STANDARD ENGINEERING SPECIFICATION for THERMAL INSULATION DESIGN

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1 STANDARD ENGINEERING SPECIFICATION for HINDUSTAN PETROLEUM CORPORATION. VISAKH REFINERY DHT PROJECT JOB NO. : 6261 DOCUMENT NO. : A /10/2008 FOR BID ENQUIRY AMS MAM JMG REV. DATE DESCRIPTION MADE BY CHECKED APPROVED LIMITED MUMBAI INDIA

2 ISSUED 6 / 10 / 08 PAGE 1 OF 23 C O N T E N T S PAGE 1 GENERAL 1.1 Intent Scope Codes and Standards Units Restrictions 3 2 EXTENT OF INSULATION 2.1 General Hot Insulation Personnel Protection Insulation Anti-Sweat Insulation Cold Insulation Dual Temperature Insulation Limitations 6 3 MATERIAL 3.1 General Hot and Personnel Protection Insulation Materials Cold Insulation Materials Anti-Sweat Insulation Materials Dual Temperature Insulation Materials Jacketing Materials Fastening Materials Other Materials 12 & 13 4 THICKNESS OF INSULATION 14 5 Inspection Pocket Requirement for Insulation 14 ATTACHMENT Table 11.1 A&B: Insulation Thickness for Heat Conservation 15,16 Table11.2A&B: Insulation Thickness for Personnel Protection 17,18 Table 11.3: Insulation Thickness for heat conservation of 19 electrically traced lines Table 11.4A: Insulation Thickness for heat conservation dual temperature 20 Table 11.4B,C&D : Insulation Thickness for Cold Insulation for Anti-sweat condition 21,22,23

3 ISSUED 6 / 10 / 08 PAGE 2 OF 23 1 GENERAL 1.1 Intent 1.2 Scope This specification covers the requirements in the design and materials of the thermal insulation for the hot and cold services in the plants constructed by Toyo Engineering India Ltd. (hereinafter referred to as TEIL). This specification shall be applied to the thermal insulation for equipment and piping shown on the P & I flow diagram and utility flow diagram, but not to the insulation to be supplied by manufacturer complete with equipment. 1.3 Codes and Standards Generally, materials of insulation shall meet the requirement of Indian Standard and/or ASTM Standard. This specification refers to the following codes and standards. (1) American Society for Testing and Materials (ASTM) a) ASTM C168 : Standard Terminology Related to Thermal Insulating Materials b) ASTM C 533 : Standard Specification for Calcium silicate Block Insulation for Piping. c) ASTM C547 : Standard Specification for Mineral Fiber Pipe Insulation d) ASTM C552 : Standard Specification for Cellular Glass Thermal Insulation e) ASTM C553 : Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications f) ASTM C591 : Standard Specification for unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation g) ASTM C592 : Standard Specification for Mineral Fiber Blanket Insulation and Blankettype Insulation h) ASTM C612 : Standard Specification for Mineral Fiber Block and Board Thermal Insulation i) ASTM C795 : Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel j) ASTM A167 : Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip k) ASTM A240 : Standard Specification for Heat-Resisting Chromium and Chromiumnickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels l) ASTM A653 : Standard Specification for Steel Sheet, Zinc-Coated(Galvanized) or Zinc- Iron Alloy-Coated (Galvanized) by the Hot-Dip Process m) ASTM E96 : Standard Test Methods for Water Vapor Transmission of Materials

4 ISSUED 6 / 10 / 08 PAGE 3 OF Units Unless otherwise specified, metric, Celsius, and kilogram units shall be applied as the measurement system for the drawings and documents to be submitted. However, nominal size of piping components shall be in accordance with inch system (B). 1.5 Restrictions Where materials are referred to by trade names within this specification, the use of such names is intended to describe the kind or quality of the material required and any deviation must be submitted in writing for TEIL s approval Galvanized or zinc coated materials shall not be in contact with metal surfaces that have temperature above 370 Deg.C. It shall not be used when, in case of fire, it could drip on stainless steel The minimum allowable value of sodium plus silicate shall be in accordance with Fig. 1 of ASTM C795 for acceptability of insulation material Insulation containing more than 100 ppm chloride is not acceptable to use on the equipment/piping of austenitic stainless steel Insulation containing sodium plus silicate shall not be used for insulating austenitic stainless steels containing molybdenum (such as type 316) operating at 815 Deg.C. or greater Insulation materials containing asbestos shall not be used No insulation material shall be applied between pipe and tracer except for spacers (by others) to prevent local overheating of the pipe Contact between dissimilar materials which might cause galvanic corrosion shall be avoided No flammable materials shall be attached to the insulation.

