INSULATION

INSPECTION
SEMINAR

QA/QC Department
Seminar Outline
I. Training Objectives
II. Terms & Definitions
III. Codes & Standards/Specifications
Required for Inspections
IV. QC Tools Required for Inspections
V. Piping Inspections General Requirements
VI. Documents Required for Inspections (i.e.
RFI, QCIR, Isometric Drawings, etc.)

QA/QC Department
I. TRAINING
OBJECTIVES

QA/QC Department
TO AVOID COMMON DEFICIENCIES DURING
INTALLATION
TO MINIMIZE / REDUCE WORK DURING PROJECT
EXECUTION
TO STRENGHTEN THE “FRONT LINE” INSPECTION
OF BOTH QC INSPECTORS AND FOG DIRECT
SUPERVISION WHO MUST CHECK/VERIFY TO SEE IF
ALL OF THE REQUIREMENTS BASED ON PROJECT
SPECIFICATIONS HAVE BEEN COMPLETED
PROPERLY.
TO PROVIDE BOTH EXPERIENCED QUALITY CONTROL
ENGINEERS / INSPECTORS A BACKGROUND IN THE
MORE CRITICAL JOB ASPECTS.
QA/QC Department
II. TERMS &
DEFINITIONS

QA/QC Department
BLANKET INSULATION
(ASTM VOL. 4.0, ASTM C 168-08b)

A relatively flat and flexible insulation in coherent

sheet form furnished in units of substantial area.

CALCIUM SILICATE
(ASTM VOL. 4.0, ASTM C 168-08b)

Insulation composed principally of hydrous

calcium silicate, and which usually contains
reinforcing fibers.

QA/QC Department
HOMOGENOUS MATERIAL
(ASTM VOL. 4.0, ASTM C 168-08b)
A material in which relevant properties are not a
function of the position within the material.
JACKETING
(ASTM VOL. 4.0, ASTM C 168-08b)
A form of facing applied over insulation
MASTIC
(ASTM VOL. 4.0, ASTM C 168-08b)

A material of relatively viscous consistency that

dries or cures to form a protective finish, suitable for
application to thermal insulation in thickness greater
than 30 mils (0.76mm) per coat.
QA/QC Department
III. CODES &
STANDARDS

QA/QC Department
ASTM – American Standard for Testing and
Materials

QA/QC Department
 IV. QC TOOLS
FOR INSPECTIONS

QA/QC Department
 VERNIER CALIPER

STEEL TAPE

INSPECTION MIRROR

FLASH LIGHT

QA/QC Department
V. INSPECTIONS
GENERAL
REQUIREMENTS

QA/QC Department
 SCOPE OF INSPECTION
SITE RECEIVING AND
STORAGE OF
INSULATION
MATERIALS
PRE, IN-PROCESS &
COMPLETED
INSPECTION OF
EQUIPMENT & PIPE
INSULATION
QA/QC Department
HOT INSULATION
(SM80-O1-MS-001 Rev. 00, Method Statement for Hot Insulation of Piping & Equipment)
All piping and equipment shall have Work Transfer Sheet and turned-over by
respective department prior to insulation.
All surfaces to be insulated shall be clean and dry.
All insulation materials shall be protected from rain and moisture.
Insulation sections shall be trimmed as required to achieve close fit to avoid
major voids and gaps.
All joints of multi layer insulation shall be staggered.
Bands used to secure the insulation shall be installed straight and in proper
tension without crushing insulation.
All external surfaces of insulation shall be weather jacketed to keep insulation dry
and provide mechanical protection to the system.
Code inspection plates, stampings, nameplates, data plates, manhole, hand hole
etc. on equipment shall be left visible by cutting back insulation and properly
sealing opening against moisture penetration using high temperature flashing
compound.
QA/QC Department
Hot Insulation (cont.)
Any interstices or hollow zones shall be completely filled with loose mineral
wool insulation material. For SS piping, pieces of mineral wool blanket shall be
used instead of cement powder.
Calcium Silicate preformed pipe and curved blocks as per ASTM 533 Type I for
materials with an operating temperature range from 100°C to 650°C continuous,
with minimum density of 220 kg/m3.
Mineral Wool blanket as per ASTM C 592 Type II with a minimum density of
120kg/m3. All wire mesh or lath shall be SS, ASTM A167 type 304L. Blocks and
boards shall be in accordance with ASTM C612 Type IV at 100kg/m3.
Insulation thickness shall be as per the requirement of the customer as specified.
However where thickness is not specified, guidelines generally as per the ASTM
standard shall be followed.
Single Layer shall be applied for insulation thickness up to 75 mm for calcium
silicate and up to 100 mm for mineral wool. Where the thickness exceeds 75 / 100
mm, multi-layer insulation shall be applied.
Insulation shall be snugly fitted with all joints closely butted together; the
circumferential joints between segments in adjacent lengths shall be staggered by
approximately 50% .
QA/QC Department
Hot Insulation (cont.)
For vertical piping, insulation shall be carried by support rings installed on the
piping with the first support ring located as low as possible in straight section of
piping and with a maximum spacing of 5.7m. Support ring shall also apply just
above every flanged connection.
Expansion joint shall be provided in every layer of insulation and filled with
mineral wool blanket.
Insulation Securing (Type 304 SS)
Each preformed pipe section used for the inside layer(s) shall be attached
using 1mmØ SS wires conforming to ASTM A167 and ASTM A580 on 300mm
centers, the twisted wire end shall be pressed into the insulation. Single layers
and for final layer of multi-layer insulation attachment shall be 12mm x .5mm
SS 304 type wire and / or bands. The maximum spacing shall be 300 mm.
Material in insulating and finishing cement shall conform to ASTM C449/C449M.
All large cracks, voids etc. outside insulation layer will be filled with above
cement.
Weather cladding shall be SS Type 304, 0.3 mm thickness in accordance with
ASTM A167 flat and corrugated as required.

