EP 11-3-4

Revision 0.0
INSULATION APPLICATION – TANKS AND SPHERES
Date: 10/2021
Page: 1 of 28

TABLE OF CONTENTS

1.0 SCOPE .......................................................................................................................................................2

2.0 REFERENCES ..............................................................................................................................................2
3.0 DEFINITIONS .............................................................................................................................................3
4.0 DRAWING AND INSULATION SCHEDULES ..................................................................................................4
5.0 DOCUMENTATION.....................................................................................................................................4
5.1 (*) PROPOSAL INFORMATION ...............................................................................................................................4
5.2 CONTRACTOR SPECIFICATION ................................................................................................................................4
5.3 QUALIFICATIONS OF FOAM APPLICATORS ................................................................................................................4
5.4 CONTRACTOR’S RESPONSIBILITY ............................................................................................................................5
6.0 ACCEPTABLE MATERIALS ...........................................................................................................................5
6.1 GENERAL ..........................................................................................................................................................5
6.2 RIGID AND RESILIENT INSULATION ..........................................................................................................................6
6.3 INSULATION COVERINGS ......................................................................................................................................7
6.4 ACCESSORIES .....................................................................................................................................................8
7.0 SPECIAL REQUIREMENTS ...........................................................................................................................8
8.0 INSULATION SUPPORTS.............................................................................................................................8
9.0 APPLICATION ............................................................................................................................................9
9.1 GENERAL ..........................................................................................................................................................9
9.2 SURFACE PREPARATION .......................................................................................................................................9
9.3 PROJECTIONS ...................................................................................................................................................10
9.4 ACCESS AND CLEARANCE ....................................................................................................................................10
9.5 APPLICATION OF BOARD, BLOCK OR BLANKET INSULATION........................................................................................10
9.6 APPLICATION OF POLYURETHANE FOAM ................................................................................................................11
10.0 WEATHERPROOFING ...............................................................................................................................12
10.1 GENERAL ........................................................................................................................................................12
10.2 METAL JACKETS................................................................................................................................................12
10.3 ELASTOMERIC COATINGS....................................................................................................................................13
10.4 MASTIC COATINGS (ASPHALTIC)..........................................................................................................................14
11.0 APPLICATION FOR FIRE PROTECTION.......................................................................................................14
12.0 INSPECTION.............................................................................................................................................15
12.1 INSTALLATION ..................................................................................................................................................15
12.2 POLYURETHANE FOAM APPLICATOR QUALIFICATION ...............................................................................................16
13.0 POLYURETHANE FOAM GUARANTEE .......................................................................................................16
14.0 TABLES ....................................................................................................................................................17
15.0 FIGURES ..................................................................................................................................................18
16.0 REVISION LOG .........................................................................................................................................28

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 EP 11-3-4
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INSULATION APPLICATION – TANKS AND SPHERES
Date: 10/2021
Page: 2 of 28

1.0 SCOPE
1.1 This Practice covers the mandatory requirements for the materials and application of external
insulation to outdoor storage tanks and spheres designed in compliance to EP 9-1-1, EP 9-2-1
and EP 9-4-1.
1.2 Any deviation from this Practice must be approved by the procedure described in EP 1-1-3.
1.3 This Practice is appropriate for attachment to an inquiry or purchase document when
accompanied by the referenced Engineering Practices and the completed data sheets included
in EP 11-3-4DS, as required.
1.4 An asterisk (*) indicates that a decision by the Owner is required, or that additional information
shall be furnished by the purchaser.
1.5 A revision bar indicates all changes made to this revision.

2.0 REFERENCES
The latest edition of the following standards and publications are referred to herein.
Standards and Publications

Equity Engineering Practices

EP 1-1-3 Deviations to Equity Engineering Practices
EP 2-5-2 Documentation Format Requirements
EP 4-1-1 Design Criteria and Loads for Structures
EP 9-1-1 Atmospheric Storage Tanks
EP 9-1-2 Welding Requirements for Atmospheric Storage Tanks
EP 9-2-1 Low Pressure Storage Tanks
EP 9-4-1 Pressure Storage Spheres
EP 10-3-1 Shop Painting
EP 11-3-1 Insulation Design
EP 11-3-4DS Insulation Application – Tanks and Spheres Data Sheet
EP 11-3-6 Insulation of Flanged Joints and Valves in Hot Service
API
API 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks
API 650 Welded Steel Tanks for Oil Storage
API 2510A Fire Protection Considerations for the Design and Operation of Liquefied Petroleum Gas
(LPG) Storage Facilities
ASTM
ASTM A240 Standard Specification for Heat-Resisting Chromium and Stainless and Heat-Resisting
Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and
General Applications
ASTM B209 Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM C449 Standard Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating and
Finishing Cement
ASTM C533 Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation
ASTM C552 Standard Specification for Cellular Glass Thermal Insulation
ASTM C591 Standard Specification for Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal
Insulation

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 EP 11-3-4
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Standards and Publications

ASTM C592 Standard Specification for Mineral Fiber Blanket Insulation and Blanket-Type Pipe
Insulation
ASTM C612 Standard Specification for Mineral Fiber Block and Board Thermal Insulation
ASTM C795 Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless
Steel
ASTM C892 Standard Specification for High Temperature Fiber Blanket Thermal Insulation
ASTM C929 Standard Practice for Handling, Transporting, Shipping, Storage, Receiving, and
Application of Thermal Insulation Materials for Use in Contact with Austenitic Stainless
Steel
AS
ASTM D1621 Standard Test Method for Compressive Properties of Rigid Cellular Plastics
ASTM D1622 Standard Test Method for Apparent Density of Rigid Cellular Plastics
ASTM D2126 Standard Test Method for Response of Rigid Cellular Plastics to Thermal and Humid
Aging
ASTM D6226 Standard Test Method for Open Cell Content of Rigid Cellular Plastics
ASTM E84 Standard Test Method for Surface Burning Characteristics of Building Materials
SSPC
SSPC SP-6 Joint Surface Preparation Standard – Commercial Blast Cleaning

