PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
REV. 0 SHEET 1 OF 13
THERMAL INSULATION DESIGN SPECIFICATION
0 FOR BASIC DESIGN
REV. DESCRIPTION DESD. DATA CHKD. DATA APPD. DATA
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
REV. 0 SHEET 2 OF 13
CONTENTS
1. GENERAL
1.1 Intent
1.2 Scope
1.3 Code and Standard
1.4 Units
2. DESIGN
2.1 General
2.2 Hot Insulation
2.3 Personnel Protection Insulation
2.4 Cold Insulation
2.5 Anti - Sweat Insulation
2.6 Insulation Thickness
3. MATERIALS
3.1 General
3.2 Hot and Personnel Protection Insulation Materials
3.3 Cold Insulation Materials
3.4 Anti - Sweat Insulation Materials
3.5 Jacketing Materials
3.6 Fastening Materials
3.7 Other Materials
ATTACHMENT
(1) Table 1 Insulation Thickness for Hot Service
(2) Table 2 Insulation Thickness for Personnel Protection
(3) Table 3 Insulation Thickness for Cold Service
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
REV. 0 SHEET 3 OF 13
1. GENERAL
1.1 Intent
This specification covers the requirements in the design and materials of the thermal
insulation for hot and cold services in PAFL CAPACITY ENHANCEMENT PROJECT.
1.2 Scope
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
Materials shall meet the requirements of applicable American Society for Testing and
Materials standard (ASTM).
Equal materials standard and manufacturer’s standard shall not be applied without
Purchaser’ s approval.
1.4 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 specified in INCH system whose abbreviation is NPS.
2. DESIGN
2.1 General
2.1.1 Classification of thermal insulation and symbols to be indicated on the Engineering
Drawing, P & I flow diagram and Piping Line Schedule are as follows:
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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Category Symbol Classification
H Normal heat conservation insulation
HO Full heat conservation insulation (Operation stability)
TS Steam tracing insulation
TO Other medium tracing insulation
Hot Service Insulation JS Steam jacketing insulation
JW Hot water jacketing insulation
JO Other medium jacketing insulation
E Electric tracing insulation
TST Steam tracing insulation where heat transfer cement is used.
C Normal refrigeration insulation
Cold Service Insulation CO Full refrigeration insulation
JC Cold medium jacketing insulation
A Anti - sweat insulation
Other Service Insulation P Personnel protection insulation
S Sound Insulation
2.1.2 The design temperature to be used for calculation of insulation thickness shall be normal
operating inside fluid temperature in case of hot, personnel protection, cold and anti -
sweat insulation.
2.1.3 Thickness of the insulation on the nozzles and other protrusions (incl. Parts of structure)
around equipment and piping shall generally be determined in the same way as stated in
Par. 2.1.2.
2.1.4 Thermal conductivity of thermal insulation materials shall be in accordance with
applicable ASTM.
2.2 Hot Insulation
2.2.1 Hot insulation shall generally be applied to equipment and piping operating at 80℃ and
above, except for the case where heat loss is desired. Where heat loss is to be restricted,
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
REV. 0 SHEET 5 OF 13
however, full heat conservation insulation (HO) shall be applied, even when the operating
temperature is below 80℃.
2.2.2 For equipment and piping with inside lining of refractory or insulating materials, external
insulation shall not be applied, except for the case where the metal temperature must be
controlled.
2.2.3 Safety valve along with its outlet piping and downstream piping of such valves as steam
blow off valve, vent and drain valve, shall not be hot - insulated, unless otherwise
specified.
2.2.4 Steam traps and the lines downstream of them shall not be hot - insulated, except when
the heat of the drain is to be recovered, when prevention of freezing - up is necessary
and when specified in the drawing.
2.2.5 The following equipment and parts of them shall not be hot - insulated, unless otherwise
specified.
(1) Pumps operating at below 230℃ without steam tracing. Pumps operating at 230℃
and above shall not be hot – insulated, if insulation would cause undesirable effect.
(2) Blowers and compressors
(3) Parts having moving element, such as expansion and swivel joints, and sliding
valves.
(4) Safety valves
2.3 Personnel Protection Insulation
2.3.1 Personnel protection insulation shall be applied to un-insulation equipment and piping
operating at 60℃ and above, within the area shown below, where operators, while
working, can inadvertently come to contact with them.
(1) Within 2500 mm height from ground of floor level.
(2) Within 1000 mm distance beyond the edge of platform or walkway.
2.3.2 Shield or guard may be provided in lieu of insulation for personnel protection, where a
dissipation of heat is desirable.
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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2.4 Cold Insulation
2.4.1 Cold insulation shall be applied to equipment and piping operating at 10℃ and below,
unless a heat gain is desired.
2.4.2 Cold insulation and anti – sweat insulation for valves shall be up to the valve bonnet.
Safety valve shall be insulated up to discharge flange.
2.4.3 In general, pumps operating at 0℃ and above shall not be cold insulated.
2.4.4 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 4 times the thickness of the insulation.
