INSULATION INSTALLATION PROCEDURE

1. OBJECTIVE
This procedure outlines site installation inspection work items that are to be carried out
by Quality Control Inspector of insulation installation in a project to ensure all standard
requirements, project or CLIENT requirements are met.

2. SCOPE
This procedure outlines minimum requirements of insulation installation for
“…………………………” Project.

3. RESPONSIBILITY
3.1 The QA/QC Coordinator at site is responsible in ensuring all inspection items outlined
in this procedure be carried out in professional manner at site. He shall monitor and
assist/support the Related Inspectors at project construction site in performing the
inspection work outlined in this procedure also report directly and being consulted
by the QC Manager on quality control procedures, methods and application.
3.2 Inspector have responsible to perform the inspection work outlined in this procedure
at project construction site.
3.3 Coordination Construction Superintendent, Engineer in Charge and CLIENT inspector
at site is required.

4. DEFINITION
The following words shall have the meaning indicated when used herein:
PROJECT : …………………
CLIENT : …………………
CONTRACTOR : PT. …………………. Engineering, Procurement and Construction Company
selected by CLIENT to perform the detailed design engineering,
procurement and construction.

5. REFERENCE
The following standards and references shall become part of this procedure and contains
detailed requirements on quality and acceptance criteria’s.
 ……. : Inspection and Test Plan (ITP) for Piping Work
 ……. : General Specification for Hot Insulation
 Manufacture’s or Vendor’s Instruction manual of installation including relevant
drawings (hereinafter called “Instruction Manual”)
6. INSULATION PROCEDURE

6.1 General Requirement

 Insulation shall be fitted on the piping and equipment according to the operating
temperature and insulation thickness as specified in the line list and the
equipment insulation schedule.
 All insulation materials shall be free of fluorocarbons, chlorides, asbestos and shall
be water tight/water repellent.
 All insulation materials shall have a neutral pH value, and shall be compatible with
the substrate paint systems specified in S-00-1360-504 (General Specification for
Painting, Coating, and Wrapping).

6.2 Preparation
 Equipment, vessels and piping requiring insulation shall be cleaned, dry and
coated in accordance with approved surface preparation and painting. All NDE and
pressure testing shall be successfully completed before any insulation is applied.
 Surfaces to be insulated shall be free from oil, grease, loose, scale or other foreign
matter before applying insulation.
 All equipment, vessels and piping shall have been tested and inspected as required
by the relevant specification prior to the installation of insulation.
 Insulation support rings, pins, clips, studs, and accessories shall be of materials
compatible with the components to which they are attached and if welded, shall
be installed by the fabricator prior to post weld heat treatment unless specifically
permitted by client.
 Nameplates shall not be insulated and shall be attached with extended brackets
to give adequate clearance for full insulation thickness.
 Manufacturer’s instructions and recommendations of insulation and vapor barrier
manufacturer’s shall be followed.
 Insulation work shall be completed in a neat and workman-like manner.

6.3 Storage
 All insulation materials shall be stored and maintained in covered, weather
protected areas above floor level and stacked in manner to prevent damage.
 Insulation materials shall be stored and maintained in a dry condition. Any
Insulation that is wetted or damaged must be discarded and replaced.
6.4 Application
 Insulation shall not be applied to damp surfaces.
 Protective measures shall be taken to prevent moisture from working underneath
or into partially applied insulation.
 Tie wire and/or band shall be drawn taut to embed them into the insulation face
with ends firmly twisted. Bands shall be jig stretched and sealed under tension.

6.5 Insulation Material

6.5.1 ??
Refer to General Specification for Hot Insulation
 properties of insulation material
……..
……..

6.5. ?? Removable Insulation

 All removable insulation assemblies shall as a minimum, be capable of
surviving in the required temperature range and environment in which
the system is to use.
 Removable insulation assemblies shall be durable and suitable for quick
removal, re-installation and shall be certified by Contractor as suitable for
the specific service conditions. All material parts used shall be grade 316
stainless steel or higher grade.
 The Assembly shall snugly fit the item it covers and all joints and opening
shall overlap the adjacent insulation and be weather tight and deluge
proof.
 Generally flexible custom made blankets shall be used. The flexible
blanket shall have an inner and outer liner to fully enclose the insulation,
and be resistant to diluted chemicals, detergents and hydrocarbons.
 For insulation thickness greater than 51mm, the liner shall include curved
gussets to ensure that the blanket conforms to the insulated item without
force or bending.
 The design and fabrication of the blanket shall ensure that the insulation
material will not sag or compress over time or due to repeated removal,
causing a reduction in the insulation properties of the blanket. The
blanket shall have its closing seam at the gravitational low point to permit
drainage of condensed water and process fluid leak detection. The
insulation material will be selected to meet or exceed the adjacent
 insulation system for the following properties: combustibility, service
temperature, water/vapor permeability and absorption.
 Each flexible insulation assembly shall be provided with an identification
plate, permanently attached to the assembly.

6.5. ?? Cladding
Refer to General Specification for Hot Insulation  material properties
……..
……..
6.5. ?? …………………….
Refer to General Specification for Hot Insulation
……..
……..