3.0 DEFINITIONS
3.1 Contractor – Company or business that agrees to furnish materials or perform specified
services at a specified price and/or rate to the Owner.
3.2 Design Temperature – Shall be the highest temperature reached during operation, steamout, or
regeneration.
3.3 Fire Exposed Area – An area is considered fire exposed if it is horizontally within 30 ft of any fire
potential equipment or of the limits of a potential pool or stream of burning liquid, or if it is
vertically within 40 feet above any level at which a fire may be initiated. When a fire can be
started above grade, the distance below (to grade) is also considered fire exposed. Outside of
battery limits, an area is considered fire exposed if horizontally within 30 ft of the edge of a
potential pool or stream of burning liquid.
3.4 Inspector – An Engro appointed engineer or inspector.
3.5 Low Melting Point Alloys – An alloy with a melting point below 1800°F. This includes the
aluminum, copper, and magnesium alloys.
3.6 Manufacturer – The recipient of a direct or indirect purchase order for materials and/or
equipment. In this context, a direct order is one issued to a manufacturer by a contractor or the
Owner. An indirect order is one issued to a manufacturer by a vendor (recipient of a direct
order) for materials, fabricated components, or subassemblies.
3.7 Owner – Engro.
3.8 Owner’s Engineer – An Engro appointed engineer.
3.9 Purchaser – The party placing a direct purchase order. The purchaser is the Owner’s
designated representative.
3.10 PSM – Process Safety Management.

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 EP 11-3-4
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4.0 DRAWING AND INSULATION SCHEDULES

(*) Drawing and insulation schedules shall be supplied to the Contractor by the Owner’s
Engineer and shall contain the following information:
1) Equipment (designated by equipment number) to be insulated and extent of insulation if
only partial coverage is required.
2) Equipment that requires special insulation to prevent stress corrosion cracking of austenitic
stainless steel.
3) Type, total thickness, and number of layers of insulation required.
4) Designing and operating temperatures.
5) Extent of insulation designated as fireproofing.
6) Equipment that requires insulation only for personnel protection.
7) Equipment to be heat traced or refrigerated and type of tracing.
8) Type of insulation weatherproof covering.
9) Designated areas and requirements for surface preparation and painting.
10) Areas specified to be insulated for noise control or combined thermal and noise control.
11) Manways and flanges to be insulated.
12) Areas where insulation is to be both removable and reusable.
13) Type and location of expansion joints.
14) Surfaces specified to be insulated for winterizing.
15) Areas to be insulated for foot traffic.

5.0 DOCUMENTATION
5.1 (*) Proposal Information
The following data, as applicable, shall be submitted to Purchaser for approval by the Owner’s
Engineer.
1) Product specifications.
2) Material storage requirements, including shelf life and temperature.
3) Design and application details of expansion joints.
4) Repair procedures for damaged areas.
5) Inspection and testing procedures.
6) Recommended safety precautions, such as the proposed method of electrical grounding of
equipment (i.e., for blast cleaning and spray application).
5.2 Contractor Specification
The Owner’s Engineer shall supply a supplemental job specification to the insulation Contractor.
The job specification shall include all applicable drawing and insulation schedules, material
specifications, and all obligations and responsibilities required for the job.
5.3 Qualifications of Foam Applicators
5.3.1 Foam shall be installed only by foam applicators who are experienced in the proposed
application methods and who use equipment with positive metering.
5.3.2 The foam spray mechanics shall have a minimum of two years’ field spraying experience.
5.3.3 Bidders shall submit a listing of similar installations completed by them, including type of foam
and weather protection, date of completion, location, and contacts. If the proposed foam or

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 EP 11-3-4
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protective coating has not been used by a bidder, he shall submit a listing of successful
installations by others and a confirmation that the manufacturer(s) will furnish field assistance.
5.3.4 Bidders shall submit resumes of recent experience of those supervisory personnel and spray
mechanics that will be used on the job.
5.4 Contractor’s Responsibility
5.4.1 The Contractor shall furnish all supervision, labor, tools, equipment, supplies, scaffolding and
transportation necessary to execute this Practice. All materials will be supplied by the
Contractor except those specifically noted otherwise.
5.4.2 The insulation/primer/weatherproofing manufacturers shall accept responsibility for their
products in writing.
5.4.3 The Contractor shall secure in writing from insulation/primer/weatherproofing manufacturers
their acceptance of responsibility for their products.
5.4.4 The application contractors shall accept responsibility for their work in writing for a period of
three years.
5.4.5 Before field work starts, the Contractor and material suppliers will be required to attend a
meeting to discuss:
1) Work Inspection including holding points, if necessary.
2) Application Procedure and Applicator Tests.
3) Location.
4) Work Schedule.
5) Safety Rules and Regulations.
5.4.6 On the days of application, the contractor shall complete and submit to the Owner daily the
“Quality Control Daily Reports” (see data sheets in EP 11-3-4DS).

6.0 ACCEPTABLE MATERIALS

6.1 General
All materials cited below shall be asbestos free. The use of materials containing asbestos is
prohibited.
6.1.1 API 650 and API 620 tanks shall be insulated with one or more of the following:
1) Cellular glass (maximum service temperature 900°F).
2) Fiberglass (maximum service temperature 450°F).
3) Mineral wool (maximum service temperature 1200°F).
4) Polyurethane foam (maximum service temperature 175°F).
5) Calcium Silicate (maximum service temp. 1200°F).
6) Perlite (maximum service temperature 1200°F).
7) Polyisocyanurate foam (maximum service temperature 300°F).
8) (*) When approved for use by the Owner’s Engineer, Aspen Aerogel Pyrogel insulation
products that conform to the requirements in EP 11-3-1 (paragraph 6.5; maximum service
temperature of 1200°F).
9) (*) When approved for use by the Owner’s Engineer, ESLIN or Hitlin insulation products
that conform to the requirements in EP 11-3-1 (paragraph 6.6; maximum service
temperature of 1400°F).