5 ISSUED 6 / 10 / 08 PAGE 4 OF 23 2 EXTENT OF INSULATION 2.1 General Classification of thermal insulation and symbols to be indicated on the Engineering Drawing, P & I flow diagram and Piping Line Schedule are as follows: CATEGORY SYMBOL CLASSIFICATION Hot service H Normal heat conservation insulation Insulation HO Full heat conservation insulation (For operational stability) TS Steam tracing insulation TW Hot water tracing insulation TO Other medium tracing insulation JS Steam jacketing insulation JW Hot water jacketing insulation E Electric tracing insulation W Winterizing insulation Cold service C Normal cold insulation Insulation CO Full cold insulation (For opera. stability) JC Cold medium jacketing insulation Other Insulation A Anti-sweat insulation Materials P Personal Protection Insulation M Dual Temperature Insulation The design temperature to be used for selection of insulation material and calculation of insulation thickness shall be normal operating inside fluid temperature in case of hot and personal protection insulation, whereas it shall be minimum operating inside fluid temperature in case of cold and anti-sweat insulation Thickness of insulation on nozzles and other protrusions (incl. parts of structure) around equipment and piping shall generally be determined in the same way as stated in Para Thermal conductivity of thermal insulation materials shall be in accordance with applicable standard as specified in the table of respective insulation material applications. 2.2 Hot Insulation Hot insulation shall generally be applied to equipment and piping operating at 60 o C and above, except for the case where heat loss is desired. Where heat loss is to be restricted, however, full heat conservation insulation (HO) shall be applied, even when the operating temperature is below 60 o C Steam tracing Insulation (TS) shall be applied to traced piping and equipment to reduce heat loss.

6 ISSUED 6 / 10 / 08 PAGE 5 OF Personnel Protection Insulation Personnel protection insulation (P) shall be applied to non insulated equipment and piping operating at 60 o C and above, within the area shown below, where operators, while working, can inadvertently come in contact with them. (1) Within 2000 mm height from ground or floor level (2) Within 600 mm distance beyond the edge of platform or walkway Shield or guard may be provided in lieu of insulation for personnel protection, where a dissipation of heat is desirable. 2.4 Anti-Sweat Insulation Anti-Sweat insulation (A) shall be applied to equipment and piping operating at above 0 Deg.C but below the ambient temperature, if surface condensation of moisture would provide an adverse effect as shown below. (1) Electrical hazard (2) Damage to equipment (3) Surface condensation providing discomfort to working personnel 2.5 Cold Insulation Cold insulation (C) shall be applied to equipment and piping operating at temperature below 0 Deg.C. where reduction of heat gain and prevention of surface condensation is desired For such attachments and protrusions as shown below, fixed without inter-lying insulation to piping or equipment (or to lugs) to be cold insulated, the cold insulation shall extend over the attachments or protrusions by four (4) times the of thickness of insulation. (1) Skirt or leg of tower and tank (2) Pipe supports (3) Branch of vent and drain piping 2.6 Dual Temperature Insulation Dual Temperature insulation shall be provided for piping and equipment which operate normally at cold temperature below 0 Deg.C. but which are subject to high temperature above 60 Deg.C. during regeneration.

