TOROMONT

PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 1 OF 18

1.0

SCOPE

1.1

This specification covers the general requirements, acceptable materials, thickness of insulation, and
methods of application for the insulation of piping, fittings, vessels, and exchangers in hot and cold
services.

2.0

RESPONSIBLITY

2.1

It is the responsibility of the Project Engineer to indicate the requirements of insulation on P&I.
Diagrams. The thickness and materials shall be based on the Tables provided at the end of this document.
Insulation thickness shown in the thickness tables are the thickness of insulating blocks or molded
sectional pipe insulation, and do not include the vapor barrier or final covering compound.

2.2

The QC Manager will be responsible for supervision, control, and acceptance of the insulation work.

3.0

INSULATION MATERIALS

3.1

Polyurethane: It is supplied in bunstock form for fabricating into sheets, and pipe, tank, and vessel
insulation. It is available in various densities, with a density of 2 lb/ft 3 being the most commonly used.
The maximum service temperature range is 320o to +300oF (-195o to +150oC), with the normally used
range being 320o to +34oF (-195o to +1oC). It has a low k-value (k = 0.19 @ 75oF), will degrade in sun
light (ultraviolet rays), burn or char when exposed to fire, has a relative low vapor permeability, a high
resistance to water absorption, a relatively high expansion/contraction coefficient, and a normal
compressive strength of 24 lb/in2.
Polyurethane is also available as a spray-on or foamed-in-place product for small, limited job site
applications or preinsulated pipe sections.
Because of its low k-value that minimizes insulation thickness, low weight, and reasonable cost when
compared to other insulations. Polyurethane is used primarily for low temperature and cryogenic piping
and equipment.

3.2

Cellular Glass: Cellular glass is the generic term for insulation comprised of rigid closed glass cells.
FOAMGLAS as manufactured by Pittsburgh Corning Corporation is the only such material available. The
insulation is made by grinding glass to a fine powder, melting it in an oven, and foaming it to form the
closed cells. It is available in block form for fabricating into pipe, tank, and vessel insulation. It has an
average density of 8.5 lb/ft3. The maximum service temperature range is 320o to +900oF (-195o to
+482oC), with the normally used range 298o to +550oF (-183o to +288oC). Usage at the higher
temperatures requires special insulation design. It has an average k-value (k = 0.35 @ 75oF), will not burn
when exposed to fire, has a vapor permeability rating of zero, a very high resistance to water absorption, a
moderate expansion/contraction coefficient (less than steel), and a nominal compressive strength of 100
lb/in2. Cellular glass is also chemically resistant, except for hydrofluoric acid and strong caustics.
Cellular glass is used for pipe and equipment in dual temperature service, in which the process operates at
temperatures above and below ambient dew point, and for high temperature applications.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 2 OF 18

3.3

Fiberglass: Fiberglass is the generic term for insulation fabricated from very fine strands of glass fibers.
It is available in various forms including blankets, boards, mats, and preformed pipe insulation. Density
varies with available form. The normal range is from 1.5 to 6 lb/ft3. The service temperature range is 0o to
+850oF (-18o to +455oC) for products manufactured using thermosetting resin binders and 320o to
+1200oF (-195o to +650oC) for products manufactured using a needling process instead of binders. The
normal range for binder type insulation is 35o to 450oF (2o to 232oC). Fiberglass has an average k-value (k
= 0.25 @ 75oF), will not burn (however, the binders will), has a very high vapor permeability, good
resistance to moisture absorption, very minimal compressive strength, and very good sound absorption
coefficients.

3.4

Calcium Silicate: Calcium silicate is made from a compound of lime and silica with reinforcing fibers. It
is available in blocks and preformed pipe sections. The average density is 14 lb/ft 3. The service
temperature range is 100o to 1200oF (38o to 650oC). it has a relatively high k-value (k = 0.35 @ 100oF),
will not burn, has a very high vapor permeability, and readily absorb moisture. Calcium silicate is
manufactured to be suitable for use over stainless steel; however, individual production run must be
certified to make its installation acceptable. It has high compressive strength, although it breaks easily and
shrinks when heated, which requires special installation details for high temperature systems.
Calcium silicate is used primarily for hot and high temperature pipe and vessels. It is preferred over
fiberglass and mineral wool in applications subject to physical abuse due to its high compressive strength
and shock resistance. It is not acceptable for dual temperature service applications in which the process
operates at temperatures above and below ambient dew point or when systems operate below 100 oF
(38oC).

3.5

Mastic and Sealers: Some newly installed insulation, such as calcium silicate, contains moisture. All
insulation is subject also to the introduction of additional moisture from rain and changing weather
conditions. Mastics and sealers provide a barrier to prevent the migration of liquid water and water vapor
into insulation. This is necessary because thermal conductivity increases rapidly with any addition of
moisture, and in cryogenic systems, the moisture will freeze within the insulation, thereby destroying it.
For hot and high temperature systems, the water vapor pressure on the heated surface is greater than the
ambient-air water vapor pressure, which results in a vapor flow from the heated surface out through the
insulation. Therefore, mastics and sealers for hot and high temperature systems are not good vapor
barriers but are good weather barriers. They are commonly called breather coatings, since they do allow
the passage of water vapor. The use of mastics and sealers on hot and high temperature systems is usually
limited to valves, fittings, and vessel heads. Pipe runs and vessel shells are covered with metal jacketing,
which provides the weather barrier.
For cold and cryogenic systems, the water vapor pressure is much greater on the outside (or ambient
temperature side) than on the cold surface. This results in a vapor flow through the insulation toward the
cold surface. Therefore, mastics and sealers for cold and cryogenic systems must be excellent vapor
barriers to keep the passage of water vapor to an absolute minimum. There is, in reality, no perfect vapor
barrier. A certain amount of vapor will always penetrate, condense, and freeze, ultimately requiring the
replacement of the insulation. The use of mastics on cold and cryogenic systems is usually limited to
valves and fittings but might include pipe runs if other type vapor barriers are not used. Sealers must be
used on all joints between insulation and between insulation and any penetrations.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