QA/QC Department
Hot Insulation (cont.)
For pipe with OD≤ 760mm, overlapping shall be 50mm for longitudinal seams
and 75mm for circumferential seams; and for pipe OD≥ 760mm, overlapping
shall be 75mm at all seams. Longitudinal overlaps shall be oriented at 4 O' Clock
and 8 ‘O' cock position to shed water Longitudinal edges shall be crimp over
their full length to allow placement of sealing mastic and S-clips shall be used to
support the next higher cladding section on vertical.
Sealant (compatible with the insulating material being joined) shall be applied
around the jacket cut outs and protrusions to prevent entry of water and
moisture inside; shall remain permanently flexible through the operating
temperature range.
Weather jacketing shall be secured with Type 304 SS bands. 12mm x 0.5 mm
bands shall be used for piping at minimum 250 mm center and with one band at
each circumferential over lap, and tightened with seals. Where necessary, SS self-
tapping screw shall be used to hold the jacketing on vertical piping.
Insulation for elbow shall be fabricated from mitered segments of the straight
pipe sections. Segments shall be assembled together over the elbow / bend
without any gap or breakage. Pipe diameter less than 2” may be insulated with
finishing cement of the same thickness as of the adjoining pipe.

QA/QC Department
Hot Insulation (cont.)
Thickness of jacketing shall be same as that of straight piping. Metal core
segments fabricated from smooth sheets shall be used for covering elbow
insulation 4" and over size. Each core will have male and female grooves to
ensure proper joint and prevent the chances of water entering. For piping less
than 4" elbow fabricated with 45 deg shall be used.
Insulation of Flanges, Valve Bodies, Expansion and Special components
Mineral wool blanket as per ASTM C592
Insulation thickness shall be as per the requirement of the customer as
specified. However where thickness is not specified, guidelines generally as
per the ASTM standard shall be followed.
Flanges, valves and special components shall be insulated with blankets
attached to pre fabricated SS cover using clips and quick release toggles so
that it can be removed and replaced to allow for maintenance without
damage to insulation or cladding. The metal box shall cover minimum 150mm
of the adjacent pipe.
Weather Jacketing same as that of straight piping

QA/QC Department
ACOUSTIC INSULATION
(SM80-O4-MS-00001 Rev. 00, Method Statement for Acoustic Insulation)

