SPECIFICATION GUIDELINES FOR THE USE OF CRYOGEL Z ON COLD PIPING AND EQUIPMENT Page 1 of 15 Ver. 3-0 March 2010
TABLE OF CONTENTS 1. Scope... 3 2. General System Requirements... 3 3. Installation Details... 4 4. QC/QA Requirements... 7 5. Appendix A: Insulation Materials and Accessory Suppliers... 9 6. Appendix B: Insulation Details... 11 Page 2 of 15 Ver. 3-0 March 2010
1. Scope 1.1.1 This specification provides design and application guidelines for the use of Cryogel Z as thermal insulation and/or passive fire protection. It applies to piping and equipment operating at below-ambient service temperatures. 1.1.2 These guidelines are not intended to be comprehensive, and other application options that are not listed may be appropriate. Please contact Aspen Aerogels for specific recommendations. 1.1.3 This document is offered as a guide only, and should be employed at the discretion of the user. No warranty of procedures, either expressed or implied, is intended. 2. General System Requirements 2.1 Approved Materials and Accessories 2.1.1 Descriptions, product names, manufacturers, and usage limitations for the specified materials and accessories can be found in Appendix A. 2.2 Storage Requirements 2.2.1 Aerogel insulation materials should be stored in a clean, dry, and protected environment. 2.2.2 If material has to be stored in an outdoor setting, it should be placed on pallets and thoroughly covered with a waterproof tarp or plastic sheeting. 2.3 Surface Preparation 2.3.1 Before any insulation material is applied, the surfaces to be insulated shall be clean and free of frost, moisture, or other imperfections. 2.4 Thickness of Cryogel Z for Thermal Insulation and/or Passive Fire Protection 2.4.1 The total insulation thickness on each piece of equipment or piping shall be determined from published k-values and project-specific parameters. For assistance in generating the correct thicknesses for thermal insulation and/or passive fire proofing, please contact Aspen Aerogels. 2.4.2 When designing for both thermal insulation and passive fire protection, the greater of the two thickness requirements shall be used. 2.4.3 Each layer shall be numbered with a grease pen to facilitate inspection. 2.4.4 Cryogel Z is manufactured in thicknesses of either 5 mm or 10 mm (0.2 in or 0.4 in). Determination as to which thickness to use shall include consideration of pipe size, as described below: Page 3 of 15 Ver. 3-0 March 2010
2.5 Insulation Support Rings For pipe or tubing diameters less than 100 mm (4 in.), either 5 mm or V- grooved 10 mm material (see Appendix A) shall be used. For pipe diameters equal to or greater than 100 mm, 5 mm or 10 mm material, or a combination of the two, may be used. 2.5.1 Insulation support rings are not required for vertical piping or vessels which do not require the insulation to serve as fireproofing. 2.5.2 Depending on the jacketing material and design, a support ring at or near the bottom of any vertical run may be necessary to support the lagging. 2.6 Expansion / Contraction Joints 2.6.1 Expansion contraction joints are not necessary with the Cryogel Z insulation system. 2.7 Jacketing 2.7.1 Cryogel Z is compatible with all forms of jacketing, including metal cladding, PVC, mastic-glass-mastic, glass reinforced plastic (GRP), and polymeric and asphaltic membrane systems. Refer to site specifications for jacketing installation procedures. 2.7.2 As a flexible material, Cryogel Z will always follow the movement of the equipment or piping to which it is affixed. For rigid, fully adhered systems jacketing systems (e.g., some forms of GRP), measures should be taken to minimize the strain buildup between the cladding and the underlying insulation. 