3.6

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 3 OF 18

Jacketing: Jacketing is used to provide physical protection for all insulation systems as well as weather
protection for hot and high temperature insulation. Jacketing is typically specified as light gauge
corrugated aluminum. The corrugations add rigidity, reduce glare, do not show dents as readily, and
eliminate coil breaks on small lines. Stucco finish on jacketing is also acceptable; however, it is more
costly and is not normally used.
Aluminum has poor chemical resistance in the pH range 7-11, which requires that an interior moisture
barrier be applied to the aluminum jacketing when it is installed over calcium silicate. The moisture
barrier prevents galvanic or chemical corrosion of the aluminum from taking place. The moisture barrier
is not required for other types of insulation, but since the cost of the moisture barrier (usually Kraft paper
over a polyethylene films) is minimal, and to provide consistent installations, a moisture barrier is
specified for all jacketing.
Aluminum has a melting point of approximately 1200oF (650oC). Therefore, if insulation is used as a
form for fireproofing, it must be protected using stainless steel jacketing that has a melting point
exceeding 2600oF (1425oC).

4.0

EXTENT OF INSULATION
4.1

Reasons for Insulation

4.2

Control heat loss (heat conservation) on hot piping and equipment

Provide personnel protection
Reduce heat gain or controlling surface condensation on cold piping and equipment
Provide freeze protection, including heat tracing applications
Provide noise attenuation
Provide fire protection

The Following Piping and Components shall not be Insulated

All flanges in piping systems receiving noise attenuation insulation.

Piping and equipment flanges operating over 850oF (455oC), unless special alloy bolting is
used to prevent bolt overstressing.
All relief devices and discharge lines.
All vessel and equipment drains, unless heat tracing is required.
Vessel skirts and saddles.
All equipment and piping for which heat loss is desired (such as compressor discharge
piping), unless personnel protection is required.
Equipment name plates.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 4 OF 18

5.0

GENERAL REQUIREMENTS

5.1

All material shall be protected from weather and damage during all stages of handling and application.

5.2

The surface to be insulated shall be cleaned of all dirt, oil, grease or other foreign matter. Prior to
application, ascertain if surface to be insulated requires blast and prime.

5.3

All testing of the pipe such as pressure test, weld X-ray, etc., shall be performed prior to the application of
any insulation.

5.4

Materials shall be applied in a manner to reduce shrinkage to a minimum. Excessive cracks that develop
in any material shall be repaired with a like material.

5.5

Aluminum covering, when used with insulation or materials which are chemically reactive with
aluminum, shall be protected on the under side by asphalt, polyethylene, or equal protective barriers.

5.6

Nameplates on hot equipment shall not be insulated. Insulation shall be tapered on a 45 degree
angle to the name plate and sealed with a 1/4 wet coat of finishing cement followed by 1/4 wet
coat of weather-proofing compound. Nameplates on cold service equipment shall be installed
outside of insulation.

5.7

Hot service insulation shall be stopped short of nozzles, manways, flanges, and union to permit removing
bolts or breaking unions without damaging the insulation.

5.8

Circumferential insulation joints shall be staggered one-half a section or block length.

5.9

Circumferential and longitudinal joints in aluminum final coverings shall be arranged for good water
drainage and lapped a minimum of 1 1/2 on piping and 2 on vessels and exchangers. The
manufacturers standard overlap for preformed and precut materials is acceptable.

5.10

Cold service equipment, including valve bodies, flanges, nozzles, fittings, and all projections shall be
completely insulated. The only exception is rotating equipment such as pumps, compressors, etc. which
shall normally remain uninsulated to facilitate maintenance.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 5 OF 18

6.0

HOT SERVICE REQUIREMENTS CALCIUM SILICATE

6.1

All insulation shall be applied in joint lengths where possible and joints shall be tightly butted. Ragged
and open joints shall be neatly filled with finishing cement.

6.2

Final covering for hot service shall be aluminum jacketing and have a factory applied vapor barrier, and
be as follows:
6.2.1

Piping and Equipment

Straight Pipe: Flat embossed aluminum sheets, 0.016 utility grade, half hard, mill or
stucco embossed finished, in cut and machine rolled sections approximately 3 feet long.
Each section of final covering shall be secured in place with #8 x 1/2 stainless steel
screws spaced at 6 intervals.
b)
Elbows: Preformed aluminum elbows. Childers Manufacturing Co., General aluminum
Supply Co., or equal.
Vessels and Exchangers Shells
a)

6.2.2

a)

b)

c)
d)

6.3

Vertical Vessels: Corrugated aluminum roofing sheet, 1 1/4 x 1/2 corrugations, 0.020
standard grade, half hard, with plain mill or stucco embossed finish with factory applied
vapor barrier.
Horizontal Vessel Shells and Vertical Transitional Sections: Flat aluminum sheets 0.020
utility grade, half hard, mill or stucco embossed finish, machine cut and rolled in section
approximately 3 feet long.
Exchanger Shell Heads: Preformed aluminum or field cut gore segments with sufficient
overlap to ensure watertight joints. Minimum thickness shall be 0.020.
Vessel Heads: Preformed aluminum or field cut gore segments with sufficient overlap to
ensure watertight joints. Minimum thickness shall be 0.020.

