Doc No:

MELAKA REFINERY EURO5-EPC-EXE-HEC-00-

PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 1 of 25 Rev: 2

DOCUMENT CLASS: X

INSULATION SPECIFICATION

2 25-Jan-2019 Approved For Construction E.H. Park K.I. Won S.D. Lee

1 19-Nov-2018 Approved For Construction E.H. Park C.S. Kim S.D. Lee

0 27-Mar-2018 Approved For Construction E.H. Park C.S. Kim S.D. Lee

A 28-Dec-2017 Issued For Review E.H. Park C.S. Kim S.D. Lee

Rev Date Status Prepared By Checked By Approved By

 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 2 of 25 Rev: 2

DOCUMENT REVISION HISTORY

Revision No Date Description

0 27-Mar-2018 The COMPANY's CRS comments have been incorporated

Typo error is corrected
0 27-Mar-2018
Insulation Code are updated as per project P&ID and Linelist
The COMPANY's CRS comments have been incorporated
1 19-Nov-2018 Some Typo error is corrected and Insulation Cover detail is included
as per TEQ (EURO5-EPC-EXE-HEC-MRC-TEQ-0096).
2 25-Jan-2019 The COMPANY's CRS comments have been incorporated
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 3 of 25 Rev: 2

TABLE OF CONTENTS

1.0 PURPOSE .......................................................................................................................4

2.0 ACRONYMS AND DEFINITIONS....................................................................................4
3.0 APPLICABLE DOCUMENTS ..........................................................................................6
4.0 ORDER OF PRECEDENCE ............................................................................................8
5.0 GENERAL DESIGN ........................................................................................................9
6.0 INSULATION MATERIALS ...........................................................................................12
7.0 JACKETING ..................................................................................................................16
8.0 FASTENING MATERIALS ............................................................................................16
9.0 APPENDICES ...............................................................................................................20
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 4 of 25 Rev: 2

1.0 PURPOSE

This project specification covers the minimum requirements for materials and application
requirement for the external hot insulation systems of piping and equipment operating
above atmospheric water dew point and below 1,000 oC which are located above ground,
either inside, or outside of buildings which are to be used for the Melaka Refinery Diesel
EURO 5 Project.

The insulation systems specified in this document are designed to serve the following
objectives:

 Controlling heat losses

 Protecting people from hot surfaces
 Minimizing heat gain during fire conditions

The requirements stated in this document shall not be applied to the following systems:

 Insulation systems for surfaces operating above 1,000oC

 Insulation systems for underground surfaces
 Exterior insulation systems for surfaces with temperatures at or below dew
point
 Refractory systems and/or internal insulation systems for
process piping and equipment.
NOTE: If any item with refractory or internal insulation requires
exterior insulation for any specific reason, the requirements for such
exterior insulation shall be the same as provided in this document.
 Insulation systems for HVAC systems

These requirements shall be used throughout all steps of the project and by all parties i.e.
CONTRACTOR, SUBCONTRACTOS, EPCC CONTRACTORS, MANUFACTURERS,
VENDORS, etc

2.0 ACRONYMS AND DEFINITIONS

The followings terms are used in this document and have meanings as specified below:

Document No Description
CONTRACT The form of agreement together with the documents in
order of priority, including the exhibits, drawings,
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 5 of 25 Rev: 2

