April 1999

Process Industry Practices

Insulation

PIP INSC2000
Installation of Cold Service Insulation Systems
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence over
this Practice. Determinations concerning fitness for purpose and particular matters or
application of the Practice to particular project or engineering situations should not be
made solely on information contained in these materials. The use of trade names from
time to time should not be viewed as an expression of preference but rather recognized as
normal usage in the trade. Other brands having the same specifications are equally
correct and may be substituted for those named. All practices or guidelines are intended
to be consistent with applicable laws and regulations including OSHA requirements. To
the extent these practices or guidelines should conflict with OSHA or other applicable
laws or regulations, such laws or regulations must be followed. Consult an appropriate
professional before applying or acting on any material contained in or suggested by the
Practice.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies may copy this practice for their internal
use.

Not printed with State funds

 April 1999

Process Industry Practices

Insulation

PIP INSC2000
Installation of Cold Service Insulation Systems
Table of Contents

1. Introduction .................................2 5. Application of Insulation............ 3

1.1 Purpose ............................................2 5.1 General ............................................ 3
1.2 Scope ...............................................2 5.2 Securement...................................... 5
1.3 Insulation Systems............................2 5.3 Metal Jacketing ................................ 5
1.4 Supporting Documents......................2 5.4 Screws ............................................. 6
5.5 Contraction Bands ............................ 6
2. References ..................................2 5.6 Insulation Contraction Joints............. 6
2.1 Process Industry Practices (PIP) .......2 5.7 Insulation Supports on Vertical
2.2 Industry Code and Standards ............2 Piping............................................... 6
5.8 Fitting, Flange and Valve Insulation.. 6
3. Definitions ...................................3 5.9 Vapor Barriers .................................. 7
5.10 Protection of Installed Insulation...... 7
4. Storage and Handling of 5.11 Damage Considerations .................. 7
5.12 General Housekeeping.................... 7
Insulation Materials ....................3
6. Extent of Insulation .................... 8

7. Documentation ........................... 8

Data Sheets:
INSC2001 - Extent of Insulation
INSC2002 - Documentation Requirements

Process Industry Practices Page 1 of 8

PIP INSC2000
Installation of Cold Service Insulation Systems April 1999

1. Introduction

1.1 Purpose
The purpose of this Practice is to provide requirements for installation of cold
service insulation systems, ambient to -290° F (-179° C).
This Practice may be used above ambient if the insulation system temperature
does not exceed material limitations.

1.2 Scope
This Practice covers requirements for storage and handling of insulation materials,
application of insulation, extent of insulation, and documentation.

1.3 Insulation Systems

Systems requiring additional insulation specifications beyond PIP Practices shall
be covered by Purchaser’s documentation.

1.4 Supporting Documents

Use of this Practice for contractual purposes requires the Purchaser to make
specific choices and assemble additional supporting documents. Listing of, or
reference to, supporting documents within this Practice does not imply suitability
for specific designs.

2. References

When adopted in this Practice, the latest edition of the following codes, standards,
specifications, and references in effect on the date of contract award shall be used, except
as otherwise specified. Short titles will be used herein when appropriate.

2.1 Process Industry Practices (PIP)

– PIP INTG1000 - Insulation Inspection Checklist

2.2 Industry Code and Standards

• American Society of Testing and Materials (ASTM)
– ASTM C450 - Standard Practice for Prefabrication and Field Fabrication
of Thermal Insulating Fitting Covers for NPS Piping, Vessel Lagging and
Dished Head Segments
• American Petroleum Institute (API)
– API RP521 - Guide for Pressure-Relieving and Depressuring Systems

Page 2 of 8 Process Industry Practices

 PIP INSC2000
April 1999 Installation of Cold Service Insulation Systems

3. Definitions

For the purposes of this Practice, the following definitions apply:

Contractor: Party responsible for furnishing and/or installing the insulation system

Owner: Principal end user

Purchaser: Owner or the Owner’s authorized agent

4. Storage and Handling of Insulation Materials

4.1 From delivery to installed finished product, insulation materials shall at all times
be protected from the elements and have adequate drainage.
4.2 Insulation materials shall be handled and stored per manufacturer’s printed
recommendations.
4.3 Mastics, adhesives, and sealers that are exposed to temperatures outside the
recommended temperature ranges during storage shall be removed from the site
and replaced with new material.
4.4 Materials that have exceeded their shelf life shall be removed from the site and
replaced with new material.

