Hot Insulation Specification Guide

SPECIFICATIONFORHOTINSULATION
SpecificationforHotInsulation
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TABLEOFCONTENTS
1.0SCOPE
.. ............................................................................................................................................. 3
2.0GENERAL . ............................................................................................................................................. 3
3.0MATERIALS ............................................................................................................................................ 3
4.0APPLICATION ......................................................................................................................................... 4
5.0REUSABLEPADTYPEINSULATIONCOVERS............................................................................................. 10
6.0STORAGETANKS .................................................................................................................................. 12
7.0INSPECTIONANDQUALITYCONTROL .................................................................................................... 13
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1.0 SCOPE
1.1 This specification covers specific materials,

fabrication,
installation,
and
inspection
requirements for insulation of hot process piping,
vessels, tanks, and equipment operating between
the temperatures of 70 F (21 C) and 1200 F
(649 C).
1.2 Theinsulationdescribedhereinislimitedto
that required for conservation of heat,
maintenance of operating temperature, and/or
personnelprotection.
1.3 Exceptions or variations shown in the

project specifications shall take precedence over
the requirements stated herein. Alternatives
stated in this specification may be exercised
subjecttopriorwrittenCOMPANYapproval.
2.0 GENERAL
2.1 Vessels, equipment, and piping shall be

insulated in accordance with the project
specifications and this document. The term
"vessel" includes towers, drums, reactors, heat
exchangers, and similar items. The term
"equipment" includes such items as engines,
turbines,andpumps.
2.2 The Insulation Material Specification and

thickness requirements are indicated on the
drawings and piping isometrics. Equipment
insulationmaterialandthicknessrequirementsare
indicatedontheequipmentschedule.
2.3 This specification requires compliance with

all applicable federal, state, and local laws and
regulations.
2.4 Insulationshallnotbeappliedtoanypiping,
vessels, or other process equipment before any
required protective coating has been applied and
such items have been inspected, tested, and
approved for the intended services unless prior
COMPANYapprovalisobtained.
2.5 The MANUFACTURER'S recommendation

shall be followed in handling, storage, and
application of insulation system components.
Strict adherence to the MANUFACTURER'S
suggestedoperatinglimitationsisrequired.
2.6 The insulation shall be protected from

moisture, weather, and damage before, during,
andafterapplication.
2.7 Allsurfacestobeinsulatedshallbedry.All
insulation shall be kept dry prior to application of
the weather barrier. Ifinsulationbecomeswet,it
shallbediscardedandreplaced.
2.8 No field welding of insulation clips or

supports, etc., is to be done except with specific
written authorization of the COMPANY
representative.Weldingmaterialsandprocedures
shallbereviewed,andweldersshallbetestedand
approvedpriortoreceivingwrittenauthorization.
2.9 Nameplates and code stamps shall be left

uncoveredandreadable.
3.0 MATERIALS
3.1 Materials (specified or referenced by

MANUFACTURER)anddesignationareintendedto
definethetypeandqualityofmaterialonlyandare
not intended to exclude equal or better items
offered by other MANUFACTURERS. Products of
reputable MANUFACTURERS and of comparable
type, quality, and other physical characteristics
may be proposed for use, subject to COMPANY
approval.
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3.2 Insulation materials shall be compatible

with the surfaces on which they are applied.
Galvanized materials such as tie wire and chicken
wire mesh shall not be used on stainless steel
piping and vessels. All such materials for use on
stainless steel piping and vessels shall be stainless
steel.
3.3 "Galvalume" jacketing shallnotbeusedon

stainlesssteelpipingandvessels.
3.4 Onlynonasbestosmaterialsshallbeused.
3.5 Flashing compounds, joint sealers,

caulkings, and mastics shall require COMPANY
approvalpriortoanymaterialcommitmentorstart
ofwork.
3.6 All materials shall be new. Materials such

as insulation blocks, pipe coverings, cements, and
weathering compounds shall be furnished at the
jobsiteinfactorysealedcontainers.
3.7 Specificmaterialrequirementsarefoundin
the Insulation Material Specifications (COMPANY
Engineering Specification IH1.0.1) and is to be
consideredapartofthisSpecification.
3.8 Insulation materials shall have a flame

spread and smoke density rating of 25/50 or less
perASTME84.
4.0 APPLICATION
4.1 General
4.1.1 Unpaintedmetalsurfacesshallhavegrease,
rust, dirt, and other foreign materials removed by
solventcleaningandwirebrushorbyothermeans
acceptable to the COMPANY prior to insulating.
Stainless steel items shall be wire brushed with
stainless steel brushes only. Painted metal
surfaces shall have grease, dirt, and other foreign
materialsremovedbysolventcleaningorbyother
means acceptable to the COMPANY prior to
insulating.
4.1.2 Chlorinated solvents shall not be used for

cleaningstainlesssteel.
4.1.3 Allinsulationsectionsshallbetrimmedand
tightlybuttedtoeliminatevoids.
4.1.4 Whenstandardflatblockstrimmedtofitin
the field are used, all joints shall be pointed up
with insulating cement before applying the
weatherbarrier.Thisdoesnotprecludetheuseof
scoredandbeveledblockswhereverpossible.
4.2 PipingandVessels
4.2.1 Pipe diameter will be that of published

nominal pipe sizes. Tolerances shall be in
accordancewiththeapplicableASTMspecification
4.2.2 When insulation is called for on piping, any

additionalitemsrelatingtothelines,suchasvents,
drains,andbypassesthatformapartofthepiping
system, shall be considered part of the insulation
work, even though they are not identified by an
individuallinenumber.
4.2.3 Piping and cylindrical vessels with outside

