TITRE DU DOCUMENT

PAGE Petrochemical Zone Phase II (Assalouyeh)

Off Site Facilities

CONTRACT NO.: 86-23-122/241

DOCUMENT NO.:SP002 B 18 PI 000 SPH - 023REV.: 0

DOCUMENT TITLE:PIPE COLD INSULATION SPECIFICATIONPAGE: 1 OF 38

PIPE COLD INSULATION SPECIFICATION

A.HA.AM.B.BM.EA.TISSUED FOR COMMENT24/06/080

AUTHORIZEAPPROVEAPPROVECHECKPREPARESTATUS / POIDATEREV.

PROJECTDISCIPLINE

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Table of Contents

51.SCOPE

52.DEFINITIONS

63.APPLICALBE CODES AND STANDARDS

63.1General

63.2List of Applicable Codes and Standards

84.REFERENCE DOCUMENTS

85.DOCUMENT PRECEDENCE

96.RESPONSIBILITY

97.SPECIFICAITON DEVIATION/CONCESSION CONTROL

98.QUALITY ASSURANCE/QUALITY CONTROL

99.DESIGN OF INSULATION SYSTEMS

99.1General

109.2Insulation Classification

109.3Insulation Codes

109.4Insulation Systems

119.5Extent of Insulation

119.6Insulation Thickness

1210.MATERIALS

1210.1General

1310.2Insulation Materials

1610.3Vapor Barriers

1810.4Joint Sealant/Adhesive Materials

2010.5Metallic Jacketing

2010.6Accessory Materials

2111.HANDLING AND STORAGE

2111.1Packaging and Shipping

2111.2Preservation and Storage

2212.APPLICATION

2212.1General Requirements

2412.2Pipe

2712.3Pipe Supports

2712.4Fittings, Valves, Flanges and Intricate Shapes

2812.5Mechanical Contraction Joints for Bellows Expansion Joints

2913.SAFETY ASPECTS

2914.INSPECTION

2914.1Inspection of Materials

2914.2Pre-Insulation Inspection

3014.3Inspection Procedure for In Situ Molded/Dispensed PUF

3014.4Final Inspection and Release

3115.TESTING

3116.DOCUMENTATION

33ANNEXES

33TABLE 1

34DETAILED SKETCHES

1. SCOPEThis Basic Design specification gives minimum requirements for the design, manufacture, testing, supply, inspection and testing of thermal insulation for cold and dual temperature services for piping of the offsite Phase II and Interconnection project at Bandar ASSALUYEH, Iran.

Cold service is defined as piping at operating temperatures below ambient where reduction of heat gain and the prevention of surface condensation are desired.Dual temperature service is defined as piping at operating temperatures below ambient and where intermittently temperatures may occur up to 250oC, or with normal pipe operating temperatures which are above ambient but intermittently reach ambient temperatures for a longer period of time where good causes for occurrence of condensation within the insulation finish exist.

Cold insulation is required to reduce the transfer of heat to piping, to control process temperatures, avoid condensation and icing on the exterior surfaces, reduce excessive viscosity of fluids and materials and personnel protection.Minimum/maximum operating temperatures shall be taken as those given for the flowing medium as stated in line lists and the equipment data sheets.

This specification covers application of Polyurethane or Polyisocyanurate Foam and Cellular Glass insulation.

This specification does not cover the insulation or coatings for underground piping or buried equipment or insulation for hot services.

Where cross references are made, the number of the section or sub-section referred to is shown in brackets.

2. DEFINITIONSFor the purpose of this specification, the following definitions shall apply:

OWNER: Petrochemical Industries Development Management (P.I.D.M.Co) is the Client.

CONCESSION REQUEST:A deviation requested by the CONTRACTOR or MANUFACTURER, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with requirements of this specification. A CONCESSION REQUEST is subject to OWNER approval.

CONTRACTOR:Contractor for Offsite Phase II and Interconnection

FIELD PROVEN:Extended continuous satisfactory operation in sufficient number of similar applications as referenced by major end-users. OWNER reserves its right to accept as valid for the Project purpose, the supporting documentation provided the term sufficient and referenced.

MANUFACTURER:The parties which manufacture and/or supply CONTRACTOR with the insulation materials, technical documents/drawings and services to perform the duties specified by CONTRACTOR.

PROJECT:Offsite Phase II and Interconnection

SHALL:Indicates a mandatory requirement.

SHOULD:Indicates a strong suggestion.

SUBCONTRACTOR:The party which carries out the installation, and testing of the insulation as specified by the CONTRACTOR.

