SECTION 15250 PROCESS PIPE INSULATION

This spec was part of the Des Plaines, IL River WRF project that bid Feb 26, 2015.


SECTION 15250 PROCESS PIPE INSULATION

PART 1 GENERAL

1.1 SECTION INCLUDES

A. This Section includes preformed, rigid and flexible pipe insulation; insulating cements; field-applied jackets; accessories and attachments; and sealing compounds.

1.2 REFERENCES

A. ASTM International:
1. ASTM A167 - Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip.
2. ASTM B209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate.
3. ASTM C177 - Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot-Plate Apparatus.
4. ASTM C518 - Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus.
5. ASTM C533 - Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation.
6. ASTM C534 - Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form.
7. ASTM C547 - Standard Specification for Mineral Fiber Pipe Insulation.
8. ASTM C552 - Standard Specification for Cellular Glass Thermal Insulation.
9. ASTM C553 - Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications.
10. ASTM C592 - Standard Specification for Mineral Fiber Blanket Insulation and Blanket-Type Pipe Insulation (Metal-Mesh Covered) (Industrial Type).
11. ASTM C610 - Standard Specification for Molded Expanded Perlite Block and Pipe Thermal Insulation.
12. ASTM C612 - Standard Specification for Mineral Fiber Block and Board Thermal Insulation.
13. ASTM C921 - Standard Practice for Determining the Properties of Jacketing Materials for Thermal Insulation.
14. ASTM C1071 - Standard Specification for Thermal and Acoustical Insulation (Glass Fiber, Duct Lining Material).
15. ASTM C1136 - Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation.
16. ASTM C1290 - Standard Specification for Flexible Fibrous Glass Blanket Insulation Used to Externally Insulate HVAC Ducts.
17. ASTM E84 - Standard Test Method for Surface Burning Characteristics of Building Materials.
18. ASTM E96 - Standard Test Methods for Water Vapor Transmission of Materials.

19. ASTM E162 - Standard Test Method for Surface Flammability of Materials Using a Radiant Heat Energy Source.
20. ASTM G21 - Standard Practice for Determining Resistance of Synthetic Polymeric Materials to Fungi.

1.3 SUBMITTALS

A. Product data: Submit product data under provisions of Division 1, including the following:
1. Product description, list of materials and thickness for each service, and locations.

B. Submit manufacturer's installation instructions under provisions of Division 1.

1.4 QUALITY ASSURANCE

A. Manufacturer's Qualifications:  Firms regularly engaged in manufacture of mechanical insulation products, of types and sizes required, whose products have been in satisfactory use in similar service for not less than 3 years.

B. Installer Qualifications:  Skilled mechanics who have successfully completed an apprenticeship program or another craft training program certified by the U.S. Department of Labor, Bureau of Apprenticeship and Training.

C. Fire-Test-Response Characteristics: As determined by testing materials identical to those specified in this Section according to ASTM E 84 (NFPA 255) and UL 723 method, by a testing and inspecting agency acceptable to authorities having jurisdiction.  Factory label insulation and jacket materials and sealer and cement material containers with appropriate markings of applicable testing and inspecting agency.
1. Insulation Installed Indoors:  Flame-spread rating of 25 or less, and smoke- developed rating of 50 or less.
2. Insulation Installed Outdoors: Flame-spread rating of 75 or less, and smoke- developed rating of 150 or less.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Packaging: Ship insulation materials in containers marked by manufacturer with appropriate ASTM specification designation, type and grade, maximum use temperature, including fire hazard indexes of products.

B. Deliver, store, protect and handle products on site under the provisions of Division 1.

C. Store insulation in original wrapping and protect from weather and construction traffic.

D. Protect against dirt, water, and chemical and mechanical damage.

1.6 COORDINATION

A. Coordinate size and location of supports, hangers, and insulation shields specified in Division 15.

B. Coordinate clearance requirements with piping Installer for insulation application.

C. Coordinate installation and testing of electric heat tracing, included in Section 16857.

1.7 ENVIRONMENTAL REQUIREMENTS

A. Maintain ambient temperatures and conditions required by the manufacturers of adhesives, mastics, and insulation cements.

