Wood Doc. No.

: 0003-9500-WGEL-S002-ISGP-U27000-LA-7770-00009
Specification for Cold Insulation Revision: 02A
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REVISION RECORD

Rev No. Reason for Review Revised on Page Date

01R Issued for Review 17/12/2017

02A Issued for Purchase 09/04/2017

ON-HOLD POINTS

No. Reason for On-Hold Status Page Date

LIST OF ATTACHMENTS

No. Description Page Date / Rev.

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CONTENT

1 INTRODUCTION ........................................................................................................... 5
2 PROJECT OVERVIEW .................................................................................................. 6

2.1 Project Objective..................................................................................................................................................... 6

3 PURPOSE OF THE DOCUMENT .................................................................................. 6

3.1 Definitions ................................................................................................................................................................ 6

3.2 Abbreviations .......................................................................................................................................................... 6

4 REFERENCE PROJECT DOCUMENT ......................................................................... 7

4.1 Project Documents ................................................................................................................................................. 7

4.2 Company Specification / Drawing ...................................................................................................................... 7

4.3 SHELL Specifications ............................................................................................................................................ 8

4.4 Codes & Standards ................................................................................................................................................ 8

5 DOCUMENT PRECEDENCE ........................................................................................ 9
6 GENERAL REQUIREMENTS ...................................................................................... 10

6.1 General .................................................................................................................................................................... 10

6.2 Engineering Design .............................................................................................................................................. 11

6.2.1 Insulation Thickness Calculation ...................................................................................................................... 11
6.2.2 Cold insulation combined with fire protection ................................................................................................. 11
6.2.3 Vapour Barrier ..................................................................................................................................................... 12
6.2.4 Vapour Stop ......................................................................................................................................................... 12
7 MATERIAL .................................................................................................................. 12

7.1 General .................................................................................................................................................................... 12

7.2 Insulation Material ................................................................................................................................................ 12

7.2.1 Cellular Glass ...................................................................................................................................................... 12
7.2.2 Polyisocyanurate (PIR) foam ............................................................................................................................ 13
7.2.3 Nano/micro porous insulation material ............................................................................................................ 15

7.3 Jacketing Material................................................................................................................................................. 16

7.3.1 Metal Jacketing ................................................................................................................................................... 16
7.3.2 UV curable Glass Reinforced Plastic (GRP) .................................................................................................. 16

7.4 Auxiliary materials ................................................................................................................................................ 17

8 APPLICATION ............................................................................................................. 18

8.1 General .................................................................................................................................................................... 18

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8.2 Surface Preparation ............................................................................................................................................. 19

8.3 Pipe Support in Cold Insulation System ......................................................................................................... 19

8.4 Shop application of sprayed or poured PUR/PIR for pre-insulated pipe work and in-situ moulded
PUR/PIR ................................................................................................................................................................................ 20
9 QUALITY ASSURANCE & QUALITY CONTROL ....................................................... 20

9.1 Quality Plan ............................................................................................................................................................ 20

9.2 Quality Control ...................................................................................................................................................... 21

10 INSPECTION AND TESTING ...................................................................................... 21

10.1 Inspection of Material .......................................................................................................................................... 21

10.2 Inspection prior to execution ............................................................................................................................ 22

10.3 Inspection during execution .............................................................................................................................. 22

10.4 Inspection procedure for In-situ Moulded / Dispensed PUR ..................................................................... 22

10.5 Final Inspection & Release ................................................................................................................................. 23

10.6 Testing ..................................................................................................................................................................... 23

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1 INTRODUCTION
Iraq is one of the largest hydrocarbon resource holders in the world. The Iraqi Ministry of Oil (MoO)
estimates that Iraq has proven hydrocarbon volumes of some 110 billion bbls of oil and 110 trillion cubic
feet (Tcf) of gas contained in about 70 discovered fields. The bulk of these fields are located in south Iraq
and some 70% of the proven gas is associated gas. Currently the vast majority of the associated gas from
producing oilfields is flared as a waste product as there is only limited domestic gas infrastructure. Flaring
volumes are estimated at ~700 MMSCFD resulting in 20 million tonnes per year of CO2 equivalent
emissions.

Basrah Gas Company (BGC) handles gas produced in southern Iraq fields operated by third parties. BGC
have been carrying out rehabilitation, expansion, upgrading and construction of associated gas processing
facilities to reduce flaring in Iraq, increase the gas production capacity and thereby capture value for the
Iraqi economy.
Figure showing relative locations of main BGC assets in West Qurna, NR NGL, KAZ and Um Qasr).

Figure 1: Main BGC assets in Southern Iraq

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2 PROJECT OVERVIEW
2.1 Project Objective

BGC has commissioned Wood to perform the detail engineering activities for the pipeline replacements for
Streams 53-54 & 50-51 between Umm Qasr Storage Terminal and Marine Terminal.
There are existing above ground pipelines between the Marine Terminal and Storage Terminal transferring
various hydrocarbon fluids. The pipelines were constructed in approximately 1981 with the intention of
exporting liquid Propane, Butane and Gasoline from the storage terminal to a tanker ship via the jetty at the
Marine terminal. Majority of these pipelines have unknown integrity, hence Company has on-going plans to
carry out Intelligent Pigging (IP) on the lines.

The project objective is to carry out feasibility studies, perform conceptual engineering to analyze and
select the most feasible concept and carry out the detailed designs for the selected concept in order for
BGC to go out to tender for pipeline procurement and construction.

