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Method Statement For Insulation Work

Method statement for insulation work of piping and equipments

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Duy Tùng
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648 views75 pages

Method Statement For Insulation Work

Method statement for insulation work of piping and equipments

Uploaded by

Duy Tùng
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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Total Sheet: _75 _ sheet Subcontractor's Name ___:_MILAMA CORPORATION Employer Nghi Son Refinery and Petrochemical LLC. Contractor 2 JGCS Consortium Zone Zone-1 Project Name NSRP Complex Project Subcontract No, Document Title Contractor Doc. No. Issue Purpose to Contractor (FAFC) CNT-6495-INS-18&2 Method Statement for Insulation Work VV3190-001-A-100__ Revision No.0 FA Review Result Sticker (Filled By JGCS) Result CODE: A, B, R, F if -B- ) Next Status: FA, FC ( i Fe ) Re-submissionDate: | ASAT ) Responsible Dept /Person: | Ry anaed Deayrg (PIE Sw) + J | Construction Zone 1 [Link] Endorsement HSSE | Zoneac Checked By (Name, Sign) | (a. Mey ded, ( | | BoD Result Code ( Date reemeeaed | 11 pr Aeon 1 ) / | it ) DEC so pom any | ¢ ) pa aoe ( Approved ay (Name, sign) |( phe | ‘A: Approved without Comment; 8: Approved with Comments R: Not Approved; F: Not Subject to Review Issue Purpose Sticker Issue Purpose to Employer: FA, FR, Fl, FC i FR) i Document Class: Z, X, Others Note: wate (neu Qeqe Glen tok Of Tetadation Galery? SRP COMPLER PRO 215 WAR 208 syed RESCS B%4 2. > x PROJECT Contractor Doe. No TION WORK METHOD STATEMENT FOR INSUL. Unit No.: Not Application Document Class: X ~yesue Purpose: 23 Mar.2015 For Approval | 0 L4 | Approved ye —] “Checked ‘Company Respor fan Thanh | Tran Wan Nhat ham Ngoc Quy ~~ LILAMA Corporation i ig | ied \ = i aaa as J 7 Page tof 74 gccs wer §6—C ‘camsanTiUM NSRP COMPLEX PROIE JOB CODE: 0-6495-20 ; ‘Contractor Doc. Ne REV-0, Tiule: Method Statement for Insulation Work. VV3190-001-A-100 23 Mar. 2013 TABLE OF CONTENTS 1, INTRODUCTION 2. DOCUMENT REFERENCE 3. SCOPE OF WORK 4, ERECTION EQUIPMENT, MATERIALS, AND TOOLS 5. TRANSPORTATION, UNLOADING, AND STORAGE 6, ERECTION SEQUENCE AND PROCEDURE, 7. HEALTH, SAFETY & ENVIRONMENT 8, APPENDIX: JSA. x Rh \ Page 2 of 74 \ SNS a \— JGcs aye> __“coxsonrium ___NSRP COMPLEX PROJECT _ ‘JOB CODE: 0-6495-20 Contractor Doc. No: |___ REV-0 Title: Method Statement for Insulation Work. VV3190-001-A-100 = 23 Mar. 2015 L. INTRODUCTION Project : NGHI SON Refinery and Petrochimical Complex Project Employer: NGHI SON Refinery and Petrochimical LLC (or NSRP) Contractor: JGCS Consortium (or JGCS) Specification: The contract specification will be used for the construction work This Method Statement details about the requirements and Installation works of Insulation. Installation of Insulation for piping and Equipments ‘The procedure includes installation of the Insulation works on Cold and Hot Service,Acoustic, Steam chests (Stop and Control valves) and miscelleaneous pipings. 2. REFERENCES 2.1 ENGINEER S-000-13A0-0001V Specification for Painting S-000-1390-0001V Specifiacation for Hot Service and Acoustic Insulation S-000-1390-0002V Specification for Cold Service Insulation S-000-1244-0001V Specification for Plant Noise Control 8-000-124-0001 Specification for Equipment Noise Control D-000-1351-0001V Standard Drawing for Pressure Vessels 2.2 INTERNATIONAL STANDARD. AS less and Heat- MAI67 Chromium-Nickel Steel Plate, Sheet and Strip Specification for Stain! _ Resisting ASTM CI77 Test Method for Steady-State Heat Flux measurements and Thermal Transmission Properties by means of the Guarded Hot-Plate Apparatus _ ‘ASTM C552 ‘Standard Specification for Cellular Galss Thermal Insulation. "ASTM C795____| Specification for Thermal Insulation for use in contact with Austenitic Stainless | | Ssteel. ‘ASTM D696 Test Mehtod for Coefficient of Linear Thermal expansion o Pasties between -30° C | and 30°C | ASTM D1621 Test method for compressive properties of rigid cellular plastics ASTM D1622___| Test method for apparent density of rigid cellular plastics ASTM D1623___| Test method for tensile nd tensile adhesion properties of rigid cellular palstics [ASTM 2856 __| Test method for open-cell contents oF rigid cellular palsties by air pyenometer ‘ASTM E84) ‘Test method for surface burning characteristics of building materials | [ASTM £96 Test m ‘materials ‘ASTM SCI77___| Test method for steady-state heat flux measurements [BS 476 Parts 23-31 | Fire test on buil 180 15665 ‘Acoustic insulation for pipes, valve, and flanges ng materials and structures Fire tests on building materials and structures Method of test to determine the classification of the surface spead of flame of products. | BS 1449 ‘Steel plate, sheet and strip. Carbon and carbon-manganese plate, sheet and strip. General specification, Page 3 of 74 ‘swGces = Be > ___“Srexsontium NSRP COMPLEX PROJECT. ‘JOB CODE: 0-6495-20 Contractor Doe. No: REV-0 Title: Method Statement for Insulation Work. VV3190-001-A-100 Date: 23 Mar. 201 [Link] OF WORK This Scope defines the minimum requirements for the material identification and installation of insulation applied to piping, instrument and equipment (pressure vessels and heat exchangers) for heat conservation, process stabilisation, temperature maintenance, acoustic attenuation, personnel protection and fire protection. The Installation of Insualation work for piping and equipment as per Construction drawings. The List of Drawings has been enclosed in Annexure-2. Responsibility to ensure that all work is carried out in accordance with the Contractor's construction documentation and drawings. In the event conflicting information, the Field Representatives shall be consulted for clarification, 3.1, Hot Service Insulation 3.2. Acoustic Insulation, 3.3. Cold Insualation [Link] EQUIPMENT, MATERIALS AND TOOLS 4.1. Crawler Crane -50 Ton Capacity. 4.2. Boom Truck, 4.3, Mobile Crane -50 Ton Capacity. 4.4, Portable hand and Power tools 4.5. Wineh-15 ton capacity -8 Pes 4,6. Winch-5 Ton capacity-8 Pes 4.7. Roll Pulling Rollor(Un-Coiler) 4.8, Plain Sheet Searing MC 4.9. Bending M.C 4.10. Beading MC 4,11. 3 rollor Bending MC 4.12 Grinding machine 4.13 Drill machine 5. TRANSPORTATION, UNLOADING, AND EQUIPMENT 5.1. SCOPE This procedure is to describe the Storage procedures for Insulation,Lagging materials supplied by Lilama for the part of the plant in accordance with the Contract. 5.2. OBJECTIVE ‘To assist at job site in 5.2.1 Quick and accurate receiving of materials. 5.2.2 Identification of missing and damaged materials. 5.2.3 Establishing the laydown area for storing of materials 5.2.4 Maintain the materials during storage, 5.2.5 Quick and accurate information of material status, 5.3, DEFINITION 5.3.1 Overage: ‘The said product is not included in packing list or bill of lading but itis actually existing in the packing ons | Page 4 of 4 _—— a6cs E’aee £F JOB CODE: 0-6495-20 | Contractor Doc. Ni [ Titte: Method Statement for Insulation Work. ‘VV3190-001-4-100 5.3.2. Shortage: ‘The materials included in the packing list or bill of lading, however actually it is not in the packing or the total is lesser than which is shown in the packing list while packing is in good condition. 5.3.3. Loss or Missing: Materials included in the packing list or bill of lading, however it is not actually or lesser while the packing is broken, 5.3.4, Damage: Product received damaged due to the handling during delivery time, which is still under Client responsibility. 5.4. DESCRIPTION OF PROCEDURE, 5.4.1. Receiving ‘The Materials are being shipped to site by returnable containers. These materials will have to be unloaded upon arrival of materials at job site. The following items shall be implemented at site by material control engineer in coordination with client representative: 5.4.2, Shipping schedule. Shipping schedule will be summited by Lilama to meet insulation schedule and will be confirmed by Supplier(Kimseo). 5.4.3, Receiving preparation + Handling equipment preparation + Storage room preparation + Document and report form preparation + Material control system 5.4.4, Material or equipment arrival ‘When material delivey to site, Lilama must be informed to constractor and inspected together. * Check the shipment is completed with packing list and shipping documents. * Check that packing and marking of each item actually exists and perfectly legible. * Check packing for good condition so as to determine the possible damage due improper handling, + Check identification and marking of materials. * Check material dimension randomly + Check materials conformity with certificate 5.4.5. Tagging or mark classification of material storage. 