Job Specification 126158-82A3 Insulation of Coke Drum

SOCAR & TURCAS AEGEAN Refinery (STAR) REF: 13-126158-02
Delayed Coker Unit 190 DATE: Dec. 15, 2010

Aliaga, Izmir, Turkey PAGE: App.D-1
REV: 1

BASIC DESIGN PACKAGE
APPENDIX D JOB SPECIFICATIONS
D-1 Insulation of Coke Drums, 126158-82A3 Rev.1
______________________CONFIDENTIAL_____________________
THIS DOCUMENT CONTAINS CONFIDENTIAL TECHNICAL INFORMATION OF FOSTER WHEELER USA CORPORATION AND IS TO BE
AND REPRODUCED, ONLY IN ACCORDANCE WITH THE WRITTEN PERMISSION OF FOSTER WHEELER USA CORPORATION,
USED,
FOR SOCAR & TURCAS RAFINERI A.S. (STRAS) AT SOCAR & TURCAS AEGEAN REFINERY (STAR), ALIAGA, IZMIR, TURKEY.
SOCAR & TURCAS RAFINERI A.S. (STRAS) FWUSAC
STAR (SOCAR & TURCAS AEGEAN REFINERY) PROJECT CONTRACT No. 126158-02
DELAYED COKING UNIT, UNIT 190 Page: 1 OF 19
ALIAGA, IZMIR, TURKEY
JOB SPECIFICATION
126158-82A3
INSULATION OF COKE DRUM
The subject job specification is issued herewith. Please discard any previous issue of this specification. For
convenience, the nature of the revision is briefly noted under remarks.
Revision Number Log

Rev Date By Pages Approved Reason for Issue
by
1 23RD AUG 2010 RP/TC 19 SD Issued for Client Review

STAR (SOCAR & TURCAS AEGEAN REFINERY) PROJECT SPECIFICATION No:126158-82A3
ALIAGA, IZMIR, TURKEY REV No: 1
TABLE OF CONTENTS
I. SCOPE 4
II. INSULATION MATERIALS 4
III. INSTALLATION OF INSULATION 6
IV. INSULATION DETAILS 9

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I. SCOPE
This standard defines the requirements for 6 thick external insulation of coke drums.
Special requirements of coke drum insulation include the following items:
- Special attachment clips and insulation support rings for insulation on shell, skirt and
cone.
- Use of inspection lanes for shell, skirt and cone for circumferential weld seams.
- For routine inspection of critical circumferential welds, use of removable insulation

blocks at critical inspection lanes. Critical inspection lanes for routine inspection of
circumferential weld seams shall be specified by owner. Critical circumferential weld
seams are, as a minimum, skirt junction, etc.
- Requirement for T.I.s be located outside the inspection lanes (Typ. shell, skirt and
cone).
II. INSULATION MATERIALS
A. Insulation
1. Insulating material for coke drums (shell, skirt, cone, and top head) shall be 6
total thick asbestos free mineral wool blanket conforming to ASTM C 592, Class
II, consisting of 2 layers. The inner layer shall be 3" thick, 12 lb/ft3 density, faced
with 22 gauge (.028" diameter) stainless steel 1" hexagonal mesh poultry netting
on both sides. The outer layer shall be 10 lb/ft3 density, 3 thick, and faced with
22 gauge stainless steel 1" hexagonal mesh poultry netting on both sides.
2. Insulating material for the shell at nuclear level devices shall be 1 thick 8 lb/ft3
density, ceramic fiber blanket conforming to ASTM C892 Grade 8 Type I. See
Figure 2 for details.
B. Weatherproofing
Metal jacketing for weatherproofing shall have a factory-applied moisture barrier

bonded to the inside surface. The moisture barrier may be polyethylene - kraft paper,
polysurlyn or other approved proprietary alternate.
1. Insulation on the cylindrical section of the drums shall be weatherproofed using

0.032" thick aluminum jacketing conforming to ASTM B209 Alloy 3003 Temper
H14, Alloy 3105 Temper H14 or equal. The jacketing shall have corrugations
measuring 1 in length (peak to peak) and in total depth.
2. Insulation on the top head shall be weatherproofed using 0.032" thick flat
stainless steel jacketing conforming to ASTM B209 Alloy 3003 Temper H14, Alloy
3105 Temper H14 or equal.
3. Insulation on the bottom cone, inside of the skirt shall be weatherproofed using
0.032" thick flat stainless steel jacketing conforming to ASTM A240 Type 304 or
equal.
4. Insulation on the outside of the skirt shall be weatherproofed using 0.032" thick
stainless steel jacketing conforming to ASTM A240 Type 304 or equal. The
jacketing shall have corrugations measuring 1 in length (peak to peak) and
in total depth.
C. Bands shall be type 304 stainless steel, wide x 0.020" thick, with 0.025" thick
closed crimp seals.
D. "J" and "S" Clips shall be type 304 stainless steel, wide x 0.030" thick.
E. Tie wire shall be 16 gauge (approx. 1/16" diameter) fully annealed Type 304 stainless
steel.
F. Sheet Metal Screws
1. Type 304 stainless steel #10 gauge x long self-tapping screws with Neoprene
gaskets shall be used for securing sheet metal to sheet metal. "Poprivets" are an
acceptable substitute. The insulation subcontractor must submit type and size for
approval.
2. Type 304 stainless steel diameter x 5/8 long self-tapping screws with
Neoprene gaskets shall be used for securing sheet metal to insulation support
angles.
G. Expansion springs for bands on insulation shall be type 302 stainless steel INSUL-
MATE ES-7 expansion springs, manufactured by RPR Products, Inc. or CHIL-
SPRING expansion springs, manufactured by Childers Products Company, Inc.
H. Compression springs for bands on jacketing shall be type 302 stainless steel Childers
MITY-SPRING or approved equal shall be used.
J. Insulation support pins on cone shall be 5 mm dia. stud pins and longer than the
insulation thickness and supplied with speed clips. Pins shall be constructed of TP
405 stainless steel with a maximum carbon content of 0.08%. Alternatively, pins may
be constructed of 410 or 409 stainless steel. Nelson Type TPC or approved equal
shall be used. If TP 405, 409, and 410 SS pins are unavailable, Cr-MO pins with a
larger diameter are permissible. Hammer testing of welded pins shall be performed
100% immediately after welding to insure integrity of the weld. Weld tips of pins shall
be free of any plating.
K. Mastic sealer shall be asbestos free Childers Chil-Joint CP-70 or equal.
L. Bulk ceramic fiber and mineral wool material shall be suitable for 1200F or higher
service temperatures.
M. Material for flashing shall be 0.010" thick type 304 stainless steel.
III. INSTALLATION OF INSULATION
A. Blanket Insulation
1. Blanket insulation shall be installed in 2 layers. Seams in the layers shall be

staggered by a minimum of 12".
2. The insulation shall be installed as tightly as possible against the supports and
against the other layer to prevent opening of the seams during vessel expansion
due to operating temperature fluctuations.
3. The blanket seams shall be further secured by means of wire lacing. Hog ringed
seams are not permitted.
4. Pins shall be used to hold the insulation blanket to the bottom cone and the
inside of the skirt. Pins shall be installed on 12 (max.) centers. Pins are to start
9 (max.) above inspection lanes on cone and 6 (max.) below inspection lanes
on the cone. Pins shall be installed by the vessel fabricator prior to post weld
heat treatment (PWHT).
5. The insulation on the cylindrical section of the drum shall be held in place by
metal bands spaced around the circumference on 12" (max.) vertical centers,
with expansion springs spaced not more than 15 ft. apart.
6. The insulation on the top head shall be held in place by metal bands attached to
the floating ring and the top insulation support ring. Bands shall be spaced 12
apart at the support ring.
7. Expansion joints shall be provided under insulation supports using bulk ceramic
fiber or mineral wool insulation.
8. Bands on field fabricated drums shall run from a vertical bar at one inspection
lane to another vertical bar at the next inspection lane.
B. Jacketing
1. Jacketing on the cylindrical on the cylindrical section of the vessel shall be

corrugated and installed in overlapping sections to shed water. The overlaps
shall be a minimum of 3 corrugations in vertical seams, and 4 in horizontal
seams. S clips shall be used between courses of jacketing. Jacketing shall be
held in place by bands spaced on 12 (max.) vertical centers with compression
springs spaced no more than 15 ft. apart. J clips, spaced 5 ft. apart shall be
used to prevent the bands from slipping. J clips shall be attached to the jacket
with self tapping screws. A minimum of 2 screws shall be used for each clip.
2. Top head and bottom cone jacketing as well as jacketing on the inside of the skirt
shall be flat. "Standing seam" construction shall be used on the top head and
bottom cone although alternative methods of jacketing installation may be used
subject to prior written approval by Foster Wheeler. Where standing seam
construction is used the height of the seams shall not exceed 2". Jacketing on
the bottom cone and the inside of the skirt shall be impaled on pins. Mastic
sealer shall be applied between the jacket overlaps. Self-tapping screws spaced
6" apart shall be used to fasten the jacket segments together.
C. Inspection Lanes
1. All circumferential weld seams on the shell, skirt and bottom cone head will have
inspection lanes. The insulation in the inspection lanes will (2)-3 layers and
banded to the shell, skirt, and cone. See Figure 1 for insulation supports and
inspection lanes on the shell. See Figures 3, 4A/B for insulation supports and
inspection lanes on the cone.
2. Insulation support will be provided directly above and below the skirt junction as
shown in Figures 4A/B.
D. Miscellaneous
1. When complete, jacketing shall present a neat appearance with no buckling.

2. Top and bottom manway flanges shall not be insulated. Temporary insulation
shall be provided during PWHT of field fabricated drums.
3. Contact between aluminum jacketing and vessel steel shall be avoided.
4. Flashing rings shall be installed on all nozzles to prevent infiltration of water.

Flashing joints shall be fully weatherproofed using a high temperature mastic
coating.
5. All temperature indicators will be mounted outside inspection lanes but as close
to circumferential weld seams as possible.
6. The temperature indicators for the bottom shell to cone head weld will be
mounted just above the inspection lane.
IV. INSULATION DETAILS
Figures 1-5 and Details A1-A3, B1-B3, and C1-C2 on the following pages show insulation
arrangements and details for the shell, skirt, bottom cone, and top head. These sketches
depict details of critical areas of insulation. Deviations from these sketches require the
prior written approval of Foster Wheeler.
FIGURE 1
ARRANGEMENT OF INSULATION SUPPORT & T.I.S
FIGURE 2
INSULATION DETAIL AT NUCLEAR LEVEL DETECTORS
DETAIL A1
INSULATION SUPPORT RING AND ATTACHMENT CLIP ON SHELL AND
SKIRT
DETAIL A2
ATTACHMENT CLIP SLOT DETAILS ON SHELL AND SKIRT
DETAIL A3
ATTACHMENT CLIP DETAILS ON SHELL AND SKIRT
FIGURE 3
ARRANGEMENT OF INSULATION SUPPORT RINGS AND ATTACHMENT
CLIPS ON CONE
FIGURE 4A
(Weld Build-Up Skirt Junction)
INSULATION DETAILS FOR BOTTOM CONE AND SKIRT
FIGURE 4B
(Forged Ring Skirt Junction)
INSULATION DETAILS FOR BOTTOM CONE AND SKIRT
DETAIL B1
INSULATION SUPPORT RING AND ATTACHMENT CLIP FOR CONE
DETAIL B2
ATTACHMENT CLIP SLOT DETAILS FOR CONE
DETAIL C1 DETAIL C2
MANHOLE IN TOP HEAD NOZZLE IN TOP HEAD
DETAIL C3
TOP L-RING
FIGURE 5
ARRANGEMENT FOR FIELD FABRICATED DRUMS

REV: 1

APPENDIX D JOB SPECIFICATIONS (Continued)
D-2 Painting, 126158-83A1 Rev.1
______________________CONFIDENTIAL_____________________
USED,
JOB SPECIFICATION
126158-83A1
PAINTING
Revision Number Log

by
1 23RD AUG 2010 UVP/TC 23 SD Issued for Client Review

STAR (SOCAR & TURCAS AEGEAN REFINERY) PROJECT SPECIFICATION No: 126158-83A1
PAINTING
TABLE OF CONTENTS
I. SCOPE 3
II. REFERENCES 5
III. GENERAL 6
IV. SURFACE PREPARATION 8
V. PAINT APPLICATION 11
VI. PAINTING OF PREVIOUSLY PAINTED SURFACES (MAINTENANCE PAINTING) 12
VII. FIELD PROTECTION, CLEANUP & INDUSTRIAL HYGIENE 13
VIII. INSPECTION 14
IX. SELECTION OF PAINT 15
TABLE A - PAINT SYSTEMS 17
TABLE B - PRIMER MATERIALS 19
TABLE C INTERMEDIATE & FINISH MATERIALS 20
TABLE D ADDITIONAL EXAMPLES OF PAINT SELECTION 22
REASON FOR CHANGES: 23

PAINTING
REVISION INDEX
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* Asterisk represents or will represent pages revised for this issue.
I. SCOPE
A. This specification outlines the general requirements for the external

painting of piping, pipe supports, steel structure, machinery and
equipment for shop and field painting. Painting includes surface
preparation, selection, application, inspection and clean-up of
paints. Internal coatings and linings are not covered in this
specification.
PAINTING
B. This specification does not apply to off the shelf, factory finished
or other items for which a vendor has a defined painting system(s) in
place equivalent to the paint systems listed herein. Vendors of such
items shall be informed of the environment to which the items will be
exposed and the coatings systems must be selected accordingly, the
finish color of the equipment item shall be Aluminum. Any deviation to
these requirements or doubt regarding a vendor supplied paint system
shall be brought to the attention of the purchaser for
approval/resolution. If required, vendor supplied standard coating
systems can generally be upgraded in the field using paint system UMS-
1A as given in Table A.
C. This specification does not specify paint systems above 1000oF. If

such are required, appropriate paint systems must be devised.
D. This specification specifies shop application of primers and finish

coats for various items. Depending on economics or specific contracts,
this activity may be transferred to the field.
E. Vessels fabricated overseas shall also be painted unless waived by the