diameters of 30 inches (760mm) and less shall
normally have "sectional preformed pipe"
insulation.
a.
Insulation may be installed in single or
multiplelayers.Noindividuallayershallbe
morethan3inches(76mm)thick.
b.
The outer layer of sectional pipe insulation
shall be secured with wire or bands on 9
inch(229mm)centers.Innerlayersshallbe
secured on 18 inch (457mm) centers.
Insulation on piping and vessels 12 inches
(305mm) in diameter and smaller shall be
securedwithwire.Insulationonpipingand
vessels larger than 12 inches (305mm) in
diametershallbesecuredwithbands.
c.
Wire ends shall be bent and pressed into
theinsulation.
d.
Inallcases,atleastfour(4)wiresorbands
per 3 foot (910mm) section of insulation
shallbeinstalledontheouterlayer.
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e.
f.
In multiple layer installations, all joints in

adjacent layers shall be staggered a
minimumof2inches(51mm).
Each layer shall be secured with wire or
bands before the succeeding layer is
applied.
4.2.4 Insulation shall be omitted 9 inches

(229mm)eithersideofpipesupportsonNPS2and
smaller pipe if the pipe rests directly on the
support.Theinsulationshallbecontinuouswhere
the pipe is heat traced or where the pipe is
supportedonpipeshoes.
4.2.5 Piping and cylindrical vessels with outside

diameters over 30 inches (760mm) shall be
insulated with preformed curved segments,
miteredlogscutfromflatblocks,orblankets.
a.
Block and curved segment insulation shall
be applied with length of block/segment
parallel to greatest length of surface to be
insulated.Allsuccessiveendjointsshallbe
staggeredandtheblocksscoredorsizedto
eliminate gaps between surfaces and
blocks. Block and curved segment
insulation can be applied in multiple layer
construction,whererequired,withalljoints
intheadjacentlayersstaggeredaminimum
of2inches(51mm).
b.
No individual layer shall be more than 3
inches(76mm)thick.
c.
The outer layer of insulation shall be
secured with bands on 12 inch (305mm)
centers.Innerlayersshallbesecuredwith
bandson18inch(454m)maximumcenters.
d.
The edges of metal mesh covered blanket
insulation shall be laced with wire to the
adjacentblanketonbothsides.
e.
Blanket insulation shall be cut to wrap
around the vessel in one piece wherever
practical.
f.
Multilayerinsulationisrequiredwherethe
operating temperature exceeds 600 F
(316 C).
4.2.6 Expansion springs shall be installed on all

bands that secure the outer layer of insulation on
cylindrical surfaces as required by Table 1 of this
specification. Expansion springs shall be evenly
spacedaroundthecircumference.4inch(102mm)
long springs shall be stretched 1/2 inch (13mm)
uponinstallation.
a.
Expansion springs shall also be installed on
all bands that secure the inner layers of
insulationinaccordancewithTable1ofthis
specification where brittle or fracturable
insulationmaterials,suchascalciumsilicate
orcellularglass,areused.
4.2.7 Attachments on vessels projecting beyond

the insulation, such as stiffening rings, shall be
considered an integral part of the vessel and shall
be insulated and finished in the same manner as
the vessel. Thickness of insulation on such
attachments and projections shall be the same as
theadjoininginsulation.
4.3 HeatTracing
4.3.1 Where heat tracing is indicated, pipe

insulation must normally be at least one pipe size
largerthanthepipeormusthaveanextendedleg
on the tracer side. No grooving or deforming of
the insulation to accommodate the tracing will be
allowed.
a.
Fortracedlineslargerthan2inch(51mm),
stabilize the insulation with 1 inch (25mm)
by9inch(229mm)longspacerson18inch
(457mm)centersbetweentheinsulationID
and the pipe OD. Spacer material shall be
the same as the pipe insulation. Center
spacer at supported butt joints. Spacer
shall be thick enough to provide firm
support.
b.
Secure insulation on electric traced piping
systems with 1 inch (25mm) wide filament
tape. Wrap the tape 1 1/2 times around.
Donotusewire.
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4.3.2 No insulation material shall be applied

betweenthepipeandtracerexceptforspacersto
prevent local overheating of the pipe where
specified.
4.3.3 On vertical piping provide draft stops of

heat transfer cement on approximately 4 feet
(1.2m)centers.
a.
For temperatures to 375 F (191 C) use
nonhardening HTM. For temperatures
375 F(191 C)andaboveusewatersoluble
HTM.
b.
Do not use insulating and/or finishing
cement.
c.
Tieapieceofscrimglassclotharoundpipe
and tracer to support the HTM. The HTM
shallbe1inch(25mm)wide.
4.4 InsulationSupports
4.4.1 Location and details of insulation supports,

ifprovided,willbeshownonvesselandequipment
drawings or piping isometrics. Where insulation
supports have not been provided, the insulation
shallbesupportedbytheinsulationCONTRACTOR
in accordance with good practice and with the
approvaloftheCOMPANYrepresentative.
a.
Goodpracticeshallincludesupportingpipe
outside the insulation, outdoors and areas
wheretheinsulationcangetwet.
4.4.2 On vertical piping runs, the insulation