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 EP 11-3-4
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Date: 10/2021
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6.1.2 Cellular glass, polyisocyanurate foam, and polyurethane foam are the preferred insulation
materials for refrigerated tanks and spheres.
6.1.3 (*) Refrigerated tanks and spheres operating at temperatures less than -60°F shall have the
insulation reviewed and approved by the Owner’s Engineer.
6.1.4 (*) Insulation systems using polyurethane foam on LPG storage spheres (API 2510) shall be
reviewed and approved by Owner’s Engineer and a PSM representative.
6.1.5 (*) Insulated tanks that require fireproofing shall have calcium silicate or woven silica blanket as
the outside layer of insulation. Alternate designs using a combination of passive fireproofing
materials and insulation must be approved by the Owner’s Engineer and a PSM representative.
If approved for use, woven silica blanket shall be Aspen Aerogel Pyrogel XTF or equivalent.
6.1.6 Insulation for noise control shall be limited to fiberglass (6-8 lb./ft3) or mineral wool (8-10 Ib./ ft3).
The requirements in Section 9.5.6 shall also apply.
6.2 Rigid and Resilient Insulation
6.2.1 Calcium silicate block insulation shall be suitable for 1200°F and comply with ASTM C533, Type
1 requirements. For fire exposed areas, calcium silicate shall be manufactured to withstand at
least 1800°F and shall comply with ASTM C533, Type 2.
6.2.2 Mineral wool products shall have a neutral pH, a nominal density not less than 8 lb/cu. ft. and be
suitable for 1200°F, except as noted. Additional requirements are:
1) Blankets shall conform to ASTM C592, Class II. They shall be faced with wire mesh on
both sides. Mesh shall not be galvanized if used on austenitic steel surfaces.
2) Blocks and boards shall conform to ASTM C612, Type 5. The minimum nominal density
shall be 10 lb/cu. ft.
3) All mineral wool shall be silicone treated for water resistance.
6.2.3 Cellular glass shall conform to ASTM C552 and is limited to a maximum service temperature of
450°F.
6.2.4 Alumina silica ceramic fiber blanket shall conform to ASTM C892 with a density of 8 lb/cu. ft.
and a maximum use temperature of 2300°F.
6.2.5 Insulating cement shall be mineral fiber ASTM C449. Cement shall set to a hard smooth
monolithic finish.
6.2.6 Polyurethane foam shall comply with ASTM C591, Type II, with a flame spread rating not
exceeding 25 per ASTM E84. For roof applications, and areas of high traffic, foam must have a
minimum compressive strength (parallel to rise) of 40 psi. Polyurethane foam is limited to a
maximum service temperature of 175°F.
1) Cellular urethane foam insulation shall have a minimum nominal density of 2 lb/ft3 per
ASTM D1622.
2) Cell structure shall be uniform throughout the core. Elongated cells shall be no longer than
3 times the smallest dimension. Test shall be per ASTM D6226, procedure A.
3) Dimensional stability shall be tested per ASTM D2126. The volumetric change shall not
exceed 2% after 7 days’ exposure at -20°F (cold aging); and after 7 days’ exposure at
200°F (hot aging).
4) Humid aging shall be determined per ASTM D2126 with a maximum 3% change in linear
dimensions.

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 EP 11-3-4
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6.2.7 Fiberglass shall be limited to a maximum service temperature of 450°F. Block and board
insulation shall have a minimum density of 6 lb/ft3 and comply with ASTM C612, type III.
6.2.8 Perlite shall comply with ASTM C610, Type II material, and shall have a sodium silicate binder.
The material shall also be subjected to a high temperature test (1200°F), and be checked for
smoking, charring, cracking, and other signs of physical deterioration. Material shall be certified
asbestos free.
6.3 Insulation Coverings
6.3.1 Weatherproofing jacket for non-fire exposed areas, except for those items which comply with
Section 6.3.2 , shall be aluminum according to the following:
1) Sheets and rolls shall be 1-1/4 inch corrugated 0.020 inch thick.
2) Flat stucco embossed aluminum, 0.020 inch thick, shall be used on heads, transitions,
stiffener rings, and flashing.
3) Aluminum alloy to be ASTM B209, Type 3003 or 5005.
4) (*) At the discretion of the Owner’s Engineer, jacketing in non-fire exposed areas may be
upgraded to stainless steel.
6.3.2 Weatherproof covering for fire exposed areas, equipment of low melting alloys, or polyurethane
foam within a process unit, shall be 0.01 inch thick stainless steel ASTM A240, Types 302, 304,
or 316. When approved by Owner, 0.016 in thick stainless steel jacketing may be used for
personnel safety when handling. Covering steel shall be according to the following:
1) Sheets and rolls shall be 0.01 inch thick with 1-1/4 inch corrugations in the long direction.
2) Formed heads, transitions, stiffener rings, and flashing shall be 0.010 inch thick, smooth,
interlocking gore type.
6.3.3 Fireproofing mastic shall be a breather type, asbestos free, with a flame spread of 4 or less
(Vimasco WC-1 or equal).
6.3.4 All jacketing materials shall have a vapor barrier of colored converted epoxy, colored
polyethylene, or 50 pound polyethylene-kraft paper moisture barrier 100 percent bonded to the
inside surface. When specified on the insulation schedules, the outside of the jacketing shall be
coated with a color converted epoxy.
6.3.5 Insulation systems on low melting alloys (such as aluminum), or on equipment where the
system is considered as fireproofing, shall be capable of withstanding the force of firehose
stream impingement.
6.3.6 Elastomeric coatings shall be used over cellular glass insulation when metal jackets are not
provided.
6.3.7 Applied coatings of mastic or elastomeric materials shall comply with the following:
1) A flame spread classification of not more than 25 per ASTM E84.
2) A demonstrated resistance to solar radiation.
3) Flexible at the lowest temperature to which they are exposed.
4) Compatible with the insulation materials.
5) Mastics shall be of the breathing emulsion type.
6.3.8 Mastic weathercoat shall be a vinyl acrylic Childers Vicryl CP-10/CP 11-11-1 or equal.