FWUSAC. Applicable painting system shall be per this specification.
E. Paint systems, including surface preparation, paint materials,

application, etc., must comply with applicable local, state and federal
laws. See also Tables A, Table B, Table C and Table D.
F. The vendor or Contractor shall advise FWUSAC, in writing, of any

conflicts between the requirements of this specification and other
requirements.
G. latest editions of any federal, state or local codes, regulations,

standards and guidelines that existed prior to January, 2009 shall
govern and supercede any prior federal, state or local codes,
regulations, standards and guidelines referenced in this specification.
PAINTING
II. REFERENCES
The latest editions and revisions of the following documents are referred
to in this specification.
A. U. S. Federal Documents
1. Occupational Safety and Health (OSHA) Standards
B. Steel Structures Painting Council (SSPC) Manual
1. Volume 2, Systems and Specifications
a. SSPC-PA1, Shop, Field and Maintenance Painting

b. SSPC-PA2, Measurement of Dry Paint Thickness with Magnetic
Gauges
c. SSPC-SP1, Solvent Cleaning
d. SSPC-SP2, Hand Tool Cleaning
e. SSPC-SP3, Power Tool Cleaning
f. SSPC-SP5, White Metal Blast Cleaning
g. SSPC-SP6, Commercial Blast Cleaning
h. SSPC-SP7, Brush-off Blast Cleaning
j. SSPC-SP8, Pickling
k. SSPC-SP10, Near-White Blast Cleaning
l. SSPC-SP11, Power Tool Cleaning to Bare Metal
m. SSPC-SP12, Ultra High Pressure Water Jetting
2. Vis 1, Pictorial Surface Preparation

a. Standard D SA 2 1/2
b. Standard D SA 2
C. National Association of Corrosion Engineers (NACE) Publications
1. NACE TM-01, Visual Standard for Surfaces of New Steel Air blast
Cleaned with Sand Abrasive
a. No. 1, White Metal Blast Cleaning

b. No. 2, Near-White Blast Cleaning
c. No. 3, Commercial Blast Cleaning
d. No. 4, Brush-off Blast Cleaning
PAINTING
III. GENERAL
A. Painting of steel surfaces shall be performed in accordance with

SSPC-PA1, manufacturer's recommendations, and OSHA (Part 1910,
Paragraph 1910.144) requirements for safety colors, unless modified by
this specification.
B. Surface preparation of steel surfaces shall be in accordance with SSPC

or NACE Specifications. In many locations, other surface preparation
standards are more widely known and more often used than the SSPC
standards (e.g. Swedish Standard SIS 05 59 00 in European locations).
The local standard may be used subject to approval by FWUSAC. A cross
reference chart is given in Paragraph IV.J.
C. Where manufacturer's instructions or those in SSPC-PA1 are given in

permissive terms, e.g., "should," "may," and "recommend" these shall be
considered mandatory.
D. The following surfaces shall not be painted:
1. Concrete
2. Building Brick, Masonry Units and Wall Tile
3. Asbestos Cement
4. Galvanized Surfaces
5. Insulation Weatherproofing
6. Aluminum, Copper, Brass, and other Nonferrous Metals
7. Uninsulated stainless steel (except in preparation for ocean
shipment or storage/installation in a coastal area).
8. Equipment supplied with manufacturer's standard finish coat
9. Tripping Mechanisms of Steam Turbines
10. Plastic and Plastic Coated Materials
11. Machined and Gasket Surfaces
12. Nameplates
E. Shop fabricated equipment, towers, vessels, structural steel,

exchangers, pumps, motors, piping, etc. requiring painting shall be
cleaned and completely painted (shop applied primer, intermediate and
finish coats) by the fabricator or manufacturer. Surface preparation
and application of primer and finish shall be performed in the field
on field fabricated piping, pipe supports, steel structures, and
equipment.
F. The general contractor shall be responsible for properly handling and

storing the painted materials prior to erection to minimize damage to
the coating system.
G. Damaged areas of the coating system shall be repaired after erection

by the painting contractor to the satisfaction of FWUSAC.
PAINTING
H. If practical, for field applied coatings the intermediate coat shall
be applied not later than 60 days after application of the prime coat.
J. If over 60 days old, the prime coat shall be inspected by FWUSAC to

determine if acceptable as the prime coat. If the prime coat has
weathered to an extent that it is not acceptable, FWUSAC will
determine how much repriming is required and will request a price from
the painting contractor for this additional work.
K. The paint system is to be based on the corrosive environment and the

operating temperature of equipment and piping except:
1. The outside temperature of internally lined items shall be used

where specified in the requisition.
2. Supports (skirts, legs, saddles, etc.) shall be considered as

operating below 300oF, unless otherwise noted.
3. Higher temperatures required for steamout, start-up, or other

non-operating conditions shall be used where specified in the
requisition.
L. Only paint and painting materials approved by FWUSAC shall be used.

These materials shall be delivered to the job site in sealed and
labeled containers. They shall be stored in a location that is
protected from the elements, well ventilated, and free from excessive
heat, open flame, or other sources of ignition. Paint materials
susceptible to freezing shall be stored in a heated area.
M. Primer and finish coats for a particular system shall be from the same
manufacturer, whenever possible, to assure compatibility.
N. Paint shall be thoroughly mixed and thinned in accordance with the

manufacturer's instructions immediately prior to application. Only
thinners of a type recommended by the paint manufacturer shall be
used.
P. The recommendations and specifications of the paint manufacturer shall

be strictly followed in applying the paint systems covered by this
specification.
PAINTING
Q. The items listed below shall be shielded to prevent damage during

surface preparation and painting operations. All openings, including
those that are flanged or threaded, shall be sealed to prevent entry
of sand, dust, or coating material. After completion of painting
operations all material used for shielding and sealing shall be
removed.
1. Nameplates
2. Packing Glands
3. Packing Seals
4. Bearings
5. Rotating Equipment Couplings
6. Rotating Equipment Shafts
7. Lubrication fittings
8. Pressure gauges
9. Gauge glasses
10. Motor starters
11. Instrument dials
12. Vents
13. Exposed linkages
14. Valve stems
15. Light bulbs
16. Light bulb enclosures
17. Light reflectors
18. Air intakes
19. Rubber parts and plastic
IV. SURFACE PREPARATION
A. Surfaces shall be thoroughly cleaned of any material conducive to

premature failure of the paint coating. The method of surface
preparation used shall be compatible with, and suitable for, the prime
coat of paint.
B. Prior to solvent cleaning, soil, cement spatter, salts, or any other

foreign matter (other than oil or grease) shall be removed by a steel
fiber brush, wire brush, or by scraping.
C. Oil, grease, or similar substances shall be removed by solvent

cleaning, scraping or brushing. Rust, mill scale, or oxides may be
removed by pickling, hand or power tool cleaning, or blast cleaning.
D. Exercise care in the use of tools, to prevent excessive roughening of

the surface and the formation of ridges and burrs. Excessive power
wire brushing produces a burnished slick surface not suitable for
coating.
E. Power sanding or water washing shall be used when cleaning of a

zinc-rich primed surface is required prior to application of topcoat.
PAINTING
F. Blast cleaning with grit or synthetic abrasives is preferred to sand.

For blast profile requirements, see Table A. Steel surfaces shall not
be blasted when surface temperature is less than 5oF above the dew
point, relative humidity is greater than 85% or there is a possibility
that the blasted surface will be subject to wetting before the first
coat of primer can be applied. Surfaces shall be blown, wiped or
vacuumed free of blasting abrasive and dust before they are primed.
G. Since freshly blasted surfaces are subject to immediate corrosion,

particularly in high humidity or salt atmospheres, no more surfaces
shall be blast cleaned than can be primed before visible or
detrimental rerusting occurs. Blasted surfaces shall be primed no
later than the end of the same work day.
H. A 12(300 mm) wide strip of uncoated, blasted surface shall be left

between primed and unblasted surfaces to prevent damage to the newly
dried prime coating. When blast cleaning is resumed, the strip of
previously blasted surface will require only a light brush blast,
accomplished by holding the cleaning nozzle in a direction away from
the coated surface, to remove any rust that may be present.
J. Following is a tabulation of acceptable cleaning and inspection

methods.
SSPC VISUAL COMPARISON

SYSTEM METHOD NACE SSPC-VIS1
Solvent Cleaning SSPC-SP1 - -

Hand Tool Cleaning SSPC-SP2 - St.2
Power Tool Cleaning SSPC-SP3 - St.3
White Metal Blast Cleaning SSPC-SP5 NACE #1 Sa.3
Commercial Blast Cleaning SSPC-SP6 NACE #3 Sa.2
Brush-Off Blast Cleaning SSPC-SP7 NACE #4 Sa.1
Pickling SSPC-SP8 - -
Near-White Blast Cleaning SSPC-SP10 NACE #2 Sa.2 1/2
Power Tool to Bare Metal SSPC-SP11 - -
Ultra High Pressure Water SSPC-SP12 - -
K. Surfaces shall be primed after cleaning before any rusting occurs (if
rust forms after cleaning, the surface shall be recleaned before
painting).
PAINTING
L. Nonferrous and Nonmetallic Surfaces
Certain nonferrous and nonmetallic surfaces require additional

preparation to that specified in the SSPC Painting Manual. A listing
of these surfaces and their requirements follows.
1. Galvanized Surfaces
Galvanized surfaces shall only be painted where required by the

client. When required, these surfaces shall be cleaned by one of
the following methods:
a. Solvent clean
b. Wash with a solution of 1-1/2 ounces ( 45 mililiter) of

trisodium phosphate and 1-1/2 ounces ( 45 mililiter) of soap
chips to each gallon of water, followed by thorough rinsing
with clean water.
c. Allow surface to weather for 2 to 4 months, depending on

exposure, for removal of oily deposits.
d. Wash surface with phosphoric acid solution, allow to dry and

remove all crystalline deposits with a stiff brush, followed
by a rinse with clear water. Any chemicals allowed to remain
on the surface will be detrimental to paint adhesion.
2. Wood
Interior surfaces shall be sanded to a smooth finish. Exterior

surfaces shall be sanded only if the surface is very rough. Nail
holes and joints in wood members shall be primed, puttied and
sanded to a smooth, flush surface. Plastic wood may be used in
lieu of putty, especially on interior surfaces. Window sashes
shall be primed before glazing. Putty or plastic wood shall not
be applied until the primer has dried.
3. Plaster and Wall Board
Plaster shall not be coated until it has dried completely. Large

cracks shall be cut out and patched. Cracks which show up after
the application of the first coating shall be spackled and
sealed.
When lime is present it shall be neutralized by washing with a

solution of 3 pounds of zinc sulphate to 1 gallon of water. The
crystals so formed shall be dusted off after drying.
PAINTING
V. PAINT APPLICATION
A. Paint shall be applied by one, or a combination, of the following

methods:
1. Brushing.
2. Roller Coating.
3. Air Spraying.
4. Airless Spraying.
5. Paint Mitt (for small diameter piping and so forth).
B. The method of application shall be governed by the paint

manufacturer's recommendation for the particular paint being applied.
For application techniques, requirements and precautions, SSPC-PAl
shall be used as a general reference.
C. Conventional solvent-base paints shall not be applied to exterior

surfaces in humid weather, when the air temperature is below 40oF or
when the surface temperature is less than 5oF above the dew point.
Chemically cured paints shall not be applied at air or surface
temperatures below 50oF or when relative humidity is above 85%.
Water-base paints may be applied to damp surfaces. Wetting of
exterior surfaces is recommended during hot weather application.
Water-base paints shall be applied at air temperatures above 50oF.
(Paint manufacturer's recommendations shall be consulted in each case
for possible special temperature requirements). No paints shall be
applied to a surface at a temperature that will cause blistering,
porosity or otherwise be detrimental to the life of the paint.
D. Contact surfaces shall be painted as follows:
1. The faying surfaces of connections specified to be slip critical

shall be blast cleaned and coated with a paint which has been
qualified as Class A (slip coefficient 0.33) by test in
accordance with Test Method to Determine the Slip Coefficient for
Coatings Used in Bolted joints as adopted by the Research Council
on Structural Connections. A certified copy of the test report
shall be included in the manufacturers certification.
2. Steel coated before erection shall not be coated within 2(50mm)

of edges to be welded.
3. Steel surfaces in direct bonded contact with concrete, embedded

in concrete, or coated with concrete, normally shall only be
painted in specific cases where corrosion of the steel is
expected to be a problem.
4. Steel to be embedded in brick or other masonry shall be given at

least one prime coat of Universal Primer (P-100).
PAINTING
5. Steel surfaces in contact with aluminum surfaces shall be given

at least one prime coat of coal tar epoxy (P-209).
6. Wooden surfaces (exterior wooden members only) in contact with

any other surfaces shall be prime coated.
7. Surfaces not in direct bonded contact, but inaccessible after

assembly, shall receive the full specified paint system before
assembly.
E. Surfaces shall not be recoated until the preceding coat has

properly dried or cured. The surface may be considered ready for
recoating when the next coat can be applied without the
development of paint film irregularities, such as lifting or loss
of adhesion of the undercoat. However, the minimum or maximum
drying or curing time specified by the paint manufacturer shall
be the acceptable recoat period. Paint shall not be force-dried
under conditions which will cause cracking, wrinkling,
blistering, formation of pores, or which will be detrimental to
its condition or appearance. Newly painted surfaces shall be
protected to the fullest extent practicable from rain,
condensation contamination, snow and freezing until the coating
has dried.
F. Successive coats of paint, preferably, should be of different colors.