CONTRACTOR shall furnish and install all clamped
insulationsupports.
a.
Ifverticallinesaresteamorelectrictraced,
these supports shall provide adequate
clearanceforthetracer.
b.
Insulation supports shall be in accordance
withdimensionsspecifiedinFigure2ofthis
specification and shall be installed at 21
foot1inch(6.43m)intervals,maximum.
4.4.3 Vessel insulation supports will be provided

by the vessel FABRICATOR in accordance with
Figures4,5,and6ofthisspecificationforvertical
vessels and Figure 7 of this specification for
horizontalvessels.
4.4.4 On vessels that are skirtsupported, the

insulation support ring for the bottom head shall
be welded to the inside of the skirt if it is not
providedbythevesselshop.Thesupportringshall
notcontactnozzlesoranyotherprotrudingmetal.
4.4.5 Welding pins may be used to support

insulation on spherical vessels or on irregular
compound curved surfaces, subject to COMPANY
approval.Insuchapplications,speedclipsshallbe
usedtoholdinsulationonstudsthatarebentover
above the clip. Split pins shall be spread, bent
over, and embedded 1/2 inch (13mm) into the
insulation. Depressions shall be filled with
insulating cement. See paragraph 2.8 of this
specification.
a.
Spacingandlayoutdetailsforweldingstuds
shallrequireCOMPANYapproval.
4.5 InsulationExpansionJoints
4.5.1 Vertical and horizontal vessels and piping

operating at or above temperatures of 500 F
(260 C) shall have insulation expansion joints
providedateachsupportorstiffeningring,21foot
1inch(6.43m)maximumspacing.
a.
The expansion space between the
underside of the ring and the insulation
shall be packed with loose mineral fiber
insulation.Theloosemineralfibershallbe
packedtoofitsunrestrainedvolume.
b.
The loose mineral fiber insulation shall be
retained by the jacketing or a suitable
flashing to prevent rainwater entering into
theexpansionjoint.
c.
Locate expansion joints at the top of
verticalrunsonpipe.
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4.5.2 At least one expansion joint shall be

providedforeachvesselorpipingruninexcessof8
feet (2.44m) in length and operating at
temperatures at or above 500 F (260 C).
Insulation expansion joints are not required for
vessels or piping runs less than 8 feet (2.44m) in
length.
4.5.3 Insulationexpansionjointsarenotrequired
on vertical vessels insulated with block insulation
where the insulation supports are designed and
spaced as shown in Figure 6 of this specification,
sincetheinsulationblocksareslightlycompressed
in this insulation system. Insulation expansion
joints are required on vertical vessels insulated
withblanketinsulationasshowninFigure5ofthis
specification.
4.6 InsulationTerminations
4.6.1 The open end of all insulation shall be

neatlyfinishedandweatherproofedbyeitherusing
preformedmetalcapsorreinforcedmasticsystem.
a.
Preformed caps shall be used wherever
practical and shall be of the same material
as the jacketing. All seams andjointsshall
be caulked. Where other than metal
jacketing is applied, use the reinforced
mastic.
b.
When it is not practical to use preformed
caps,theopenendoftheinsulationshallbe
beveled and sealed with glass cloth
reinforced mastic, applied as described in
paragraph4.12.6ofthisspecification.
4.6.2 Insulation adjoining flanges shall be

terminated at a suitable distance from the flange
to allow easy removal of nuts and stud bolts
withoutdamagetotheinsulation.Recommended
distance is the length of flange bolts plus 1 inch
(25mm).SeeFigure3ofthisspecification.
4.7 FlangesandValves
4.7.1 Flangesandflangedvalvesininsulatedlines
shallbeinsulatedwherespecifiedbythedrawings
or project specifications. Reusable pad type
insulation covers shall be used where they are
required to be insulated. See Section 5 of this
specification for reusable pad type cover
specifications.
4.7.2 Screwed valves shall be insulated with

insulating cement and finished with mastic or
covered with continuous pipe insulation where
feasible.SeeFigure3ofthisspecification.
4.7.3 Flangesonexchangersandvesselmanways
shallbeinsulatedwithreusablepadtypeinsulation
covers. The permanent insulation on exchangers
shallbeterminatedatasuitabledistancefromthe
flangestoallowtheremovalofflangeboltswithout
damagetotheinsulation.Recommendeddistance
isthelengthoftheflangeboltsplus1inch(25mm).
4.7.4 Where specified, a stainless steel drip ring

shall be installed around flanged connectionswith
anNPS1/2driptubeextendingthroughagrommet
inthebottomoftheinsulationcover.
4.7.5 Flanged joints shall not be insulated until

thepipingsystemhasreachedoperatingconditions
andanyleakshavebeeneliminated.
4.8 Fittings
4.8.1 Fittings shall be insulated with premolded

fittingsinsulation.Miteredpipeinsulationmaybe
usedwherepremoldedcommercialfittingsarenot
available.
a.
Where premolded fittings insulation is not
practicalonNPS11/2orsmallersizes,high
temperaturetempmatfiberglassinsulation
shallbeused.
b.
Mitered pipe insulation may be used only
withpriorCOMPANYapproval.
c.
Fibrousadhesiveshallbeusedforinstalling
calcium silicate and perlite silicate
fabricatedelbowsandfittings.Themitered
edges shall be contoured to provide
clearanceforthefittingcover.
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d.
The thickness of the insulation on fittings

shall be equaltothethicknessofadjoining
pipeinsulation.
4.9 VesselHeads
4.9.1 Insulation of fixed vessel heads shall be

installed per Figures 4, 5, 6, and 7 of this
specification.
4.9.2 Vesselheadsshallbeinsulatedtothesame
thicknessastheshells.Blanketorblockinsulation,
neatlybeveledtoensureaclosefit,shallbeused.
a.
Engineered vessel head segments shall be
considered to insure tight insulation joints
and ease of installation. The FABRICATOR
willrequireavesseldetaildrawing.
4.9.3 Insulation for removable heads on
exchangers,strainers,etc.,shallberemovableand
reusablepadtypecovers.
4.10 VesselSkirts
4.10.1 Insulation on both the inside and the

outside of skirts shall be equal to the shell
insulation thickness where the skirt is required to
beinsulated.
4.11 InsulatingandFinishingCement
4.11.1 Finishing and insulating cements shall only

beappliedtofacilitatetheapplicationofaweather
barrier.
4.11.2 Allcementsshallbecompletelydrypriorto
coatingand/orcoveringwithaweatherbarrier.
4.11.3 Theinsulatingandfinishingcementshallbe
mixed and applied according to the
MANUFACTURER'Srecommendations.
4.11.4 Insulating and finishing cement shall be