All piping and equipment shall have Work Transfer Sheet and turned-over by
respective department prior to insulation.
All surfaces to be insulated shall be clean and dry.
All insulation materials shall be protected from rain and moisture.
Insulation sections shall be trimmed as required to achieve close fit to avoid
major voids and gaps.
All joints of multi layer insulation shall be staggered as possible.
Bands used to secure the insulation shall be installed straight and in proper
tension without crushing insulation.
Any interstices or hollow zones shall be completely filled with material similar to
the adjacent insulation material. Material shall be Loose Mineral Wool as per
ASTM C547. There should be no voids.
Acoustic Insulation - Mineral wool as per ASTM C 547. Density shall be 100
Kg/m3. Preformed pipe section shall be used depending upon the commercial
availability. Blanket type with wire mesh facing on one side shall be used where
preformed pipe sections are not commercially available.
QA/QC Department
Acoustic Insulation (cont.)
Acoustic Insulation class shall be selected as follows.
Class Material & Thickness (Inside & Outside)
IA1 Mineral Wool 150 mm + SS Jacketing 0.3mm

IA2 Not Applicable

IA3 Mineral Wool 150mm+Vinyl Sheet + SS Jacketing

0.3 mm
IA4 Mineral Wool 150mm+Vinyl Sheet + Mineral Wool
150mm + SS Jacketing 0.3 mm
IA5 Mineral Wool 150mm+Vinyl Sheet + Mineral Wool
150mm + Lead Sheet + SS Jacketing 0.3 mm

Sectional insulation shall be applied on:

Insulation Thickness Layer

50 mm One Layer

100 mm Double Layer

QA/QC Department
Acoustic Insulation (cont.)
One of the longitudinal joints of each layer shall be staggered as first layer in 3
O’ clock position, 2nd layer as 4 ‘O’ clock position and 3rd layer in 5 ‘O’ clock
position.
Insulation shall be snugly fitted with all joints closely butted together and
staggered.
Combined Thermal & Acoustic insulation:
Hot & Acoustic Services:
Where acoustic insulation is required in conjunction with thermal
insulation for hot service, mineral wool may be used for both purposes.
Acoustic insulation material shall be mineral wool as per ASTM C 547
having density 100 kg/m3.
Cold & Acoustic Services:
Where acoustic insulation is required in conjunction with thermal
insulation for cold service, cellular glass as per the requirement for cold
insulation shall be applied first and acoustic insulation shall be applied on
top.

QA/QC Department
Acoustic Insulation (cont.)
Insulation Securing (Type 304 SS)
Securing of Insulation shall be done as per specifications using SS 304 type
of wire and / or bands.
Where acoustic insulation is required in conjunction with thermal
insulation for hot service, mineral wool may be used for both purposes.
Material Description Type Size Application
SS Wire 304 16 G Insulation up to 6” OD

SS Bands 304 12 x 0.5mm Insulation > 6” OD and < 30” OD

SS bands 304 19 x 0.5mm OD > 30”

The maximum spacing of wire and band shall not exceed 300 mm.

Weather jacketing
SS Jacketing as per ASTM A167 temper smooth finish 0.3 mm thickness
shall be used for insulation class IA1. SS jacketing 0.3 mm thick shall be
used for insulation class IA3, IA4 and IA5.

QA/QC Department
Acoustic Insulation (cont.)
Weather jacketing (cont.)
Overlapping of longitudinal joint shall be minimum 50mm Longitudinal
joints shall have outer portion facing downwards to allow for draining rain
water.
For horizontal piping longitudinal overlaps shall be oriented at 4 O’ Clock
and 8 O' Clock position to shed water. On vertical piping, upper course of
jacketing shall have minimum of 50mm over lap with lower course.
Metal Joint Sealant
Sealant shall be applied around the jacket cut outs and protrusions to
prevent entry of water and moisture inside.
Securing of Weather Jacketing
Weather jacketing shall be secured with Type 304 SS bands. 12mm x 0.5
mm bands shall be used for piping up to 30” OD and 19 mm x 0.5 mm shall
be used for piping above 30” OD at maximum 200mm center and with one
band at each circumferential over lap, and tightened with seals. Where
necessary SS self-tapping screw shall be used to hold the jacketing on
vertical piping.
QA/QC Department
COLD INSULATION
(SM80-O2-MS-00001 Rev. 00, Method Statement for Cold Insulation)

All piping and equipment shall have Work Transfer Sheet and turned-over by
respective department prior to insulation.
All carbon and low alloy steel surface to be insulated shall be prepared cleaned
and painted. Insulation shall not be applied over wet surface.
All insulation materials shall be protected from rain and moisture. PIR insulation
material shall be stored inside or protected from UV radiation to prevent
degradation.
Insulation sections shall be trimmed as required to achieve close fit to avoid
major voids and gaps.
Bands used to secure the insulation shall be installed straight and in proper
tension without crushing insulation.
All external surfaces of insulation shall be weather jacketed to keep insulation dry
and provide mechanical protection to the system.