However, if they are of the same color, alternate coats shall be
tinted to produce sufficient contrast to ensure complete coverage and
specified film thickness of each coat. The final finish coat shall
not be tinted. Tinting material shall be compatible with the paint
and shall not be detrimental to its service life.
G. Sprayed coatings shall be cross-spray-applied to insure uniform

coverage, free of runs and sags.
H. When not otherwise specified, prime coats shall be a minimum of 1.5

mils dry-film thickness per coat; finish coats shall be a minimum of 1
mil dry-film thickness per coat. Where the required thickness is not
achieved, additional coats shall be applied until the proper thickness
is obtained. Application shall be such that the film thickness will
not affect appearance or service life of the paint.
J. The type of paint to be used and the number of coats to be applied

shall be in accordance with Paragraph IX and Table A.
VI. PAINTING OF PREVIOUSLY PAINTED SURFACES (MAINTENANCE PAINTING)
A. Surfaces to be painted shall be cleaned by blasting, power tools, hand

tools, or solvents, or by a combination of these methods. All grease,
PAINTING
oil, dirt, foreign material, rust, and loose, cracked, brittle, or
nonadhering paint shall be removed.
B. The remaining sound paint on the surface shall have the edges
feathered by sanding prior to painting. Any paint that curls or lifts
after the application of the spot or priming paint shall be removed
and the area repainted.
C. Surfaces coated with cement-type paints, preferably, shall be

blast cleaned wherever possible; alternatively, the surfaces may
be scraped and power brushed to a sound, solid substrate prior to
painting. Chalked surfaces of exterior walls shall be completely
removed by hand wire brushing and washing with water.
D. Glossy surfaces shall be roughened by light sanding or a

trisodium phosphate wash to provide a bond for successive coats
of paint.
E. The minimum coating requirement for spot painting shall be as follows:
1. No Rusting, Prime Coat Exposed - Apply 1 or 2 finish coats to

regain specified mil thickness.
2. Rusted Area or Prime Coat Damaged - Clean damaged or rusted area

to base material and apply prime and finish coats to regain
specified mil thickness.
F. Existing paint coatings shall be checked or tested for compatibility

with the paints with which they are to be overcoated to ensure that
lifting or wrinkling of the existing coating will not take place.
VII. FIELD PROTECTION, CLEANUP & INDUSTRIAL HYGIENE
A. The paint applicator shall fully protect all equipment, walls, floors,
ceilings and other surfaces from damage and shall provide the
necessary drop cloths or other protection required to fully protect
all surfaces from dust, paint droppings, paint mist, other
contaminants during the execution of his work.
B. While painting around switches and controls, painters shall be careful

to avoid tripping of switches. It is imperative that all switches
remain unmoved and undisturbed by painters.
C. Shipping tags, wires, strings and other means of temporary or shipping

identification on surfaces to be painted shall be removed, but only
after checking with and receiving authorization from FWUSAC's
representative.
PAINTING
D. The paint applicator shall clean all surfaces which have been spotted
with paint such as window glass, floors, walls, equipment, etc.,
leaving the premises clean to the satisfaction of FWUSAC.
E. The paint applicator shall provide a temporary shelter for storage and
mixing of paint materials. Applicator shall provide adequate fire
fighting equipment, satisfactory to FWUSAC, for the temporary shelter
and at all locations where painting work is in progress.
F. A protective hood with a positive fresh-air supply shall be used

during blast cleaning operations.
G. A filter-type dust mask shall be used during hand tool or power tool
cleaning operations in enclosed areas or in other situations where
excessive concentrations of dust result.
H. Protective clothing, such as gloves, goggles and aprons, shall be worn

during pickling or solvent cleaning operations. Hands should be
cleaned with a waterless hand cleaner after exposure to solvents.
Clothing or protective equipment wet with solvents or paint should be
promptly removed and laundered before reuse.
J. Prior to the start of daily work, the contractor shall ascertain that
all necessary tests have been made for toxic gasses, chemicals or
explosives mixtures (see API Publ 2015). The safety conditions
covered by OSHA, as well as those deemed necessary by the contractor,
shall be met.
K. Particular care must be exercised when working in close or confined

spaces, especially when spraying. The paint contractor shall
ascertain that all necessary tests have been made for oxygen
sufficiency and hydrogen sulfide. The Threshold Limit Value (TLV) and
Volatile Organic Content (VOC) as prescribed by OSHA or local
government agencies for the particular solvent vapor in the air shall
not be exceeded unless fresh-air masks, as approved by the National
Institute of Occupational Safety and Health (NIOSH), are worn by
workmen. When volatile solvents are flammable, the concentration in
the air shall be kept to one-quarter or less of the lower explosive
limit (LEL) by adequate exhaust or ventilation facilities.
VIII. INSPECTION
A. Surfaces prepared for painting are to be inspected and approved as

satisfactory by the Owner's representative or paint inspector before
any paint is applied by the contractor. The contractor shall also
inspect all surfaces after cleaning and shall notify the Owner's
representative of any defects, improper material or workmanship, or
other conditions which in his opinion will affect the satisfactory
performance and permanency of his work. Where such defects have been
pointed out to, or by, the contractor, no painting shall be started
PAINTING
until all such faulty conditions have been corrected or until a
written agreement has been made with the Owner's representative
regarding any subsequent defects which may develop because of the
conditions noted.
B. The Owner's inspector shall monitor wet and dry film thicknesses of
the paint and shall compare his findings with those recommended. In
cases of inadequate film build, the contractor shall be required to
recoat the surface at his own expense.
C. The inspector shall determine the adequacy of:
1. Surface preparation using blast cleaning by comparison with NACE

TM-01, "Visual Standards" prior to application of the first coat
of paint.
2. Dry film thickness by measurement of each coat and of the total

system by procedures specified in SSPC-PA-2.
IX. SELECTION OF PAINT
A. Paint system selection is based upon environment, humidity, location,

presence of chemical fumes, splash and spillage, and other special
factors.
B. The following surfaces are not normally painted. When specified, they
shall be painted as follows:
1. Wood
a. Exterior - One coat of oil alkyd primer (P-103) and one coat
of alkyd resin medium gloss enamel (P-206).
b. Interior - One coat of oil alkyd primer (P-104) and one coat
of alkyd resin medium gloss enamel (P-207).
2. Concrete
a. Concrete block walls (interior and exterior) - One coat of

silicone water repellent (P-106) as primer and one coat of
(P-106) as finish coat.
b. Precast concrete roof members (interior) & gypsum board walls

- One coat of latex flat (P-107) as primer and one coat
(P-107) as finish coat.
c. Concrete block walls in toilet rooms and laboratory - One

coat of fill coat (P-108) and one coat of tile coat (P-208).
PAINTING
3. Galvanized Steel
a. For field touchup of galvanized steel, remove weld spatter,

round off welds, hand tool clean and paint with one coat, 2.5
mils DFT minimum, organic zinc (P-105) or equal.
C. Paint systems are shown in Table A and Table C, and are applicable for
the environment noted. Paint manufacturers should be consulted for
recommendations before selecting systems for areas where paints will
be subject to acid, alkali, solvent, etc., fumes, spillage, immersion
or any other environment than that noted. A listing of primers and
paints is given in Table B and Table D as a guide; equivalent paints
are acceptable, subject to approval by FWUSAC. Where coatings in
Table B and Table D do not meet local VOC rules, low VOC equivalent
coating shall be submitted for approval by FWUSAC.
PAINTING
TABLE A - PAINT SYSTEMS
Environment: Mild refinery/chemical plant/industrial service. Mild atmospheric conditions

Not recommended for: Immersion in water, acid or alkali spillage or immersion, prolonged exposure to mineral and organic acids.
PAGE 1 OF 2
SURFACE
SYSTEM APPLICATION SURFACE PAINT TYPE NUMBER DRY FILM COATING
PREPARATION
NO. TEMP. (in order of SSPC ANCHOR OF THICKNESS NUMBER
LIMITS application) STD. PROFILE COATS EACH COAT
(MILS) (MILS)
BCS-1A Uninsulated c.s. Up to 200F Inorganic SP - 6 1.0 - 1 3.0 5.0 P-101
Zinc primer 2.0
equipment High build, PRIMER
including epoxy sealer
structural steel, P-203
Heat exchangers, High build, 1 4.0 6.0 INT
acrylic
Vessels, heaters, P-210
Stacks, tanks, polyurethane 1 2.0 - 4.0 FINISH
etc.
BCS-2A Uninsulated c.s. ABOVE Inorganic SP - 6 1.0 - 1 2.5 - 3.0
P-101
Zinc 2.0
equipment 200F - 350F
including
structural steel, Silicone 1 1.5 - 2.0
P-204
Acrylic
piping,
exchangers,
vessels, heaters,
stacks, etc.
BCS-3A Uninsulated c.s. ABOVE Inorganic SP - 6 1.0 - 1 2.5 - 3.0
P-101
Zinc 2.0
Equipment 350F 1000F
including
structural steel, Silicone 1 0.8 - 1.5 P-205
piping,
exchangers,
vessels, heaters,
stacks, etc.
ICS-1A Insulated c.s. Up to 300F Epoxy Mastic SP - 6 1.0 - 1 4.0 - 6.0
P-109
2.0
equipment
including
Exchangers,
vessels,
heaters, stacks
etc.
ICS-2A Insulated c.s. ABOVE 300F Inorganic SP-6 1.0 - 1 2.5 - 3.0
P-101
Zinc 2.0
equipment
(for
including
exchangers, (continuously
Overseas
vessels, )
heaters, stacks
Shipping)
etc.
PAINTING
TABLE A - PAINT SYSTEMS
PAGE 2 OF 2
SURFACE
SYSTEM APPLICATION SURFACE PAINT TYPE NUMBER DRY FILM COATING
PREPARATION
NO. TEMP. (in order SSPC ANCHOR OF THICKNESS NUMBER
LIMITS of STD. PROFILE COATS EACH COAT
application) (MILS) MILS)
ICS-3A Insulated C.S. Normally Silicone SP - 6 1.0 - 2 0.8 1.5
P - 205
below 2.0
equipment 300F but
including with
exchangers, Intermittent
vessels,
heaters, stacks excursions to
etc. 1000F
BP-1A Uninsulated C.S. Up to 200F Inorganic SP-6 1.0 1 2.5 3.0
P-101
Zinc 2.0
Piping Alkyd Resin 1 1.5 2.5 P-200
IP-1A Insulated C.S. Up to 300F Inorganic SP-6 1.0 - 1 2.5 - 3.0

P-101
Zinc 2.0
Piping Epoxy Mastic 1 4.0 - 6.0 P-109
IP-2A Insulated C.S. ABOVE 300F Inorganic SP-6 1.0 - 1 2.5 - 3.0
P-101
Zinc 2.0
Piping (continuously
)
ISS-1A Insulated Up to 300 F Epoxy SP-10 2.0 to 2 4 to 6
P-102
Austenitic Novolac 3.0
Stainless steel
and Duplex SS
equipment and
piping
UMS-1A Misc. equipment Per Man. EPOXY Finish SP-6 N.A. 1 2.0 - 3.0
P-203
that Standard coat
requires field type and
upgrade of thickness
manufacturers to match
standard adjacent
coating system equipment
PAINTING
TABLE B - PRIMER MATERIALS
EXAMPLES OF ACCEPTABLE PRIMER MATERIALS

Paint (1) Generic Manufacturer's Acceptable Low VOC
No. Identification Equivalent
Type
P-100 Universal Ameron 185 Ameron 385
Primer (lead Carboline Multi-bond 150 Carboline Multi-bond 150
free, chromate Sherwin Williams Kem Kromik Kem Kromik Metal
free) Metal Primer B50N2 Primer B50NZ6
P-101 Inorganic Zinc, Ameron Dimetcote 9 Ameron Dimetcote 9HS

Self Cure, Carboline Carbo-Zinc 11 Carboline Carbo-Zinc 11
Solvent Base, Sherwin Williams Sherwin Williams
Multi-Package Zinc Clad II Zinc Clad II
B69V3/B69D11 B69VZ1/VZ3/D11
P-102 Silicone (for Carboline 4674 (Black) Carboline 4631WB (Black)

stainless steel) Dampney Thurmalox 70
(Black)
P-103 Exterior Oil- Ameron 5105 Ameron 5105
Alkyd Carboline Multi-bond 150 Carboline Multi-bond 150
Primer (Wood) Sherwin Williams Y24W20 Sherwin Williams Y24W20
P-104 Interior Alkyd Ameron 5105 Ameron 5105

Primer (Wood) Carboline Multi-bond 150 Carboline Multi-bond 150
Sherwin Williams B49W2 Sherwin Williams B49WZ2
P-105 Epoxy, Zinc Ameron 68HS Ameron 68HS

Rich Carboline 858 Carboline 858/859
Sherwin Williams Zinc Clad Sherwin Williams Zinc
4, B69A8/V8 Clad 4, B69A8/V8
P-106 Silicone, Ameron 2011

Water Repellent Carboline Carbocrete 700
P-107 Latex, Flat Ameron VG61 Ameron VG61

Carboline 3350 Carboline 3359
Sherwin Williams Pro Mar Sherwin Williams Pro Mar
400 B-30 Series 400 B-30 Series
P-108 Tile Fill Coat Ameron Amerguard 147 Ameron Amerguard 147
Sherwin Williams B42W46 Carboline Multi-Gard
954HB
Sherwin Williams B42W46
P-109 Epoxy Phenolic Sherwin Williams, Sherwin Williams,

Novalac Epo-Phen Hi Temp Epo-Phen Hi temp
Coating Coating
PAINTING
TABLE C INTERMEDIATE & FINISH MATERIALS
EXAMPLES OF ACCEPTABLE INTERMEDIATE & FINISH MATERIALS

( 2 PAGES)
Paint Generic Type Manufacturer's Acceptable Low VOC

Sherwin Williams Sherwin Williams
Polyamine Epoxy Epoxy Mastic Epoxy Mastic
P-200
Aluminum filled Aluminum II Aluminum II
Ameron 5450 Ameron 5405

Carboline Rustarmor 139 Carboline Rustarmor 139
Alkyd Resin Sherwin Williams Tank
P-201 Guard CL9255
(White)
Sherwin Williams Tank Guard
CL9255
Ameron 5450 Ameron 400AL
Carboline GP-62 Al/ Carboline
Alkyd Resin
P-202 Rustarmor 139AL Carbomastic 90
(Aluminum)
Sherwin Williams B59S4 Sherwin Williams B59S4
Ameron 383HS Epoxy Ameron 385

Carboline 890HB Carboline 890 Sherwin
High-Build
P-203 Sherwin Williams Williams
Polyamide
Multimil II B62 Series Multimil II B62 Series
Ameron 892HS Ameron 892HS

Carboline 1248 Carboline 4631WB
Silicone-
P-204 Sherwin Williams Heat- Sherwin Williams Heat-Flex
Acrylic
Flex 450 450
Ameron 878 Ameron 892HS

Carboline 4674 Carboline 4631WB
P-205 Silicone
Sherwin Williams B59S8

Exterior Alkyd Carboline Rustarmor 139 Carboline Rustarmor 139
P-206
Enamel Sherwin Williams B54 Sherwin Williams B54Z Series
Series
PAINTING
TABLE C ( PAGE 2 OF2)
EXAMPLES OF ACCEPTABLE INTERMEDIATE & FINISH MATERIALS
Paint Generic Type Manufacturer's Acceptable Low VOC

Carboline Rustarmor 139 Carboline Rustarmor 139
Interial Alkyd
P-207 Sherwin Williams Pro Sherwin Williams Pro Mar200
Enamel
Mar 200 Alkyd B34W200 Alkyd B34WZ2000
Ameron 72 Ameron 320HS