applied to the same thickness as the adjoining
insulation.
4.12 WeatherBarriers
4.12.1 The insulation shall be inspected and

approvedbytheCOMPANYrepresentativepriorto
applicationoftheweatherbarrier.
4.12.2 All insulated outdoor piping, vessels,

exchangers, and other equipment except as
excluded in paragraph 4.12.6 of this specification
shall be weatherproofed with metal jacketing as
follows:
a.
The jacketing material requirements are
found on the Insulation Material
Specificationattachedtothisspecification.
b.
Smooth jacketing over insulation for
cylindrical surfaces 30 inches (760mm)
diameterandsmallershallbesecuredwith
1/2 inch by 0.015 (13mm by 0.38mm)
stainlesssteelbandsandsealsplacedat12
inch(305mm)centers,maximum,overeach
circumferential overlap and at least at the
centerofeachcourseofjacketing.
c.
Screws are not permitted to secure
jacketingonelectricallytracedlines.
d.
Smooth jacketing for cylindrical surfaces
indoors or 10 feet (3m) ODorlessshallbe
secured with minimum 3/4 inch by 0.015
inch (19mm by 0.38mm) stainless steel
bandsandsealsplacedon12inch(305mm)
centers and over each circumferential
overlap.
e.
Pipe jacketing shall be applied with 2 inch
(51mm)circumferentialorlongitudinallaps
as applicable. Vessel and tank jacketing
shall be applied with minimum 3 inch
(76mm) circumferential and longitudinal
laps. Corrugated sheeting shall lap 1 1/2
corrugationsontheverticalseam.
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f.
g.
h.
i.
j.
k.
Smooth jacketing and corrugated sheeting

outdoors for cylindrical surfaces greater
than10feet(3m)ODshallbesecuredwith
11/4inchby0.020inch(32mmby0.51mm)
stainlesssteelbandsandsealsplacedon18
inch (460mm) centers and over each
circumferentiallap.Oncorrugatedsheeting
the bands and seals are placed on 3 feet
(.9m) and over each circumferential lap.
The vertical seams shall be secured with
stainless steel No. 6 selfdrilling, self
tapping screw 1/2 inch (13mm) long on 6
inch (152mm) centers on the ridge of the
corrugation.
On all vertical vessels and piping, "S" clips
shall be used on every circumferential lap
to support the jacket. "S" clips shall be
spaced no more than 18 inches (460mm)
apart around the circumference with a
minimum of 2 clips per sheet of jacketing.
Theupperlegofthe"S"clipshallretainthe
band and be screwed to the upper course
of jacketing. The screw shall not bind
adjacentcoursesofjacketingtogether.See
Figures5and6ofthisspecification.
"U" clips shall be installed on all bands on
vertical vessels larger than 12 feet (3.7m)
diameterthatarenotretainedby"S"clips.
Thebandshallrestinthepocketofthe"U"
clip and both ends of the clip shall be
secured to the jacketing by one of the
screws at each longitudinal jacket seam.
The clips shall be spaced 4 foot (1.2m) on
center except at expansion springs where
they shall be 12 inches (305mm) on each
sideofthespring.
On horizontal equipment and piping, the
longitudinalfinishlapshallbepositionedto
shed rainwater and minimize dust
collecting.Theoverlapsshallbepositioned
30degreebelowhorizontal.
Preformed2piecefittingcoversforfittings
shall be used wherever possible to the
largest commercially available size. On
largersizesusethemetalgoresystem.
Sheet metal screws shall not bind adjacent
courses of jacketing together at the
circumferentiallap.
l.
A square frame made from 20 gauge by 1

inchwide(0.89by25mm)stainlesssteelflat
bar, welded together at the corners, shall
be used for anchoring bands at manways
andotherlargevesselopenings.Theframe
shallbeplacedoverthenozzleandtheends
ofthejacketbandsattachedtothevertical
sidesoftheframe.
4.12.3 Expansion springs shall be installed on all

bands that secure the jacketing on cylindrical
surfacesasrequiredbyTable1ofthisspecification.
Expansion springs shall be evenly spaced around
the circumference. 4 inch (102mm) long springs
shall be stretched 1/2 inch (13mm) upon
installation. Super MitySprings shall be
compressedinch(6.4mm)uponinstallation.
4.12.4 Alloverlapsinmetaljacketingwhicharenot
installed in a watershed fashion, such as
longitudinal seams in vertical piping and
circumferentialseamsinhorizontalpiping,shallbe
sealed with a continuous bead of caulking
compoundunderthelaps.
4.12.5 All openings in the jacket for nozzles,

brackets,nameplates,etc.,shallbecutascloseas
possible to achieve a tight fit and sealed with a
minimum 3/8 inch (8mm) bead of caulking
compound.Anygapgreaterthan1/4inch(6mm)is
not acceptable. Do not feather edge the bead of
caulking.Caulkingshallbeappliedonaclean,dry
surface. Caulk all openings on the same day the
jacketisinstalled.
4.12.6 Irregularly shaped surfaces on which metal

jacketing cannot be made to fit properly shall be
weatherproofedwithanacrylicwaterbasemastic
systeminthefollowingmanner:
a.
Thesurfaceoftheinsulationshallreceivea
tackcoatofmasticaminimum0.015inches
(0.38mm)dryfilmthickness(DFT).
b.
Reinforcing cloth shall be neatly stretched
over the surface with edges overlapping at
least2inches(51mm)andembeddedinthe
tackcoat.
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c.
d.
e.
A second finish coat of mastic shall be