Insulation for Hot Piping

6.3.1

Sections shall be placed on the pipe with end joints staggered and tightly butted together and shall
be held in place with three loops of 16 gage stainless steel wire per three foot section. The twisted
ends of the wire shall be bent over and forced into the insulation. All cracks and broken edges
shall be filled with insulating cement and smoothly pointed up.

6.3.2

At flanges in insulated lines, the insulation shall be beveled so that flange bolts may be removed
without damage to adjacent insulation.

6.3.3

Insulated piping shall be weatherproofed with aluminum jacketing with integral moisture barrier.
Aluminum sheet shall be machine rolled to fit the O.D. of the insulation and shall be fastened in
place with stainless steel screws on 6 centers. Circumferential and end seams shall lap a
minimum of 1 1/2. Circumferential seams on hot pipe shall not be fastened together with screws.

6.3.4

Fittings shall be insulated to the same thickness as adjacent piping. Insulation for fittings shall be
preformed and covered with 0.020 molded aluminum sheet.

6.3.5

Hot valves will not be insulated unless otherwise specified.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

6.4

6.5

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 6 OF 18

Hot Vertical Vessels & Exchangers

6.4.1

Blocks shall be applied with end joints staggered and edges butted tightly together. Blocks shall
be held in place with 3/4 x 0.020 stainless steel bands spaced on 9 centers. All cracks and
broken edges shall be filled with asbestos cement and smoothly pointed up.

6.4.2

Vessel shells shall be finished with aluminum with integral moisture barrier as specified.
Corrugated sheets shall be lapped two corrugations at side seams and at least 2 at end seams.
Flat aluminum sheets shall be lapped at least 3 at all seams. Sheets shall be held in place with
stainless screws on approximately 6 centers. 3/4 x 0.020 stainless steel bands shall be used at
all sheet laps and mid sheet. Spacing shall be 3 feet minimum.

6.4.3

Vessel heads shall be prefabricated from gored flat aluminum sheet and shall be installed so as to
be watertight.

6.4.4

Insulation shall be neatly beveled back to the vessel surface at all nozzles, manways, and other
connections and at the nameplate on the vessel. These bevels shall be completely sealed with
flashing cement to prevent moisture from entering behind the aluminum jacket.

6.4.5

Expansion joints shall be provided in the insulation on approximately 18 foot centers. Vessels
will be provided with insulation rings tack welded to the vessel.

6.4.6

A 2 space shall be left between the top of the insulating block and the insulation ring. Loose
rock wool shall be packed between the insulation ring and top of the insulating block before the
corrugated sheets are applied.

6.4.7

The heads of vessels and exchangers shall be insulated with one layer of flat block insulation; two
layers if over 3 thick; and have 1/4 layer of mineral or rock wool or one coat cement to fill
voids and to finish exterior of block.

Personnel Protection
Insulation shall be provided on all lines and equipment operating above 150oF and located where an
operator in the normal course of his work might be burned. Such insulation shall be labeled PP on the
prints and shall be stopped 7 foot above grade or operating platform and 3 foot out from operating
platform. This insulation shall be applied and finished as outlined for hot piping. Where insulation is
stopped, it shall be beveled to the pipe and flashing cement used to waterproof the ends of the insulation.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

7.0

COLD SERVICE REQUIREMENTS - POLYURETHANE

7.1

General

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 7 OF 18

7.1.1

This specification covers the application of Polyurethane insulation and accessories to piping and
equipment.

7.1.2

Adequate vapor barriers, having a permeability rating of 0.01 under ASTM C-355 and seals shall
be effected in insulation of all cold equipment and piping.

7.1.3

All single layers, or outer layer of double layer insulation, shall be applied in joint lengths where
possible and joints (including contraction slip joints) shall be tightly butted and buttered with
joint sealer to provide a single homogenous mass impermeable to water vapor.

7.1.4

Polyurethane insulation shall be furnished shop-coated with asphalt such that all pores are sealed
or furnished with factory-applied-foil-scrim-kraft-reinforced vapor barrier jacket.

7.1.5

Insulation shall be secured with 1wide reinforced tape on 9 centers. If a foil-kraft-vapor-barrier

is used, all laps shall be sealed with 2 wide polyvinyl tape.

7.1.6

Final covering for cold service

7.1.6.1 Piping and Equipment
a)

b)

c)

Straight Pipe: Flat embossed aluminum sheets, 0.016 utility grade, half hard,
mill or stucco embossed finished, in cut and machine rolled sections
approximately 3 feet long. Securement to be 1/2 stainless steel bands on 12
centers.
Elbows: Preformed aluminum elbows. Childers Manufacturing Co., General
aluminum Supply Co., or equal.
Valves flanges, contraction joints shall be finished with preformed or field
fabricated aluminum covers.

