----------------------Install Insulation

Module 12314
Instrumentation Trainee Task Module 12314
INSTALL INSULATION-
Ob|ectves
Upon completion of this module, the trainee will be able to:
1. Identfy and seect types of nsuaton.
2. Identfy nstrument devces and nes to be nsuated usng
approprate specfcatons and drawngs.
3. Dscuss and perform nsuaton nstaaton usng approprate
specfcatons and drawngs.
Prerequstes
Successfu competon of the foowng Task Modue(s) s requred before
begnnng study of ths Task Modue: Instrumentaton Leve 3, Task
Modues 12307 and 12316.
Requred Tranee Materas
1. Tranee Modue
2. Requred Safety Equpment
Instrument Tranee Task Modue 12314 2
COURSE MAP
Ths course map shows a of the Wheels of Learning task modues n the
thrd eve of the Instrumentaton currcua. The suggested tranng order
begns at the bottom and proceeds up. Sk eves ncrease as a tranee
advances on the course map. The tranng order may be ad|usted by the
oca Tranng Program Sponsor.
LEVEL 3 COMPLETE
TABLE OF CONTENTS
Insta Insuaton - Modue 12314 3
Section Topic .
Page
1.0.0 Introducton
.............................. 5
2.0.0 Identfcaton and Seecton of Types of Insuaton ..........
5
2.1.0 Fbergass and Mnera Wood Insuaton ...............
6
2.1.1 Gypsum (Cacum Scate) Insuaton .................
6
2.1.2 Pre-Fabrcated (Pedte) Insuaton ..................
6
2.1.3 Banket (Gass Fber) Insuaton ...................
7
3.0.0 Identfcaton of Instrument Devces and Lnes to be Insuated per
Specfcatons and Drawngs ....................
7
4.0.0 Insuaton Instaaton ........................
7
4.1.0 Ppe Insuaton
............................ 8
4.1.1 Ppe Ebow Insuaton
........................ 9
4.1.2 Fange Insuaton
..........................10
4.1.3 Vave Insuaton
............................ 10
4.1.4 Duct Work Insuaton
........................ 11
4.1.5 Tank and Drumhead Insuaton ....................
12
Instrument Tranee Task Modue 12314 4
Trade Terms Introduced In Ths Modue
Fastening: Matera used to attach nsuaton.
Insulating material: Matera used to retard heat transfer.
Lagging: Coverng apped over nsuatng materas.
1.0.0 INTRODUCTION TO INSTALLATION OF INSULATION-
The purpose of nsuaton s to retard the transfer of heat FROM a system
that s hotter than the surroundng atmosphere or TO a system that s
cooer than the surroundng atmosphere. Insuaton heps to mantan the
desred temperatures n a systems. In addton, t prevents sweatng of
ppng that carres coo or cod fuds. Insuaton aso serves to protect
personne from beng burned by comng n contact wth hot surfaces.
Insuaton represents the composte ppng coverng whch conssts of the
nsuatng matera, aggng, and fastenng. The insulating material offers
resstance to the fow of heat; the lagging, usuay made of panted canvas,
s the protectve and confnng coverng paced over the nsuatng
materas; and the fastening attaches the nsuatng matera to the system,
and to the aggng.
Insuaton covers a wde range of temperatures, from the extremey ow
temperatures of the refrgeratng pants to the very hgh temperatures of
steam systems. No one matera coud possby be used to meet a the
condtons wth the same effcency.
Ths modue w dscuss varous types of nsuatng materas and provde
the tranee wth practce n performng nstaaton of nsuaton materas.
2.0.0 IDENTIFICATION AND SELECTION OF TYPES OF INSULATION-
The foowng Ouaty Requrements for the varous nsuatng materas are
taken nto consderaton n the seecton of these materas:
1. Low heat conductvty
2. Noncombustbty
3. Lghtweght
4. Easy modng and nstaaton capabty
5. Mosture repeent
Insta Insuaton - Modue 12314 5
6. Noncorrosve, nsoube, and chemcay nactve
7. Composton, structure, and nsuatng propertes unchanged by
temperatures at whch t s to be used.
8. Once nstaed, shoud not custer, become umpy, dsntegrate or
bud up n masses from vbraton.
9. Vermn proof
10.Hygencay safe to hande
0
The servce requrements and ocaton must be anayzed to determne
whch products w, for exampe, meet the temperature requrements and
aso be abe to wthstand the abuse antcpated. Aso, speca
consderatons such as fre protecton, removabty, and chemca
resstance must a be revewed n the seecton process.
