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1. GENERAL
1.1 Scope
a. This Standard Specification covers the general requirements for external insulation and
weathershielding applied to equipment and piping operating from 70°F (20°C) through
1500°F (815°C). Selection of the insulation system and its attachment method shall be the
responsibility of the Owner/Contractor, consistent with the requirements of UOP Project
Specifications.
c. Exceptions or variations shown in the UOP Project Specifications take precedence over the
requirements shown herein.
1.2 References
Unless noted below, use the edition and addenda of each referenced document current on the
date of this Standard Specification. When a referenced document incorporates another
document, use the edition of that document required by the referenced document.
Form QUA-03-2
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Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
(11) C 533 “Standard Specification for Calcium Silicate Block and Pipe Thermal
Insulation”.
(14) C 553 “Standard Specification for Mineral Fiber Blanket Thermal Insulation
for Commercial and Industrial Applications”.
(15) C 585 “Standard Practice for Inner and Outer Diameters of Rigid Thermal
Insulation for Nominal Sizes of Pipe and Tubing (NPS System)”.
(16) C 592 “Standard Specification for Mineral Fiber Blanket Insulation and
Blanket-Type Pipe Insulation (Metal-Mesh Covered) (Industrial
Type)”.
(17) C 610 “Standard Specification for Molded Expanded Perlite Block and Pipe
Thermal Insulation”.
(18) C 612 “Standard Specification for Mineral Fiber Block and Board Thermal
Insulation”.
(19) C 647 “Standard Guide to Properties and Tests of Mastics and Coating
Finishes for Thermal Insulation”.
(20) C 795 “Standard Specification for Thermal Insulation for Use in Contact
with Austenitic Stainless Steel”.
Form QUA-03-2
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Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
b. American Petroleum Institute (API) Recommended Practice (RP) 521, “Guide for
Pressure-Relieving and Depressuring Systems”.
1.3 Definitions
2. DESIGN
b. Equipment and piping with a bare metal temperature above 140°F (60°C) and that do not
require insulation for heat conservation shall be provided with personnel protection.
c. The outer surface temperature of insulation system(s) shall not exceed 140°F (60°C) within
the envelope defined in Section 2.1.a.
d. Where the operating temperature is 250ºF (120ºC) or less and personnel protection is
required, protection shall be by barriers, shield, or open guards, not insulation.
Form QUA-03-2
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Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
The rate of heat loss per unit area through the selected insulation system(s) shall be limited to
the values specified below:
a. Equipment
(1) Equipment shall be insulated for the highest operating temperature listed in the UOP
Project Specifications. For compressors and exchangers, use the higher of the inlet
or outlet temperature.
(2) Steam turbines shall be insulated for the maximum operating temperature of the
steam supply listed in the UOP Project Specifications.
b. Piping
(1) With the exception of steam supply, exhaust, and condensate, piping shall be
insulated for the highest operating temperature of the connected equipment. The
temperatures are listed in the UOP Project Specifications.
(2) Steam supply, exhaust, condensate piping and flanges, including valve body to
bonnet flanges, shall be insulated for the maximum operating temperature listed in
the UOP Project Specifications. Lines exhausting to atmosphere do not require
insulation.
a. Equipment and piping requiring insulation for process reasons are indicated on the UOP
Piping and Instrument Diagrams (P&ID’s).
b. Manways and exchanger heads shall be insulated with easily removable and reusable
insulation system(s).
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
d. Expansion joint bellows, ball joints, strainers, steam traps, and valve packing glands shall
not be insulated.
e. Insulation shall be applied so that there is no interference with either the operation or
function of the equipment, instrument, or valves. Gauges, dials, sightglasses, etc. shall
remain unobstructed and in clear view.
f. External stiffening rings on vessels and piping shall be insulated with the same thickness as
required for vessels or piping. The entire stiffening ring shall be maintained at the same
temperature as the shell.
g. An air space, as defined in Figure 1, is required at vessel to skirt connections when the
operating temperature of the vessel exceeds 700°F (370°C) or is greater than 500°F
(260°C) with a wall thickness greater than 2 inches (50 mm).
h. Insulation shall be applied behind the nameplate mounting bracket(s) but insulation shall
not cover the nameplate.
a. General
(1) Flanges, including valve body to bonnet flanges, on insulated process lines or
equipment with an operating temperature over 800°F (425°C) shall not be insulated.
(2) Flanges in toxic, or severe cycling services as defined in ASME B31.3, Paragraph
300.2 shall not be insulated.