B. Maintain temperatures during and after installation for a minimum period of 24 hours.


PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers:  Subject to compliance with requirements, provide products by one of the following:
1. Process Piping Insulation:
a. CertainTeed Corporation.
b. Manville Products Corporation.
c. Owens-Corning Fiberglass Corporation.
d. Armstrong
e. Or equal.
2. Mineral-Fiber Insulation:
a. CertainTeed Manson.
b. Knauf FiberGlass GmbH.
c. Owens-Corning Fiberglas Corp.
d. Schuller International, Inc.
3. Flexible Elastomeric Thermal Insulation:
a. Armstrong World Industries, Inc.
b. Rubatex Corp.
4. Cellular Glass Insulation:
a. Pittsburgh Corning

2.2 INSULATION MATERIALS

A. Mineral-Fiber Insulation: Glass fibers bonded with a thermosetting resin complying with the following:
1. Preformed Pipe Insulation: Comply with ASTM C 547, Type 1, with factory- applied, all-purpose, vapor-retarder jacket.
2. Fire-Resistant Adhesive:  Comply with MIL-A-3316C in the following classes and grades:
a. Class 1, Grade A for bonding glass cloth and tape to unfaced glass-fiber insulation, for sealing edges of glass-fiber insulation, and for bonding lagging cloth to unfaced glass-fiber insulation.
b. Class 2, Grade A for bonding glass-fiber insulation to metal surfaces.
3. Vapor-Retarder Mastics:  Fire- and water-resistant, vapor-retarder mastic for indoor applications. Comply with MIL-C-19565C, Type II.
4. Mineral-Fiber Insulating Cements:  Comply with ASTM C 195.

5. Expanded or Exfoliated Vermiculite Insulating Cements: Comply with ASTM C 196.
6. Mineral-Fiber, Hydraulic-Setting Insulating and Finishing Cement:  Comply with ASTM C 449/C 449M.

B. Flexible Elastomeric Thermal Insulation: Closed-cell, sponge- or expanded-rubber materials. Comply with ASTM C 534, Type I for tubular materials and Type II for sheet materials.
1. Adhesive:  As recommended by insulation material manufacturer.
2. Ultraviolet-Protective Coating:  As recommended by insulation manufacturer.

C. Prefabricated Thermal Insulating Fitting Covers:  Comply with ASTM C 450 for dimensions used in preforming insulation to cover valves, elbows, tees, and flanges.

D. Cellular Glass Thermal Insulation: Glass material, closed-cell structure.  Insulation shall comply with ASTM C552.

1.
Adhesive:  As recommended by insulation material manufacturer.


2.3
       2.

JACKETS
Ultraviolet-Protective Coating:  As recommended by insulation manufacturer.

A. General: ASTM C 921, Type 1, unless otherwise indicated.

B. Foil and Paper Jacket:  Laminated, glass-fiber-reinforced, flame-retardant kraft paper and aluminum foil.

C. PVC Jacket:  High-impact, ultraviolet-resistant PVC; 20 mils (0.5 mm) thick; roll stock ready for shop or field cutting and forming.
1. Adhesive:  As recommended by insulation material manufacturer.
2. PVC Jacket Color: White or gray.

D. Standard PVC Fitting Covers: Factory-fabricated fitting covers manufactured from 20- mil- (0.5-mm-) thick, high-impact, ultraviolet-resistant PVC.
1. Shapes:  45- and 90-degree, short- and long-radius elbows, tees, valves, flanges, reducers, end caps, soil-pipe hubs, traps, mechanical joints, and P-trap and supply covers for lavatories for the disabled.
2. Adhesive:  As recommended by insulation material manufacturer.