applied over the reinforcing cloth at a
minimum 0.04 inches (1mm) DFT or at the
MANUFACTURER'Srecommendedrate.
All mastic coats shall extend at least 3
inches (76mm) under any adjoining metal
jacket.
Do not dilute or water down the mastic.
The mastic system shall be completed on
thesameday.
4.13 UltrasonicInspectionPorts
4.13.1Ultrasonicinspectionportsshallbeinstalled
by the CONTRACTOR at points designated by the
COMPANY. Ultrasonic inspection ports are
generallyrequiredasfollows:
a.
Piping As shown in Figure 12 of this
specification.
b.
Vessels:
1.
Two inspection ports shall be
installedoneachvesselhead.
2.
Aninspectionportshallbeinstalled
on vertical vessel shells at each
platform.
3.
Two inspection ports shall be
installed on horizontal vessel shells
for each 10 feet (3m) of length,
except that a minimum of 2 ports
shall be provided at each end (one
ontopandoneonbottom).
4.13.2 Inspection ports shall not be installed

throughsupportwireorbanding.
4.13.3 The type of inspection port to be used is

specified on the drawings or in the project
specifications.
4.13.4 Where "Speedcheck" plugs are specified,

theyshallbeinstalledinallinspectionholescutin
theinsulation.
4.13.5 Where "V.I.P." inspection ports are

specified,theyshallbeinstalledinaccordancewith
the MANUFACTURER'S recommendations, Figure
13 of this specification, and the following

requirements:
a.
Inspection ports installed in insulation
where the outside diameter of the
insulation is less than 12 inches (305mm)
shallbe11/2inches(38mm)indiameter.
b.
Inspection ports installed in insulation
where the outside diameter of the
insulation is 12 inches (305mm) or more
shallbe21/2inches(64mm)indiameter.
c.
An 'O' ring gasket supplied with the plug
shall be applied under the grommet lip
beforeitisinsertedintotheinsulationand
when installed shall provide a watertight
seal between the grommet and the
jacketing.
d.
The insulation plug used in the inspection
portshallbehightemperature,highdensity
TempMattypefiberglassblanket.
5.0 REUSABLEPADTYPEINSULATIONCOVERS
5.1 General
5.1.1 Reusablepadtypeinsulationcoversshallbe
usedinthefollowingapplicationswhereinsulation
isrequired,unlessotherwisespecified:
a.
Flangedvalvesininsulatedlines.
b.
Flangesininsulatedlines.
c.
Piping through the first valve from heat
exchangers, pumps, and turbines, provided
the valve is not more than 15 feet (4.6m)
fromthepieceofequipment.
d.
Vesselnozzleflangesandnozzlenecksupto
thepermanentinsulation.
e.
Vesselmanwaysandinspectionopenings.
f.
Removable heat exchanger channels,
channelcovers,andshellcovers.
g.
Pumps,turbines,andcompressors.
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5.1.2 Nominalinsulationthicknessshallbebased
on the operating temperature of the item to be
insulatedwithanoutsidecovertemperaturenotto
exceed140 F(60 C)whichshallbeasfollows:
Temperature
Thickness
F
C
Inches
mm
Upto400 Upto204
1
25
400500
204260
2
51
500600
260316
21/2
64
600800
316427
31/2
90
800900
427482
4
102
5.1.3 Covers may be either field or shop

fabricated.
5.1.4 Shopfabricated covers shall be boxed and

shippedwiththeidentificationtaginformation(see
paragraph 5.4 of this specification) legibly printed
oneachbox.
5.1.5 The cover FABRICATOR shall provide an

installation drawing for large covers which consist
of multiple pieces. Each cover piece shall be
labeled with a piece number on the installation
drawing, and the piece number shall be included
on the cover identification tag. Installation
drawings are not required with flange and valve
covers unless specifically requested for
replacementpurposes.
5.2 Materials
5.2.1 Insulation shall be a flexible fibrous glass

insulation manufactured in mat form and
containing no binders. Material to be
Insulbatte/Tempmat by JPS Glass Fabrics Div., or
COMPANYapprovedequal.
5.2.2 The outer fabric shall be a PTFEcoated

fiberglass cloth, approximately 16 oz./yd. sq.
Material to be Textiles Coated, Inc. EJ1650 or
COMPANYapprovedequal.
5.2.3 Theinnerliningforoperatingtemperatures
upto600 F(316 C)shallbethesameastheouter
fabric.Theinnerliningforoperatingtemperatures
over600 F(316 C)shallbehightemperatureglass
cloth(18oz./yd.sq.)impregnatedwithvermiculite,
Textiles Coated Inc., PyroJac 1800 or COMPANY
approvedequal.
5.2.4 Lacinganchorsshallbe12gauge(2.66mm)
thick, 1 1/2 by 3/16 inch (38 by 5mm) lead, Type
304stainlesssteel.
5.2.5 For high mechanical abuse areas, a 60

density knitted wire mesh with 0.011 inch
(0.28mm) diameter type 304 stainless steel wire
shall be required to cover over the other cover
finishes.
5.2.6 Thecoversshallbemachinesewnwithhigh
temperature thread, Teflon coated for
temperatureexposureupto650 F(343 C).Above
650 F (343 F) use stainless steel wire thread,
nyloncoated.
5.2.7 Tiewireshallbe18gauge(1.2mm)stainless
steelwire.
5.2.8 Velcrostrappingmaybeusedtosecurethe
covers,howeveritshallbestainlesssteel.
5.3 Design
5.3.1 Covers shall be designed and fabricated in

as few pieces as practical. Weight for any one
pieceshallnotexceed50pounds(23kg).
5.3.2 The seams of all covers shall be machine

sewn8to10stitchesperinch(25mm).Eachseam
shall be double stitched. The seams shall be
hemmed with no exposed edges. All cover ends
shall be gusseted for full insulation thickness.
Pillowconstructionisnotacceptable.
5.3.3 All covers exposed to high mechanical