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 EP 11-3-4
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6.4 Accessories
6.4.1 Bands shall be stainless steel, Type 302, 304, or 316, annealed temper. Sizes shall be 3/4 inch
wide by 0.020 inch minimum thickness, with wing type seals. Breather springs shall be used
where required for expansion. Bands shall be held in place with screwed keepers.
6.4.2 Bands shall be marked (color coded or stamped as specified by the refinery) to indicate non-
asbestos containing insulation. Bands on asbestos containing insulation shall be color coded
yellow.
6.4.3 Seals shall be stainless steel to match bands (regular-wing type, long shank).
6.4.4 Wire shall be 14 BWG stainless steel, Type 302, 304, or 316 annealed temper.
6.4.5 Reinforcing for applied coatings shall be as follows:
1) Wire mesh shall be 1 inch hexagonal woven wire poultry mesh, 0.035 inch (20 BWG)
minimum wire diameter. Wire shall be either stainless steel or Monel. The mesh shall be
laced into place with wire at least 0.08 inch diameter of the same material.
2) Glass Fabric shall be per the coating manufacturer’s recommendation for reinforcing fabric
in mastic finishes. If not specified, use 10 x 10 open mesh, Childers Chil-Glas #10 or
equal.
6.4.6 Sheet metal screws for securing metal to metal shall be Number 8 by 1/2 inch long self-tapping,
type 304 stainless steel, with neoprene gaskets.
6.4.7 Breather springs shall be stainless steel to match bands, 5 inch minimum expansion, and a 110
pound load limit (minimum). Double springs (lNSUL-MATES-7 RPR Products, Inc., or equal)
shall be used for jacketing.
6.4.8 Sealer/flashing mastic shall be non-shrinking permanently flexible, less than one perm water
vapor per 1/16 inch thickness.
6.4.9 S-Clips for jacketing on vertical tanks shall be stainless steel, Type 304 annealed temper (see
Figure 1).
6.4.10 Welded studs for insulation jacket supports shall be stainless steel, Type 302, 304, or 316 (see
Figure 2).
6.4.11 Insulation rectangular welding pins (per Figure 2). See paragraph 8.4 for material requirements.

7.0 SPECIAL REQUIREMENTS

7.1 (*) Insulation in high traffic areas shall have a minimum compressive strength of 40 psi.
Materials with a compressive strength less than 40 psi and a high elastic rebound may be used
if approved by Owner’s Engineer. When this is not possible, roof walkways shall be installed,
per Section 9.1.5.
7.2 (*) Insulation “systems” involving prefabricated panel systems will be evaluated individually.
The Contractor shall submit proposals to the Owner’s Engineer for review and approval.

8.0 INSULATION SUPPORTS

8.1 Insulation supports for cylindrical tanks shall be per Figure 3 - Figure 5 and Section 9.5.5.
Support clips for spheres shall be per Figure 6.
8.2 Support rings for use on vertical surfaces shall be spaced no more than 12 feet apart.
8.3 The insulation angle, welded to the top angle, and the insulation support plate at the bottom of
the tank shall be furnished in accordance with Figure 3.

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 EP 11-3-4
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8.4 Vessel attachments required for support of insulation and fireproofing shall be as follows:
1) Support clips welded to the vessel shall be fabricated from the same material as the
vessel.
2) Insulation support ring material shall be:
• Carbon steel for carbon steel and low alloy tanks.
• The same as the tank material for all other cases.
8.5 Heat treated items requiring welding pins, clips or studs shall have pins installed prior to heat
treatment.
8.6 An angle support ring shall be welded around the base of the tank per Figure 5. This is required
for block, blanket, or board insulation.

9.0 APPLICATION
9.1 General
9.1.1 Pressure tests on tanks or spheres shall be completed before insulation is installed.
9.1.2 Care shall be taken to avoid contact between dissimilar materials which might cause galvanic
corrosion (e.g. aluminum in contact with steel, etc.).
9.1.3 Insulation shall be kept dry and protected against the elements during storage and all stages of
application until the weatherproofing has been installed.
9.1.4 All hot work, welding and burning must be completed prior to insulation application.
9.1.5 When a tank roof is to be insulated, the following shall apply:
1) Roof walkways, which provide access to all roof openings and fittings, shall be installed
where the insulation is unsuitable for walking per Section 7.1.
2) The roof slope shall be at least 1-1/2 inches in 12 inches.
3) Gauge hatches, when required, shall be bolted to a roof nozzle.
9.1.6 When overflows are installed, the overflow detail shall be designed to prevent the overflowing
liquid from soaking the tank insulation. Relocating the insulation angle and/or providing
adequate splash plates on the overflow connections are two of the methods that may be
employed to satisfy this requirement.
9.2 Surface Preparation
9.2.1 Surface preparation, including any washing of stainless steel surfaces, and primer painting will
be the responsibility of the applicator and shall comply with EP 10-3-1.
9.2.2 (*) Unless otherwise specified, all tanks operating at less than 225°F shall have as a minimum,
a prime coat and finished coat of paint. All tanks operating at 225°F or over shall have a prime
coating of paint. All alloy tanks shall be coated regardless of operating temperature. Steam out
temperatures shall be considered when choosing the coating material.
9.2.3 Surfaces to be insulated shall be dry, and shall have foreign matter removed by solvent
cleaning (as necessary, after surface has been prepared).
9.2.4 Blast clean all surfaces and welds before priming to SSPC SP-6 (minimum). Follow the
Manufacturer’s recommendations for additional requirements, as applicable.
9.2.5 Before blasting, grind smooth sharp edges, welds, steel slivers, etc., and remove all oil and
weld spatter and flux.