5.46. Certification All materials, which required certificates or letter of compliance in accordance with specification, shall be checked on receiving, 5.4.7, Reporting 3.5, STORING The Materials can be divided into two categories according to storage requirements, ~ Materials that must be stored in Lay down with covered sheets - oR Page 4 \L- Te oo Jgcs «ss We CONSaRTIUM __NSRP COMPLEX PROJECT. JOB CODE: 0-6495-20 Contractor Doc. REV __| Title: Method Statement for Insulation Work,_ _VV3190-001-A-100 Date: 23 Mar. 2015 | - Materials that must be stored in container or warehouse. Ideally all the materials should be stored in covered area or shed a).Make certain that the aluminium lagging and casing is stored in dry place and ventilated .Care shall be taken to avoid water stain to the aluminium Lagging They can be stored outdoor with protection of tarpauline sheets or Plastic sheets. The cover should be firmly secured with temporary frames. b).Mineral fibre insulation materials are shipped with [Link] is very important that these materials should protected from rain and water. They must be stored in covered area Handling time care shall be taken to avoid damage to the packing as they easily [Link] wool materials should be Stored elevated off the ground by placing them on the wooden platform. ©). The Galvanized,aluminized,and stainless materials must be stored in warehouse (Indoor). d).All carbon steel items carbon steel metal lath, flat bars and steel plates shall be stored indoor to prevent rusting before they are installed. e) The items Tie wire, Insulation bands, sewing thread, studs, sheet metal screws, neoprene sheets etc., ‘must be stored in containers with locking facilities, 5.5.1 All Insulation and refractory materials should be identified by stock number, description, location codes and tagging. The material control engineer should maintain the material identification through out the project life. 5.5.2 Maintenance Material checking at storage area is to ensure the material quality will remain same, in accordance with ‘what has been initially conditioned a) Periodical visual check ) Routine check 5.5.3 Lay out and Location code Large area of open-air storage yard shall be sub divided to storage sections and allocated identifying area codes. 5.5.4 Package inspection report ‘The report of package or material receiving inspection before the material is unloaded at storage area from the transportation means. Attach photograph wherever required with this report. [Link] . Open Package Inspection Report Unpacking shall be witnessed by GCS. In this report the condition of materials should be clearly mentioned and necessary photographs shall be. [Link]. Material status report This report shall be clarifies the status of materials received, issued, and balance stock. 5.6. REQUISITION AND ISSUING All materials distrisbution shall be requested with material request as Lilama’s form, Any materials issued shall be recorded in issuance note. 5.1. STOCKTAKING. Stocktaking of materials held by material controller and witnessed by client representative/MC/ Manufacturer will include visual count of materials held in the warchouse and open-air storage yard. <= B Page 6 of 74 JGGS #27 raxsentiune NSRP COMPLEX PROJECT JOR CODE: 0-6495-20 Contractor Doe. No: Tiite: Method Statement for Insulation Work. vv3190-001-4-100 | Date: 23 Mar. 2015} 6. ERECTION SEQUENCE AND PROCEDURE 6.1 GENERAL REQUIREMENTS-INSULATION AND LAGGING 1) Insulation shall be installed on piping and equipment where indicated on the construction drawings, in line lists and equipments lists. Insulation shall only be applied over coated piping and equipment. 2) All materials shall be new, undamaged nor crushed and shall be installed prior to the expiration date, if applicable. Sealants, mastics and adhesives shall be applied from factory sealed containers. 3) Insulation shall be maintained dry at all times during storage and installation. Do not install wet insulation. If the insulation becomes wet during or after installation, remove and replace with new dry insulation, Insulation shall be protected with plastic film, but shall be vented to prevent condensation. If there is a work delay, seal all possible points of moisture penetration before work is halted. 4) Insulation supports, anchor nuts, ete., will normally be welded to equipment and clamped to piping, unless otherwise noted. Welding will not be permitted on piping or equipment after stress relieving, without written approval by vendors. 5) All valves including control valves and relief valves, all flanges, including manway flanges, vessel skirts, heat exchanger closures and connectors, expansion joints, instruments and other similar items ‘which require periodic access shall be insulated for energy conservation or for personnel protection. ‘Where hot insulation is required for these items, the insulation shall be permanent insulation; however removable blanket type insulation may be used where specifically indicated on the drawings. 6) Hot Insulation of flanges shall be beveled to the pipe at a sufficient distance from the flange to allow removal of bolting without damaging adjacent insulation, Cold insulation of flange shall be a removable sealed type box assembly. 7) Manufacturer's equipment nameplates and code name plates shall not be covered by insulation. Insulation shail be cut to angle from the nameplate edges and sealed off with mastic followed by ‘weatherproofing compound, 8) Nameplates and identification tags hotter than 65°celsius, shall be insulated for burn protection. Asan alternate, an extended mounting bracket with approved equal insulating flange may be used, thus allowing nameplate to extend beyond the piping insulation, 9) All welded and screwed fittings, except unions, in insulated lines shall be insulated, 10) Make sure to protect adjacent equipment, etc. from the application of insulating materials, for ‘example drippings, sprayed paint, mastics, and compounds. 11) All hydrostatic tests on piping and equipment, including steam tracing systems, shall be carried out before insulating material is applied. The Lilama shall only insulate those sections of the Permanent ‘works that have been specifically released by an authorize agent. [f however, it has been planned and decided to insulate prior to other trades work and before tests have been completed, insulation shall terminate a suitable distance before and after welded and flanged joints, and sealed against water ingress ‘an mechanical damage which may be caused by other trades and during subsequent testing. Surfaces to bbe insulated shall be clean, dry and free from loose rust scale. It shall be the Insulation Applicator's responsibility (0 remove the loosely adhering scale and dry appropriate method which does not scar, scour or damage the metal surface, 12) Insulated carbon, low alloy and stainless steel piping and equipment require protective coatings as specified in the Specification for Painting (S-000-13A0-0001V), Page 7 of 74 wees § suse & MEER TUN NSRP COMPLEX PROJECT_ se ‘JOB CODE: 0-6495-20 Contractor Doc. No: REV-0 Title: Method Statement for Insulation Work. VV3190-001-4-100___[ Date: 23 Mar. 2015 13) A minimum clearance of 25mm between the outside surface of any isulation finish and adjacent equipment, piping or structural members shall be maintained, Care shall be taken where isulation is shop applied to ensure this minimum clearance. 14)Stiffener rings where provided on vacuum equipment and/or piping shall be insulation with the same thickness of isulation as specified for that piece of equipment or piping. The rings shall be fully isulated independent of the equipment or piping. Initial layers of insulation shall be applied with all joints tightly butted and staggered relative to each ther. 15) Each layer of multiple layer insulation shall be held in place separately. 6.2, PRE - PLACEMENT INSPECTION ~ EQUIPMENT Prior to placing the insulation the following inspections to be performed. ) Confirm the equipment is tested and accepted b) Check the proper insulation support rings have been installed, where required. ¢) Confirm that all clips for piping supports, ladders, platforms, etc. have been installed, 6) Ensure that the steam tracing is completed, where required. €) Confirm that the equipment is properly painted and inspected, if specified. 