Carboline Multi-Gard Carboline Multi-Gard 954HB
P-208 Tile Glaze Coat 954HB Sherwin Williams Tileclad
Sherwin Williams B62 HS B62WZ/B60VZ70
Series/B60V70
Ameron 78HB Ameron 78HB
Carboline Carbomastic 14 Carboline Bitumastic 300M
P-209 Coal Tar Epoxy
Sherwin Williams Sherwin Williams B69B60/V60
B69B60/V60
Ameron 450 HS Ameron Amershield
Carboline 134HG Carboline 134HS/134HG
Aliphatic Valspar V40 Series
P-210
Polyurethane Sherwin Williams Sherwin Williams
B65W300/B60V30 B65W300/B60V30
Ameron 450 SA Ameron Amershield SG

Carboline 133HB Carboline 833
High Build
(Polyurethane) (Polyurethane)
Aliphatic
Carboline 3359 (Acrylic) Carboline 3359 (Acrylic)
Polyurethane
P-211 Sherwin Williams DTM Sherwin Williams DTM B66WW1
Satin
B66WW1 (Acrylic) (Acrylic) Sherwin
or Modified
Sherwin Williams Williams Corothane II
Acrylic
Corothane II B65- B65-200/B60V2
200/B60V2 (Polyurethane) (Polyurethane)
PAINTING
TABLE D ADDITIONAL EXAMPLES OF PAINT SELECTION
PAINT NUMBER OF SHERWIN WILLIAMS CARBOLINE

SYSTEM CAOTINGS
BP-1A 1st Coat Zinc Clad II Carboline 859

Surface preparation SP-6 ( 1.5 2.0) SP-10 ( 1.0 2.0)
DFT (mils) 3.0 5.0 3.0 5.0
2nd Coat Epoxy Mastic Aluminum II Carboguard 893
DFT (mils) 4.0 6.0 4.0 5.0
3rd coat None Carbothane 134HG
DFT (mils) None 2.0 3.0
IP-1A 1st Coat Epo- Phen Carboguard 187

Surface preparation SP- 10(1.5 2.0) SP-10( 2.0 3.0)
DFT (mils) 7.0 9.0 5.0 6.0
2nd Coat None Carboguard 187
DFT (mils) None 5.0 6.0
BCS-2A 1st Coat Zinc Clad II Carbozinc 11

Surface preparation SP-6 ( 1.5 2.0) SP-10( 1.0 2.0)
DFT (mils) 3.0 5.0 2.0 3.0
2nd Coat Kem Hi-Temp Heat Flex II 450 AL Thermaline 4900 AL( C901)
DFT (mils) 1.0 1.5 1.5 2.0
ICS-1A 1st Coat Epo- Phen Thermaline 450

Surface preparation SP- 10(1.5 2.0) SP-10(1.0 2.0)
DFT (mils) 7.0 9.0 8.0 10.0
2nd Coat Kem Hi-Temp Heat Flex II 450 AL Thermaline 4900 AL( C901)
DFT (mils) 1.0 1.5 1.5 2.0
BCS-3A 1st Coat Zinc Clad II Carbozinc 11

DFT (mils) 3.0 5.0 2.0 3.0
2nd Coat Hi-Temp 1000V AL Thermaline 4700 AL( C901)
DFT (mils) 1.5 2.0 1.5 2.0
IP-1A 1st Coat Zinc Clad II Carbozinc 11

DFT (mils) 3.0 5.0 2.0 3.0
PAINTING
REASON FOR CHANGES:
REV 1: Projectised per project requirements and FW procedure. Rev 0 is not

issued on the project Since FW standard is considered Rev 0.

REV: 1

D-3 Fire Proofing, 126158-84A1 Rev.1
______________________CONFIDENTIAL_____________________
USED,
JOB SPECIFICATION
126158-84A1
FIREPROOFING
Revision Number Log

by
1 23RD AUG 2010 UVP/TC 17 SD Issued for Client Review

FIREPROOFING
TABLE OF CONTENTS
I. SCOPE ........................................................................................................................................................................ 3
II. REFERENCES............................................................................................................................................................ 4
III. DEFINITIONS............................................................................................................................................................ 4
IV. REQUIREMENTS ...................................................................................................................................................... 5
V. MATERIALS.............................................................................................................................................................. 8
VI. APPLICATION OF CONCRETE FIREPROOFING ............................................................................................... 10
VII. APPLICATION OF OTHER FIREPROOFING MATERIALS............................................................................... 12
FIGURE 1: CONCRETE FIREPROOFING DETAILS ......................................................................................................... 13
FIGURE 2: CONCRETE FIREPROOFING DETAILS ......................................................................................................... 14
FIGURE 3: CONCRETE FIREPROOFING DETAILS AT SKIRT....................................................................................... 15
FIGURE 4: FIRED HAZAARD ZONE.................................................................................................................................. 16
REASON FOR CHANGES: ................................................................................................................................................... 17
FIREPROOFING
REVISION INDEX
1 1 08/23/10
2 1 08/23/10
3 1 08/23/10
4 1 08/23/10
5 1 08/23/10
6 1 08/23/10
7 1 08/23/10
8 1 08/23/10
9 1 08/23/10
10 1 08/23/10
11 1 08/23/10
12 1 08/23/10
13 1 08/23/10
14 1 08/23/10
15 1 08/23/10
16 1 08/23/10
17 1 08/23/10
* Asterisk represents or will represent pages revised for this issue.
I. SCOPE
A. This job specification defines the basic requirements for design,

materials, and application of fireproofing for steel structures,
equipment, and supporting elements of piping and equipment located in
fire hazardous areas of process plants.
B. The extent of fireproofing will be shown on Equipment Fireproofing

Summary Drawings and Structural Steel Drawings.
C. The vendor or Contractor shall advise Foster Wheeler, in writing, of any

conflicts between the requirements of this specification and other
requirements.
D. The latest editions of any federal, state or local codes, regulations,

standards and guidelines that existed prior to January, 2010 or latest
applicable to the project shall govern and supercede any prior federal,
state or local codes, regulations, standards and guidelines referenced
in this specification
FIREPROOFING
II. REFERENCES
The latest editions and revisions of the following documents are referred
to in this specification.
A. Job Specification 43A1, Foundations and Elevated Concrete Structures
B. ACI 506, Recommended Practice for Shotcreting
C. ASTM Standards:
1. ASTM C33, Specification for Concrete Aggregates

2. ASTM C150, Specification for Portland Cement
3. ASTM E119, Method for Fire Tests of Building Construction and
Materials
D. NFPA Code No. 30, Flammable and Combustible Liquids Code.
E. UL Fire Resistance Directory
F. ANSI/UL1709 Rapid Rise Fire Tests of Protection Materials for

Structural Steel.
III. DEFINITIONS
A. The following equipment is considered fire hazardous:
1. Equipment containing hydrocarbons.
2. Equipment in hydrogen service. Hydrogen service is defined as

>50% hydrogen by volume or hydrogen partial pressure >100psia.
3. Equipment which operates at or above the autoignition temperature

of the liquid it contains.
4. Equipment containing flammable or combustible liquids other than

hydrocarbons as classified by NFPA Code Number 30 -Flammable and
Combustible Liquids Code.
FIREPROOFING
B. Equipment not meeting the criteria for fire hazardous equipment in
Paragraph A which is located from other fire hazardous equipment shall
be considered non-fire hazardous.
C. An area within a horizontal radius of 30 (9 m) and 40 (12 m)

vertically upward from any fire hazardous equipment shall be considered
a fire hazardous area. (Fig.4A)
D. Fire Protection
Ratings of fireproofing materials, in hours of protection on steel,

shall be as listed by Underwriters Laboratories Inc. or other
acceptable testing laboratory, using test procedures described in ASTM
E 119 and UL1709. Where the words shall be fireproofed appear in
this job specification, the fireproofing system shall be rated for a
minimum of 3 hours per ASTM E119 or 2 hours per UL1709. Hours of
protection are defined as the number of hours of exposure to fire while
maintaining steel temperatures below 1000F (538C).
IV. REQUIREMENTS
A. General
1. Structural elements supporting fire hazardous equipment shall be

fireproofed.
2. Structural elements supporting equipment which is not considered

fire hazardous shall be fireproofed if one or both of the
following conditions exist.
a. The equipment is essential for controlled shutdown of the

plant.
b. Failure of the equipment would damage fire hazardous

equipment, or other equipment essential to controlled shutdown
of the plant.
3. Terminations of fireproofing on steel shall be sloped to shed

water and sealed with mastic to prevent moisture from entering
between the fireproofing material and the steel surface. Typical
examples are top edges of fireproofing on horizontal beams whose
top flanges are not fireproofed, top edges of fireproofing on
columns, vessel legs, and vessel skirts of noninsulated vessels.
4. Fireproofed members shall have their base plates and anchor

bolting fireproofed unless otherwise noted on the drawings.
FIREPROOFING
B. Structures
Columns, beams and horizontal strut bracing of structural steel shall

be fireproofed from grade to an elevation where the highest important
equipment load is applied to the structure. All bracing except wind
and earthquake bracing shall be considered as structural steel
requiring fireproofing.
C. Vessel Supports
1. Vessel skirts 4' (1.2 m) in diameter and larger shall be

fireproofed on both the inside and the outside.
2. Vessel skirts less than 4' (1.2 m) in diameter shall be

fireproofed as follows.
a. Skirts with one access opening which is 16" (400 mm) diameter
or smaller, and having only welded connections within the
skirt, shall be fireproofed on the outside only.
b. Skirts with an access opening larger than 16" (400 mm) in

diameter, or more than one access opening, or with non-welded
(flanged or screwed) connections within the skirt, shall be
fireproofed on both the inside and the outside.
c. Where the inside of the skirt is required to be fireproofed,

bottom heads of uninsulated vessels shall be fireproofed using
4 of calcium silicate insulation and stainless steel
jacketing. Polyvinyl acetate mastic may be used for
weatherproofing where it is impractical to use metal
jacketing.
3. Extent of fireproofing on vessel skirts shall be as follows.
a. On insulated vessels, fireproofing shall extend from the

foundation up to the insulation.
b. On vessels having no insulation, fireproofing shall extend

from the foundation to the top of the skirt. The fireproofing
shall terminate in a 45 angle sloped downward and sealed with
mastic. The top of the mastic shall be approximately 1"
(25mm) below the skirt to shell weld (Figure 3).
4. Saddles supporting horizontal vessels and exchangers, measuring

over 2' (610 mm) in height at their lowest point, shall be
fireproofed in the same manner as vertical vessel skirts (Figure
3) on all surfaces.
FIREPROOFING
5. Legs, lugs, and brackets supporting vessels and exchangers shall

be completely fireproofed.
6. On supports of vessels and exchangers having slots in their base

plates for thermal expansion, fireproofing shall not interfere
with the sliding motion of these supports.
D. Fired Heaters
Main structural members and bracing supporting fired heaters shall be

fireproofed from the foundation to the floor of the heater.
E. Pipe Supports
1. In fire hazardous areas, pipe rack bents supporting piping only

shall be fireproofed to the first level, including horizontal
members at the first level (Fig.4B) Pipe rack bents supporting
fire hazardous equipment in addition to piping shall be
fireproofed up to the point of support of the equipment (Fig.4C)
2. Fireproofing of pipe supports is meant to include vertical and

horizontal load-bearing members and load-bearing bracing. Top
flanges of pipe-bearing beams, wind and earthquake bracing and
longitudinal members which do not carry direct loads shall not be
fireproofed.
3. Where pipe racks require fireproofing, either precast concrete

bents or fireproofed steel bents shall be used.
F. Instrumentation
1. Aboveground instrument tubing and cable supported on pipe racks in

fire hazardous areas shall be enclosed in ladder type aluminum or
unperforated galvanized steel raceways. The raceways shall be
fireproofed with materials lighter than concrete for a minimum of
1 hour protection per UL1709.
2. Critical instrumentation and power cable not covered by Paragraph

1 shall be protected so as to permit emergency function for at
least 30 minutes under fire environment conditions as defined by
UL1709. Critical instrumentation shall include but not be limited
to the following.
FIREPROOFING
a. Controls needed during emergency shutdown.
b. Emergency block valves.
c. Critical alarms
3. Alternative methods of fireproofing such as burying cable and/or

routing cable around fire hazardous areas are acceptable.
G. Air Cooled Heat Exchangers
Structural members supporting air cooled heat exchangers shall be

fireproofed as follows.
1. All members of supports for exchangers handling flammable liquids

shall be fireproofed.
2. Only those structural members that are within fire hazardous

areas, for exchangers handling nonflammable liquids shall be
fireproofed.
3. Wind and earthquake bracing and longitudinal members which do not

carry a direct load shall not be fireproofed.
V. MATERIALS
A. Concrete
Components for concrete fireproofing shall be as follows:
1. Cement shall be Type 1 Portland Cement conforming to ASTM C 150.

Other cements may be used if required for special reasons, such as
early strength or sulfate resistance.
2. Sand shall be a commercial, high silica sand with clean, sharp,

hard, durable particles conforming to ASTM C 33.
3. For general purposes, aggregate shall be sharp and angular in

nature, and range in size from (6 mm) to (13 mm), and shall
conform to ASTM C 33. Where light weight is essential, insulating
type aggregates, such as perlite, vermiculite, expanded shale, or
slag may be used.
4. Water shall be free of oils, acids, alkalis, salts or other

substances injurious to concrete. Use of potable water is
desirable.
FIREPROOFING
5. Concrete mix shall be proportioned so that the minimum compressive

strength of concrete after 28 days shall be 3,000 psi (210
kg/cm2).
6. Welded galvanized steel wire mesh, 2" x 2" x 12 gage, (50 mm x 50

mm x 3 mm) shall be used for reinforcement.
7. Lacing wire shall be No. 16 BWG (1/16", 1.5 mm) galvanized wire.
8. Carbon steel rectangular welding studs, Nelson R6P or equal, shall

be used for securing wire mesh reinforcement to steel. The length
of the studs shall provide for (19 mm) to 1" (25 mm) spacing
between the steel and the wire mesh. Carbon steel square or
hexagonal nuts are also acceptable anchors for attachment of wire
mesh.
9. Mastic material for fireproofing terminations shall be waterproof,

nonflammable when dry, durable under weather conditions, and able
to withstand temperatures to 250F (121C).
B. Ceramic Fiber
1. Ceramic fiber, 1(38 mm) thick, 8 lb/ft3 (128 kg/m3) density, may
be used for fireproofing of instrument runs.
2. Wire for holding ceramic fiber in place shall be annealed 18%Cr-

8%Ni stainless steel 16 BWG (1/16", 1.5 mm).
3. Jacketing for ceramic fiber shall be 0.010" (0.25 mm) thick 18%Cr-
8%Ni stainless steel.
4. Bands for securing jacketing on ceramic fiber shall be (13 mm)

wide, 0.020" (0.5 mm) thick stainless steel
C. Light Weight Proprietary Fireproofing Materials
1. Several light weight proprietary materials are available for

fireproofing steel structures and instrument trays for cables and
conduits. They are cementitious, subliming, and intumescent
coatings. They may be applied as described in Section VII or if
available, in rigid panels.
These materials may be used in areas where exposure to damage from

maintenance activities is minimal, and where considerable savings
may result due to weight reduction of fireproofed structural
FIREPROOFING
elements. Typical places include support legs and bracing for air
cooled heat exchangers or similar equipment located on elevated
structures such as pipe racks and other structural members at
higher elevations. Panel shapes and intumescent coatings are
especially suited for use on instrument trays (Paragraph IV.F.).
2. Use of these materials is acceptable only if their manufacturers

can document the fire endurance of the products backed-up by the
acceptable laboratory tests and proven experience as well as ease
of application and repair. Examples of acceptable materials are as
follows.
a. Lightweight Cementitious:
Carboline Company - Pyrocrete 240 series.