3 PURPOSE OF THE DOCUMENT

This specification defines the minimum technical requirements for external Cold insulation of above ground
pipelines for Pipeline Replacement project for Streams 53-54 & 50-51. The requirements on the external
cold insulation provided shall be read in conjunction with CINI Manual for Cold Insulation. The requirements
applicable for the Cold Insulation mentioned in CINI Manual but not specified in this specification are still
applicable and shall be considered in the design of external cold insulation.
3.1 Definitions

The following definitions have been used in this specification:

COMPANY/ PRINCIPAL / OWNER Basrah Gas Company (BGC)

PROJECT Pipeline Replacement Project for Streams 53-54 & 50-51
ENGINEERING WOOD.
The party, which manufactures and/ or supplies, equipment and
MANUFACTURER/ SUPPLIER/
services to perform the duties as specified by COMPANY in the
VENDOR
scope of supply
Any other party appointed by MANUFACTURER for supply of
SUB-CONTRACTOR
any services
is to be understood as mandatory in relation to the requirements
Shall
of this document
is to be understood as recommended in relation to the
Should
requirements of this document

3.2 Abbreviations

Table 3.2 illustrates the abbreviations and terms used in this document, alongside their description.

Table 3.2 – Abbreviations

API American Petroleum Institute

ASME American Society of Mechanical Engineers

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ASTM American Society for Testing and Materials

BGC Basrah Gas Company

CA Corrosion Allowance

CUI Corrosion Under Insulation

DEP Design and Engineering Practice

DF Design Factor

ID Internal Diameter

MT Marine Terminal

NPS Nominal Pipe Size

OD Outside Diameter

SMYS Specified Minimum Yield Strength

ST Storage Terminal

TSA Thermal Spray Aluminum

WT Wall Thickness

4 REFERENCE PROJECT DOCUMENT

4.1 Project Documents

Doc no. Description

0003-9500-WGEL-S002-ISGP-U27000-AA-7704-
Basis of Design
00001
0003-9500-WGEL-S002-ISGP-U27000-LA-7880-
Specification for Pipeline Construction
00001
0003-9500-WGEL-S003-ISGP-U27000-LA-2105-
Data sheet for Line pipe
00001
0003-9500-WGEL-S002-ISGP-U27000-LA-7770-
Specification for Line Pipe
00001

4.2 Company Specification / Drawing

Doc no. Description

External Painting Specification for

1000-BGC-G000-ISGP-G00000-RA-7754-00001
Equipment, Structural and Piping
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4.3 SHELL Specifications

Doc no. Description

DEP 30.46.00.31-Gen Thermal Insulation

DEP 30.48.40.31-Gen Thermal Sprayed Coatings of Aluminium
Protective Coatings for Onshore and
DEP 30.48.00.31-Gen
Offshore facilities

4.4 Codes & Standards

Doc no. Description

American Petroleum Institute (API)

API Specification 5L Specification for Line Pipe.

American Society of Mechanical Engineers (ASME )

ASME B31.4 Pipeline Transportation System for Liquid and Slurries.

ASME BPVC.IX ASME Boiler and Pressure Vessel Code

ASME B36.10 Welded and Seamless Wrought Steel Pipe.

ASTM
Standard Specification for Chromium and Chromium-Nickel Stainless
ASTM A 240 Steel Plate, Sheet, and Strip for Pressure Vessels and for General
Applications.

Standard Specification for Steel Sheet, Aluminium-Coated, by the

ASTM A 463 Hot-Dip Process.

Standard Test Method for Measuring Compressive

ASTM C 165
Properties of Thermal Insulations.
Standard Test Method for Steady-State Heat Flux
ASTM C 177 Measurements and Thermal Transmission Properties by Means of the
Guarded-Hot-Plate Apparatus.
Standard Test Method for Dimensions and Density of Preformed
ASTM C 303
Block and Board–Type Thermal Insulation.
ASTM C552 Standard Specification for Cellular Glass Thermal Insulation

Standard Specification for Unfaced Preformed Rigid Cellular

ASTM C 591 REV B
Polyisocyanurate Thermal Insulation.
Standard Test Methods for Coefficient of Linear Thermal
ASTM C 871 Expansion of Plastic Between – 30 °C and 30°C with a Vitreous Silica
Dilatometer.
Standard Test Methods for Compressive Properties of Rigid Cellular
ASTM D 1621
Plastics.
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Standard Test Methods for Apparent Density of Rigid Cellular

ASTM D 1622
Plastics.
Standard Test Methods for Tensile and Tensile Adhesion Properties
ASTM D 1623
of Rigid Cellular Plastics.
Standard Test Methods for Water Absorption of Rigid Cellular
ASTM D 2842
Plastics.

Standard Test Method for Open Cell Content of Rigid Cellular

ASTM D 6226
Plastics.

Standard Test Method for Surface Burning Characteristics of Building

ASTM E 84 REV A
Materials.

ASTM E 96/E 96M Standard Test Method for Water Vapour Transmission of Materials.
British Standards (BS)

BS 8010-1 Code of Practice for Pipelines - Pipelines on land- General

Thermal insulation of pipework, ductwork, associated equipment and
BS 5970 other industrial installations in the temperature range of −100 °C to
+870 °C – Code of practice

International Organisation for Standardization

Quality Systems Model for Quality Assurance in Design/Development,
ISO 9001
Production, Installation and Servicing.