4) Ensure the surface to be insulated is dry, clean, and free from dirt, grease, rust, loose mill scale, etc. If required wash with clean water to remove the dirt or salt contamination 18) Confirm sufficient accessibility and clearance is provided for both the insulation thickness to be applied and the space necessary for workmen to apply it. 6.3, PRE-PLACEMENT INSPECTION - PIPING Prior to placing insulation on piping the following inspections are to be performed. 4) Ensure that testing of the piping system is completed and the system released for insulation. Insulation may be applied to the piping prior to piping, as long as, all welded and screwed connections are left bare until after leak testing is completed, and approval from client. ) Cheek insulation supports, specifically for vertical pipes. ©) Inspect pipes for correct shoes, guides, anchors, etc. 4) Confirm that all temporary attachments to the piping system have been removed and all tack welds are flushed. ¢) Ensure that steam tracing is tested and complete, where required. 4) Ensure that instrumentation wiring / tubing is tested and complete. &) Verify thatthe post leak test puch list items designated as affecting insulation are complete. h) When specified, confirm that painting is complete. 6.4, PLACEMENT INSPECTION During the placement of insulation, the following inspection shall be performed: 4) Ensure that all materials are according to engineering specification and contract standards b) Check thickness of insulation and jacketing. ©) Check distance between bands. screws, ete. d) Ensure that nameplates, couplings. electrical traced signs. etc, are left exposed, ©) Where double layer insulation used, ensure that the outer layer have no common joints with inner layer 4) Ensure that insulation is dry when applied and kept dry until properly waterproofed £8) Check insulation expansion or contraction joints, where required \ Page of WOR} | | JGcs | Me? paxsonTrune 7 NSRP COMPLEX PROJECT ___ JOB CODE: 0-6495.20 GONE Fatehog | Contractor Doe. No: Title: Method Statement for {nsulation Work. VV3190-001-A-100 bh) Ensure that protrusions through jacketing are sealed or caulked, i) Confirm that all insulation is beveled at flanged connections to allow removal of bolts without damage insulation. [Link] OF INSULATION 6.5.1 COLD SERVICE INSULLATION: 1. Classify Insulation and General Conditions of Use. Tablel. ‘asia ona Jinsutation | Insulation x ssfcation smbol hehe Pees service Notes frabie Selection Reference Consideration Notes Pobjsoeyanur| Each defined ; ate (PIR) | section of -vention of io : ‘equipment at gin cc — eociae [process lines) lormal operating, 7 different free normal Table dor femp of process ee peratng eps. | CC Table $id and nominal fase fre bein 31°C bipe size a With steam-out | Cellular Glass] individual temp. For shell and tube cc exchanger shells and | chanel use te lower ofthe inlet and outlet | temps Personnel on er piping protection ce ‘and equipment provige open ties meal Personne! guards over Surfices which protection with | pg ‘Stood off metal woe os sar normally a lett urnsulated | and which may be | sccessble, See Nowe Note: For personnel protection, pipe and equipment shall be preferably protected by stood off metal guard. Only where this is not feasible, thermal insulation shall be insulated. Pipe and equipment for personnel protection shall be fully paint in accordance with the Spec. for Paint(S- 000-13A0-0001).Basically CPG shall be applied if CPG is not feasible CP(thermal insulation) shall be applied. Page 9 of 74 JGcs 42> | & ToNsonTium NSRP COMPLEX PROJECT “JOB CODE: 0-6495-20 Gd ] Contractor Doc. No: REV-0 Tide: Method Statement forasuiaion Work, | “wwsis0-001-4-100 25 Mar. 2075 I. Piping and Cylindrical Equipment 900mm Diameter or Less (4) Insulation to the specified thickness shall be applied by the use of pre-formed two (2) half pipe sections wherever possible. For diameters where half sections are not available, multi segments or radiused and bevelled lags shall be used. 2) Insulation shall be applied starting with a full-length piece and a half-length piece so as to stagger the circumferential joints. When more than one layer is employed, the joints in the second layer shall not match the joints of the previous layer. (3) When applying Cellular Glass, the bore ofthe inner layer shall be coated with a thin application (o fill surface cells only) of anti abrasion compound and allowed to dry before application of insulation to the surface. (@) All joints of single or outermost layers of insulation, with the exception of contraction joints, shall be buttered with the specified joint sealer before installation and then firmly butted together. (6) Inner insulation layers applied in two half sections, shall be secured with 19mm wide pressure sensitive filament tape bands spaced at 220mm maximum centres applied with a 50% overlap. Single or outer layers and where inner layers are applied in radiused and bevelled segments, securing shall be by 12mm wide x 0.5mm thick stainless steel bands at 220mm. maximum centres, machine tensioned and sealed. (6) Insulation on bent pipe shall be neatly cut and mitred to suit the contour of the bend. All the ‘external surfaces of the insulation shall be rasped smooth to facilitate the vapour barrier. (7) Insulation of flanges, flanged fittings and valves shall consist of prefabricated fitting covers of the same material and thickness and applied in the same manner as specified for pipe insulation, The insulation shall stop short of studs and/or nuts to permit easy removal without damage to the insulation. Voids created by stopping short at studs and/or nuts shall be packed with glass fibre in-fill material, Securing bands shall be so located that maximum strength and security is obtained. (8) The installed insulation shall be vapour sealed with a vapour barrier as follows: 4) A thin coat of mastic shall be sprayed or towelled on to a minimum thickness. 2) While the mastic is still tacky, an open weave reinforcing fabric shall be laid smoothly and thoroughily embedded in the coating, Care shall be exercised that the weave does not rupture and, the fabric shall be overlapped a minimum of 80mm at joints to provide strength equal to that maintained elsewhere. 3) Before the first coat becomes dry to the touch a second coat of mastic shall be sprayed or towelled over the reinforcing fabric with a smooth unbroken surface and allowed to dry. 4) The total thickness of barrier material shall be 3mm (nominal) (®)_ Insulation on cylindrical straight sections of piping shall be covered with an additional protective sheet metal jacketing to the requirements of Table 3 rolled to conform to the pipe diameter and applied in 1.0 metre lengths. The jacketing shall be applied with minimum 50mm overlaps at both longitudinal circumferential overlaps. (10) All longitudinal overlaps on horizontal pipes shall be arranged weatherside down to shed Water and shall be located along the lower half at approximately 135°C or 225°C _positons Longitudinal overlaps on vertical pipes shall be arranged away from the prevailing site weather conditions. (11) The metal covering shall be secured tightly around the insulated pipe and help in place with stainless stell bands at a maximum of 220mm [Link] band shall be located on each _=awh \ Page 10 of 74 ‘JOB CODE: 0-6495-20 Title: Method Statement for Insulation Work. VV3190-001-A-100 | Date: cirumferential lap and the distance between laps divided at equal band spacing, (12) Each section of metal covering on vertical piping with insulation diameters larger than 250mm shall be supported from the next lower sections with two'S' clips fabricated from banding material. The’S' clips shall be of sufficient length to allow the minimum overlap of 50mm, (13) Insulated bends and elbows on piping 80mm (3") NPS and larger, shall be metalled with "lobster back’ segments using 10mm minimum ball swage to assist shaping, The metal segments shall be banded. (14) Insulated bends and elbows on piping smaller than 80mm (3") NPS and where constrioted at the throat bend, shall use fabricated ‘stove pipe’ elbows. (18) Butt weld, socket weld and threaded valves, where insulated, shall be clad and secured as pipe. (16) Removable covers on flange joints, flange valves etc. shall be fitted with snap fasteners for quick and easy removal, IML Vertical Vessels and Pipe Greater than 900mm Diameter (1) Insulation to the specified thickness shall be applied by the use of pre-formed radiused and bevelled lags for vessel, shells and pipes, and pre-formed sets for vessel heads. Insulation shall be bonded to the vessel