Thermal Insulation

UNCONTROLLED WHEN PRINTED
BBS amendment to DEP GEN 04.00.4076
AMENDMENT TO DEP GEN:
THERMAL INSULATION (PERNIS/MOERDIJK)
Wec : Veiligheidsrapport : WWW-Contractors : Emergency plan : FCM related :
No No Yes No No
Comm. Index : Risk : Classification : HSE critical :
B/C L Unrestricted Yes
Objective / scope
Objective Application of thermal insulation of equipment, above ground piping and tanks. Design requirements and execution of an insulation system should be such that: Corrosion under insulation due to ingress of rainwater or condensation of water vapour is prevented. Heat loss of equipment and piping is minimised, if economically justified. Personnel protection is provided viz. surfaces with a temperature of 60C or higher, if these present a danger. Damage to equipment and piping from exposure to freezing conditions is prevented. Condensation, solidification or a too high viscosity is avoided.
Scope This BBS document specifies the requirements and gives recommendations for the engineering and application of insulation. Parties involved Checked by Suppliers, principals, engineers, supervisors, consultants and contractors DMS/746 (SPFP - CEA) DMS/71VP4 (DPFP - CEA) DMS/946 Risk G. Ritzema E. Karam R. Heemskerk
This document is, according to the Risk Matrix, potential (L)ow. The risk is covered by this document and by training and application of this document. Last revision D Date 08-10-2012 Reason Harmonized with Thermal Insulation DEP and updated insulation tables
Revision info
More revision information
Table of contents
1 2 3 4
SUMMARY..................................................................................... 3 CONTEXT AND REFERENCES .................................................... 3 GENERAL REGULATIONS ........................................................... 3 AMENDMENT TEXT DEP 30.46.00.31-GEN................................. 4
4.1 4.2 4.3 4.4 4.5 REF. CHAPTER3.2, MATERIALS .......................................................... 4 REF. CHAPTER 3.1.2.1, 3.3.2, 4.3.2SURFACE PREPARATION ......... 4 INSULATION THICKNESS FOR PIPING AND EQUIPMENT WITH TRACING (HOT INSULATION) .............................................................. 6 INSULATION THICKNESS FOR STORAGE TANKS (HOT INSULATION) ......................................................................................... 6 INSULATION THICKNESS CELLULAR GLASS, (COLD INSULATION)7
Rev.: D Custodian: DMS/746, DMS/946 Owner: Chairman BBS process 04 Page: 1 van 14 Level: 2
Filename: 04004076.docx
4.6 4.7
REF. APPENDICES, APPENDIX F, INSULATION THICKNESS PUR/PIR (COLD INSULATION) ............................................................. 8 REF. PART III, AMENDMENTS/SUPPLEMENTS TO THE CINI HANDBOOK............................................................................................ 9
INSULATION CODES .................................................................. 10

5.1 5.2 5.3 GENERAL ............................................................................................. 10 INSULATION CODES FOR HOT INSULATION MATERIALS ............. 10 SPECIFICATION COLD INSULATION FOR PIPING FOR THE TYPICAL DETAILS OF THE CONSTRUCTION OF COLD INSULATION SEE FIGURE 1 ..................................................................................... 10 SPECIFICATION COLD INSULATION AROUND EQUIPMENT ......... 11
5.4
Rev.: D
Custodian: DMS/746, DMS/946 Owner: Chairman BBS process 04
Page: 2 van 14 Level: 2
SUMMARY
This specification is an amendment to DEP 30.46.00.31-GEN and is applicable for the installation of thermal insulation at Shell Pernis/Europoort and Moerdijk.