Thermal Insulation for Building Equipment and Industrial Installations

ISO 12241
– Calculation Rules

European Committee for Standardization (CEN)

EN 10204 Metallic Products - Types of Inspection Documents.

NACE International Standard Practice (NACE)

Control of Corrosion Under Thermal Insulation and Fireproofing
NACE SP 0198
Materials

5 DOCUMENT PRECEDENCE
The MANUFACTURER shall notify the COMPANY of any conflict between this specification, the related
data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or
interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the
design or manufacture.

In case of conflict, the order of precedence shall be:

1. National and/or Local Regulations.

2. Data Sheets.

3. Project Specification/Amendments to Shell DEP.

4. Shell DEPs.

5. Industry Codes and Standards.

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6 GENERAL REQUIREMENTS
6.1 General

All metal surfaces under insulation shall be suitably protected with a complete Thermal Spray Aluminum
coating system in accordance with Shell DEP 30.48.40.31-Gen. Since the Propane and Butane pipelines
may have varying temperature between -46°C to +51°C, Thermal Spray Aluminum (TSA) coating is
required to be applied to prevent any corrosion under insulation (CUI).

All insulation, jacketing and auxiliary materials shall be asbestos free. No Chlorofluorocarbon (CFCs) or
Hydrochloric-fluorocarbon (HCFCs) shall be used in the production of insulation materials.

Each line shall be insulated separately.

Insulation covers for valves and flanges in piping systems shall be removable and reusable. The mass of
each removable part shall be less than 25 kg (55 lb.). Sharp edges shall be avoided.

All insulation material shall be stored in a dry place and shall be protected from any contact with water,
water vapour or other destructive substances, e.g., salts, from the time it is produced until it is installed and
protected by the cladding.

All pressure testing and necessary repairs shall be satisfactorily completed prior to the application of any
insulating materials.
Insulation and accessory materials shall be applied only to surfaces that are clean, dry, and frost-free. In
order to prevent any Corrosion Under Insulation (CUI), the insulation system that holds the least amount of
water and dries most quickly shall be selected.
Insulation systems for piping shall permit access to parts requiring maintenance without destruction of the
adjacent insulation system.

Insulation expansion or contraction joints shall be provided, taking into account the following:
 The expansion or contraction of the piping or equipment based on the design temperature of the
item

 The expansion, contraction, or shrinkage of the insulation material, based on the design
temperature of the item

 The resilience of the insulation

 The method of supporting the insulation

Thermal stress calculations shall be provided as the basis for required expansion and/or contraction joints.

Expansion and/or contraction joints and their positions shall be designed based on the expected differential
contraction between piping/equipment and insulation material as a result of extreme temperatures.

Each contraction joint shall be filled up with a resilient insulating material for compression and/or extension.

Spacing of expansion or contraction joints shall be based on the Insulation Manufacturer’s recommendation
for pipe size and design temperature.

All materials shall be supported by test certificates from a qualified laboratory and/or test reports. These
tests shall be carried out in accordance with the applicable test method as defined this Specification.

Insulation adjacent to flanges in piping and equipment shall be terminated to allow removal of bolts without
damage to that insulation. Bolt clearance from the flange to the insulation jacketing shall be at least the bolt
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length plus an additional 30 mm (1⅛ in). If hydraulic bolt tension or torque equipment is used, a
greater bolt clearance may be required.

The termination of the jacketing shall be water tight. In metal jacketing drain holes shall be provided at the
lowest point to allow drainage of condense water that may have entered the insulation system.

CINI 1.3.02 shall be referred for the general requirements of external Cold Insulation.

6.2 Engineering Design

Cold insulation systems may be defined as insulation systems for pipelines and equipment that operates
below ambient temperatures.

Cold insulation systems shall be water vapour tight.

Personnel protection for cold service is not required and shall be specified only after instruction of the
COMPANY.

The layering of cold and cryogenic insulation shall be in accordance with the table provided in Appendix-G
of DEP 30.46.00.31.
To prevent water or water vapour from penetrating into the insulation system, a vapour barrier is applied at
the outside of the system as the primary vapour barrier. In case of more layers of insulation material and at
an operating temperature of -50°C or below, in addition to the primary vapour barrier, a secondary vapour
barrier shall be applied between the outermost layer and the next insulation layer. When use is made of
cellular glass, no secondary vapour barrier shall be installed.

6.2.1 Insulation Thickness Calculation

Surfaces that operate below the local ambient dew point temperature for more than 5 percent of the time
require cold insulation to prevent condensation.

Insulation thickness calculations shall be performed to avoid surface condensation and to avoid
exceedance of the maximum allowable heat ingress of 25 W/m2 (8 Btu/hr./ft2).

Detailed heat transfer calculations shall be performed by the Insulating Vendor and the thickness of the
insulation required shall be calculated to ensure heat ingress do not exceed 25 W/m2. References shall be
made to CINI 6.1.00 and ISO 12241 for heat transfer calculations as required to arrive at the appropriate
insulation thickness.

The thickness of cold Insulation is considered as per Appendix F2 of DEP 30.46.00.31 which is based on
maximum allowable heat ingress of 25 W/m2. The Insulating vendor shall verify this thickness based on
the heat transfer calculations.

