2013

Construction Training

PAINTING / INSULATION
 Contents

Ⅰ. INSULATION
1. Outline
2. Material & Application
3. Construction

Ⅱ. PAINTING
1. Outline
2. Construction

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Ⅰ. INSULATION 1. Outline

1. Purpose
1) Maintenance of process temperature for process control
2) Energy conservation when a gain or loss of heat is not desired
3) Personnel protection from heat or cold
4) To avoid the change of phase ( Liquid <-> Vapor / Solid <->Liquid)

2. Type

HOT INSULATION
EQUIPMENT
COLD INSULATION
INSULATION
HOT INSULATION
PIPE
COLD INSULATION

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Ⅰ. INSULATION 2. Material & Application

1. Basic insulation materials (Hot)

Material Material specification Insulation form Application (1) Temperature limit (1)

Calcium ASTM C533 Block Piping or equipment

silicate Type Ⅰ or equal (Flat, curved or grooved) (Over 30 inch in O.D) Up to
Pipe Piping or cylindrical 650℃
equipment
(30 inch in O.D and smaller)
Expanded ASTM C610 Block Piping or equipment
perlite Type Ⅰ, Type Ⅱ (Flat or curved) (Over 30 inch in O.D)
or equal Up to
Pipe Piping or cylindrical 650℃
equipment
(30 inch in O.D and smaller)
Mineral ASTM C612 Block and Board Equipment Up to
fiber Class4 or equal 538℃
ASTM C592 Blanket (Metal mesh Equipment or irregular surface
Class Ⅱ or equal facing on one side) Large bore piping Up to
Pipe (Metal mesh Piping 650℃
facing on outer side)
ASTM C547 Pipe Piping Class2 :
Class2, Class3 Up to 345℃
or equal Class3 :
Up to 650℃

NOTE (1) Size limit on the application column and temperature limit are only for reference.
Vendor's available manufacturing range shall be considered.

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Ⅰ. INSULATION 2. Material & Application

1. Basic insulation materials (Cold)

Material Material specification Insulation form Application (1) Temperature limit (1)
Cellular glass ASTM C552 Block Piping or equipment
Type I, Type II (Flat, curved or grooved) (Over 30 inch in O.D)
Class 1, Type III,
Type IV or equal Pipe Piping or cylindrical equipment -268℃ ~ 120℃
(For pipe insulation, (30 inch in O.D and smaller)
ASTM D312
Type III or better
fabricating adhesive to
be used)

Cellular ASTM C591 Block Piping or equipment

Type 2, or equal (Flat, or curved) (Over 30 inch in O.D) -40℃ ~ 107℃
Pipe Piping or cylindrical equipment
(30 inch in O.D and smaller)

Mineral ASTM C612 Block and Board Equipment Up to

fiber Class4 or equal 538℃
ASTM C592 Blanket (Metal mesh Equipment or irregular surface
Class Ⅱ or equal facing on one side) Large bore piping
Up to
Pipe (Metal mesh Piping 650℃
facing on outer side)

ASTM C547 Pipe Piping Class2 :

Class2, Class3 Up to 345℃
or equal Class3 :
Up to 650℃

NOTE (1) Size limit on the application column and temperature limit are only for reference.
Vendor's available manufacturing range shall be considered.

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Ⅰ. INSULATION 2. Material & Application

2. Weatherproofing materials
Material Material Application
Specification Min. THK Sheet form Applied for
Metal ASTM B209 0.4mm Flat Piping 36 inch in O.D and smaller
jacket Type 3003, (0.016") (including insulation)
Type 5005
5mm Corrugated All horizontal vessels
or equal
Heat exchanger
(Aluminium)
Vertical vessel up to 1500mm in O.D
0.5mm Flat Piping over 36 inch in O.D
(0.02") Pipe fitting
Flashing (2)
Vessel head, Tank roof
Irregular surface

32mm Corrugated Vertical vessel over 1500mm in O.D

Storage tank
ASTM A167 (1) 0.25mm Flat Same as aluminium flat jacket
Type 301, 302 (0.01")
304, 316 or equal 5mm Corrugated Same as aluminium 5mm corrugated jacket
(Stainless steel)
32mm Corrugated Same as aluminium 5mm corrugated jacket

Mastic ASTM C647 Irregular surface

Vapor permeable Flashing (2)
Type or equal

NOTE (1) Stainless steel metal jacket shall be used only in atmospheric corrosion areas specially specified.
(2) Aluminium jacket for flashing, which will be in contact with metal surface of piping or equipment, shall be used on piping
or equipment operating 260℃ and below. For where operating over 260℃, stainless steel jacket shall be used for flashing.
Mastic for flashing may be used on piping or equipment operating below 90℃.