heads using.a suitable bedding compound as recommended by the insulation manufacturer (2) Insulation shall primarily be supported on rings welded to the steel surfaces. Additional support and application aid shall be provided by the use of adhesive. (@) Insulation shall be applied starting from the bottom with vertical joints staggered. When more than one layer is employed, the joints in the second layer shall not match the joints of the previous layer. (4) When applying Cellular Glass the base of the inner layer shall be coated with a thin application (Qo fill cells only) of anti abras on compound and allowed to dry before application of insulation to the surface. (5) All joints of single or outermost layers of insulation, with the exception of contraction joints, shall be buttered with the specified joint sealer before installation and then firmly butted together. (©) Insulation shall be held against the metal surface with stainless steel bands in accordance with Table 2 at 300mm maximum centres. (7) Heads of vessels shall be insulated with pre-formed vessel head insulation sets. Where fabrication is necessary the material shall be cleanly cut and shaped to closely follow the contour of the head. ‘The joints shall be buttered in accordance with paragraph 5.3.5. The insulation shall be secured to the heads by bands drawn radially from the tan line circumferential body bands attached at 300mm centres, to a centralised floating ring of 10mm diameter bar. The bands shall be tensioned in suitable sequence to ensure a positive sercuting of the insulation material .Adhesive shall be used for initial support on bottom heads. (8) An additional layer of insulation shall be applied over the outside layer where insulation supports are located. (9) The installed insulation shall be vapour sesled in accordance with paragraph 11.8. (10) Insulation shall be covered with an additional protective sheet metal jacketing employing flat sheeting to the requirements of Table 3. (11) The panels shall be applied commencing at the bottom of the vessel. Each circumferential ring ‘of panels shall be tensioned by means of temporary tensioning bands until the final joint is made. awe \ ee = “dG6GS == Bas > eee [___NsRP COMPLEX ProuEcT TOR CODE: 0-6495-20 Gontactr Doe Noe | Tide: ethed Settotot for Insulation Work. [EErrstones eon roa 'S' clips shall be used as additional sheeting supports at circumferential overlaps. (12) The panels shall have a minimum overlap of 80mm on both horizontal and vertical edges. The overlaps shall be arranged to shed water at all times. (13) The panels shall be held tight to the vessel by means of circumferential bands and seals. The bands shall be positioned on all horizontal overlaps and at 450mm max. centres, (14) Over vessel heads the metal sheet shall be fabricated in an orange peel construction with all radial seams overlapping a minimum of 25mm. Radius direction joints shall be double lap seam joints and Circumferential direction joints shall be folded seam joints to ensure the sheeting does not become loose. (15) All equipment projections shall have the jacketing sealed using metal flashing cut to fit the projections. (16) Insulation and vapour barrier on the bottom head ofa vessel protected by a closed skirt shall not require weather protection. IV. Horizontal Vessels and Pipe Greater than 900mm Diameter (1) Insulation to the specified thickness shall be pre-formed radiused and bevelled lags for vessels shells and pipes, and pre-formed insulation sets for vessel heads (2) Insulation shall be applied starting with full length and half-lengths lags, with all circumferential joints being staggered. When more than one layer is employed, the joints in the second layer shall not match the joints in the previous layer. @) When applying Cellular Glass, the base of the inner layer shall be coated with a thin application (to fill cells only) of anti abrasion compound and allowed to dry before application of insulation to surface (4) All joints of single or outermost layers of insulation, with the exception of contraction Joints, shall be buttered with the specific joint sealer before installation and then firmly butted together (6) The applied insulation shall be sercured in place with circumferential stainless steel bands in accordance with Table 2 spaced at 220mm maximum centres. (6) Heads of vessels shall be insulated with pre-formed vessel head insulation sets. Where fabrication is necessary the material shall be cleanly cut and shaped to closely follow the contour of the head. The joints shall be buttered in accordance with paragraph IIL.4, The insulation shall be secured 10 the heads by bands drawn radially from the tan line circumferential body bands to a centralised floating ring of 10mm diameter bar. The radial bands shall be fastened to the body bands at 300mm centres and when attached to the floating, ring shall be tensioned in suitable sequence to ensure a positive securing of the insulation material (7) The installed insulation shall be vapour sealed in accordance with specified requirements (para 11.8), (8) Horizontal cylindrical equipment shall be finished with flat metal jacket arranged in circumferential bands with the longer dimension edge applied around the circumference of the equipment insulation, (®) The panels shail have a minimum of 80mm overlap on both longitudinal and circumferential edges, both overlaps being finished with a 4mm minimum ball swage and rendered water tight Page 12 of 74 JGcs eye” | & ams un _NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 ‘Contractor Doe. No: REV-0, Tile: Method Statement for Insulation Work. vv3190-001-4-100__ | Date: 23 Mar. 2015 | ‘with a 4mm bead of metal seam sealer located in the ball swage. (10) The jacketing shall be held tight to the vessel by means of circumferential bands and seals. The band sizes and spacing shall be 20mm wide x 0.5mm thick bands on all circumferential laps and at 300mm maximum centres. (11) For vessel heads the metal sheet shall be fabricated in an ‘orange peel” construction with all radial seams overlapping @ minimum of 25mm, Radius direction joints shall be double lap seam joints and circumferential direction joints shall be folded seam joints to ensure the sheeting does not become loose (12) All equipment projections shall have the jacketing sealed using metal flashing cut to fit the projections, (13) Where applicable, exchangers shall be insulated, vapour sealed and clad as horizontal vessels, with the exception that the channel cover and/or bonnet covers shall have removable cladding ‘must ensure: Cellular Galss and PIR blocks shall be applied using a bedding compound to avoid voids in the inner layer that could contract water. Such bedding compound shall be approved by Employed and meet the material manufacturers insulation requirements. V. Contraction Joints. (1) Contraction joints shall be positioned in sufficient number and at such distance to allow the contraction of piping and equipment to take palce without disturbance or damage occurring within the insulating system, Contraction joints shall be determined based on the expected movement. Joints on horizontal piping and equipment shall be installed at 6 m max. centres and ‘a minimum of one mid way between fixed points. (2) On vertical piping and equipment contraction joints shall be provided directly below insulation support rings where practical. The same method described for non vertical piping shall be employed, with the added provision that the side of the contraction joint cover adhered to the outer layer of insulation shall be above the contraction joint. (3) Contraction joints on non vertical piping shall be provided using a 25mm wide break in the insulation. Contraction joints in multi layers of insulation shall be positioned approximately 200mm apart. A layer of insulation sealer shall be applied to the mating surfaces between layers in the area between contraction jo nts. All joints are to be packed ‘with mineral fibre in-fill material compressed to 50% of its thickness. Single or outer layer insulation contraction joints shall be covered with a 150mm by 25mm thick collar of insulation centred over the joint. One side of this cover layer of insulation shall be fixed using insulation adhesive. The other side is to be liberally coated with insulation sealer fon the inner surface which mates to the outer layer of insulation. A heavy fillet of insulation sealer shall be applied to the butt end of the sealed side. Bands shall be used at each end of the contraction joint cover for security. The mastic vapour