Carboline Company - Pyrocrete 241 series ( 2 hours Rating)
b. Intumescent:
Textron Specialty Materials - Chartek IV

PPG Industries, Inc. - Pitt-Char XP
Carboline Company - Nullifire System E
Foster Wheeler shall have final approval regarding the use of all
proprietary materials.
VI. APPLICATION OF CONCRETE FIREPROOFING
A. General
1. Steel to be fireproofed shall be thoroughly cleaned to remove

loose paint, grease, rust, and foreign matter which would impair
the bond between the fireproofing and the fireproofed surface.
Where fireproofing is applied to a painted surface, the paint
shall be fully cured.
2. Concrete fireproofing shall be applied to a minimum thickness of

2" (50 mm) in all cases to obtain the necessary protection.
Typical details of fireproofing with concrete are shown in Figures
1, 2 and 3. Either pneumatic (shotcrete, gunite) or formed
encasement application is acceptable.
3. In certain instances, at the discretion of Foster Wheeler, it may

be economical and feasible to fireproof structural members before
they are erected. The joint connections shall be fireproofed
FIREPROOFING
after erection to the same degree of protection as the structural
member.
4. Exposed concrete corners shall be chamfered or rounded.
5. Reinforcement for Concrete Fireproofing
Wire mesh shall be used for reinforcement and shall be supported

on the member being fireproofed by means of welded studs or nuts
on edge. Clearance between the mesh and the structural member
shall be a minimum of 3/4" (19 mm). Edges of adjacent sheets of
mesh shall lap a minimum distance of 2" (50 mm), and shall be
secured with lacing wire spaced 18" (455 mm) apart.
6. Precautions
a. The surface to which the concrete is applied shall be kept

free from frost and ice. Placing of concrete at temperatures
below 40F (4C) is not permitted, unless facilities are
available for keeping the concrete above this temperature
during placing and curing.
b. During operation, the application equipment shall be properly

grounded to prevent static electricity, especially in areas
where the atmosphere may contain flammable vapors.
c. Surfaces and equipment adjacent to the member being

fireproofed shall be shielded by screens, tarpaulins, or heavy
paper covering to shield them from spatters and prevent
excessive cleanup.
7. Curing
The concrete shall be kept damp, but not dripping wet, to prevent
loss of moisture, for at least 5 days after placement. Other
suitable curing means, such as the application of resin based
commercial compounds, may be employed.
B. Pneumatic Application of Concrete
The work shall be performed by qualified workmen experienced in the

application of concrete by the method chosen. Application shall be in
accordance with ACI-506, Recommended Practice for Shotcreting.
C. Formed Encasement Application of Concrete

FIREPROOFING
The form work, mixing, pouring and curing shall be in accordance with
ENG STD 43A1.
VII. APPLICATION OF OTHER FIREPROOFING MATERIALS
A. Required thickness of fireproofing materials other than concrete shall

be obtained from the UL Fire Resistance Directory. In all cases
thicknesses shall be sufficient to provide a minimum of 22 hours of
protection per UL1709 unless otherwise allowed by this job
specification. Materials shall be applied over reinforcement such as
expanded metal lath, as recommended by the manufacturer or as called
out in the UL Directory. The fireproofing subcontractor shall submit
application details for approval with his quotation. Prior to
application, the subcontractor shall prepare a sample of the same
thickness as required for the project, to be approved by Foster Wheeler
and the Owner. The finish of this sample shall be used as an
inspection aid for acceptance of the work. The sample shall be on a 3'
(1 m) long wide flange structural member.
B. Intumescent and Subliming Coatings
These materials are generally applied by spray method. Preparation of

steel surfaces, application and finishing shall be in accordance with
the manufacturer's written instructions and the requirements of
Paragraph VII.A. above. The applicator shall be experienced in
handling these materials and shall be recommended by the coating
manufacturer. Priming of steel surfaces and painting of the finished
work is required as recommended by the manufacturer.
C. Light Weight Cementitious Materials
These materials can be applied by spraying or troweling. If smooth

surfaces are required, sprayed-on material shall be smoothed with a
trowel, or trowelled application shall be used. A plastic nose corner
bead shall be used on trowelled smooth boxed column design to ensure
regularity and trueness of corners. Metal surface preparation,
reinforcement, application, and finishing shall be in accordance with
the manufacturer's recommendations and the requirements of Paragraph
VII.A. above. The applicator shall be experienced in handling these
materials and shall be recommended by the manufacturer.
FIREPROOFING
FIGURE 1: CONCRETE FIREPROOFING DETAILS

FIREPROOFING
FIGURE 2: CONCRETE FIREPROOFING DETAILS

FIREPROOFING
FIGURE 3: CONCRETE FIREPROOFING DETAILS AT SKIRT
FIREPROOFING
FIGURE 4: FIRED HAZAARD ZONE

FIREPROOFING
REASON FOR CHANGES:
REV 1: Projectised per project requirements. Rev 0 is not issued

on the project Since FW standard for the preparation of this specification is
considered Rev 0.

REV: 1

D-4 Flake Glass Polyester (Carboline Carboglas 1601SG), 126158-83A9 Rev.1
______________________CONFIDENTIAL_____________________
USED,
JOB SPECIFICATION
126158 - 83A9
FLAKE GLASS POLYESTER

(CARBOLINE CARBOGLAS 1601SG)
The subject job specification is issued herewith. Please discard any

previous issue of this specification.
Revision Number Log

by
1 10/5/2010 UVPATEL 10 SDemko ISSUE FOR BDP

CONTENTS
REVISION INDEX 3
I. SCOPE 3
II. REFERENCES 4
III. MATERIALS AND DESIGN 4
IV. PERFORMANCE OF THE WORK 5
V. SAFETY PRECAUTIONS 5
VI. SURFACE PREPARATION 5
VII. COATING THICKNESS AND APPLICATION 6
VIII.CONFLICTING INSTRUCTIONS 9
IX. PRESERVATION OF WORK 9
X. CLEANING AND STORAGE 10


REVISION INDEX
1 1 10/5/2010 complete revision-SPEC Projectised

2 1 10/5/2010
3 1 10/5/2010
4 1 10/5/2010
5 1 10/5/2010
6 1 10/5/2010
7 1 10/5/2010
8 1 10/5/2010
* Asterisk (when noted) will represent page content revised for this issue.
I. SCOPE
A. General
1. This job specification (JOB SPEC) covers the requirements for a shop
or field applied internal non metallic lining for decoking water
storage tanks and other tanks when noted in order to insure the
materials and workmanship necessary to produce a quality tank
lining.
2. The work entails the preparation, coating and inspection of the tank
interior surfaces.
3. The vendor or Contractor shall advise Foster Wheeler, USA in

writing, of any conflicts between the requirements of this JOB SPEC
and vendor requirements
4. The latest editions of any federal, state or local codes,

regulations, standards and guidelines that existed prior to
September 2010 , shall govern and supercede any prior federal,
state or local codes, regulations, standards and guidelines
referenced in this JOB SPEC.
5. The vendor or Contractor shall advise Foster Wheeler, USA in

writing, of any conflicts between the requirements of this JOB SPEC

II. REFERENCES
A. Steel Structures Painting Council (SSPC)
1. SSPC-SP 5/NACE #1 White Metal Blast Cleaning
2. SSPC-PA 2 Measurement of Dry Paint Thickness with

Magnetic Gages
B. U.S. Federal Documents - Occupational Safety and Health Specifications

(OSHA)
C. National Association of Corrosion Engineers (NACE) Recommended Practice

RP0178.
III. MATERIALS AND DESIGN
A. Coating shall be CARBOLINE CARBOGLAS 1601SG for DECOKING WATER TANK and for
the other tanks when noted. This is Flake Glass Polyester coating from
CARBOLINE only.
B. A specific lining guarantee is required to be supplied to the owner by the

applicator insuring the lining will be free from failure caused either by
poor workmanship, application or material failure for a minimum period of 2
years. The applicator shall form a liaison with the coating manufacturer in
order to ensure that not only is the surface preparation and application
guaranteed, but the lining as well.
C. All coating materials shall be delivered to the jobsite in the original and
unopened containers, plainly marked with the proper designation of the
product, as well as the name of the manufacturer.
D. The coatings shall be used and applied per coating manufacturers most
recent printed instructions without being extended or modified. The correct
surface preparation and condition of the surface to be coated shall be
rigidly adhered to.

E. All coating materials at the jobsite shall be subject to inspection by the

resident engineer or inspector.
F. The minimum tank nozzle diameter shall be 3 inch ( 76 mm) in order to

facilitate lining application.
G. Tank design and fabrication details shall be in accordance with NACE RP0178.
All sharp edges and welds shall be ground smooth to a rounded contour in
accordance with NACE weld preparation designation C. All weld splatter
shall be removed prior to abrasive blasting.
H. Butt welded joints shall be used in lieu of lap-type joints.
IV. PERFORMANCE OF THE WORK
All work shall be performed in strict accordance with this specification and the
coating manufacturer's current application instructions. The applicator shall
furnish all labor, equipment, appliances and materials and shall ensure that all
work is performed in a safe and workmanlike manner. All phases of the work
shall be available to the coating manufacturer and the resident engineer or
inspector for observation or inspection at any time.
V. SAFETY PRECAUTIONS
All pertinent OSHA safety regulations shall be adhered to rigidly. In addition,

all safety precautions noted on the manufacturer's product data sheets and
application instructions shall be observed.
VI. SURFACE PREPARATION
A. General
1. All surfaces to be coated shall be prepared in a workmanlike manner

with the objective of obtaining a clean, dry and properly prepared
substrate.
2. No coating work shall begin before the prepared surfaces have been
inspected and approved.

B. Steel Surfaces
1. Remove any oil or grease from surfaces to be coated using clean rags
soaked in toluol. Any chemical contamination shall be eliminated by
means of neutralization, flushing or both, prior to additional surface
preparation. Solvent and rags shall be changed frequently to ensure
their cleanliness.
2. All surfaces to be coated shall be abrasive blast cleaned to white

metal in accordance with SSPC-SP 5/NACE #1.
3. The proper abrasive to obtain the specified profile (anchor pattern)

designated in the coating manufacturer's most recent printed
application instructions shall be used. Abrasive blasting shall be
performed using grit or synthetic abrasives. After abrasive blasting,
dust and spent abrasive shall be removed from the surfaces by brush or
vacuum. The coating shall be applied as soon as possible after the
blasting operation is finished and always before the surface starts to
rust. No abrasive blasted surface shall stand overnight before
coating.
4. Only unused fresh abrasive shall be used. Abrasive shall be free of

oil, grease, chlorides, copper and clay.
5. Imperfections in surfaces to be coated shall be repaired by grinding

or welding prior to abrasive blasting.
VII. COATING THICKNESS AND APPLICATION
A. General
1. Coatings shall be applied in accordance with the instructions of the

coating manufacturer. Coating thickness shall be 40 mils minimum.
2. All coatings shall be applied under favorable conditions by an

applicator with successful previous experience applying the same
coating.

3. All blast-cleaned metal shall be coated, as specified, within the same

day of cleaning to prevent new rusting or oxidation of cleaned
surfaces. Any oxidation or rusting of cleaned surfaces shall require
reblasting to a white metal finish.
4. The application shall leave no sags, brush marks, pinholes, or other

defects.
5. Drying time between coats and for final cure shall adhere to the
coating manufacturer's recommendations with conditions of temperature,
humidity and ventilation taken into consideration.
6. Cleaning and coating shall be scheduled so that dust and other

contaminants from the cleaning process will not fall on wet, newly
coated surfaces.
7. All coating shall conform to the following conditions:
a. The dry film thickness of each coat and of the entire system shall
follow the coating manufacturer's recommendations.
b. All equipment shall be maintained in good working order and shall

be comparable to that described in the coating manufacturer's
application instructions. Equipment shall be thoroughly cleaned
and inspected daily. Worn spray nozzles, tips, etc. shall be
replaced regularly. Effective oil and water separators shall be
used and serviced on all air lines.
c. Thinning shall be done only if necessary for the workability of

the coating material and then, only in accordance with the coating
manufacturer's application instructions. The approved
manufacturer's supplied thinner shall be used.

d. No coatings shall be applied when the air temperature is below

60F or above 100F, or when the temperature of the surface to be
coated is below 60F, unless allowed in the coating
manufacturers application instructions. No coatings shall be
applied if a predicted temperature of 60F or lower is forecast
within 24 hours of application unless the coating area is
enclosed and heated. No coatings shall be applied when the
surfaces may become damaged by rain, fog or condensation or when
it is anticipated that these conditions will prevail during the
drying period, unless suitable enclosures to protect the surface
are used. Where heat is necessary, it shall be supplied by the
applicator and shall be of such type that it will maintain a
minimum air and coated surface temperature of 70F during the
coating period. The heater shall be of such type as not to
contaminate the surface area to be or being coated with
combustion products. The responsibility for supplying utilities
to run electric or gas heaters shall be carried by the owner.
B. Inspection
1 Visual inspection for pinholes, holidays, dry spray, sags and other
flaws shall be performed after each coat is applied. All such flaws
shall be corrected before the next coat is applied.
2 After the final coat is applied and visually inspected, a holiday

detector, equivalent to a Tinker Rasor Model AP-W (3000 to 3500 volts)
or approved equal, shall be used over the entire tank interior to
ensure no holidays exist in the coating. The coating shall set for a
minimum of 48 hours at a minimum temperature of 70F before high
voltage holiday inspection is performed.
2. Coating thickness shall be inspected in accordance with SSPC-PA 2.


