Hot & Cold Insulation Construction Standard

Eng No. :
Ver. : 1.0
Page: 1/ 10
Hot & Cold Insulation Construction Standard
Index
Document Revision
Table 2/ 10
I. Project Name 3/10
2. Construction Area 3/10
3. Construction Date 3/ 10
4. Construction and Delivery Place 3 /l 0
5. Related Document. 3/ 10
6. Purpose of Hot & Cold Insulation 3 /l 0
7. Requirements of Hot & Cold Insulation 3 /l 0
8. Construction of Hot Insulated Equipment.. 5/ 10
9. Construction of Hot Insulated Piping 6/ 10
10. Construction of Cold Insulated Equipment 8/ 10
II. Construction of Cold Insulated Piping 9 /l 0
12. Appendix 10/10
12.1. Construction Drawings of Hot & Cold Insulation 10 /l 0
Shine Yen Corporation
Hot and Cold Insulation Standard
Eng. No.:
Ver:l.O Page:2/l0
Document Revision Table
Revised No.
o
Revised Date
21/04/1997 1. New Ver.
?
Revised Content
Shine Yen Corporation
Eng. No.:
Hot and Cold Insulation Standard
Ver:l.O Page:3/l0
1. Project Name
2. Construction Area
3. Construction Date
From Day Month Year, till__Day__Month__Year
4. Construction & Delivery Place
5. Related Documents
5.I.(KSE-05)In/Out Plant Work Procedure
5.2.(KSE-S5)Public Security Work Instruction Prior to Contractor's Construction
5.3 .(KSE-S 1)Hot Work Control Procedure
6. Purpose of Hot (Cold) Insulation
6.I.Saving Energy to prevent any fluid heat loss inside the equipment or pipes.
6.2. To make the operation stable and simple; the manufacturing process steady and
balanced.
6.3.To ensure the sensibility of the equipment without any influence from outdoor
temperature difference.
6.4.Guarantee the personnel protection.
6.5.0ther specific purpose.
7. The General Requirements of Hot (Cold) Insulation
7.1. The hot (cold) insulation contractor should propose the construction schedule
before kick-off so that we can control the engineering schedule in hand.
7.2.The equipment contractor with materials and equipments should fill in the
"supplier tools list" before entering our company. With the signatures and
approval of engineering department and guards, the contractor can carry out the
tools from our plant.
7.3.During the equipment contractor's work, they should follow "the Work Safety
Instruction" by our company and assign a supervisor on site to charge of the
quality control, safety maintenance on site and communications.
7.4.The contractor can start to construct and hot work after the approval of the
safety department and the permission form of safe work during the construction.
7.5.All the hot( cold) insulation materials should comply with CNS or JIS standard
no matter provided by our company or contractor.
I II f r h 7.5.1. T e qua ltv requests 0 water-repe ent millera woo :
Density Fiber Dia. Shot Thermal Conductivity Water Chloride
(kg/m
3
) (f.l m) Content (kcal/mhrC) Repellent Ion (ppm)
(%) (Testing Temp. 705C) (%)
Mineral > 120 <7 ":;4 ,,:; 0.039 > 98 <50
Wool
Pipe
Mineral > 100
Wool
Board
7.5.2. The quality requests of PIR
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Shine Yen Corporation Eng. No.:
Hot and Cold Insulation Standard Ver: 1.0 IPage:4/1 0
Density Closed Absorption Thermal Conductivity Permeability Flammability
(kg/m
3
) Cell (g/cm
2
) (kcal/mhrC) (glm
2
h.mmHg)
Content
(Testing Temp. 705C)
(%)
> 35
Self extinguish
> 95 <0.02 < 0.0174 < 0.09 time< 20
sec ' burning
length < 30mm
fPU f r 753 The qua ltv requests 0 oam
Density Compressive Absorption Thermal Permeability Flammability
(kglm
3
) Strength
(g/cm
2
) Conductivity (g/m
2
h.mmHg)
(kg/cm
2
) (kcal/mhrC)
(Testing Temp.