barrier system shall be applied over the contraction joint cover. (4) On vertical piping contraction joints shall be provided directly below insulation support rings where practical. The same method described above for non-vertical piping shall be employed, with the added provision that the side ofthe contraction joint cover adhered to the outer layer of insulation shall be above the contraction joint (5) Detailed drawings of contraction joint design shall be submitted for review, prior to execution of the work. < 150mm [Multi-piece pipe sections [I2mm wide stainless F radiused and bevelled steel band lags |Welded valves and butt- [All-sizes Wersized sections and JAS for “straight pipe” eld tees and reducers lags as per "straight" pipe feut and shaped to fit [Bends and Elbows [Al sizes TAs for "straight pipe” cut [As for “straight pipe” and shaped to fit [Flanged Valves and Joints |All sizes Wversized sectionsand [AS for “straight pipe” lags as per "straight pipe” lcut and shaped to fit 00mm >D [Fat blocks shaped to fit 20mm wide stainless steel bands Equipment Heads See 00mm CONSORTIUM NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 Contractor Doe. REV-0 Title: Method Statement for Insulation Work. __¥V3190-001-4-100 Date: 25 Mar. 201: Double and Triple Layer shall be constructed layer thickness as follows: | 30 aw [os | 30 50 | 40 50 5 50 50 5 so_| 60 | 5 30 60 6 60 60 6 Page 17 of 74 | amet | é& | NSRP COMPLEX P 6495-20 Contractor Doe. No: REV-0 [ Tite: Method Statement for Insulation Work. VV3190-001-A-100__[ Date: 23 Mar-2015 Table 5: Insulation thickness for Prevention of Heat Gain (Cellular Glass) ____Normal Operating Temperature °C) and Thickness (mm) 431 | -I1to] -21t0| -31t0} -41to) 51 | -61 | -71 10) -81 to] -91t0 remington | | 30 | zo | go | oso 1 | | ogo | on | ton in mm fi 2s | 40 | so | so joo | 7 | | % | 8 | 9 [90 | L 4o_| 40 | so | 60 | 70 70_| 80 [80 90_| 99 | 100 2 so_| 40 | so | 60 | 70 70_|g0 100 | _100_| 3__| so | so | 6 | 7 | 7 | so [ 90 uo | 10 4 100 | so _| 60 | 70 | 380 30 _| 90 ho |_ 120 6 1so_| 50 | 60 | 70 | 80 | 90 | 100 120 | 130 | 8 200 | so_| 7 | 80 | 90 | 90 | 130 | 130, to | 250 | so | 7 | so | 90 | 100 | 110 130 | 140 12_| 300 | 60 | 7 | so | 90 | 100 | tio] 130 | 140 | 4 | 350 | 60 | 7 | so | 90 | 100 | 110 140 | 140 i6_| 400 | 60 | 7 | so | 90 | 100 | 110 140 | 150 is_| 450 | 60 | 7 | so | 90 | 100 | 110 140 | 150 20 | soo | oo | 7 | so | 100 | iso | 120 140 | 150 24 | 600 | 60 | 7 | 80 | 100] ito | 120 150 | 150 Fla_| Flat_| 60 | 80 [po | 110 | 120 | 130} 150 | 160 | 170 | 180_ Single Laver ——}——> Mull ayers Design Basis: Maximum Heat gain = 25w/m2 Ambient Temp.: 23.6°C Wind speed: 3.6 m/sec Emissivity: 0.15 Humidity: 90% ‘Note1: 80mm is the maximum single layer thickness above 80mm multilayer application is required. Page 18 of 74 | gees a2 |S ae CONSORTIUM Ti 7 JOB CODE: 0-6495-20 ] Contractor Doe. No: REV-0 Title: Method Statement for Insulation Work. | __vv3190-001-4-100___[ Date: 23 Mar.2015 Double and Triple Layer shall be constructed with layer thickness as follows: Thk | IstLayer] 2nd | 3rd Some sates L 100 | 50 n0 | 50 0 | 30 5 sO |code |r s0 5 140 | 40 so |_s 150 | 50 lad 160 | 30 oo | 3 1 | 30 | 60 | 6 130 | 60 o | 6 | Y. Insulation Instruction Figures. LPiping. Method of insulation and Cladding for Straight piping Page 19 of 74 “ | Eyer | ee JOB CODE: 0-6495-20 | Contractor Doc. No: REV -0 [Te Methed Sxtenct for Inaation Work, Tame Aun [Dita a NUTS] ‘Method of insulation and Cladding for Welded valves and butt-weld tees and reducers. ‘cONSuRTIUM _NSRP COMPLEX PROJECT. JOB CODE: 0-6495-20 ] ‘Contractor Doc. No: Title: Method Statement for Insulation Work. |__VV3190-001-4-100 5. Personnel Protection. “| a eee SERRE \ Method of Expanding Wire mesh for Personnel Protection. Page 34 of 74 JGCS e928 > NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 | Titie: Method Statement for Insulation Work. 6.5.2 Hot Service Insualtion, Contractor Doe. No: ‘VV3190-001-A-100 I. Classify Insulation and General Conditions of Use. ‘Table 1: INSULATION AND PROTECTION SYMBOL, CLASSIFICATION AND GENERAL CONDITIONS OF USE INSULATION [INSULATION THK riickness SELECTION SYMBOL [CLASSIFICATION ragieNo, [CONSIDERATION NOTES REF. HC Heat Conservation TableNo.3 | Normal Operating temp. | Each setion ofthe (Process Lines) ofpracess fuidand | equipment having defined | Where normal operati g nominal pipe size sections operating at | temperatures exceed different temperatures may | 93°C 0 be insulated to suit its indi | ‘dual temperature, For | Hs. Heat Conservation (Steam | shett and Tube Exchanger | ‘and Condensate Shells and Channels use the Lines) | higher ofthe inlet and outet | temperatres Ps Process Stabilisation to | Special | Special Consideration | Piping and equipment assist process contol Consideration subject to special spect | considerations to determine insulation thickness ané | design which shall be clearly indicated on the Engineering Flow Diagrams sand Line Lists. sm Steam Tracing Low TubleNo,3 | Normal Operating temp. | Insulation where operating Presace of process fluid and one | Permaneat works requires a Z pipe size greaterthan | protective heating system 10 parent pipe. protect piping, equipment and instruments against the effects of ambient temperatures including s™ ‘Steam Tracing Medium ie nace Pea | condensation, viscosity — change and pour point tS Bream Tracing with spaces suppression), Stearn ‘Tracing with heat | transfer cement | Page 35 of 74 'gGes By ee hm ‘Caxsanriun | NSRP COMPLEX PROJECT Ee JOB CODE: 0-6495-20 Contractor Doe. No: REV Title: Method Statement for Insulation Work. _ __VV3190.001-4-100__| Date: 23 Mar 2015 INSULATION TaucKyess | INSULATION TABLENO, | THK syMpo1 | CLASSIFICATION | ep seLecTion | NoTES - Lcossinenati_| ut HotwaterorSolvent | Tabie No.3 | Normal Operating, | insulation where operating | temp. of process ‘Permanent works requires & Trasing (liquid) | fsidandone pipe | protest heaing ptm poet or Hot Oil Tracing size greater than | piping, equipment and instruments | parent pine agains the effects of ambient, temperatures ineluding hyde TL Contro Trace Low | Table No.3 Normal Operating | formation, condensation, viscosity j | tem. ofheating | SH#RBE #4 POU Pont suppression ae | fluid and one pipe crm | ControtTrace Medium size water than | Pressure parent pipe Et lectiea! Tracing Normal Operating | tem. of process | fluid s Steam Jacking TableNo.3 | Normal u ‘Hot water or liquid Operating temp. | orjackeiog tus jnchting | o Hoo jacking | P Fire hazard protection | TbleNo. Sor | Special Insulate tw preven fast oiloff of special considerion | liquids. Vesel bottom heads inside consideration skins shal be protested by butno grester aluminised sto ciading than Table No.3 Page 36 of 74 JGcs ate | & CoNsoRTIUM | NSRP COMPLEX PROJECT [JOB CODE: 0-6495-20 Contractor Doe. No: REV-0 Title: Method Statement for Insulation Work. ___VV3190-001-4-100___ Date: 23 Mar: INSULATION THICKNESS | INSULATION TABLENO, | THK SYMBOL | CLASSIFICATION | Rep, SELECTION | NOTES CONSIDERATIO. PP | PersonnelProseetion | Table No.4 | Nominal pipe size | Over unlined piping and (suation) ‘and normal equipment insulate or provide ‘operatingtemp. | open mesh metal guards on ‘operating Permanent works which operating Temp | would normally be left un- >2008C insulated and which may be accessible during the performance of routine duties by opersting (not PG | Personnel Proteeon | Figure Operating Temp < (ery nae ‘maintenance only) personne, SEE _— Note* PC | Pessonnel Protection | Fiaurea Normal operating | (Stood-off metal guard) temp. 200 | snd interment temp>200C NE Notinsulated : Ino ther symbol applies NI shall 2 indicated for definition and larity and fs required for computer ITO purposes. NOTE* ‘The intent of Engineering Flow Diagrams, Line Classification lists, {nsulati designate insulation for types PP and PG is to call attention only to the eligibility of such service. The actual extent of such insulation shall be determined by Field Construction Personnel and/or operating personnel using the following crite -Exposed surfaces operating above 60°C and located with 600 mm horizontally or 2100 mm vertically of anormal access, walkway, or work area. -Paint and coating for pipe and equipment designated for personnel protection (*PP” or *PG") shall comply with Specification for Painting (S-000-13A0-0001V). IL Piping Insulation Appication, (1) Insulated piping systems shall have straight pipe, bends, tees and non-flange pipe fittings completely insulated. = 08g @ Y wees Ae * TOR CODE: 048539 Conteatoe os Nar Titec MethodSatement for Insulation Work | Ssionor ron (2) Insulation shall not be applied to the following unless otherwise specified for Acoustic, Attenuation, Personnel Protection or other special reasor iping which becomes hot intermittently, such as relief valves, vents, steam-out and snuffing steam systems, flare and blowdown systems and by-passes at control valves. = Supports for piping. -Steam Traps. [except : Insulation on inlet piping to Thermostatic and Thermodynamic steam traps. shall terminate a minimum of 450mm from the trap leaving the remainder of piping and the trap uninsulated = Pipe union fittings. = Thermowell bosses and pressure tapings - Expansion joints, hinged joints and hose assemblies. = Sight flow indicators. (3) Piping shall be designed to provide an absolute minimum clearance of 25mm between the outside surface of any insulation finishing material and adjacent surface (4) Preformed insulation shall be applied, supported and secured to straight length sighle pipe runs usng ‘two half sections up to the maximum manufactured sizes, above this size piping shall be insulated with minimum number of cut segments. (5) Insulating material shall be applied to fit snugly against the contours presented to the applicator and neatly cut and shaped only where necessary to achieve this requirement. The insulation shall be carried ‘out with the least number of material pieces as possible and all unavoidable gaps, cavities, and voids shall be suitably filled with compatible loose fill material. (6) Shop fabricated piping shall be amply supported and positioned in such a manner that allows complete all-round uninterrupted access to the work piece, At temporary support points during shop fabrication, insulation shall be terminated and sealed and closure pieces fabricated for later installation at site. (7) The insulation materials shall be secured to the pipes by means of circumferential tie wires or bands in accordance with Design - Table 2-1 of this method, Tie wires or bands shall be positioned sufficient to provide three ties or securing positions for each length of pipe insulation section. Ends of tie wires shall be turned into the insulation material Page 38 of 74 t wae > UGGS cnc | JOB CODE: 0-6495-20 ] ‘Contractor Doc. No: Titie: Method Statement for Insulation Work. _ VV3190-001-A-100 ‘Table2-1; Insulation Form and Securement Method. NOMINAL SIZE | INSULATION ITEM |OF INSULATION MATERIAL Straight pipe Upto200m(8") | Preformed Pipe Sections | 1.2mm minimum diameter ie | stainless steele (acing) _| Straight pipe | 250mm (10")t0 | Preformed pipe section or | 12mm wide stainless steel 300mm multi-seements hands Straight pipe | Above 500mm (20°) | Multi-segments 20mm wide stainless steel bands. | Welded valves and] All sizes As per straight pipe cut and | As per straight pipe. butt-weld tees, and shaped to fit | Flanged Valves, ~~ | Prongs, studs, rivet, Flanged J eae Suitable Preformed | adhesive as necessary to | Bends and Elbows Allsizes | As for straight pipe cut and. | As for straight pipe. = spaned to ft (8) When piping insulation require two or more layers we use Table below: OR) \ Page 39 of 74 Tie: Metied Staterent for Isuation Work. | Swsis0'oorea00 |; Bee 2 l NSRP COMPLEX PROJECT ‘Contractor Doc. No: ‘Table3 :Insulation Thickness for Heat Conservation. INORMAL OPERATING TEMPERATURE (°C) AND THICKNESS (MM) ]OMINAL PIPESIZE Up ]10r [151 [201 ]251 [301 [351 [401 [451 501 | 551 mw | |t0 |to |to Jio to |t |to |to fio 100 | 150 | 200 [250 | 300 | 350 | 400 | 450 | 500 | 550 | 600 MM THK| THK | THK | THK | THK | THK | THK | THK | THK | THK | THK. 15 _{2s_[2s_ [2s [40 [40 [so [os [os [0 [90 [100 20 25 [2s [ao [40 [so [6s [6s [80 [90 [io [us [2s 2s_{2s_ [40 [40 [so [6s [6s [so [90 [100 [125 40 2s_[2s [40 [40 |s0 [os [6s [so 100 [iis [125 50 2s_|2s [40 [40 [so [6s [ao [90 | 100 [125 [140 65 25 [2s [40 [40 |6s_|os 90 | 100 [125 [150 80 2s_[2s_[40 [so [6s [80 |90 [io0 [iis [125 [iso 100 25_[2s [40 [so [6s [0 [90 |ioo [iis [140 [16s 150 2s_|2s_|40 |so_|6s_|so [90 | tis | 125 | 150_| 175 200 2s_|2s [40 [so [6s [so |100 [iis [140 [165 [190 250 2s_[2s [40 [so [6s [90 [100 [i2s [150 [165 [190 300 2s_|2s [40 [so [so [90 | 100 [125 | 150 [175 | 200 350 2s [2s [40 [6s [so [90 [iis [i2s {iso [175 fais 400 2s_[2s_ [40 [6s [so [90 [iis [140 | 165 [190 | 215 | 450 25_[2s_ [40 [6s_|8o [oo [iis [io | 165 | 190 | 21s 500 25_|2s_|40 80_[90 [iis [140 [16s [190 [22s | Over sooe|2s [25 |40 [6s [80 [100 | 140 | 165 | 200 | 240 | 290 FLAT. | | Single Layer—— [+ Multi layers Desigh basis: Maximum Heat Loss = 200w/m2 Ambient Temp.: 23.55°C (Annual average) Wind speed: 3.6 misee (average velocity) Emissivity: 0.15 Material: Mineral wool preformed pipe section: 140kg/m? =a \ Page 40 of 74 ine) \ g6cs #842? €& CONSORTIUM NSRP COMPLEX PROJECT JOB CODE: 0-6495-20 ‘Contractor Doe. Nor REV Title: Method Statement for Insulation Work. _VV3190-001-A-100___ Date: 23 Mar.2015, ‘Note-1: 25 mm thickness of insulation shall be provided on potable water piping to avoid direct solar exposure. Double and Triple Layers shall be constructed with layer thickness as follows: Thk | jst nd id 5 2 2 6 4 ote 8 4 4 9 4 5 5 5 5 6 1 5 8 6 8 1 9 7 10 7 10 o | z 7 60 7 7 75. 1 7 85 | $ | 80 | L290 100 90 (9) Where necessary the insulation on vertical or near vertical piping (i.e. greater than 45° angle from horizontal) shall be supported by bolted-on metal clips provided and installed by the Insulation Applicator who shall assume responsibility of adequate pipe insulation support. Support positions shall be at no greater distance apart than the following: (19) _ : Pipe Operating Temp°C|__ SupportSpacingmm Up to 370 4,57 ym 371 10 480 3,66 From 481 to 650 (11) Where muttilayer insulation is used, supports shall be extended to provide for each layer. If support positions are used to create expansion joints, care shall be taken to ensure that expansion joints, in each layer Page 41 of 74 JGES ‘JOB CODE: 0-6495-20 Title: Method Statement for Insulation Work. Date: 23 Mar.3015, shall be offset at leat 150mm from ech other. (12). Over pipe bends and elbows the insulation shall be correctly sized mitre cut pipe sections or segments to suit the contour of the bends without gaps and il fitting pieces. The mitred pieces shall be secured in place with at least two ties per complete mitred collar of insulation (13) Preformed pipe sections or segments of insulation shall be carefully cut and shaped around "tec’ junctions and the insulating material of the tangential pipe shall be carefully and neatly cut to mate up to the material applied to the parent pipe without the creation of voids or gaps at the junction. (14) Insulation shall be stopped short of flanged joints and unions by a sufficient distance to permit easy removal of the flange nuts and bolts or breaking of the unions to take place without disturbance to and damage of the insulating material. At these positions the insulation shall be straight edged and sealed against water ingress with a metal closure. (15) Insulation at solid welded or clamped pipe supports shall be cut and shaped to fit around the support and tied securely to enable the insulation to be carried with the pipe movement. Pipe supports designed to allow the pipe to move independently shall be insulated to allow movement to take place without damage to the insulating material (16) Traced pipe and fittings shall be insulated with oversized insulating sections to allow accommodation of both parent pipe and tracer without damage or deformation of the insulation, Traced instrument lines and fittings shall be totally enclosed by the insulation in a similar manner and the designed warm air annulus shall be maintained throughout the traced pipe length. (17) Where specified valves and flanged joints shall be insulated with lined removable covers held into position with bands or quick release toggle clips. Designs of these covers shall be submitted to Contractor, for approval prior to fabrication, Insulated valves shall be completely covered, but the insulation shall be cut and shaped around the valve stem and kept clear of the stuffing-box gland. Insulation covers shall overlap and totally enclose the sealed ends of piping insulation. [Link] Application. (1), The piping insulation protective metal sheeting finish shall provide a weatherproofed and mechanical damage resistant covering over the whole of the insulated areas and be applied and fitted in such ‘manner as to provide a close fitting assembly without gaps. (2) Straight pipe shall have metal jacketing cut and machine rolled (approx. | metre long) wrapped around, ‘with SOmm minimum overlaps on both longitudinal and circumferential overlaps. All laps shall be arranged to shed water. (8) A single bead shall be made on all circumferential overlaps. Longitudinal overlaps shall be ‘cracked! with a 45° angle inward turn of the overlapping edge to ensure a tight metal to metal contact. (4) All the seams at overlap positions shall be rendered watertight by the use of a metal seam sealer which shall be applied between overlapping metal edges in sufficient quantity and care to ensure that insulation remains dry and unwetted whether the possible water impingement is from rain, hose, or fire sprinklers. Page 42 of 74 YJGcs Th ‘CONSORTIUM NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 Contractor Doe. Noz Title: Method Statement for Insulation Work. vv3190-001-4-100__| Date: 23 Mar.2015 (5) The metal covering shall be secured tightly around the insulated pipe and held in place with stainless steel bands on a maximum of 300mm centres, One band shall be located on each circumferential lap and the distance between laps divided at equal band spacing, The band securing seals shall be kept neatly in line and positioned away from viewing angles as much as is possible. ‘Table-4: Metal cover and Securement Method. INSULATION DOF ‘COVER THICKNESS [NSULATIONCOVER IMETAL COVERING frcKNess | \SECUREMENT ITEM lover IETHOD InNsULaTIoN Straight Pipe Flat Metal - Al. Upto 150mm — | 0.7mm thick [12mm wide stantess steel. | fans. ‘Straight Pipe Flat Metal -Al }isimmupto | 0.8mm thick 0mm Straight Pipe Flat Metall {Slmm and above | |.Omm thick 12mm wide stainless Welded Valves and | Flat Metal - Al All sizes ‘As persvaight pipe | As per straight pipe. Butt-Weld Tees and Reducers Flanged Valves lat Metal ® All sizes [Link] thick 2mm wide siainless Flanged Joints Removable Covers steel bands and quick release toggle clips Bendsand Elbows | Flat Metal* Stove pipe | Uptosomm — | As forstright pipe, | As for stsight pipe. cor pressed elbows, I Flat Metal fabricated | Simm and ‘As for straight pipe. | Sovews and rivets, rmitred elbows larger (6) Vertical overlaps on vertical or near vertical piping shall be staggered to provide overlaps at ‘North’ and 'South' positions in altemate sections of covering (7). Each section of metal covering on vertical piping with insulation OD's larger than 250mm shall be supported from the next lower section with two'S' clips fabricated from banding material. The 'S' clips shall be of sufficient length to allow the minimum overlap of Somm. (@ On vertical piping with insulation OD's of 600mm and larger, the securing bands shall be supported by ‘y clips fabricated from banding material. The ‘' clip spacing shall be a minimum of two per band. All 'Y' clips shall be screwed into position and secured. (9) Insulated bends and elbows in piping 80mm and larger, shall be metalled with ‘lobster back’ ‘segments using 10mm minimum ball swage to assist shaping. The metal segments shall be screwed with self tapping screws and include metal sealants to provide a completely waterproofed arrangement. Page 43 of 74 ay 2 zg ssa” conusx protec JOB CODE: 0-64 — | Contractor Doc. No: Te: Method Statement for Insulation Work, | __W3190-001-4-100 (10) Insulated bends and elbows in piping smaller than 80 mm may use complete pressed humped back flat metal elbows or fabricated ‘stove pipe' elbows but these fitments shall be completely and positively waterproofed (11) All cladding overlaps both longitudinal and ciircumifrential shall be reinforced with a self adhesive, crease resistant flashing tape covered with heavy duty aluminium foil anda high grade bitumen backing. 3. Figure instruct Insulation and Cladding for Piping. ‘Method of Insulation and Cladding Work for straight pipe. . CRRA) (gees = Bee cencenriese | SRP COMPLEX prosecr eS [70B CODE: 0-6495-20 - Contractor Doe. No: REV-0 Tide: Method Statement for Insulation Work. ____|__Vv3190.001-A-100__[Dafer 23 Mar 3015 ‘Method of insulation and cladding for bend and elbow pipe. Page 45 of 74 eet |e ae ‘JOB CODE: 0-6495-20 ] Contractor Doc. No: Title: Method Statement for Insulation Work. 190-001-A-100 | Date: ‘Method of Cladding for bent and elbow pipe. Consanrium NSRP COMPLEX PROJECT | JOB CODE: 0-6495-20 Contractor Doc. No: Title: Method Statement for Insulation Work. YV3190-001-4-100__ 7) Nozzles, manholes and hand holes, and flanges of equipment. 8) Surfaces of coolers and condensers. 9) Nameplates on all equipment items. 10)Thermowell bosses and pressure tappings. 2. Jacketing Application, (1) When Jacketing for equipment we base on Table below to apply: INSULATION DOF [INSULATIONCOVER ITEM METAL COVERING [TincKNess lover cover Tuickness| INSULATION Equipment Heacs | Flat Metal*‘Orarge | Allsizes 1.0mm thick Serews rivets. (Except Bottom | Peel Pbriaton Heeds of Vertical Equipment) Equipment Shells | Flat Metal * Talisizes "Om hick mm wide tiles tel | ands Yerical Equipment | Flat Metal * Fabricated All sizes "ome hk Sorews orvivets Bottom Heads wast without ski. Vertical Equipment | Notrequired : Bottom Heads With Skirt Casings of Pumps, | Flat Metal * shest | All sizes |LOmum thick 20mm wide stainless steel Compressors, etc, | fabricated removable bunds. | Mantotes, covers. Hiandholes, and where required, [ Exehanger Channels NOTE MATERIAL : For fire hazard protection aluminised steel sheeting shall be used. All other areas to be clad in aluminium sheet (2) The protective metal weatherproof jacket over vertical vessel shells shall be constructed of rectangular shieet metal panels applied in a “wallpaper” pattern with the short width of panel in a circumferential direction parallel to the equipment insulation support rings and the longer length of panel in a parallel direction to the vessel centre line. The weight of the panel shall be taken on the equipment insulation support rings, via angle brackets bolted to the panel in accordance with Fig . There shall be a minimum of two brackets per panel. Shop applied insulation shall ensure that angle brackets remain in contact with support rings. The short width of panel shall be rolled to suit the outside curvature of the vessel insulation, The long side of panel shall be cut to suit the distance between insulation support rings. Page 52 of 74 | a84 6 gees avast JOB CODE: 0-6495-20 ‘Contractor Doc. No: REV-0 Title: Method Statement for Insulation Work. VV3190-001-A-100_| Date: 23 Mar.2015 (3) The panels shall be applied commencing at the bottom of the vessel. Each circumferential ring of panels shall be tensioned by means of temporary tensioning bands until the final joint is screwed tight. clips shall be used as sheeting support at unscrewed circumferential overlaps. 'S' clips shall be riveted into position on shop applied systems, to prevent slippage during transportation, (4) The panels shall be held tight over the vessel insulation by means of ¢ireum erential bands and seals. The bands shall be positioned on all horizontal overlaps and at 450mm centres. Bands shall be held in their relative positions with ‘' clips and be machine stretched and sealed to remove slack only (5) The panels shall have a minimum overlap of 75mm on both horizontal and vertical edges. The overlaps shall be arranged to shed water at all times. (6) The vertical and horizontal overlaps shall be secured with self tapping screws at 75mm pitch except the horizontal overlaps pre-selected to act as expansion joints, these shall be constructed with a 150mm overlap and shall remain unscrewed and left free to permit expansion. Allo erlaps shall be rendered watertight by use of a metal scalant positioned between overlapping metal edges. (1) All equipment projections such as nozzles shall have the metal jacketing sealed using a metal flashing cut to fit the projection and extend over the jacket by at least 75mm. The seal between the flashing and Jacket shall be made water tight by use of self tapping screws and metal sealing mastic. (8) Horizontal cylindrical equipment shall be finished with flat metal jacket arranged in circumferential bands with the edge of the sheets with the longer dimension applied around the circumference of the equipment insulation. (9) The panels shall have a minimum of 75mm overlap on both longitudinal and circumferential edges, both overlaps being finished with a simple ball swage and rendered watertight with a metal seam sealer applied between over apping metal edges. (10) Horizontal overlaps shall be secured with No. 8 x 15mm long, self tapping serews set in the overlap at "75mm intervals, and shall be so arranged that staggered bands of panelling