ANOH Gas Processing Company Limited

Security Classification: Restricted

AGP-GPS-ANOGP-Z05-0004

ANOH GAS PLANT PROJECT

(AGPP)

INSULATION SPECIFICATION
SEP, 2019

Rev Date Description Issued by Checked by Approved by

Amresh
Srinivasan Singh Magudapathi M
Nachiappan 2019.09.26 2019.09.26
2019.09.26 16:39:35 16:40:18 +04'00'
16:36:27 +04'00' +04'00'

A01 26-SEP-19 Issued for Approval NSV AKS MM

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 2 OF 53

ADDITIONAL APPROVAL / REVISION HISTORY TABLE

Party Name Sign Date

Revision Philosophy
All documents for approval will be issued at A01 as required.
If the document is for information, it will also be issued as A01.
All revisions re-Issued for approval will be issued as A02, with subsequent A03, A04, etc as
required.
Documents approved for Construction will be issued at C01, C02, and C03 respectively.
Documents or drawings revised as “As built” will be issued as Z01, Z02 Z03 etc.
Previous revision highlighting to be removed at subsequent issues
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the
affected areas and by the use of a triangle containing the revision status.

Revision History

Revision No. Date of issue Reason for change

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 3 OF 53

Table of Contents
1 INTRODUCTION ....................................................................................................... 5
1.1 Project Background ........................................................................................................ 5
1.2 Purpose .......................................................................................................................... 6
2 TERMS AND DEFINITIONS ........................................................................................ 6
3 REFERENCES DOCUMENTS ....................................................................................... 7
3.1 Project Documents and Specifications ............................................................................ 7
3.2 Standards and Procedures .............................................................................................. 7
3.3 Order of Precedence....................................................................................................... 9
4 GENERAL DESIGN REQUIREMENTS ............................................................................ 9
5 EXTENT OF INSULATION......................................................................................... 10
5.1 General......................................................................................................................... 10
5.2 Heat Conservation (H) .................................................................................................. 10
5.3 Cold Medium Conservation (C) ..................................................................................... 10
5.4 Personnel Protection (P) .............................................................................................. 11
5.5 Electric Heat Tracing (E) ................................................................................................ 11
5.6 Limitations.................................................................................................................... 11
6 INSULATION MATERIALS ........................................................................................ 13
6.1 General......................................................................................................................... 13
6.2 Materials ...................................................................................................................... 14
7 APPLICATION OF INSULATION ................................................................................ 20
7.1 Heat Conservation ........................................................................................................ 20
7.2 Personnel Protection .................................................................................................... 23
7.3 Cold Medium Conservation........................................................................................... 23
8 WEATHER PROOFING & PROTECTIVE COVERING...................................................... 26
8.1 General......................................................................................................................... 26
8.2 Weather Proofing for Piping ......................................................................................... 26
8.3 Weather proofing of Equipment ................................................................................... 27
8.4 Weatherproofing Sealers and Mastics........................................................................... 28
9 CLEARANCE ........................................................................................................... 28
10 INSULATION PRECAUTIONS.................................................................................... 28
11 INSULATION SUPPORTS ......................................................................................... 28
12 ACCESSORIES REQUIREMENT FOR INSULATION ....................................................... 29

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 4 OF 53

12.1 Vertical Vessels ............................................................................................................. 29

12.2 Horizontal Vessels ........................................................................................................ 29
12.3 Vessel Heads ................................................................................................................ 29
12.4 Stiffener Rings .............................................................................................................. 29
12.5 Insulation Placements ................................................................................................... 29
12.6 Breather Springs ........................................................................................................... 29
12.7 Name Plates ................................................................................................................. 30
13 QUALITY CONTROL ................................................................................................ 30
13.1 General......................................................................................................................... 30
13.2 Inspection ..................................................................................................................... 30
13.3 Pre-Insulation Survey and Inspection ............................................................................ 31
13.4 Inspection during installation of Cold/Heat Conservation Insulation Systems ................ 31
13.5 Final inspection and Release ......................................................................................... 31
14 APPENDICES.......................................................................................................... 32
14.1 Heat Conservation Insulation Thickness ........................................................................ 32
14.2 Personnel Protection Insulation Thickness (Mineral Wool)............................................ 33
14.3 Personnel Protection Insulation Thickness (Mess Guard) .............................................. 34
14.4 Cold Medium Conservation Insulation Thickness .......................................................... 35
14.5 Figure for Heat Conservation ........................................................................................ 38
14.6 Figure for Cold Medium Conservation........................................................................... 47

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 5 OF 53

1 INTRODUCTION

1.1 Project Background

The Assa North - Ohaji South (ANOH) project is a Greenfield Nigerian gas development aimed at
supporting the domestic market and targeting production for Q2 2020. Assa North field is located
in block OML 21 and is operated by Shell Petroleum Development Company.

The field extends into block OML 53, where it is called Ohaji South and is operated by SEPLAT
Petroleum Company. In combination, the fields are called ANOH. ANOH field is located in Imo
State, close to Owerri and about 70 km North-West of Port Harcourt. ANOH field will be developed
by a Joint Venture (JV) consisting of the Nigerian Government holding 55% 57.5%, SEPLAT holding
22.5% 20%, Shell holding 15%, TOTAL holding 5% and AGIP holding 2.5%.The JV will be operated
by Shell Petroleum Development Company (SPDC).

The midstream will be operated by Seplat Petroleum Resources Ltd on behalf of the ANOH Gas
Processing Company Ltd. (AGPC).

The Midstream will be developed and delivered into the market in two phases:

• Phase 1: 300mmscfd Q1 2019 subject to offtake agreements being in place.

• Phase 2: 300mmscfd Future subject to offtake agreements and feed stock gas being in place
from OML 53 and ANOH/Unit..
The plant will be designed for 600 mmscfd on plot suitable for 1,200 mmscfd.

The ANOH Gas Processing Facilities in its entirety is defined as the integrated Gas and Gas Liquids
development of the unitized ANOH field straddling OMLs 21 and 53.

The overall purpose of the ANOH Gas facilities is to receive wet gas from the ANOH field, deliver
processed gas into the OB3 pipeline and evacuate the resulting condensate to the export terminals
in Brass or Bonny.

For further details of the project including please refer to the Project Execution Plan ref SEP-OPS-
ANOH-B01-00002.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 6 OF 53

ANOH GAS PROCESSING COMPANY LIMITED

PROJECT LOCATION

1.2 Purpose
This specification defines the minimum requirement for Heat Conservation (H), Electric Heat
Tracing (E), Personnel protection (P) & Cold Medium Conservation (C) design, materials and their
application procedure for the exterior hot & cold surfaces of new construction piping and
equipment for ANOH Gas Development.

The temperature used to determine the need for the insulation and the insulation thickness is the
normal operating/ service temperature.

2 TERMS AND DEFINITIONS

Within this specification, the following definitions will apply.

PROJECT :ANOH Gas Processing plant(AGPP)

COMPANY :ANOH Gas Processing Company

CONTRACTOR :Global Process systems LLC

PURCHASER :It is defined as the entity responsible for engineering and

procurement and who executes the PURCHASE ORDER for the
supply of equipment and services detailed in this specification.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 7 OF 53

SUPPLIER (or VENDOR) :Any person, firm, partnership, company, corporation or

combination thereof with whom the CONTRACTOR has sent the
MATERIAL REQUISITION or placed the PURCHASE ORDER.

SUB-SUPPLIER :Any person, firm, partnership, company, corporation or

combination thereof other than CONTRACTOR supplying to
SUPPLIER SUPPLY or parts thereof in connection with the
PURCHASE ORDER.