305C)
Self extinguish
> 35 >2 < 0.02 < 0.021 < 0.06 time < 30sec '
burning length s;:
40mm
The contractor should start construction of hot (cold) insulation after equipment or
pipes pressure testing and painting. Unless the emergency of the project, the space
for nozzles, flanges and valves should be left before hot (cold) insulation pressure
test. After pressure test passes, the construction can be started.
7.6.Before hot(cold) insulation construction, the surfaces of equipment and pipes
should be clean without any grease or any other substances of the like and
moisture by cotton cloth.
7.7. When the scaffoldings for hot (cold) insulation are needed, the contractor
should make sure the firmness of the scaffoldings for work's safety.
7.8. The contractor should make sure the security measures of elevated work. Build
up safety net and ask the workers to use the protections such as safety belts
helmets. Ensure to proceed the security check and work by "the Contractor's
Work Safety Instruction before Construction".
7.9.Clean up the job site after daily work to keep the vehicle pass clean and move
the engineering rubbish to scrapes iron piles or garbage yard sorting out by the
environmental protection classification. Any violation will be a penalty
according to the contract.
7.10. The thickness of equipment, materials for cold and hot insularion should be
complied with design drawings. Contractors should check the job site with our
supervisors before construction.
7.11. The contractor should construct fully complied with designed drawings and
the construction standards. Should any vague marks or questions, please contact
our company supervisor immediately. Design changes without approval are not
allowed.
7.12.As the contractor is disagreed with the standard, the contractor should bring
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Shine Yen Corporation
Hot and Cold Insulation Standard
Eng. No.:
Ver:1.0 Page:5/l0
up the written statement as soon as propose the quotation, or regarded as fully
agree.
8. Construction of Equipment Hot Insulation
8.l.Thickness of equipment hot insulation < 100mm for single layer' > 100mm for
double layers' > 225mm for three layers' > 350mm for four layers' the rules
of insulation layers and thickness as below: (If suppliers provide other specific
products, the contractors can change this rule after our company's approval)
T=125 : 75+50
T=150 : 75+75
T=175 : 100+75
T=200 : 100+100
T=225 : 100+75+50
T=250: 100+100+50
T=275 : 100+100+75
T=300: 100+100+100
T=350: 100+100+100+50
T=375: 100+100+100+75
8.2.Equipment bare body, terminal plates and water-repellent mineral wool
8.2.1. Construction steps of hot insulation of equipment bare body:
I)Cover repellent mineral wool on the surfaces of bare pipes in order.
2)Secure with BWG#16 stainless steel wire at the openings and joints of
mineral wool.
3)Tie with 3/4" stainless steel banding and secured at approximated 300 mm
ofmineral wool.
4)Secured with B&S#26 flat coating steel sheets for jacketing. (thickness
0.476mm with 35+40=75 fl m PVDP painting with both sided) Overlapping
50mm with cladding steel at the longitudinal joints and secured with SS
self-tapping screws at 250mm. Overlapping 75mm at the circumferential
joints and secured with B&S#26 "s" clip.
5)Sealed with weatherproof sealantat the joints and the thickness of dry film
is 2mm.
6)Coiled with B&S#26 coating steel sheets and secured in place over the flat
steel cladding at 300-350mm outside.
7)Details of vertical and horizontal equipment bare body hot insulation,
shown as drawing 1 and 2.
8.2.2. Construction steps of hot insulation of terminal boards:
I )Extended repellent mineral wool blankets on the surfaces of terminal boards.
(padding at the joints)
2)Make the insulation bolts on theterminal boards through insulated blankets.
(the tail of insulated bolts appear on the surface of insulated blankets)
3)Secured insulated blanket with BWG# 16 SS wire on the insulated bolts.
4)Bind insulated nails with pliers tCi secure insulated blankets on the
equipment.
5) Secured with B&S#26 flat coating steel for jacketing. (thickness 0.476mm
with 35+40=75 fl m PVDP painting with both sided) Overlapping 50mm with
cladding steel at the longitudinal joints and secured with SS self-tapping
screws at 250mm.
6) Sealed with weatherproof sealant at the joints and the thickness of dry film
is 2mm.
7) Secured with B&S#26 coating steel banding radiately outside the flat
Shine Yen Corporation
Hot and Cold Insulation Standard
Eng. No.:
Ver: 1.0 Page:6/l0
coating steel sheets.