E. Aluminum Jackets:
1. Cover piping and insulation with 0.016-inch thick aluminum jacket.
2. Hold jacket in place by a continuous friction type joint, providing a positive weatherproof seal over entire length of jacket.
3. Secure the circumferential joints with preformed snap straps containing weatherproof sealant.
4. Cover outdoor fittings with matching preformed aluminum jackets, two-piece elbows and flange covers, secured with stainless steel bands.
5. Provide fitting covers as manufactured by Childers, Papco, or equal.

2.4 ACCESSORIES AND ATTACHMENTS

A. Glass Cloth and Tape:  Comply with MIL-C-20079H, Type I for cloth and Type II for tape. Woven glass-fiber fabrics, plain weave, presized a minimum of 8 oz./sq. yd. (270 g/sq. m).
1. Tape Width: 4 inches (100 mm).

B. Bands: 3/4 inch (19 mm) wide, in one of the following materials compatible with jacket:
1. Stainless Steel: ASTM A 666, Type 304; 0.020 inch (0.5 mm) thick.
2. Aluminum:  0.007 inch (0.18 mm) thick.
3. Nickel-Copper Alloy:  0.005 inch (0.13 mm) thick.

C. Wire: 0.080-inch (2.0-mm), nickel-copper alloy; 0.062-inch (1.6-mm), soft-annealed, stainless steel; or 0.062-inch (1.6-mm), soft-annealed, galvanized steel.

2.5 VAPOR RETARDERS

A. Mastics: Materials recommended by insulation material manufacturer that are compatible with insulation materials, jackets, and substrates.


PART 3 EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions for compliance with requirements for installation and other conditions affecting performance of insulation application.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 PREPARATION

A. Surface Preparation:  Clean and dry pipe and fitting surfaces. Remove materials that will adversely affect insulation application.

3.3 GENERAL APPLICATION REQUIREMENTS

A. Apply insulation materials, accessories, and finishes according to the manufacturer's written instructions; with smooth, straight, and even surfaces; free of voids throughout the length of piping, including fittings, valves, and specialties.

B. Refer to schedules at the end of this Section for materials, forms, jackets, and thicknesses required for each piping system.

C. Use accessories compatible with insulation materials and suitable for the service. Use accessories that do not corrode, soften, or otherwise attack insulation or jacket in either wet or dry state.

D. Apply insulation with longitudinal seams at top and bottom of horizontal pipe runs.

E. Apply multiple layers of insulation with longitudinal and end seams staggered.

F. Do not weld brackets, clips, or other attachment devices to piping, fittings, and specialties.

G. Seal joints and seams with vapor-retarder mastic on insulation indicated to receive a vapor retarder.

H. Keep insulation materials dry during application and finishing.

I. Apply insulation with tight longitudinal seams and end joints.  Bond seams and joints with adhesive recommended by the insulation material manufacturer.

J. Apply insulation with the least number of joints practical.

K. Apply insulation over fittings, valves, and specialties, with continuous thermal and vapor- retarder integrity, unless otherwise indicated.  Refer to special instructions for applying insulation over fittings, valves, and specialties.

L. Hangers and Anchors: Where vapor retarder is indicated, seal penetrations in insulation at hangers, supports, anchors, and other projections with vapor-retarder mastic.
1. Apply insulation continuously through hangers and around anchor attachments.
2. For insulation application where vapor retarders are indicated, extend insulation on anchor legs at least 12 inches (300 mm) from point of attachment to pipe and taper insulation ends. Seal tapered ends with a compound recommended by the insulation material manufacturer to maintain vapor retarder.
3. Install insert materials and apply insulation to tightly join the insert. Seal insulation to insulation inserts with adhesive or sealing compound recommended by the insulation material manufacturer.
4. Cover inserts with jacket material matching adjacent pipe insulation.  Install shields over jacket, arranged to protect the jacket from tear or puncture by the hanger, support, and shield.

M. Insulation Terminations:  For insulation application where vapor retarders are indicated, taper insulation ends. Seal tapered ends with a compound recommended by the insulation material manufacturer to maintain vapor retarder.