Insulation design temperature for cold conservation shall be the normal operating temperature, but the
insulation itself is to withstand the emergency and maximum (or minimum) operating temperature.
Reference tables for thermal insulation thickness in cold service to avoid condensation and reduce heat
gain with various input parameters shall be referred from Appendix-F.2 of DEP 30.46.00.31.

6.2.2 Cold insulation combined with fire protection

The fire protection of pipelines or equipment is required; accordingly cellular glass shall be used as the
insulation material. When cellular glass is used in combination with other insulation materials, the Cellular
glass layer shall be the outer layer provided with a vapour barrier.
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Similarly for the fire protection of pipelines or equipment, only aluminized steel or stainless steel jacketing
material shall be used.

Insulating system shall be capable of withstanding fire hose impingement.

6.2.3 Vapour Barrier

Vapour barrier shall be applied over the insulation to prevent ingress of water and water vapour through the
insulation material. The vapour barrier shall be of material with a very low permeability.

Accordingly, a primary vapour barrier shall be applied at the outside of the insulation system. In case of
more layers of insulation material, in addition to the primary vapour barrier, a secondary vapour barrier
shall be applied between the outermost layer and the next insulation layer.

6.2.4 Vapour Stop

Vapour stops shall be applied in order to divide the system into closed compartments and to
prevent water (vapour) transport between the metal surface and the insulation material, from a
damaged area to a sound section of the insulation system. The compartmentalisation shall coincide
preferably with the existent supports and shall include flanges and valves. Vapour stops shall also be
applied at each side of valves, flanges etc. in accordance with CINI 5.1.08.

7 Material
7.1 General

For all materials, documentation such as certificates of origin, quality control records, product
information and safety material data sheets shall be made available and shall indicate Health Safety
Environment related hazards during application, use, removal and disposal.
Only the materials provided in this Specification are allowed for use. Other materials require approval from
the COMPANY.

For the insulation and jacketing material selection, reference shall be made to the flow diagram in
Appendix-C of DEP 30.46.00.31.

7.2 Insulation Material

7.2.1 Cellular Glass

Cellular glass shall be finished with weather resistant bitumen-based vapour barrier (cell filler) in cold
climates to prevent frost damage.

Cellular glass material properties shall comply with the requirements in Table-1 and ASTM C552. The
material properties shall be demonstrated by the applicable test standard provided in Table-1.
Table-1 Cellular Glass material properties

Data Acceptable Applicable Standard

Temperature Range From +427 °C to -200 °C N.A.
3
Density 115 Kg/m ASTM C303

Closed cell content 100% ASTM D6226

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2
Water vapor permeability Maximum 0 gr/m .hr at 23 °C and 50% ASTM E96/E96M,proc.A
relative humidity
Leachable chlorides Maximum 45 ppm ASTM C871, proc. 2

pH value Between 6 and 10 ASTM C871

Flame spread index Maximum 0 ASTM E84

Compressive Strength 500 kPa, from +427°C to -200°C in all ASTM C165
directions

The thermal conductivity values of cellular glass shall be based on measurements performed by an
independent institute in accordance with ASTM C177 and shall be as per Table-2.

Table-2 Cellular Glass maximum thermal conductivity values

Mean material Maximum thermal Maximum thermal

conductivity in
temperature in °C conductivity in W/m.K
BTU/(hr.ft.F)
+ 400 °C (752 °F) 0.130 0.076
+ 350 °C (662 °F) 0.120 0.070
+ 300 °C (572 °F) 0.100 0.058
+ 250 °C (482 °F) 0.087 0.051
+ 200 °C (392 °F) 0.074 0.043
+ 150 °C (302 °F) 0.063 0.036
+ 100 °C (212 °F) 0.053 0.031
+ 50 °C (122 °F) 0.044 0.025
0 °C (32 °F) 0.036 0.021
- 50 °C (-58 °F) 0.029 0.017
-100 °C (-148 °F) 0.023 0.013
-150 °C (-238 °F) 0.018 0.011
-180 °C (-292 °F) 0.016 0.009

The inside segments and section shall be provided with an anti-abrasive paste as specified by the Supplier
of the insulation material.

Cellular glass insulation material shall be finished with a weather resistant bitumen based vapour barrier.
As an alternative, factory-applied vapour barrier mastic at segments/ section may be applied. The joints
shall be sealed with the same material and shall be smoothed over with the pre-applied layer to achieve a
monolithical finish.

7.2.2 Polyisocyanurate (PIR) foam

Polyisocyanurate rigid cellular foam with a mainly closed cells structure shall be in accordance with ASTM
C591. Temperature range shall be +120 °C to -200 °C.

PIR material properties shall comply with the requirements as per Table-3.
Table-3 PIR material properties
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Data Acceptable Applicable Standard

3
Density 40 Kg/m ASTM D1622

Closed cell content 95% ASTM D6226

Water Absorption Maximum 5% Vol ASTM D2842

2
Water vapour permeability Maximum 0.8 gr/ (m .hr.) at 23 °C and 50% RH ASTM E96/E86M, proc.A

Chlorides Maximum 60 mg/kg (ppm) ASTM C871, proc. 2

pH value Between 5.5 and 7.0 ASTM C871

Flame spread index <25 ASTM E84

The thermal conductivity values of PIR shall be based on measurements performed by an independent
institute in accordance with ASTM C177 on aged foam samples with a minimum ageing of 180 days at 23
°C (in accordance with ASTM C591). The average thermal conductivity shall not exceed the values as per
Table-4.
Table-4 PIR maximum thermal conductivity values

Mean material Maximum Thermal Maximum Thermal

Temperature in °C Conductivity in W/m.K Conductivity
BTU/(hr.ft.F)

+40 0.029 0.016

+20 0.027 0.015

0 0.024 0.014

-30 0.025 0.014

-50 0.024 0.014

-100 0.021 0.012

-120 0.019 0.011

-160 0.016 0.009

PIR mechanical properties shall comply with the requirements as per Table-5.