7.1.6.2 Vessels and Exchangers Shells

a)

b)

c)
d)

Vertical Vessels: Corrugated aluminum roofing sheet, 1 1/4 x 1/2 corrugations,

0.020 standard grade, half hard, with plain mill or stucco embossed finish with
factory applied vapor barrier.
Horizontal Vessel Shells and Vertical Transitional Sections: Flat aluminum
sheets 0.020 utility grade, half hard, mill or stucco embossed finish, machine cut
and rolled in section approximately 3 feet long.
Exchanger Shell Heads: Preformed aluminum or field cut gore segments with
sufficient overlap to ensure watertight joints. Minimum thickness shall be 0.020.
Vessel Heads: Preformed aluminum or field cut gore segments with sufficient
overlap to ensure watertight joints. Minimum thickness shall be 0.020.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

7.2

7.3

7.4

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 8 OF 18

Cold Piping
7.2.1

Pipe insulation thru 3 thickness shall be applied in a single layer.

7.2.2

Pipe insulation 3 1/2 thickness and above shall be applied in double layer construction with
joints staggered.

7.2.3

Pipe insulation shall be applied with end joints staggered and with all edges of single layer or
outer layers of double layer buttered with a trowel grade of joint sealer and butted tight together.
Chipped places in any layer shall be filled with seam filler before the next layer is applied. Each
succeeding layer shall be offset so that the joints do not coincide.

7.2.4

Finish shall be 0.016 flat mill or stucco embossed aluminum sheet rolled to fit the O.D. of the
covering. Side and end seams shall overlap a minimum of 1 1/2. The aluminum sheet shall be
held in place with 1/2 x 0.020 stainless steel bands and chip on 1-foot centers. The use of
screws is prohibited.

Cold Fittings
7.3.1

Fittings for purposes of this specification shall include weld elbows, tees, reducers, screwed
fittings, unions, flanges, and valves.

7.3.2

Fittings shall be insulated at the same time and in the same manner as specified for pipe. Fitting
insulation shall be prefabricated from Urethane in the same thickness as specified for the adjacent
piping.

7.3.3

Fitting insulation covers shall be made in two or more sections to snugly fit the piece for which
they are intended and shall extend beyond the weld far enough to allow for a band at each end of
the cover. The pipe insulation shall be butted tight against the fitting cover.

7.3.4

Insulation for fittings shall be covered with preformed aluminum or field cut gore segments with
sufficient overlap to ensure watertight joints. Minimum thickness 0.020 molded aluminum sheet.

Cold Insulated Vessels & Exchangers

7.4.1

Vessels shall be insulated with urethane either curved to fit the O.D. of the vessel or straight
blocks cut and mitered to closely fit the vessel contour and fit snugly together at their edges. The
inside skirt on smaller vessels may be insulated by filling with urethane foam in situ if more
practical. Supports of any kind that protrude through the insulation shall be insulated for a
distance equal to four times the insulation thickness.

7.4.2

Insulation thickness thru 3 shall be applied in a single layer.

7.4.3

Insulation thickness 3 1/2 and above shall be applied in double layer construction with all joints
staggered.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

7.5

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 9 OF 18

7.4.4

End of block shall be staggered. The block shall be fastened in place with 3/4 x 0.020 stainless
steel bands on approximately 9 centers. Bands shall be machine stretched and fastened with
stainless steel clips while under tension. Chipped and broken places in the block shall be pointed
up with joint sealer. Succeeding layers, if required, shall be laid as specified above with the joints
offset from the previous layer. Each layer of insulation shall be thoroughly sealed at all nozzles,
manways and other protrusions.

7.4.5

Block shall extend beyond body of the vessel for a distance equal to the insulation thickness so
those discs for the heads can be inserted inside the shell shall be packed solid with fine granulated
polyurethane.

7.4.6

Insulation on bottom levels of vertical vessels shall be cut and mitered to fit the shape of the head.
It shall be laid up in adhesive, held in place with 3/4 x 0.020 bands laced around a rod bent to
the I.D. of the skirt, and tacked welded to it on a 2 center. Insulation on the inside of vessel skirt
shall be secured with adhesive cement and thoroughly sealed against the bottom head insulation.

7.4.7

On vertical vessels, 0.020 x 1 1/4 corrugated sheet shall be applied overlapped 2 corrugations
on sides and 3 at ends. Sheets shall be fastened in place with 3/4 x 0.020 stainless steel bands
and clips on 12 centers. The use of screws is prohibited.

7.4.8

Horizontal vessels shall be finished with 0.020 flat aluminum sheet lapped at least 2 at all
seams and fastened in place with 3/4 x 0.020 stainless steel bands and clips on 12 centers. The
use of screws is prohibited.

7.4.9

Providing an extra inch beyond the length of insulation between insulation supports shall
compensate for longitudinal contraction on vertical vessels. Insulation above and below supports
shall be fitted to form a 2 long male and female slip joint, which shall completely cover the
support and the void below the support. The 1 void shall be filled with loose mineral wool
insulation.

Protrusions
7.5.1

Supports attachments and other non-operating protrusions shall be insulated a minimum of 8

beyond the finished insulation.