QA/QC Department
Cold Insulation Materials
Polyisocyanurate (PIR) in accordance with ASTM C591 with a density of 40~45
kg/m3
For pipe
Rigid PIR blocks shall be factory shaped / cut in two half sections for sizes
up to including 12” OD.
Shall be supplied in radius and beveled segments for all sizes over 12” OD.
For equipment
In excess of 3600mm OD, the PIR maybe supplied in flat beveled blocks of
maximum 300mm wide.
For heads, PIR flat and beveled blocks shall be used with minimum joints.
Pipe sections shall be oversized to accommodate thermal expansion
contraction.

QA/QC Department
Cold Insulation Materials (cont.)
Cellular Glass in accordance with ASTM C552 with average density between
112~128 kg/m3.
Rigid CG shall be factory shaped/cut into half sections, radiused and
beveled segments and slabs.
For pipe
Sizes up to and including 8” OD, CG insulation shall be supplied in two half
sections.
For equipment
In excess of 7000mm OD, CG insulation shall be supplied in flat blocks of
minimum 300mm wide.
Sizes exceeding 8” OD and for equipment up to 7000mm, CG insulation
shall be supplied in radiused and beveled segments having width on the
outside radius of 140 and 160mm for outside diameter up to 1000mm; and
a width on outside radius of between 210 and 435mm for outside radius
diameters from 1000mm up to 7000mm.

QA/QC Department
Cold Insulation Materials (cont.)
Mineral / Glass Fiber
Loose fill mineral wool shall have a maximum water content of 0.5% and
maximum organic material content of 0.1% and an expanded density of
48~80kg/m3.
Shall be in the form of 16~24 kg/m3 if used for filling contraction joints
and voids in valve and flange boxes.
Adhesives & Sealers and Vapor Stop
All mastics, cements, adhesives, sealants and tape that come in contact
with the stainless steel shall have a maximum leachable chloride content
of less than 50ppm when tested in accordance with ASTM C871. Joint
sealer shall be non-hardening, have low vapor permeability, minimum
shrinkage, shall remain flexible at all temperatures down to -160°C and
shall contain 4% or less by weight volatile solvents.
The vapor stop adhesive shall be a two-part elastomeric material suitable
for use down to 160°C.

QA/QC Department
Cold Insulation Materials (cont.)
Vapor barrier
Primary: mastic reinforced with glass cloth or synthetic fabric or barrier
membrane sheet.
Secondary: same as primary barrier or 1 layer of multiplex foil and sealing
tape.
Cladding
Shall be Stainless Steel as per ASTM A167 and 480, Type 304 with
minimum thickness of 0.3mm.
Flat, for all piping & horizontal equipment
Flat, for vertical equipment up to 760mm OD
Corrugated, for all vertical equipment over 760mm OD
Fastening Materials
SS Bands and locking clips, Type 304 as per ASTM A167 and 480
12mm and 19mm with a minimum thickness of 0.5mm bands
13mm and 20mm with a minimum thickness of 0.7mm clips
20mm with minimum of 0.5mm for U,S and Z clips
SS Screws / Rivets
QA/QC Department
Cold Insulation Materials (cont.)
Metal joint sealant
Silicon based metal joint sealant, non-hardening
Cold Insulation Thickness
Insulation thickness for piping shall be specified on the Line Designation Table
while for Equipment will be specified as per project specification.
Application Procedure
Insulation shall be applied only to the piping, vessels and equipment that have
been released for insulation. Longitudinal and circumferential insulation joints
shall be staggered. Joints in the following layer of more than one layer shall not
match the location of joints in the previously applied layer.
All voids between insulation and equipment shall be packed with loose filler
insulation.
Preformed format of insulation shall be used for pipe and vessels up to
168.3mm O.D. while Blocks & Lags for the larger O.D. with corresponding
attachment banding; two bands per insulation section, block or lag on all layer.

