thermal insulation

UNCONTROLLED WHEN PRINTED BBS amendment to DEP GEN 04.00.4076

Filename: 04004076.docx Rev.: D Custodian: DMS/746, DMS/946 Page: 1 van 14

Owner: Chairman BBS process 04 Level: 2

AMENDMENT TO DEP GEN:

THERMAL INSULATION (PERNIS/MOERDIJK)

Wec : No Comm. Index : B / C Veiligheidsrapport : No Risk : L WWW-Contractors : Yes Classification : Unrestricted Emergency plan : No HSE critical : Yes FCM related : No

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 60°C 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 Suppliers, principals, engineers, supervisors, consultants and contractors

Checked by DMS/746 (SPFP - CEA) G. Ritzema

DMS/71VP4 (DPFP - CEA) E. Karam

DMS/946 R. Heemskerk

Risk 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.

Revision info Last revision

Date Reason

D 08-10-2012 Harmonized with Thermal Insulation DEP and updated insulation tables

More revision information

Table of contents 1 SUMMARY ..................................................................................... 3

2 CONTEXT AND REFERENCES .................................................... 3

3 GENERAL REGULATIONS ........................................................... 3

4 AMENDMENT TEXT DEP 30.46.00.31-GEN ................................. 4

4.1 REF. CHAPTER3.2, MATERIALS .......................................................... 4 4.2 REF. CHAPTER 3.1.2.1, 3.3.2, 4.3.2SURFACE PREPARATION ......... 4 4.3 INSULATION THICKNESS FOR PIPING AND EQUIPMENT WITH

TRACING (HOT INSULATION) .............................................................. 6 4.4 INSULATION THICKNESS FOR STORAGE TANKS (HOT

INSULATION) ......................................................................................... 6 4.5 INSULATION THICKNESS CELLULAR GLASS, (COLD INSULATION) 7




4.6 REF. APPENDICES, APPENDIX F, INSULATION THICKNESS PUR/PIR (COLD INSULATION) ............................................................. 8

4.7 REF. PART III, AMENDMENTS/SUPPLEMENTS TO THE CINI HANDBOOK ............................................................................................ 9

5 INSULATION CODES .................................................................. 10

5.1 GENERAL ............................................................................................. 10 5.2 INSULATION CODES FOR HOT INSULATION MATERIALS ............. 10 5.3 SPECIFICATION COLD INSULATION FOR PIPING FOR THE

TYPICAL DETAILS OF THE CONSTRUCTION OF COLD INSULATION SEE FIGURE 1 ..................................................................................... 10

5.4 SPECIFICATION COLD INSULATION AROUND EQUIPMENT ......... 11




1 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.

2 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

3 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 Cold insulation

Average ambient temperature : 8C Max. ambient temperature : 25C

Wind velocity : 5 m/s Wind velocity : 1.4 m/s

Capital charge : 17.5% Humidity : 85%

Heat cost : € 8/GJ 1) Emissivity : 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 175ºC 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.

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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 AMENDMENT TEXT DEP 30.46.00.31-GEN

4.1 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).

4.2 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).










INSULATION THICKNESS IN MM

Normal operating temperature in °C

diameter. type <50*) 51-100

101-150

151-200

201-250

251-300

301-350

351-400

401-450

451-500

501-550

551-600

< 1" "A" 30 30 30 30 40 40 50 50 60 60 70 70

"B" 30 30 30 40 50 60

1" "A" 30 30 30 30 40 40 50 50 60 60 70 70

"B" 30 30 40 40 50 60

1,5" "A" 30 30 30 40 50 50 60 60 70 80 80 80

"B" 30 30 40 40 50 70

2" "A" 30 30 40 40 60 60 60 70 80 80 90 90

"B" 30 40 40 50 50 70

3" "A" 30 30 40 50 60 70 70 80 80 90 90 90

"B" 30 40 40 50 60 80

4" "A" 30 50 50 60 60 70 80 90 90 100 100 100

"B" 30 40 50 50 60 80

6" "A" 50 50 50 70 70 90 90 100 100 100 120 120

"B" 30 40 50 60 70 80

8" "A" 50 50 60 80 90 100 100 110 120 130 130 130

"B" 30 40 50 60 80 80

10” “A” 50 50 70 80 90 100 100 110 120 140 140 150

“B” 40 40 60 70 80 100

12" "A" 50 50 70 80 90 100 110 120 140 140 140 150

"B" 40 50 60 70 80 100

14" "A" 50 60 70 90 100 110 110 120 140 150 150 150

"B" 40 50 60 70 80 100

16" "A" 50 60 70 90 100 110 120 120 150 150 150 150

"B" 40 50 60 70 90 100

18" "A" 50 60 80 100 120 120 120 150 150 150 150 160

"B" 40 50 60 70 90 100

20" "A" 50 70 80 100 120 120 120 150 150 150 150 160

"B" 40 50 60 80 90 100

> 20" "A" 50 80 100 110 130 140 160 180 180 200 200 200

"B" 40 50 70 80 90 100

Equipment "A" 50 80 100 110 130 140 160 180 180 200 200 200

Equipment "B" 25 25 25 40 40 50 70 80 90 100

"A" Economic insulation thickness.

"B" Personnel protection.