5. Application of Insulation

5.1 General
5.1.1 All materials shall be stored, mixed, thinned, and applied in accordance
with the manufacturer’s printed instructions. All conflicts between this
Practice and the manufacturer’s instructions shall be brought to the
attention of the Purchaser for resolution.
5.1.2 Authorization to proceed with application of insulation shall be obtained
in writing from the Purchaser.
5.1.3 Unless otherwise specified, insulation shall not be applied until completion
of the following has been verified in accordance with
PIP INTG1000:
a. Required hydrostatic and/or pneumatic pressure testing
b. Application of required substrate protective coating systems,
including touch-up of previously applied coatings
c. Installation and testing of required tracing systems
d. Cleaning of surfaces that are to receive insulation

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PIP INSC2000
Installation of Cold Service Insulation Systems April 1999

5.1.4 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.
5.1.5 Multi-layer insulation is required for polyisocyanurate at temperatures of
-1° F (-18° C) and below.
5.1.6 Multi-layer insulation is required for cellular glass thicknesses greater
than 3 inches (90 mm) in accordance with the following table:

Total Thickness Thickness

Thickness Inner Layer Outer Layer(s)
3-1/2" 1-1/2" 2"
4" 2" 2"
4-1/2" 2" 2-1/2"
5" 2-1/2" 2-1/2"
5-1/2" 2-1/2" 3"
6" 3" 3"
6-1/2" 3" 3-1/2"
7" 2" 2-1/2" plus 2-1/2"
7-1/2" 2-1/2" 2-1/2" plus 2-1/2"
8" 2-1/2" 2-1/2" plus 3"
8-1/2" 2-1/2" 3" plus 3"
9" 3" 3" plus 3"
9-1/2" 3" 3" plus 3-1/2"

5.1.7 When applying insulation, the circumferential butt joints of each section
shall be staggered.
5.1.8 When applying multi-layer insulation, each succeeding layer shall be
staggered to the longitudinal and circumferential joint of the layer beneath.
5.1.9 Joint sealer shall be applied to all joints of single layer and only to joints
of the outer layer of multi-layer applications.
5.1.10 Each layer of multi-layer insulation shall be held in place separately.
5.1.11 All insulation shall be smooth and free from cracks, voids and depressions
greater than 1/8 inch (3 mm). All cracks, voids and depressions in the
insulation greater than 1/8 inch (3 mm) shall be refitted, not filled.
5.1.12 The Purchaser shall identify areas that require bore coating of cellular
glass such as the following:
a. The surface being insulated cycles or swings through an operating
temperature range greater than 400° F.
b. The surface being insulated experiences high vibrations.
c. The insulation is carrying the load of the pipe such as at a pipe
hanger or supports.

Page 4 of 8 Process Industry Practices

 PIP INSC2000
April 1999 Installation of Cold Service Insulation Systems

5.1.13 Protrusions, other than nozzles, through the insulation on equipment and
piping shall be insulated for a minimum distance equal to 4 times the
adjacent insulation thickness measured from the surfaces of the equipment
or pipe.
5.1.14 The insulation thickness for protrusions shall be 1/2 the insulation
thickness of the adjacent insulated surface but not less than 1-1/2 inches
(38 mm).
5.1.15 Vapor stops that seal the insulation to the pipe or equipment shall be
installed at all insulation terminations and changes in configurations.
These include, but are not limited to, elbows, flanges, pipe supports,
instrument connections, uninsulated vents, and relief valves.

5.2 Securement
5.2.1 Insulation up to 12 inches (300 mm) outside diameter (OD) shall be held
in place with fiberglass reinforced pressure-sensitive tape or stainless steel
tie wires applied over the tape. All cut ends of wire shall be embedded into
the insulation.
5.2.2 Insulation 12 inches (300 mm) OD to 24 inches (610 mm) OD shall be
held in place with 1/2 inch (13 mm) wide by 0.020 inch (0.51 mm) thick
Type 304 stainless steel bands and wing seals. Larger than 24 inches
(610 mm) OD, use 3/4 inch (19 mm) wide by 0.020 inch (0.51 mm) thick
bands and wing seals.
5.2.3 Metal jacketing up to 24 inches (610 mm) OD shall be held in place with
1/2 inch (13 mm) wide by 0.020 inch (0.51 mm) thick Type 304 stainless
steel bands and wing seals. Larger than 24 inches (610 mm) OD, use 3/4
inch (19 mm) wide by 0.020 inch (0.51 mm) thick bands and wing seals.