Throughout this specification the following technical abbreviations have been used:

PUF- Polyurethane or Polyisocyanurate foam.

3. APPLICALBE CODES AND STANDARDS

3.1 General

The following codes and standards shall, to the extent specified herein, form a part of this specification. Where a specific edition date is not indicated, it shall be taken that the most current edition (including addenda) in effect at the time of SUBCONTRACTORS proposal or submittal shall apply.

3.2 List of Applicable Codes and StandardsThe publications listed below form a part of this specification to the extent referenced. The publications are referred to, in the text, by the basis designations only.

American StandardsASTM B 209MAluminum-Alloy Sheet and Plate (Metric)

ASTM C 165Test Method for Measuring Compressive Properties of Thermal Insulations

ASTM C 167Tests for Thickness and Density of Blanket or Batt-type thermal insulating Materials.

ASTM C 177Steady State Thermal Transmission Properties by means of the Guarded Hot Plate

ASTM C 240Cellular Glass Insulating block, Standard Method of testing

ASTM C 303Density of Preformed Block-Type Thermal Insulation

ASTM C 518Steady State Heat Flux Measurements and Thermal Transmission Properties by means of Heat Flow Meter Apparatus.

ASTM C 547Specification for Mineral Fiber Performed Pipe Insulation

ASTM C 552Cellular Glass Block and Pipe-Thermal Insulation.

ASTM C 591Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation.

ASTM C 612Specification for Mineral Fiber Block and Board Thermal Insulation.

ASTM C 623Youngs Modulus, Shear Modules and Poissons Ratio of glass and glass Ceramics by Resonance.

ASTM D 696Coefficient of linear thermal expansions of plastics

ASTM D 1621Compressive Properties of Rigid Cellular Plastics

ASTM D 1623Tensile and tensile adhesion properties of rigid cellular plastics

ASTM D 1622Density Apparent or Rigid Cellular Plastics

ASTM D 1692Rate of Burning and/or Extent and Time of Burning of Cellular Plastics using a Specimen Supported by a Horizontal Screen.

ASTM D 2126Test Method for Response of Rigid Cellular Plastic to Thermal and Humid Ageing.

ASTM D 2842Water absorption of rigid cellular plastics

ASTM D 2856Open Cell Content of Rigid Cellular Plastics by the Air Pycnometer

ASTM D 3014Flame Height, Time of Burning and Loss of Weight of Rigid Cellular Plastics in a Vertical Position.

ASTM D 3039Tensile properties of polymer matrix composite material.

ASTM E 96Water Vapor transmission of Materials in Sheet Form

British StandardsBS 476Fire Tests on Building Materials and Structures Part 7, Surface Spread of Flame Test for Materials.

BS 1470Wrought Aluminum and Aluminum Alloys, Sheet and Strip

BS 2972Methods of Test for Inorganic Thermal Insulating Materials

BS 4370Quality Systems4. REFERENCE DOCUMENTS

In this publication reference is made to the publications listed below. The latest issue of each publication shall be used together with any amendments/supplements/revisions unless otherwise stated.

Project SpecificationSP002-B-18-PI-000-SPH-022Pipe Hot Insulation SpecificationSP002-B-18-PI-000-SPH-024Pipe Painting SpecificationSP002-B-18-PI-000-SPH-015Standard Pipe Support Specification

5. DOCUMENT PRECEDENCE

It shall be the MANUFACTURER and SUBCONTRACTORS responsibility to be or to become, knowledgeable of the requirements of the referenced codes and standards.

The SUBCONTRACTOR shall notify the CONTRACTOR of any apparent conflict between this specification, product data sheets, the codes and standards, and any other specification or document noted herein. Resolution and/or interpretation precedence shall be obtained from the CONTRACTOR in writing before proceeding with application of any insulation material.6. RESPONSIBILITYThe SUBCONTRACTOR shall assume unique responsibility and overall guarantee for the installed insulation system.

7. SPECIFICAITON DEVIATION/CONCESSION CONTROL

Any technical deviation to the purchase order/contract and its attachment including, but not limited to, the data sheets and narrative specification shall be sought by the MANUFACTURER and SUBCONTRACTOR only through the CONCESSION REQUEST format. CONCESSION REQUESTS require the CONTRACTORs and the OWNERs review and approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to OWNER approval are subject to rejection.

8. QUALITY ASSURANCE/QUALITY CONTROL

The SUBCONTRACTOR shall have in effect at all times, a QA/QC program which already establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.

The SUBCONTRACTOR is solely responsible for all quality control activities and documentation. If the SUBCONTRACTOR is unable to comply with this specification, he shall inform the CONTRACTOR for resolution.

