Johny George

STANDARD SPECIFICATION FOR HOT INSULATION ISSUED : - IBCE DOC NO. : IBCE-6373-C00-PIP-SPC- Rev-3 Page 1 of 4 For equipment and piping with inside lining of refractory or insulating material, except for the case where the metal temperature must be controlled. B) Personnel Protection Insulation a) Visible parts such as Name plate, code inspection plates, stampings, sight glass and level gauge. Shield or guard Safety valves along with its outlet piping and downstream piping of such valves as steam blow off valve, vent and drain valve. Support-legs and inside of skirts For equipment and piping with inside lining of refractory or insulating material except for the case where the metal temperature must be controlled. b) c) d) e) 3.0 MATERIAL – HOT INSULATION 3.1 General a) g) h) Material shall generally be in accordance with specified standard or applicable standard. Selected material for a particular job shall be as per Process Design Basis in consideration of the following:  The materials shall be endurable to the service temperature.  The materials shall not deform as a result of absorbing moisture.  The materials shall not be corrosive against equipment and piping surface.  The materials shall be easy to work with.  All materials shall be of high quality and good appearance.  Insulation materials shall be of low chloride content, chemically inert, non-sulphurous , rot proof, vermin proof, impervious to hot water and steam, non-injurious to health and non- corrosive to steel and aluminum (even if soaked in water at ambient temperatures for extended periods). No inflammable material shall be attached to the insulation. Fibrous insulants, calcium silicate, perlite and ceramic fibers can be used for the full temperature range mentioned against the respective material, for all applications except for electrically heated applications. For low operating temperature up to 125°C services a suitable moisture barrier shall be used. Dimensions and dimensional tolerances for pipe sections, mattresses & slabs shall generally be as per respective codes unless otherwise mentioned. The number of pieces to be used shall be as less as possible. When installed the insulation shall fit snugly and shall have a tight joint. The insulation materials shall be as per ASTM/IS standards/codes. Insulation Material shall be water repellent type. 3.2 Insulation materials for hot and personal protection 3.2.1 Fibrous Materials (Rockwool & Glass Wool) a) Shall be a preformed insulation and shall be of long fibred rock or glass material processed from a molten state into fibrous form bonded with a binder and suitable for the intended b) c) d) e) f) STANDARD SPECIFICATION FOR HOT INSULATION ISSUED : DOC NO. : IBCE-6373-C00-PIP-SPC- Rev-3 Page 2 of 4 IBCE - operational temperature range from ambient to 550°C and 350°C for Rockwool and glass wool respectively. Slag wool is not acceptable. b) Unless otherwise specified, insulation material shall strictly conform to all the requirements of quality standards listed below: Preformed pipe insulation Bonded Mineral fibre slab insulation Bonded Mineral fibre slab insulation Metal-mesh covered bonded mineral fibre blanket and blanket type pipe insulation c) IS:9842/ASTM C547 TYPE II or TYPE III IS:8183/ASTM C612 ASTM C612 TYPE IV/ TYPE V IS:8183/ASTM C592 CLASSII for piping & equipment. Blankets shall be faced on one side with 20mm galvanized 22 SWG wire mesh stitched through with 22 SWG galvanized lacing wire. For insulation over ‘Austenitic SS Piping & Equipment’ instead of galvanized wire mesh & lacing wire SS304/316 wire mesh & lacing wire shall be applied. Insulation shall conform to the requirements of respective codes, unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per IS: 8183/IS: 9842/ASTM: C547/ ASTM:C592 /ASTM:C612. Density(min) 140 & 128 