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REAFFIRMATION WITH EDITORIAL REVISION October 2010 Process Industry Practices I

REAFFIRMATION WITH EDITORIAL REVISION October 2010 Process Industry Practices Insulation PIP INEG1000 Insulation Design Guide PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. © Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users’ purposes. These purposes include but are not limited to the procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific project by Authorized User’s client. PIP’s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PRINTING HISTORY December 1997 Issued October 2005 Complete Revision October 2010 Reaffirmation with Editorial Revision April 1999 Complete Revision July 2007 Editorial Revision Not printed with State funds REAFFIRMATION WITH EDITORIAL REVISION October 2010 Process Industry Practices Page 1 of 33 Process Industry Practices Function Team PIP INEG1000 Insulation Design Guide Table of Contents 1. Introduction ................................. 2 1.1 Purpose ............................................. 2 1.2 Scope ................................................. 2 2. References .................................. 2 2.1 Process Industry Practices ................ 2 2.2 Industry Codes and Standards .......... 2 2.3 Other References .............................. 3 3. Insulation Materials .................... 3 3.1 Categories ......................................... 3 3.2 Closed-Cell Insulations ...................... 3 3.3 Fibrous Insulations ............................. 4 3.4 Granular Insulations ........................... 5 3.5 Jacket Materials and Accessories ..... 5 3.6 Vapor Barriers .................................... 7 4. Insulation System Design .......... 7 4.1 General .............................................. 7 4.2 Basic Design Criteria ......................... 8 4.3 Other Design Criteria ....................... 11 5. Corrosion under Insulation ..... 13 6. Insulation Material Selection ... 14 6.1 General ............................................ 14 6.2 ASTM Considerations ...................... 14 6.3 Insulation Materials Properties Table ................................................ 15 7. Extent of Insulation .................. 15 8. Insulation Thickness ................ 16 8.1 General ............................................ 16 8.2 3E Plus ............................................ 17 9. Type Codes ............................... 18 9.1 General ............................................ 18 9.2 Hot Insulation Types ........................ 18 9.3 Cold Insulation Types ...................... 19 9.4 Insulation Types for Traced and Energy Transfer Jacketed Systems ........................................... 20 9.5 AC – Acoustic Control Insulation ..... 21 9.6 FP – Fire-Protection Insulation ........ 21 Table 1: Insulation Materials Selection Table (US Customary Units) .................. 22 Table 1M: Insulation Materials Selection Table (SI Units) ...................................... 28 Data Forms INEG1000-D1 – Documentation Requirements Sheet The following data forms shall be part of this Practice only if indicated on the purchaser’s completed Documentation Requirements Sheet. INEG1000-D2 – Hot Service Insulation Design Parameters INEG1000-D3 – Cold Service Insulation Design Parameters PIP INEG1000 REAFFIRMATION WITH EDITORIAL REVISION Insulation Design Guide October 2010 Page 2 of 33 Process Industry Practices 1. Introduction 1.1 Purpose This Practice provides guidance for the design of insulation systems. 1.2 Scope This Practice describes the types of insulation systems that are indicated by the type code on the Piping and Instrumentation Diagrams (P&IDs), data sheets, and other design documents. This Practice provides guidance on insulation design criteria, insulation materials, extent of insulation, determination of insulation thickness, and insulation material properties. 2. References Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles will be used herein where appropriate. 2.1 Process Industry Practices (PIP) – PIP CTSE1000 – Application of External Coatings – PIP INSC2000 – Installation of Cold Service Insulation Systems – PIP INSH1000 – Hot Service Insulation Materials and Installation Specification – PIP INSR1000 – Installation of Flexible, Removable/Reusable Insulation Covers for Hot Insulation Service 2.2 Industry Codes and Standards  American Petroleum Institute (API) – API RP521 – Guide for Pressure-Relieving and Depressuring Systems – API RP2001 – Fire Protection in Refineries – API PUBL 2218 – Fireproofing Practices in Petroleum and Petrochemical Processing Plants  American Society of Testing and Materials (ASTM) – ASTM C240 – Standard Test Methods of Testing Cellular Glass Insulation Block – ASTM C533 – Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation – ASTM C547 – Standard Specification for Mineral Fiber Pipe Insulation – ASTM C552 – Standard Specification for Cellular Glass Thermal Insulation REAFFIRMATION WITH EDITORIAL REVISION PIP INEG1000 October 2010 Insulation Design Guide Process Industry Practices Page 3 of 33 – ASTM C591 – Standard Specification for Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation – ASTM C610 – Standard Specification for Molded Expanded Perlite Block and Pipe Thermal Insulation – ASTM C680 – Standard Practice for Determination of Heat Gain or Loss and the Surfaces Temperatures of Insulated Pipe and Equipment Systems by the Use of a Computer Program – ASTM C800 – Standard Specification for Glass Fiber Blanket Insulation (Aircraft Type) – ASTM C871 – Standard Test Methods for Chemical Analysis of Thermal Insulation Materials for Leachable Chloride, Fluoride, Silicate, and Sodium Ions – ASTM C1055 – Heated System Surface Conditions That Produce Contact Burn Injuries – ASTM C1104 – Standard Test Method for Determining the Water Vapor Sorption of Unfaced Mineral Fiber Insulation – ASTM E96 – Standard Test Methods for Water Vapor Transmission of Materials  NACE RP0198-2004 – The Control of Corrosion Under Thermal Insulation and Fireproofing – A Systems Approach, NACE International  North American Insulation Manufacturers Association (NAIMA) – 3E Plus 2.3 Other References  Federal Energy Administration Report – Economic Thickness for Industrial Insulation/ASM Metals Handbook, “Corrosion” Volume 13, ASM International  National Oceanic and Atmospheric Administration (NOAA), U.S. Department of Commerce – www.noaa.gov 3. Insulation Materials 3.1 Categories Insulation materials fall into the following three major generic categories based on the structure of the insulation material and each has properties that give it unique performance characteristics: a. Closed cell b. Fibrous c. Granular 3.2 Closed-Cell Insulations 3.2.1 Closed-cell insulations include: PIP INEG1000 REAFFIRMATION WITH EDITORIAL REVISION Insulation Design Guide October 2010 Page 4 of 33 Process Industry Practices a. Cellular glass b. Various organic materials such as rigid polymer foams, polyisocyanurate, polyurethane, and polystyrene c. Elastomeric foams 3.2.2 The closed-cell structure of these materials provides a natural resistant to absorption and permeation by external water and water vapor as well as to absorption of leaking process chemicals. Closed-cell insulations are frequently chosen for low-temperature applications in which control of moisture penetration is important. ASTM E96 is a test method for water vapor permeability that can be applied to all insulation materials. ASTM C240 is a water absorption test method that is published for cellular glass. Some insulation manufacturers test their materials using both of these procedures and publish the results in their product literature. For both test methods, the lower the value, the more resistant the material is to absorption and permeability. 3.2.3 The upper-use temperature of the rigid polymers and elastomeric foams is limited, and the manufacturer’s recommended maximum temperature should be followed. Cellular glass is made from inorganic material that gives a wider, usable temperature range and applicability in elevated temperature service in which absorption resistance is needed. 3.2.4 In applications below ambient, most of these materials should be used with a separate vapor barrier and with a weather-proof jacket. All outer- layer joints should be sealed using the insulation manufacturer’s recommended material in any application in which uploads/s1/ insulation-design-guide.pdf