A copy of the SUBCONTRACTORS QA/QC program shall be submitted to the CONTRACTOR with its quotation for the CONTRACTORS review and approval prior to award.

The MANUFACTURER shall submit certified reports of production tests as soon as the tests are satisfactorily completed.

The OWNER/CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests.

9. DESIGN OF INSULATION SYSTEMS

9.1 General

The insulation of cold and dual temperature services is required for:

Cold conservation.

Heat flux control of processes and product lines.

Preventing vapor condensation on the outside surface of the insulating system of piping having a temperature below the dew point of the surrounding atmosphere.

Personnel protection from hot or cold surfaces (cold burns and falling ice).

An important requirement of a cold insulation system is prevent water ingress into the insulation. The presence of water as vapor, liquid or ice in the insulation will decrease its insulating value and may eventually lead to under lagging corrosion of the insulated metal surfaces. In order to prevent water ingress and under lagging corrosion, the vapor barriers should be properly selected and applied and insulated metal surfaces shall be suitably painted in accordance with Project specification for Painting.

9.2 Insulation Classification

9.2.1 Cold Insulation

Where required cold insulation prevents condensation or icing on the outside surface of the insulating system conserves low temperatures or controls heat input into the contained fluid within a temperature range of ambient and below.

9.2.2 Dual Temperature

Where required cold insulation prevents surface condensation, conserves low temperatures or control heat input into the contained fluid within the temperature range of 40oC up to +150oC.9.3 Insulation CodesCFor cold conservation and process temperature control

DDual insulation (Cold and Hot)

KAnti condensation

ACCold and Acoustic insulation

NNot insulated

9.4 Insulation SystemsFor cold and dual-temperature services in the temperature range from below ambient up to 90oC PUF shall be used. Above 90oC, cellular glass shall be used.

The insulation system for cold service shall consist of application of pre-formed sections or radiused and beveled segments of PUF. The insulation system for dual temperature service shall consist of application of pre-formed sections or radiused and beveled segments of cellular glass.

9.5 Extent of Insulation9.5.1 General

When cold insulation is required, the entire system shall be fully insulated to such an extent that all piping are properly included.

All metal parts which protrude through the insulation, except saddle mounted vessels, shall be insulated to a distance of at least 4 times the insulation thickness. Wherever possible, there should be a minimum of 300mm of bare metal after termination of the insulation.

Protruding metal parts include, but are not limited to, skirts, lugs, legs, saddles, clips and pipe trunnion supports.

Each line shall be insulated as a single unit. A minimum clearance of 50 mm shall be provided between the outer surface of the insulation and any obstruction such as structural steel, electrical conduits, piping or other insulated lines, to prevent unnecessary cut outs, thickness reductions etc., which would influence the thermal performance.

9.5.2 Pumps and compressors

When pumps and compressors are to be insulated, thermal dams shall be provided to isolate the pump support from supporting steel or concrete.

9.5.3 Personnel protection

Where personnel protection is specified for uninsulated process piping having an operating temperature of minus 10oC and below and whose location presents a personnel hazard, the surfaces shall be determined and provided with a suitable protection. The extent shall be limited to within the confines of a normal working area bounded by distances of not more than 2.0 m vertically or 0.8 m horizontally beyond access ways, ladders, platforms and work areas at ground level or elevations used by operating and maintenance personnel.

Insulation should only be used for personnel protection if other alternative protective measures such as expanded metal shields, hand railings or other physical barriers are not suitable.

9.6 Insulation ThicknessCold insulation thicknesses shall be as per table 1 in annexes.

Single layer insulation shall be 50 mm maximum.

The thickness of the basic insulation on pipe fittings, valves and flanges shall be the same as the thickness applied on the adjoining pipe.

The thickness of insulation for protruding parts shall be based upon the fluid temperature of the pipe or equipment to which the part is attached and the size determined as follows:

For cylindrical attachments, use the nearest pipe size corresponding to the diameter of the attachment.

For structural shapes, use the longest dimension (of the nominal section size) corresponding to the pipe size. For example:

a 8 wide flange (WF) is equivalent to a 8 pipe

a 6 x 4 angle is equivalent to a 6 pipe.

The insulation thickness for personnel protection shall be a minimum of 25 mm thick.

10. MATERIALS

10.1 General

Materials furnished under this specification shall be standard catalogued products, new and commercially available, suitable for service requiring high performance and reliability with low maintenance and free from all defects.

Materials include insulation materials, accessories (bands, mesh wire, rivets, pins, screws, tape, and similar recommended accessories) and compounds (adhesive, coatings and sealers) and protective finishes and similar items recommended for the applications indicated.