CONTEXT AND REFERENCES

This specification is based on the CINI Manual Insulation for Industries (English, latest version). This specification is an amendment to: DEP 30.46.00.31-GEN Thermal Insulation
GENERAL REGULATIONS
Engineering For new construction projects and major rejuvenation/maintenance works the engineering contractor or the project department shall submit an engineering instruction at the kick-off meeting 03.05.3000 (P) / 03.03.3000 (M) reflecting the basis of design of insulation systems and specification. The insulation instruction shall be approved by the Civil Engineering Section. The economic insulation thickness for hot insulation shall be determined by means of the data of the table below. For those cases where this is not applicable the insulation thickness as indicated in the tables of paragraph 5 shall be used. The following design criteria shall be used to determine the (economic) insulation thickness: Hot insulation Average ambient temperature : Wind velocity Capital charge Heat cost : : : 8C 5 m/s 17.5% 8/GJ
1)
Cold insulation Max. ambient temperature Wind velocity Humidity Emissivity : : : : 25C 1.4 m/s 85% 0.3
Drawings The required thermal insulation and finishing materials for piping and equipment shall be indicated and specified on the drawings, including all details with respect to the required mechanical provisions. The insulation details for cold insulation (supports of piping and equipment) shall be completely indicated on drawings, including all necessary required mechanical provisions and shall be submitted to the Civil Engineering Section for approval. Materials All materials indicated on the drawings shall be specified with the codes mentioned inDEP 30.46.00.31-Gen. The use of individual engineering contractor codes is not allowed. Nano/micro porous insulation material not to be used without explicit permission of Civil Engineering Department (DMS/746 - DMS/946). Insulation collars Waterproof insulation collars to avoid water ingress shall be fitted around all protruding parts of tanks, vessels and columns with operating temperatures between ambient and 175C or with intermittent operation. These collars shall be executed in accordance with standard drawing S-10.056. For existing equipment (maintenance), alternative solutions should be submitted to the Principal for approval, e.g. cellular glass collars (ref. Figure 2 and 3) in case welding on existing equipment is not allowed.
1)
Heat costs to be confirmed by the principal at the start of the project. Rev.: D Custodian: DMS/746, DMS/946 Owner: Chairman BBS process 04 Page: 3 van 14 Level: 2
Existing piping and equipment When modifications are made to existing pipe work and equipment, the existing insulation thickness shall be applied. Electrical tracing In case electrical tracing has been applied under the insulation, the electrical tracing shall be switched off (by others) prior to remove and/or install the insulation system. Deviation is only possible with an approved work instruction or TRA. Asbestos/Ceramic fibres containing materials One should take into account that existing insulation materials may contain asbestos and/or ceramic fibres. To determine the presence of asbestos samples shall be tested by a Shell approved laboratory (e.g. Daniel C.Griffith Holland B.V.) The handling of asbestos and or ceramic fibres shall be in accordance with 05.03.1021 / 05.05.1021 Minerale vezels (asbest en MMMF).
4
4.1
AMENDMENT TEXT DEP 30.46.00.31-GEN

REF. CHAPTER3.2, MATERIALS The hot insulation material on stainless steel piping and equipment, shall be of AS Quality in accordance with EN 13468 (maximum contents of leach able chloride ions is < or = 10 mg/kg of insulation material). REF. CHAPTER 3.1.2.1, 3.3.2, 4.3.2SURFACE PREPARATION The paint system shall be in accordance with: BBS Maintenance painting 04.00.4053. BBS Painting and coating of new equipment 04.00.4054. BBS QA/QC Conservering 04.00.1028. BBS QA/QC Isolatie 04.00.1029. Ref. appendices, appendix D en E, INSULATION thickness (hot insulation).
4.2
Rev.: D
INSULATION THICKNESS IN MM Normal operating temperature in C diameter. < 1" 1" 1,5" 2" 3" 4" 6" 8" 10 12" 14" 16" 18" 20" > 20" Equipment Equipment type "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" A B "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" "A" "B" 50 80 25 100 25 110 25 130 40 50 80 100 110 130 50 70 80 100 120 50 60 80 100 120 50 60 70 90 100 50 60 70 90 100 50 50 70 80 90 50 50 70 80 90 50 50 60 80 90 50 50 50 70 70 30 50 50 60 60 30 30 40 50 60 30 30 40 40 60 30 30 30 40 50 30 30 30 30 40 <50*) 30 51100 30 101150 30 151200 30 201250 40 251300 40 30 40 30 50 30 60 30 70 30 70 30 90 30 100 30 100 40 100 40 110 40 110 40 120 40 120 40 140 40 140 40 301350 50 30 50 30 60 30 60 40 70 40 80 40 90 40 100 40 100 40 110 50 110 50 120 50 120 50 120 50 160 50 160 50 351400 50 30 50 40 60 40 70 40 80 40 90 50 100 50 110 50 110 60 120 60 120 60 120 60 150 60 150 60 180 70 180 70 401450 60 40 60 40 70 40 80 50 80 50 90 50 100 60 120 60 120 70 140 70 140 70 150 70 150 70 150 80 180 80 180 80 451500 60 50 60 50 80 50 80 50 90 60 100 60 100 70 130 80 140 80 140 80 150 80 150 90 150 90 150 90 200 90 200 90 501550 70 60 70 60 80 70 90 70 90 80 100 80 120 80 130 80 140 100 140 100 150 100 150 100 150 100 150 100 200 100 200 100 200 200 160 160 150 150 150 150 130 120 100 90 90 80 70 551600 70
"A" Economic insulation thickness. "B" Personnel protection.