VIII. CONFLICTING INSTRUCTIONS
A. Copies of both this specification and coating manufacturer's most recent

printed application instructions shall be at the jobsite.
B. Resolution of conflicts between these documents shall be provided in writing

by the coating manufacturer.
IX. PRESERVATION OF WORK
A. During construction, the applicator shall assume the responsibility for

preservation of all his work against damage.
B. The applicator shall complete the coating work and subject it to inspection
by the resident engineer, inspector and/or a representative of the owner.
C. All work which is rejected or which must be retouched shall be redone by the
applicator at his expense.

X. CLEANING AND STORAGE
A. Cleaning
1. All work not to be coated, or previously coated, shall be carefully

protected during the coating of adjacent work.
2. Any coated surfaces which were not specified to be coated and/or any
coating materials not per this specification shall be thoroughly
cleaned and the original or specified finish restored at the
applicator's expense.
3. Name and data plates on equipment shall not be coated and shall be
left clean and legible upon completion of the project.
4. Upon completion of the project the jobsite shall be left neat and
clean.
B. Storage
All coating materials shall be stored under cover in a controlled atmosphere

as recommended by the coating manufacturer.

REV: 1

D-5 External Insulation, Hot Service, 126158-82A1 Rev.1
______________________CONFIDENTIAL_____________________
USED,
JOB SPECIFICATION
126158 - 82A1
EXTERNAL INSULATION HOT SERVICE
The subject job specification is issued herewith. Please discard any

previous issue of this specification.
Revision Number Log

Rev Date By Pages Approval Remarks
1 5th Oct Udayan 28 S. Demko Issued for Client

2010 Patel Review
STAR (SOCAR & TURCAS AEGEAN REFINERY) PROJECT Specification No. 126158 - 82A1
ALIAGA, IZMIR, TURKEY Rev No: 1
REVISION INDEX
1 1 10/05/2010 Entire specification is projectized

2 1 10/05/2010
3 1 10/05/2010
4 1 10/05/2010
5 1 10/05/2010
6 1 10/05/2010
7 1 10/05/2010
8 1 10/05/2010
9 1 10/05/2010
10 1 10/05/2010
11 1 10/05/2010
12 1 10/05/2010
13 1 10/05/2010
14 1 10/05/2010
15 1 10/05/2010
16 1 10/05/2010
17 1 10/05/2010
18 1 10/05/2010
19 1 10/05/2010
20 1 10/05/2010
21 1 10/05/2010
22 1 10/05/2010
23 1 10/05/2010
24 1 10/05/2010
25 1 10/05/2010
26 1 10/05/2010
27 1 10/05/2010
* Asterisk, when noted, will represents page content revised for this issue
I. SCOPE
A. This job spec defines the requirements for the external

insulation of piping and equipment in hot service (above ambient
temperature), for the purpose of conserving heat and protecting
personnel. This job spec does not define insulation for systems
operating above 1200F (649C).
B. The insulation described in this job spec is suitable for use in

outdoor service with normal process plant atmosphere. Where the
atmosphere and/or potential spills or leaks contain chemicals
that will react with standard insulation materials, specialized
insulation systems shall be developed.
The vendor or Contractor shall advise Foster Wheeler, USA in

writing, of any conflicts between the requirements of this JOB
SPEC. The latest editions of any federal, state or local codes,
regulations, standards and guidelines that existed prior to
September, 2010 shall govern and supercede any prior federal,
state or local codes, regulations, standards and guidelines
referenced in this JOB SPEC
C. Requirements regarding the extent of insulation, based on the

intended service, shall be specified on the following project
documents:
1. Engineering Flow Diagrams / Piping and Instrument Diagrams
2. Line Classification Lists
3. Piping Isometric Drawings
4. Instrument Piping Details
5. Equipment Insulation Summary

II. REFERENCES
The following documents are referred to in this job spec.
A. ASTM Standards
1. ASTM B 209 Specification for Aluminum and Aluminum-Alloy

Sheet and Plate.
2. ASTM C 195 Specification for Mineral Fiber Thermal Insulating

Cement.
3. ASTM C 449 Specification for Mineral Fiber Hydraulic-Setting

Thermal Insulating and Finishing Cement.
4. ASTM C 533 Specification for Calcium Silicate Block and Pipe

Thermal Insulation.
5. ASTM C 547 Specification for Mineral Fiber Preformed Pipe

Insulation.
6. ASTM C 592 Specification for Mineral Fiber Blanket Insulation

and Blanket-Type Insulation (Metal Mesh Covered).
7. ASTM C 610 Specification for Expanded Perlite Block and Pipe

Thermal Insulation.
8. ASTM C 612 Specification for Mineral Fiber Block and Board

Thermal Insulation.
9. ASTM C 795 Specification for Wicking-Type Thermal Insulation

for use over Austenitic Stainless Steel.
10. ASTM C 892 Specification for High-Temperature Fiber Blanket

Thermal Insulation.
11. ASTM C 1086 Specification for Glass Fiber Felt Thermal

Insulation.
III. DESIGN
A. The service or purpose for which insulation is required shall be

classified and identified as follows. For insulation thickness
requirements refer to Tables 1 through 4.
1. HC - Heat Conservation
Insulate where heat loss is not desirable.
2. PP - Personnel Protection
The extent of protection for PP shall be within 2' (610 mm),
horizontally of normal working areas or access ways for a
height of 7' (2.1 m) above grade or a platform.
B. The normal operating temperature of the fluid shall be used to

determine insulation requirements, with the following
clarifications:
1. Where an equipment item has sections operating at different

temperatures, each section may be insulated as required to
suit its operating temperature.
2. For heat traced items, the normal operating temperature of

the process fluid shall be used.
3. For jacketed items, insulation requirements shall be based on

the temperature of the fluid in the jacket.
C. Instrument components subject to flow and/or temperature

conditions approximating those in the piping/equipment to which
they are connected shall be insulated using the same criteria as
the connected piping/equipment.
D. The following items shall not be insulated.
1. Equipment and piping where heat loss is desired.
2. Internally insulated items. Such items shall have a

conspicuous warning note painted on external surfaces stating
that external insulation is prohibited.
3. Flanged joints, except those listed in Para. III.E.
4. Valve bodies, including control valves, whose operating

temperature is between ambient and 300F (149C).
5. Items which become hot intermittently, such as relief valves,

relief systems, vents, drains, pump-out and blowdown systems,
steam-out and purge steam systems.
6. Pipe union fittings
7. Strainers and filters
8. Steam traps
9. The bellows portion of expansion joints, hinged joints and

hose assemblies
10. Sight flow indicators
11. Nameplates on vessels, exchangers and machinery
12. Supports for piping or equipment.
Note: If the support skirts for vertical vessels are not

fireproofed, insulation on vessels shall be carried below the
tangent line for a distance of 2' (610 mm), but it shall end not
less than 1' (305 mm) above support concrete or steel. If the
skirt is fireproofed, the insulation shall extend to the top of
the fireproofing.
E. The following flanged joints shall be insulated. For insulated

flanges, bolt and flange material stresses must be acceptable at
the increased temperature.
1. Those in steam service.
2. Those heated by a tracer or jacket.
Insulation applied to flanged joints shall be removable and

reusable. It may be fabricated as shown in Detail "H" or it may
be of prefabricated blanket type as described in Paragraph V.B.
F. Bodies of flanged valves, including control valves, in insulated

lines which operate at temperatures over 300F (149C), shall be
insulated using the same insulation thickness as the pipe. Valve
bonnets shall not be insulated. Screwed or welded valves shall
be insulated with insulating cement and weatherproofed with
mastic.
G. Uninsulated expansion loops and cross-overs in heat tracer tubing

shall be wrapped with waterproof fiberglass cloth tape to a
thickness of 1/4" (6 mm).
H. Insulated piping in pipe racks shall be supported on steel shoes.

The height of the shoe shall be such that the bottom of the
insulation is at least 1" (25 mm) above the support upon which
the shoe rests.
J. Tanks shall be equipped with the same type of insulation and

supports as vessels. Requirements for tank insulation shall be
determined for the specific tank and incorporated on the tank
drawing.
K. Compressors, pumps, and other mechanical equipment shall be

insulated on an individual basis with consideration given to the
requirements for process access and equipment maintenance. The
equipment manufacturer shall be consulted prior to the insulation
of each piece of equipment.
L. Insulation shall be protected by a metal jacket from the weather,

spillage, mechanical wear, or other damage. Weatherproofing
mastic may be used on irregular surfaces or on surfaces for which
metal jacketing is not practical.
M. Insulation support rings shall be provided on vertical vessels.

The spacing of the rings shall coincide with the insulation
expansion joints. Vertical vessels shall have a minimum of two
insulation support rings; one at or below the bottom tangent line
and one at the top tangent line. Additional rings shall be added
as required by the expansion joint spacing.
N. Support rings, studs, clips, etc. shall be fabricated using the

same material as the equipment item and shall be welded in place
by the fabricator. Carbon steel rings shall be bolted to the
clips. See Figure 2 detail "B".
P. Clamp type support rings shall be furnished and installed by the

insulation contractor at the lower end of vertical piping (piping
inclined more than 45 from horizontal) and above each flange,
ell, tee, etc. for pipe sizes greater than NPS 3. Intermediate
support rings shall be supplied for uninterrupted vertical runs
as follows:
Pipe Diameter Length of Run # of Spacing

(D) (L) Intermediate
Suppts.
NOTE 1
NPS 3 < D L < 30(9m) 0 N/A
NPS 16 30 L <40(12m) 1 20(6m)max.
L 40(12m) >1 1 suppt.
every
20(6m)
L < 20(6m) 0 N/A
D > NPS 16 20 L < 30(9m) 1 15(4.5m)max
L 30(9m) >1 1 suppt.
every
15(4.5m)
NOTE 1 Where only one intermediate support is required, the

support shall be placed as close to the midpoint of the run
as possible. Where more than one is required, the supports
shall be placed at equal intervals.
Q. Clamp type support rings shall be manufactured from 3/16" (4.5mm)

to 1/4" (6mm) thick plate and shall match the piping material.
The clamp shall be coated to resist corrosion if the piping is
coated. Galvanized clamps are not permitted on alloy steel,
stainless steel or items operating above 700F (370C).
R. Support rings at flanges shall be located a minimum of 1" (25 mm)

above all welds and a minimum of one bolt length plus 1" above
the back face of the top flange. Support rings at fittings
(ells, tees, etc.) shall be located at least 6" (150 mm) above
the pipe to fitting weld.
S. Expansion joints in the insulation shall be used to provide for

differential thermal expansion between the insulation material and
the piping or equipment material. Expansion joints shall be
packed with a loose fiber insulation material. On vessels, a 1"
(25 mm) wide space packed with loose insulating fiber shall be
provided around all nozzle and manway necks, and any other
attachment to the vessel wall in addition to the required
expansion joints. Maximum spacing for circumferential and
longitudinal expansion joints on equipment and piping shall be as
follows:
TEMPERATURE MAX. JOINT SPACING

Up to 250F (Up to 121C) 30 (9m)
251 to 400F (122 to 204C) 15 (4.5m)
401 to 600F (205 to 316C) 12 (3.6m)
601 to 900F (317 to 482C) 9 (2.7m)
901 to 1200F (483 to 649C) 6 (1.8m)
On vertical piping and vessels, expansion joints shall be located

under the insulation support rings where such rings are required.
IV. MATERIALS
A. All insulating materials shall be asbestos-free, non-corrosive to the

metal being covered, and where applicable, shall comply with OSHA
requirements.
B. Acceptable insulation materials for specific applications are as

follows.
APPLICATION TEMPERATURE ACCEPTABLE MATERIAL(S)

150F (65C) No Insulation Required
Heat Conservation 151-300F (66-149C) Expanded Perlite
and Steam Tracing >300F (149C) Perlite, Mineral Wool,
Calcium Silicate
150F (65C) No Insulation Required
Personnel Protection
>150F (65C) Metal Shields1,2
Prefabricated 1000F (538C) Glass Fiber
Blanket Removable >1000F (538C) Ceramic Fiber
Covers (Para. V.B.1) (Hot Face Only)
1. If both heat conservation and personnel protection are required,

metal shields shall be installed over insulation where necessary.
2. Where metal shields are not practical from a design or installation
standpoint, acceptable insulation materials shall be in accordance
with the Heat Conservation and Steam Tracing portion of the above
table.
C. Insulation and accessory materials shall conform to the following

requirements. Temperature limits listed by the manufacturers and in the
applicable ASTM standards shall not be exceeded.
1. Calcium silicate block and preformed pipe insulation shall conform to

the requirements of ASTM C 533 Type I.
2. Expanded perlite block and preformed pipe insulation shall conform to

the requirements of ASTM C 610.
3. Mineral fiber insulation shall conform to ASTM C 547 Type II for

preformed pipe insulation, ASTM C 592 Type II for blanket insulation,
and ASTM C 612 Type IV for block and board insulation.
4. Ceramic fiber insulation shall conform to the requirements of ASTM C892