PURCHASE ORDER : The PURCHASE ORDER together with requisition and all the
documents referred therein.

SCOPE OF WORK :The goods/service and / or equipment and /or documentation to

be provided under the PURCHASE ORDER.

The word “shall” indicate a requirement.

The word “should” indicate a recommendation.

3 REFERENCES DOCUMENTS

3.1 Project Documents and Specifications

The following Project Documents and Specifications shall be used in conjunction with this
Specification:

AGP-GPS-ANOGP-Z21-0010 : Piping Material Specification

AGP-GPS-ANOGP-Z10-0010 : Line List

SEP-OPE-GEN-P15-00007 : Painting and Coating Specification

3.2 Standards and Procedures

Codes, Standards and other documents generally applicable to this project have been as listed
below.

ASME B31.3 Process Piping.

ASTM A167 Specification for stainless and Heat-Resisting Chromium-

Nickel Steel plate, Sheet, and Strip.

ASTM A463 Specification for Steel Sheet, Aluminium-Coated, by the

Hot Dip Process.

ASTM C547 Standard specification for mineral Fiber Pipe Insulation.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 8 OF 53

ASTM C592 Standard Specification for Mineral Fiber Blanket Insulation

and Blanket-type Pipe Insulation

ASTM C612 Standard Specification for Mineral Fiber Block and Board
Thermal Insulation.

ASTM B209 Standard Specification for Aluminium and Aluminium Alloy

Sheet.

ASTM C795 Standard Specification for Thermal Insulation for Use in

Contact with Austenitic Stainless Steel.

ASTM C929 Standard Practice for Handling, Transporting, Shipping,

Storage, Receiving, and Application of Thermal Insulation
Materials for Use in Contact with Austenitic Stainless Steel

ASTM C195 Specification for Mineral fiber thermal insulating cement.

ASTM C449 Specification for Mineral fibre Hydraulic-setting Thermal

Insulating and Finishing Cement.

ASTM C871 Standard Test Methods for Chemical Analysis of Thermal

Insulation Materials for Leachable Chloride, Fluoride,
Silicate, and Sodium Ions

ASTM C692 Standard Test Method for Evaluating the Influence of

Thermal Insulations on External Stress Corrosion Cracking
Tendency of Austenitic Stainless Steel

ASTM C892 Standard Specification for High-Temperature Fiber

Blanket Thermal Insulation.

ASTM C531 Standard Specification for Unfaced Preformed Rigid

Cellular Polyisocyanurate Thermal Insulation

ASTM E-84 Standard Test Method for Surface Burning Characteristics

of Building Materials.

ASTM E96 Standard Test Methods for Water Vapor Transmission of

Materials.

BS2972 Methods of test for inorganic thermal insulating materials

BS3927 Phenolic Foam materials for thermal insulation and

building application

BS3958 Specification for Thermal Insulation Materials.

BS5422 Specification for the use of thermal insulating materials.

BS5608 Specification for preformed rigid polyurethane (PUR) and

polyisocyanurate (PIR) foams for thermal insulation of
pipework and equipment

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 9 OF 53

BS5970 Thermal insulation of pipe work and equipment (in the

temperature range -100°C to 870°C

3.3 Order of Precedence

In the event of any conflict or contradiction between the specifications and standards, the same
shall be brought to the attention of company. The conflict shall be resolved, unless specifically
stated otherwise, in order of precedence starting with:

• Mandatory Nigerian Statutory and Regulatory Requirements

• Project Philosophies.
• Material requisitions and Job Specification
• Company Standards and Specifications
• International codes & standards
• CONTRACTOR Standards & Specifications
• Manufacturer’s proven standards wherever applicable

4 GENERAL DESIGN REQUIREMENTS

The insulation designed to provide an economic thickness to prevent heat loss, so that the
insulation cold face surface temperature does not exceed 80°C in an ambient still air temperature
of 26°C.

The insulation shall comprise of a layer or layers of a heat resisting material enclosed within
protective metal sheeting designed to prevent the ingress of moisture and to allow differential
expansion.

Instruments and instrument piping that is subject to the temperature condition of the associated
piping system or equipment shall be insulated to the same requirement.

All metal surfaces under insulation shall be fully painted before any insulation is applied except
for Insulated steam line.

Usually, each single line should be insulated separately; adjacent lines shall not be enclosed by
common insulation cover.

All insulated stainless-steel piping, equipment, etc. shall be protected against chloride attack by a
suitable painting system.

New equipment, tanks and piping which will be pressure tested shall not be insulated until such
test have been successfully completed.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 10 OF 53

All insulation shall be covered with weather protection designed and installed to prevent ingress
of water during normal operation throughout the design life.

All design shall allow for necessary room for insulation and insulation jackets and preformed
boxes.

Particular care shall be taken in piping design to ensure sufficiently long straight pipe runs around
e.g. branches, bends, valves and supports, to enable proper installation of insulation.

When a rigid type of insulation is used, provision shall be made for longitudinal expansion and
contraction.

5 EXTENT OF INSULATION

5.1 General
Classification of insulation and symbols to be indicated on the Engineering Drawing, P&ID and
Piping Line List are as follows:

Symbol Classification
H Heat Conservation
C Cold Medium Conservation
P Personnel Protection
E Electric Heat Tracing

5.2 Heat Conservation (H)

The plant piping and equipment operating at temperatures above ambient temperature requires
Heat Conservation insulation (H) type insulation when process fluid system demands the
requirement of insulation to avoid any temperature loss within the system due to external
ambient conditions. The type of insulation and insulation thickness as per this specification shall
be specified in the piping line list and Equipment drawings. Heat Conversation insulation shall be
of removable & reusable type in order to do the maintenance & inspection as on when required.

The Heat conservation insulation thickness values are specified in Table X.

5.3 Cold Medium Conservation (C)

Cold Conservation insulation (C) required to prevent condensation on the outside surface of the
insulating
system, conserve low temperature or control heat input to the contained fluid within a
temperature range of ambient and below.
The Cold conservation insulation thickness values are specified in Table XIII.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 11 OF 53

5.4 Personnel Protection (P)

Surfaces at temperatures (of piping/equipment) above 70°C and accessible from normal working
areas and access ways and is not provided with Heat Conservation Insulation (H), shall be provided
with personnel protection (P).

Personnel protection insulation shall extend to a minimum height of 2100 mm above the walking
level and 800 mm horizontally from either side of any operating walkway or platform.

For process temperatures above 70°C physical barrier protections such as open mesh guards,
protective metal sheeting/screens should be applied for personnel protection. For surface
temperatures > 250°C, insulation material shall be used for personnel protection.

For the equipment (vessels) and piping, which requires Personnel Protection insulation (P) type,
insulation with insulating material can also be used if wire mesh application is not feasible.

The insulation thickness requirements for P- type insulation and recommendations for the
distances of open mesh guards from bare surface for personnel protection are given in Table XII & ?
Where it is impractical to use guards the surfaces shall be insulated, protected and
weatherproofed according to this specification for hot surfaces, thickness shall be according to
Table XI.

Do not insulate coolers, condensers, hot pump cases, or instruments for personnel protection.
Some of these may require expanded-metal guards instead of insulation when it is desirable to
dissipate heat.

5.5 Electric Heat Tracing (E)

The purpose is to maintain the temperatures of intermittent operating lines above freezing points
for liquids and above condensation point for gases.

The Electrical Heat Tracing insulation thickness values are specified in Table X.

5.6 Limitations
Thermal insulation is required for:

• Thermal conservation of equipment and piping if economically justified;

• Temperature control of processes or products, e.g. to avoid condensation, freezing,
solidification, or too high a viscosity;
• Personnel protection, i.e. on surfaces with a temperature of 70°C or higher if these present a
danger;

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 12 OF 53

• Preventing or reducing damage to equipment and piping from exposure to freezing

conditions.