abuse shall be completely encapsulated in a
covering of type 304 stainless steel, 60 density,
0.011inch(0.28mm)diameterknittedwiremesh.
11of55
5.3.4 Flange and valve covers to be installed in

the horizontal position shall have a seam on the
bottom side of the cover. If it is not practical to
locateaseamonthebottomofthecover,adrain
grommetshallbeprovided.Draingrommetsshall
alsobeprovidedwheredriptubesarerequiredby
paragraph 4.7.4 of this specification, located such
thatthedriptubeextendsthroughthegrommet.
5.3.4.1Strappingfabricatedfromtheoutsidecover
materialandtiedwithstainless'D'ringsorVelcrois
anacceptablemethod.
5.3.5 Allreusableblanketsshallbeinstalledwith
lacinganchorsandsoftstainlesssteelwire.Lacing
anchors shall be secured to the blanket with self
locking type 304 stainless steel speed clips, which
are1inch(25mm)longerthanthethicknessofthe
pad. Other types of fasteners may be acceptable
5.3.6 The cover insulation shall overlap

permanent insulation by the 2 inches (51mm) or
the thickness of the insulation. If this is not
possible then flaps 2 inches (51mm) wide
constructed of double layer outside cloth material
shallbepartofthecover.
5.3.7 Adequate stitching (tucks) with heavy glass

threadorotherapprovedmeansshallbeinstalled
through large covers to prevent migration of the
insulation inside the cover. A minimum of one
stitchpersquarefootshallbeused.
5.3.8 Wheninstalled,thecovershallfitsnuglyon
the item to be insulated. Cover edges and seams
shall fit together tightly such that no gaps are
present.Providedrawstringsatthecircumferential
ends.
5.4 Identification
5.4.1 A stainless steel tag shall be permanently

attachedtoeachseparatecoverorcoversegment.
The following information shall be shown in the
following format. If the cover is one of several
segments of a large cover, the piecenumbershall
be included on the identification tag (see
paragraph 5.1.5 of this specification). All
informationshallbestampedinraisedletters.
Valves
6"Class300
ValveSizeandRating
6"HR1HA21
LineNumber
RE0288403PN6B
DrawingNumber
Flanges
6"300lb
FlangeSize
6HR1HA21
LineNumber
RE0288403PN6B
DrawingNumber
Equipment
X126
EquipmentNumber
ChannelHead
Description
40.5/35.25
FlangeSize/ChannelSize
Nozzles
X126
EquipmentNumber
ChannelNozzle
Descriptions
6"300lbRFWN
NozzleSize
6.0 STORAGETANKS
6.1 Prefabricated insulation panel systems are

preferred for insulating storage tanks and shall be
used unless prior COMPANY approval is obtained
for another insulation system. The materials and
installation procedures used shall be subject to
COMPANYapproval.
6.1.1 Acceptablematerialsuppliersare:
ThermaconIndustriesInc.
345NewAlbanyRoad
Morrestown,NewJersey08057
8002220773
12of55
IsoPanels,Inc.
P.O.Box54173
Pearl,Mississippi39208
6019397640
6.2 As an alternate, storage tanks may be

insulatedinthefollowingmanner:
6.2.1 Blockorblanketinsulationfortanksshallbe
supportedbyweldedclipsat4foot(1.22m)vertical
intervals about the circumference of the tank. A
formedanglefastenedtotheclipsshallcompletely
encircle the tank. The insulation shall be banded
on12inch(305mm)centers.RefertoFigure11of
thisspecificationfordetails.
6.2.2 Roofs on insulated storage tanks requiring

fiberglass or mineral wool block insulation shall
havebuiltupinsulationasdescribedbelowandas
shown on Figure 11 of this specification. The
system shown on Figure 11 shall be used where
weldingispermittedontankroofs.Insulationshall
be designed to withstand foot traffic where
specified. A high compressive strength insulation,
such as calcium silicate, foam glass, or 13pound
per cubic foot (200 kg per cubic meter) mineral
fibershallbeusedinthiscase.
a
Insulationondeckshallbeproperlyapplied
to MANUFACTURER'S specification and be
dryandclean.
b.
Lay0.040inchthickaluminumsheetwith3
mil polyethylene moisture barrier over the
insulation and screw to the "Z" bars on 9
inch(229mm)centers.
c.
Coat the aluminum sheet with hot asphalt.
Asphalt shall be applied at 350 F (177 C)
minimum at a rate of 40 pounds per 100
squarefeet.
d.
Finalcoattheentiresurfacewith50pounds
per 100 square feet GAF A720 mineral
shield granules or a COMPANY approved
equal.
6.2.3 Otherinsulationsystemsmaybeacceptable
7.0 INSPECTIONANDQUALITYCONTROL
7.1 COMPANYrepresentativesshallhaveaccess
toallworkwhilebeingperformed.
7.2 All materials and equipment furnished for

this project shall be subject to inspection by
COMPANY.
7.3 Material thickness shall have a zero minus