7 ISSUED 6 / 10 / 08 PAGE 6 OF Limitations The following piping components & equipment shall not be insulated unless otherwise specified Hot Insulation (1) Visible parts such as Name plate, code inspection plates, stampings, sight glass and level gauge. (2) Shield or guard (3) The following parts of the rotating machinery, which need a heat dissipation and cooling, unless otherwise specified. (a) (b) (c) (d) (e) (f) (g) Stuffing box Packing ground Piping and jacket for cooling water Packing sealed piping Bearing Oil cooler Gear shift case, etc. (4) Fans, compressors, blowers or other rotating or reciprocating equipment or machinery, unless otherwise specified. (5) Down stream piping of block valves without tracing insulation. (6) Safety valves along with its outlet piping and down stream piping of such valves as steam blow off valve, vent and drain valve. (7) Steam traps and the lines down stream of them which require no recovery of heat of the drain and no prevention of freezing-up, unless specified in the drawing. (8) Flanges in Hydrogen services (9) Parts having moving element, such as expansion and swivel joint, and sliding valves. (10) Support legs and inside of skirts (11) For equipment and piping with inside lining of refractory or insulating material, except for the case where the metal temperature must be controlled Personnel Protection Insulation (1) Visible parts such as Name plate, code inspection plates, stampings, sight glass and level gauge. (2) Shield or guard (3) Safety valves along with its outlet piping and down stream piping of such valves as steam blow off valve, vent and drain valve. (4) Support-legs and inside of skirts (5) For equipment and piping with inside lining of refractory or insulating material except for the case where the metal temperature must be controlled.

8 ISSUED 6 / 10 / 08 PAGE 7 OF Cold and Anti-Sweat Insulation (1) Visible parts such as Name plate, code inspection plates, stampings, sight glass and level gauge. (2) The parts dislikes cold exposing such as gland of valves (3) Nozzle end for maintenance such as blind flange equipped with the drain valves (4) Safety valves along with its outlet piping and down stream piping of such valves as vent and drain valve. (5) Fans, compressors, blowers or other rotating or reciprocating equipment or machinery, unless otherwise specified. 3 MATERIAL 3.1 General Material shall generally be in accordance with specified standard in consideration with the following. - The materials shall be endurable to the service temperature - The materials shall not deform as a result of absorbing moisture - The materials shall not be corrosive against equipment and piping surface - The materials shall be easy to work with The use of finishing materials containing Asbestos in any forms are Not permitted Insulation and jacketing material backed with paper or other flammable material is not acceptable Many common flammable liquids such as Oil, Butanol, Diethanolamine and Hexanol will react and start fire when they leak into inorganic absorbent insulation s. Such insulation can store large quantities of combustible liquids should a leak occur. This is a decisive factor while specifying insulating materials The insulation shall be non water repellent quality when measured in accordance with BS-2972 Section11, partial immersion based on the following: a) Water Depth : 6mm b) Maximum absorption :0.5kg/m 2

9 ISSUED 6 / 10 / 08 PAGE 8 OF Hot and Personnel Protection Insulation Materials Specification and standard application of insulation material for hot and personnel protection services shall be as follows: Material (1) Reference Code Application (a) Mineral wool (Pipe Cover) (b) Mineral wool (Metal-Mesh Blanket) ASTM C547 Class 2 and Class 3 Density: 96kg/m 3 ASTM C592 Class II(2) Density: 192kg/m 3 For equipment and piping (up to Opt.Temp 550 Deg C) (c) Mineral wool (Board) (d) Mineral wool (Blanket- Loose) ASTM C612 Type IV, Density: 240kg/m 3 ASTM C553 Type VII Density: 224kg/m 3 For expansion joints of tower and vessels, flanges and valves. (up to Opt. Temp. 550 Deg.C) e) Calcium Silicate ASTM C 533 For Steam service (MP/HP) Density 220Kg/m 3 except for LP steam The insulation material shall meet the requirements of ASTM C795, when applied on austenitic stainless steel surfaces Galvanized wire mesh shall be used up to 370 Deg.C operating temperature, and Stainless steel wire mesh shall be used above 370 Deg.C operating temperature and on austenitic stainless steel surfaces. 3.3 Cold Insulation Materials Specification and standard application of cold insulation material shall be as follows: Material (1) Reference Code Application (a) Poly Urethane Foam (b) Cellular Glass (3.3.2) (c) Mineral wool (Blanket-Loose) ASTM C591 Type2 Density: 40kg/m ASTM C552 Density: 147kg/m 3 ASTM C553 Type I, II and III. Density: 96kg/m 3 For equipment and piping -180 Deg C to 80 Deg C For equipment and piping -180 Deg C to 80 Deg C For construction joints of towers, vessels, and piping, For irregular surfaces -180 Deg.C to 230 Deg.C