Rev.: D
4.3
INSULATION THICKNESS FOR PIPING AND EQUIPMENT WITH TRACING (HOT INSULATION) Heat medium LP-steam tracing Run pipe < 3" 4" en 6" 8" 20" Equipment MP-steam tracing < 3" 4" en 6" 8" 20" Equipment Electrical tracing < 3" 4" en 6" 8" 20" Equipment Insulation thickness 50 mm 50 mm 50 mm 50 mm 60 mm 60 mm 80 mm 60 mm 50 mm 50 mm 50 mm 50 mm
4.4
INSULATION THICKNESS FOR STORAGE TANKS (HOT INSULATION) INSULATION THICKNESS IN MM Storage tanks Tank walls Tank roofs Normal operating temperature in C < 50 50 51-100 80 101-150 100 2) 80 2) 151-200 120 2) 80 2) 201-250 140
2)
80 2)
To be executed in two layers. Uit te voeren in twee lagen. Rev.: D Custodian: DMS/746, DMS/946 Owner: Chairman BBS process 04 Page: 6 van 14 Level: 2
4.5
INSULATION THICKNESS CELLULAR GLASS, (COLD INSULATION) Ambient temperature Humidity Wind velocity Emissivity : : : : 25C 85% 1.4 m/s 0.3 INSULATION THICKNESS IN MM Diameter 20 1 1 2 3 4 6 8 10 12 14 16 18 20 24 Vessel Notes Thickness may be rounded off to the nearest higher manufacturer's thickness (min. thickness 25 mm). All piping over 24 inch shall be insulated in accordance with the thickness specified for vessels. 12 12 13 14 14 15 16 17 17 17 18 18 18 18 18 19 19 0 14 15 16 17 18 19 20 21 22 23 23 23 24 24 24 25 26 -20 23 24 26 28 30 32 34 36 38 39 40 41 42 42 43 44 46 -40 30 32 34 38 40 43 45 49 52 54 55 56 58 59 60 61 64 Operating temperature C -60 37 39 41 46 48 53 56 60 64 67 69 70 72 73 74 76 106 -80 43 46 48 53 56 61 65 71 75 78 81 82 84 86 86 90 126 -100 48 51 54 59 63 69 73 80 85 89 92 93 96 98 100 103 145 -120 53 56 59 65 69 76 81 88 93 98 101 103 106 108 111 114 162 -140 57 61 64 70 74 82 87 96 101 106 110 112 115 118 120 124 178 -160 61 65 69 76 80 88 94 103 109 115 119 121 125 128 130 135 195 -180 65 69 73 80 85 94 100 109 116 122 127 129 133 136 139 144 209
Rev.: D
4.6
REF. APPENDICES, APPENDIX F, INSULATION THICKNESS PUR/PIR (COLD INSULATION) Ambient temperature Humidity Wind velocity Emissivity : : : : 25C 85% 1.4 m/s 0.9 INSULATION THICKNESS IN MM Diameter 20 1 1 2 3 4 6 8 10 12 14 16 18 20 24 Vessel Notes Thickness may be rounded off to the nearest higher manufacturer's thickness (min. thickness 25 mm). All piping over 24 inch shall be insulated in accordance with the thickness specified for vessels. 7 7 8 8 8 9 9 9 10 10 10 10 10 10 10 10 11 0 18 19 20 21 22 24 25 26 27 28 28 29 29 29 30 30 31 -20 26 27 29 31 33 35 37 40 41 43 44 44 45 46 46 47 50 -40 33 35 37 40 43 46 49 52 55 57 58 59 60 61 62 63 69 Operating temperature C -60 43 45 48 52 55 60 64 69 73 75 78 79 80 82 83 84 94 -80 53 56 59 65 68 75 79 86 91 95 98 99 102 103 104 107 123 -100 63 67 70 77 81 89 95 103 109 114 118 120 123 125 127 130 153 -120 69 73 77 85 89 98 104 114 120 126 130 132 135 138 140 143 171 -140 75 79 83 91 96 106 112 123 130 136 141 143 146 149 151 155 188 -160 80 84 89 97 103 113 120 131 139 146 151 153 157 160 162 167 203 -180 84 89 94 103 108 119 127 138 147 154 159 162 166 169 172 177 218
Rev.: D
4.7
REF. PART III, AMENDMENTS/SUPPLEMENTS TO THE CINI HANDBOOK Tab 1 CINI 1.3.01 4.4 Application of the metal finishing layer. General Requirements + Installation Instructions General requirements for the thermal insulation of "hot" pipelines and equipment. Add to this clause: Sealing of furrowed edges in the cladding is not required for hot-insulation.