Fnay, three nsuaton cost factors shoud be carefuy anayzed. The
nta cost of matera and nstaaton s straghtforward; compettve
products can be ready compared. Mantenance costs are not as cear-cut
and vary greaty from one matera to another, wth the softer materas
usuay requrng more mantenance n ndustra envronments. The ast
cost eement s that of the heat ost through the nsuaton system. If the
same thckness s specfed for severa dfferent materas, the product
wth the owest therma conductvty w provde the owest ost-heat cost.
Smary, a matera that requres ess mantenance may we retan ts
orgna performance onger than a matera whch s easy damaged and
degraded.
2.1.0 FIBERGLASS AND MINERAL WOOL INSULATION
Fbergass and mnera woo are actuay two separate and dstnct types of
nsuaton; however, many of ther appcatons and physca propertes are
smar. These products are generay used n hot appcatons but wth
some restrctons can be used n cod appcatons as we. Fbergass s
often used for ched water ppng, and other ppng, up to a maxmum of
850F. Mnera woo has a peak temperature mt of 1200F. Fbergass s
made from gass fbers bonded together wth resn bnders. Mnera woo s
made from rock sag fbers and bonded together wth resn or cay bnders.
These materas are generay apped wth meta bands, wre, or tape and
covered wth a meta or nonmetac fexbe |acket. On ndoor appcatons,
they are frequenty covered wth an a-servce |acket.
2.1.1 Gypsum (Cacum Scate) Insuaton
Cacum scate s a very rgd heavy-densty matera used excusvey for
appcatons above 250F. Ths nsuaton matera has been a standard for
hgh-temperature appcatons for many years. Its compressve strengths
are very good, and t s noncombustbe. It s sutabe for temperatures
from 250F up to 1000F. Cacum scate s manufactured from a surry
that s poured nto mods to make varous ppe coverng shapes. It s
generay avaabe n haf-sectons, quad-sectons, and fat bocks. Cacum
scate s apped to the ppng wth meta bands and generay covered
wth a meta |acket.
2.1.2 Pre-Fabrcated (Perte) Insuaton
Instrument Tranee Task Modue 12314 6
Perte nsuaton s generay used n the same types of appcatons as
cacum scate. It s somewhat ghter n densty and ower n compressve
strength than cacum scate; however, t s usuay treated wth a water
nhbtor whch tends to keep t drer than cacum scate. Perte
nsuaton s aso made n mods to ft the range of ppe-coverng shapes
requred by ndustry. It s usuay apped wth meta bands and covered
wth a meta |acket.
2.1.3 Banket Insuaton (Gass Fber Banket)
Ths type of nsuaton s made of fbergass nsuatng matera as
mentoned n Secton 2.1.0 of ths modue. It s formed nto a fexbe
"banket" that can be draped across or wrapped around arge ppng or
components. Ths form of nsuaton s easy nstaed and commony used
to nsuate duct work.
3.0.0 IDENTIFICATION OF INSTRUMENT DEVICES AND LINES TO BE
INSULATED PER SPECIFICATIONS AND DRAWINGS-
Pror to nstang nsuaton, the techncan must frst dentfy whch
sectons of system are to be nsuated. Ths requres specfc gudance
because n many cases an entre system w not be nsuated. Certan
processes requre heat to be transferred to the surroundng atmosphere.
There are severa methods by whch drawngs are marked to dentfy
nstruments and ppng or tubng sectons to be nsuated. One such
method empoys the use of dotted nes around sectons of ppng and
nstruments to be nsuated. A note n the b of materas for the drawng
w descrbe the type and sze of nsuatng matera to be used.
In certan cases a separate drawng w be provded specfcay for use by
techncans showng a sectons and nstruments to be nsuated.
4.0.0 INSULATION INSTALLATION-
The foowng genera precautons shoud be observed wth regard to the
appcaton and mantenance of nsuaton:
a. F and sea a ar pockets and cracks. Faure to do ths w cause
arge osses n the effectveness of the nsuaton.
NOTE: Use proper seaant to cose a cracks or modfcatons to
encosures.
2. Sea the ends of the nsuaton and taper off to a smooth, artght
|ont.At |ont ends or other ponts where nsuaton s abe to
damage,use sheet meta aggng. Fanges and |onts shoud be
cuffed wth 6-nch aggng.