specifications and documents referred to and in the

order of precedence listed in the form of agreement.
EPCC CONTRACTOR The person or persons, company, join venture, or
consortium whose proposal has been accepted by for
Engineering, Procure- ment, Construction and
Commissioning Contract for the PROJECT including its
personnel, representatives, and successors and permitted
assignee.
OWNER Melaka Refining Company Sdn Bhd
PROJECT Melaka Euro 5 Diesel Project
SCOPE OF WORK The scope of work to be performed and services to be
rendered by CONTRACTOR under the CONTRACT in
relation to the realization of the PROJECT
WORK Works, tasks and WORK to be performed by
CONTRACTOR as specified in or to be inferred from the
CONTRACT, more specifically set out in the SCOPE OF
WORK which may be modified by CHANGE ORDER
CONCESSION REQUEST Technical or other deviation requested by the contractor or
vendor to owner. Its submission is often linked to an
authorization to modify the design, to use, repair,
recondition, reclaim, or release materials, components or
equipment already in progress or completely manufactured
but which does not meet or comply owner requirements
which is subjected to OWNER’s approval.
GOODS Any and all things, including but not limited to materials
and equipment (including spare parts) required to be
incorporated in the work.
OPERATING Continuous operating temperature, of the item to be
TEMPERATURE insulated, during normal operating conditions. For steam
jacketed piping and equipment, the jacket metal
temperature shall be considered as the operating
temperature. For refractory lined items, the metal
temperature during normal operating conditions shall be
considered as the operating temperature for insulation
purposes if external insulation is specifically required. For
heat traced piping and equipment, the operating
temperature of the heat tracer shall be considered the
operating temperature unless otherwise stated by OWNER.
Temperatures reached during upset conditions and steam-
out temperature shall not be considered as the operating
temperature.
SUBCONTRACTOR Any third party engaged by CONTRACTOR in connection
with the WORK
VENDOR VENDOR means a supplier of materials and/or equipment
for the FACILITIES including related documentation and
services, where necessary, in connection with the
installation, testing, pre-commissioning, and commissioning
and start-up support of any such materials of equipment.
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 6 of 25 Rev: 2

3.0 APPLICABLE DOCUMENTS

List of documents is applicable to the scope of supply. Other relevant project specifications,
which are not listed in this section 2.0 (but referred in Applicable documents) shall also be
applied.

3.1 Malaysian Legislations

Code Description

MS 761 Code of Practice for the Storage and Handling of Flammable and
Combustible Liquid

DOSH Department of Occupational Safety and Health

EQA Environmental Quality Act 1974 and its Applicable Regulations

FMA Factories and Machinery Act 1967 (FMA) and its Applicable Regulations

DOE Department of Environment

• Other relevant Malaysian Legislations

3.2 PTS (PETRONAS Technical Standards)

PTS Description

PTS 15.13.01 Thermal Insulation ( Amendments/Supplements to the Cini Manual )

3.3 CODES AND STANDARDS

In addition to the project specifications and documents listed in this specification, the Codes
and Standards stated in each specification together with any documents referred to therein
shall apply. If not stated, the latest edition of the Codes and Standards in force at time of
tender shall govern.

Code Description
Standard Specification for Stainless and Heat Resisting
ASTM A167
Chromium-Nickel Steel Plate, Sheet and Strip
Standard Test Methods and Definitions for Mechanical
ASTM A370
Testing of Steel Products
Standard Specification for Steel Sheet, Aluminum-
ASTM A463
Coated, by the Hot-Dip Process
ASTM A653 Standard Specification for Steel Sheet, Zinc-Coated
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 7 of 25 Rev: 2

(Galvanized) or Zinc-Iron Alloy- Coated (Galvannealed)