N. Apply adhesives and mastics at the manufacturer's recommended coverage rate.

O. Apply insulation with integral jackets as follows:
1. Pull jacket tight and smooth.
2. Circumferential Joints:  Cover with 3-inch- (75-mm-) wide strips, of same material as insulation jacket.  Secure strips with adhesive and outward clinching staples along both edges of strip and spaced 4 inches (100 mm) o.c.
3. Longitudinal Seams:  Overlap jacket seams at least 1-1/2 inches (40 mm).  Apply insulation with longitudinal seams at bottom of pipe. Clean and dry surface to receive self-sealing lap. Staple laps with outward clinching staples along edge at 4 inches (100 mm) o.c.
a. Exception:  Do not staple longitudinal laps on insulation having a vapor retarder.

4. Vapor-Retarder Mastics: Where vapor retarders are indicated, apply mastic on seams and joints and at ends adjacent to flanges, unions, valves, and fittings.
5. At penetrations in jackets for thermometers and pressure gages, fill and seal voids with vapor-retarder mastic.

P. Roof Penetrations:  Apply insulation for interior applications to a point even with top of roof flashing.
1. Seal penetrations with vapor-retarder mastic.
2. Apply insulation for exterior applications tightly joined to interior insulation ends.
3. Extend metal jacket of exterior insulation outside roof flashing at least 2 inches (50 mm) below top of roof flashing.
4. Seal metal jacket to roof flashing with vapor-retarder mastic.

Q. Exterior Wall Penetrations: For penetrations of below-grade exterior walls, terminate insulation flush with mechanical sleeve seal.  Seal terminations with vapor-retarder mastic.

R. Interior Wall and Partition Penetrations: Apply insulation continuously through walls and floors.

S. Fire-Rated Wall and Partition Penetrations:  Apply insulation continuously through penetrations of fire-rated walls and partitions.

T. Floor Penetrations:  Apply insulation continuously through floor assembly.
1. For insulation with vapor retarders, seal insulation with vapor-retarder mastic where floor supports penetrate vapor retarder.

3.4 MINERAL-FIBER INSULATION APPLICATION

A. Apply insulation to straight pipes and tubes as follows:
1. Secure each layer of preformed pipe insulation to pipe with wire, tape, or bands without deforming insulation materials.
2. Where vapor retarders are indicated, seal longitudinal seams and end joints with vapor-retarder mastic. Apply vapor retarder to ends of insulation at intervals of 15 to 20 feet (4.5 to 6 m) to form a vapor retarder between pipe insulation segments.
3. For insulation with factory-applied jackets, secure laps with outward clinched staples at 6 inches (150 mm) o.c.
4. For insulation with factory-applied jackets with vapor retarders, do not staple longitudinal tabs but secure tabs with additional adhesive as recommended by the insulation material manufacturer and seal with vapor-retarder mastic.

B. Apply insulation to flanges as follows:
1. Apply preformed pipe insulation to outer diameter of pipe flange.
2. Make width of insulation segment the same as overall width of the flange and bolts, plus twice the thickness of the pipe insulation.
3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with mineral-fiber blanket insulation.

C. Apply insulation to fittings and elbows as follows:
1. Apply premolded insulation sections of the same material as straight segments of pipe insulation when available. Secure according to manufacturer's written instructions.
2. When premolded insulation elbows and fittings are not available, apply mitered sections of pipe insulation, or glass-fiber blanket insulation, to a thickness equal to adjoining pipe insulation.  Secure insulation materials with wire, tape, or bands.
3. Cover fittings with standard PVC fitting covers.

D. Apply insulation to valves and specialties as follows:
1. Apply premolded insulation sections of the same material as straight segments of pipe insulation when available. Secure according to manufacturer's written instructions.
2. When premolded insulation sections are not available, apply glass-fiber blanket insulation to valve body. Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.  For check valves, arrange insulation for access to stainer basket without disturbing insulation.
3. Apply insulation to flanges as specified for flange insulation application.
4. Use preformed standard PVC fitting covers for valve sizes where available. Secure fitting covers with manufacturer's attachments and accessories. Seal seams with tape and vapor-retarder mastic.
5. For larger sizes where PVC fitting covers are not available, seal insulation with canvas jacket and sealing compound recommended by the insulation material manufacturer.