Table-5 PIR mechanical properties

Data Acceptable Applicable Standard

Compressive Strength
At 23 °C, in all directions: 200 kPa ASTM D1621
At -165°C, in all directions: 280 kPa
Linear thermal expansion coefficient
At 23°C, maximum 70.10-6m/(m.K) ASTM D696
At -165°C,maximum 50.10-6m/(m.K)
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Tensile strength
At 23 °C, in all directions: 320 kPa ASTM D1623
At -165°C, in all directions: 265 kPa

E-modulus
At -165 °C, in all directions max 16 ASTM D1623
MPa
Poisson’s ratio
At -165°C: 0.4

PUR/PIR foam shall be protected against prolonged UV exposure during transport, storage and installation.

7.2.3 Nano/micro porous insulation material

Nano/micro porous insulation material for cold service should be used in case there is a requirement to
save space or weight.
Nano/micro porous insulation material for cold service shall comply with the requirements as per Table-6.
Table-6-Nano/micro porous insulation material properties for cold service

Data Acceptable level Applicable standard

Temperature range From – 200 °C to + 90 °C ASTM C447, ASTM
(-328 °F to194 °F) C411
3 3
Density 130 kg/m (8.12 lb/ft. ) ASTM C303
Fire rating Class A ASTM E84
Compressive strength 51 kPa (7.4 psi) at 10% compression ASTM C165
172 kPa (24.9 psi) at 25% compression ASTM C165

The thermal conductivity values of Nano/micro porous insulation material for cold and dual service shall be
based on measurements performed by an independent institute in accordance with ASTM C177 and shall
be as per Table-7.

Table-7-Nano/micro porous maximum thermal conductivity values for cold service

Mean material Maximum thermal conductivity in W/m.K Maximum thermal

temperature in °C (°F) conductivity in BTU/(hr.ft.F)

+ 50 (122 °F) 0.0155 0.0090

0 (32°F) 0.0138 0.0080
- 50 (-58 °F) 0.0129 0.0075
- 100 (-148 °F) 0.0123 0.0071
- 150 (-238 °F) 0.0114 0.0066
- 200 (-328 °F) 0.0098 0.0057

Nano/micro porous insulation material shall be applied in layers of 5 mm and 10 mm thickness depending
on the required thickness as calculated. See Section 6.2.1. The layers shall be provided with a factory
applied primary vapour barrier.
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7.3 Jacketing Material

Screws for securing jacketing materials shall not be used. Jacketing in cold and dual service shall be
secured by metal bands as per Section 7.4 - Auxiliary Materials.

7.3.1 Metal Jacketing

If metal cladding is applied, it shall be an “open” jacket, with drain holes at the bottom to allow
condensation water at the inside of the cladding to drain. Drain holes shall be drilled before installation of
the metal jacketing to avoid damage to the primary vapour barrier.

 Aluminized Steel Jacketing

Aluminized steel jacketing shall have Coating Type T2-300 in accordance with ASTM A463/A463M.
Additional requirements are as follows:
a) The copper, nickel and manganese content of the coating bath shall each be less than 0.040%
wt.
b) All cut edges of the aluminized steel Type T1 shall be coated to ensure corrosion protection.
The aluminium coating shall not crack, flake or peel during required mechanical processing.
Aluminized steel jacketing shall not be used in climates where salt-containing condensation can
evaporate due to high daytime temperatures.
The aluminized steel jacketing mechanical properties, chemical composition and corrosion resistance
shall be in accordance with ASTM A463/A463M.
Aluminized steel jacketing shall be at least 0.8 mm (0.03 in) thick and sections shall be at least 500
mm width.

 Stainless Steel Jacketing

Stainless steel Type 304 or Type 316 in accordance with ASTM A240 shall be used.
Mechanical and chemical properties and corrosion resistance shall be in accordance with ASTM
A240.
Thickness of the stainless steel jacketing shall be as per Table-8.

Table-8 Thickness of Stainless Steel Jacketing

Outside diameter Minimum thickness of the SS

insulation in mm sheeting in mm

< 140 0.5

140 – 300 0.6

> 300 0.8

Removable covers for flanges, valves, etc. shall be made of 0.8 mm sheets.

7.3.2 UV curable Glass Reinforced Plastic (GRP)

Weather resistant, UV curable, GRP jacketing shall be a laminate based on glass fiber reinforced polyester
resins, which cures by UV-radiation.

The surface to be finished with UV curable GRP shall be even, clean and dry.
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Joints in the finishing material have an overlap of minimum 30 mm (1¼ in).

The finishing layer shall be of even thickness across the surface.

UV curable GRP material requirements shall be as per Table-9.