2.7.3 For situations where the thermal insulation is also to be used as passive fire protection, the jacketing shall be stainless- or galvanized steel. 2.7.4 Screws and rivets are to be avoided unless absolutely necessary. 2.7.5 In areas where screws or rivets are necessary to secure the jacketing (i.e., vessel heads), a sacrificial layer of 25 mm (1 in) polyolefin foam shall be applied to prevent puncture of the primary vapor barrier. Discrete strips oriented to allow drainage are preferred over full-area coverage. 2.7.6 When pre-drilling rivet holes, use a mechanical stop or marking tape to prevent penetration of the vapor barrier. 3. Installation Details 3.1 Straight Piping and Horizontal Equipment 3.1.1 Cryogel Z insulation materials shall be applied by cigarette wrapping around the pipe (Figure 2, Appendix B). Insulation shall be applied square to the longitudinal axis of the pipe and pulled tight around the circumference. Page 4 of 15 Ver. 3-0 March 2010
3.1.2 Circumferential joints shall be tightly butted with no visible gaps. Longitudinal joints shall either be tightly butted, or overlapped by 25-50 mm (1-2 in). All joints shall staggered by a minimum of 100 mm (4 in). 3.1.3 Material may be temporarily affixed with strapping tape, spray adhesive, stainless steel wire, or stainless steel bands (see Appendix A). 3.2 Securement of Thermal Insulation and Fire Protection 3.2.1 19 mm (¾ ) stainless steel bands shall always be placed around the second-tolast layer of Cryogel, between the primary and secondary vapor barrier layers. Bands shall be spaced 450 mm (18 ) apart (refer to Figure 1). 3.2.2 On vertical piping and equipment, additional intermediate banding shall be installed over every fourth layer. Bands shall be spaced 450 mm (18 ) apart. 3.2.3 Where the insulation is to serve as passive fire protection, additional intermediate banding shall installed over every second layer. Bands shall be spaced 450 mm (18 ) apart. 3.2.4 Stainless steel bands shall not be applied directly to either the primary or secondary vapor barriers. 3.3 Vapor Barriers 3.3.1 The primary vapor barrier shall consist of the factory-applied mylar on the outermost layer of Cryogel Z, with all joints sealed with the appropriate tape or mastic (see Appendix A). 3.3.2 As an option to provide greater puncture resistance, an additional membrane or mastic can be applied over the outermost layer of the Cryogel Z (see Appendix A). If this option is used, separate joint sealing of the outermost layer is not required. 3.3.3 On piping or equipment operating below -40 C (-40 F), a secondary vapor barrier shall be installed two layers beneath the primary (see Figure 1). The secondary vapor barrier shall consist of Cryogel Z s factory-applied mylar, with all joints sealed with tape. 3.4 Vapor Stops 3.4.1 To insure end-to-end integrity of the vapor barrier, vapor stops shall be installed at all insulation terminations and penetrations, and on either side of all flanges, valves, hangars, and supports. See Appendix A for acceptable vapor stop materials. 3.4.2 The vapor stop shall tie into both the secondary (where required) and primary vapor barriers with a minimum lap of 50 mm (2 in), as illustrated in Figure 3. 3.4.3 All liquid- or paste-applied mastics and sealants shall be constructed with a membrane reinforcement. Page 5 of 15 Ver. 3-0 March 2010