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Ⅰ. INSULATION 2. Material & Application

3. Fastening materials

Material Material Application

Specification Min. Size (mm) Applied for

Wire Galvanized steel, Φ 1.3 (1) Piping insulation 36 inch in O.D and smaller
annealed (2) (16 AWG) (including insulation)
Irregular surfaces where bands are impratical

Stainless steel, Φ 1.3 (1) Lacing of blanket insulation and wire mesh
annealed (16 AWG) Insulated bottom head of vessel

Band ASTM A167 12 wide×0.5 thick Equipment insulation and metal jacket up to 1500mm in O.D
Type 301, 302 Piping insulation over 36 inch in O.D
304, 316 or equal, All metal jacket for piping
annealed

19 wide×0.5 thick Equipment insulation and metal jacket over 1500mm in O.D

NOTE (1) AWG menas American wire gage number.

(2) Galvanized steel wire shall not be used for fastening inner layer insulation in multiple layers.

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Ⅰ. INSULATION 2. Material & Application

4. Miscellaneous materials
Material Material specification Application
Loose fill Loose mineral fiber per ASTM C553, Class B-4 or equal Expansion joint
insulation Void space

Insulating and Mineral fiber per ASTM C449 or equal Void filling
finishing cement Irregular surface insulation

Wire mesh Galvanized hexagonal wire netting, 16mm mesh×0.5mm Insulating cement reinforcing
wire
Floating ring 10mm diameter stainless steel rod or Type 304 stainless Vessel head insulation
steel wire 1.6mm×6 twisted rope
Aluminium foil Same as flat aluminium jacket Over heat tracer under insulating cement
Insulation support Carbon steel clamp : up to 426℃ Vertical piping
ring (for piping) Same meterial as piping : above 426℃
with bolt/nut Carbon steel bolt/nut (Φ9.5mm×30mm length) : up to 426℃
and washer Stainless steel bolt/nut (Φ9.5mm×30mm length) : above
426℃
Insulation support To be indicated on the equipment drawings and attached To fasten insulation or metal jacket on
ring (for equip- by equipment manufacturers. equipment
ment), clip, nut,
stud, etc.

Cloth tape Waterproof fiber glass Heat tracer that is external to the
insulation

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Ⅰ. INSULATION 2. Material & Application

5. Miscellaneous materials
Material Material specification Application
(1) Metal Jacket Same as metal jacket in para 3.3.1 Edge of insulation openings,
Flashing
material Mastic Same as mastic in para 3.3.1 such as manhole, nozzle and cut out for flange, pipe
support, etc.
Compound Non-shrinking, flexible non-volatile

"S"- Clip 19mm wide×0.5mm thick Circumferencial overlap of metal jacket on vertical
To be made of band piping and equipment larger than 200mm in O.D

"J"- Clip Same as "S"- Clip Band on vertical equipment larger than 3000mm in
O.D
Sheet metal screw Type 304 stainless steel, hexagon head, self All longitudinal overlaps of metal jacket
tapping and with washer under head #8×½" Flashing metal jacket
long Orange peel segment
Expansion spring 100mm long, flat, spiral wound, Band for cylindrical equipment
AISI Type 302 stainless steel (see para. 4.3.8)

Lap sealer for Non-shrinking, permanently All longitudinal seams on vertial piping and
metal jacket flexible, non-volatile equipment
All circumferential seams on horizontal piping and
equipment
Orange peel segment seam
Band seal 18-8 Cr-Ni Stainless steel AISI Type 302 or 304, Each band (to tighten band by machine)
T-5005 hard temper, 0.8mm thick

Fabric Plain open 10×10 mesh asphalt impregnated Mastic reinforcing

fiber glass or nylon scrim fabric

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Ⅰ. INSULATION 3. Construction

1. General

- To check the completion of inspection

(Hydro Test, Paint Touch Up, Surface)

PIPE
-To check the obstacle or work space
FITTING

V/V . FLG.
-To check using required materials
EQUIPMENT

-To check the surface impact to be insulated

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Ⅰ. INSULATION 3. Construction

2. Equipment Insulation

Pipe Insulation
(for equipment) Secure with a band or two band per each required standard length