Insulation shall not be applied to piping or equipment that has been designed to emit heat or
where cooling is required or acceptable by the process (e.g. piping to air coolers, blow down
systems and condensate return lines) if there is no heat recovery at the end of the line.

If not specified/justified on Isometric drawing(s) or datasheet (s) or Line List, piping/equipment

shall not be insulated.

Each line should be insulated separately; a common insulation cover should not enclose adjacent
lines.

Inspection windows shall be provided as required, by way of removable plugs or similar.

Nameplates, identification plates and stampings shall be left clear of insulation or shall be fitted
on the outside of the jacketing. For Heat Conservation insulation, SUBCONTRACTOR shall design
an alternative which shall consider the avoidance of condensation and heat losses. All metal
surfaces under insulation shall be suitably protected with a complete paint system in accordance
with project painting specification.

The extent of insulation requirement details for piping and equipment are given in below table,
after the confirmation of insulation type (H /C/P/E) based on process requirement.

EXTENT OF INSULATION FOR PIPING AND EQUIPMENT:

Heat Conservation Cold Medium Personnel

Application Description (H) / Electric Heat Conservation Protection
Tracing (E) (C) (P)
Straight or Bend Pipe, Socket-weld, Threaded
or Butt-weld Pipe Fittings, socket weld, Yes Yes Yes
Threaded or Butt-welded Valves.
Pipe flanges, Flanged Manual Valves. Yes Yes Yes
Instrument valves PSV, Control valves, Shut Yes Yes Yes
down valves etc.
Instrument items Level instruments , Gauge No No No
glasses , Pressure instruments and leads etc.
Primary Piping for Instrument Connections,
Sample Piping, Vent and Drain Piping Yes Yes No
(downstream of isolation valve)
SP Items (Deadman Valve; Spring Loaded
Yes Yes Yes
Valve; Strainer & Auto Drain Trap)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 13 OF 53

Heat Conservation Cold Medium Personnel

Application Description (H) / Electric Heat Conservation Protection
Tracing (E) (C) (P)

Vessels Yes Yes Yes

Vessel Handholes, Name plates, code No No No
inspection plates
Vessel Manways No No No
Vessel Instrument Stand Pipe Yes Yes No
Heat Exchanger Shell and Fixed Rear Bonnet Yes Yes Yes
Surfaces
Heat Exchanger Channel, Channel Cover,
Channel Bonnet and Channel/Body Flange No Yes No
Joints
Pump casings No No No
Compressors Note:1 Note:1 Note:1
Blower, Fans Note:1 Note:1 Note:1
Note:-

1. Insulation shall be furnished in accordance with the equipment supplier’s

recommendations.

6 INSULATION MATERIALS

6.1 General
All insulation materials shall comply with ASTM C795 and ASTM C929, as received to avoid chloride
corrosion on austenitic stainless-steel pipe or equipment.

Any insulation components of dissimilar metals subject to galvanic corrosion shall not be brought
in contact with each other to avoid galvanic corrosion. Contact between galvanized steel and
stainless-steel piping components shall be avoided. Aluminium jacketing material shall be
separated from steel by a bead of mastic.

All insulating materials, insulating cements, and mastics must have a method of indicating that
they are asbestos-free.

The use of substitute/alternate materials other than specified in this specification requires
CONTRACTOR approval.

All non-metallic materials shall have a flame-spread index of not greater than 25 when tested per
ASTM E84.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 14 OF 53

Insulation containing sodium silicate shall not be used over alloys containing molybdenum, e.g.
316 stainless steel, Incoloy-825, operating at 815°C or hotter.

Materials shall be new and shall be used prior to the expiration date. Sealants, mastics, and
adhesives shall be supplied in factory sealed containers.

Multi-layer pipe insulation shall be ordered factory-nested.

The material manufacturer shall also furnish a chemical analysis in accordance with ASTM C871
for material from the same production lot tested under ASTM C692.

Thermal insulation products shall be qualified for use on austenitic stainless steel in accordance
with ASTM C795. The material manufacturer shall demonstrate that the material that will be
furnished for this project has passed the pre-production corrosion test in accordance with ASTM
C692.

All mastics, cements, adhesives, caulks, labels, marking pens and tapes that come in contact with
stainless steel shall have a maximum leachable chloride content of less than 50 ppm, when tested
in accordance with ASTM C871.

Use curved segments, bevelled lags and V-grooved materials manufactured to specific inside
diameters that assure complete inside and outside diameter closure.

From delivery to installed finished product, insulation materials shall always be protected and have
adequate drainage.

Insulation materials shall be handled and stored per manufacturer's printed recommendations.
Mastics, adhesives, and sealers that are exposed to temperatures outside the recommended
temperature ranges during storage shall not be used and shall be replaced with new material(s).

Materials with expired shelf life and dates shall not be used and shall be replaced with new
materials.

6.2 Materials

6.2.1 Material for Heat Conservation Insulation

Specification and standard application of insulating material for Heat Conservation Insulation and
personnel protection services shall be as follows:

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 15 OF 53

TABLE I TYPICAL PHYSICAL PROPERTIES OF INSULATION MATERIAL FOR HEAT CONSERVATION

INSUALTION & ELECTRICAL HEAT TRACING

Material Reference Code Insulation Type Application

(Note:1)
Thermal conductivity at 200 oC - 0.065 W/mK.
For use on
Mineral wool
ASTM C547 Class II Core density of not less than 100kg/m3 Horizontal Vessels
(Preformed and Class III and Exchangers.
Pipe Cover) Insulation shall be suitable for use up to 300 oC Piping Up to 16”

Thermal conductivity at 200oC - 0.065 W/mK. For use in hot

Mineral wool ASTM C612 service piping
Core density of not less than 100kg/m3
(Board / Slab) Type IV (Piping above 16”)
Insulation shall be suitable for use up to 300 oC & Equipment’s

Thermal Conductivity at 200o C -0.065 W/mK

Mineral wool For use in hot
ASTM C592 Core density of not less than 70Kg/ m3. service piping &
(Blanket- Type II Equipment’s
Loose)
Insulation shall be suitable for use up to 300 oC

Note:-

1. The insulation material shall meet the requirements of ASTM C795, when applied on
austenitic stainless-steel surfaces.

Mineral wool insulation for pipe insulation, mattress and slab shall satisfy the following
requirements.

6.2.2 Material for Cold protection

Specification and standard application of insulating material for cold services shall be as follows:

TABLE II TYPICAL PHYSICAL PROPERTIES OF INSULATION MATERIAL FOR COLD INSUALTION

Material Reference Code Insulation Type Application

Thermal conductivity at 10 oC -0.023w/mK

PIR
(Polyisocyanurate) Core density of not less than 32kg/m3. For use in Cold
/ ASTM C591 service piping &
Type 2 Compressive strength of not less than Equipment’s
PUR (Poly 172KN/ m2
Urethane) foam

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 16 OF 53

• The insulation for general application shall consist of factory cut sections, lags or slabs of
polyurethane or polyisocyanurate material in accordance with the following specification:

Approved Temperature Range : -196OC to +140 OC

Close Cell Content : 95%

Nominal Density : 32 kg/m3 min

‘K” value at 10 OC aged : 0.023 W/(mK)

Compressive Strength : 172kN/m2

Moisture Vapour Transmission : 30 gm/Nh

(i.e. 30 microgram meters per Newton hour)

Water Absorption : 4 grams water for every

ISO 2896 -7 days: 50mm head : 100 cc of foam

Fire Resistance. Ignitability : Class P

Chemical/Solvent resistance : Good

Alkalinity : Neutral
• The mineral wool, used to form contraction joints, shall be in loose wool form of 48 to 64 kg/ m3
density and able to withstand expansion and contraction throughout the service range.