kg/m3 for resin bonded pipe sections and resin bonded LRB blankets respectively of rockwool; 80 & 64kg/m3 for resin bonded pipe sections and resin bonded curved beveled segments or LRB slabs respectively of glasswool. Max resin content at the above mentioned densities shall be 2% and 5% for rockwool and glasswool respectively.140 kg/m3 for IS8183 bonded mineral fibre slabs and 240 kg/m3/320kg/m3 for ASTM C612 TYPE IV/TYPE V respectively. Thermal Conductivity(max)* **Mean Temperature (°C ) Thermal Conductivity (mW/cm °C ) 50 0.43 100 0.52 150 0.62 200 0.68 250 0.80 300 0.90 *The values mentioned are for insulation material as per IS code; For Apparent thermal conductivity for material as per ASTM codes refer respective ASTM code. **Mean Temperature = (Hot Face Temperature + Cold Face Temperature) / 2 Linear Shrinkage Compressive (minimum) deformation Chloride Content Not more than 2 percent when subjected to soaking heat at the stated max. temperature of use (550°C ), for 24 hours at Strength 10% 250 kg/m2 for resin bonded pipe sections, curved beveled segments and LRB slabs; 120 kg/m2 for LRB blankets(mattresses) unless otherwise specified For stainless steels, with inhibitors less than 10 PPM, for other materials not to exceed 20 ppm. STANDARD SPECIFICATION FOR HOT INSULATION ISSUED : 3.2.2 - DOC NO. : IBCE-6373-C00-PIP-SPC- Rev-3 Page 3 of 4 IBCE Rigid Materials (Calcium Silicate, Molded Expanded Perlite, Cellular Glass) 1. Calcium Silicate It shall be suitable for temperatures up to 760°C. Insulation shall conform to the requirements of respective codes, unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per IS 9428/ASTM C533 TYPE II. Bulk Density Compressive Strength Heat Resistance 200 to 280 kg/m3. Reduction in thickness shall not exceed 5% when tested a) Dry under a load of 415 kN/m² and b) Wet (after 18 hrs immersion in water) under a load of 170 kN/m². When tested at increasing temperatures, the material shall be deemed suitable for use under conditions of soaking heat, for 24 hrs, upto a temperature at which the following requirements are met: Max.Linear Shrinkage(length) Max. Loss in Mass Compressive Strength *Thermal Conductivity (max) Chloride content 2% 15% Reduction in thickness Not exceeding 10% under a load of 345 kN/m2 **Mean Temperature °C Thermal Conductivity (W/mk) 200 0.080 250 0.088 300 0.097 350 0.110 400 0.121 450 0.135 500 0.148 Not to exceed 50 ppm for CS & 25 ppm for SS *The values mentioned are for insulation material as per IS code; For Apparent thermal conductivity for ASTM code material refer respective ASTM code. **Mean Temperature = (Hot Face Temperature + Cold Face Temperature) / 2 2. Molded Expanded Perlite Insulation shall be block form and pipe sections in accordance with ASTM C 610. It shall be compounded from molded expanded perlite & sodium silicate binder and shall be suitable for temperatures up to 550°C.Insulation shall STANDARD SPECIFICATION FOR HOT INSULATION ISSUED : - DOC NO. : IBCE-6373-C00-PIP-SPC- Rev-3 Page 4 of 4 IBCE conform to requirements of respective codes, unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per ASTM C 610. 'Perlite material shall be tested as per C-692 for application over SS surfaces'. Bulk Density(min) 192 (pipe) Compressive Strength (for blocks only) at 5% deformation 412 kPa (Min). Test as per ASTM C165. Apparent Thermal Conductivity Shall be as given below: Water Absorption thermal insulation After heat aging & 48 hr water immersion, moisture gain, % by weight (max) Linear shrinkage kg/m3. Test as per ASTM & ASTM C303(block) C302 Test method shall be as per ASTM C177/C518 (Block) & ASTM C335 (Pipe) Thermal Conductivity Mean Temp Max. W/mK °C 93 0.079 149 0.086 204 0.095 260 0.106 316 0.111 371 0.126 149 50 260 50 371 60 For length & width 2%(max) and for thickness 8%(max) at 649 OC for 24hrs