Blanket / Board Insulation applied on cylindrical surface shall be secured by bands

/ Block

Exposed
Insulation shall be shaped so that all sections closely fit the contour of the head
Vessel Head

Unexposed
Vessel Head Wires shall be used to secure insulation and fixed by insulation supports

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Ⅰ. INSULATION 3. Construction

2. Equipment Insulation

Expansion / The joint shall be formed by a 30mm wide space packed with loose fill
Contraction joint insulation and located under the insulation support rings

Overlap Area The area is secured by sheet metal screws and sealed with lap sealer

Vessel
(over 3000mm in “J”-clips shall be used to support the bands
diameter)

Bottom Head
(Contained Insulation shall be weatherproofed by mastic or thick layer of cement.
within a skirt)

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Ⅰ. INSULATION 3. Construction

Vertical Vessel Insulation

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Ⅰ. INSULATION 3. Construction

Horizontal Vessel Insulation

R1 - BAND (FOR BASE INSULATION)

R2 - BAND (FOR METAL JACKET)

N1 : METAL JACKET (CORRUGATED) S - WIRE

N2 : METAL JACJET (FLAT) T2 - INSULATION SUPPORT ATTACHMENT

P : SHEET METAL SCREW (FOR LAP JOINT) (FOR SECURING INSULATION BY WIRE)

J : LAP SEALER W - BAND SEAL

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Ⅰ. INSULATION 3. Construction

Insulation Details for Horizontal Vessel Head

NO.3 PROJECT VR HCR

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Ⅰ. INSULATION 3. Construction

Heat Exchanger Insulation (HOT)

SHELL AND TUBE HEAT EXCHANGER

DOUBLE PIPE HEAT EXCHANGER

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Ⅰ. INSULATION 3. Construction

3. Pipe, Valve, Flange, Support Insulation

Secure the pipe with wire on maximum 300mm centers

Pipe Insulation shall be stopped at just before the non-insulated items.
All insulation shall be continuous at supports

Cut and shape around “Tee” junction to mate with the parent pipe insulation
Tee Branch
without voids or gaps at the junction

Larger side shall be extended to the smaller side of reducer.

Reducer
Voids between pipe insulation and reducer are filled with loose fill insulation

Flanged Distance from the end of insulation to back of flange shall be minimum one stud
Connection length plus 30mm to permit removal of the studs

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Ⅰ. INSULATION 3. Construction

3. Pipe, Valve, Flange, Support Insulation

Horizontal
Piping The piping shall have the insulation continuous
(Elevated on shoe)

Vertical & The piping shall have the insulation cut away for a distance of 150mm on each
Horizontal Piping side of the support and weatherproofed
(Without shoe)

Expansion / The joint shall be formed by a 30mm wide space packed with loose fill
Contraction joint insulation between the pipe insulation section

A minimum of 50mm overlap shall be required for longitudinal and

Metal Jacket circumferential seams. And band intervals shall not exceed 300mm

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Ⅰ. INSULATION 3. Construction

Piping Insulation

NO.3 PROJECT VR HCR

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Ⅰ. INSULATION 3. Construction

Valve , Flange Insulation

NO.3 PROJECT VR HCR

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Ⅰ. INSULATION 3. Construction

Pipe Support’s Insulation Details

NO.3 PROJECT VR HCR

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Ⅰ. INSULATION 3. Construction

Pipe Insulation

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Ⅰ. INSULATION 3. Construction

elbow Insulation

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Ⅰ. INSULATION 3. Construction

Drain Pot Insulation

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Ⅰ. INSULATION 3. Construction

Dummy Support Insulation

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Ⅰ. INSULATION 3. Construction

Shoe Support Insulation

FRONT VIEW SIDE VIEW

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Ⅰ. INSULATION 3. Construction

Ring Support Insulation

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Ⅰ. INSULATION 3. Construction

4. EQUIPMENT INSULATION(COLD)

Amarflex (COLD)

HEAD

SHELL AND TUBE

LEG

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Ⅰ. INSULATION 3. Construction

Amarflex(COLD)

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Ⅰ. INSULATION 3. Construction

Equipment Jacketing (COLD)

TOWER & VESSEL SHELL TOWER & VESSEL HEADER

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Ⅰ. INSULATION 3. Construction

Pipe & Fitting (COLD)

Armaflex pipe insulation

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Ⅰ. INSULATION 3. Construction

Pipe Insulation (COLD)