7.5.2

Insulation supports shall be completely covered with insulation and sealed with vapor seal
compound.

7.5.3

Cutouts for nozzles, manways, support attachments, etc., shall be carefully fitted, flashed and
sealed with sealing compound to prevent water penetration.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

8.0

COLD SERVICE REQUIREMENTS CELLULAR GLASS (FOAMGLAS)

8.1

Application of Insulation
8.1.1

EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 10 OF 18

Straight Piping
a)
b)

c)

d)
e)

f)

g)

8.2

PRACTICE NO.
TPS-TP-00X

Insulation shall be single layer through 4 thickness and double layer construction 4 1/2
and above.
Where piping is subjected to excessive vibration the bore surface of the inner layer of
cellular glass insulation shall receive a coating of anti-abrasive coating, sufficient to fill
the surface cells, which shall be given time to dry before being applied to the pipe.
The first layer of a double layer system shall be applied dry with all joints closed tightly
and the circumferential joints staggered. The first layer shall be secured with high
strength tape wrapped around the insulation, at two wraps per section, with a 50%
overlap of the tape per wrap.
Succeeding layers of insulation shall be applied in the same manner as the first layer but
with all joints staggered from those of the preceding layer.
The final layer in insulation shall be applied dry except that the mating surfaces of all
joints shall receive a coat of joint sealer. The joint sealer shall cover the joint surface
through the entire thickness of the insulation. The joint sealer shall be applied to the
mating butt ends of succeeding adjacent sections of insulation to insure that a thin
continuous seal is provided for the full length and depth of each joint. If a single layer of
insulation is all that is required, this procedure would also apply.
The outer layer of cellular glass insulation shall be secured with stainless steel bands at
the rate of two bands per section of insulation. All joints in the outer layer must be
staggered from those of the preceding layer.
Care must be taken that the outer layer of cellular glass insulation is not cracked when
secured with stainless steel bands. Cracked or broken Foamglass insulation shall be
replaced.

Fittings and Valves, etc.

8.2.1

All fitting insulation shall be applied with all fabricated sections to rest with no voids or gaps.
Insulation shall be single layer through 4 thickness and double layer construction 4 1/2 and
above.

8.2.2

The fitting insulation shall be sized to match adjacent straight run piping insulation and shall
provide a step type juncture with the straight run piping insulation.
a)

b)

c)
d)

The application of the layers of fabricated fittings shall be the same as for straight run
piping; that is, the inner layer applied dry and secured with high strength tape and the
outer layer sealed at all joints and secured with stainless steel bands.
All fabricated sections of cellular glass insulation shall be adhered with hot asphalt
through the entire thickness of the insulation. The hot asphalt shall be held at the lowest
workable temperature to assure a complete through seal.
Valve body insulation need not conform to the valve but all void areas shall be packed
with light density cellular glass.
If stainless steel banding cannot be correctly positioned over the fitting insulation, it shall
be the responsibility of the insulation contractor to ensure that the insulation is properly
secured.

SUBJECT
INSULATION SPECIFICATION

TOROMONT
PROCESS
SYSTEMS

DEPARTMENT
ENGINEERING
REVISION
A

8.2.3

PRES. / VICE PRES.

EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 11 OF 18

Insulation shall be single layer through 4 thickness and double layer construction 4 1/2
and above. All equipment insulation shall be applied in the same manner as for piping,
that is, the inner layers applied dry and the outer layer sealed at all joints.

b)
c)

All equipment securement shall be with 3/4 wide x 0.020 thick stainless steel
bands.
Securement band spacing shall be a minimum of two bands per course of block.

All junctures between straight side wall insulation and head insulation on vessels or
equipment shall be of a step fashion to provide a minimum 6 step pattern.
Inside skirts of small vessels, filling with urethane foam may be used in lieu of block
cellular glass.

Insulation Finish
8.3.1

Metal Jacketing
a)

Piping

b)

8.4

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRACTICE NO.
TPS-TP-00X

Equipment
a)

8.3

APPROVALS
REQUIRED

All pipe metal jacketing shall be applied with the longitudinal joint positioned to shed
water.
All circumferential joints shall overlap a minimum of 1 1/2.
There shall be a minimum of three stainless steel bands per section of metal
jacketing.

Equipment

All equipment metal jacketing shall be applied starting from the bottom of the
equipment and working toward the top. The longitudinal overlaps shall be positioned
to shed water.

Metal jacketing over the roof (or top head) of any piece of equipment shall overlap
the side wall finish so as to shed water. Securement at this juncture shall be screws
and bands as required by site wind and weather conditions.

Contraction/Expansion Joints
8.4.1

Piping
a)

b)
c)
d)

Contraction joints in the piping insulation shall be located at intervals along the pipe that
will limit the total contraction per joint to 1. The contraction joint shall be of the step
pattern.
Joint sealer shall be used between layers of cellular glass insulation to provide a slip
plane.
The outside vapor barrier sheet is to be wrapped around the joint and sealed with joint
sealer, then banded with stainless steel bands. It is to be 1/8 closed-cell neoprene.
Mechanical expansion joints shall be insulated as detailed.

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

8.4.2

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 12 OF 18

Equipment
Contraction joints in equipment insulation shall be located on the under side of insulation
supports by providing clearance between the cellular glass insulation and the horizontal leg of the
support.