3.4.4 When vapor-stopping over the cut ends of the Cryogel Z, it may be necessary to smooth over the ragged surface with a bridge layer of tape or Cryogel Z (see example in Figure 3). 3.5 Elbows 3.5.1 Pre-fabricated construction is preferred. Shop- or field-fabricated gore sections are acceptable, as is spiral wrapping with 5 mm thick material. 3.5.2 For fabricated elbows, gored, or lobster back patterns shall be used on all short-radius, long-radius, swept, and socket-weld elbows larger than 50 mm (2 in) NPS. 3.5.3 Each layer shall be installed separately and held in place with tape, spray adhesive, wire, or stainless steel bands, subject to the restrictions given in Sections 3.2.4. 3.5.4 On bent tubing and welded pipe < 75 mm (3 NPS), the elbow shall be insulated as a tee (see Figure 4). 3.6 Small or Irregular Surfaces 3.6.1 On small diameter tubing and pipe (<4 NPS), pre-fabricated V-groove (see Appendix A), or cigarette- or spiral-wrapped 5 mm Cryogel is acceptable. 3.6.2 On irregular surfaces, spiral wrapping with 5 mm Cryogel is preferred. Spiral wrapped material should be pre-cut in widths of 50 75 mm (2" 3"). Provide an overlap of 50% when wrapping. 3.6.3 Strapping tape, wire, or adhesive spray may be used to secure the ends of the spiral wrap. 3.7 Flanges 3.7.1 Flanges shall be completely insulated to the same thickness as the adjacent piping. 3.7.2 Flange insulation shall be built up from the adjacent pipe insulation with a shoulder measuring at least 2X the change in radius (see Figure 5). The shoulders shall be banded in place. 3.7.3 Void spaces shall be filled with Cryogel Z, or wadded mineral or glass fiber. 3.8 Tees, Bonnets and Other Changes In Direction of the Insulation 3.9 Valves 3.8.1 Install aerogel blanket using the same bird s-mouth technique as would be used for installing cladding. Insulation joint shall be staircased as shown in Figure 6. 3.9.1 Valves shall be insulated to the same thickness as the adjacent piping. The only exception to this is bottom drain lines and bypass tubing, which may be insulated to the thickness prescribed for their diameter. Page 6 of 15 Ver. 3-0 March 2010
3.9.2 Consult the valve manufacturer for the recommended insulation height on the valve bonnet. 3.9.3 Flanged valves shall be insulated similarly to flanges, with the bonnet treated as a tee and capped (refer to Figure 6). The cap shall be shaped to shed water. 3.9.4 Wherever the insulation makes a change in direction, the joint shall be staircased to avoid a cold-pass (see Figure 7). 3.9.5 Void spaces shall be filled with Cryogel Z, or wadded mineral or glass fiber. 3.10 Transitions to Other Insulation Types 3.10.1 Transitions between Cryogel Z and other insulation materials (e.g., at highdensity polyurethane supports) shall be constructed as shown in Figure 8. The shoulder shall be at least twice as wide as it is tall. 3.10.2 The adjacent insulation system shall be fully vapor stopped before the transition is constructed. 3.11 Vessel Heads 3.11.1 Pre-fabricated construction is preferred. Field-fabricated is acceptable. 3.11.2 Seams shall be butt joined. Joints on multi-layer applications shall be staggered. Securement prior to banding and jacketing shall be with spray adhesive. 3.11.3 Secure insulation with a harness of stainless steel bands or galvanized steel chicken wire, anchored to two circumferential bands located behind the tangent line (see Figure 9). For heads with a central nozzle, use a floating ring. Bands shall be spaced no wider apart than 450 mm (18 in) at the tangent line. 4. QC/QA Requirements 4.1.1 All aspects of valve insulation are subject to inspection, sampling, and monitoring by the owner. Work shall not proceed past a hold point without written acceptance. 4.1.2 Surveillance Point: Verify Work Release Before insulation, written confirmation shall be provided that the piping or equipment has been released for insulation. All adjacent joints and terminations have been adequately sealed, with no holidays, fish-mouths, tears, or punctures. 4.1.3 Surveillance Point: Verify Secondary Vapor Barrier The correct number of layers have been applied and marked. Intermediate banding, if necessary has been installed and located correctly. All joints and terminations have been adequately sealed, with no holidays, fish-mouths, tears, or punctures. Page 7 of 15 Ver. 3-0 March 2010