(1) Skirt of leg of tower and tank
(2) Pipe supports
(3) Branch of vent and drain piping
2.5 Anti - Sweat Insulation
2.5.1 Anti - Sweat Insulation shall be applied to equipment and piping operating at above
10℃ but below the ambient temperature, if surface condensation of moisture would give
adverse effect as shown below.
(1) Electrical hazard
(2) Damage to equipment
(3) Surface condensation giving discomfort to working personnel.
2.6 Insulation Thickness
2.6.1 The nominal insulation thickness for hot service, personnel protection and cold service
shall be in accordance with Table 1, 2 and 3.
2.6.2 For towers in which inside temperature varies with height, insulation thickness shall be
varied accordingly.
3. MATERIALS
3.1 General
Materials shall generally be in accordance with applicable ASTM and shall pass the
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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inspection before use.
3.2 Hot and Personnel Protection Insulation Materials
Specification and standard application of insulation materials for hot and personnel
protection services shall be as follows:
Materials Density (Kg/m3) Available Temp (℃) Application (1)
Mineral Wool ASTM
MAX. 288 MAX. 649 For piping. (with NPS 24 and under)
C547 Class 3
Mineral Wool ASTM
MAX. 240 MAX. 649 For equipment.
C612 Type Ⅳ
For equipment and piping.
(with NPS 26 and over).
For expansion joints of towers and
Mineral Wool ASTM
MAX. 192 MAX. 649 vessels, flanges and valves (to have
C592 Class Ⅱ (2)
split type cover).
For insulation at irregular surface of
equipment.
Notes: (1) The insulation materials shall meet the requirements of ASTM C795, when
applied on austenitic stainless steel surface.
(2) Wire shall not be galvanized for use on austenitic stainless steel surface with
operating temperature greater than 370℃.
3.3 Cold Insulation Materials
Specification and standard application of cold insulation materials shall be as follows:
Materials Density (Kg/m3) Available Temp (℃) Application (1)
Rigid Cellular
- -180 ~ 107 For equipment and piping. (1)
Polyurethane
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
REV. 0 SHEET 8 OF 13
ASTM C591 Type 2
For contraction joints of towers
Mineral Wool ASTM and vessels and piping.
MAX. 192 ~ 649
C592 Class Ⅱ For irregular surface (e.q. valve
flange etc.)
Notes: (1) External metal surface of equipment and piping shall be coated with tar – epoxy
or epoxy resin prior to application of insulation, when rigid foam urethane
insulation materials is applied for them with operating temperature of 10℃ and
above.
3.4 Anti - Sweat Insulation Materials
Specification and standard application of anti - sweat insulation materials shall generally be
as per Par. 3.2.
3.5 Jacketing Materials
Specification and standard application of t insulation jacketing materials shall generally be
as follows:
Materials Thickness (mm) Application
0.3 For piping
Precoated galvanized sheets For towers, vessels, heat exchangers, valves,
0.4
flanges, etc.
3.6 Fastening Materials
3.6.1 Specification and standard application of fastening for insulation materials shall be as
follows:
Materials Dimension (mm) Application
S . W . G. #20 For piping 12 NPS and under
Stainless steel wires
S . W . G. #18 For piping 14 NPS to 18 NPS
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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For piping 20 NPS and over, and cylindrical equipment
0.4 x 13
Stainless steel bands with diameter of 450 up to 900 mm.
0.4 x 19 For cylindrical equipment with diameter above 900 mm.
3.6.2 Specification and standard application of fastening for jacketing materials shall be as
follows:
Materials Dimension (mm) Application
For piping 30 NPS and over, and cylindrical equipment
0.4 x 13
Stainless steel bands with diameter 450 up to 900 mm.
0.4 x 19 For cylindrical equipment with diameter above 900 mm.
3.7 Other Materials
3.7.1 Specification and standard application of auxiliary materials for hot insulation shall be as
follows:
Use Materials Application
Water -kneaded powder of the same quality For filling voids of heat insulation
(a) Joint Filling Materials
as the heat insulating materials materials
For openings on insulation finish
(b) Flashing Compound 30 - 45 Foamseal sealant or equivalent
penetrated by lugs, etc.
(c) Weatherproofing For bent pipe, heads of
90 - 07 H. I. Mastic or equivalent
Mastic equipment, pumps, etc.
Galvanized hexagonal wire netting, 16 mm
mesh x 0.5 mm wire dia. (for bent pipe);
(d)Reinforcing Materials 16 mm mesh x 0.63 mm Wire dia.
For reinforcement of mastic, etc.
(for equipment)
Glass cloth (10 x 10 mesh)
3.7.2 Specification and standard application of auxiliary materials for cold insulation shall be as
follows:
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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Use Materials Application
60 - 25 C. I. Mastic or equivalent For vapor barrier of cold insulation
(a) Vapor Barrier Coating For vapor barrier of anti - sweat
Asphalt roofing or asphalt felt
insulation
For joint sealer of cold insulation.