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9.2.6 All paints shall be applied to a surface free from oil, moisture, dust, grit, or any other
contaminants and discoloration.
9.2.7 All surfaces shall be primed during the same day they are blasted.
9.3 Projections
9.3.1 All projections from surfaces shall be insulated completely or to the maximum practical extent
9.3.2 When the circumferential stairway is made with a stringer on the tank side of the stairs, the
stringer shall be supported from the tank shell. Clearance from the insulation shall comply with
Section 9.4.1.
9.3.3 (*) For polyurethane foam applications wrap steam lines, or other items operating above the
foam temperature limit with 1 inch thick fiberglass blanket or Owner approved insulation
material prior to the foam application.
9.4 Access and Clearance
9.4.1 When practical, a minimum clearance of 4 inches between the outside of any insulation and
adjacent equipment, piping, or structural members shall be maintained. This clearance shall
take into account the thickness of any fireproofing coating or insulation applied to such adjacent
equipment, piping, or structural members.
9.4.2 (*) Insulation systems shall permit access to parts requiring maintenance without requiring
destruction of the entire insulation system. These areas must be clearly identified by the Owner
prior to the installation of any insulation points.
9.4.3 Insulation at flanged joints shall be tapered to permit stud removal without damage to the
insulation. When practical, nozzles shall be extended, by the insulation thickness (minimum), to
ensure clearance for bolting.
9.4.4 Edges of insulation openings such as around manholes, nozzles, cutouts for stud removal, pipe
supports, and other attachment, shall be sealed to prevent water from entering. Metal covers
shall be used if temperatures are beyond the usable range of weatherproofing coatings.
9.4.5 Nameplates (including code inspection plates) shall not be insulated. Insulation surrounding
these plates shall be beveled away from such markings and sealed to prevent water from
entering. Preferably nameplates will be attached to an offset support such that they are outside
the insulation.
9.4.6 Manway covers shall be provided when units are insulated with polyurethane foam. The covers
shall be removable and comply with EP 11-3-6.
9.5 Application of Board, Block or Blanket Insulation
9.5.1 All insulation shall be installed butted together and shall be either impaled on studs or banded to
the shell.
9.5.2 Each layer of insulation shall be installed with transverse and longitudinal joints staggered.
9.5.3 If more than one layer of insulation is applied, each layer shall be secured in place, and joints of
each layer offset.
9.5.4 All gaps shall be filled with insulating cement, except when insulating stainless steel use blanket
insulation to point-up the cracks.
9.5.5 Spacing of clips or pins for securing insulation on vertical surfaces shall be on no more than 16
inch centers for blanket insulation. Block insulation shall be installed with no less than 2 studs
(clips or pins) per block. The insulation shall be secured by lacing wire to the pins.

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9.5.6 When dual layer insulation systems employing different insulation materials are used for
combined thermal and noise control, the insulation for noise control shall be installed as the
outer layer.
9.5.7 Install each panel of board or blanket insulation in a slightly compressed condition in both
directions.
9.5.8 Insulation shall be installed in two staggered layers of nearly equal thickness if:
1) The insulation thickness is greater than 2 inches.
2) Insulation is used for fireproofing.
9.5.9 When the insulation is not impaled, the insulation shall be secured in place with bands spaced
on 12 inch centers (maximum). The blocks shall be carefully mitered to fit all surfaces without
rocking. Where double layers are used the inner layer shall be secured with wire or bands on
18 inch spacing (maximum). Weatherproofing shall be supplied over the insulation.
9.5.10 The bands should be supported vertically with bands and “belt loops” as shown in Figure 7 to
prevent them from sliding or slipping down.
9.5.11 Breather springs shall be installed for every 50 feet of circumference.
9.5.12 With tank or sphere in the cold condition, each spring shall be installed in tension to produce a
3/4 inch spring expansion.
9.6 Application of Polyurethane Foam
9.6.1 Prior to application, all flanges, manholes, equipment, stairs, and other non-insulated surfaces
shall be wrapped with suitable coverings and secured. The covering shall be removed after
foam and protective coating application is complete. DO NOT WRAP THE BREATHER
VENTS.
9.6.2 The equipment used for spraying shall be capable of metering the components, continuously or
intermittently, within the accuracy required to meet the component supplier’s recommendations.
There shall be instantaneous synchronization between the metering equipment and the gun.
The foam applicator shall perform any required calibrations before commencing foam
application each day and as often as necessary during operation.
9.6.3 The foam spray gun shall provide thorough mixing of the components prior to atomization and
be mechanically self-cleaning. The equipment shall be capable of maintaining the foam
manufacturer’s recommended temperatures.
9.6.4 The foam applicator shall furnish the required compressed air equipment.
9.6.5 During foaming, the temperature of the substrate shall be as follows:
1) A minimum of 5°F above the dew point. This minimum temperature also applies to the
foam surface for the application of additional layers.
2) A minimum of 90°F. If it is impossible to heat the substrate to this temperature, it may be
as low as 60°F providing the foam manufacturer’s recommendations for the installation
temperature are followed.
3) A maximum of 120°F.
9.6.6 The substrate area to be insulated each day must be limited by the Applicator’s ability to apply a
protective coating to the insulation and also protect the applied foam from precipitation.
9.6.7 The foam on the roof shall be applied to provide drainage and prevent free standing water. See
Section 9.1.5.

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9.6.8 The foam shall not be applied until the metal primer is completely cured.
9.6.9 The manufacturer’s application instructions shall be followed at all times. A representative from
the foam manufacturer shall be present for the first 25% of the surface that is foamed on each
tank. If problems are experienced, the representative shall stay through completion of the tank.
9.6.10 (*) Extreme caution shall be taken to prevent spraying in the presence of water, rain, fog,
condensation, etc., or wind velocities above 12 miles per hour. All applications shall stop under
these conditions. (With approval of Owner’s Engineer, shielded scaffolds or wind breaks can be
used to allow spraying during high wind velocity). Foam shall not be applied when the ambient
temperature is below 60°F. The weather forecast shall be checked each day prior to
commencing application.
9.6.11 The foam shall be applied in minimum 1/2 inch, maximum one inch thick passes to reach the
desired insulation thickness with a tolerance of -0 inch, +1/4 inch nominal foam thickness. The
Contractor shall gauge the foam for proper thickness at least once every 100 square feet
applied. In areas where obstacles do not allow proper spray techniques, this tolerance cannot
be adhered to and the minimum thickness shall apply. The completed job shall be monolithic.
9.6.12 The finished surface of the foam shall be smooth textured (orange peel appearance) and free
from overspray, blow holes, and soft, spongy, or friable areas. Surfaces that are rougher than
the acceptance criteria and that are over 2 ft2 in area shall be planed smooth and resprayed to
provide a smooth surface. Foam degraded by ultraviolet (UV) light must be removed. Any
surface “dusting” due to UV attack shall be brushed off prior to coating application.
9.6.13 Any depressions in horizontal or nearly horizontal surfaces that will trap more than 1/4 inch of
water over an area larger than 11 ft2 shall be filled with foam prior to the coating application.
9.6.14 Roof projections: All items projecting through the roof structure such as vents, pipes, or conduits
shall have the urethane foam carried in a smooth transition to a minimum of 6 inches up the
side of any projection of parapet. Extreme caution must be used to prevent blocking or
interfering with functionality of breather vents.
9.6.15 Projections on vertical and spherical shells shall have the foam carried in a smooth transition to
a minimum of 3 inches up/onto the projection. See Figure 8.
9.6.16 Insulation stops shall be provided at the bottom and top of the tank. In addition, insulation stops
shall be provided around all manways and nozzles that have flanges that do not project beyond
the foamed surface.