5.3 Metal Jacketing

5.3.1 Metal jacketing on all vessels and piping smaller than 48 inches
(1219 mm) in diameter shall be aluminum, 0.016 inch (0.406 mm) thick,
and machine-rolled for circumferential fit. The Purchaser shall specify
finish (i.e., smooth, corrugated, crossed crimped, embossed, coated, etc.).
5.3.2 Metal jacketing on piping and horizontal equipment 48 inches
(1219 mm) and larger in diameter shall be aluminum, 0.024 inch
(0.61 mm) thick. Finish shall be specified by Purchaser (i.e., smooth,
corrugated, cross-crimped, embossed, coated, etc.).
5.3.3 Metal jacketing on vertical equipment 48 inches (1219 mm) and larger in
diameter shall be aluminum sheets, 0.024 inch (0.61 mm) thick with
1-1/4 inches (32 mm) pitch corrugations, measuring approximately 33 to
48 inches (838 to 1220 mm) wide by 10 feet (3 m) long. The length of
corrugated jacketing may be modified to minimize waste and cutting.
5.3.4 Vessel head segments, fittings, valves, etc., shall be fabricated from
smooth metal.

Process Industry Practices Page 5 of 8

PIP INSC2000
Installation of Cold Service Insulation Systems April 1999

5.3.5 Stainless steel jacketing 0.010 inch (0.254 mm), or as otherwise specified,
shall be used on equipment and piping when fire protection is required to
comply with API RP521.
5.3.6 Exposed edges of metal jacketing shall be machine-bent or rolled to
minimize sharp edges.

5.4 Screws
Screws, if used, shall not penetrate the vapor barrier. The Contractor shall submit
a proposed procedure for the use of screws for the Purchaser’s approval.

5.5 Contraction Bands

Jacket banding on vessels larger than 8 feet (2.4 m) in diameter shall have 4-inch
(100 mm) stainless steel compression springs. Springs shall be located every 30
feet (9.1 m) of band length. Each spring shall be installed and loaded in
accordance with the manufacturer’s printed instructions.

5.6 Insulation Contraction Joints

Insulation contraction joints shall be installed with maximum distance between
joints as specified in the table below. Contraction joints shall also be provided in
uninterrupted straight pipe insulation when the run length is equal to or greater
than 1/2 the maximum allowed distance.
Maximum Contraction Joint Spacing, Ft (m)
Operating Temperature Carbon Steel Stainless Steel
o o
F C Cellular Polyiso Cellular Polyiso
Glass cyanurate Glass cyanurate
to 0 to -18 200 (61.0) 37 (11.3) 113 (34.4) 43 (13.1)
-1 to -50 -19 to -46 118 (36.0) 22 (6.7) 66 (20.1) 25 (7.6)
-51 to -100 -47 to -73 N.A. N.A. 47 (14.3) N.A.
-101 to -150 -74 to -101 N.A. N.A. 36 (11.0) N.A.
-151 to -200 -102 to -129 N.A. N.A. 30 (9.1) N.A.
-201 to -250 -130 to -157 N.A. N.A. 26 (7.9) N.A.
-251 to -300 -158 to -184 N.A. N.A. 23 (7.0) N.A.

5.7 Insulation Supports on Vertical Piping

Vertical pipe insulation shall be supported by a pipe insulation support located
directly above all elbows, flanges, or flanged valves. Additional supports are
required at a maximum spacing of 24 feet (7.3 m) of uninterrupted length, but not
less than spacing required for contraction joints.