QA/QC Department
Application Procedure (cont.)
All metal parts which protrude on piping and equipment shall be insulated for a
distance equal to insulation thickness times four (4) or 300mm whichever is
greater measured from outside surface of insulation.
A coat of approved joint sealer shall be applied in the ends and edges of the
outermost layer of insulation.
On flange joints, insulation shall be stopped short of studs and nuts to permit
removal from one side only without damage to insulation. Clearance is equal to
bolt length plus 25mm. Bolt removal space shall always be packed with
compressible insulation before flange insulation.
Finishing or vapor sealing mastic reinforced with synthetic fiber fabric shall be
carried under the adjacent metal covering for a minimum of 5mm.
Vapor barrier
All piping and equipment shall be insulated with a vapor stop at each
interruption. A vapor stop shall be applied at each side of valves, flanges,
supports and at the lowermost point of vertical pipes having more than 4
meters length.

QA/QC Department
Application Procedure (cont.)
Vapor barrier (cont.)
Shall be applied over the end of insulation and sealed to the metal surface
where the insulation terminates to avoid cracks, holes, thin spots or open
joints such that air is excluded from the finished insulation.
Insulation shall be sealed at protrusion to form a vapor stop. Insulation
extended onto protrusions shall also be sealed.
Where the insulating material is Cellular Glass, only primary vapor barrier
shall be required .
All exposed edges of rigid insulation shall be rounded before application.

Blinded connections shall be furnished with removable metal covers lined with
insulation.
Where insulation is to be removed for maintenance access, it shall be fabricated
with a minimum number of field joints from rigid insulation and the vapor
barrier shall be marked such that the joints can be identified for removal of
insulation with minimum of damage to either pipe or equipment insulation.