10 ISSUED 6 / 10 / 08 PAGE 9 OF When cold insulation material is furnished with pre-laminated vapor barrier such as aluminized polyester film or equivalent, vapor barrier coating and reinforcing material as specified in Par are not required Cellular Glass shall be applied if nonflammable insulation material is required Requirements Prior to Insulation Refer Painting Specification (Doc No: O 301), for details of paint to be applied prior to Insulation. In case of SS pipes, pipes to be wrapped by 0.19 mm thk Al sheet for temp upto C & 0.1 mm thk SS sheet for Op.Temp >400 0 C. 3.4 Anti-Sweat Insulation Materials Specification and standard application of anti-sweat insulation material shall generally be as per Par Dual Temperature Insulation Materials Insulation for dual temperature shall consist of multiple layers The inner layer shall be as per hot insulation material to keep the surface temperature below the available maximum temperature of the outer layer insulation material The outer layers shall be as per cold insulation material.

11 ISSUED 6 / 10 / 08 PAGE 10 OF Jacketing Materials Specification and standard application of insulation jacketing material shall be as follows: Material (1) Aluminium sheet with site applied moisture barrier made up of Bituminous paint RUSTEX No.1 of Shalimar make or equivalent 35 microns DFT (For Hot Insulation) Aluminised Steel (Type T 2-100) as per ASTM A 463 or ALUZINK GRADE 185 OR INDIAN APPROVED EQUAL (For Cold Insulation) Weatherproofing Mastic Reference Code or Brand Name (mm) ASTM A653 ASTM A H.I.Mastic or equivalent Thickness Application 22 SWG For all piping For towers, vessels, heat exchangers, flanges, valves and piping with NB 8 & below and 75 MM THK INSUL. 20 SWG For towers, vessels, heat exchangers, flanges, valves and piping other than above. 0.7 MM For all piping For towers, vessels, heat exchangers, flanges, valves and piping 0.9 MM For removable covers for flanges & valves - For bent pipe, equipment, pumps etc (1) Stainless steel jacketing shall be used in contact with metal surfaces, such as flashing collars, whose normal operating temperature exceeds 260 Deg.C and in atmospheric corrosion areas. (2) For details of circumferential lap & screw arrangement for fixing metal jacket to Insulation refer sketch HP001,HP002,HP006.

12 ISSUED 6 / 10 / 08 PAGE 11 OF Fastening Materials Specification and standard application of fastening for insulation materials shall be as follows: Material Dimension Application (mm) (a) Galvanized S W G # 20 For piping NPS 12 and smaller steel wires S W G # 18 For piping NPS 14 to NPS 18 (b) Galvanized steel bands (For Opt.Temp upto 370 Deg C) 0.4 mm THK x 13 mm wide 0.5 mm THK x 19 mm wide For piping NPS 20 and over and cylindrical equipment with outside diameter of 450mm up to 900 mm For cylindrical equipment with (c) Stainless wires Type 304 (Soft/Fully Annealed)(1) S W G # 20 outside diameter above 900 mm For piping NPS 12 and smaller S W G # 18 For piping NPS 14 to NPS 18 For hot insulation and 1-layer cold insulation material For cold insulation material (d) Stainless steel bands Type 304 (Soft/Fully Annealed) (For Opt.Temp > 370 Deg C) 0.4 mm THK x 13 mm wide 0.5 mm THK x 19 mm wide. For piping NPS 20 and over, and cylindrical equipment with diameter of 450mm up to 900 mm For cylindrical equipment with outside diameter above 900 mm outside diameter above 900 mm insulation material heaps up in two or more layers (1) Stainless steel wires and bands shall be used for fastening insulation to CS pipes with Opt.Temp above 370 DEG. C and for SS pipes at all Opt.Temp Specification and standard application of fastening for jacketing materials shall be as follows: Material Galvanized steel bands Stainless steel bands Type 304 Dimension (mm) 0.4 mm THK x 13 mm wide 0.5 mm THK x 19 mm wide 0.4 mm THK x 13 mm wide 0.5 mm THK x 19 mm wide Application For piping NPS 30 and over and cylindrical equipment with outside diameter up to 900 mm For cylindrical equipment with outside diameter above 900 mm For piping NPS 30 and over and cylindrical equipment with outside diameter up to 900 mm For cylindrical equipment with outside diameter above 900 mm