Table-9-UV curable GRP material properties

Data Acceptable level Applicable standard

Temperature range 0-90 °C (32-194°F)

2
Weight 2 kg/m
Bending strength 130 MPa (18850 psi)
Tensile strength 50 MPa (7250 psi)
Elongation at break 1%
Compressive strength 125 MPa (18130 psi)
2
Impact resistance 57 kJ/m
Temper 45 Barcol
Layer thickness 1.5 mm
2
Water vapour permeability 0.001 g/(m .h.mmHg) ASTM E96/E96M proc. E
Flame spread index ≤ 20 ASTM E84
Class I BS 476-7
Flash point ≥ 32 °C (90 °F) ASTM D93

In cold services, UV curable GRP shall be applied over a multiplex foil vapour barrier.

Packaging shall be such that the material is fully protected against light and that damage during transport
and storage under normal conditions shall be avoided.

For curing, natural UV light shall be used. When natural light is insufficient, UV lamps shall be used for
curing.

7.4 Auxiliary materials

Non-metallic jacketing sealants, synthetic tape and contact adhesives shall be selected and installed per
the Jacketing Manufacturer’s recommendations.

Metal band shall be stainless steel according to ASTM A240 type 304 or 316.

For temperature < 300 °C a one component polysiloxane based permanent flexible sealer shall be used.
For temperatures > 300 °C, a sodium silicate based sealer shall be used.

Wire mesh shall be stainless steel according to ASTM A240 type 304 or 316. Wire diameter shall be 3 mm
(1/8 in) and the mesh dimensions 50x50 mm.

Binding wire shall be stainless steel according to ASTM A240 type 304 or 316, 1 mm thick.

Adhesive synthetic tape shall be glass fiber reinforced. The adhesiveness shall be 200 gr/25 mm2.
Self-tapping screws shall be in accordance with the jacketing material 4.8 x 13 mm (ISO 1481 type C).
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For vapour barriers, the durability against mechanical abuse, Ultraviolet (UV) light degradation, water and
chemicals is of prime importance. Also the materials shall not contain leachable components that increase
corrosiveness within insulation system. The following materials for vapour barriers are applicable:
 Multiplex foil
 Butyl rubber tape with aluminium backing
 Vapour barrier mastic, latex, polymer, bitumen or elastomer based.
Multiplex foil shall have a thickness of 25 μm polyester film, 50 μm aluminium foil and 25 μm polyester film.
Total thickness shall be 100 μm.

Water vapour permeability shall be in accordance with ASTM E96/E96M, procedure E, maximum 10*10-6
g/m2.h.mm.Hg.

To control the lateral mitigation of water vapour, polyurethane insulated systems need more frequent
vapour stops than cellular glass systems. Mastics and sealant materials shall be used to close the
openings around protrusions in the insulating system.

Contraction joints shall be provided and shall be designed based on the expected differential contraction
between the piping and insulation material. Thermal stress calculations shall be provided by Insulating
Vendor and spacing of contraction joints shall be based by referring to CINI 1.3.53 and CINI 5.2.06.

8 Application
8.1 General

Materials shall be protected against weather and environmental influences during transport.

Before the insulation work is started, the surfaces to be insulated shall be clean, dry and provided with the
appropriate surface protection. Prior to the application of the insulation is clean, dry and prepared as
required.

Provisions shall be made to ensure that the materials can also be fitted under poor weather conditions.
Prior to application of the finishing material the insulation material shall be dry.

When cold insulation is applied, the entire system shall be completely insulated, including all parts, such as
piping, instrumentation lines, drains, nozzles, supports etc. which shall have same thickness. All metal
parts which protrude through the insulation shall have the same insulation thickness over a length of atleast
4 x the insulation thickness, with a minimum 300mm as indicated in CINI 5.1.11, 5.2.09, 5.3.01.

When the insulation is applied in two layers, the sections and segments shall be staggered both radial and
axial. An overlap of at least 150 mm shall be observed for the joints.

Insulation activities including the jacketing shall be completed in one day. Exposed insulation material shall
be properly covered for water and moisture ingress.

Nameplates, reference and measuring points shall remain visible at all times. Discharge and air relief
valves shall remain operable.

Edges of the recesses shall have a weatherproof finish.

Insulation through walls, partitions and floors shall be uninterrupted and of uniform thickness.
A minimum space of 25 mm shall be observed between the insulation finishing and the adjacent surfaces.

The jacketing shall be without counter-swages and be constructed in such a way that any condensation
moisture can drain from the cladding.
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Metal jacketing shall be fastened with stainless steel bands with a minimum cross- section of 13x0.5 mm.

Horizontal joints shall be installed so that rainwater cannot enter the insulation system.

Longitudinal joints shall be installed opposite the prevailing wind direction. At the joints, the jacketing shall
have an overlap of at least 50 mm (2 in). The longitudinal seams shall be staggered.

The flange and fitting insulation shall be fitted over the connected pipe insulation over a distance that is at
least equal to the thickness of the pipe insulation, with a minimum of 50 mm.
The installation requirements of insulation over the piping surface shall meet the requirements of CINI
1.3.53 for Insulating material of PIR and shall meet the requirements of CINI 1.3.54 for Insulating material
of Cellular glass.

The installation requirements of vapour barrier shall be in line with the requirements specified in CINI
1.3.02 section 4.4.

For cold/cryogenic insulation pre-formed sections shall be used. In-situ moulded PUR/PIR (see (8.4)) may
be used for flange/valve boxes.