by the Hot-Dip Process
Standard Specification for Aluminum and Aluminum-Alloy
ASTM B209
Sheet and Plate
Standard Test Method for Measuring Compressive
ASTM C165
Properties of Thermal Insulations
Standard Test Methods for Thickness and Density of
ASTM C167
Blanket or Batt Thermal Insulation
Standard Terminology Relating to Thermal Insulating
ASTM C168
Materials
Standard Test Method for Steady-State Heat Flux
ASTM C177 Measurements and Thermal Transmission Properties by
Means of the Guarded-Hot-Plate Apparatus
Standard Specification for Mineral Fibre thermal
ASTM C195
insulating cement
Standard Test Method for Density and Dimensions of
ASTM C302
Preformed Pipe-Covering-Type Thermal Insulation
Standard Test Method for Dimensions and Density of
ASTM C303
Preformed Block and Board-Type Thermal Insulation
Standard Test Method for Steady-State Heat Transfer
ASTM C335
Properties of Pipe Insulation
Standard Test Method for Linear Shrinkage of Preformed
ASTM C356 High-Temperature Thermal Insulation Subjected to
Soaking Heat
Standard Test Method for Tumbling Friability of
ASTM C421 Preformed Block-Type and Preformed Pipe-Covering-
Type Thermal Insulation
Standard Practice for Estimating the Maximum Use
ASTM C447
Temperature of Thermal Insulations
Prefabrication and Field Fabrication of Thermal Insulating
ASTM C450
Fitting Covers
Standard Specification for Calcium silicate block and pipe
ASTM C533
thermal insulation
Standard Specification for Mineral fibre performed pipe
ASTM C547
insulation
Standard Specification for Mineral Fibre blanket insulation
ASTM C592 and blanket type pipe insulation (metal mesh covered)
(industrial type)
Standard Specification for Mineral Fiber Block and Board
ASTM C612
Thermal Insulation
Standard Specification for Thermal insulation for use in
ASTM C795
contact with austenitic stainless steel
Standard Test Methods for Chemical Analysis of Thermal
ASTM C871 Insulation Materials for Leachable Chloride, Fluoride,
Silicate, and Sodium Ions
Standard Specification for High-Temperature Fiber
ASTM C892
Blanket Thermal Insulation
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 8 of 25 Rev: 2

Standard Practice for Handling, transporting, shipping,

ASTM C929 storage, receiving, and application of thermal insulation
materials for use in contact with austenitic stainless steel
Test Method for Determining the Water Vapor Sorption of
ASTM C 1104
Unfaced Mineral Fiber Insulation
Standard Test Methods for Flash Point by Pensky-
ASTM D93
Martens Closed Cup Tester
Standard Test Method for Coefficient of Linear Thermal
ASTM D696 Expansion of Plastics Between -30°C and 30°C with a
Vitreous Silica Dilatometer
Standard Test Method for Compressive Properties Of
ASTM D1621
Rigid Cellular Plastics
Standard Test Method for Apparent Density of Rigid
ASTM D1622
Cellular Plastics
Standard Test Method for Tensile and Tensile Adhesion
ASTM D1623
Properties of Rigid Cellular Plastics
Standard Test Method for Water Absorption of Rigid
ASTM D2842
Cellular Plastics
Standard Test Method for Open Cell Content of Rigid
ASTM D6226
Cellular Plastics
Standard Test Method for Surface Burning Characteristics
ASTM E84
of Building Materials
Standard Test Methods for Water Vapor Transmission of
ASTM E96
Materials
BS 476 Part 4 Non - combustibility test for materials
Fire tests on building materials and structures - Part 7.
BS 476 Part 7 Method of test to determine the classification of the
surface spread of flame of products
Method for specifying thermal insulating materials for
BS 5422 pipes, tanks, vessels, ductwork and equipment operating
within the temperature range -40°C to +700°C
Code of practice for thermal insulation of pipework and
BS 5970
equipment in the temperature range of -100 ºC to +870 ºC
CINI Handbook Insulation for Industries
ISO 15665 Acoustic Insulation for Pipes, Valves and Flanges

4.0 Order of Precedence

In case of conflict between Laws, Project Specifications and Codes & Standards, the
following order of precedence shall be considered:
1) Malaysian Laws and applicable regulatory requirements
2) Project Specifications
3) Applicable Malaysian Codes and Standards
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 9 of 25 Rev: 2

4) Applicable International Codes and Standards.

5.0 GENERAL DESIGN

5.1 Site Condition

The local climate is classified as equatorial with no true distinct seasons. It is
characterized by uniform temperature and pressure, high humidity and abundant rainfall.