13 ISSUED 6 / 10 / 08 PAGE 12 OF 23 (1) For piping size less than 30 NPS aluminium band 12mm wide x 24 SWG thick shall be used for fastening of jacket materials. Centre to centre distance between bands shall be 300mm. 3.8 Other Materials Specification and standard application of auxiliary materials for hot insulation shall be as follows: Use Material Application (a) Joint filling material Water-kneaded powder of the same quality as the heat insulating material For filling voids of heat insulating material (b) Flashing compound Foam seal sealant or equivalent For openings on insu lation finish pene trated by lugs etc. (c) Finishing cement ASTM C449 or equivalent For affording a smooth surface as a final finish for heated surfaces (d) Insulating cement ASTM C195 or equivalent For affording resistance to heat transmission on surfaces (e) Reinforcing material Galvanized hexagonal wire netting 16 mm mesh x 0.5 mm wire dia. (for bent pipe). 16 mm mesh x 0.63 mm wire dia. (for equipment) For reinforcement of mastic etc. (f) Auxiliary insulation Glass cloth(10 x 10 mesh) Glass tape with aluminum foil For instrument piping in sizes below NPS ½

14 ISSUED 6 / 10 / 08 PAGE 13 OF Specification and application of auxiliary materials for cold insulation should be as follows: Use Material Application (a)vapor barrier coating C.I. mastic or a non breathing (vapor barrier) type mastic composing of elastomeric polymer based resin(nonflammable & having water vapor transmission rate of 0.05 perms for 0.35 mm dry film thickness ASTM E96) For vapor barrier of cold insulation Asphalt roofing or asphalt felt (b) Joint sealer and Foam sealant or oil modified clastomer with extended fillers and aluminum pigment For vapor barrier of anti-sweat insulation For joints sealer of cold insulation, for openings on insulation finish penetrated by lugs etc. (c) Sealing materials Caulking For jacketing (d) Reinforcing materials Glass cloth (10 x 10 mesh) For reinforcement of mastic (e) Anti-abrasive Hydro cal B-11 Anti-abrasion For cellular glass (e) Anti-abrasive insulation compound Hydro cal B-11 Anti-abrasion coating or equivalent For cellular glass (f) Auxiliary insulation materials Glass tape with aluminum foil For instrument piping in sizes below NPS 1/2

15 ISSUED 6 / 10 / 08 PAGE 14 OF 23 4 THICKNESS OF INSULATION The nominal insulation thickness shall be in accordance with the Tables.* (1) The calculation of insulation thickness shall be based on normal operating inside fluid temperature. (2) The thickness of insulation on the nozzles and other protrusions (including parts of structure) around equipment and piping shall generally be equal to the thickness of adjoining pipe insulation. (3) For towers, vessels, heat exchangers and rotating machinery, the insulation thickness specified as FLAT in the Table shall be applied except that the thickness of pipe insulation shall be applied for the equipment with outside diameter up to 600 mm (NPS 24) which can be regarded as pipes instead of FLAT. (4) For towers in which inside operating temperature varies with height, the thickness of Hot insulation may vary depending on the temperature. * As specified in ATTACHMENT( Tables 1,2 &3) 5 INSPECTION POCKET REQUIREMENT FOR INSULATION Insulation contractor should provide arrangement for insulation inspection. Insulation contractor should provide insulation inspection pocket arrangement. ATTACHMENTS

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PIPEWORK INSULATION. 14/ Page 1 of 10 Pipework Insulation Rev D

PIPEWORK INSULATION. 14/ Page 1 of 10 Pipework Insulation Rev D PIPEWORK INSULATION 14/10-2014 Page 1 of 10 Pipework Insulation Rev D Contents INTRODUCTION General Scope Surfaces to be Insulated Pumps, Turbines etc Performance Minimum Pipe Insulation Thickness Physical