6.2.3 Material for Personnel Protection

Specification and standard application of insulating material for Personnel Protection shall be as
follows:

TABLE III TYPICAL PHYSICAL PROPERTIES OF INSULATION MATERIAL FOR PERSONNEL

PROTECTION
Guard Material

Item Material & Application

(a) Guard 3.15mm iron wire with mesh dimensions shall not be greater
than 50mm. The whole fabrication including straps or
brackets shall be hot dip galvanized

(b) Cages and screens i. 0.5mm galvanized mild steel with 3mm hole dia. x 5mm
pitch
ii. Stainless steel ASTM A167 Type 304 for stainless steel
pipework

Where it is impractical to use guards the surfaces shall be insulated, protected and
weatherproofed according to this specification for hot surfaces.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 17 OF 53

6.2.4 Materials For Weather Proofing & Protective Coatings

TABLE IV WEATHER PROOFING MATERIAL FOR EQUIPMENT (HORIZONTAL) AND PIPING

Type of Area Reference Code Material Thickness(mm) Remarks

0.6 Up to 6” dia
Straight piping bends Flat aluminized steel
ASTM A463
and fittings sheet
0.8 Above 6” dia
Horizontal vessels
Flat aluminized steel
exchangers and vessel 0.8
ASTM A463 sheet
heads,
Removable bonnets,
channels of
ASTM A463 Flat aluminized steel
exchangers, manhole 0.8
sheet
cover and kicking
plates

TABLE V WEATHER PROOFING MATERIAL FOR VERTICAL EQUIPMENT

Type of Area Reference Code Material Thickness(mm) Remarks

0.6
ASTM A463 Flat aluminized steel sheet
Straight shells up
to 150mm
diameter Stainless steel ASTM 304
2B mill finish with
0.4
moisture barrier
transverse reeded.

Flat aluminized steel sheet 0.8

ASTM A463
Straight shells
above 150mm Stainless steel ASTM 304
diameter 2B mill finish with
0.4
moisture barrier
transverse reeded.

Note: Exposed edges of metal jacketing shall be machine-bent or rolled to eliminate sharp edges.
Removable covers for flanges, valves etc.. shall be made of 1.0mm thickness sheet irrespective of
the material.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 18 OF 53

6.2.5 Fastening Materials

TABLE V I TYPICAL PHYSICAL PROPERTIES OF INSULATION MATERIAL FOR FASTENING MATERIALS

• For Insulation
Material Standard Nominal size(mm) Application
Stainless steel wire 1.6 Ø Piping < 12”
ASTM A240 Type 316 13 mm W x 0.5 mm T Piping 12” to 24”
Stainless steel Band
and Seal
19 mm W x 0.5 mm T Piping >12”

• For metal jacketing

Material Standard Nominal size(mm) Application

Stainless steel Self- Piping Elbow,

4.2Ø x 13 mm L
Tapping screw Equipment Head

Stainless steel Self- 6.0 mm x 19 mm L Support Ring

Drilling screw

13 mm W x 0.4 mm T Piping < 24”

Stainless steel Band
ASTM A240 Type 316
and seal
19 mm W x 0.5 mm T Piping > 24” &
Equipment head
Stainless steel 2.4 Ø x 30mm W x 100 To be attached
Expansion springs mm L to band

Stainless Steel Toggle Removal cover

clips
Ø – Diameter L- length T- Thickness W - width

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 19 OF 53

6.2.6 Auxiliary Materials

TABLE V II TYPICAL PHYSICAL PROPERTIES OF INSULATION MATERIAL FOR AUXILARY MATERIALS

Specification and standard application of auxiliary materials for Heat Conservation Insulation &
Personal Protection shall be as follows.

Use Material Application

(a) Joint filling Water-kneaded powder of the same For filling voids of heat
material quality as the heat insulating material insulating material

(b) Flashing For opening on insulation

30 -45 Foam seal sealant or equivalent
compound finish penetrated by lugs etc.

For affording a smoot surface

(c) Finishing cement ASTM C 449 or equivalent as a final finish for heated
surfaces.
(d) Reinforcement Galvanized Steel Size 25mm mesh X For reinforcement of mastic
material 0.7 mm dia. etc..

Specification and standard application of auxiliary materials for Cold Conservation Insulation shall
be as follows.

Use Material Application

(a) Vapor barrier 60-25 C.I. mastic or non-breathing For vapor barrier of cold
coating (vapor barrier) type mastic composing of insulation.
elastomeric polymer-based resin (non-
flammable & having water vapor
transmission rate of 0.02 perms for
0.725mm dry film thickness ASTM E96
(b) Joint sealer and 30 -45 Foam seal sealant or equivalent For Joint sealer of cold
Flashing compound insulation for openings on
insulation finish penetrated
by lugs etc. etc.
(c) Sealing material caulking For jacketing

(d) Reinforcement Glass cloth (10 X 10 Mesh). For reinforcement of mastic

material etc..

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 20 OF 53

7 APPLICATION OF INSULATION

7.1 Heat Conservation

This clause describes the requirements for the following insulation classes:
• Heat conservation
• Electric Heat Tracing.

7.1.1 Surface Preparation

• Piping & equipment shall be clean, dry and free from grease, dirt, loose rust and scale.
• Austenitic stainless steel up to 500°C shall be coated with a heat resisting coating prior to the
application of insulating materials when the operating temperature of the line exceeds 70°C.
This coating is to combat chloride stress corrosion attack.
All necessary hydrostatic and pressure test, painting, etc., must be completed prior to the
application of insulation over any pressure bearing seams or connections
• Before any section of the insulation on piping and equipment is commenced, all hangers,
brackets and pipe clips shall be in position.

7.1.2 Application Methods (Heat conservation)

• All insulating materials shall be in close contact with the surfaces to which they are applied,
unless an air space is specifically required.
• Where the insulation consists of performed or flexible material, all joints shall be closely
butted. For Material Refer Table I.
• Where insulating materials are applied in multi-layers, all-joints shall be staggered.
• Insulation shall, wherever possible, be carried out at ambient temperatures.
• The Surface of foamed insulation in contact with the pipe shall be coated with an anti-
abrasion coating.
• Where tell-tale holes are provided in branch reinforcement rings, small weep pipe shall be
fitted projecting clear of the insulation.
• All Fastening Material Refer Table VI & For Auxiliary Material Refer Table VII.

7.1.3 Piping
• The inner layer of insulation shall not be bonded to the pipe with adhesive. Subsequent layer
to be bonded to previous layers. Adhesive to be applied to the ends and the edges of each
slab including the inner layer. Where it is impracticable to bond insulation with adhesive it
shall be secured in place with wire loops or bands at 250mm centers according to TABLE VIII.
Each section must have a minimum of three loops or bands. The inner layer, of multi-layer
insulation shall have wire loops or bands at approximately 450mm centres.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 21 OF 53

• On vertical piping, metal support clips shall be provide at the bottom, above flanges and at
intervals according to TABLE IX. These clips shall be welded to the pipe. They shall not be
more than 6mm thick and shall extend within 12mm of the outer surface of the insulation.
Their area need not be greater than 10% of the cross sectional area of insulation. Support
clips shall be of a material equal or compatible with the piping material, and shall be welded
onto the piping prior to hydro testing by mechanical erection subcontractor. Bolted support
clips can be used as alternative method, If welding is not feasible, but design should be sturdy
& support weight of insulation.
• Where preformed material is used on piping bends it shall be mitred and shall have a
reasonably smooth contour. Alternatively, prefabricated or fully moulded half bends may be
used if these are available.
• Expansion joints shall be provided wherever temperature exceeds 200°C.
• Valves, flanges & flanged fitting shall be provided with removable boxes lined with performed
material suitable for the temperature range. The thickness of insulation shall be as specified
for the line. Space for withdrawal of bolts shall be filled with calcium silicate. Refer Fig 16.5.5.
• Steam tracing is not envisaged. Electrical heat traced piping & equipment shall be wrapped
suitably to protect heating cables & improve heat distribution (refer figure 16.5.1). Where
heat cables penetrate jacketing, edge protection for cables shall be provided & sealed to
prevent ingress of water.