Minimum temperature : 20 ℃
Maximum temperature : 36.5 ℃
Average temperature : 27.5 ℃
Wind velocity : 0.3-12.4 m/s
Design wind velocity : 32.5 m/s
Jacket emissivity : 0.8

5.2 Insulation Codes

Insulation requirements shall be identified using the following codes:
AA Acoustic Insulation(Class A)
AB Acoustic Insulation(Class B)
AC Acoustic Insulation(Class C)
AD Acoustic Insulation(Class D)
FP Fire Proofing
IH Heat Conservation
HA Heat Conservation +Acoustic Insulation(Class A)
HB Heat Conservation +Acoustic Insulation(Class B)
HC Heat Conservation +Acoustic Insulation(Class C)
HD Heat Conservation +Acoustic Insulation(Class D)
PP Personnel Protection
ET Electrical Tracing
EA Electrical Tracing +Acoustic Insulation(Class A)
EB Electrical Tracing +Acoustic Insulation(Class B)
EC Electrical Tracing +Acoustic Insulation(Class C)
ED Electrical Tracing +Acoustic Insulation(Class D)
ST LP Steam Tracing
SM MP Steam Tracing (if applicable)
SJ Steam Jacketed
NI No Insulation
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 10 of 25 Rev: 2

5.3 Painting
Prior to insulation, all surfaces shall be suitably painted in accordance to Specification for
Blasting and Painting, EURO5-EPC-EXE-HEC-00-MCI-SPN-0001.

5.4 Design Guidance for Insulation

5.4.1 Acoustic Insulation

Acoustic insulation is installed to reduce the amount of noise radiated from a surface.
Acoustic insulation is often used in conjunction with hot insulation. The codes used for
acoustic insulation are A and AH. Acoustic insulation is divided into four classes:

• Class A: The lightest and the most economic class

• Class B: Medium noise reduction

• Class C: Heavy noise reduction

• Class D: Special applications, where no other means are available to achieve the
needed noise attenuation

The minimum insertion loss required for each class is defined in ISO 15665 Table 1. The
dimensions of the acoustic insulation for the three defined classes shall be as indicated
in the table below, unless otherwise specified.
Thickness of porous layer Minimum mass of cladding
Class
(mm) (kg/m2)
A 50 4.5Note 1
B 100Note 2 6Note ３
7.8 for pipe diameter < DN 300
C 100Note 2
10Note 4 for pipe diameter ≥ DN 300
6.0 (first porous layer) 50
D
7.0 (second porous layer) 10Note 5
NOTES
1. A thickness of 0.5 mm for steel cladding already exceeds this minimum mass requirement;
2. The porous layers shall be applied in two layers of 50 mm with staggered joints;
3. The steel cladding will be 0.6 mm thick (i.e. 4.8 kg/m2). The minimum mass
requirement will be provided by an additional layer of reinforced material;
4. The steel cladding will be 0.8 mm thick (i.e. 6.4 kg/m 2). The minimum mass
requirement will be provided by an additional layer of reinforced material;
5. For pipe diameter higher and similar to DN 650.

5.4.1.1 Class A
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 11 of 25 Rev: 2

The minimum requirements are given in Section 5.4.1. Flanges and valves do
not need to be covered
5.4.1.2 Class B
The minimum requirements are given in Section 5.4.1. The porous layer shall
be applied in two layers of 50 mm with staggered joints. Distance and support
rings should avoided whenever possible. All flanges and valves shall be
insulated to the same class as the pipe except where insulation of the device
is not allowed for safety reasons (e.g. in hydrogen service). Rigid pipe
supports shall be insulated down to the concrete or steel base (Appendix 1).
5.4.1.3 Class C
The minimum requirements are specified in Section 5.4.1. Pipe supports (not
including guides and anchors), shall be mounted on a vibration-isolating pad
(Appendix 1). All the other requirements are similar to Class B.

5.4.2 Heat Conservation

Heat conservation is defined as insulation used for piping and equipment to maintain
process temperature or save energy. It is typically applied for process temperature
between 20 and 1000℃. The relevant codes are H and AH. For process temperatures
between 20 and 80℃, cellular glass shall be used. See section 6.2 for jacketing. For
process temperature between 80 and 600℃, rock wool shall be used. See section 6.2
for jacketing. For temperatures above 600℃, ceramic fiber shall be used.