QA/QC Department
Application Procedure (cont.)
Seal all joints, seams in metal cover and joints between cover and piping or
equipment with joint sealer.
Polyisocyanurate(PIR) Insulation
Fabrication of foam glass to suit the curved surfaces
Insulation may cut by the circular or band saw and shaped by grinding.
The fabricated insulation shall be checked with a pipe of the required
diameter to ensure its correct contour and curvature.
Both primary and secondary barrier shall be applied.
HORIZONTAL AND VERTICAL PIPING:
Insulation:
Insulation shall be preformed to fit the pipe O.D.
Fabricated pipe sections shall be applied in such a manner that all voids
are eliminated and with a staggered joint arrangement as much as
possible clearance shall provided between the pipe surface and the inner
layer of insulation.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
Insulation (cont.):
Unless otherwise specified; multilayer insulation shall be provided for PIR
where thickness exceeds 50mm, while cellular glass where thickness
exceeds 100mm.
For double layer, both circumferential and longitudinal joints shall be
staggered. Joints in the outer layer shall be fully sealed.
Joint Sealer
The butt edges shall be coated with a thick layer of joint sealer. (All joints
in the outermost layer of insulation for multilayer insulation or all joints of
single layer insulation system shall be completely sealed with joint sealer).
Securements
Inner layer applied in two halves shall be secured with 19mm pressure
sensitive filament tape bands with 500mm spacing applied with 50%
overlap.
In radiused and beveled segments, it shall be 12mm x 0.5 SS bands at
500mm centers machine tension and sealed.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
Support Ring
Same as pipe material.
The bolted support ring shall be installed for vertical run at every 5.7
meters for carbon steel and at 3.7 meters for SS and also at the start of
the vertical rise. Thickness of support ring shall be 5mm and width shall
be half the width of the thickness of the insulation for single and 13mm
less of the insulation thickness for multilayer.
Contraction Joint
38mm thick compressible insulating material compacted into 25mm wide
joint.
On vertical piping, contraction joint shall be installed below the support
ring.
On horizontal piping, overlapped shall not be located over contraction
joint.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
Vapor barrier
Where necessary vapor barrier shall be applied as laid down.
Secondary multiplex foil vapor barrier shall preferably be factory/shop
applied. Otherwise, it shall be site applied between the outermost layer
and the next inner layer of the insulation with overlap of 50mm.
For double layer installation, secondary vapor barrier is not required for
cellular glass.
Metal Jacketing
Cladding thickness is 0.3mm minimum smooth metal jacketing with
moisture barrier shall be used for piping weather proofing.
Overlaps shall be:
Minimum of 50mm at longitudinal seams and 75mm at circumferential
seams shall be provided for pipes sizes up to 760mm, longitudinal laps
shall be located in 4 & 8 O'clock position.
Minimum of 75mm for all seams at 760mm OD and above.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
Metal Jacketing (cont.)
Longitudinal edges shall be crimped over their full length.
Cladding shall be fitted carefully around piping attachments which pass
through it. Flashing shall be provided wherever necessary to prevent the
entrance of water.
Securement of Metal Jacketing
Insulation up to 30" OD shall be secured in place with 12mm x 0.5mm SS
band seal with 13mm x 0.7mm clips. Piping above 30” shall be secured
with SS band 19mm x 0.5mm and seal with 20mm x 0.7mm clips. The
maximum spacing is 200 mm.
Metal Joint Sealant
The Metal joint sealant shall be applied around the jacket cut outs and
protrusions to prevent the entry of moisture. Seal the longitudinal and
circumferential overlaps of the vapor barrier jacketing with an adhesive.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
Cold Pipe Shoe Interface:
Cold pipe insulation (Polyisocyanurate) shall be fitted tight against
installed cold pipe shoe. There shall not be any gap between insulation
joints. The circumferential joint in the polyisocyanurate shall be
completely sealed with joint sealer.
Vapor barrier being applied over the PIR insulation shall completely cover
the exposed surface of the polyisocyanurate insulation. Pipe insulation
jacketing shall fit to the cold shoe cover.
ELBOWS, REDUCERS & SMOOTH BENDS
Material: Cellular Glass in accordance with ASTM C552 with average
density between 112~128 kg/m3
Insulation Thickness
Thickness and insulation material for elbows, reducers and bends shall be
same as for straight piping. Insulation material for bends and elbows shall
be fabricated from straight piping to fit the curvature of bend/elbow/tee/
etc.
QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
ELBOWS, REDUCERS & SMOOTH BENDS (cont.)
Joint Sealer
The butt edges shall be coated with a minimum of 1.6mm thick layer of
joint sealer. In case of double layer inner layer shall be applied without
joint sealer.
Securements
Securement of insulation for elbows, reducers and smooth bends shall be
done the same way as that of straight piping.
Vapor Barrier
Primary: mastic reinforced with glass cloth or synthetic fabric or barrier
membrane sheet.
Secondary: same as primary barrier or 1 layer of multiplex foil and sealing
tape.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
ELBOWS, REDUCERS & SMOOTH BENDS (cont.)
Metal Jacketing
Material and its thickness for jacketing shall be same as that of straight
piping. Smooth sheet shall be used.
Cladding Thickness
Thickness of jacketing shall be same as that of straight piping.
Metal core segments fabricated from smooth sheets shall be used
for covering elbow insulation 4" and over size. Each core will have
male and female grooves to ensure proper joint and prevent the
chances of water entering. For piping less than 4" elbow
fabricated with 45deg shall be used if client agrees after seeing
sample and may give authorization in writing.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL PIPING (cont.):
ELBOWS, REDUCERS & SMOOTH BENDS (cont.)
Metal Jacketing (cont.)
Securement of Metal jacketing
Pop rivets shall be used for securing metal jacketing where
securing by band is not practical. Where pop rivets are used, all
holes shall be drilled before metal is put in place over the
insulation. Backing plate to be used to stop screw or pop rivets
puncturing the vapor barrier. On large elbows, secure the
insulation using 13mm SS band instead of pop rivets. One band
for each cored metal elbow shall be used.
Metal Sealant
The metal joint sealant shall be applied around the jacket cut
outs and protrusions and on all seams.