If pre-formed PIR/PUR insulation sections are used, the insulation shall be pre-formed or fabricated in
single matched halves to the maximum extent possible. The last layer of pre-formed section may include
the primary vapour barrier and jacketing. ln such cases the joints shall be finished in the field. Where multi-
layering is necessary, longitudinal and circumferential joints shall all be staggered. All individual segments
shall be cemented together with suitable fabrication adhesive.
During application of insulation materials personnel shall be protected against dust and skin irritation.

8.2 Surface Preparation

Ingress of rainwater and corrosive products or condensation of water vapour in the insulation can cause
severe corrosion under insulation, and increases the thermal conductivity (reducing insulation values)
significantly. To protect the steel from corrosion under insulation, a surface protection system in the form of
Thermal Spray aluminium coating shall be applied in accordance with Shell DEP 30.48.30.31-Gen:
Thermally Sprayed Aluminium Coatings. The external coating with Thermal Spray Aluminium on the
surface of the steel is not part of Insulating Vendor scope. Accordingly, the technical details on the external
coating are not detailed in this specification.

Before the insulation work is started, the surfaces to be insulated shall be clean, dry and provided with the
appropriate surface protection. Prior to the application of the insulation material the Contractor shall obtain
a “released for insulation” document stating the surface is clean, dry and prepared as required.

8.3 Pipe Support in Cold Insulation System

The insulation thickness at the supports shall be the same as the piping insulation.
The material of the insulation sections at the supports shall match with the adjacent insulation system. In
doing so, a similar material with a higher compressive strength may be applied with different density and
thermal coefficient.
The dimensions of the pipe supports shall be calculated in detail. Governing factors shall be as follows:
 The maximum design load of the support, based on two span lengths.
 Compressive strength of the insulation material.
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 Safety factor 5:1 for the compressive strength at minimum operating temperatures.
 Load transfer based on 60° load spread.
 Load spread underneath the brackets / steel support cradles during fixing of the bolt.
 Clamping forces on the pipeline, such that the support moves with the pipe.
NOTE: The support shall not move across the insulation system (cladding) and the pipe shall
not move inside the insulation system.
 Length of the base plates of the support based on maximum contraction/expansion of the
pipeline.

The HD PIR/PUR foam at the bottom part of the support shall have a minimum density of:

3
160 kg/m for pipe diameters up to 200 mm

3
224 kg/m for pipe diameters between 200 mm and 600 mm

3
320 kg/m for pipe diameters above 600 mm

The top part of the support shall have a minimum density of 160 kg/m3.

Pipe support design and application in cold insulation systems shall be submitted to the Principal for review
and comments.
The maximum stresses in the foam shall be limited to 0.2 times the ultimate compressive strength, ultimate
tensile strength and shear strength respectively.

The PUR/PIR cradles shall be designed for all specified operating conditions, including differential
expansion and contraction between PUR/PIR cradles and pipe. The design shall also cope with the
tolerances of the outside diameters of HD PUR/PIR supports.

The insulation system for the sliding supports shall consist of insulation material with proper compressive
strength, finished with a vapour barrier and an external bracket. Brackets shall be formed by two steel half
sections clamped around the insulating material by bolts meeting requirements of CINI 5.1.09 and CINI
5.1.10 as applicable, such that support moves with the pipeline during contraction/expansion. The
connection to the pipeline shall be executed in accordance with Detail-A of CINI 5.1.09 and CINI 5.1.10.

8.4 Shop application of sprayed or poured PUR/PIR for pre-insulated pipe work and in-situ
moulded PUR/PIR

Shop applied sprayed or poured PUR/PIR for pre-insulated pipe work shall have the same material
properties as preformed PUR/PIR sections. Reference is made to EN 13941 and EN 253.

In-situ moulded and dispensed PUR/PIR insulation shall have the same material properties as preformed
PUR/PIR sections.

9 Quality Assurance & Quality Control

9.1 Quality Plan

For application of insulation systems, a Quality Plan based on ISO 9001 shall be provided.
The Quality plan shall include:
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 The delegated responsibilities of the several sections of the works and all procedures, method
statements and inspection and test plan (ITP).
 The method statements shall describe the execution plan, materials, and trade and quality
procedures.
 In the ITP, all the test procedures shall be described, such as the number of samples,
hold/witness points, test frequencies, acceptance/rejection criteria etc. of all the applicable
insulation systems.
 Inspections shall be carried out prior, during and after completion of any stage of the work,
beginning with materials checks and ending with final performance checks.
 The Quality Plan shall clearly indicate how and in which stages material test reports shall be
available and how it is documented.
 The following stages shall be indicated:
 The time the materials arrive in storage on site
 Before the materials are processed or applied
 During application
 Before and during the installation of the jacketing

9.2 Quality Control

Insulating Vendor shall submit to COMPANY a quality system manual based on ISO 9001. The quality
system shall include specific QA/QC procedures for the work and test procedures for all materials.

The QC procedure shall include an inspection and test plan (ITP) with references to all test procedures,
number of samples, hold-points and witness points, acceptance and rejection criteria and frequency of
tests.

Insulating Vendor shall provide facilities for the inspection of all materials and application procedures
before and during the insulation work, up to the contractual completion date.

Inspection shall be carried out during and after completion of any stage and before commencement of the
following stage, beginning with material checks and ending with final performance checks.

10 Inspection and Testing

10.1 Inspection of Material

All materials shall comply with the minimum requirements as stated in this Specification.