5.8 Fitting, Flange and Valve Insulation

5.8.1 Prefabricated, molded, or routed insulation fittings shall be used when
commercially available.

Page 6 of 8 Process Industry Practices

 PIP INSC2000
April 1999 Installation of Cold Service Insulation Systems

5.8.2 Insulation for all fittings shall be fitted and assembled with tight joints.
Joining prefabricated assemblies shall be done with adhesives designed for
use in low temperature applications.
5.8.3 Insulation for fittings, flanges, and valves shall be fabricated in
accordance with ASTM C450 and the Adjunct.

5.9 Vapor Barriers

5.9.1 Before the application of weatherproof jacketing, all surfaces shall be
sealed with a vapor barrier mastic or membrane type vapor barrier sheet,
as indicated on the Material System Data Sheet.
5.9.2 Membrane type vapor barrier sheet shall be installed without fish
mouthing gaps or folds and shall have a minimum 2-inch (50 mm) overlap
at all joints.
5.9.3 Vapor barrier mastic and reinforcing fabric shall be installed in
accordance with the manufacturer’s printed instructions to the minimum
thickness indicated on the Material System Data Sheet. Vapor barrier
mastic shall be applied in a minimum of two coats: a tack coat followed
by a minimum of one finish coat after installation of reinforcing fabric.
Care shall be taken to completely fill and seal the fabric openings.
5.9.4 All other commercially available vapor barrier systems shall be installed
in accordance with the manufacturer’s printed instructions.

5.10 Protection of Installed Insulation

5.10.1 Installed insulation shall have the required permanent protection or
temporary protection applied before the conclusion of that day’s work.
5.10.2 Installed insulation shall have temporary protection applied if the
insulation can be damaged by rain or other forms of atmospheric
moisture.

5.11 Damage Considerations

5.11.1 Unless otherwise specified by Purchaser, insulation that becomes wet shall
be removed and replaced with dry insulation.
5.11.2 Damaged insulation shall be replaced.

5.12 General Housekeeping

5.12.1 Insulation materials shall be handled and disposed of in accordance with
applicable laws and regulations.
5.12.2 Insulation related materials, such as mastics, shall be handled and applied
with care to prevent splattering on adjacent facilities (e.g., concrete
foundations, paving, structural steel, equipment, piping, gauge glasses,
instruments, machined surfaces, valve stems, and packing).
5.12.3 All mastic overspray and splatter shall be cleaned up as soon as it occurs.

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PIP INSC2000
Installation of Cold Service Insulation Systems April 1999

5.12.4 Flammable materials shall be stored away from ignition sources such as
welding operations.
5.12.5 Debris resulting from insulation application work shall be removed from
the work area at the end of each shift, unless otherwise directed.

6. Extent of Insulation

For extent of insulation, see Data Sheet PIP INSC2001.

7. Documentation

Documents required to define the scope of the work shall be listed on Data Sheet
PIP INSC2002.

Page 8 of 8 Process Industry Practices

 Installation of Cold Service Insulation Systems INSC2001
Page 1 of ____
Data Sheet for Extent of Insulation April 1999

Project _____________________________________________ Date ___________________________

Insulation Requirements for Piping and Equipment
(Note: Project piping and equipment insulation specifications may modify these requirements.)

Insulation Codes:

FP - Fire Protection Insulation CC - Cold Service Insulation CT - Chilled Fluid Trace

CJ - Chilled Fluid Jacketed CP - Condensation Control

Items AMB to -290°° F AMB to 32°° F

CC CP
Straight or bend pipe; socketweld, threaded or YES YES
buttweld pipe fittings; socketweld, threaded or
buttweld valves
Pipe unions YES NO
Flanged pipe fittings, flanged valves, flange YES NO
orifice sets, piping flanges connected to equipment
nozzles, and flanged special items (i.e., strainers)
Primary piping for instrument connections, sample YES NO
piping, vent and drain piping
Expansion or rotation joints, slide valves, etc. YES NO
Instruments and associated tube YES NO
Relief valves YES NO
Control valves YES NO
Tee and inline strainers YES NO
Vessels, shell and head surfaces YES YES
Vessel handholes YES NO
Vessel manways YES YES
Vessel instrument trim YES NO
Shell and tube heat exchangers, excluding flanged YES YES
joints
 Installation of Cold Service Insulation Systems INSC2001
Page 2 of _____
Data Sheet for Extent of Insulation April 1999