8)Details of terminal boards hot insulation, shown as picture 3.
9)As diameter of equipment is :5: cp 1500 mm, wrap terminal boards with
mineral wool blankets and flat coating steel sheets as cylinder. The rest
construction steps are as above, shown as picture 5.
8.2.3. For the hot insulation of nozzle, manhole, saddle and ladder,
repellent mineral wool blankets should be wrapped with similar
shapes and sizes and filled with mineral wool at the cracks. Secured
with B&S#26 flat coating steel sheets, along with self-tapping screws
and B&S#26 coating steel banding. Spread weatherproof sealant over
the joints and the thickness of dry film is 2 mm. Details of hot
insulation shown as picture 6, 7, 8.
9. Construction of Piping Hot Insulation
9.1.Construction of Pipes Hot Insulation
9.1.1. Cover insulated pipes onto the pipings, horizontal hot insulation for
single layer joint and inner vertical insulation and outer
circumferential seams for double layers.
9.1.2. Each insulated pipes should tie with BWG#18 at center and both ends.
9.1.3. Covered with B&S#28 flat coating steel sheets (thickness about
0.376mm with35+40=75 fl m PVDF coating for both sides)
Overlapping 50mm at axial and circle and secured with SS self
tapping screws at 250mm, shown as picture 11.
9.1.4. When OD > 200mm, secured with B&S#28 coating steel banding at
500mm.
9. 1.5. Sealed with weatherproof sealant at the joints and the thickness of
dry film is 2mm.
9.1.6. Construction with repellent mineral wool, wrapped with hot insulated
pipes for 112"-20" piping and with blankets for pipings OD > 22".
9.1.7. Thickness of hot insulation pipes > 175mm for double layers, >
325mm for three layers, the rules of layers and thickness are as
below: (Once supplier has other specification, the contractor can
change the rules after our approval.)
T<150 : Single Layer T=175 : 100+75
T=200 : 100+100 T=225 : 125+100
T=250: 150+100 T=275: 150+125
T=300: 150+150 T=325: 125+100+100
T=350: 125+125+100
9.1.8. Q.D :5: 20" for single layer hot insulation, e t i l ~ shown as picture 9.
9.1.9. OD < 22" for double layers hot insulation, details shown as picture
10.
9.1 .10.Details of different tracing pipes hot insulation shown as picture 13.
9. 1.1 I.Construction details of vertical piping hot insulation shown as picture
12.
9.2.Construction of Elbows Hot Insulation
9.2. I. OD elbow < 2 112", thickness of hot insulation < 50t, hot insulated
Shine Yen Corporation
Hot and Cold Insulation Standard
Eng. No.:
Ver: 1.0 IPage:7/10
pipes should be angular cut and wrapped at 45 degrees as picture 14.
The rests should be angular cut and wrapped as Lobster Back.
9.2.2. For the Lobster Back numbers of hot insulation and flat coating steel
sheets, please referring to the table below:
Hot Insulation OD Lobster Back Numbers
<200mm 5
201-450mm 7
:::: 451 mm 9
9.2.3. Elbow OD > 22", wrapped with mmeral wool blankets or boards and
secured with #18 SS wire, covered with B&S#28 flat steel sheets cut
as Lobster Back, details as picture 15.
9.2.4. The rest construction works are same as 9.1 Construction of Pipes
Hot Insulation.
9.3.Construction of Tees Hot Insulation:
9.3.1. Leave openings according to Tee OD of the main pipe and wrapped
the pipe. Filled with mineral wools if any seams.
9.3.2. Secured with BWG#18 SS wire on the hot insulated pipes. The rest
construction works are same as 9.1 Construction of Pipes Hot
Insulation.
9.3.3. Sealed with weatherproof adhesive between the main pipe and
insulated pipe of tee and the joints of flat coating steel sheets.
9.3.4. Insulation details as picture 16.
9.3.5. The wrapping works of flat coating steel sheets are shown as picture
17.
9.4.Construction of Expansion Joints Hot Insulation:
9.4.1. Circled with B&S#26 flat steel sheets as a cylinder and wrapped
expansion joints in. Insulated with mineral wool pipes(boards).
9.4.2. The rest construction works are same as 9.1 Construction of Pipes
Hot Insulation.