8.5

8.6

Insulation Supports
8.5.1

Insulation supports shall be located on vertical piping and equipment so as to limit the movement
of the insulation during contraction of the piping or equipment to a maximum of 1.

8.5.2

Insulation supports shall be sized so that the horizontal leg will support all inner layers of cellular
glass insulation and one-half the total thickness of the outer layer.

Hangers & Cradles for Piping

8.6.1

All hangers shall be located on the outside of the final layer of insulation and finish.

8.6.2

The cradle shall be designed to provide a sufficient bearing area to limit the compressive force on
the insulation to 33 psi.

SUBJECT
INSULATION SPECIFICATION

TOROMONT
PROCESS
SYSTEMS

APPROVALS
REQUIRED

DEPARTMENT
ENGINEERING
REVISION
A

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

ENGINEERING STANDARD
TOROMONT
PROCESS
SYSTEMS

PAGE 13 OF 18

PRES. / VICE PRES.

REVISION

DATE

08-Nov-99

COLD INSULATION SPECIFICATIONS

TABLE "A"

LOW TEMPERATURE INSULATION THICKNESS

(CELLULAR GLASS WITH METAL WEATHERPROOFING)
NOMINAL PIPE SIZE
(NPS) SYSTEM

OPERATING TEMPERATURE, F
70 to
36

36 to
0

-1 to
-30

-31 to
-60

-61 to
-90

-91 to
-120

-121 to
-160

-161 to
-200

-201 to
-250

-251 to
-300

INSULATION THICKNESS, INCHES

1/2"

1.5

2.5

2.5

3.5

4.5

3/4"
1"
1 1/2"
2"
2 1/2"
3"
4"
5"
6"
8"
10"
12"

1
1
1
1
1
1.5
1.5
1.5
1.5
1.5
1.5
1.5

1.5
1.5
2
2
2
2
2
2.5
2.5
2.5
2.5
2.5

2
2
2
2.5
2.5
3
3
3
3
3.5
3.5
3.5

2.5
2.5
2.5
3
3
3.5
3.5
3.5
4
4
4.5
4.5

2.5
3
3
3.5
3.5
4
4
4
4.5
4.5
5
5

3
3.5
4
4
4
4.5
4.5
5
5
5.5
5.5
6

3.5
3.5
4
4
4
5
5
5.5
5.5
6
6.5
6.5

4
4
4.5
5
5
5.5
5.5
6
6.5
7
7
7.5

4.5
4.5
5
5.5
5.5
6
6.5
6.5
7
7.5
8
8

4.5
5
5.5
6
6
6.5
7
7.5
7.5
8
8.5
9

14"
16"
18"
20"
24"
28"
32"
36"
42"
48"
60"
72"

1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2
2

3
3
3
3
3
3
3
3
3
3
3
3

4
4
4
4
4
4
4
4
4.5
4.5
4.5
4.5

4.5
4.5
5
5
5
5
5
5
5.5
5.5
5.5
5.5

5.5
5.5
5.5
5.5
6
6
6
6
6
6.5
6.5
6.5

6
6
6.5
6.5
6.5
6.5
7
7
7
7
7.5
7.5

6.5
7
7
7
7.5
7.5
7.5
7.5
8
8
8
8

7.5
8
8
8
8.5
8.5
8.5
9
9
9
9.5
9.5

8.5
8.5
9
9
9.5
9.5
10
10
10
10
10.5
10.5

9
9.5
9.5
10
10
10.5
10.5
11
11
11
11.5
11.5

96"
120"
144"
Over 144" to Flat

2
2
2
2

3
3
3
3

4.5
4.5
4.5
4.5

5.5
5.5
5.5
6

6.5
6.5
6.5
7

7.5
7.5
7.5
8

8.5
8.5
8.5
9

10
10
10
10.5

11
11
11.5
12

12
12
12
12

Notes:
o

1.

Relative Humidity: 85% @ 85 F Dry Bulb & Zero Wind Speed.

2.

Emmissivity: 0.9

SUBJECT
INSULATION SPECIFICATION

TOROMONT
PROCESS
SYSTEMS

APPROVALS
REQUIRED

DEPARTMENT
ENGINEERING
REVISION
A

EFFECTIVE DATE
NOVEMBER 10, 1999

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PAGE 14 OF 18

PRES. / VICE PRES.

ENGINEERING STANDARD
TOROMONT
PROCESS
SYSTEMS

PRACTICE NO.
TPS-TP-00X

REVISION

DATE

08-Nov-99

COLD INSULATION SPECIFICATIONS

TABLE "B"

LOW TEMPERATURE INSULATION THICKNESS

(RIGID POLYURETHANE FOAM)
o

OPERATING TEMPERATURE, F
NOMINAL PIPE
SIZE (NPS)
SYSTEM

60 to
45

44 to
30

29 to
15

14 to
0

-1 to
-25

-26 to
-50

-51 to
-75

-76 to
-100

-101 to
-150

-151 to
-200

-201 to
-250

INSULATION THICKNESS, INCHES

3/4"
1"
1 1/2"

1
1
1

1
1
1

1.5
1.5
1.5

1.5
1.5
1.5

2
2
2

2
2
2.5

2.5
2.5
2.5

2.5
2.5
3

3.5
3.5
3.5

3.5
3.5
4

3.5
3.5
4

2"
3"
4"
5"
6"
8"
10"
12"
14"
16"
18"
20"