Project _____________________________________________ Date ___________________________

FP
Items AMB to - 290°° F AMB to 32°° F
(As Required
CC CP by the
Purchaser)
Heat exchanger flanged joints YES NO
Pump casings NO NO
Compressors NO NO

Other
 INSC2002
Installation of Cold Service Insulation Systems
Data Sheet for Documentation Requirements Page 1 of ______
April 1999

Project ___________________________________ Date ______________________

Number Title Rev Date Notes
INEG1000 Insulation and Type Codes
INGG1000 Document Use Guidelines
INSC1000 Requirements for Cold Service Insulation Materials
INSC2000 Installation of Cold Service Insulation Systems
INSC2001 Data Sheet for Extent of Insulation
INTG1000 Insulation Inspection Checklist

Selected Insulation Thickness Tables

INEG1051 YES ¨ NO ¨ Cellular Glass Insulation for CC
INEG1052 YES ¨ NO ¨ Cellular Glass Insulation for CP
INEG1053 YES ¨ NO ¨ Cellular Glass Insulation - Combined
Table
INEG1054 YES ¨ NO ¨ Polyisocyanurate Insulation for CC
INEG1055 YES ¨ NO ¨ Polyisocyanurate Insulation for CP
INEG1056 YES ¨ NO ¨ Polyisocyanurate Insulation - Combined
Table

Cold Insulation Installation Details

INIC0001 YES ¨ NO ¨ General Arrangement - Piping
Insulation
INIC0002 YES ¨ NO ¨ Piping - Layered Insulation
INIC0003 YES ¨ NO ¨ Piping - Vertical Insulation Support
Single Layer
INIC0004 YES ¨ NO ¨ Piping - Vertical Insulation Support
Multiple Layers
INIC0005 YES ¨ NO ¨ Piping - Single Layer Horizontal
Contraction Joint
INIC0006 YES ¨ NO ¨ Piping - Multiple Layer Horizontal
Contraction Joint
INIC0007 YES ¨ NO ¨ Piping - Vapor Barrier and
Weatherproof Jacketing
INIC0008 YES ¨ NO ¨ Piping - Flange Insulation
 INSC2002
Installation of Cold Service Insulation Systems
Data Sheet for Documentation Requirements Page 2 of ______
April 1999

Project ____________________________________________________ Date ______________

Number Title Rev Date Notes
INIC0009 YES ¨ NO ¨ Piping - Insulation Connections
INIC0010 YES ¨ NO ¨ Valves with Extended Bonnets
INIC0011 YES ¨ NO ¨ Valves without Extended Bonnets
INIC0012 YES ¨ NO ¨ Spacer Blocks for Typical Tracer
Arrangements

INIC0050 YES ¨ NO ¨ Vertical Vessels with Outside Diameters

Larger than 36" (915 mm)
INIC0051 YES ¨ NO ¨ Vertical Vessels with Outside Diameters
36" (915 mm) and Less
INIC0052 YES ¨ NO ¨ Vessel Head

INIC0054 YES ¨ NO ¨ Vertical Vessel Bottom Head

Insulation
INIC0055 YES ¨ NO ¨ Nozzle
INIC0056 YES ¨ NO ¨ Vessel Stiffener Insulation Detail

INIC0059 YES ¨ NO ¨ Typical Clip Details

INIC0061 YES ¨ NO ¨ Lap Seam Details

INIC0062 YES ¨ NO ¨ Horizontal Vessels with Outside
Diameters Larger than 96" (2440 mm)
INIC0063 YES ¨ NO ¨ Application of Metal Gores on Horizontal
Vessel Heads
INIC0064 YES ¨ NO ¨ Head Insulation Securement

Selected Materials System Data Sheets

INSC1001 YES ¨ NO ¨ Cold Service Insulation System for
Project Specific Requirements
INSC1002 YES ¨ NO ¨ Cellular Glass Block and Fabricated
Sections Insulation System
INSC1003 YES ¨ NO ¨ Polyisocyanurate Insulation System
 INSC2002
Installation of Cold Service Insulation Systems
Page ______ of ______
Data Sheet for Documentation Requirements April 1999

Project __________________________________________________ Date _________________

Other
Number Title Rev Date Notes