7. INSULATION ASSEMBLY
 Application of the insulation shall not commence until all equipment, piping flanges,
valves or fittings requiring hydraulic tests have been tested for leakage and made
tight, in practical terms this means that piping spools shall not be insulated until
hydro tests have been completed and flange joints and valves shall not be insulated
until leak testing have been completed, unless removable flanges and valve boxes are
fitted.
 Valves, flanges, and nozzles of piping and equipment shall be insulated, unless
otherwise stated. All surfaces which are to be insulated, shall be cleaned free of all
dirt and grease and construction dust, and shall be perfectly dry and any mechanical
damages on paint to be repaired as per procedure and contractor to arrange
inspection with all trades involved to proceed before application of the insulation.
 Insulated flanges, fittings, valves and pipe support shall be provided with removable
non-metallic weatherproofing shield cladding.
 The stuffing box gland or valves handle shall be kept outside of the insulation of
cladding. Insulation with the same thickness as that used for the piping shall be
secured to the inside of the boxes. The stuffing shall be secured inside the boxes by
hooks made from metal strips, or similar. Overlapping edges of the cladding shall be
furrowed and sealed with sealant.
 For all covers, e.g. of heat exchangers and manholes, liable to comparatively frequent
removal, a box shall be made from metal sheet and lined with insulation to secure
the cover in position around protruding parts of vessels e.g. nozzles, brackets, cleats,
stack saddle, shall be sealed using adhesive to prevent moisture intrusion.
Mechanical methods such as banding or wiring are not permitted.
  Vertical surfaces over 400 mm shall be provided with angular support rings: for rigid
insulation the rings shall be spaced at intervals of 2-4m and shall form a break in the
insulation to allow wall expansion.
 For flexible insulation the rings shall be spaced at intervals of approximately 2 m.
 Where possible, all equipment shall have insulation supports supplied by the
equipment fabricators prior to delivery or during erection at site.
 All insulated equipment and piping shall be weatherproofed with non-metallic
material sheet. The sheets shall be in both longitudinal and circumferential direction
with a minimum overlap of 50 mm and sealed using sealant.
 Insulation shall be applied in the minimum number of layers. All joints in the
insulation between successive layers and also between adjacent sections of
insulation shall be staggered.
 Where insulation is applied in more than one layer the inner layer and final layer
should be glued over the entire surface.
 Galvanized steel materials shall not be used for insulation of piping or equipment.
 Insulation must be wrapped in plastic covers after application until the cladding can
be applied to keep insulation materials dry.
 Before application of any insulation finish, the surface of the insulation shall be made
reasonably smooth and shall present a neat appearance.
 When necessary pumps and other equipment shall be insulated using removable
prefabricated covers in accordance with vendor’s instruction and the equipment
insulation schedule.
 For all insulation systems for equipment there shall be 15mm diameter drain holes in
all low points, and a minimum of one hole every 3 meters on horizontal runs. The
drainage hole shall be provided in such a manner that water cannot enter into the
internals of the cover and saturate the insulation material. The drainage holes shall
have silicone mastic between the reinforced ring and the silicone rubber sheets on
both sides of the jackets. Each tailor made jackets shall be provided with a hole for
drainage at its low point.

8. INSULATION APPLICATION
8.1 Insulation thickness
Refer to General Specification for Hot Insulation
………………..
 Man-ways, valves, flanges and stiffening rings on vessels and heat exchangers shall
not be insulated unless specifically required by the equipment insulation schedule.
It is preferred that removable type insulation boxes to be fabricated and installed
on Manways, valves & flanges on vessels.
  Valves and flanges in piping shall be insulated.
 Heat exchanger surfaces shall be provided where possible with protective
insulation plates or where this is not possible or practical provided with warning
signs.

8.2 Personnel protection

Refer to General Specification for Hot Insulation
………………..
9. INSULATION METHOD
 Methods of testing and inspection shall be in accordance with the requirements
of the applicable codes and standards stated in General Specification for Hot
Insulation.
 All quality records and report shall be accepted by CONTRACTOR. QC and the
client representative.
 Material inspection for client approved product.
 The Insulation metal jacketing shall be visually inspected for voids, cracked
segments, open joints etc. to ensure compliance with the requirements with this
procedure. All quality inspection records shall be coincident with the insulation
construction.
 The insulation metal jacketing shall be visually inspected for voids, cracked
segments, open joints etc. to ensure compliance with the requirements with this
procedure.
 The recorded information shall be real and reliable.
 Inspection shall be done as per approved ITP and relevant check lists shall be
signed off.

10. HEALTH AND SAFETY

 MSDS for all materials, chemicals and substances that are knows to be hazardous
to health.
 Removal and or disturbance of existing insulation shall not proceed without Client
approval.
 PPE compliance shall be adhered as per the Client Standard.
 Induction training and periodical specific training shall be imparted to all the
employees working at site.
 The equipment used for insulations works will be inspected by Safety Supervisor
and color coding as per the Client recommendations shall be adhered.