1
1
1
1
1
1
1
1
1
1
1
1

1
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5

1.5
1.5
1.5
1.5
1.5
1.5
2
2
2
2
2
2

1.5
1.5
2
2
2
2
2
2
2
2
2
2

2
2.5
2.5
2.5
2.5
2.5
2.5
2.5
3
3
3
3

2.5
2.5
2.5
3
3
3
3
3
3
3
3
3.5

2.5
3
3
3
3
3.5
3.5
3.5
3.5
3.5
3.5
3.5

3
3.5
3.5
3.5
3.5
4
4
4
4
4.5
4.5
4.5

3.5
4
4
4.5
4.5
5
5
5
5
5.5
5.5
5.5

4
4.5
4.5
5
5
5
5.5
5.5
5.5
5.5
6
6

4
4.5
4.5
5
5
5.5
5.5
5.5
6
6
6
6

24"
30"
36"
48"
72"
96"
120" & UP

1
1
1
1
1
1
1

1.5
1.5
1.5
1.5
1.5
1.5
1.5

2
2
2
2
2
2
2

2
2
2
2
2
2
2

3
3
3
3
3
3
3

3.5
3.5
3.5
3.5
3.5
3.5
3.5

4
4
4
4
4
4
4

4.5
4.5
4.5
5
5
5
5

5.5
5.5
6
6
6
6
6.5

6
6
6.5
6.5
6.5
7
7

6.5
6.5
6.5
7
7
7
7.5

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PRES. / VICE PRES.

ENGINEERING STANDARD
TOROMONT
PROCESS
SYSTEMS

PRACTICE NO.
TPS-TP-00X
EFFECTIVE DATE
NOVEMBER 10, 1999
PAGE 15 OF 18

REVISION

DATE

08-Nov-99

COLD INSULATION SPECIFICATIONS

TABLE "C"

COLD SERVICE INSULATION AND COATING MATERIALS

MATERIAL

MANUFACTURER / DESCRIPTION ***

POLYURETHANE
Block & Sectional Pipe Insulation

Dow Chemical Polyisocyanurate

Trymer 2000

Preformed Valve, Flange & Fitting Insulation

Dow Chemical Polyisocyanurate

Trymer 2000

Mineral Wool Insulation

1. MF Pipe Insulation
2. Forty Eight Insulation Co.
3. John Manville Spin Glass # 1000
Fosters 30-45

Joint Sealer
Vapor Seal Compound
Tape
Aluminum Jacketing
Banding

Fosters 65-07, 60-25, 60-26

3M Co. Scotch Tape No. 880
Childers or General Aluminum Supply
0.020 Thick 304 Stainless Steel
1/2 Wide for Piping
3/4 Wide for Equipment

CELLULAR GLASS (FOAMGLAS)

Block & Sectional Pipe Insulation

Pittsburgh Corning Corporation

Foamglas

Preformed Valve, Flange & Fitting Insulation

1. Pittsburgh Corning, PITTSEAL 111 or 444

Anti Abrasive Bore Coating

Exterior Pore Sealer Vapor Barrier
Contraction Joint Vapor Barrier
Tape
Aluminum Jacketing
Banding

***

2. Foster 30-45
1. Pittsburgh Corning, 1A FR or 2A
2. Foster 30-45
Asphalt
Goodyear Rubber Co; 1/8 Thick Closed Cell Neoprene Sheeting
3M Co. Scotch Tape No. 880
Childers or General Aluminum Supply
0.020 Thick 304 Stainless Steel
1/2 Wide for Piping
3/4 Wide for Equipment

Manufacturers are listed to identify types and quality standards for insulation materials. Other
manufacturers material having equivalent insulation value and quality can be used.

SUBJECT
INSULATION SPECIFICATION

TOROMONT
PROCESS
SYSTEMS

APPROVALS
REQUIRED

DEPARTMENT
ENGINEERING
REVISION
A

EFFECTIVE DATE
NOVEMBER 10, 1999

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PAGE 16 OF 18

PRES. / VICE PRES.

ENGINEERING STANDARD
TOROMONT
PROCESS
SYSTEMS

PRACTICE NO.
TPS-TP-00X

REVISION

DATE

08-Nov-99

HOT INSULATION SPECIFICATIONS

TABLE "D"

PERSONNEL PROTECTION INSULATION THICKNESS

(CALCIUM SILICATE)
o

OPERATING TEMPERATURE, F
NOMINAL PIPE
SIZE (NPS)
SYSTEM

150 to
200

201 to
250

251 to
300

301 to
400

401 to
500

501 to
600

601 to
700

701 to
800

801 to
900

901 to
1000

1001 to
1100

INSULATION THICKNESS, INCHES

1/2"
3/4
1"

0.5
0.5
0.5

0.5
0.5
0.5

0.5
0.5
0.5

1
1
1

1
1
1

1
1.5
1.5

1.5
1.5
1.5

1.5
1.5
2

2
2
2

2
2
2.5

2.5
2.5
2.5

1 1/2
2"
3"
4"
5"
6"
8"
10"
12"
14"
16"
18"

