide X 0.5 thickness.
d) For vertical piping, minimum 2 place of S-clip’s per one sheet shall be instaleed
for the circumferential lapping to avoid slipping down.
5.4.2 Elbows and Bands
a) Insulation of elbows and bends shall be weatherproofed with 0.5 mm thickness
flat alumunium cladding.
b) Cladding over elbows and bands shall be atrranged in lobster back segments
which accurately fit waterproof ball be fabricated joint between adjacent
segments. Accordingly, each segment shall be fabricated with both sides sweged
paralleled to the curved adge one adge swaged for fitting under and edge
swaged for fitting over. Metal sealent shall be put into the swage during
fabrication, or over swages after the installation of each segment at site.
c) Elbows and bands ½ inch pipe size and smaller, may be covered with “Stove-
Pipe” cladding (single miter segment).
5.4.3 Valves and Flanges
a) The insulation over valves and flanges shall be enclosed in metal boxes. Boxes
shall be fabricated from flat alumunium cladding with circumferential loking
means. Metal boxex shall be secured with stainless steel bands for a removable,
reusable construction.
b) The termination between metal boxes and line insulation cladding shall be
sealed with metal sealant.
5.4.4 Vessel Shall
a) Vertical vessels 30 m in diameter and larger shall be clad with 32 mm
corrugated X 0.5 mm alumunium on the straight sheel area.
Horizontal and smaller vertical vessels shall be clad with 5 mm corrugated x 0.5
mm T alumunium
b) All metal cladding shall be overlapped a minimum of 75 mm, with laps placed so
as to shed water. Stainless steel bands for the alumunium cladding shall be
tightended at intervals of approximately 600 mm so the jacket is held snugly in
contact with the insulation, and a stainless steel band shall be located at the
center of each overlap of the metal cladding.
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

Cladding shall be additionally secured through vertical overlap with S/S screw at
approximately 150 mm intervals. For horizontal vessel, S/S Screw at
approximately 150 mm intervals. For horizontal vessel, S/S Screw shall be
applied to the horizontal overlap of alumunium cladding at approximately 150
mm intervals.
c) On vertical vessels, S-clip’s made from 19 mm wide steel bands shall be used on
approximately 600 mm centers to support upper of cladding on the lower
course of cladding.
d) The circumferential bands on all metal cladding shall have expansion spring
installed for each 7.6 m of bond.
5.5 Vessel Heads
a) Heads of vessels shall be clad with flat 0.4 mm T alumunium gores pre-cut in the
fabrication shop and secured with S/S screw at 150 mm intervals. The exposed edge of
the gores shall have a continuous swage its full length.
b) Metal sealant shall be placed in the lap before it is riveted. Drill all holes possible in the
fabrication shop, make sub-assemblies in the shop whenever possible.
6. ATTACHMENET
6.1 Form of Allocation of Hours FM/ENG/01.01
6.2 Form of Inspection Control Sheet FM/ENG/01.02
6.3 Form of Inspection for Insulation Work FM/ENG/01.03
6.4 Form of Inspection Punch List FM/ENG/01.04
6.5 Table of Insulation Material TB/ENG/01.01
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STANDARD OPERATIONAL PROCEDURE TITLE : HOT INSULATION

REVISI RECORD

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