Insta Insuaton - Modue 12314 7
3. Keep mosture out of a nsuaton work. Mosture s an enemy of
heat nsuaton fuy as much as t s n the case of eectrca
nsuaton. Any dampness ncreases the conductvty of a heat-
nsuatng materas.
NOTE: Provde for condensaton dranage where necessary.
4. Insuate a hangers and other supports at ther pont of contact
from the nes or other unts they are supportng, otherwse a
consderabe quantty of heat w be ost by conducton through the
support.
5. Sheet meta coverng shoud be kept brght and not panted uness
the protectng surface has been damaged or has worn off. The
radaton from brghtboded and ght-coored ob|ects s
consderaby ess than from rough and darkcoored ob|ects.
6. Once nstaed, heat nsuaton requres carefu nspecton, upkeep,
and repar. Laggng and nsuaton removed to make repars shoud
be repaced |ust as carefuy as when orgnay nstaed. When
repacng nsuaton, make certan that the repacement matera s
of the same type as had been used orgnay.
7. Insuate a fanges wth easy removabe forms whch can be
made up as pads of nsuatng matera, wred or bound n pace,
and the whoe covered wth sheet meta casngs whch are n
haves, and easy removabe. The man steam, auxary steam,
auxary exhaust, feedwater, and steam heatng ppng systems
are agged to hod n the heat. The crcuatng dranage, fre, and
santary ppng systems are agged to prevent condensaton of
mosture on the outsde of the ppng.
8. Asbestos Contro: Inhaaton of excessve quanttes of asbestos
fber can produce severe ung damage n the form of dsabng or
fata fbross of the ungs. Asbestos has aso been found to be a
causa factor n the deveopment of cancer of the membrane nng
the chest and abdomen. Lung damage and dsease usuay deveop
sowy and often do not become apparent unt years after the
nta exposure.
WARNING! Be aware of the potenta presence of asbestos. Ony certfed
asbestos abatment personne are quafed to work wth
asbestos.
The nstaaton and remova of nsuaton s governed by standard
engneerng specfcatons because of the appcaton requrements,
temperature requrements, and the wde varety of nsuatng materas
avaabe to meet these requrements.
Pror to any nstaaton or remova, these specfcatons must be revewed
and adhered to.
Because of ths wde varety of nsuatng methods ony a few of them w
be mentoned to aow you to become famar wth the nsuatng process
n genera.
4.1.0 Ppe Insuaton
Instrument Tranee Task Modue 12314 8
Rgd poyurethane foam s normay used for coo temperature ppe at
temperatures rangng between 35F and 300F. Ths type of nsuaton s
apped n a snge ayer wth straght butt |onts as shown n Figure 1. A
speca type of nsuaton uses offset butt |onts. The |onts do not need to
be coated and seaed. Tape can be used as a temporary fastener. Lnes
covered wth one ayer of nsuaton shoud have the |onts that run aong
the ppe staggered to prevent the segments from rong or otherwse
workng oose.
Fgure 1. Types of Butt |onts
4.1.1 Ppe Ebow Insuaton
To start, nsta and wre a preformed ebow n pace. After the preform s
on, you use the nstructons that foow.
To nsuate a ppe ebow wth pre-gued gass fber, cut out a square pece
of pre-gued gass fber coth whose sdes are seven-eghths tmes the
crcumference of the preformed ppe nsuaton. In Figure 2, the nsuaton
crcumference s about 33 nches, so the coth shoud be cut to a 28 nch
square.
Fgure 2. Coverng a Ppe Ebow
Insta Insuaton - Modue 12314 9
Dp the coth n water and appy to the ebow. The coth dagona
measurement (pont to pont) w run aong the outsde edge of the ebow
radus. Trm and make cuts n the coth as necessary to make a smooth ft.
When the coth s dry, sea t wth a aggng adhesve.
4.1.2 Fange Insuaton
The ne coverng shoud come wthn one fange bot ength pus one nch
of the fange, to aow for remova of the bots durng mantenance as seen
n Figure 3.

Fgure 3. Insuatng a Fange
When the ne nsuaton thckness s such that the outsde dameter of the
ppe coverng s equa to the fange dameter, and a arger sze ppe cover
w ft the fange, no bockng s necessary. When the ne nsuaton
thckness s such that a arger sze ppe cover w not ft snug, bockng
must be used to f n the gap. Fange covers shoud overap ne nsuaton
by at east 2 nches.