10.0 WEATHERPROOFING
10.1 General
10.1.1 Insulation must be thoroughly dry at time of weatherproofing.
10.1.2 The type of insulation covering will be specified, on the drawings and insulation schedules.
10.2 Metal Jackets
10.2.1 Use corrugated sheets on vertical surfaces and rolls on horizontal or inclined surfaces.
10.2.2 (*) Metal jacketing for vertical surfaces shall be supported on welded studs (See Figure 2).
Studs shall be spaced on 14 inch centers circumferentially. Studs shall be installed below
support rings on 24 foot (maximum) vertical centers at locations where adjacent courses of
jacketing will overlap. Other methods of support require Owner’s Engineer Approval.

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10.2.3 On vertical surfaces, for those courses where welded studs are not required, support at the
circumferential overlap shall be provided by “S” clips fabricated per Figure 1. S-clips shall be
spaced on 14 inch centers (maximum), with a minimum of 2 per sheet.
10.2.4 Laps of jackets shall be positioned to shed water. Minimum lap (horizontal and vertical) shall be
3 inches but in no case less than 2 full corrugations.
10.2.5 Jackets shall be lapped, or sealed where not practical to lap, to prevent entrance of water.
Insulating cements shall not be used for sealing purposes. This includes lapping the bottom
course over the lower insulation support ring.
10.2.6 Jacket attachment shall be designed to hold the jacket in place for the condition of design wind
speed listed in EP 4-1-1.
10.2.7 Metal covering shall be secured with bands spaced not less than one band on each
circumferential lap and one at the middle of each sheet, but not to exceed 12 inches on center.
On vertical surfaces, secure bands to sheets with screws on not more than 2 foot centers to
prevent sliding (See Figure 9).
10.2.8 Metal screws shall be installed on longitudinal seams centered between all bands.
10.2.9 Breather springs shall be installed for every 50 feet of circumference.
10.2.10 Metal jacketing for spheres shall be supported on welded studs (see Figure 2). Studs shall be
spaced on 24 inch centers (maximum).
10.2.11 Jacketing for roofs, and the top half of spheres, shall have a metal cover fabricated with
weatherproof seams. Secure gore sections of fabricated head-jackets with screws on not more
than 6 inch centers. The cover shall extend a minimum of 3 inches down over the shell
jacketing. Screws shall be installed on 6 inch centers around the circumferential overlap.
10.2.12 Stiffener rings on vertical surfaces shall be insulated and weatherproofed in accordance with
Figures 10 and 11.
10.2.13 Nozzles on vertical surfaces shall be insulated and weatherproofed in accordance with Figures
3 and 5.
10.3 Elastomeric Coatings
10.3.1 (*) Total elastomeric coating film thickness shall be per the coating manufacturer’s
recommendations. Coatings shall be applied in a minimum of two coats. Recommended total
film thickness is 30-40 mils dry (64-86 mils wet). The final proposed thickness shall be
approved by the Owner’s Engineer prior to application.
10.3.2 A representative from the mastic manufacturer shall be present while the first 25% of the
surface is being coated (on each tank). If problems are experienced, the representative shall
stay through completion of the tank. The representative shall check thinning, mixing, handling
and application of manufacturer’s product.
10.3.3 The coating shall not be applied during rain, fog, mist, low ambient temperature (below 40°F).
The coating shall not be applied when the ambient temperature is expected to drop to 32°F
before it has had time to dry.
10.3.4 The coating shall be applied by a cross-hatch technique to obtain complete coverage.
10.3.5 No heavy traffic shall be permitted on coated surfaces for at least 24 hours after application.
10.3.6 The coating shall be carefully applied around valves, manholes, pipes, nameplates, etc., to
insure complete sealing and coverage.
10.3.7 A vapor barrier, elastomeric coating is required over all polyurethane foam insulation.

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10.3.8 Elastomeric coatings shall have a final top coat of aliphatic urethane; metal jacketing shall be
used when required for fire protection or when located within a process unit.
10.3.9 The foam shall be dry, clean, oil-free, grease-free, dust free, foam overspray-free, and
structurally sound before application of the coating.
10.3.10 Foam surfaces shall receive the first coat of mastic on the same day as the foam application.
10.3.11 The elastomeric coating shall be stopped about 4-6 inches from the vertical edge of applied
foam. Do not apply mastic to metal primed surfaces that are to be insulated.
10.3.12 Elastomeric coatings shall be reinforced with synthetic fiber fabric when coating cellular glass
insulation.
10.3.13 Reinforcing fabric, when used in conjunction with the coating, shall be applied without wrinkles;
metal fasteners (e.g., staples) shall not be used to hold fabric.
10.3.14 Application of multi-coat system:
1) Immediately after application of the first coat, and while still wet, a layer of reinforcing fabric
shall be pressed smoothly into the coating. Fabric overlap shall be 3 inches.
2) After a minimum of 4 hours drying time, the 2nd coating shall be applied.
10.3.15 Double layers of fabric shall be used at joints of attachments, or other configurations, requiring a
smooth transition of the weatherproofing coatings.
10.4 Mastic Coatings (Asphaltic)
10.4.1 (*) Mastic coatings shall be reinforced and the final thickness shall be per the coating
manufacturer’s recommendations. A minimum thickness of 3/16 inch thick (dry film) is
recommended. The final proposed thickness shall be approved by the Owner’s Engineer prior
to application.
10.4.2 Application shall be per the manufacturer’s recommendations. As a minimum, when mastic is
used there shall be a tack coat (1/8 inch thick) of mastic applied over the insulation, followed by
a layer of fabric installed wrinkle free [overlap fabric 4 inches (min.)]. After the first layer
containing the fabric has dried, a 1/8 inch layer of mastic weather coat shall be trowelled to a
smooth finish. After drying, no porosity or laminations shall exist in coating.
10.4.3 This finish shall extend approximately 2 inches under any adjacent weatherproofing jacket.
10.4.4 Vertical joints between mastic and jacketing shall be sealed to prevent entrance of moisture.
10.4.5 Weatherproofing with mastic and fabric shall be done so that all seams are completely covered.
10.4.6 Apply a 1/4 inch minimum fillet of sealer/flashing mastic (Paragraph 6.4.8) to weatherproof small
openings between the jacket and vessel surfaces such as at nozzles, manholes, etc.