Grade 8 Type I.
5. Glass fiber insulation shall conform to the requirements of ASTM C1086.
6. Insulating material on austenitic stainless steel shall comply with the

requirements of ASTM C 795. If a special grade of material must be
manufactured to meet these requirements, the manufacturer shall make
provisions to avoid the possibility of interchanging standard and

special grade materials.
7. All mastics, cements, binders, and other materials used in conjunction

with insulation on austenitic stainless steels shall contain less than
50 ppm leachable chlorides. Potable water shall be used for mixing
these materials.
8. Mineral fiber thermal insulating cements shall conform to the

requirements of ASTM C 195.
9. Mastic for weatherproofing shall be breathable asphalt, acrylic, or

polyvinyl acetate. Mastic shall be weather and fire resistant and
capable of withstanding surface temperatures of 200F (93C). An
example of an acceptable weatherproofing mastic is Foster Products
Company Sealfas G-P-M 35-XX/45-XX.
10. Combined insulating and finishing cement shall conform to ASTM C449 and
shall be compatible with all materials with which it comes in contact.
It shall be suitable for application to the required dry thickness in
one operation and shall produce a smooth surface after being troweled.
11. Metal jacketing shall be 0.016 (0.4 mm) thick aluminum per ASTM B209
Grade 3003 or 3105 with H14 or H16 temper and a factory-applied bonded
layer of moisture barrier on its inside surface. The moisture barrier
may be polyethylene - kraft paper, polysurlyn, or other approved
alternate. Jacketing on vertical cylindrical equipment shall be
corrugated as follows. For outside diameters (including insulation) of
36" (915 mm) to 60" (1.5 m), pitch of corrugations shall be 3/16" (4.5
mm). For outside diameters (including insulation) larger than 60" (1.5
m), pitch of corrugations shall be 1-1/4" (30 mm). Metal jacketing for
vessel heads, machinery, pipe and pipe fittings, horizontal vessels,
vertical vessels less than 36" (915 mm) in diameter and other irregular
surfaces shall be flat sheets.
12. Joint sealer for metal jackets shall be Childers Chil-Joint CP-70,
Foster Elastolar Sealant 95-44 or equal.
13. Accessory and attachment materials shall be as follows.
a. Wire for securing insulation shall be 16 gage (1.7 mm) fully

annealed Type 18-8 stainless steel.
b. Bands and seals for securing insulation and jacketing shall be

0.020" (0.5 mm) thick stainless steel. Width of bands on jacketing
shall be (13 mm) for jacket outside diameters 5(1.5 m) and
(19 mm) for diameters > 5 (1.5 m). Width and spacing of bands on
insulation shall be per Para. V.A.12.
c. Expander-type bands shall be Gerrard Company or equal.
d. Expansion springs for bands on insulation shall be Type 302

stainless steel INSUL-MATE ES-7 manufactured by RPR Products, Inc.,
CHIL-SPRING manufactured by Childers Products Company, Inc. or
equal.
e. Compression springs for bands on jacketing shall be Type 302

stainless steel Childers MITY-SPRING or equal.
f. Screw fasteners shall be No. 8 (4 mm), stainless steel, 1/2" (13

mm) long, self-tapping panhead or hexhead.
g. Reinforcing material for mastic finishes shall be 10 x 10 mesh

glass fabric.
h. Wire mesh shall be 1" (25 mm) hexagonal pattern annealed 18-8
stainless steel poultry netting with a minimum wire size of 0.036"
(0.9 mm).
j. "S" and "J" clips shall be 0.020" (0.5 mm) thick stainless steel.
k. Flashing materials shall be 0.010" (0.25 mm) aluminum grade 3003 or

3105.
V. INSTALLATION
A. General
1. Equipment and piping surfaces shall be cleaned by brushing off all

foreign matter, such as dirt, loose rust, loose scale, plaster,
etc., and shall be wiped clean of oil and water to a dry condition
before insulation is installed. Painted surfaces shall be
insulated only after the paint has completely dried.
2. Insulation shall not be installed over joints (welds, flanges, pipe

threads, etc.) or tracers until required field testing has been
completed and all such joints or tracers are proven tight.
3. Dry insulation material which becomes wet prior to or during

installation shall be thoroughly dried before proceeding with its
installation.
4. Working parts of valves, turbines, or other mechanical equipment

shall be protected when insulation is applied. Until all
insulation materials, including cement or mastic, have been removed
from these parts (e.g., valve stems, governor linkages, etc.) the
scope of insulation work shall be considered incomplete.
5. Insulation up to 3" (75 mm) in thickness may be applied in a single

layer with vertical joints staggered. Thicker insulation shall be
applied in 2 or more layers with staggered joints. Adjacent
insulation sections shall be butted firmly together. Preformed
pipe insulation and preformed insulation fittings may be installed
in one layer if available in the required thickness however, the
maximum layer thickness in a multi-layer system shall be 3 (75
mm).
6. Voids due to fitting of rigid insulation shall be filled with

insulating-finishing cement. Cement shall not be used in contact
with stainless steel components (including steam tracing), with
electrical tracers or in insulation expansion joints. In these
cases, rigid insulation shall be cut to eliminate voids.
7. Insulating cement may be used on irregular surfaces where the use

of insulation is impractical. The applied thickness of the
insulating cement shall be 25% greater than the required insulation
thickness.
8. Pipe insulation shall be discontinued at flanged connections to

permit removal of the studs. The distance from the end of the
insulation to the back of the flange on both sides of the
connection shall be equal to one stud length plus 1" (25mm). The
ends of insulation shall be beveled at noninsulated flanges. At
insulated flanges, the ends of the insulation shall be straight.

In both cases, insulation terminations shall be weatherproofed
using aluminum flashing.
9. Stiffening rings on equipment shall be covered with the same

insulation thickness as the equipment itself.
10. If blanket insulation is used on large vessels, fans, ducts,

boilers, etc. it may be strapped on or it may be impaled on pins
welded to the vessel as shown on Fig. 2 Detail "D." All welding
required for installation of insulation supports shall be approved
by the purchaser prior to welding.
11. In cases where large diameter piping requiring heat conservation

insulation passes through a vessel skirt, the insulation thickness
may be reduced by the Detailed Design Contractor with the approval
of the Owner to avoid increasing the size of the openings in the
skirt. The resulting insulation thickness shall under no
circumstances be less than 3 (75mm).
12. Insulation material shall be held in place with tie wires or bands
as follows:
INSULATION INSULATION WIRE OR SPACING*

LAYER OUTER DIAM. BAND SIZE
Single or <3 ft.(1 m) Wire 9-12
Outer Layer (Para. IV.Q.1) (225-305 mm)
Single or 3 to 6 ft. 0.5(13 mm) 12-18
Outer Layer (1 to 2 m) Band (305-455 mm)
Inner Layer <3 ft.(1 m) Wire 12-18
(Para. IV.Q.1) (305-455 mm)
Inner Layer 3 to 6 ft. 0.5(13 mm) 12(305 mm)
(1 to 2 m) Band
Any Layer 6 to 10 ft. 0.5(13 mm) 12(305 mm)
(2 to 3 m) Band
Any Layer >10 ft. 0.75(19 mm) 12(305 mm)
(>3m) Band
* Not less than two wires or bands shall be used per standard
length of insulation.
13. Bands over rigid insulation shall have expansion devices (Para.
IV.Q.3 and IV.Q.4) as follows:
OPERATING TEMPERATURE
Vessel OD 400-600F 601-800F 801-1000F
(204-316C) (317-427C) (428-538C)
<4'(1.2m) 0 0 1
4 8' 0 1 1
(1.2-2.4m)
8 - 12' 1 1 1
(2.4-3.6m)
12 - 20' 1 2 2
(3.6-6.0m)
>20'(6.0m) 2 3 3
NUMBER OF EXPANSION DEVICES
For vessels up to 8' (2.4m) in diameter, expansion devices may be

deleted if the block is cut 1/2" (13mm) greater in circumference
than the vessel. The blocks shall be secured in such a way that
the tension of the bands produces a compression on the butt edges
rather than the block surface. A cushioning blanket insulation
layer (i.e., mineral fiber) is also an acceptable substitute for
expansion devices on vessels up to 8' (2.4m) in diameter.
B. Construction of Prefabricated Blanket Removable Covers
1. Insulating material shall be glass fiber or ceramic fiber blanket.

Ceramic fiber shall only be used for the hot face and only at
operating temperatures in excess of 1000F (538C).
2. Insulation thickness shall be 1" (25 mm) at operating temperatures

350F (177C) and 2" (50 mm) at operating temperatures above
350F (177C). Where ceramic fiber is used the thickness of the
ceramic fiber layer shall be 1" (25 mm).
3. External jacketing over insulation shall be silicone-impregnated

fiberglass fabric, 16 oz/yd3 (approx. 600g/m3). The inner surface
("hot face") shall be covered with the same material at operating
temperatures up to 500F (260C). Where "hot face" temperatures
exceed 500F (260C), the covering shall consist of 13 oz/yd3
(approx. 500g/m3) fiberglass fabric with 2 mil (0.05 mm) aluminum
foil laminate or 16 oz/yd3 (approx. 600g/m3) fiberglass fabric
bonded to 3 mil (0.075 mm) 304SS foil.
4. In all cases, the hot face of the covers shall be lined with Type
302 or 304 stainless steel knitted wire mesh 0.011" (.28 mm) in
diameter. Insulation covers shall be sewn with lock stitching
using 10 to 14 stitches per inch (25 mm). Hog ringed seams are not
permitted.
5. Flaps shall be provided to cover mating edges of the cover to shed

water. Ends of covers shall overlap fixed insulation by 3" (75
mm). Lacing with Type 18-8 stainless steel wire (16GA)(1.5 mm)
shall be used to secure covers. Lacing hooks shall be on maximum
8" (200 mm) centers. Flaps overlapping fixed insulation shall be
constructed thinner than the removable jacket to minimize gaps and
flexibility problems during installation.
6. All removable insulation shall have 1/2" (13 mm) diameter drain
holes at low points.
C. Expanded Metal Shields
1. Shields shall be galvanized steel and fabricated from flattened

1/2" (13mm) No. 18-20 expanded metal. Typical metal shields are
shown in Figure 5.
2. Expanded metal supports may be provided by structural steel

supports anchored at the equipment foundation or by stainless steel
clips banded to piping/equipment. Typical support clips are shown
in Figure 6.
3. Shields on flanged connections and equipment shall be designed for

convenient removal for maintenance access.
4. Individual sections shall not weigh more than 40-50 pounds (18-23
kg).
5. The insulation subcontractor in conjunction with field engineering

shall have the authority to alter the shield and shield support
design for the purpose of constructability.
6. In all cases the shields shall be located a minimum distance of 3"

(75 mm) from the hot surface. This distance may be increased as
required by OSHA standards, plant safety requirements or other
applicable codes.
D. Weatherproofing
1. Metal jackets shall be installed in such a manner as to shed water.

Longitudinal and circumferential seams shall have a 3" (75 mm)
minimum overlap. Where jacket surfaces are cut to provide for
protrusions, flashing shall be provided and installed in such a
manner as to keep water from entering behind the jacket. Orange
peel segments of head jackets shall be lapped a minimum of 3" (75
mm) and shall be sealed with joint sealer.
2. Mastic weatherproofing shall be applied in two coats. For pipe

sizes larger than NPS 2, and equipment, the mastic shall be
reinforced between coats with 10 x 10 mesh glass fabric.
3. Transitions between metal jacketing and mastic cover protection, or

terminations of either type of cover, shall be in such a manner as
to provide for water runoff. This may be accomplished either by
flashing or overlapping.
a. For horizontal conditions, the mastic shall extend under the

metal jacketing for at least 3" (75 mm).
b. For joints at the top of vertical cylinders, the mastic or head

jacketing shall overlap the outside surface of the metal
jacketing, or flashing shall be used. The overlap, in any
case, shall be at least 3" (75 mm).
c. For joints at the bottom of vertical cylinders, the mastic or

head jacketing shall be installed under the jacket of the
cylinder.
d. In locations where mastic extends over the outside of metal

jackets or steel rings, etc., masking tape shall be used during
application of the mastic, and later removed to ensure an even
termination of the mastic.
4. Metal jackets shall be held in place with bands and selftapping

screws.
a. Bands shall be provided at each circumferential joint and at

least one intermediate location. Maximum spacing shall be 12
(305 mm).
b. Screws shall be used on longitudinal joints and for securing

flashing. Spacing shall not exceed 6 (150 mm).
5. On vertical piping and equipment, "S" clips shall be used to keep

jacket sheets from sliding. "S" clips shall be spaced at 12" (305
mm) intervals. No less than two clips shall be used per sheet.
6. "J" clips shall be used to support the bands on vertical piping and
equipment over 10' (3 m) in diameter. "J" clips shall be attached
to the jacket with self-tapping screws and shall be spaced about 6'
(1.8 m) apart.
E. Vessels and machinery nameplates and code inspection plates shall not be
covered with insulation. Insulation shall be beveled away from such
markings and sealed against water entry. Cavities created by the
absence of insulation over the nameplates, which are positioned so that
water, dust, or other matter may accumulate in them, shall be fitted
with removable plugs made from the insulation material. Such plugs
shall be clearly and permanently marked with the word "NAMEPLATE".
F. Typical insulation details are shown on the following pages. Deviation

from these sketches requires prior approval.
G. Thickness and heat loss values in Tables 1 through 4 are based upon
calcium silicate insulation with aluminum jacketing, 80F (27C) ambient
temperature and no wind. The economic thickness for heat conservation
was calculated based on an arbitrary fuel cost of $3/MMBTU and various
inflation and economic factors. The maximum calculated jacket
temperature for personnel protection is approximately 150F (65C). The
thickness specified in the tables shall be used regardless of the
insulation material selected. Where the thickness listed is not
commercially available, the next larger commercially available thickness
shall be used.