0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

1
1
1
1
1
1
1
1
1
1
1
1

1
1
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5

1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2
2
2
2

1.5
1.5
2
2
2
2
2
2
2
2
2
2

2
2
2
2
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5

2
2.5
2.5
2.5
2.5
2.5
3
3
3
3
3
3

2.5
2.5
3
3
3
3
3
3.5
3.5
3.5
3.5
3.5

3
3
3
3.5
3.5
3.5
3.5
4
4
4
4
4

20"
24"
30"
36"
48"
60"
72"
84
96"
108"
120" & UP

0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5

1
1
1
1
1
1
1
1
1
1
1

1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5

2
2
2
2
2
2
2
2
2
2
2

2
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5

2.5
2.5
2.5
3
3
3
3
3
3
3
3

3
3
3
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5

3.5
3.5
3.5
4
4
4
4
4
4
4
4

4
4
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5

SUBJECT
INSULATION SPECIFICATION

TOROMONT
PROCESS
SYSTEMS

APPROVALS
REQUIRED

DEPARTMENT
ENGINEERING
REVISION
A

EFFECTIVE DATE
NOVEMBER 10, 1999

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PAGE 17 OF 18

PRES. / VICE PRES.

ENGINEERING STANDARD
TOROMONT
PROCESS
SYSTEMS

PRACTICE NO.
TPS-TP-00X

REVISION

DATE

08-Nov-99

HOT INSULATION SPECIFICATIONS

TABLE "E"

HEAT CONSERVATION INSULATION THICKNESS

(CALCIUM SILICATE)
o

OPERATING TEMPERATURE, F
NOMINAL PIPE
SIZE (NPS)
SYSTEM

150 to
200

201 to
250

251 to
300

301 to
400

401 to
500

501 to
600

601 to
700

701 to
800

801 to
900

901 to
1000

1001 to
1100

INSULATION THICKNESS, INCHES

1/2
3/4
1"

1
1
1

1
1
1

1
1
1

1.5
1.5
1.5

1.5
1.5
2

2
2
2

2
2
2.5

2.5
2.5
2.5

2.5
3
3

3
3.5
3.5

3.5
3.5
4

1 1/2
2"
3"
4"
5"
6"
8"
10"
12"
14"
16"
18"

1
1
1
1
1
1
1.5
1.5
1.5
1.5
1.5
1.5

1
1
1
1
1
1
1.5
1.5
1.5
1.5
1.5
1.5

1
1
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2
2
2

1.5
1.5
1.5
1.5
2
2
2
2.5
2.5
2.5
2.5
2.5

2
2
2
2.5
2.5
2.5
2.5
2.5
3
3
3
3

2.5
2.5
2.5
3
3
3
3
3
3
3.5
3.5
3.5

2.5
2.5
3
3
3
3
3.5
3.5
4
4
4
4

3
3
3.5
3.5
3.5
4
4
4
4
4
4.5
4.5

3.5
3.5
4
4
4
4.5
4.5
4.5
5
5
5
5

4
4
4.5
4.5
4.5
5
5
5.5
5.5
5.5
5.5
6

4
4.5
5
5
5.5
5.5
6
6
6
6.5
6.5
6.5

20"
24"
30"
36"
48"
60
72"
84
96"
120" & UP

1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5

1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5

2
2
2
2
2
2
2
2
2
2

2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5

3
3
3
3
3
3
3
3
3
3

3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
4
4

4
4
4
4
4
4
4
4
4
4

4.5
4.5
4.5
4.5
5
5
5
5
5
5

5
5
5.5
5.5
5.5
5.5
6
6
6
6

6
6
6
6
6.5
6.5
6.5
6.5
7
7

6.5
7
7
7
7.5
7.5
7.5
7.5
8
8

TOROMONT
PROCESS
SYSTEMS

SUBJECT
INSULATION SPECIFICATION
DEPARTMENT
ENGINEERING
REVISION
A

APPROVALS
REQUIRED

EFFECTIVE DATE
NOVEMBER 10, 1999

DEPT. MANAGER

REVISION DATE
NOV. 16, 1999

PAGE 18 OF 18

PRES. / VICE PRES.

ENGINEERING STANDARD
TOROMONT
PROCESS
SYSTEMS

PRACTICE NO.
TPS-TP-00X

REVISION

DATE

08-Nov-99

HOT INSULATION SPECIFICATIONS

TABLE "F"

HOT SERVICE INSULATION AND COATING MATERIALS

MATERIAL

MANUFACTURER / DESCRIPTION ***

Block & Sectional Pipe Insulation

1. Owens Corning Kaylo

2. Fiber Board Corp. Pabco
3. Calsilite

Preformed Valve, Flange & Fitting Insulation

1. Owens Corning Kaylo

2. Fiber Board Corp. - Pabco
1. Eagle Picher Co. Super 66
2. Forty Eight Insulation Co. Super 48
3. Ryders One Coat M.W.P.
1. Eagle Pitcher Co.
2. Forty Eight Insulation Co.
1. Eagle Pitcher Co. One Coat
2. Ryders One Coat
1. Foster 65-07
2. Monsanto Nokorode
3. American Petrofina 0.025 Mastic

Monolithic Insulation

Mineral Wool Insulation

Finishing Cement
Sealing Compound

Weatherproofing Compound

***

1. Foster 90-07
2. Monsanto Seal Cote
3. American Petrofina 033

Manufacturers are listed to identify types and quality standards for insulation materials. Other
manufacturers material having equivalent insulation value and quality can be used.