(5) Provide adequate space for removal of flange bolting without damage to the
surrounding insulation. Void areas are to be packed with a mineral fiber
insulation.
(6) Heat traced flanges for hydrogen, toxic, and severe cyclic services shall be
insulated but shall meet the requirement of Paragraph 2.5.b.(1).
(1) For hydrocarbon and other hazardous services, a flange leak detection system shall
be provided. The use of sniffers shall be determined on a case by case basis
consistent with local laws and codes.
(2) Insulation systems around flanged joints shall be provided with 1/2 inch (12 mm)
drain and vent tubes ("telltales"). The drains and vents shall be piped to a safe
location.
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
(3) The design shall permit removal of the insulation system and flange bolting without
damage to the insulation.
(4) Bolting materials shall be suitable for the insulated flange maximum operating
temperature, considering stress, strain, and creep.
(5) Flanges with spectacle blinds shall be provided with flexible type removable and
reusable insulation systems.
c. Weathershielding
(1) Requirements for weathershielding are indicated on the UOP P&ID's and UOP
Project Specifications.
Insulation for steam and electric heat tracing shall be in accordance with UOP Project
Specifications. The equipment and pipe insulation may be oversized to accommodate the
tracer(s).
Credit for the insulation may be considered for evaluation of the fire exposure relief case of
equipment and piping. Where this credit is taken, the insulation thickness and other
requirements shall be in accordance with API RP 521, Section 3.15.5.
Where noise reduction is needed, a composite system of a sound absorber and sound barrier
shall be utilized. For more effective treatment, multiple layers of the composite system shall
be used, resulting in a decoupled barrier system. Securement shall be by glass reinforced
adhesive tape. No screws or “Z” clips are permitted.
2.9 Weatherproofing
3. MATERIALS
3.1 Insulation
(1) Mineral fiber thermal insulating cement in accordance with ASTM C 195.
(2) Mineral fiber hydraulic setting thermal insulating and finishing cement in
accordance with ASTM C 449/C 449M.
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
(3) Calcium silicate block and pipe thermal insulation in accordance with
ASTM C 533.
(6) Mineral fiber blanket thermal insulation in accordance with ASTM C 553.
(8) Molded expanded perlite block and pipe thermal insulation in accordance with
ASTM C 610.
(9) Mineral fiber block and board thermal insulation in accordance with ASTM C 612.
(10) High temperature fiber blanket thermal insulation in accordance with ASTM C 892.
c. Thermal insulation and accessories to be used in contact with austenitic stainless steel
surfaces shall be in accordance with ASTM C 795.
d. Inner and outer diameters of rigid insulation for piping and tubing shall be in accordance
with ASTM C 585.
e. Insulation used for fire exposure or as part of a fireproofing system shall function
effectively, retaining its integrity and insulating value, when exposed to fire temperatures
and duration in accordance with API RP 521, Paragraphs 3.15.5.2 through 3.15.5.4 for up
to two hours. The insulation shall also resist dislodgment by fire water streams.
f. Consideration shall be given to select the insulation materials to be used for wet (e.g.
coastal) locations where moisture absorption is a concern. The typical rankings for
resistance to moisture from best to worst are cellular glass, perlite, mineral wool, and
calcium silicate.
g. Insulation in areas subjected to abuse shall be selected considering its ability to resist
damage. The typical ranking for resistance to damage from best to worst are calcium
silicate, perlite, cellular glass, mineral wool and glass fiber.
h. Insulation materials and vapor barriers for weatherproofing shall have a maximum flame
spread of 25 in accordance with ASTM E 84.
i. Joint sealers and flashing compounds shall be non-shrinking and permanently flexible.
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
a. General
(1) Jacketing material shall be stainless steel, zinc or aluminum coated steel, or
aluminum in accordance with ASTM C 921.
(2) Stainless steel or steel jackets are required on any insulation system where insulation
is considered to be in place for the relief valve fire exposure design case, or is a part
of a fireproofing system.
(3) Stainless steel or steel jackets are required in areas subject to severe mechanical
damage.
(4) Jacketing shall be provided with a heat laminated factory-installed moisture barrier.
(5) Jacketing for exposed heads of vessels and tanks shall be fabricated from stucco
embossed sheet and either a multi-segmented or single piece tapered type
installation. Edges shall be overlapped with a bead of flexible joint sealant applied
on the lap.