MULTI LAYER PIPE INSULATION SINGLE LAYER PIPE INSULATION

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Ⅰ. INSULATION 3. Construction

Typical Details for VALVE / FLANGE Insulation (COLD)

VALVE FLANGE

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Ⅰ. INSULATION 3. Construction

Acoustic Insulation

E-GLASS Amaflex Insulation

Jacketing
Armachek R Covering

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Ⅰ. INSULATION 3. Construction

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Ⅰ. INSULATION 3. Construction

• Fireproofing

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Ⅱ. PAINTING 1. Outline

1. Purpose

1) To protect the materials and surface

2) To identify the materials and service
3) Aesthetic effects
※ Painting work includes the identification marking for piping & equipment

2. Work Flow

Surface Primer Intermediate Final

Preparation Coating Coating Coating

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Ⅱ. PAINTING 1. Outline

3. Grade of Surface Preparation

* Steel Structures Painting Council (SSPC)

* Swedish Standards Institution (SIS)
* British Standards Institution (BS)
* National Association of Corrosion Engineers (NACE)

Relevant Standards Surface Preparation

Co
Criteria of Surface Preparation
de
SSPC SIS NACE Grades

TM-0170 White metal blast Blast cleaning to pure metal. Millscale, rest and foreign shall be
Ⅰ SP5 Sa-3
No.1 cleaning removed completely.

Very thorough blast cleaning. Millscale, rust and foreign matters shall
TM-0170 Near white blast
Ⅱ SP10 Sa-2-1/2 be removed to the extent the only traces remaining are slight stains in
No.2 cleaning
the form spots or stripes.

TM-0170 Commercial blast Thorough blast cleaning. Almost all millscales, rust and foreign matters
Ⅲ SP6 Sa-2
No.3 cleaning shall be removed.

Removing rust, loose millscales and loose paint by using power tools
Ⅳ SP3 St-3 Power tool claning
to sand, grind, chip or otherwise.

Removing loose rust, loose millscales andloose paint by using hand

Ⅴ SP2 St-2 Handtool Cleaning
tools to sand, scrape, brush, chip or otherwise.

Ⅵ SP1 Solvent cleaning Solvent (Chloride-free) wash to assure oil and grease free

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Ⅱ. PAINTING 1. Outline

4. Grade of Coating

Primer Intermediate and Finish Coats

P-1:Epoxy Primer F-1:Epoxy Finish Coat

P-2:Inorganic Zinc F-2:High Temperature Intermediate and Finish Coats

P-3:Modified Alked Paint F-3:Finish Coat-Tank

P-4:High Temperature Primer F-9:High Temperature Intermediate and Finish Coats

P-13:Zinc Rich Epoxy Primer F-11:High Temperature Finish

5. Painting Method

Airless
Brushing Roller Coating Air Spraying
Spraying

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Ⅱ. PAINTING 1. Outline

6. Extent of Works

MATERIALS and SURFACE MATERIALS and SURFACE

REQUIRED PAINTING NOT REQUIRED PAINTING

Non Ferrous Alloys

Carbon Steel

Stainless Steel
Low Alloy Steel

Galvanized Steel Surface

Steel Structure
Concrete Structure and Foundation

Other surface of materials which are

subject to corrosion. Other surface of materials which are
corrosion resisting

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Ⅱ. PAINTING 2. Construction

Shot Blast Material

SAND BLAST
GARNET 100 %

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Ⅱ. PAINTING 2. Construction

Surface after Blasting (SSPC-SP10)

1. Before BLASTING 2. After BLASTING

- Material : Steel Plate - Material : Steel Plate
- Surface : Rusted - Code : SSPC-SP10
- Roughness : 35㎛ ~ 75㎛

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Ⅱ. PAINTING 2. Construction

Painting Work Flow

SHOP COATING FIELD COATING

Damage
Shot Blasting Inspection

Field Welding
Inspection after Coating Welding
Preparation
Surface Preparation SHOP
Coating

Coating
Thickness
Finish Coating Inspection

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Ⅱ. PAINTING 2. Construction

Shop Painting Work Flow (Stl/Str)

1.Surface Preparation 2. Painting

3. Dryness 4. Stock

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Ⅱ. PAINTING 2. Construction

Shop Painting Work Flow (Piping)

1.Surface Preparation 2. Welding Point Masking

3. Painting 4.Dryness

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Ⅱ. PAINTING 2. Construction

Piping Painting

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Ⅱ. PAINTING 2. Construction

Field Erection Storage Tank Painting

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