tolerance.
7.4 Insulation will be judged defective and

rejectedforanyofthefollowingreasons:
a.
If there are any cracks or voids extending
throughtheinsulation.
b.
If there are any cracks which would cause
insulation to break upon sawing or gently
flexing.
c.
Iftherearebrokenordamagedpieces.
d.
Ifthejacketing/finishisnotwatertight.
e.
Ifthereisanyothernoncompliancewiththe
specifications.
13of55
TABLE1
EXPANSIONSPRINGREQUIREMENTS
NUMBEROF4INCHEXPANSIONSPRINGSREQUIREDPERBAND
Dia.
(ft)
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
24.0
28.0
32.0
36.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
110.0
120.0
130.0
10 12 15 20 25 30 35
0 5 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 1
0 0 1 1 1 1 2
0 0 1 1 1 1 2
0 0 1 2 1 1 2
0 0 1 2 1 2 2
0 0 1 2 1 2 2
0 0 1 2 1 2 2
0 0 1 2 2 2 2
0 0 1 2 2 2 2
0 0 1 1 2 2 2
0 0 1 2 2 2 2
0 1 1 2 2 2 2
0 1 1 2 2 2 2
0 1 2 2 2 2 2
0 1 2 2 2 2 3
0 1 2 2 2 2 3
1 1 2 2 2 3 3
1 1 2 2 3 3 4
1 1 2 2 3 4 5
1 1 2 3 3 4 5
1 2 2 3 4 5 6
1 2 2 3 4 5 6
1 2 2 3 5 6 7
1 2 2 4 5 6 7
1 2 3 4 5 7 8
OperatingTemperature(F
40 45 50 55 60 65 70
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 1 1 1
0 0 0 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 2
1 1 1 1 1 2 2
1 1 1 1 2 2 2
2 2 2 2 2 2 2
2 2 2 2 2 2 2
2 2 2 2 2 2 2
2 2 2 2 2 2 2
2 2 2 2 2 2 2
2 2 2 2 2 2 2
2 2 2 2 2 2 3
2 2 2 2 2 3 3
2 2 2 2 2 3 3
2 2 2 2 3 3 3
2 2 2 2 3 3 3
2 2 3 3 3 3 4
2 3 3 3 4 4 4
3 3 3 4 4 4 5
3 3 4 4 4 5 5
3 4 4 4 5 5 6
4 4 5 5 6 6 7
5 5 6 6 7 8 8
5 6 7 7 8 9 10
6 7 8 8 9 10 11
7 8 8 9 10 11 12
7 8 9 10 11 12 13
8 9 10 11 12 14 15
9 10 11 12 14 15 16
9 11 12 13 15 16 17
75
0
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
4
4
5
6
6
7
9
10
12
13
14
16
17
19
80
0
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
4
4
5
5
6
7
8
10
11
13
14
16
17
19
20
85
0
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
5
6
6
7
9
10
12
13
15
17
18
20
21
90
0
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
5
5
6
7
7
9
11
12
14
16
18
19
21
23
95 100
0 0
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 3
3 3
3 3
3 3
3 3
3 4
4 4
4 4
4 4
4 4
5 5
6 6
6 7
7 7
8 8
10 10
11 12
13 14
15 16
17 18
19 20
20 22
22 23
24 25
14of55
140.0 1 2 3 4 6 7 9 10 11 13 14 16 17 19 20 22 23 24 26 27
150.0 1 2 3 5 6 8 9 11 12 14 15 17 18 20 21 23 25 26 28 29
160.0 1 2 3 5 6 8 10 11 13 15 16 18 20 21 23 25 26 28 29 31
170.0 2 2 3 5 7 9 10 12 14 16 17 19 21 23 24 26 28 30 31 33
180.0 2 3 3 5 7 9 11 13 15 16 18 20 22 24 26 28 29 31 33 35
190.0 2 3 4 6 8 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37
200.0 2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 31 33 35 37 39
Notes:
(seenextpage)
Notes:
1.
Thistableisapplicableto4inchlongexpansionspringsandtheSuperMitySprings.
2.
Forintermediatetemperaturesordiameters,installthenumberofspringsrequiredforthenexthigher
temperatureorlargerdiameter.
3.
1inchequals25.4millimeters.
15of55
Figure1a
PIPEINSULATIONDETAILS
NOTES
1.
ALLCOVERINGSHALLHAVEAMINIMUMENDANDSIDELAPOF3INCHES.
2.
1INCHEQUALS25.4MILLIMETERS.
16of55
Figure1b
NOTES
1.
2.
17of55
Figure1c
NOTES
1.
2.
18of55
Figure2a
NOTES
1.
ALLVERTICALINSULATEDLINESSHALLBESUPPORTEDATBOTTOMANDATAPPROXIMATELY20FOOT
INTERVALS.SEESPECIFICATION.
19of55
Figure2b
NOTES
1.
20of55
Figure2c
NOTES
1.
21of55
Figure2d
NOTES
1.
22of55
Figure3a
NOTES
1.
PREMOLDEDINSULATIONANDJACKETINGSHALLBEUSEDONFITTINGSWHEREVERPOSSIBLE.
2.
23of55
Figure3b
NOTES
1.
2.
24of55
Figure3c
NOTES
1.
2.
25of55
Figure3d
NOTES
1.
2.
26of55
Figure3e
NOTES
1.
2.
27of55
Figure4a
INSULATIONDETAILSFORVERTICALVESSELS
2FOOT6INCHDIAMETERANDUNDER
NOTES
1.
PROVIDEBOLTEDSUPPORTRINGSFORINSULATIONEVERY12FEET.
2.
THE INSULATION DETAILS FOR VESSELS OVER 2 FEET 6 INCHES DIAMETER MAY BE USED AS
ALTERNATEDETAILSFORSMALLERVESSELS.
28of55
Figure4b
NOTES
1.
2.
29of55
Figure4c
NOTES
1.
2.
30of55
Figure5a
INSULATIONDETAILSFORVERTICALVESSELSOVER
2FOOT6INCHDIAMETERBLANKETINSULATION
31of55
Figure5b
32of55
Figure5c
33of55
Figure5d
34of55
Figure5e
35of55
Figure6a
2FOOT6INCHDIAMETERBLOCKINSULATION
36of55
Figure6b
37of55
Figure6c
38of55
Figure6d
39of55
Figure7a
INSULATIONDETAILSFORVERTICALVESSELSLARGERTHAN2FOOT6INCHDIAMETER
NOTES
1.
THEINSULATIONDETAILSFORVESSELSLARGERTHAN2FEET6INCHESDIAMETERMAYALSOBEUSED
ASALTERNATIVEDETAILSFORSMALLERVESSELS.
2.
40of55
Figure7b
NOTES
1.
2.
41of55
Figure7c
NOTES
1.
2.
42of55
Figure7d
NOTES
1.
2.
43of55
Figure8a
INSULATIONDETAILSFORHEATEXCHANGERS
SHELLANDTUBE
NOTES
1.
APPLYBLANKETINSULATIONWITHJOINTSSTAGGEREDANDLACEDTOGETHERWITHWIRE.
2.
STAGGERMOLDEDPIPEINSULATIONASSHOWNONFIGURE1.
3.
PREMOLDEDPIPEINSULATIONISPREFERREDFORALLTUBULAREXCHANGERSWHEREREQUIREDSIZES
AREAVAILABLE.
4.
FILLALLJOINTSANDCRACKSWITHINSULATINGCEMENT.
5.
44of55
Figure8b
SHELLANDTUBE
NOTES
1.
APPLYBLANKETINSULATIONWITHJOINTSSTAGGEREDANDLACEDTOGETHERWITHWIRE.
2.
STAGGERMOLDEDPIPEINSULATIONASSHOWNONFIGURE1.
3.
PREMOLDEDPIPEINSULATIONISPREFERREDFORALLTUBULAREXCHANGERSWHEREREQUIREDSIZES
AREAVAILABLE.
4.
FILLALLJOINTSANDCRACKSWITHINSULATINGCEMENT.
5.
45of55
Figure9a
REBOILERS
NOTES
1.
ENDSOFINSULATIONSHALLBEASSHOWNONFIGUREB.
2.
46of55
Figure9b
REBOILERS
NOTES
1.
ENDSOFINSULATIONSHALLBEASSHOWNONFIGUREB.
2.
47of55
Figure10a
STEAMTURBINES
48of55
Figure10b
STEAMTURBINES
49of55
Figure11a
INSULATIONDETAILSFORTANKS
NOTES
1.
PREFABRICATEDPANELSYSTEMSAREPREFERREDFORSTORAGETANKS.
50of55
Figure11b
NOTES
1.
51of55
Figure11c
NOTES
1.
52of55
Figure11d
NOTES:
1.
53of55
Figure12
ULTRASONICTHICKNESSMONITORINGLOCATIONSFORINSULATEDPROCESSPIPING
54of55
Figure13
V.I.P.ULTRASONICINSPECTIONPORT
1.
USE11/2DIAMETERINSPECTIONPORTSFORINSULATIONOUTSIDEDIAMETERSLESSTHAN12.USE2
1/2DIAMETERINSPECTIONPORTSFORINSULATIONOUTSIDEDIAMETERSOF12ORMORE.
55of55