(b) Joint Sealer and
30 - 45 Foamseal or equivalent For opening on insulation finish
Flashing Compound
penetrated by lugs, etc.
(c) Reinforcing Materials Glass cloth (10 x 10 mesh) For reinforcement of mastic
30 - 16 F. R. Anti - abrasion For cellular glass
(d) Anti - abrasive Compound
coating or equivalent insulation materials
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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Table - 1 Insulation Thickness for Hot Service (mm)
(Materials: Mineral Wool)
Nominal Operating Temperature (℃)
Pipe Size 66 94 150 205 261 316 372 427 483 539 594
Or Vessel to to to to to to to to to to to
Dia. (NPS) 93 149 204 260 315 371 426 482 538 593 648
1/2 25 38 38 38 50 50 50 50 76 76 90
3/4 25 38 38 50 50 50 50 50 90 90 90
1 25 38 38 50 50 50 50 50 90 90 90
1 1/2 38 38 50 50 50 50 50 76 90 101 101
2 38 38 50 50 50 50 63 101 101 114 114
3 38 38 63 63 63 63 90 114 127 127 127
4 38 50 63 63 76 90 114 114 127 127 127
6 38 50 63 63 90 90 114 114 127 127 152
8 38 63 63 63 90 90 114 114 140 140 152
10 38 63 63 63 90 114 114 140 140 140 152
12 38 63 63 76 90 114 127 140 140 140 179
14 38 63 63 90 101 114 127 140 152 165 179
16 38 63 76 90 101 114 140 140 152 179 179
18 38 63 76 90 114 127 140 152 152 179 179
20 38 63 76 90 114 127 140 152 152 179 179
22 50 63 76 90 114 127 140 152 152 179 179
24 50 63 76 90 114 127 140 152 152 179 179
Flat 50 63 76 90 114 127 140 152 152 179 179
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
DOC. NO 00-46-0000-01-004
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Table - 2 Insulation Thickness for Personnel Protection (mm)
(Materials: Mineral Wool)
Nominal Operating Temperature (℃)
Pipe Size Ambient 150 205 261 316 372 427 483 539 594
Or Vessel to to to to to to to to to to
Dia. (NPS) 149 204 260 315 371 426 482 538 593 648
1/2 25 25 25 38 50 50 63 63 76 90
3/4 25 25 38 38 50 63 63 76 90 114
1 25 25 38 38 50 63 63 76 90 114
1 1/2 25 25 38 38 50 63 76 90 101 114
2 25 25 38 50 50 63 76 90 114 127
3 25 25 38 50 63 76 90 101 127 140
4 25 25 38 50 63 76 90 114 127 152
6 25 25 50 50 76 90 101 127 140 165
8 38 38 50 63 76 90 114 127 152 179
10 38 38 50 63 76 101 114 140 165 190
12 38 38 50 63 76 101 127 140 165 203
14 38 38 50 63 90 101 127 152 179 203
16 38 38 50 63 90 101 127 152 179 215
18 38 38 50 76 90 114 140 179 203 215
20 38 38 50 76 90 114 152 179 203 230
22 38 38 50 76 90 114 152 179 215 230
24 38 38 63 76 101 127 152 190 230 240
Flat 38 38 63 76 101 127 152 190 230 240
PAFL CAPACITY ENHANCEMENT PROJECT (PACE135 )
PAK-AMERICAN FERTILIZERS LIMITED (PAFL)
THERMAL INSULATION DESIGN SPECIFICATION
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Table - 3 Insulation Thickness for Cold Service (mm)
(Material: Rigid Urethane Foam)
Nominal
Operating Temperature (℃)
Pipe Size
Or Vessel
+20 +10 0 -5 -10 -15 -20 -30 -40 -50 -60 -70 -80 -90 -100 -110
Dia. (NPS)
3/4 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
1 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
1 1/2 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
2 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
2 1/2 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
3 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
4 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 80
6 30 30 30 30 30 30 40 40 50 50 60 70 70 70 80 90
8 30 30 30 30 30 30 40 40 50 50 60 70 70 80 90 90
10 30 30 30 30 30 30 40 40 50 50 60 70 80 80 90 90
12 30 30 30 30 30 30 40 50 50 50 70 80 80 80 90 90
14 30 30 30 30 30 30 40 50 50 50 70 80 80 80 100 100
16 30 30 30 30 30 30 40 50 50 50 70 80 80 80 100 100
18 30 30 30 30 30 30 40 50 50 50 70 80 80 90 100 100
20 30 30 30 30 30 30 40 50 50 60 70 80 80 90 100 110
22 30 30 30 30 30 30 40 50 60 60 70 80 90 90 110 110
24 30 30 30 30 30 40 40 50 60 60 70 80 90 90 110 110
26 30 30 30 30 30 40 40 50 60 60 70 80 90 90 110 110
28 30 30 30 30 30 40 40 50 60 60 70 80 90 90 110 110
30 30 30 30 30 30 40 40 50 60 60 70 90 90 100 110 120
Flat 30 30 30 30 30 40 40 50 60 70 80 90 100 100 110 120