5.4.3 Personnel Protection

Personnel protection consists of barrier systems made of insulation material or metal
screens used to prevent people from touching hot surfaces of piping and equipment
when they are accessible from normal working areas. The extent of personnel
protection shall not excess 2 m above or more than 1 m away from the accessible
areas. It is typically used for operating temperature of above 70℃. The code of
personnel protection is PP.

For process temperatures from 71 to 250℃, barrier protection shall be applied, without
insulation (e.g. wire mesh or perforated metal sheet) as described in Appendix 2. If
wire mesh is used, it shall be stainless steel according to AISI type 304. The wire
diameter shall be 3 mm with a mesh dimension of 50 x 50mm. If perforated metal
sheet is used, the metal sheeting shall be in accordance with AISI type 304. For
process temperature higher than 250 until 600℃, rock wool shall be used. See section
6.2 for jacketing. For the process temperature higher than 600℃, ceramic fiber shall
be used. See section 6.2 for jacketing.

5.4.4 Fire Proofing

 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 12 of 25 Rev: 2

Fire proofing is defined as a fire protection system that functions without having to be
activated. The code is FP. When passive fire proofing is requested in addition to heat
insulation, the complete system shall be approved and shall pass the relevant fire tests

5.4.5 Tracing
Tracing along the piping may be required for process reasons to hold the temperature
of the line which can either be identified as electrical tracing or steam tracing. The
relevant codes are ET, ST and SM. SJ code is used for steam jacketed items. The
design for tracing shall be done as per heat conservation.

5.5 Insulation and Accessory Material

Materials for insulation, fastenings and jacketing shall be selected from the materials
described in Section 6, unless otherwise agreed by OWNER/ CONTRACTOR.
Insulation materials shall be non-corrosive to the substrate material in wet and dry
conditions. The amount of leachable chloride in the insulation material before application
shall not exceed 10 mg/kg. The pH of all insulation materials shall be between 6 and 9 in
wet conditions. Chemical analysis of insulation materials shall be done as per ASTM
C871.
All insulation materials shall be free from asbestos, lead and chromate.

6.0 INSULATION MATERIALS

6.1 Cellular Glass

Rigid cellular glass, factory shaped/cut into half sections, radiused and beveled segments,
and slabs of minimum 600 mm in length shall be used for a temperature up to 80oC.
Density of the cellular glass material shall be as per ASTM C303 which is 115 kg/m3.
Table below describes the thermal conductivity for cellular glass material.

Average temperature (oC) Maximum thermal conductivity (W/m.K)

as per ASTM C518
80 0.053
50 0.044
20 0.042
The following table addresses the material property as a minimum for cellular glass.

Data Acceptable level Applicable Standard

Closed cell content 100%

Water vapor permeability 0 g/m2h at 23oC/ 50% RH ASTM E96 procedure A
Cl- content Max value of 45 ppm ASTM C871
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 13 of 25 Rev: 2

pH value Min 6, Max 10 ASTM C871

Combustibility Flame spray index = 0 ASTM E84
From 420 oC to -200 oC :
Compressive strength ASTM C165
500 kPa in all directions
Linear thermal expansion +20 oC: max 9.106 m/(m.K)
ASTM E228
coefficient -160 oC: max 7.106 m/(m.K)
E modulus +23 oC: 800 MPa in all directions ASTM C623
Poisson’s ratio -165 oC: 0.4 -
Fire resistivity Non-combustible BS 476
The cellular glass shaped shall be as per the following table:

Size Shape
Pipe: ≤ DN 200 2 half sections of 600 mm long
Radius and bevel segments
Pipe: > DN 200 & Equipment: Ø ≤ 7000mm
Width of the outside radius of insulation
Pipe & Equipment: Ø ≤ 1000mm
Min 140 mm, max 160 mm
Pipe & equipment: 1000mm < Ø ≤ 7000mm Width of the outside radius of insulation
Min 210 mm, max 435 mm
Equipment: Ø > 7000mm Flat bevel blocks (min 300mm wide)
Special factory radiused and beveled
Equipment heads and spherical tanks: 900mm < segments to
Ø suit the curvature of heads/tanks
as much as possible

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

6.2 Rock Wool

Rock wool shall be manufactured from mineral rock processed from a molten state into
the fibrous form which can be used at a temperature up to 600 oC as per the properties
described in the following table.