Any necessary repairs shall be made with joint sealing tape, and/or mastic and/or caulk. 4.1.4 Surveillance Point: Verify Primary Vapor Barrier The correct number of layers have been applied and marked. Banding has been installed and located correctly. All joints and terminations have been adequately sealed, with no holidays, fish-mouths, tears, or punctures. Any necessary repairs shall be made with joint sealing tape, and/or mastic and/or caulk. 4.1.5 Consult site specifications for jacketing inspection requirements. Page 8 of 15 Ver. 3-0 March 2010
5. Appendix A: Insulation Materials and Accessory Suppliers Table 1: Insulation, fire-protection and accessory materials and suppliers. System Component Insulation System Material Description Manufacturer / Brand Names Applicable Surfaces Insulation 5 mm (0.2 in) thick Aspen Aerogels / All and/or Passive aerogel blanket Cryogel Z Fire Protection 10 mm (0.4 in) thick aerogel blanket Aspen Aerogels / Cryogel Z Piping 100 mm (4 in) NPS; all vessels, and equipment V-grooved aerogel Sproule Mfg. / Piping <100 mm (4 in) Joint Sealing Tape Vapor Barrier Mastics Optional Sheet Mastics Vapor Stop Sealant Membrane Reinforcement Elbow Covers Spray Adhesive blanket Cryogel Z V-Groove Pre-cut elbows Sproule Mfg. / Precision CNC AA Fitting Covers Foil-faced butyl tape, 25-50 mm (2-4 in) wide Foil / polyester laminate, 25-50 mm (2-4 in) wide Hypalon rubber vapor barrier mastic 1.2 mm (0.050 in) foilfaced butyl sheet Hypalon rubber vapor barrier coating Cryogenic vapor barrier coating Glass or polyester open-weave cloth Pressed aluminum jacket covers sized for aerogel thicknesses Chloride-free spray adhesive (can or bulk) Covalence Adhesives / Polyken 360-17 Denso / Denso Butyl 35 Tape Venture Tape / 1555CW Foster Products / Monolar II 60-38/39 Polyguard / Insulrap 50 Or equivalent Foster Products / Monolar II 60-38/39 Foster Products / 90-66 Foster Products / Mast-a-Fab Or equivalent Sproule Mfg. / AA WeatherJacs Foster Products / 85-45 FOS-STIK 3M / 78-Spray Nashua / 357SA NPS All short-radius, long radius, socket-weld, and swept elbows For application temps at or above 15 C (59 F) For application temps at or above -18 C (0 F) All All For process temperatures down to -40 C (-40 F) For process temperatures down to -196 C (-320 F) All All short- and long-radius elbows up to 900 mm (36 in) All Page 9 of 15 Ver. 3-0 March 2010
Table 1 (cont.): Insulation, fire-protection and accessory materials and suppliers. System Component Insulation System Material Description Manufacturer / Brand Names Applicable Surfaces Strapping Tape 12 mm (1/2 in) wide 3M / 3297 All fiber-reinforced packing tape Or equivalent Sacrificial Cushion Layer 25 mm (1 in) thick polyolefin foam K-Flex / LS Sheet Nomaco / EPFI All Armacell / AP Sheet Or equivalent (compliant with ASTM C534) Page 10 of 15 Ver. 3-0 March 2010
6. Appendix B: Insulation Details Figure 1: Vapor barrier and band locations for Cryogel installations of 1 to 15 layers. Figure 2: Installation of second layer on piping. Page 11 of 15 Ver. 3-0 March 2010
Figure 3: Vapor stop detail on a 7-layer termination, showing the tie-ins with both the primary and secondary vapor barriers. Figure 4: Insulation detail for tubing or small-bore, butt-welded elbows. Figure 5: Flange insulation detail. Page 12 of 15 Ver. 3-0 March 2010
Figure 6: Correctly staircased joint at a change of insulation direction (e.g., at a tee). Page 13 of 15 Ver. 3-0 March 2010
Figure 7: Valve insulation detail. Figure 8: Insulation transition detail. Page 14 of 15 Ver. 3-0 March 2010
Figure 9: Vessel head band harness detail. Page 15 of 15 Ver. 3-0 March 2010