9.4.3. Insulation details as picture 18. 0
9.5.Construction of Flanges Hot Insulation:
9.5.1. Finish both ends pipes insulation of flanges as picture 19.
9.5.2. After pressure testing, put on flange insulated box(B&S#26 flat
coating steel sheets) and filled with repellent mineral wool as picture
20.
9.5.3. The rest construction works are same as 9.1 Construction of Pipes
Hot Insulation.
9.6.Construction of Valves Hot Insulation:
9.6.1. Finish both ends pipes insulation of valves as picture 21.
9.6.2. After pressure testing, put on valve insulated box(B&S#26 flat
coating steel sheets) and filled with repellent mineral wool as picture
22.
9.6.3. The rest construction works are same as 9.1 Construction of Pipes
Hot Insulation.
9.7.Hot Insulation of Piping Supports
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Shine Yen Corporation
Hot and Cold Insulation Standard
Eng. No.:
Ver:l.O Page:8/l0
9.7.1. As thermal insulated for single-pipe-support, cut insulation pipe
section as the same single-pipe-support part and cover the insulation
pipe section onto it. Tied with BWG#18 SS wire and cladding with
B&S#28 coating steel sheets for the outer layer and secured with
B&S#28 coating steel banding. Applied with weatherproof glue
between steel sheets and supports.
9.7.2. Same construction as single-pipe-support for double-pipe-support.
Stuffed with mineral wool pipe inside the double-pipe-support with
the same size. Tied and secured with BWG#18 SS wire and applied
with weatherproof glue.
9.7.3. Insulation details as picture 23.
I O.Construction of Equipment Cold Insulation
10.1. Thickness of cold insulation < 75mm for single layer. > 75mm for double
layers. The rules of layers and thickness are as below. (Once supplier has other
specification, the contractor can change the rules after our approval.)
T=IOO: 50+50 T=125: 50+75
I 0.2.Insulated Boards(Curved) Cold Insulation Construction Steps of Equipment
Bare Body:
I 0.2.I.Covered with insulated boards onto surfaces of equipment in order
and sealed with waterproof adhesive. Tied and secured with 3/4" SS
banding at approximated 300mm.
I 0.2.2.Cladding with B&S#26 flat coating sheets(thickness is about
0.476mm). Overlapping with coating steel sheets 75mm at
longitudinal seams and secured with B&S#24 S clips at 500mm.
10.2.3.Secured with B&S#26 coating steel banding and buckles at 300-
350mm outside of flat coating steel sheets.
I 0.2.4.For double layers should be installed in a staggered manner and
sealed with waterproof adhesive.
10.2.5.The coverage of waterproof is 2 kg/m
2
(1.30.2mm).
I 0.2.6.Sealed with waterproof adhesive at the flat coating steel sheet seams,
and the thickness of dry film is 2 mm.
10.2.7.Cold insulation details of vertical and horizontal equipment bare body
as picture 24, 25.
10.2.8.Cold insulation details of flange bare body as picture 27.
I 0.3.Cold Insulated Boards (Curved) Construction Steps of Equipment Terminal
Board:
10.3 .1.Covered with cold insulated materials onto the surfaces of terminal
boards in order.
10.3.2.Nailed through the terminal boards with cold insulated bolts.
10.3.3.Secured cold insulated materials with BWG#16 SS wire on the
insulated bolts.
10.3.4.Bind insulated nails with pliers to secure cold insulated materials on
the equipment.
10.3.5.Wrapping way of flat coating steel sheets is the same as 10.2.2 and
10.2.3.
I 0.3.6.Secured with B&S#26 coating steel banding radiately outside the flat
coating steel sheets.
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Shine Yen Corporation
Eng. No.:
Hot and Cold Insulation Standard
Ver:l.O Page:9/10
sheets, please re erflng to t e ta e e ow:
Cold Insulation OD Numbers of Lobster Back
:5: 200mm 5
201-450mm 7
2:451mm 9
10.3.7.Details of terminal boards cold insulation, shown as picture 26.
10.3.8.As diameter of equipment is < <p 1500 mm, wrap terminal boards
with cold insulated materials and flat coating steel sheets as cylinder.
The rest construction steps are as above, shown as picture 5.