TABLE 1
HEAT CONSERVATION - ENGLISH UNITS
INSULATION THICKNESS AND HEAT LOSS
OPERATING TEMPERATURE (F)
Pipe Size 151- 201- 301- 401- 501- 601- 701- 801- 901- 1001- 1101-
(In.) 200 300 400 500 600 700 800 900 1000 1100 1200
0.5 th 1.5 1.5 1.5 1.5 1.5 1.5 2.5 2.5 2.5 2.5 2.5
hl 14 28 44 61 80 100 98 117 137 159 183
0.75 th 1.5 1.5 1.5 1.5 1.5 2.5 2.5 2.5 2.5 2.5 3
hl 16 32 50 67 92 89 109 130 153 177 191
1 th 1.5 1.5 1.5 1.5 1.5 2.5 2.5 2.5 2.5 3 3
hl 18 35 55 76 100 101 123 147 173 187 215
1.5 th 1.5 1.5 1.5 2 2 2.5 2.5 2.5 2.5 3 3
hl 22 44 68 78 102 117 143 171 201 216 248
2 th 1.5 1.5 1.5 2 2.5 2.5 2.5 3 3 3 3
hl 25 49 77 93 110 138 168 185 217 252 289
2.5 th 1.5 1.5 1.5 2 2.5 2.5 3 3 3 3 3
hl 26 51 80 98 117 147 179 214 252 269 309
3 th 1.5 1.5 1.5 2.5 2.5 2.5 3 3 3 3 4
hl 32 65 101 107 127 176 195 233 274 318 311
4 th 1.5 1.5 1.5 2.5 3 3 3 3 3 4 4
hl 39 77 120 125 146 184 225 269 316 314 360
6 th 1.5 1.5 2.5 2.5 3 3 4 4 4 4 4
hl 53 106 118 165 193 243 244 292 343 398 457
8 th 1.5 1.5 2.5 2.5 3 3 4 4 4 4 4
hl 64 128 139 194 227 286 292 349 411 477 547
10 th 1.5 1.5 2 3 3 4 4 4 4 4 4
hl 75 150 195 208 273 284 347 415 488 566 650
12 th 1.5 2 2.5 3 3 4 4 4 4 4 4
hl 87 144 193 238 312 323 394 471 555 644 739
14 th 1.5 2 2.5 3 4 4 4 4 4 4 4
hl 99 162 216 264 276 347 424 507 596 692 794
16 th 1.5 2 2.5 3 4 4 4 4 4 4 4
hl 111 181 241 294 306 385 471 563 662 769 883
18 th 1.5 2 2.5 3 4 4 4 4 4 4 4
hl 122 201 266 325 337 424 518 620 729 846 972
20 th 1.5 2 2.5 3 4 4 4 4 4 4 4
hl 134 220 292 356 368 462 565 676 795 923 1060
24 th 1.5 2 2.5 3 4 4 4 4 4 4 4
hl 159 259 343 417 429 540 659 789 928 1077 1237
30 th 1.5 3 4 4 4 4 4 4 6 6 6
hl 25 28 33 46 60 76 93 111 90 104 119
NOTES:
1. th = Nominal thickness of insulation (inches). Thicknesses listed on the last
line, labeled "30" shall be used for vessels, exchangers, and flat surfaces.
2. hl = Heat Loss, BTU/lin ft/hr for pipe sizes less than 30"; BTU/ft2/hr for
cylinders 30" diameter and for flat surfaces.
TABLE 2
PERSONNEL PROTECTION - ENGLISH UNITS
OPERATING TEMPERATURE (F)
Pipe Size 151- 201- 301- 401- 501- 601- 701- 801- 901- 1001- 1101-
(In.) 200 300 400 500 600 700 800 900 1000 1100 1200
0.5 th 1.5 1.5 1.5 1.5 2 2 2.5 2.5 3 4 5
hl 14 28 44 61 72 90 98 117 130 138 147
0.75 th 1.5 1.5 1.5 1.5 2 2.5 2.5 3 4 4 5
hl 16 32 50 70 81 89 109 122 130 151 161
1 th 1.5 1.5 1.5 1.5 2 2.5 3 4 4 5 5
hl 18 35 55 76 88 101 115 123 146 147 179
1.5 th 1.5 1.5 1.5 2 2 2.5 3 4 4 5 6
hl 22 44 68 78 102 117 133 141 185 176 194
2 th 1.5 1.5 1.5 2 2.5 3 3 4 5 5 6
hl 25 49 77 93 110 127 155 167 172 199 214
2.5 th 1.5 1.5 1.5 2 2.5 3 4 4 5 6 7
hl 26 51 80 98 117 135 144 172 183 204 219
3 th 1.5 1.5 1.5 2.5 2.5 3 4 5 5 6 7
hl 32 65 101 107 127 159 166 176 207 525 240
4 th 1.5 1.5 2 2.5 3 4 4 5 6 7 7
hl 39 77 102 125 127 157 192 202 221 237 272
6 th 1.5 1.5 2 2.5 3 4 5 6 6 7 8
hl 53 106 136 165 193 200 213 235 276 294 314
8 th 1.5 1.5 2 2.5 4 4 5 6 7 8 9
hl 64 128 166 194 159 239 154 277 297 319 343
10 th 1.5 1.5 2 3 4 5 5 6 7 8 9
hl 75 150 195 208 190 245 299 322 343 367 392
12 th 1.5 1.5 2 3 4 5 6 7 8 8 9
hl 87 173 224 238 226 277 303 328 354 410 437
14 th 1.5 1.5 2.5 3 4 5 6 7 8 9 9
hl 99 197 216 264 257 303 325 350 377 406 465
16 th 1.5 1.5 2.5 3 4 5 6 7 8 9 9
hl 111 221 241 294 306 336 359 385 414 444 510
18 th 1.5 1.5 2.5 4 4 5 6 7 8 9 10
hl 122 245 266 258 337 369 392 421 451 483 516
20 th 1.5 1.5 2.5 4 4 5 6 7 8 9 10
hl 134 269 292 281 368 402 426 456 487 521 556
24 th 1.5 1.5 2.5 4 4 5 6 7 8 9 10
hl 159 318 343 328 429 467 493 525 560 596 635
30 th 1.5 1.5 2.5 4 4 5 6 7 8 9 10
hl 25 49 50 46 61 62 64 66 68 71 73
NOTES:
1. th = Nominal thickness of insulation (inches). Thicknesses listed on the last line,

labeled "30" shall be used for vessels, exchangers, and flat surfaces.
2. hl = Heat Loss, BTU/lin ft/hr for pipe sizes less than 30"; BTU/ft2/hr for cylinders
30" diameter and for flat surfaces.
TABLE 3
HEAT CONSERVATION - METRIC UNITS
OPERATING TEMPERATURE (C)
Pipe Size 66- 94- 150- 205- 261- 317- 372- 428- 483- 539- 594-
(In.) 93 149 204 260 316 371 427 482 538 593 649
0.5 th 40 40 40 40 40 50 65 65 65 65 65
hl 15 29 46 63 83 104 100 122 143 165 190
0.75 th 40 40 40 40 50 65 65 65 65 65 75
hl 17 33 52 70 96 93 113 135 159 184 199
1 th 40 40 40 40 50 65 65 65 65 75 75
hl 19 36 57 79 104 105 128 153 180 195 224
1.5 th 40 40 40 50 65 65 65 65 65 75 75
hl 23 46 71 81 106 122 149 178 209 225 258
2 th 40 40 50 65 65 65 65 75 75 75 75
hl 26 51 80 97 114 144 175 193 226 262 301
2.5 th 40 40 50 65 65 65 75 75 75 75 75
hl 27 53 83 100 122 153 186 223 262 280 322
3 th 40 40 50 65 65 65 75 75 75 75 100
hl 33 68 105 111 132 183 203 242 285 331 324
4 th 40 40 50 65 75 75 75 75 100 100 100
hl 41 80 125 130 152 191 234 280 329 327 375
6 th 40 50 65 65 75 75 100 100 100 100 100
hl 55 110 123 172 201 253 254 304 357 414 476
8 th 40 50 65 65 75 75 100 100 100 100 130
hl 67 133 145 202 236 298 304 363 428 496 569
10 th 40 50 65 75 75 100 100 130 130 130 130
hl 78 156 203 216 284 296 361 432 508 589 676
12 th 40 50 65 75 75 100 100 130 130 130 130
hl 91 150 201 248 325 336 410 490 578 670 769
14 th 50 65 65 75 100 100 130 130 130 130 130
hl 103 169 225 275 287 361 441 528 620 720 826
16 th 50 65 65 75 100 100 130 130 130 130 130
hl 116 188 251 306 318 401 490 586 689 800 919
18 th 50 65 65 75 100 100 130 130 130 150 150
hl 127 209 277 338 351 441 539 645 759 880 1012
20 th 50 65 65 75 100 100 130 130 130 150 150
hl 139 229 304 370 383 481 588 703 827 961 1103
24 th 50 65 65 75 100 100 130 130 130 150 150
hl 165 270 357 434 446 562 686 821 966 1121 1287
30 th 50 75 100 100 100 100 130 130 130 150 150
hl 26 29 34 48 62 79 97 116 94 108 124
NOTES:
1. th = Nominal thickness of insulation (millimeters). Thicknesses listed on the
last line, labeled "30" shall be used for vessels, exchangers, and flat surfaces.
2. hl = Heat Loss, W/m for pipe sizes less than 30"; W/m2 for cylinders 30" diameter
and for flat surfaces.
TABLE 4
PERSONNEL PROTECTION - METRIC UNITS
OPERATING TEMPERATURE (C)

Pipe Size 66- 94- 150- 205- 261- 317- 372- 428- 483- 539- 594-
(In.) 93 149 204 260 316 371 427 482 538 593 649
0.5 th 40 40 40 40 50 50 65 65 75 100 125
hl 15 29 46 63 75 94 100 122 135 144 153
0.75 th 40 40 40 40 50 65 65 75 100 100 125
hl 17 33 52 73 84 93 113 127 135 157 168
1 th 40 40 40 40 50 65 75 100 100 125 125
hl 19 36 57 79 92 105 120 128 150 153 186
1.5 th 40 40 40 50 50 65 75 100 100 125 150
hl 23 46 71 81 106 122 138 147 193 183 202
2 th 40 40 40 50 65 75 75 100 125 125 150
hl 26 50 80 97 114 132 161 174 179 207 223
2.5 th 40 40 40 50 65 75 100 100 125 150 175
hl 27 53 83 102 122 140 150 179 190 212 228
3 th 40 40 40 65 65 75 100 125 125 150 175
hl 33 68 105 111 132 165 173 183 215 546 250
4 th 40 40 50 65 75 100 100 125 150 175 175
hl 41 80 106 130 132 163 200 210 230 247 283
6 th 40 40 50 65 75 100 125 150 150 175 200
hl 55 110 142 172 201 208 222 245 287 306 327
8 th 40 40 50 65 100 100 125 150 175 200 225
hl 67 133 173 202 165 249 160 288 309 332 357
10 th 40 40 50 75 100 125 125 150 175 200 225
hl 78 156 200 216 198 255 311 335 357 382 408
12 th 40 40 50 75 100 125 150 175 200 200 225
hl 91 180 233 248 235 288 315 341 368 427 455
14 th 40 40 65 75 100 125 150 175 200 225 225
hl 103 205 225 275 267 315 338 364 392 423 484
16 th 40 40 65 75 100 125 150 175 200 225 225
hl 116 230 251 306 318 350 374 401 431 462 531
18 th 40 40 65 100 100 125 150 175 200 225 250
hl 127 255 277 268 351 384 408 438 469 503 537
20 th 40 40 65 100 100 125 150 175 200 225 250
hl 139 280 304 292 383 418 443 475 507 542 579
24 th 40 40 65 100 100 125 150 175 200 225 250
hl 165 331 357 341 446 486 513 546 583 620 661
30 th 40 40 65 100 100 125 150 175 200 225 250
hl 26 50 52 48 63 65 67 69 71 74 76
NOTES:
1. th = Nominal thickness of insulation (inches). Thicknesses listed on the last
line, labeled "30" shall be used for vessels, exchangers, and flat surfaces.
2. hl = Heat Loss, W/m for pipe sizes less than 30"; W/m2 for cylinders 30" diameter
and for flat surfaces.

REV: 1

D-6 Notes to Detail Engineering Contractor and Vessel Fabricator for the Coke
Drums,
126158-4-11-001 Rev.A
______________________CONFIDENTIAL_____________________
USED,

Job Specification 126158-82A3 Insulation of Coke Drum

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SOCAR & TURCAS AEGEAN Refinery (STAR) REF: 13-126158-02

Delayed Coker Unit 190 DATE: Dec. 15, 2010

APPENDIX D JOB SPECIFICATIONS

D-1 Insulation of Coke Drums, 126158-82A3 Rev.1

INSULATION OF COKE DRUM

Revision Number Log

1 23RD AUG 2010 RP/TC 19 SD Issued for Client Review

II. INSULATION MATERIALS 4

III. INSTALLATION OF INSULATION 6

IV. INSULATION DETAILS 9

PAGE REV DATE REASON FOR REVISION

* Asterisk represents pages revised for this issue.

Special requirements of coke drum insulation include the following items:

- For routine inspection of critical circumferential welds, use of removable insulation

II. INSULATION MATERIALS

Metal jacketing for weatherproofing shall have a factory-applied moisture barrier

1. Insulation on the cylindrical section of the drums shall be weatherproofed using

F. Sheet Metal Screws

K. Mastic sealer shall be asbestos free Childers Chil-Joint CP-70 or equal.

III. INSTALLATION OF INSULATION

1. Blanket insulation shall be installed in 2 layers. Seams in the layers shall be

1. Jacketing on the cylindrical on the cylindrical section of the vessel shall be

1. When complete, jacketing shall present a neat appearance with no buckling.

3. Contact between aluminum jacketing and vessel steel shall be avoided.

4. Flashing rings shall be installed on all nozzles to prevent infiltration of water.

IV. INSULATION DETAILS

APPENDIX D JOB SPECIFICATIONS (Continued)

D-2 Painting, 126158-83A1 Rev.1

Revision Number Log

1 23RD AUG 2010 UVP/TC 23 SD Issued for Client Review

IV. SURFACE PREPARATION 8

VI. PAINTING OF PREVIOUSLY PAINTED SURFACES (MAINTENANCE PAINTING) 12

VII. FIELD PROTECTION, CLEANUP & INDUSTRIAL HYGIENE 13

IX. SELECTION OF PAINT 15

TABLE A - PAINT SYSTEMS 17

TABLE B - PRIMER MATERIALS 19

TABLE C INTERMEDIATE & FINISH MATERIALS 20

TABLE D ADDITIONAL EXAMPLES OF PAINT SELECTION 22

REASON FOR CHANGES: 23

PAGE REV DATE REASON FOR REVISION

Entire JOB SPEC is projectised.

* Asterisk represents or will represent pages revised for this issue.

A. This specification outlines the general requirements for the external

C. This specification does not specify paint systems above 1000oF. If

D. This specification specifies shop application of primers and finish

E. Vessels fabricated overseas shall also be painted unless waived by the

E. Paint systems, including surface preparation, paint materials,

F. The vendor or Contractor shall advise FWUSAC, in writing, of any

G. latest editions of any federal, state or local codes, regulations,

1. Occupational Safety and Health (OSHA) Standards

B. Steel Structures Painting Council (SSPC) Manual

1. Volume 2, Systems and Specifications

a. SSPC-PA1, Shop, Field and Maintenance Painting

2. Vis 1, Pictorial Surface Preparation

C. National Association of Corrosion Engineers (NACE) Publications

a. No. 1, White Metal Blast Cleaning

A. Painting of steel surfaces shall be performed in accordance with

B. Surface preparation of steel surfaces shall be in accordance with SSPC

C. Where manufacturer's instructions or those in SSPC-PA1 are given in

D. The following surfaces shall not be painted:

E. Shop fabricated equipment, towers, vessels, structural steel,

F. The general contractor shall be responsible for properly handling and

G. Damaged areas of the coating system shall be repaired after erection

J. If over 60 days old, the prime coat shall be inspected by FWUSAC to