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SPECIFICATIONFORHOTINSULATION

1.1 This specification covers specific materials,

1.3 Exceptions or variations shown in the

2.1 Vessels, equipment, and piping shall be

2.2 The Insulation Material Specification and

2.3 This specification requires compliance with

2.5 The MANUFACTURER'S recommendation

2.6 The insulation shall be protected from

2.8 No field welding of insulation clips or

2.9 Nameplates and code stamps shall be left

3.1 Materials (specified or referenced by

3.2 Insulation materials shall be compatible

3.3 "Galvalume" jacketing shallnotbeusedon

3.5 Flashing compounds, joint sealers,

3.6 All materials shall be new. Materials such

3.8 Insulation materials shall have a flame

4.1.2 Chlorinated solvents shall not be used for

4.2.1 Pipe diameter will be that of published

4.2.2 When insulation is called for on piping, any

4.2.3 Piping and cylindrical vessels with outside

In multiple layer installations, all joints in

4.2.4 Insulation shall be omitted 9 inches

4.2.5 Piping and cylindrical vessels with outside

4.2.6 Expansion springs shall be installed on all

4.2.7 Attachments on vessels projecting beyond

4.3.1 Where heat tracing is indicated, pipe

4.3.2 No insulation material shall be applied

4.3.3 On vertical piping provide draft stops of

4.4.1 Location and details of insulation supports,

4.4.2 On vertical piping runs, the insulation

4.4.3 Vessel insulation supports will be provided

4.4.4 On vessels that are skirtsupported, the

4.4.5 Welding pins may be used to support

4.5.1 Vertical and horizontal vessels and piping

4.5.2 At least one expansion joint shall be

4.6.1 The open end of all insulation shall be

4.6.2 Insulation adjoining flanges shall be

4.7.2 Screwed valves shall be insulated with

4.7.4 Where specified, a stainless steel drip ring

4.7.5 Flanged joints shall not be insulated until

4.8.1 Fittings shall be insulated with premolded

The thickness of the insulation on fittings

4.9.1 Insulation of fixed vessel heads shall be

4.10.1 Insulation on both the inside and the

4.11.1 Finishing and insulating cements shall only

4.11.4 Insulating and finishing cement shall be

4.12.1 The insulation shall be inspected and

4.12.2 All insulated outdoor piping, vessels,

Smooth jacketing and corrugated sheeting

A square frame made from 20 gauge by 1

4.12.3 Expansion springs shall be installed on all

4.12.5 All openings in the jacket for nozzles,

4.12.6 Irregularly shaped surfaces on which metal

A second finish coat of mastic shall be

4.13.2 Inspection ports shall not be installed

4.13.3 The type of inspection port to be used is

4.13.4 Where "Speedcheck" plugs are specified,

4.13.5 Where "V.I.P." inspection ports are

13 of this specification, and the following

5.1.3 Covers may be either field or shop

5.1.4 Shopfabricated covers shall be boxed and

5.1.5 The cover FABRICATOR shall provide an

5.2.1 Insulation shall be a flexible fibrous glass