QA/QC Department
Application Procedure (cont.)
FLANGES, FLANGED VALVES & BUTT WELD VALVES / SOCKETS & SCREW VALVES:
Materials: Polyisocyanurate (PIR)
Insulation Thickness
Thickness and insulation material for valves and flanges shall be same as
for straight piping and installed in but joint construction and joints shall
sealed with joint sealer.
The termination of piping insulation at each side of the flanged joint or
valve shall allow sufficient space (at a distance of bolt length +25 mm) for
bolt removal. The cavity between pipe insulation and flange or valve is to
be placed with glass fiber blanket.
The resultant cavity between the piping insulation and the flange or valve
shall to be packed tightly with fiber glass.
Joint Sealer
Insulation for all valves and flanges shall be supplied and installed in butt
joint construction and all the butt joints shall be coated with a min 1.6 mm
thick layer of joint sealer.
QA/QC Department
Application Procedure (cont.)
FLANGES, FLANGED VALVES & BUTT WELD VALVES / SOCKETS & SCREW VALVES
(Cont.):
Securements
Insulation shall be secured with SS bands to ensure that the insulation is
held tightly to the valve and flange. Minimum two bands per section shall
be used.
Vapor barrier
Primary: mastic reinforced with glass cloth or synthetic fabric or barrier
membrane sheet.
Secondary: same as primary barrier or 1 layer of multiplex foil and sealing
tape.
Metal Jacketing
Material for jacketing shall be same as that of straight piping. Smooth S/S
sheet shall be used.

QA/QC Department
Application Procedure (cont.)
FLANGES, FLANGED VALVES & BUTT WELD VALVES / SOCKETS & SCREW VALVES
(Cont.):
Metal Jacketing (cont.)
Cladding Thickness
Minimum 0.3 mm thick smooth jacketing with moisture barrier shall be
used.
Securement of Metal Jacketing
Cladding for valves and flanges insulation shall be fabricated and installed
to allow removability without damage to the adjacent insulation. Pop
rivets and toggle clip / Catches shall be used for securing where
securement by band is not practical.
Metal Joint Sealant
The metal joint sealant shall be applied around the jacket cut outs and
protrusions to prevent the entry of moisture. Seal the longitudinal and
circumferential overlaps of the vapor barrier jacketing with an adhesive.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL & VERTICAL EQUIPMENT (COLUMNS & VESSELS)
Material: Polyisocyanurate blocks/curved segments shall be used for
vessel.
Insulation Thickness
Insulation thickness for Equipment will be specified as per project
specification.
Equipment Insulation
Curved segment block insulation shall be applied in such a manner that all
voids are eliminated and with a staggered joint arrangement. When
applying multi layer insulation, stagger outer layer joints from the inner
layer joints.
Joint Sealer
The butt edges shall be coated with a 1.6 mm thick layer of joint sealer. In
case of double layer inner layer shall be applied without joint sealer.
Securement of Insulation
Insulation shall be secured with SS bands and SS wire ASTM 167

QA/QC Department
Application Procedure (cont.)
HORIZONTAL & VERTICAL EQUIPMENT (COLUMNS & VESSELS) (cont.)
Contraction Joint
Contraction joints for vertical equipment shall be provided at each
insulation support and shall be filled with fiber glass insulation. Joints shall
be 38 mm wide compacted to 25mm, packed with 50mm fiberglass or
mineral wool insulation.
Vapor barrier
Primary: mastic reinforced with glass cloth or synthetic fabric or barrier
membrane sheet.
Secondary: same as primary barrier or 1 layer of multiplex foil and sealing
tape.
Metal jacketing
Material for cladding shall be as in clause no. 4.1.7.6 of this procedure.
Minimum 0.3 mm smooth SS (cold rolled-bright finish) with moisture
barrier shall be applied.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL & VERTICAL EQUIPMENT (COLUMNS & VESSELS) (cont.)
Cladding Application
Shall be Stainless Steel as per ASTM A167 and 480, Type 304 with
minimum thickness of 0.3mm.
Flat, for all piping & horizontal equipment
Flat, for vertical equipment up to 760mm OD
Corrugated, for all vertical equipment over 760mm OD
Overlap for horizontal vessels shall have 75 mm in all seams. Vertical
vessels shall have 2 corrugation at vertical seams and 75mm at
circumferential seam. Upper course of metal jacketing on vertical
equipment shall be supported by 'S' clips on 450mm centers.