Paragraaf 4.4.4 The cladding shall be installed such that moisture at the inside can be drained. At horizontal piping, in the middle between two supports, at the lowest point, drain holes shall be provided, min. 1 hole6 m1, diam 10 mm and at the lowest point of vertical bends, connections etc. In practice it will not always be possible to work without sealing by means of mastic or tape, but this must be very selectively. Example: Horizontal equipment and piping in the vicinity of water spray systems, no sealing shall be applied to the bottom segment (between 4 and 8o clock), and certainly not to the longitudinal joints in this segment
CINI 1.3.02 1.1 3.2.1
General requirements for the thermal insulation of "cold" pipelines and equipment. Replace this clause by: The ambient temperature is 25C. The following materials shall not be applied without approval of the Civil Engineering Section: flexible elastomeric foam (FEF). cellular glass (CG) Aluminium cladding shall not be applied. For cold insulation only aluminised steel cladding Type 2 shall be applied.
3.5 Metal finishing materials. CINI 1.3.10 CINI 1.3.37 1.1
Add to this clause:
Installation instructions for the thermal insulation of "hot" pipelines, fittings and equipment. The following materials shall not be applied without approval of the Civil Engineering Section: polyisocyanurate (PIR) and polyurethane (PUR) cellular glass (CG)
Tab 3 CINI 3.2.01 CINI 3.2.05 Page 1 of 1
Finishing materials + auxiliary materials Weather resistant mastics. The following materials shall not be applied without approval of the Civil Engineering Section: weather resistant ethyl vinyl acetate based mastic, weather resistant latex based, vapour barrier mastic, weather resistant elastomer based, vapour barrier mastic, weather resistant bitumen based vapour barrier mastic, contact adhesive.
Rev.: D
5
5.1
INSULATION CODES
GENERAL For engineering and contracting-out purposes the various insulation systems shall be indicated with insulation codes. INSULATION CODES FOR HOT INSULATION MATERIALS Insulation codes shall be applied for the selection of hot insulation materials as per DEP. 30.46.00.31-GEN. SPECIFICATION COLD INSULATION FOR PIPING FOR THE TYPICAL DETAILS OF THE CONSTRUCTION OF COLD INSULATION SEE FIGURE 1 The insulation material shall consist of pre-formed PUR/PIR sections in accordance with the requirements of CINI 2.7.01, type TARECPIR CR40 (Supplier Coolag Holland B.V. or equal). The total insulation thickness shall be made up of one or two layers, depending on the insulation thickness. Transverse and longitudinal joints shall be overlapping ("ship lapped") in the case of single layer insulation. The inner and outer layer of multi-layer insulation can be butt jointed, seams of multiple layer systems shall be staggered. The outer surface of the inner layer shall be covered with a secondary vapour barrier foil (no overlaps), Mylar Multiplex Foil type TF3/50, or equal. The vapour barrier foil shall be in accordance with the requirements of CINI 3.3.05. The seams of the secondary vapour barrier foil shall be taped off with 50 mm wide InsuW-Rapid Multifoil Alu tape. Each layer of insulation shall be fixed with Scotch 3M filament tape type 895 or equal, three (3) tapes per meter pipe length. The outer primary vapour barrier on both one and two layer systems shall be Insu-W-Rapid IWR 701 Instant Butyl Sealing tape with aluminium backup (300 mm wide minimum for straight lengths of pipe) or TEMBUTIL-ALU PLUS. Overlap shall be at least 50 mm. In piping systems at each interruption (a.o. at support locations, valves, flanges etc.), vapour stops shall be installed in accordance with CINI 1.3.53 par 3.3 and CINI 5.1.08.