7.1.4 Horizontal vessels and Exchangers

• All horizontal vessels and exchangers shall be insulated with preformed insulation in the form
of pipe covering, lags or flat blocks. Refer Fig 16.5.9.
• Lags and slab insulation shall have bands spaced every 250mm on a single or outside layer,
every 500mm on an inside layer. Size of bands shall be according to TABLE VIII.
• For vessels 2.0m in diameter or larger, supports (clips, rings etc) for the insulation is
mandatory & shall be provided by the vessel supplier.
• Slab insulation shall be used on heads of horizontal vessels and shall be secured by bands
extending from a floating ring at the centre to the two circumferential bands on the shell. The
bands shall be 20mm x 0.5mm thick.
• Manholes and flanges shall be insulated on those vessels and exchangers operating at 245°C
and above unless specified otherwise.
• Bonnets & channels of exchangers, manholes etc. shall be provided with removable boxes.
Boxes shall be constructed in separate pieces no larger than can be handled by one or two
men. The boxes shall be lined with slab insulation of thickness equal to that specified for the
vessel.

7.1.5 Vertical vessels and Exchangers

• Rings, bars and clips shall be provided on vessels to support the weight of insulation and
weather-protecting cladding. Refer Fig 16.5.7. & Refer Fig 16.5.8.
• In addition to the support rings and clips the insulation shall be supported by banding with
20mm wide insulation compression bands spaced at 300mm centers for single or outer layers
and 450mm centers for all inner layers.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 22 OF 53

• Vent holes in vessel skirts shall be kept free of insulation.

• Manholes and flanges shall be insulated on those vessels and exchangers operating at 245°C
and above unless specified otherwise.
• Bonnets & channels of exchangers, manholes etc. shall be provided with removable boxes.
Boxes shall be constructed in separate pieces no larger than can be handled by one or two
men. The boxes shall be lined with slab insulation of thickness equal to that specified for the
vessel.
• Where mattress insulation is used, bands shall be drawn up only so far as compress the
insulation beneath it to the specified thickness. All mattresses shall be fully laced together,
with all joints staggered.

7.1.6 Miscellaneous Equipment

Turbines, pumps and miscellaneous irregularly shaped equipment shall be insulated by
mitered segment of moulded or block insulation, same type and thickness as specified for
vessels. Wherever this is not practical, insulation cement shall be applied in layers 25mm
thick. Over every second layer of cement, a reinforcing layer of galvanized iron mesh shall
be secured. Over this smooth layer of weatherproofing shall be applied.

7.1.7 Application Of Protection And Weatherproofing

Insulation shall be weatherproofed with metal sheeting and jacketing as follows:

7.1.8 Piping
• Jacket of all diameters shall be furnished in coils, with a factory applied vapour barrier
backing.
• Circumferential and longitudinal laps shall be 50mm wide. The longitudinal seam shall be
located on alternate sides of the pipe at the horizontal centre line.
• All laps shall be arranged to give maximum protection against windblown rain. Where
necessary lapped joints should be sealed with a suitable sealer.
• Screws shall not be used at circumferential joints on horizontal lines. On vertical lines, every
other joints shall have not less than three screws-the intermediate joints being free to act as
expansion joints.
• The jackets shall be clamped tight along the horizontal overlaps, with self-tapping screws at
approximately 150mm centers fixed through the 25mm hem.
• Boxes over valves, flanges and flanged fittings shall be removable & shall have snap fasteners,
quick-release toggles or band fitted with snap fasteners. Refer Fig 16.5.5.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 23 OF 53

7.1.9 Vertical Vessels and Exchangers

• Cladding on vertical vessel shells, shall be constructed of transverse reeded or corrugated
panels appropriately sized for the vessel. The panels shall have a 75mm overlap on the
horizontal and vertical edges.
• The weight of the cladding shall be supported on rings via angle brackets bolted to the panel
(2 per panel supported) and on the support rings. Angle brackets shall have a toe length
12mm less than the thickness of insulation.
• The panels shall be held tight to the vessel by means of circumferential bands and shall be
spaced over the cladding at approximately 900mm centres. Horizontal overlaps shall be
seamed by self-tapping screws expect where it is necessary to permit expansion movement.
Vertical overlaps shall not be screwed.
• Insulated top and bottom heads of vertical vessels shall be weatherproofed with flat panels.
The cladding shall be built up of sector pieces riveted or screwed together. Overlaps shall be
approximately 50mm wide and they shall be beaded and so arranged that at all times they
shed water.
• Seams shall be rendered rain tight by use of a sealing strip or sealer compound.
• Insulation within vessel skirts shall not be protected.

7.2 Personnel Protection

To avoid accidents, caused by touching hot or cold surfaces, not required to be insulated for heat
conservation or control operating stability, personnel protection shall be given by one of the
following
• Guard shall be fabricated from 3.15mm iron wire, with mesh dimensions shall not be greater
than 50mm to a height of 2100mm above the working floor level on vertical surfaces and
800mm either side of a horizontal surface. The whole fabrication including straps or brackets
shall be hot dip galvanized.
• A physical barrier with warning signs attached to hot surface is preferred to insulation.
• For personnel protection cages and screens shall be made of perforated sheet 0.5mm
galvanized mild steel with 3mm hole dia X 5mm pitch. Stainless steel ASTM A167 Type 304
for stainless steel pipework. . For Material Refer Table III.
• All Fastening Material Refer Table VI & For Auxiliary Material Refer Table VII.

7.3 Cold Medium Conservation

7.3.1 General

This clause describes the requirements for the Cold medium conservation. Generally, the
installation shall be in accordance with the standards and practice expresses in BS 5970-“code of
practice for thermal insulation of pipe work and equipment”. Polyurethane/Polyisocyanurate
insulation must not be used for oxygen service because of the risk of spontaneous combustion.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 24 OF 53

7.3.2 Surface Preparation

All Surfaces which are to be insulated, except 18-8 stainless steel, shall be prepared and primed in
accordance with specification.

Painted surface shall be clean and dry when insulation is applied.

7.3.3 Application Methods (Cold Medium conservation)

7.3.2.1 Piping And Fitting

• The inner layer of insulation shall not be bonded to the pipe with adhesive. Subsequent layer
are to the bonded to the previous layers. Adhesive to be applied to the ends and edges of
each slab, including the inner layer. Care shall be taken to ensure that the adhesive is evenly
spread over the entire surface. Refer Fig 16.6.
• Insulation material should be check for requirement of anti-abrasion coating.
• Mating surfaces, between adjacent pieces of insulation, shall be tightly butted together so
that no gaps or voids occur. The joint faces of the outer layer of insulation shall be completely
filled and sealed using joint compound.
• Contraction joints shall be provided in the line around each flange and on the line side of the
flange at each flanged fitting. On straight runs contraction joints shall be provided at intervals
appropriate to the service, but not exceeding 6.0 m.
• Insulation for formed piping shall be mitred from pipe covering to make two piece covers.
The pieces, comprising one half of a cover, shall be adhered together to form a unit.
• Two piece covers shall also be made from pipe covering & block insulation for valve & fittings.
The cover shall be made with bolt clearances as shown in the Refer Fig 16.6.3. The component
parts of each half of these covers shall be adhered together, but the joints between the halves
and between the covers and the insulation on the adjacent piping, shall be sealed with joint
sealer.
• Valves and Flanges should be insulated with standard factory formed insulation and covered
with jacketing. Refer Fig 16.6.3.
• For required insulation thickness see table XIII. For method of securing insulation see table
VIII. For Material Refer Table II.

7.3.2.2 Vessels, Exchangers, Etc.

• The blocks of insulation in any layer shall fit snugly over the surface between them and the
surface of the outer layer shall appear to have a smooth contour. The use of curved segments
meets these requirements best, but flat block on the larger diameter vessels may be used.
• On vessel heads etc., the insulation shall be built up from shaped segments of insulation.
Refer Fig 16.6.
• All layers shall be erected with joints staggered at least 75mm from the preceding layer and
each layer shall be secured with tape or bands at 450mm maximum centers.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 25 OF 53

• When butted joints do not fit closely, the voids shall not be filled with joint sealer or vapour
sealing mastic, nor adhesive, neither of which has any value as insulation, but shall be
eliminated by refitting or replacing the insulation. Any damaged corners shall trued before
application.
• Contraction joints shall be provided in the insulation at appropriate locations and in sufficient
number to allow movement without damage to the insulation.
• Vessel and exchanger flanges, manhole covers and such shall have insulation installed so as
to allow removal and re-use without damage to the insulation or adjacent insulation.
• Duplicate nameplates and code stampings, when provided, shall be attached to wooden or
plastic blocks cemented into the insulation. All surfaces of the wood shall be well sealed,
including all of the face to which the plate is attached.
• All attachments and projections fastened directly to the vessel, shall be insulated a minimum
distance of four times the adjoining insulation thickness. The thickness of insulation on such
attachments or projections shall be the same as the vessel insulation thickness.
• For required insulation thickness see table XIII. For method of securing insulation see table
VIII. For Material Refer Table II.

7.3.2.3 Finish Application

• The finish coating required shall be specified on the isometric drawing or piping schedule.
• The surface finish of equipment and piping not metal clad shall consist of fire resistive mastic
over the vapour barrier.
• Metal cladding shall be applied where mechanical damage is anticipated and/or where fire
protection is deemed necessary. The cladding shall be lapped at the edge for a minimum of
50mm and retained with tensioned bands at the overlaps and further at 450 mm centers
maximum equally distributed between overlaps.
• All joints shall be arranged to shed water. Self-tapping screws,” pop” rivets or other
mechanical fastening that may damage the vapour seal shall not be used.
• All Fastening Material Refer Table VI &
• For Auxiliary Material Refer Table VII.

7.3.2.4 Cladding
• Aluminized steel sheet should be used.
Diameter Thickness
Up to 6” (150 mm) dia 0.6mm
Above 6” (150 mm) dia 0.8mm

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 26 OF 53

TABLE VIII METHOD OF SECURING HEAT CONSERVATION INSULATION

Pipe Insulation O.D Securing Method

150mm and below 1.3/1.6mm dia. lacing wire

Above 150mm to 12.7mm x 0.5mm bands

600mm

TABLE IX VERTICAL PIPING-SPACING OF BOLTED SUPPORT CLIPS

Temperature of Pipe Clip spacing table

o
C
Up to 149 10.0m

150-299 5.0m

300-499 4.0m

500 and over 3.0m

8 WEATHER PROOFING & PROTECTIVE COVERING

8.1 General
All external surfaces of insulation, both indoor and outdoor, shall have a weather barrier finish to
keep insulation dry and provide mechanical protection to insulated system.

All jacket joints or openings shall be fabricated with proper overlaps and installed to prevent
moisture penetration.

All joints shall be sealed where moisture can penetrate.

8.2 Weather Proofing for Piping

Jacketing for horizontal and vertical cylindrical piping shall have minimum 50 mm circumferential
and longitudinal laps.

The longitudinal lap on horizontal piping shall be between four o'clock and eight o'clock position
to shed rain water.

On vertical piping, the upper course of jacketing shall overlap the lower course of jacketing.

On vertical pipes, upper courses shall be supported by "S" clips every maximum 300 mm pitch on
outer surface.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 27 OF 53

Jacketing shall be secured with stainless steel bands on approx. 300 mm centers.

All protrusions including pipe supports and attachments through metal jacketing shall be caulked
with flashing compound to prevent intrusion of moisture.

For elbow 3" and less, metal jacketing may be fabricated with two pieces and applied on the
insulation. The jacketing shall be secured with self-tapping screws.

For elbow 4" and over, metal jacketing shall be fabricated with multi pieces and applied on the
insulation so called "Lobster Back Installation". The jacketing shall be secured with self-tapping
screws. For detail Refer Table IV

8.3 Weather proofing of Equipment

Jacketing shall be applied with 75 mm overlaps on all seams. On vertical vessels, provide a
minimum of two corrugations overlap.

On vertical vessel, upper course of jacketing shall be supported by S-clips, on max. 450 mm centers.

Jacketing shall be secured with bands on 450 mm centers. A band shall be installed over
circumferential lap. To prevent bands from sliding on vertical vessels, U-clips, 0.5 mm thick, shall
be installed on maximum of 1,220 mm (48 in.) centers.

Vessels over 2.4 m in diameter and all vessels in cyclic service shall have a breather spring per
every 7.6 m length of band.

Sheet metal screws if required shall be installed on longitudinal joints at 150 mm centers to hold
down jacketing. The metal screws shall not be installed on circumferential lap.

Insulation of equipment heads shall be covered with finishing cement prior to installation of metal
gores.

Install metal gores at the top head of vertical equipment and both heads of horizontal equipment
using sheet metal screws or pop rivets. Metal gores shall overlap shell jacketing by a minimum of
100 mm.

Metal gore joints on top head of vertical vessels shall be sealed with flashing compound.

Bottom head of vertical equipment within the skirt shall be weatherproofed using insulating
cements, glass fabric and mastic. After insulating cement is set, apply 3 mm thick weatherproofing
mastic. While weatherproofing mastic is tacky, a woven glass fabric reinforcing membrane shall
be tightly embedded into it and smoothed out to avoid wrinkles and voids. After first coat is dry,
a second coat of weatherproofing mastic 3 mm thick shall be applied.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 28 OF 53

All protrusions through metal jacketing shall be caulked with flashing compound to prevent
intrusion of moisture. For detail Refer Table IV & V

8.4 Weatherproofing Sealers and Mastics

Sealing strip for rendering cladding joints weather-tight and flashing compound where used shall
be extruded sealant tape or Foam seal sealant, glass fabric for reinforcing foam seal shall be glass
cloth.

Sealers and compound shall be permanently flexible through a temperature range up to 121°C
and shall withstand repeated expansion and contraction without cracking.

Weatherproofing mastic shall be fire resistive.

9 CLEARANCE
Maintain a 25mm minimum clearance between the outside surface of any insulation and any other
adjacent equipment or structural members under all temperature conditions of operation or
shutdown.

10 INSULATION PRECAUTIONS
Instrument drain plugs, flange bolts, unions, removable flanges for strainers, and similar items
shall be free of insulation to permit their removal. If flanges are to be insulated, the insulation shall
be readily removable to permit access to the bolting.

Special care will be taken to avoid the inlet of water through the upper part of isolation cover. Use
mastic if necessary.

11 INSULATION SUPPORTS
The insulator shall provide ring supports for insulation on vertical piping. Supports shall be
installed immediately above all flanges where there is more than 1 meter of vertical pipe above
the flange, and above elbows and tees where there is more than 4.5m of vertical pipe.

Each section of jacket on vertical piping shall be supported from the next lower section with two
S-clips. The bottom jacket section shall be supported by extending the insulation support ring.

The procedure for insulating electrical traced lines shall be the same as for non-traced lines. The
thickness of insulation is based on the normal operating temperature.

All anchors or supports on electrically traced lines shall be completely insulated.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 29 OF 53

12 ACCESSORIES REQUIREMENT FOR INSULATION

12.1 Vertical Vessels

Insulation supports are required on vertical vessels.

Special care shall be taken and there will be joints that absorb the vertical expansion of all diameter
vessels.

12.2 Horizontal Vessels

Horizontal vessels over 2.5m in diameter require banding anchor bars along each side on the
horizontal centreline. Insulation SUBCONTRACTOR standard shall be followed upon CONTRACTOR
review & approval.

12.3 Vessel Heads

Insulation on vessel heads shall be held in place with bands radiating from a floating ring. The
floating ring shall be made of 6mm minimum round steel rod. The bands shall be spaced not more
than 300mm apart at the head tangent line or one band per block, whichever requires the most
bands.

12.4 Stiffener Rings

Unless otherwise noted, insulate all stiffener rings. Stiffener rings may be used as insulation
support rings if the spacing permits.

12.5 Insulation Placements

On cylindrical vessels the long dimension of the insulation shall parallel the vessel axis. All joints
shall be staggered.

CONTRACTOR will specify where apparatus fabrication has to supply welding pins and tie-bars to
secure insulation bands. A floating ring shall be provided by the insulation SUBCONTRACTOR
around man ways, large nozzles, support brackets, and vessel heads for band ties. The insulation
SUBCONTRACTOR is not permitted to weld additional pins to pressure vessels.

12.6 Breather Springs

Circumferential breather springs, as specified in the application pages, are required for apparatus
operating at temperatures exceeding 150ºC when the vessel is 1200mm diameter and larger.
Breather springs shall be installed over the outermost layer of insulation and the jacket.

The numbers of breather springs required are as follows.

Diameter of Apparatus Number of Springs

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 30 OF 53

Diameter No. of springs

1.2 m to less than 4.5m 1

4.5m to less than 6.0 m 2

6.0m to less than 9.0m 3

9m to less than 12.0m 4

12.7 Name Plates

Vessel name plates shall remain visible after insulation is applied. The equipment Fabricator will
raise the nameplates so as to be flush with the outer surface of the insulation. The surrounding
insulation shall be sealed to prevent water from entering.

13 QUALITY CONTROL

13.1 General
A Detailed work method statement together with specific ITP shall be submitted.
Vendor/subcontractor shall include specific QA/QC procedures for the work and test procedures
for all materials / application.

The inspection and test plan (ITP) shall include references to all test procedures, number of
samples, hold-points and witness points, acceptance and rejection criteria and frequency of tests
etc. All test and inspection results shall be recorded and submitted.

13.2 Inspection
Inspection of Materials

Inspection of materials shall be performed either at the manufacturer’s works or in the field.
Vendor has to carry out all inspection whenever necessary. Submit final report to owner’s for
review.

Laboratory test results for various insulation and ancillary materials obtained by independent test
laboratories shall be submitted prior to the commencement of the work together with the data
sheets, manufacturer’s instructions and method statement.

Should the material be delivered in multiple production batches, one laboratory test shall be
performed at the manufacturer’s works and the test results submitted. All other batches a
“Compliance Certificate” shall be submitted certifying that the materials are in accordance with
the technical specifications and relevant standards.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 31 OF 53

13.3 Pre-Insulation Survey and Inspection

After released for insulation (normally after completion of hydrostatic testing, painting and if
applicable testing of electrical/steam tracing), inspect the following:

a. Surfaces
The surfaces are coated and clean/dry. The surfaces should be washed with fresh water to remove
salt deposits and shall be dried.
b. Contraction joints
All positions for installation of the contraction joints in the insulation are clearly defined and
marked in the installation drawings
c. Clearances
Has Sufficient accessibility and clearance shall be provided for both the insulation thickness to be
applied and the space necessary for workmen to apply it.

13.4 Inspection during installation of Cold/Heat Conservation Insulation Systems

Inspections shall be carried out on material and applications to ensure compliance with the
specifications, procedures and in accordance with the approved ITP.

13.5 Final inspection and Release

All parties involved when the system is considered complete or as soon as possible thereafter shall
conduct a final inspection. After final completion of a system, a “release for system insulation
completion” shall be issued.

The application shall be inspected to determine that the insulation is of the proper thickness and
that its materials, workmanship and finishes meet the specifications.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 32 OF 53

14 APPENDICES

14.1 Heat Conservation Insulation Thickness

The thickness shown below is insulation only rounded up to the nearest commercially available
thickness. This table is applicable to item with insulation code H and E.

TABLE X ECONOMIC THICKNESS OF INSULATION (MM) HEAT CONSERVATION SERVICE &

ELECTRICAL HEAT TRACING

PIPE SIZE HOT FACE TEMPERATURE O C WITH AMBIENT AIR AT 18 O C

NOMINAL OD Amb 131oC 151oC 201oC 301oC 401oC 501oC 601oC

BORE - - - - - - - -
mm NPS mm 130oC 150oC 200oC 300oC 400oC 500oC 600oC 700oC

20 3/4 26.7 25 25 40 50 75 90 100 115

25 1 33.4 25 25 40 50 75 90 100 115
40 1.5 48.3 25 25 40 65 90 100 115 130
50 2 60.3 25 25 40 65 90 100 130 140
80 3 88.9 30 38 40 65 100 130 140 150
100 4 114.3 30 38 50 65 100 130 150 180
150 6 168.3 30 38 50 75 130 150 170 190
200 8 219.1 40 38 50 75 130 150 190 205
250 10 273 40 38 50 75 130 150 205 215
300 12 324 40 38 50 90 130 180 215 225
350 14 355 40 38 50 90 130 180 215 240
400 16 406 40 38 50 90 130 180 225 240
450 18 457 40 50 65 90 130 180 225 255
500 20 508 40 50 65 90 130 180 225 265
600 24 609.6 40 50 65 90 130 180 225 265
FLAT / VESSEL 40 50 65 90 130 180 225 265

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 33 OF 53

14.2 Personnel Protection Insulation Thickness (Mineral Wool)

The thickness shown below is insulation only rounded up to the nearest commercially available
thickness. This table is applicable to item with insulation code P. The table is for Mineral Wool

TABLE XI ECONOMIC THICKNESS OF INSULATION (MM) PERSONNEL PROTECTION- INSULATION

PIPE SIZE HOT FACE TEMPERATURE ° C WITH AMBIENT STILL AIR AT 20 ° C

NOMINAL BORE OD AMBIENT to

mm NPS mm 130 150 200 300 400 500 600 700

20 3/4 26.7 20 25 25 25 40 50 65 75
25 1 33.4 20 25 25 25 40 50 65 75
40 1.5 48.3 25 25 25 40 50 65 75 90
50 2 60.3 25 25 25 40 50 65 75 90

80 3 88.9 25 25 25 40 50 65 90 100
100 4 114.3 25 25 25 40 50 65 90 100

150 6 168.3 25 25 25 40 50 75 100 115

200 8 219.1 25 25 25 40 50 75 100 115
250 10 273 25 25 25 40 70 90 100 115
300 12 324 25 25 25 40 70 90 100 115

350 14 355 25 25 25 40 70 90 115 130

400 16 406 25 25 25 40 70 90 115 130

450 18 457 25 25 25 40 70 90 115 130

500 20 508 25 25 25 40 70 90 115 130
600 24 609.6 25 25 25 40 70 90 115 130
FLAT / VESSEL 25 25 25 50 75 100 140 150

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 34 OF 53

14.3 Personnel Protection Insulation Thickness (Mess Guard)

The thickness shown below is insulation only rounded up to the nearest commercially available
thickness. This table is applicable to item with insulation code P. The table is for Mess Guard.
Distance of mesh guard and insulation thickness details for Personnel Protection - Type ‘PP’ for
equipment and piping
TABLE XII ECONOMIC THICKNESS OF INSULATION (MM) PERSONNEL PROTECTION- MESS GUARD

NORMAL OPERATING TEMPERATURE, ° C ( DISTANCE

PIPE SIZE FROM SHEET/METAL GUARD TO BARE SURFACE )

NOMINAL BORE OD AMBIENT to

mm NPS mm 130 150 200 250

20 3/4 26.7 50 50 50 50

25 1 33.4 50 50 50 50

40 1.5 48.3 50 50 50 50

50 2 60.3 50 50 50 50

80 3 88.9 50 50 50 50

100 4 114.3 50 50 50 50

150 6 168.3 50 50 50 50

200 8 219.1 50 50 50 50

250 10 273 50 50 50 50

300 12 324 100 100 100 100

350 14 355 100 100 100 100

400 16 406 100 100 100 100

450 18 457 100 100 100 100

500 20 508 100 100 100 100

600 24 609.6 100 100 100 100

FLAT 100 100 100 100

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 35 OF 53

14.4 Cold Medium Conservation Insulation Thickness

Notes:
1. The dimensions shown are the economic thickness, in mm of polyurethane or
polyisocyanurate thermal insulation, which are to be used. This table is applicable to item with
insulation code C.

2. The recommended thickness applies under still air conditions of 20°C and 85% relative
humidity.
TABLE XIII THICKNESS OF POLYURETHANE/POLYISOCYANURATE INSULATION FOR LOW
TEMPERATURE SERVICES TO CONSERVE COOLING WITHIN

PIPE SIZE NORMAL OPERATING TEMPERATURE(°C)

NOMINAL
OD PIR/PUR
BORE

4 to -4 to -19 to -33 to -47 to -61 to -75 to -88 to

NPS mm 4>
-3 -18 -32 -46 -60 -74 -87 -100

3/4 26.7 25 25 25 40 40 50 63 63 75
1 33.4 25 25 40 40 50 50 63 75 75
1.5 48.3 25 25 40 40 50 65 63 75 90
2 60.3 25 25 40 50 50 65 75 75 90
3 88.9 25 25 40 50 50 65 75 90 100
4 114.3 25 25 40 50 65 65 75 90 100
6 168.3 25 25 40 50 65 75 90 90 100
8 219.1 25 25 40 50 65 75 90 100 115
10 273 25 40 40 50 65 75 90 100 115
12 324 25 40 40 50 65 75 90 100 115
14 355 25 40 50 50 65 75 100 100 125
16 406 25 40 50 65 65 75 100 100 125
18 457 25 40 50 65 75 90 100 115 125
20 508 25 40 50 65 75 90 100 115 125
24 609.6 25 40 50 65 75 90 100 115 125

VESSEL & FLAT

25 40 50 65 75 90 100 125 140
SURFACES

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 36 OF 53

14.4.1 Layering of Insulation for PIR/PUR

Total Insulation Insulation layering

(mm) arrangement (mm)
50 50
60 60
70 30/40
80 40/40
85 40/45
90 40/50
100 50/50
105 50/55
110 50/60
115 50/65
120 60/60
125 60/65
130 30/50/50
135 35/50/50
140 40/50/50
145 45/50/50
150 50/50/50
155 50/55/50
160 50/60/50
165 50/65/50
170 50/70/50
180 50/80/50
190 50/90/50
200 50/100/50
210 70/70/70
215 70/70/75

14.4.2 QUALITY CONTROL

14.4.3 General
A Detailed work method statement together with specific ITP shall be submitted.
Vendor/subcontractor shall include specific QA/QC procedures for the work and test procedures
for all materials / application.
The inspection and test plan (ITP) shall include references to all test procedures, number of
samples, hold-points and witness points, acceptance and rejection criteria and frequency of tests
etc.
All test and inspection results shall be recorded and submitted.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 37 OF 53

14.4.4 Inspection

14.4.5 Inspection of Materials

Inspection of materials shall be performed either at the manufacturer’s works or in the field.
Vendor has to carry out all inspection whenever necessary. Submit final report to owner’s for
review.
Laboratory test results for various insulation and ancillary materials obtained by independent test
laboratories shall be submitted prior to the commencement of the work together with the data
sheets, manufacturer’s instructions and method statement.
Should the material be delivered in multiple production batches, one laboratory test shall be
performed at the manufacturer’s works and the test results submitted. All other batches a
“Compliance Certificate” shall be submitted certifying that the materials are in accordance with
the technical specifications and relevant standards.

14.4.6 Pre-Insulation Survey and Inspection

After released for insulation (normally after completion of hydrostatic testing, painting and if
applicable testing of electrical/steam tracing), inspect the following:
a. Surfaces
The surfaces are coated and clean/dry. The surfaces should be washed with fresh water to
remove salt deposits and shall be dried.
b. Contraction joints
All positions for installation of the contraction joints in the insulation are clearly defined and
marked in the installation drawings
c. Clearances
Has Sufficient accessibility and clearance shall be provided for both the insulation thickness to be
applied and the space necessary for workmen to apply it.

14.4.7 Inspection during Installation of Cold/Heat Conservation Insulation Systems

Inspections shall be carried out on material and applications to ensure compliance with the
specifications, procedures and in accordance with the approved ITP.

14.4.8 Final Inspection and Release

All parties involved when the system is considered complete or as soon as possible thereafter
shall conduct a final inspection. After final completion of a system, a “release for system
insulation completion” shall be issued.
The application shall be inspected to determine that the insulation is of the proper thickness and
that its materials, workmanship and finishes meet the specifications.

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 38 OF 53

14.5 Figure for Heat Conservation

14.5.1 Horizontal Pipe (Single, Multiple layer)

Electrical Tracing

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 39 OF 53

14.5.2 Vertical Pipe (Single, Multiple layer) and Piping insulation ends (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 40 OF 53

14.5.3 Elbows (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 41 OF 53

14.5.4 Guard Material

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 42 OF 53

14.5.5 Valve (Single, Multiple layer) and Flange (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 43 OF 53

14.5.6 Expansion bellow (Single, Multiple layer) and Pipe supports (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 44 OF 53

14.5.7 Vertical equipment – Head (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 45 OF 53

14.5.8 Vertical equipment – Head & Bottom (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 46 OF 53

14.5.9 Horizontal equipment – Body (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 47 OF 53

14.6 Figure for Cold Medium Conservation

14.6.1 Horizontal pipe (Single layer and multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 48 OF 53

14.6.2 Elbows (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 49 OF 53

14.6.3 Valve and Flange (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 50 OF 53

14.6.4 Tee (Single layer)

14.6.5 Vertical Equipment - Body (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 51 OF 53

14.6.6 Vertical Equipment - Head (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 52 OF 53

14.6.7 Vertical Equipment - Bottom (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004

 Document No. AGP-GPS-ANOGP-Z05-0004 REV. A01

Document Title INSULATION SPECIFICATION PAGE 53 OF 53

14.6.8 Horizontal Equipment - Body (Single, Multiple layer)

GPS DOC NO. D1034-01-EL-SP-0004