(6) 3/16 inch (5 mm) pitch corrugated or crimped jacketing shall be used on piping over
24 inches in diameter and horizontal vessels, exchangers, and equipment. Flat or
smooth jacketing may be used on piping through 24 inches in diameter, and on
equipment heads.
(7) 1-1/4 inch (32 mm) pitch corrugated or crimped jacketing shall be used on vertical
vessels and storage tanks.
(8) Circumferential corrugations shall be used for services subject to severe mechanical
damage.
(1) Stainless steel jacketing materials shall be in accordance with ASTM A 240, Type
304 or 316.
(2) Aluminum jacketing materials shall be in accordance with ASTM B 209/ B 209M,
Type 3003-H14 or 5005-H14.
(4) Zinc coated steel jacketing materials shall be in accordance with ASTM A 653/
A 653M.
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Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
(5) 55% aluminum alloy-coated steel materials (hot dipped) shall be in accordance with
ASTM A 792.
a. Mastic and coating finish materials shall be in accordance with ASTM C 647.
c. Weatherproofing shall be asbestos-free, non-corrosive whether wet or dry, and suitable for
application to the substrate surface.
4. APPLICATION
4.1 General
a. Insulation contractor shall have previous experience with the materials, insulating system,
and installation procedures to be used.
b. Insulation and weatherproofing shall only be applied on dry and clean surfaces.
c. Weld seams, flanged and threaded connections, and “telltale” holes shall not be insulated
until pressure and leak testing, non-destructive examination, and heat treatment are
completed.
d. Valves, gauges, piping, etc. shall be inspected, tested and repaired prior to application of
insulation.
e. Working parts of valves and other mechanical equipment shall be protected when
insulation is applied.
f. Insulation systems for equipment and piping shall permit access to parts requiring
maintenance without damaging the insulation system.
g. The insulation system shall accommodate expansion and contraction of equipment and
piping.
4.2 Insulation
a. Materials shall be kept dry. Insulation showing any evidence of moisture exposure shall
not be used.
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
c. Insulation shall conform to the contour of the item to be insulated. Before applying
weatherproofing, the insulation shall be inspected for open joints, voids, cracks, and
defacing. Insulation with open joints, voids, and cracks shall be completely removed,
replaced, and resealed. Defaced insulation shall be filled with sealing compound.
d. A single layer of insulation shall be used up to 3 inches (75 mm) thick. Over 3 inches (75
mm), the insulation may be applied in single or multiple layers. Minimum thickness of
insulation shall be 1½ inch (40 mm).
e. The bottom 3 feet (900 mm) of tank shells shall be insulated with cellular glass or
expanded perlite.
g. When applying multi-layer insulation, each succeeding layer shall be staggered relative to
the longitudinal and circumferential joints of the preceding layer.
h. The inner layers of multiple-layer insulation and insulation on irregular equipment surfaces
(where use of bands and seals is impractical) shall be secured using stainless steel wire.
The wire shall be taut and embedded in the insulation. The ends shall be bent over and
embedded into the insulation.
b. Jacketing shall be installed with a minimum lap of 3 inches (75 mm) for circumferential
joints and the greater of 3 inches (75 mm) or two corrugations for longitudinal joints.
Jacketing shall overlap mastic weatherproofing coatings by a minimum of 3 inches (75
mm). Each lap shall be filled with a sealer.
c. Jacketing for vertical piping and equipment shall be installed starting at the bottom and
working upward. Corrugated sheets shall be applied with the corrugations positioned
vertically, except as noted in paragraph 3.2.a (8), and supported at the horizontal joints by
components fabricated from stainless steel. Vertical joints shall be staggered between
courses.
d. Jacketing shall be secured with stainless steel bands. Bands shall cover seams between
sections of jacketing. Breather springs shall be used where required for expansion and
contraction.
Form QUA-03-2
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Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
a. For valves, fittings, and other irregular surfaces, mastic coating with reinforcing fabric may
serve as the weatherproofing. In abused areas metal jacket weatherproofing shall be
provided.
b. Spheres, tanks, pumps, and compressors shall be weatherproofed with reinforcing fabric
and mastic weatherproofing.
a. Health and safety concerns associated with thermal insulation materials, accessories, and
their application shall be evaluated in accordance with ASTM C 930.
b. Handling, transporting, and application of thermal insulation materials and accessories for
use in contact with austenitic stainless steel shall be in accordance with ASTM C 929.
Form QUA-03-2
Revision
Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
Form QUA-03-2
Revision
Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
Form QUA-03-2
Revision
Indication STANDARD SPECIFICATION
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UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
Form QUA-03-2