Data Acceptable level Applicable standard

Melting temperature ≥ 800oC Not applicable.
Average diameter ≥ 5μm
Fiber dimension Not applicable.
Length ≥ 50mm
Shot content < 30% by weight ASTM C612
Water absorption ≤ 10% volume AGI Q136
Leachable chloride content ≤ 10 mg/kg ASTM C871
pH value Min 6, max 10.5 ASTM C871
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 14 of 25 Rev: 2

Flame spread index Max 0 ASTM E84

6.3 Blanket Type Insulation

Blanket type insulation shall be as per ASTM C592. The insulation shall be made of
molten rock without binder with unloaded density of 100 kg/m3 as per ASTM C167.
Mesh blankets shall have on side stitched with 0.8 mm high alloy wire galvanized or
stainless wire mesh with a maximum width of 0.1”. The thermal conductivity shall be as
per the following table.

Average Temperature (oC) Thermal conductivity (W/m.K) as per

ASTM C177

600 0.215
500 0.158
400 0.115
350 0.093
300 0.082
250 0.070
200 0.058
150 0.052
100 0.043
50 0.038

6.4 Preformed Type Piping Insulation

Preformed type of piping insulation shall be in accordance with ASTM C547. The
insulation shall consist of rock wool and shall be made rigid with an organic binder. Its
unloaded density shall be between 100 and 125 kg/m3 as per ASTM C302. The length
of the insulation sections shall be 1 or 2 m. The thermal conductivity shall be as per the
following table.

Average Temperature (oC) Thermal conductivity (W/m.K) as per

ASTM C177

600 0.215
500 0.158
400 0.111
350 0.094
300 0.082
250 0.070
200 0.059
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 15 of 25 Rev: 2

150 0.051
100 0.044
50 0.038
Data Acceptable Level 100
Compressive strength 8.0 kPa at 10% compression ASTM C165
Dimensional stability and
Not applicable. ASTM C547
tolerance for dimensions
6.5 Preformed Boards or Slabs Insulation
Preformed boards or slabs insulation shall be as per ASTM C612. The insulation shall
consist of rock wool and shall be made rigid with an organic binder with unloaded density
of 100 kg/m3 as per ASTM C177. The thermal conductivity shall be as per the following
table.

Average Temperature (oC) Thermal conductivity (W/m.K) as per

ASTM C177
600 0.215
500 0.158
400 0.118
350 0.095
300 0.083
250 0.072
200 0.061
150 0.052
100 0.045
50 0.037
Data Acceptable Level 100
Compressive strength 11.9kpa at 10% compression ASTM C612
Dimensional stability and
Not applicable. ASTM C612
tolerance for dimensions

6.6 High Temperature Silica Fiber Blanket (Ceramic Fiber Blanket)

The ceramic fiber shall be refractory oxides consisting of primarily alumina and silica,
processed from a molten state into fibrous form without binder. Alumina-silica ceramic
fiber insulation shall be suitable for temperatures up to 1,000oC and conform to the
requirements of ASTM C892 Type III. The minimum density shall be 96 kg/m3 tested at
1,000 oC with a thermal conductivity of maximum 0.11 W/m.K at 400 oC.
Thermal conductivity (W/m.K) as per ASTM
Average Temperature (oC) C177
1000 0.3166
900 0.2623
850 0.229
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 16 of 25 Rev: 2

800 0.1950
600 0.1300
500 0.1100
400 0.0900
300 0.0740
200 0.0580
50 0.038

7.0 JACKETING

No flammable materials are allowed on the metal jacketing. Galvanized sheeting shall not
be used over insulation or near austenitic SS and/or austenitic nickel steel alloy piping and
equipment. Galvanized sheeting is vulnerable to corrosion in coastal areas.