The MANUFACTURER, unless clearly otherwise stated, shall supply materials which meet the requirements in this specification with respect to design criteria, thermal conductivities and all other noted standards.

All accessories and materials (i.e. coatings, adhesives, sealants, sealers etc.) are to be shipped to the job site in the original, marked, unopened containers/boxes as provided by the MANUFACTURERS.

The following methods of manufacture/transportation of the PUF materials should be considered and the MANUFACTURER is required to submit details for consideration:

Manufactured and fabricated at the MANUFACTURERs workshop for straight shell pipe runs only.

Manufactured at the MANUFACTURERS workshop and transported as bun stock for fabrication in field workshop facilities.

Basic premixed chemicals for the in situ molded foam shall be produced freshly and used within the factory advised shelf life of the product, taking into account all time lapses for transportation and storage.

Transport of the basic premixed chemicals for the in situ molded foam shall be done in accordance with the factory instructions for transporting/storing of the chemicals.

10.2 Insulation Materials10.2.1 Pre-formed PUF

Pre-formed PUF shall have the following minimum properties:

Thermal conductivity at 20oC mean temperature per ASTM C-177 measured on 25mm thick foam, cut on both sides and aged at 21oC for 180 days shall be no greater than 0.023 W/m.K. The thermal conductivity for freshly blown foam shall be no greater than 0.020 W/m.K.

Minimum percentage of closed cells 90% (percent) per ASTM D-2856.

Maximum water vapor permeance at 38oC and 100% RH shall be 4.38 x 10-3 g/Ns (ASTM E-96).

Linear coefficient of thermal expansion/contraction 70x10-6 per oC (BS 4370).

Fire resistive properties:

ASTM D-1692 (10/10 SE): self-extinguishing

ASTM D-3014: 90% retention of weight

Maximum leach able halides content 90 ppm.

In addition to the above requirements the foam shall have:

A minimum density of 45 kg/m3, measured per ASTM D-1622.

Compressive strengths of at least 200 kPa and 250 kPa at 10% deformation and at 20oC, perpendicular and parallel to foam rise respectively, as per ASTM D-1621.

The above thermal and structural properties shall be supplemented by the following data:

Test reports on compressive, tensile and shear strength and moduli in X, Y and Z directions at 21oC and also at -165oC. (ASTM C 165).

Thermal conductivity versus temperature curve of the foam from 165oC to 65oC with adequate definition as per ASTM C-177 or C-518 measured on sample cut from freshly blown foam, after initial cure, parallel to foam rise. Minimum of six data points are required.

Thermal conductivity versus time curve of foam aged for 180 days at 21oC and 50% RH measured by ASTM C-158 at 24oC parallel to foam rise. Adequate points are required to define curve.

Thermal conductivity versus temperature curve of foam aged for 180 days from 40oC to 65oC measured by ASTM C-158 parallel to foam rise. Minimum of six data points are required.

Contraction/expansion coefficients versus temperature curves from -165oC to 21oC in X, Y and Z directions.

Where site pre-fabricated in two halves, pipe sections shall be oversized to accommodate contractions.

For all sizes up to and including 10 the PUF shall be applied in two half sections.

For sizes over 10 NPS The foam injection (Dispensed PUF) shall be used.

10.2.2 Pre-formed Spacers

Pre-formed Spacers shall be of PUF with the following minimum properties:

The spacers shall consist of fully monolithic (180o) half pipe sections with a minimum density of 50 kg/m3, designed to form compartments for the in-situ molding operation.

The foam shall have a fire-resistive property as defined in ASTM D-1692 (10/10 SE): self-extinguishing.

Minimum percentage of closed cells 90% per ASTM D-2856.

Thermal conductivity at 20oC mean temperature per ASTM C-177, measured on 25mm thick foam cut on both sides and aged at 21oC for 180 days shall be no greater than 0.025 W/m.K.

The leach able halides content shall not exceed 90 ppm.

10.2.3 In-situ Molded/Dispensed PUF

The foam injection process shall be compatible with the atmospheric site conditions and a minimum temperature of 15oC shall be maintained for foam components.

The products are to be delivered on site in two components ready for use with the following foam properties:

Fire properties Self-extinguishing in accordance with ASTM D-1692 (10/10 SE).

Density after molding shall be 45 kg/m3, 5%, in accordance with ASTM D-1622.

The free rise density shall be 28 ( 2) kg/m3, to ensure good compaction of the foam and good homogeneity due to high compression rate.