All materials and application methods shall be suitable for the local weather conditions.

The materials shall be inspected at the Supplier's workshop and at arrival on site.

Prior to commencement of the work, data sheets, the safety data sheets and method statements of the
various materials shall be submitted, together with the laboratory test certificates from independent test
laboratories.

Laboratory test results for various insulation and ancillary materials obtained by independent test
laboratories shall be submitted prior to the commencement of the work together with the data sheets,
Manufacturer's instructions and method statements.
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Should the material be delivered in multiple production batches, one laboratory test shall be performed at
the Manufacturer's works and the test results submitted. For all other batches a "Compliance Certificate"
shall be submitted certifying that the materials are in accordance with the technical specifications of the first
production batch. Each batch used on site shall be clearly marked to allow rapid tracing of the origin of the
supply should discrepancies be noted.

10.2 Inspection prior to execution

Before insulation application, a pre-insulation survey and measurement of the system to verify the design
shall be performed.

Application of insulation is only allowed after submission of a release for insulation document. The release
for insulation document shall include:
 Equipment and pipelines, complete with supports, are ready and pressure tested.
 Flange connections are accepted.
 The corrosion protection systems has been applied and accepted.
 The surface to be insulated is clean and dry, free of grease, salt deposits, oil and dirt.
 The hangers and supports shall be of the correct size, and properly located according to the
specifications? Are all supports, anchors, guides or hangers on low temperature piping free
from obstructions to allow sufficient space for support insulation application and condensation
control treatment, and normal expansion and contraction of the system? Are supports properly
installed, e.g. for cold insulation in the so-called "hot-mode".
 Expansion/Contraction joints - Are all positions for installation of the expansion/contraction joints
in the insulation clearly defined and marked.

10.3 Inspection during execution

Inspections shall be carried out on materials and applications during all execution of the works to ensure
compliance with the specifications and procedures, as laid down in the Quality Plan. Beforehand, the steps
shall be established in which the insulation system shall be applied and which phase may be started after
hold/witness point.

10.4 Inspection procedure for In-situ Moulded PUR

Foam injection shall be done only after the control scheme has been examined for each unit to be
insulated.
Insulating Vendor shall draw up the inspection procedure and control sheets will be established for each
pipe/spool in order to assess the step-by-step inspection status on a continuous basis.

The inspection procedure shall include but not be limited to the following tests, documented in appropriate
data sheets and performed daily:

- For each machine each day and before the start of dispensing work, a sample shall be made in a closed
mould to simulate conditions in practice. Each sample shall be examined for density, closed cell content,
thermal conductivity and visual appearance. Samples shall be tested in accordance with (10.6).

- Machine foaming test in free expansion to determine the same values as specified.
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- Measuring and recording of all data such as:

• Ambient temperature

• Relative humidity
• Operating and re-circulation pressures for the pouring machines.

- Inspection of the cavities to be injected for the following:

• Temperature;
• Humidity I water pockets;

• Accessibility;

• Properly placed pouring and vent holes.

Inspection of the foamed cavities shall be carried out by examination of the quantity and quality of the foam
escaping from the de-aeration, drain and injection holes.

Daily checks by cutting samples. On these samples the compressive strength shall also be tested.
Injection control data sheets shall be maintained for all insulated pipes/spools to record all operating and
material data for easy cross-reference in case of failure.

All samples shall be numbered to ensure full traceability and shall be stored by Insulating Vendor under
such conditions that they remain suitable for further testing if necessary, until all dispensing work has been
completed. Test results shall be submitted weekly.

10.5 Final Inspection & Release

After completion of the insulation system or sections thereof, a final inspection shall be conducted. The
application shall be inspected to determine that the insulation is of proper thickness and that its materials,
workmanship and finishes meet the specifications. The insulation Contractor shall remain responsible for
the performance of insulation systems until the warranty period has expired. Damages shall be repaired.

After start-up, the thermal performance of the hot insulation systems shall be verified by measuring the
surface temperature or by infrared surveys. Cold insulation systems shall be subjected to thermographic
surveys between 3-6 months after initial start-up to identify deficiencies. These deficiencies shall be
marked and shall be made good at the earliest opportunity.

10.6 Testing

Insulating Vendor shall submit test reports and adhere to the quality control requirements on all insulation
materials.
For the In Situ Moulded PUR or sprayed PUR/PIR Insulating Vendor shall establish a site laboratory to
carry out the daily testing in accordance with the QA/QC programme and testing of the foam
characteristics.
For each day production of pre-formed foam or whenever a fresh blend of chemicals is used the following
tests shall be carried out according to the standards mentioned in CINI 2.7.01.

- Density.
- Thermal conductivity at ambient temperature.
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- Closed cells content.

- Cell structure uniform and free of voids and bubbles in excess of 1.5 mm in diameter across the rise of the
foam, or 5 mm in depth in direction of rise. No more than 5 smaller voids or bubbles per 250 x 250 mm
area on any cut standard length of half pipe section or slab shall be allowed. The surface shall be free of
striations, sheared cells, and planes of weakness and uncured areas.

- Compressive strength.
- Tensile strength.

- Flammability.

- Dimensional tolerances.

Results of the above Quality Control tests shall be recorded for two samples of foam from each batch of
chemicals and reported to COMPANY. Serial number and expiry shall identify batch date or manufacturing
date. In case of non-conformance all defective materials shall be replaced.