7.1 Aluminum
Aluminum jacketing shall be used in onshore conditions (i.e. in a non-corrosive
atmosphere) except fire proofing zone. Aluminum jacketing is not allowed for high risk of
2
Mercury release area.
Aluminum jacketing shall be in accordance with ASTM B209M- Alloy 1060 or 1050.
Tensile strength, yield strength, and elongation and temper shall be as per ASTM
B209M-H14 (1/2 hard). Chemical composition and corrosion resistance shall be in
accordance with ASTM B209M. The minimum thickness of sheeting shall be as per the
following Table.
Outside diameter of insulation (mm) Minimum thickness of sheeting (mm)
<140 0.6
140-300 0.8
>300 1

7.2 Stainless Steel

Stainless steel jacketing shall be used in fire proofing zone. Type 316 SS shall be used
in accordance with AISI. In some particular conditions, AISI 430 can be requested.
Minimum thickness of sheeting shall be in accordance with the following table.
Outside diameter of insulation (mm) Minimum thickness of sheeting (mm)
<140 0.4
140-300 0.5
>300 0.6

8.0 FASTENING MATERIALS

 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 17 of 25 Rev: 2

8.1 Binding Wire

Wire shall be of 1 mm diameter of austenitic stainless steel AISI 304.

8.2 Insulation Support Rings

The pipe fabricator is responsible for installing insulation supports for all vertical items
fabricated in the shop. All equipment insulation supports shall be installed by the
equipment manufacturer. The SUBCONTRACTOR is responsible for all other insulation
supports. Welded type supports may be used only if installed in the shop prior to heat
treatment. The use of welded supports by the SUBCONTRACTOR is not allowed unless
the SUBCONTRACTOR investigates and verifies that the item to be insulated in not heat
treated only after written approval from CONTRACTOR.
Insulation support rings shall have spaced support webs between vessel/pipe and
support ring to allow any water to drain as specified in the following table.
Outside insulation diameter (mm) Thickness (mm)
<125 1.5
125 up to 760 3
>760 5

8.3 Bands for Metal Sheeting

The band material for strapping banks and distance ring bands shall be a minimum of
0.5 mm thick and be of 13 mm (up to DN 200) to 25 mm (DN 250 and above) wide
stainless steel AISI 304.

8.4 Self-Tapping Screws

Self-tapping screws shall be 4.8 mm diameter x 13 mm long and stainless steel AISI 304.

8.5 Rivets
Rivets shall be 3.2 x 1 mm and 4.8 mm x 1 mm, stainless steel or aluminum

8.6 Clips and Quick Release Toggles

Clips and quick release toggles shall be of stainless steel or aluminum.

8.7 Insulation and Metal Boxes for Outdoors

Insulation boxes fabricated of metal sheet with insulation installed inside the box shall be
custom fabricated for use over flanges, flanged valves, pumps, and other irregular
surfaces in cases where removability is required and removable covers are not suitable.
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 18 of 25 Rev: 2

The SUBCONTRACTOR shall submit the construction details to the CONTRACTOR for
approval before initiation of fabrication. Insulation boxes shall comply with the following
minimum requirements:
 The box shall have an integral metal flashing extending at least 50 mm
on the adjacent pipe insulation
 The boxes for valves shall cover the bonnet flange
 The boxes shall be constructed with 1.0 mm thick metal sheet. The box
shall have stainless steel latches and a metal identification tag.
 The insulation shall be of the same type and thickness as the adjacent
pipe or equipment insulation. Insulation shall be installed in such a way
that no gaps exist at the joints when the box is closed.