encircle the equipment. Vertical overlaps shall not be screwed. (11) The metal protective finish shall be banded and sealed at 450mm centres ensuring that one band is set over each vertical overlap (12) The insulated heads of vertical and horizontal equipment shall be fabricated from flat metal in an orange peel” construction with all radial seams overlapping a minimum of S0mm and secured with self tapping screw at 75mm centres. All overlap shall be ball swaged and be rendered water tight by the use of metal seam sealer between metal overlaps. (13) Projections from the heads shall be sealed using meta flashings neatly cut to fit around the ‘projections and extending over the jacket for a minimum of 75mm. The seal between flashing and Jjacket shall be weatherproofed with self tapping sorew and seam sealing mastics. (14) Insulation on bottom heads of fully skirted equipment does not require weatherproofing. (15) Heads of equipment 550mm OD and smaller shall be finished and waterproofed with square ended fabricated covers. (16) On shop insulated items at temporary shop support, the insulating system shall be terminated and sealed, and closure pieces shall be designed and fabricated to fit the open [Link] of closure pieces shall take into account the insulating requirements together with support and securement and the necessity of maintaining waterproofing and weatherproofing after closures are Page 53 of 74 \ 2 — } \ z Sy. @ i A gGcs EGS 2 | CONSURTIUM NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 Contractor Doe. No: REV-0 | Title: Method Statement for Insulation Work. vv3190-001-A-100___[Date: 23 Mar.2015 in place. Design proposals shall be approved by Contractor before fabrication of closures commences. Closure pieces shall be fitted at site by the site appointed Insulation Applicator. (17) All jacketing overlaps both longitudinal and circumferential shall be reinforced with self adhesive, ‘crease resistant flashing tape covered with heavy duty aluminium foil and a high grade bitumen backing (18) The following flanges of equipment and piping shall be provided with weather protection. The ‘weather protection shall consist of thin steel without insulation. a, Flanges without insulation in the operating temperature above 350°C. b. Valves without insulation in the operating temperature above 350°C c. Valves of austenitic stainless steel without insulation to prevent ESCC (Environmental Stress Corrosion Crack) by chloride of a splash of sea water The weather protection has to be provided with the structure of preventing the rainwater, easy disassembling and reassembling, and having the sufficient ventilation. The structure shall be approved prior to construction Page 54 of 74 wes B47 | & | NSRP COMPLEX PROJECT JOB CODE: 0-6495-20 ] Contractor Doc. No: REV-0 Title: Method Statement for Insulation Work. |___vv3i90.001-A-100__| Date: 23 Mar 3015 3. Figure instruct Insulation and Cladding for Equipment. [Link] Insulation and Cladding for Vertical Equipment. —) Z sermon Gg ae y gape Y 4} Z HLT Y ~en—_(H enc Mar L ——— Sr wen a on a ee y or 4 ohh, is = General Method of insulation and cladding for vertical equipment. TOR \ Page $5 of 74 . eo NSRP COMPLEX PROJECT ] Contractor Doe. No: Title: Method Statement for Insulation Work. _ |__Vv3190-001-4-100 suptectyinttoncanscoy SS, PTY vera Moet i | aaa : Eoarpe amc, Site a! eeameTION 1 | nn newer ; Bae SNES sears man DETAIL ‘1 ERs. BP Sora en car L payer maces ieee nae 4 SecH0N Method Insulation and Cladding for Support Ring and Header. Page $6 of 74 le mye > JGcs edie Contractor Doe. No: ‘JOB CODE: 0-6495-20 vv3190-001-4-100 | Date: 23 Mar.2015 | Tide: Method Statement for Insulation Work, jade soem orcrar Sh J wan DETAIL ee eet eu. var ‘Semeen oe sectoow ee Sg Be ge ae poe, ee Rae Method Cladding with J and S clip. B°ae? NSRP COMPLEX PROJECT Jgccs AF IUM | JOB CODE: 0-6495-20 Title: Method Statement for Insulation Work. Contrast Des No ‘WW5190-001-4-100 [Link] Equipment. ie Tees sca I JN rae eeu spats rrr Conte ep lana SetGete Sas" vessen Becher Stants rEr aict eh SAGE BSE ro Plugs cronies cul outs iat suet GRiSE iar ibe Steven to Leet tom TR rd Se epee oF irmanign teens Rote i oe ra oe tne han ‘Method Insulation and Cladding for General Vessel. Page 58 of 74 | Ges Consonrium B°9 ¢? NSRP COMPLEX PROJECT JOB CODE: 0-6495-20 Title: Method Statement for Insulation Work. Contractor Doe. No: VV3190-001-A-100 FIN TUBE EXCH NGER eh neggenin wn ver cot <4 7 eta SECU WH ee FRESE SHELL & TUBE EXCHANGER Page 9 of 74 (awGqs | mse ‘cONsaRTIUM NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 Contractor Doe. Ni Title: Method Statement for Insulation Work. VV3190-001-A-100 REV-0 Date: 23 Mar 2015 S Tatty esuaTion 0 view ea SEL TePPIe SENS, | seg gro : seme pegation ne ao Ci JACKED SECURIE BHO Fe -yeuLation Seas suLATION sera ener SS Paaecarion ELL 0, Someone mi. ‘Siok oy vessel ragnicater seane ae (Supplied by Insulation oe Oe Loar ae, cea Sore SPER AIS conmmacton, Method Insulation and Cladding for Header Equipment. Page 60 of 74 | mae? NSRP COMPLEX PROJECT ‘JOB CODE: 0-6495-20 Contractor Doc. No: Title: Method Statement for Insulation Work. ___|___vv3190-001-a-100___ Dat [Link] Insulation and Cladding for Stiffener Rings and Conical Shapes. Bee sou eos, scnewen aa Her eter Gt a geo oe ste octane General Method Insuation and Cladding for Equipment, Page 61 of 74 wees 8422 | | RTI | NSRP COMPLEX PROJECT | ___aom 7 JOB CODE: 0-6495-20 Contractor Doc. No: | __REV-0 Title: Method Statement for Insulation Work. VV3190-001-A-100 [Dat DETAIL SUF taPPI scm SECURE BOO AT OVERLAP sonm OHERP — PREFORMED SATION esse, SHELL greg, SHFeeR SI Sani sc eae eee ag Ss A bers ee Sea! SULATION SEUNG BOO eau sta anew SEEMS eb? Stiroa? ae Detail Insulatin and Cladding for Stiffener Rings. Page 62 of 74 goer NSRP COMPLEX PROJECT S&S OB CODE: 0-6495-20 a ] Contractor Dos. No: Title: Method Statement for Insulation Work. | ‘VV3190-001-4-100 REV-0 23 Mar.2015 a, DETAIL 6 seh ns sessee suin) oto verre = DSuLATION SCCURI BAS Pacechnads rg gee Sand SATION see mo pgm OETAIL ‘Cc’ Looted sh CONSORTIUM NSRP COMPLEX PROJECT [708 CODE: 0-6495-20 ‘Contractor Doe. No: REV-0 Tite: Method Statement for Insulation Work. _VV3190-001-A-100 23 Mar.2015, 2) Hot Acoustic Insulation: (6) Removable acoustic enclosures (e.g. for valves, flanged joints, etc.) shall have an outer surface of Jacketing with a mass per unit area at least equal to that of the jacketing of adjacent pipes and ‘equipment. The lining of porous layer material shall be similar to that used on the piping and equipment and shall be retained by an inner surface layer of perforated metal sheeting with an open area of about 30%. It shall be at least 10mm away from the surfaces of flanges or valves Page 69 of 74 | JGes ayo > Toxeeneten NSRP COMPLEX PROJECT | JOB CODE: 0-6495-20 | ‘Contractor Doc. REV-0 Te: Method Statement for Insulation Work. |_ Swatsetoor. Date Method of Acouste Insulation for Flanged. (7) For Class 'B' and 'C' acoustic insulation all flanges, valves, man ways, fittings supports etc. shall be fully insulated (8) Rigid pipe supports shall be insulated down to the concrete or steel base where acoustic insulation is required for class B&C: ann Page 70 of 4 AVN? \po— CaNsomTrrun NSRP COMPLEX PROJECT JOB CODE: 0-6495-20 | Contractor Doe, No: Title: Method Statement for Insul |__VV3190-001-A-100 wGes | aver) @& | 23 Mar.2015 TYPICAL FOR SUPPORT IN CLASS & AND SESE BL Tavenins 7. HEALTH, SAFETY & ENVIRONMENT - Insulation work shall be carried out in accordance with approved health and safety management plan and local environment regulation. = Carry out the work in such a manner as to minimize noise, vibration and other disturbance. Comply with all current regulation and environmental controls. = Necessary barricades, safety signboard warming lamps shall be installed to warn on crossroand between public road and access road. - safety activities shall be carried out according to the safety plan, - All site engineer and worker will be trained as stated in the safety plan. The contact numbers of the hospital, police station and any other related authorities will be give to the FM and the engineers to take required actions on the spots. - All worker must wear the standard safety equipment - Protective equipment should be warn while welding to avoid electric shock. = Minimum safe distance from operating equipment shall be maintained. [Link] :JSA. Page 71 of 74 ° ore hay anoyy voumpsetowiogerysrong aide] | o | 0 ele] fo ‘rrp sou sen sunboy| yd wed way supe! 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