11.0 APPLICATION FOR FIRE PROTECTION

Application of combined thermal insulation and fireproofing shall be per Sections 9.0 and 10.0
with the following additions:
11.1 Insulation used to fireproof equipment shall be installed in two layers regardless of the insulation
design temperature.
11.2 A band shall be installed not more than 2 inches above all rows of studs supporting fireproofing
jacket on vertical cylindrical surfaces.
11.3 (*) Fireproofing mastic when specified by the Owner’s Engineer, shall be reinforced with wire
mesh.

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11.4 Jacketing shall be designed to remain intact during firewater impingement.

11.5 (*) Submit all proposals for a dual insulation/passive fireproofing system (e.g., Chartek or SW
Firetex M90-02 under polyurethane foam) to the Owner’s Engineer and PSM representative for
review and approval.

12.0 INSPECTION
12.1 Installation
12.1.1 All materials and equipment furnished, and work done, will be subject to inspection by the
Owner or his designated representative. Such inspection shall not relieve the Contractor
responsibility for furnishing qualified labor and materials in strict accordance with these
Practices.
12.1.2 The first 100 studs welded on each tank shell are to be hammer tested to insure good bond
between stud and substrate. After the first 100, spot checks shall be carried out. If problems
occur, the weld area must be ground to bare metal prior to welding to remove all paint and
oxidation. All stud welding shall be done per ASME IX.
12.1.3 Compliance with governing specifications shall be checked by the Inspector during the course
of installation of the insulation system.
12.1.4 Work shall not proceed with the next step in the insulation system sequence (i.e., surface
preparation, priming, insulation, weather barrier application) until the previous work has been
inspected and approved.
12.1.5 Applied coatings shall be inspected for pinholes, blister, voids, or insufficient thickness. Any
repairs shall be done at the Contractor’s expense.
12.1.6 Any materials or equipment not meeting the specified requirements shall be rejected and
replaced at once by the Contractor – at no cost to the Owner.
12.1.7 The top coat thickness (mastic, elastomeric, and aliphatic urethane) shall be measured and
reported in one location within each 300 square feet of surface area, with a minimum of four
locations for each tank shell and roof. An average coating thickness less than that specified or
failure to meet the manufacturer’s specifications shall require application of an additional
coating.
12.1.8 Polyurethane Foam
1) Prior to coating application, the Owner and the Contractor shall inspect the foam surface.
Foam surface roughness shall not exceed Type B Surface Inspection Standards for
Polyurethane Foam Roughness, see Figure 12. Any surfaces exceeding this standard
shall be repaired at the Contractor’s expense.
2) On each vessel, the applicator shall check foam adhesion to the substrate within 48 hours
of application. The foam/primer bond shall exceed the foam’s cohesive strength. In these
test areas, the substrate shall be scraped to remove residual foam without damaging the
primer and foam then applied to repair the test areas. Test samples and frequency shall
comply with Section 12.1.8.6.
3) All cracks, unbonded insulation, spongy areas, and large holidays shall be removed and
repaired to the Owner’s satisfaction.
4) During installation foam thickness shall be checked. Frequency of testing and tolerances
are specified in Section 9.6.11.
5) Samples at least 1 inch in diameter shall be cored or cut and removed from the item being
insulated for examination by the Inspector. After removal of a sample, the area shall be

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refoamed. No more than two samples per spray mechanic per day need be taken unless
substandard foam is evident. These samples shall be used for testing and visual
inspection.
6) Random samples taken in accordance with the previous paragraph shall be sent by the
applicator to an independent laboratory and tested as follows:
• The density shall be determined in accordance with ASTM D1622 at the start,
midpoint, and end of the job.
• The closed cell content shall be determined in accordance with ASTM D6226 at least
at the start of the job.
• The compressive strength shall be determined in accordance with ASTM D1621 on at
least three samples at the start of the job.
• Friability shall be checked daily (onsite).
• Adhesion to the substrate shall be checked daily (onsite). This may be done in
conjuncture with core sampling.
12.2 Polyurethane Foam Applicator Qualification
Prior to spraying foam on the substrate, each spray mechanic shall spray a 4 foot x 4 foot test
panel to meet the criteria of paragraph 9.6.12. The samples shall be inspected for visual
compliance with Figure 12. One panel shall be selected to serve as the standard of
performance for the work.

13.0 POLYURETHANE FOAM GUARANTEE

The installation shall be guaranteed for a period of five years from the date of acceptance
against blistering, cracking, peeling, or stripping caused by inherent defects of the installed
materials.

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14.0 TABLES

Table 1 – Documentation Requirements for Insulation Application per EP 11-3-4

The following information shall be shown on drawings and included in job specifications:
Item Description Format As-Built
1 Product specifications See EP 2-5-2 Yes
Material storage requirements, including shelf life and
2 See EP 2-5-2 Yes
temperature.
3 Design and application details of insulation expansion joints. See EP 2-5-2 Yes
4 Repair procedures for damaged areas. See EP 2-5-2 Yes
5 Inspections and testing procedures. See EP 2-5-2 Yes
Recommended safety precautions, such as proposed
6 method of electrical grounding of equipment (i.e., for blast See EP 2-5-2 Yes
cleaning and spray application).
Contractor Specification
The Owner’s Engineer shall supply a supplemental job
7 specification to the insulation Contractor. The job See EP 2-5-2 Yes
specification shall include all applicable drawing and
insulation schedules, material specifications and all
obligations and responsibilities required for the job.
Qualifications of Foam Applicators
8 Foam shall be installed only by foam applicators who are See EP 2-5-2 Yes
experienced in the proposed application methods and who
use equipment with positive metering.
The foam spray mechanics shall have a minimum of two
9 See EP 2-5-2 Yes
years’ field spraying experience.
Bidders shall submit a listing of similar installations
completed by them, including type of foam and weather
protection, date of completion, location, and contacts. If the
10 proposed foam or protective coating has not been used by a See EP 2-5-2 Yes
bidder, he shall submit a listing of successful installations by
others and a confirmation that the manufacturer(s) will
furnish field assistance.
Bidders shall submit resumes of recent experience of those
11 supervisory personnel and spray mechanics that will be See EP 2-5-2 Yes
used on the job.