10.3.9.mineral wool blankets should be wrapped with similar shapes and
sizes and filled with glasswool. Secured with B&S#26 flat coating
steel sheets, along with self-tapping screws and B&S#26 coating steel
banding. Spread weatherproof sealant over the joints and the
thickness of dry film is 2 mm. Details of hot insulation shown as
picture 28, 29, 30. 0
II.Construction of Piping Cold Insulation
11.I.Cold Insulation Construction of Pipes
11.1.I.After painting on the surfaces of pipings, installed with cold
insulated materials onto the cover in order and sealed with waterproof
adhesive at the seams.
11.1.2.Each insulated pipes should tie with BWG# 18 at center and both ends.
11.1.3.Covered with B&S#28 flat coating steel sheets (thickness about
0.376mm with35+40=75 f1 m PVDF coating for both sides)
Overlapping 50mm at axial and circle and secured with SS self
tapping screws at 250mm, shown as picture II.
11.1.4. When OD 2: 200mm, secured with B&S#28 coating steel banding at
500mm.
11.1.5.Sealed with weatherproof sealant at the flat coating steel sheet joints
and the thickness of dry film is 2mm.
11.1.6.For double layers should be installed in a staggered manner and
sealed with waterproof adhesive.
11.1. 7.The coverage of waterproof is 2 kg/m
2
(1.30.2mm).
11.1.8.Thickness of cold insulation < 75mm for single layer. > 75mm for
double layers. The rules of layers and thickness are as below. (Once
supplier has other specification, the contractor can change the rules
after our approval.)
T=IOO: 50+50 T=125: 50+75
11.1.9.Details for single layer cold insulation, shown as picture 31.
11.1.10.Details for double layer cold insulation, shown as picture 32.
11.2.Cold Insulation Construction of Elbows
11.2.1.0D elbow < 2 1/2", thickness of cold insulation :5: 50t, cold
insulated pipes should be angular cut and wrapped at 45 degrees as
picture 33. The rests should be angular cut and wrapped as Lobster
Back.
11.2.2.For the Lobster Back numbers of hot insulation and flat coating steel
f h bl b I
11.2.3.Elbow OD > 3", wrapped With cold lllsulated materials and secured
9
Shine Yen Corporation
Hot and Cold Insulation Standard
Eng. No.:
Ver:l.O Page:IOII
with #18 SS wire, covered with B&S#28 flat steel sheets cut as
Lobster Back, details as picture 34.
11.2.4. The rest construction works are same as 11.1 Construction of Pipes
Cold Insulation.
11.3 .Cold Insulation Construction of Tees:
11.3.I.Leave openings according to Tee OD of the main pipe and wrapped
the pipe. Filled with glass wools if any seams.
11.3.2.Secured with BWG#18 SS wire on the cold insulated pipes. The rest
construction works are same as 11.1 Construction of Pipes Hot
Insulation.
11.3.3.Sealed with weatherproof adhesive between the main pipe and
insulated pipe of tee and the joints of flat coating steel sheets.
11.3.4.Insulation details as picture 35
11.4.Cold Insulation Construction of Expansion Joints
Il.4.1.Circled with B&S#26 flat steel sheets as a cylinder and wrapped
expansion joints in. Insulated with cold insulated pipes(boards).
11.4.2.The rest construction works are same as 11.1 Construction of Pipes
Cold Insulation.
Il.4.3.Insulation details as picture 36.
11.5.Cold Insulation Construction of Flanges:
11.5.l.Finish both ends pipes insulation of flanges as picture 37.
11.5.2.After pressure testing, put on flange insulated box(B&S#26 flat
coating steel sheets) and filled with repellent glass wools as picture
38.
11.5.3. The rest construction works are same as ILl Construction of Pipes
Cold Insulation.
11.6.Cold Insulation Construction of Valves
11.6.I.Finish both ends pipes insulation of valves as picture 39.
Il.6.2.After pressure testing, put on valve insulated box(B&S#26 flat
coating steel sheets) and filled with repellent mineral wool as
picture40.
11.6.3. The rest construction works are same as ILl Construction of Pipes
Cold Insulation. 0
12.Appendix
12.I.Drawings of hot(cold) insulation equipment
10