Secure of Metal Jacketing

Secure metal jacketing with SS bands at 300 mm centers. To prevent
bands from sliding on vertical vessels, U clips 0.5 mm shall be provided
on maximum 1220 mm centers.
QA/QC Department
Application Procedure (cont.)
HORIZONTAL & VERTICAL EQUIPMENT (COLUMNS & VESSELS) (cont.)
Secure of Metal Jacketing (cont.)
SS Bands and locking clips, Type 304 as per ASTM A167 and 480
12mm and 19mm with a minimum thickness of 0.5mm bands
13mm and 20mm with a minimum thickness of 0.7mm clips
20mm with minimum of 0.5mm for U,S and Z clips
SS Screws / Rivets

Metal joint sealant:

The metal joint sealant shall be applied around the jacket cut outs and
protrusions.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL VESSELS HEADS, TRANSITIONS, STIFFENER RINGS,
PUMPS AND COMPRESSORS
Insulation Thickness
Thickness and insulation materials for vessels and equipment heads shall
be same as for shell.
Head Insulation
Heads shall have the block shaped so that all sections closely fit the
contour of the head. Insulation for exposed heads shall be secured with
bands attached to a floating ring at the top and to a circumferential band
at the tangent line of vessel head. For unexposed heads the bands shall be
fastened to the attachments provided by the vessel manufacturers.
Joint Sealer
The butt edges shall be coated with a thick layer of joint sealer. In case of
double layer inner layer shall be applied without joint sealer.

QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL VESSELS HEADS, TRANSITIONS, STIFFENER RINGS,
PUMPS AND COMPRESSORS (cont.)
Secure Insulation
Insulation shall be secured in place with 0.5mm x 12mm and 19mm SS
band and sealed with 0.7mm x 13mm, with maximum spacing 300mm. U,
S and Z clips shall be Type 304 SS 20mm x 0.5mm.
Vapor barrier
Primary: mastic reinforced with glass cloth or synthetic fabric or barrier
membrane sheet.
Secondary: same as primary barrier or 1 layer of multiplex foil and sealing
tape.
Metal Jacketing
Metal core segment jacketing fabricated from smooth sheet shall be
applied for vessel heads. All head cores shall be lapped a minimum of
75mm. Metal core shall overlap shell jacketing by a minimum of 100mm.
Bottom head of vertical equipment within the skirt shall be weather
proofed using glass fabric and mastic where application of metal is not
practical and shall extend 100mm under adjacent metal cladding.
QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL VESSELS HEADS, TRANSITIONS, STIFFENER RINGS,
PUMPS AND COMPRESSORS (cont.)
Cladding Thickness
Same with Horizontal & Vertical Equipment (columns and vessel).
Secure Metal Jacketing
Top heads on vertical vessels and equipment shall be finished with metal
jacketing with a minimum of 100mm turn down on the straight side of the
vessel as overlap. The metal head cover shall be secured in place at the
circumferential overlap with the SS band 0.5mm x 12mm and 19mm as
applicable. All metal joints shall have weather proof seams.
Transitions and stiffener rings shall be finished with metal jacketing and
weatherproof seams. The jacketing shall extend under the upper shell a
minimum of 100mm and over the lower shell a minimum of 100mm. The
circumferential overlaps shall be secured with SS bands.
Pop rivets shall be used for securing metal jacketing where securing by band
is not practical. Where pop rivets are used, all holes shall be drilled before
metal is put in place over the insulation. Backing plates shall be used to stop
puncture of vapor barrier.
QA/QC Department
Application Procedure (cont.)
HORIZONTAL AND VERTICAL VESSELS HEADS, TRANSITIONS, STIFFENER RINGS,
PUMPS AND COMPRESSORS (cont.)
Metal Joint Sealant / Flashing Compound
The metal joint sealant shall be applied around the jacket cut outs,
protrusions and also to all metal joint seams.
Insulation of Inspection Windows:
Where periodic inspection is required, such as at code inspection plates,
nameplates, data plates etc. vapor sealed insulation with provision for
removability and replacement without damaging the insulation shall be
provided.
If weather jacketing is not possible in the same day of insulation, such
insulated surface shall be temporary be covered with polyethylene sheet
to protect the insulation from weather.

QA/QC Department
VII. DOCUMENTS
REQUIRED FOR
INSPECTION

QA/QC Department
DOCUMENTS TO BE REVIEW PRIOR INSPECTIONS
PROJECT CONTRACT / SCOPE OF WORK
PROJECT SPECIFICATION
METHOD STATEMENTS / INSPECTION AND TEST PLAN
CODES AND STANDARDS
TOLERANCES
ISOMETRIC DRAWINGS

QA/QC Department
QA/QC Department
 END OF
PRESENTATION

QUALITY IS A LINE FUNCTION DO IT RIGHT THE FIRST TIME