5.2
5.3
Where boxes are used the inside of the box shall be lined with the composite vapour barrier (see above). Protective jacketing shall be aluminised steel plate. The cladding of straight lengths of pipe shall be fixed with stainless steel tension bands (19 x 0.5 mm). DO NOT use parkers. The seams need not be sealed.
Rev.: D
5.4
SPECIFICATION COLD INSULATION AROUND EQUIPMENT Supply and application of pre-formed PUR/PIR slabs, type TARECPIR CR40 (Supplier Coolag Holland B.V. or equal). The total insulation thickness shall be made up of one or two layers. Transverse and longitudinal joints shall not be overlapping ("ship lapped"). The outer surface of each layer shall be covered with a secondary factory applied vapour barrier foil (no overlaps) (Mylar Multiplex Foil type TF3/50, or equal). The vapour barrier foil shall be in accordance with the requirements of CINI 3.3.10. For the insulation of spherical shaped parts of equipment (heads of heat exchangers, columns, tanks, etc.) factory shaped segments (spherically and tangentially shaped) shall be applied. All insulation layers shall be sealed-off on the outside with a vapour barrier foil. The PUR/PIR-slabs shall not be glued to the equipment. The joints of secondary vapour barrier foil shall be taped-off with 50 mm wide Insu-W-Rapid Multifoil Alu tape. On other insulation layer 19 mm wide Filament tape CR 110 shall be applied with a centre to centre distance of 25 cm. The outer insulation layer shall be fixed with 19 mm stainless steel straps. On both the one layer system as well as the two layer system a vapour barrier layer of TEMBUTIL-ALU-PLUS shall be applied on top of the outer vapour barrier foil. Overlap shall be at least 50 mm. The complete system shall be finished with aluminised steel plate. The cladding shall be fastened by means of stainless steel bands (19 x 0,5 mm) instead of parkers and/or blind rivets. The use of dispersed PUR/PIR in situ shall be limited as much as possible. For valves and flanges, removable covers are preferred; if this is not possible or desirable, dispersed PUR/PIR in situ may be considered. The quality of the foam shall be in accordance with CINI 2.7.01. In order to facilitate future removal of in situ dispersed PUR/PIR, valves shall be wrapped in a rockwool blanket in accordance with DEP 30.46.00.31-GEN, , prior to dispersing the PUR/PIR. For the same reason it is recommended to apply a non-stick coating to the interior of covers used in this application.
The cladding of spherical heads/fronts shall be fixed with blind rivets. For the fixation of cladding on tank roofs the cladding shall be fixed to a specially designed supporting structure. The joints of cladding do not need to be sealed.
Rev.: D
Rev.: D
Figure 2: Insulation detail T-bracket
Rev.: D
Figure 3: Insulation collar detail (alternative to S10.056)
back to front page Revision information Revision 0 A B C Date 2001-03-01 2002-09-15 2003-07-14 2005-09-13 Reason First issue Added figure 2 and 3 Specification changes in para 6.3 and 6.7 Changed: revisions DEP 30.46.00.31 Gen incorporated
Rev.: D

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UNCONTROLLED WHEN PRINTED

BBS amendment to DEP GEN 04.00.4076

AMENDMENT TO DEP GEN: