Plant Project No.

Client/Consultant Doc ID Code

Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Project Phase 1

Cold insulation Procedure

De-Methanizer 10-V-106 REV. 00 Attached Pages 25
EGY. Office

Cold insulation Procedure

De-Methanizer 10-V-106

00 IFE ISSUED FOR APPROVAL 09-08-2023 A.Ibrahim 09-08-2023 M.M 09-08-2023 AMIR

Rev. Status Description Date Prepared Date Checked Date Approved AC

Category Code:

1 Barcode
 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Project Phase 1

Cold insulation Procedure

De-Methanizer 10-V-106 REV. 00 Attached Pages 25
EGY. Office

Table of content
1.0 GENERAL

2.0 SCOPE

3.0 References

4.0 DEFINITIONS

5.0 INSULATION MATERIALS

6.0 BASIC PROCEDURE

6.1 Scope of Work & Explanation of Procedure
6.2 Release Note

7.0 INSTALLATION OF Cold INSULATION

7.1 Equipment Insulation
7.2 VALVES & FLANGES
7.3 INSULATION SUPPORT RINGS
7.4 EXPANSION JOINTS
7.5 Vessel Skirts & Heads

8.0 WEATHER PROTECTION INSTALLATION PROCEDURE

9.0 INSTALLATION OF SOUND INSULATION

10.0 QUALITTY CONTROL

Attachment:
Materials data sheet
 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

1. GENERAL
The purpose of this procedure is ensure that the requirements for the supply and installation of cold insulation for heat
conservation & anti sweat purposes comply with the project technical specifications titled Project Specification No05027-
200-400-008 Rev 1
2. SCOPE

This documentation applies for cold insulation scope of work for De-Methanizer Equipment in Western Desert Gas Complex
– Train D Project. This document describes the minimum technical requirements related to the application of cold insulation
system using cellular glass insulant & aluminum weather jacketing, material specifications, installation method of statement,
storage requirements, safety precautions as well as quality control & inspection.
3. References, Codes, Standard & Regulations:

Standard Description

Doc No 0000-000-400-208 Enppi Standard Specification Rev 2

ASTM C 522 Standard specification for cellular glass thermal insulation

ASTM C1136 Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation

ASTM C1423 Standard Guide for Selecting Jacketing Materials for Thermal Insulation

ASTM C168 Standard terminology relating to thermal insulating materials

ASTM C240 Standard test methods of testing cellular glass insulation block

ASTM C755 Selection of vapor retarders for thermal insulation

Standard specification for thermal insulation for use in contact with austenitic stainless
ASTM C795
steel

ASTM E84 Standard test method for surface burning characteristics of building materials

ASTM E96 Standard test method for water vapor transmission of material

4. DEFINITIONS
4.1 Client
Egyptian Natural Gas Company (GASCO)
4.2 Consultant
Engineering for the Petroleum & Process Industries (ENPPI)

4.3 Main Contractor

The Petroleum Projects & Technical Consultations Company (PETROJET)

4.4 Insulation subcontracting

Egyptian Office For Thermal Insulation Works

 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

5-INSULATION M A T E R I A L S

Item
Material Category Manufacturer Origin
no.
Cellular glass block and fabricated sections shall
Insulation
conform to ASTM C552, GRADE 1, TYPES I, II,
materials for Cold
AND III, including annexes, and be fabricated to
1 applications Glass Rock EGYPT
the dimensions OF ASTM C450.
Egypt
Aluminum flat /plain and smooth for head
Weather protective
segments/fittings, corrugated for shells, sheets Insu-W-
Jacketing over
2 0.6 0mm thicknesses with factory applied Rapid
Polysurlyn moisture barrier – Alloy 3003 insulation Europe
Conformed to ASTM B209
a) Stainless steel Bands 19 mm width and 0.5
mm thickness 304 Stainless Steel Band with
matching seals shall be used when the
insulation outside diameter is over 24 inch
3 Accessories
b)Wing Seals : Material 304 stainless steel and
width shall be 19 mm Insu-W- Europe & USA
Rapid & rpr

4 A factory coating of ASTM D 312 Type II or III

hot asphalt shall be applied on the exterior Anti-Abrasion Local
curved surfaces and interior bore of all Compound NIROL-W
layers. The bore coating may be field-applied
VAPOR BARRIERS:
Vapor Barrier
a)For uniform shapes : Membrane type vapor
Butyl Rubber Self Europe
barrier sheet shall be installed without fish Adhesive Vapor
Barrier Membrane Insu-W-Rapid
mouthing gaps or folds and shall have a minimum
5 r
50-mm (2-in) overlap at all joints.

Vapor Barrier For Non-Uniform/irregular shapes Bico Industries Romania

like flanges, fittings, etc.: Fiberglass Mesh 75 Foster 65-05
EU
gm/sqm impregnated
Reinforcing membrane for vapor retardant in mastic
6
mastic shall be a leno weaves, synthetic fabric,
with a maximum 8 x 8 mesh density
Mastic shall be applied in two coats, total 3 mm
film thickness

Insulation contraction joint material shall be a

7 16 to 24 kg/m³ nominal density un-faced
fiberglass blanket, consisting of random
oriented fiberglass, suitable for service from -
 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

198°C to 232°C Glass Rock Local

A 4-inch long by 2-inch wide Breather Spring

Contraction Joint
shall be used for vessels and equipment for
insulating external diameters over 1800 mm. The RBR Products USA
Material shall be stainless steel AISI 302 or
approved equal.

Sealant for aluminum cladding: Sealant tape Joint Sealant AIRTECH

8 USA
Butyl Rubber based used as vapor barrier sealant Cellular Glass Joint Foster 95-50
in joints of cellular glass Sealant

Toggle Clips: Stainless Steel 304 toggles - 2" long Ancillaries Insu-W-Rapid Europe
9 for securing the valve and flange caps securements

6- BASIC PROCEDURES

Scope of work & Explanation of procedure

The basic activities for Deep Cut project shall be:

▪ Supply the Cold insulation, weather protection & ancillaries as per attached material List table.
▪ Installation of insulation for equipment/vessels according to the project specification & client requirements.
▪ Installation and Securing of outer metal cladding.

This procedure of activities including quality control checks for insulation work.
A copy of the attached manufacturer product DATA SHEETS and this application manual will be available at site throughout
the duration of the project.
Release Note

Prior to commencement of insulation, an approved release shall be issued from PETROJET for release of any equipment, the
concerned engineer / authorized person will sign the Release Note and hand over to the insulation subcontractor. No
activities will be carried out without release note in order to avoid problems at a later stage. The release note receipt should
be signed by PETROJET QC or representative
In general, the insulation shall not commence unless the followings are completed:

▪ Required hydrostatic and/or pneumatic pressure testing

▪ Application of required substrate protective coating systems, including touch-up of previously applied coatings.
▪ Installation and testing of required tracing systems.
▪ Cleaning of surfaces that are to receive insulation.
 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

7- INSTALLATION OF Cold Insulation:

Equipment Insulation:

▪ Surfaces to be insulated shall be free from oil, grease, dirt and other foreign materials.
▪ Surfaces to be dry and if painted, shall be conformed to client instructions. All Paints on surfaces to be insulated should
be dry.
▪ Cellular glass blocks/sections shall be coated internally with anti-abrasion compound NIROL-W bitumen emulsion will
be applied according to the manufacturer instruction & attached datasheet.
▪ Cellular glass sections shall be cut to fit the outer circumference of the insulated equipment. They shall be laid with
closely butted joints.
▪ Foster 95-50 Joint sealer to be applied on all joints for single layer installation & for the outer layer only in multi layers
insulation
▪ Insulation shall be secured with banding & wing seals spaced 9-inches centered.
▪ For applications requires insulation thickness up to
100mm the insulation materials shall be supplied as
one layer, over 100mm the insulation materials shall
be supplied in Multi-layers. In Multi layers
applications, Cellular glass joints shall be staggered
ways in both longitudinal & circumferential
directions.
▪ Thickness of cellular glass insulation shall be
conformed to specifications no. 0000-000-400-0208
Rev 2, equipment data sheet & drawings.
▪ Before application of the aluminum jacket & on the
external layer of the insulation only, a vapor barrier of
butyl rubber self-adhesive membrane will be applied
on uniform shapes only
▪ Section of membrane will be cut to fit the required
circumferences
▪ Membrane will be applied with overlapping minimum
50 mm.
▪ Rain sheds to be respected for overlaps
▪ Rollers or hand-pressure will be applied to ensure
adequate adhesion & gap-free installation.
▪ As an alternative when application of the membrane
sheet is not possible for irregular shapes, Foster 65-05
mastic vapor barrier reinforces by a wire mesh will be
used
▪ Tack coat is applied first of the specified mastic,
followed by placing the membrane and application of
the finish coat within maximum one hour of tack coat application.
▪ Complete coverage of the membrane shall be ensured, smooth & free of wrinkles membrane
▪ The Vapor barrier shall be applied at least 150 mm beyond the end of the insulation applied to projections

7.1 VALVES & FLANGES

• Flanges & valve boxes shall be insulated with the same thickness of the adjoining equipment
 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

• The valves & flanges boxes shall be fixed by means of toggle clips
• The valves and flanges insulation boxes shall be extended to a distance of 25mm plus the flanges bolt length to allow
ease maintenance for valves & flanges boxes without any damage to the existing piping insulation.
• The fabrication and installation shall be conformed to specification
7.2 Expansion /Contraction Joints

• Unless stipulated by a drawing, the contraction joints are provided to

compensate the thermal movements
• Below the insulation support expansion joints shall be installed
The thickness of the covering insulant has to be minimum 50% of
equipment insulation
thickness and has to overlap at both sides minimum 100 mm. The mineral
wool inside the gap must not be compressed during installation.
• Where insulation is applied in multi layers, each layer shall have
staggered expansion joint.
• Contraction Joints spacing shall be as indicated
A Anti- abrasion component to be applied & insulation with a beveled joint
BExpansion joint filler (Mineral Wool)
CAnti-slip Mastic
DSealing Mastic
7.3 Vessels Skirts & Heads, :

The vessel shell insulation shall extend down the skirt to the insulation support ring. The top section
of the inside of the skirt shall also be insulated to the support ring

For vessel head, cellular glass section be suitably cut shaped. Floating ring made of steel rod shall be
placed in the center of the head. circumferential straps shall be placed on the shell, over the insulation, to
form a girth. Radial straps shall be placed between floating ring and girth with maximum pitch of 200 mm
Approved adhesive for bonding insulation to substrates where use of mechanical fasteners is not
practical shall be a used to aid fixation

8 Weather protection installation procedure

▪ Flat aluminum jacket is proposed for installation due to local market limitations for stucco embossed sheets.
▪ The weather protection metal will be cut to size, rounded and placed concentric with longitudinal & circumferential
overlap of minimum 50mm.
▪ The jacketing shall always be water proofed and shall be fixed in such a way to shed water.
▪ The longitudinal joints will be arranged on horizontal centerline.
▪ The joints on vertical lines shall be arranged away from prevailing winds wherever possible.
▪ The weather protection metal shall be fixed by means of Stainless steel banding with seals 200 mm spaced, with one
banding at each lap
▪ All cut outs and gaps shall be sealed with metal sealant.
▪ On vertical lines “S” clip fabricated from S.S bands 19 X 0.5mm will be inserted at joints to avoid any slippage of
cladding material.
 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