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15.0 FIGURES
Figure 1 – “S” Clip

L/2 To Fit Weather-

Proofing Jacket

L/2 0.030 In. Thick

Width Of Jacket
Banding
Notes:
Length (L) to equal overlap of jacketing per Section 10.

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Figure 2 – Insulation Studs and Clips

When Used For Insulation,

Length=Thickness Of Insulation
1-1/4 In. Minus 1/4 In. See Note (1)
(Min.)
1/4 In. Thick Plate Or
1/2 In. Rectangular Welding Pin (2).

1-1/4 In.

CL 11/16 In. C Hole

1/4
Outside Shell
Insulation Clip Or Rectangular Welding Pin

Insulation
Metal Jacket
1/4 In. Stainless Steel
Stud Bolt (3)
Neoprene Washer
Gasket (Typical)

Shell Stainless Steel

Nut (Typical)
Stainless Steel
Washer (Typical)

Stud Bolt Detail

Notes:
1) For insulation thickness less than 1-1/2 inches, use 1/2 inch nut or U-shaped 1/4 inch diameter rod welded to
vessel.
2) See Section 8.0 for material requirements.
3) Studs are spaced on 14 inch centers circumferentially, but in no case shall there be less than 3 studs. Install
studs below support rings.

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Figure 3 – Insulated Fixed Roof Tanks

10 Gage x 4 In. Wide Mild 3/16 Special Slope (For

Steel Flashing See Note 1 Cone Roof Tanks)

Roof Insulation A 12
1-1/2
30°

1 In. Minimum Clearance Between

Outer Edge Of Flashing And
3 x 3 x 3/16 In. Surface Of Roof Insulation
Tank Shell
Angle

Metal Jacket

1/4
6 In. For Shells < 1/2 In. Thick
Insul. Thk. x 1/4 In. 10 In. For Shells > 1/2 In. Thick
See Note 2
Tank Bottom

Notes:
1) Dimension “A” = API 650 recommended roof nozzle and roof manhole projection.
2) Circumferential support bars shall not be continuous but shall be 8 feet long (max) with 1/2 inch gaps between
adjoining pieces.
3) Fire tube and heating coil connections shall be boxed in as shown regardless of their height (“B”) above tank
bottom.
4) Weld requirements for Insulation and fireproofing supports shall comply with EP 9-1-2, EP 9-2-1 and EP 9-4-1
as applicable.

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Figure 4 – Shell-to-Roof Angle

Top Angle
3/16

4 In.

Shell

Continuous Seal Weld

Angle Or 3/16 In. Bent Plate

Storage Tank
Metal Jacketing

Insulation

Continuous Seal Weld

Angle Or 3/16 In. Bent Plate

Storage Tank
Metal Jacketing

Insulation

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Figure 5 – Details for Insulated Fixed Roof Tanks

Steel Support Angle

6 In. Min. 6 In. Min.

1/2 In. Gap (Typ.)
6 In. Min.

Manhole Cover

Tank Bottom Plate

Detail Of Support Plate At Shell Manhole

Steel Support Angle

Nozzle Flange

6 In. Min. 6 In. Min.

1/2 In. Gap (Typ.)
6 In. Min.
Nozzle Flange
Steel Support Angle
B

B
Tank Bottom Plate Tank Bottom Plate

When "B" Is < 12 In. (See Note 3) When "B" Is 12 In.

Detail Of Support At Nozzles

Notes:
For notes see Figure 3.

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Figure 6 – Spacing of Clips on Spheres

2 Ft.
Insulation Clips Or 6 Ft.
Rectangular Welding
Pins Per Figure 2
6 Ft.

2 Ft. Max.
6 Ft.
(Typ.)

3 Ft.
Horizontal
3 Ft. Centerline

3 Ft.

3 Ft.
3 Ft. Insulation Clips Or
3 Ft. Rectangular Welding
2 Ft. Pins Per Figure 2

Notes:
Dimensions shown are maximum and shall be measured on periphery.

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Figure 7 – “Belt Loop” Detail

60 In. Max.
12 In.
Vertical
3/4 In. Band 12 In.

"Belt Loop"
3/4 In. x 0.020 In.
12 In.
Bands On
Insulation
12 In.

Stainless
Steel Screw

Loop Made From

Stainless Steel
Strap

Stainless
Steel Band

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Figure 8

Steel
Reinforcing Fabric To Be Installed Prior
Shell
To The Second Coat Of The Protective
Coating In An Area Approximately
18 In. x 18 In. Around Each Protrusion,
Turning Up Onto The Protrusion
Approximately 3 In.

Pipe Nozzle,
Valve, Etc.

Spray Applied
Polyurethane

Exterior
Protective
Coating

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Figure 9 – Expansion Joint and Bonding Details

10 To 12 In.
Tank Steel Roof
(Not Insulated)
Exterior Protective
Coating (Extended
Minimum 3 In. Beyond
Foam Edge)

Spray Applied
Polyurethane

Exterior Protective
Coating (Extended Tank Steel Shell
Minimum 3 In. And Bottom
Beyond Foam Edge)
10 To 12 In.

Figure 10 – Stiffener Ring Insulation

Insulation

Bands And Seals Are

Secured With Screws

Insulation
Support Ring

3 In. Thick Resilent

1-1/2 In. Fiber Blanket
Compressed To 1-1/2 In.

Metal Jacket

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Figure 11 – Sheathing at Stiffeners

Block Type Insulation

Only Placed Around
Stiffener Rings
(Typical For All)

Sheathing
Vessel Insulation

Beam Section Channel Section

T Section Plate

Figure 12 – Foam Surfaces Compared

Sheathing

Lock Seam
See Detail A

Flat Sheet

Stiffener
Insulation Detail A - Locking Seam (Typ.)

Screw

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16.0 REVISION LOG

Action Date Rev. Approver Description

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