8.8 Removable Insulation Covers

Removable insulation inspection plugs or windows shall be installed to allow ultrasonic
testing and/ or CUI visual inspection without having to remove portions of the insulation
system. Installation locations where the removable plus or windows are to be installed
shall be determined and noted on piping and equipment drawings during detailed
engineering by CONTRACTOR. The design of the removable plug and windows shall be
approved by CONTRACTOR/OWNER prior to fabrication. Inspection window and
location sticker detail will be specified on RBI(Risk Based Inspection) report.
Removable insulation shall be used to the maximum extent for flanged items requiring
internal access or frequent maintenance. This includes, but is not limited to, valves,
flanges man ways, access openings which must be blinded for service of equipment
including spectacle blinds, strainers, filters, machinery and removable vessel and heat
exchanger heads.
Steam or electrically traced pumps shall be insulated with removable insulation covers.
Jacketed pumps shall be insulated with removable insulation covers.
Valves provided with removable insulation covers shall have an anti-vibration seal
incorporated in the annular space between the metal cover and the valve stem.
A removable cover insulation system shall be made of a minimum number of 2 pieces.
Joints shall be arranged to eliminate any water penetration into the insulation. The
weight of any single piece of cover shall not exceed 25 kg in accordance with the
following:
 Insulation cover shall be constructed so that their natural seam is
positioned on the gravitational bottom of the fitting
 Insulation cover shall fit tightly over fittings and protrusions and shall be
held in place with straps and stainless steel buckles. The insulation
covers shall be of a sufficient width to overlap the adjacent
weatherproofing by a minimum of 125 mm on each side of the fitting.
 Each piece of a removable cover shall have an embossed metal tag
permanently attached with applicable information such as equipment or
pipe line number size, rating and fitting type.
Removable covers for valves shall cover the body, bonnet and flanges as
applicable.
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 19 of 25 Rev: 2

Fabrication of pipe fitting covers, flange and valve covers, beveled lags and dished head
segments as applicable shall be in general accordance with the guideline of ASTM C450.
The insulation material shall be a mechanically bound glass fiber comprised of 100%
Type E glass, fabricated in needled mat form, having a density of 120 kg/m3 and
operational temperatures of up to 550°C.

8.9 Insulation Cover for Clamped support shoe

In case that clamped support shoe is applied on insulated line, the cover shall be
installed to prevent water ingress at clamp bolting parts, as below.
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 20 of 25 Rev: 2

9.0 APPENDICES
9.1 Appendix 1 : Acoustic Insulation for Vertical Pipe Support
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 21 of 25 Rev: 2

9.2 Appendix 2 : Personnel Protection Physical Barrier

The minimum distance between the hot surface and perforated sheet for personnel
protection shall be as per the following table for temperature 250°C and below.
Pipe diameter Minimum distance (mm)
<DN 150 50
DN 150 to DN 300 75
>DN 300 100
Equipment and flat surfaces 100
Wire mesh shall be stainless steel according to AISI Type 304 and the diameter shall be
3 mm with a mesh dimension of 50x50 mm. Perforated metal sheet shall be in
accordance with AISI Type 304 with thickness of 1mm, perforation holes of 5 mm, and
maximum of 40% free passage.
 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 22 of 25 Rev: 2

9.3 Appendix 3 : Insulation Thickness for Cellular Glass – Heat Conservation

 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 23 of 25 Rev: 2

9.4 Appendix 4 : Insulation Thickness for Rock Wool – Heat Conservation

 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 24 of 25 Rev: 2

9.5 Appendix 5 : Insulation Thickness for Ceramic Fibers – Heat Conservation

 Doc No:
MELAKA REFINERY EURO5-EPC-EXE-HEC-00-
PIP-SPN-0012
DIESEL EURO 5 PROJECT
(CONTRACT NO: CTC/PPM/2017/43) Date: 25-Jan-2019

INSULATION SPECIFICATION Page: 25 of 25 Rev: 2

9.6 Appendix 6 : Insulation Thickness for Rock Wool – Personnel Protection