4.3 INSULATION THICKNESS FOR PIPING AND EQUIPMENT WITH TRACING (HOT INSULATION)

Heat medium Run pipe Insulation thickness

LP-steam tracing < 3" 50 mm

4" en 6" 50 mm

8" … 20" 50 mm

Equipment 50 mm

MP-steam tracing < 3" 60 mm

4" en 6" 60 mm

8" … 20" 80 mm

Equipment 60 mm

Electrical tracing < 3" 50 mm

4" en 6" 50 mm

8" … 20" 50 mm

Equipment 50 mm

4.4 INSULATION THICKNESS FOR STORAGE TANKS (HOT INSULATION)


Storage Normal operating temperature in °C

tanks < 50 51-100 101-150 151-200 201-250

Tank walls 50 80 100 2) 120 2) 140 2)

Tank roofs 80 2) 80 2) 80 2)

2

) To be executed in two layers. Uit te voeren in twee lagen.




4.5 INSULATION THICKNESS CELLULAR GLASS, (COLD INSULATION)

Ambient temperature : 25C

Humidity : 85%

Wind velocity : 1.4 m/s

Emissivity : 0.3


Diameter Operating temperature C

20 0 -20 -40 -60 -80 -100 -120 -140 -160 -180

½” 12 14 23 30 37 43 48 53 57 61 65

¾” 12 15 24 32 39 46 51 56 61 65 69

1” 13 16 26 34 41 48 54 59 64 69 73

1½” 14 17 28 38 46 53 59 65 70 76 80

2” 14 18 30 40 48 56 63 69 74 80 85

3” 15 19 32 43 53 61 69 76 82 88 94

4” 16 20 34 45 56 65 73 81 87 94 100

6” 17 21 36 49 60 71 80 88 96 103 109

8” 17 22 38 52 64 75 85 93 101 109 116

10” 17 23 39 54 67 78 89 98 106 115 122

12” 18 23 40 55 69 81 92 101 110 119 127

14” 18 23 41 56 70 82 93 103 112 121 129

16” 18 24 42 58 72 84 96 106 115 125 133

18” 18 24 42 59 73 86 98 108 118 128 136

20” 18 24 43 60 74 86 100 111 120 130 139

24” 19 25 44 61 76 90 103 114 124 135 144

Vessel 19 26 46 64 106 126 145 162 178 195 209

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.




4.6 REF. APPENDICES, APPENDIX F, INSULATION THICKNESS PUR/PIR (COLD INSULATION)

Ambient temperature : 25C

Humidity : 85%

Wind velocity : 1.4 m/s

Emissivity : 0.9


Diameter Operating temperature C

20 0 -20 -40 -60 -80 -100 -120 -140 -160 -180

½” 7 18 26 33 43 53 63 69 75 80 84

¾” 7 19 27 35 45 56 67 73 79 84 89

1” 8 20 29 37 48 59 70 77 83 89 94

1½” 8 21 31 40 52 65 77 85 91 97 103

2” 8 22 33 43 55 68 81 89 96 103 108

3” 9 24 35 46 60 75 89 98 106 113 119

4” 9 25 37 49 64 79 95 104 112 120 127

6” 9 26 40 52 69 86 103 114 123 131 138

8” 10 27 41 55 73 91 109 120 130 139 147

10” 10 28 43 57 75 95 114 126 136 146 154

12” 10 28 44 58 78 98 118 130 141 151 159

14” 10 29 44 59 79 99 120 132 143 153 162

16” 10 29 45 60 80 102 123 135 146 157 166

18” 10 29 46 61 82 103 125 138 149 160 169

20” 10 30 46 62 83 104 127 140 151 162 172

24” 10 30 47 63 84 107 130 143 155 167 177

Vessel 11 31 50 69 94 123 153 171 188 203 218

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.




4.7 REF. PART III, AMENDMENTS/SUPPLEMENTS TO THE CINI HANDBOOK

Tab 1 General Requirements + Installation Instructions

CINI 1.3.01 General requirements for the thermal insulation of "hot" pipelines and equipment.

4.4 Application of the metal finishing layer.

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 hole⁄6 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 8’o clock), and certainly not to the longitudinal joints in this segment

CINI 1.3.02 General requirements for the thermal insulation of "cold" pipelines and equipment.

1.1 Replace this clause by:

The ambient temperature is 25C.

3.2.1 The following materials shall not be applied without approval of the Civil Engineering Section:

flexible elastomeric foam (FEF).

cellular glass (CG)

3.5 Metal finishing materials.

Add to this clause:

Aluminium cladding shall not be applied.

For cold insulation only aluminised steel cladding Type 2 shall be applied.

CINI 1.3.10 … CINI 1.3.37 Installation instructions for the thermal insulation of "hot" pipelines, fittings and equipment.

1.1 The following materials shall not be applied without approval of the Civil Engineering Section:

polyisocyanurate (PIR) and polyurethane (PUR)

cellular glass (CG)

Tab 3 Finishing materials + auxiliary materials

CINI 3.2.01… CINI 3.2.05 Weather resistant mastics.

Page 1 of 1 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.




5 INSULATION CODES

5.1 GENERAL

For engineering and contracting-out purposes the various insulation systems shall be indicated with insulation codes.

5.2 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.

5.3 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 Insu-W-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.

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.




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.




Figure 2: Insulation detail T-bracket




Figure 3: Insulation collar detail (alternative to S10.056)

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Revision information

Revision Date Reason

0 2001-03-01 First issue

A 2002-09-15 Added figure 2 and 3

B 2003-07-14 Specification changes in para 6.3 and 6.7

C 2005-09-13 Changed: revisions DEP 30.46.00.31 Gen incorporated

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