Instrument Tranee Task Modue 12314 10
4.1.3 Vave Insuaton
For a vave n a 6" ne covered wth 6" x 2" nsuaton, fgure a 6" ne wth
2" nsuaton on ether sde for a new ppe dameter of 10" and cover the
vave body wth a 10" x 2" ppe coverng. Cut to ft as snug as possbe,
overap nsuaton on the ppe by at east 2", and wre securey wth 14 or
16 gage bang wre as seen n Figure 4. F n vods and the top of the
vave bonnet wth nsuatng cement and scraps of bock.
Fgure 4. Insuatng a Vave
4.1.4 Duct Work Insuaton
To nsta gass fber banket nsuaton on duct work, frst appy a water-
resstant adhesve n 4 nch brush wdths about one foot apart as shown n
Figure 5. Insta the gass fber banket (1-1/2 nches thck by 36 nches
wde, n ths case), makng sure that each strp s tghty butted to the
nearest strp. If the ducts are greater than 18 nches n wdth, spnde
anchors shoud be used nstead of adhesve to secure the nsuaton.
The gass fber banket aso acts as sound attenuaton on ar-condtonng
and heatng ducts. Appy chcken wre wth a vny acryc mastc fnsh
coat to renforce the gass fber banket.
Insta Insuaton - Modue 12314 11
Fgure 5. Insuatng Duct Work
4.1.5 Tank or Drumhead Insuaton
The nsuaton on heads or ends of cyndrca tanks shoud be secured by
bands or wres that are no more than 4 nches apart and fastened to cps,
ange ron bands or stee bands encrcng the tank behnd the rvet heads
or crcumferenta head wed as shown n Figure 6. The use of sprngs w
hep provde temporary securng before permanent band or wre s
nstaed.
Fgure 6. Insuatng a Tank
The nsuaton on the tank shoud be hed n pace at the center of the
heads by rada wres or bands fastened to cps or a foatng rng. Fbrous
adhesve can be used to support nsuaton on overhead surfaces unt
bands or wres can be apped.
Chpped edges, cracks, and mperfectons shoud be fed and smoothed
wth nsuaton seaer. Chcken wre shoud be apped over the nsuaton
and bands, drawn tght, and aced nto pace.
SUMMARY
Insuaton of ppng, tubng, and components n a process system s
essenta for proper operaton and personne safety. Each type of
Instrument Tranee Task Modue 12314 12
nsuaton dscussed n ths modue has a specfc use and method of
nstaaton whch you shoud be famar wth. There are numerous other
types avaabe but those mentoned are most commony used n ndustry
today.
References
For advanced study of topcs covered n ths Task Modue, the foowng
works are suggested:
Piping Handbook, Sxth Edton, McGraw-H, Inc., 1992.
Standard Handbook of Plant ngineering, McGraw-H, Inc., 1983.
SELF-CHECK REVIEW / PRACTICE OUESTIONS
1. Whch s not a quaty requrement for an nsuatng matera?
a. Hgh heat conductvty.
b. Lghtweght.
c. Mosture repeant.
d. Non-corrosve.
2. What s the peak temperature mt for mnera woo nsuaton?
a. 1000F.
b. 850F.
c. 1200F.
d. 1500.
3. What type of nsuaton s usuay used for duct work?
a. Cacum scate.
b. Mnera woo.
c. Poy-foam.
d. Gass fber banket.
4. How cose shoud the ne coverng come to a fange?
a. One fange bot ength pus one nch.
b. Four nches from fange.
c. As cose as possbe.
d. Two fange bot engths.
5. Why does asbestos nsuaton remova requre speca precautons?
a. Asbestos s chemcay unstabe.
b. Asbestos s fammabe.
c. Asbestos fber may cause ung dsease f nhaed.
d. None of the above.
PERFORMANCE / LABORATORY EXERCISES
1. Gven a "mock-up" of an nstrument ppng system provded by
nstructor:
Step 1 Insta nsuaton on a straght ppng run.
Step 2 Insta nsuaton on a ppe ebow.
Step 3 Insta nsuaton on a vave.
Insta Insuaton - Modue 12314 13
Step 4 Insta nsuaton up to an ebow.
Step 5 Insta nsuaton on an nstrument.
ANSWERS TO SELF-CHECK REVIEW / PRACTICE OUESTIONS
1. a
2. c
3. d
4. a
5. c
Instrument Tranee Task Modue 12314 14