Thermal conductivity shall be as in (10.2.1). Minimum percentage of closed cells 90% (percent) per ASTM D-2856.

The leach able halides content shall not exceed 30 ppm.

Structural properties shall be as follows:PropertyUnitRequirementTest

Water absorption% vol.3 or lessASTM D-2842

Coefficient of linear thermal contractionm/moC(50-100) 10-6ASTM D-696

Tensile strength parallel to rise:

- at room temperature

- at-196oCkPa

kPa500-700

600-800ASTM D-1623

ASTM D-1623

Tensile strength perpendicular to rise: - at room temperature

- at-196oCkPa

kPa500-700

600-800ASTM D-1623

ASTM D-1623

Tensile strength parallel to rise:

- at room temperature

- at-196oCMPa

MPaAverage 14

Average 27.5ASTM D-1623

ASTM D-1623

Tensile strength perpendicular to rise:- at room temperature

- at-196oCMPa

MPaAverage 13

Average 28.5ASTM D-1623

ASTM D-1623

10.2.4 Cellular Glass

Cellular glass (bun stock) shall have the following minimum properties:

Rigid cellular glass, site pre-fabricated into half sections, radiused and beveled segments, and slabs of minimum 600 mm length.

Average density 120 kg/m3 (+/-10%) in accordance with ASTM C-303.

Thermal conductivity, as per ASTM C-518:

Mean temperature, oC

W/mK

+20

0.042

0

0.038

-20

0.035

Average compressive strength in accordance with ASTM C-165 shall not be less than 415 kPa.

Water vapor transmission: 0 (ASTM E-96).

Linear coefficient of thermal expansion: 9.0 x 10-6/oC. (10%).

Fire resistive properties as per BS 476: Non-combustible.

Average modulus of elasticity as per ASTM C-623: 800 Mpa.

For pipe sizes involving a diameter of 8 diameter and under, cellular glass insulation shall be supplied in two half sections a minimum of 600 mm long.

For pipe sizes with diameters exceeding 8 cellular glass insulation shall be site pre-fabricated in radiused and beveled segments. For pipe diameters up to 1000 mm, the width of the outside radius of the insulation shall be between 140mm to 160mm. For pipe diameters above 1000mm and up to 7000 mm, the width of the outside radius of the insulation shall be between 210 mm and 435 mm.

All circumferential and longitudinal joints in pipe sections, radiused and beveled segments and slabs shall be of the butt type.

For all temperature from 175oC up to +150oC, the fabrication adhesive for laminating cellular glass billets shall be hot asphalt (ASTM D 312 Type III).

For temperatures exceeding 150oC a double layer construction shall be used. Both layers shall be bonded by means of a high temperature gypsum adhesive.

10.2.5 Medium Density Rock Wool Board

Medium density rock wool board stock having the following properties shall be used for contraction joints:

Density 32 kg/m3 ( 10%).

Thermal conductivity at 25oC mean temperature: 0.035 W/m.K or less.

The material shall be free from delamination or fiber fallout when tested to BS 2972.

10.2.6 Low Density Rock Wool Blankets

Low Density rock wool blankets having the following properties shall be used for packing voids between piping and insulation.

Density: 24 kg/m3 ( 10%).

Thermal conductivity at 25oC mean temperature: 0.034 W/m.K or less.

The material shall be free from delamination and fiber when tested to BS 2972.

10.3 Vapor Barriers10.3.1 Vapor Barrier Mastic for PUF

The vapor barrier mastic shall be a heavy duty highly durable flexible electrometric polymer Hypalon based fire-retardant coating with exceptional dry film strength and good puncture resistance and shall have the following minimum properties:

PropertyUnitValue

Temperature resistanceoC-40 to +120

Water vapor transmission ASTM E-96 at 0.75mm dry film thicknessperms*0.02

Average non-volatileVol.%30

Fire resistance:

ASTM E-84/76A flame spread20

Smoke developed5

Fuel Contribution10

Spread of flame (BS 476)Class 1

Specific gravitykg/11.1-1.3

ConsistencyThixotropic soft paste

Minimum applied thickness (dry film)mm1.2

Minimum HYPALON content%15

Minimum coats3

10.3.2 Vapor Stop Coating/AdhesiveThe vapor stop coating/adhesive shall be a two-part elastomeric material suitable for use in cryogenic conditions with the following minimum properties:

PropertyUnitValue

Specific gravitykg/l1.1-1.2

Non-volatile contentvol.%55-60

Tensile strength (ASTM D-412)kg/cm2>8

Two-component minimum thickness (dry film)mm1.2

Service temperatureoC-196 to +120

Halidesppm