9 QUALITY CONTROL

The quality of the insulation depends on strict adherence to specification and stringent supervision throughout the execution
of insulation works.
Before performance of any insulation works the insulation, contractor shall establish an adequate quality control system for
insulation work. To ensure that the quality requirements as stated in the specifications are achieved, a number of measures
shall be taken:
▪ At the earliest stage of the works, it shall be decided all flanges and valves shall be insulated.
▪ Inspection Department of the client shall be consulted in order to establish what has to be inspected in relation to
insulated surfaces.
▪ Detailed job planning shall take place with other disciplines to avoid damages of newly installed insulation jacketing.
▪ All steel surfaces to be insulated shall be dry, clean and free of rust, loose mill scale, grease and dirt before the
application of insulation.
▪ Protective coatings shall be checked and approved by client before insulation starts.
▪ The insulation and jacketing material shall be kept thoroughly dry during and after its installation.
▪ Metal jacketing shall be fitted soon after the insulation.
▪ Checking of all insulation joints that they are closely butted before installation of the jacketing.
▪ Electrical/instrumentation cables or piping shall not be fixed to the jacketing of insulated surfaces.
▪ Immediately on arrival of the jacketing material on site the supply shall be checked that the seaworthy packing is still
undamaged.
▪ In case of damage of the packing, the sheeting has to be separated when flat sheeting or declined when coils are
supplied
▪ All insulation material & accessories samples will be submitted prior to use for approval
▪ Internal inspection will be performed by our side to ensure compliance with specification according to the attached ITP
& Inspection Check List

Inspection Check List

INSPECTION CHECKLIST

ITEM YES NO COMMENTS

A. Safety

1.All appropriate safety equipment is present and in use.

2.Appropriate Manufacturer safety data sheets (msds) are

available.

3.All personnel have received safety training appropriate to do the

job.

4.Housekeeping in compliance with site requirements.

B. Material

1. All materials have been received in approved condition.

 Plant Project No.
Client/Consultant Doc ID Code
Western Desert Gas GASCO/ENPPI EGO-MOS-000099-00 Deep Cut Ethane Recovery
Complex – Train D Phase 1
Project

Cold insulation Procedure

EGY. Office De-Methanizer 10-V-106
REV. 00 Attached Pages 25

2. All materials have been stored in a manner that prevents

contamination by water or process chemicals or physicaldamage.

3. The materials are correct per the project specifications.

4. Insulation samples have been obtained for testing.

C. Insulation Installation

1. All required testing is complete and systems released for insulation by

the appropriate authority.

2. The surface to be insulated is clean and dry.

3. The surface to be insulated has been coated and released for insulation
by the appropriate authority.

4. Existing installed insulation is protected from damage.

5. All insulation supports are installed properly.

6. The insulation is the correct thickness and numbers of layers

7. All joints are correctly staggered.

8-Joints are cut & fit to maximum 1/8 inches

9. The insulation securement is correct.

10. Vapour barrier is correctly installed and undamaged.

11. All joints are sealed / buttered.
12. Contraction joints are correctly installed and spaced.

13. The extent of insulation is correct.

14. Contraction springs are correctly installed and spaced.

D. Installation, Weatherproofing, Jacketing and Fitting Covers

1. The correct material has been used (type, thickness, finish, etc.).
2. Metal jacket overlap, amount and placement, are correct.
3. Metal jacket securement is correct.

4. Mastic type, thickness, reinforcement and overlap are correct

5. Joints are properly caulked / sealed.

6. Flashing is properly installed.

7. Metal gores are properly installed.

S clips are used as specified

9. Contraction springs are correctly installed and spaced.

10. Securement is properly spaced.
11. Banding ends and seals are configured to prevent sharp ends.

12. All terminations have been caulked / sealed.

E. Installation Flanges, Valves and Equipment

1.Allowance for bolt removal is correct.

2.Removable/reusable covers properly made and installed.
3.Jacketing properly caulked.

4.Valve extension handles are installed.

F. Workmanship
1. The workmanship are skilled