3.5 FLEXIBLE ELASTOMERIC THERMAL INSULATION APPLICATION

A. Apply insulation to straight pipes and tubes as follows:
1. Follow manufacturer's written instructions for applying insulation.
2. Seal longitudinal seams and end joints with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

B. Apply insulation to flanges as follows:
1. Apply pipe insulation to outer diameter of pipe flange.
2. Make width of insulation segment the same as overall width of the flange and bolts, plus twice the thickness of the pipe insulation.
3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with cut sections of sheet insulation of the same thickness as pipe insulation.
4. Secure insulation to flanges and seal seams with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

C. Apply insulation to fittings and elbows as follows:
1. Apply mitered sections of pipe insulation.
2. Secure insulation materials and seal seams with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

D. Apply insulation to valves and specialties as follows:
1. Apply preformed valve covers manufactured of the same material as pipe insulation and attached according to the manufacturer's written instructions.
2. Apply cut segments of pipe and sheet insulation to valve body.  Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.  For check valves, fabricate removable sections of insulation arranged to allow access to stainer basket.
3. Apply insulation to flanges as specified for flange insulation application.
4. Secure insulation to valves and specialties and seal seams with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

3.6 CELLULAR GLASS THERMAL INSULATION APPLICATION

A. Apply insulation to straight pipes and tubes as follows:
1. Follow manufacturer's written instructions for applying insulation.
2. Seal longitudinal seams and end joints with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

B. Apply insulation to flanges as follows:
1. Apply pipe insulation to outer diameter of pipe flange.
2. Make width of insulation segment the same as overall width of the flange and bolts, plus twice the thickness of the pipe insulation.
3. Fill voids between inner circumference of flange insulation and outer circumference of adjacent straight pipe segments with cut sections of sheet insulation of the same thickness as pipe insulation.
4. Secure insulation to flanges and seal seams with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

C. Apply insulation to fittings and elbows as follows:
1. Apply mitered sections of pipe insulation.
2. Secure insulation materials and seal seams with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

D. Apply insulation to valves and specialties as follows:
1. Apply preformed valve covers manufactured of the same material as pipe insulation and attached according to the manufacturer's written instructions.
2. Apply cut segments of pipe and sheet insulation to valve body.  Arrange insulation to permit access to packing and to allow valve operation without disturbing insulation.  For check valves, fabricate removable sections of insulation arranged to allow access to stainer basket.
3. Apply insulation to flanges as specified for flange insulation application.
4. Secure insulation to valves and specialties and seal seams with manufacturer's recommended adhesive.  Cement to avoid openings in insulation that will allow passage of air to the pipe surface.

3.7 JACKET APPLICATION

A. Apply glass-cloth jacket, where indicated, directly over bare insulation or insulation with factory-applied jackets.
1. Apply jacket smooth and tight to surface with 2-inch (50-mm) overlap at seams and joints.
2. Embed glass cloth between two 0.062-inch- (1.6-mm-) thick coats of jacket manufacturer's recommended adhesive.
3. Completely encapsulate insulation with jacket, leaving no exposed raw insulation.

B. Foil and Paper Jackets:  Apply foil and paper jackets where indicated.
1. Draw jacket material smooth and tight.
2. Apply lap or joint strips with the same material as jacket.
3. Secure jacket to insulation with manufacturer's recommended adhesive.
4. Apply jackets with 1-1/2-inch (40-mm) laps at longitudinal seams and 3-inch- (75-mm-) wide joint strips at end joints.
5. Seal openings, punctures, and breaks in vapor-retarder jackets and exposed insulation with vapor-retarder mastic.

C. Apply PVC jacket where indicated, with 1-inch (25-mm) overlap at longitudinal seams and end joints.  Seal with manufacturer's recommended adhesive.

3.8 FINISHES

A. Glass-Cloth Jacketed Insulation:  Paint insulation finished with glass-cloth jacket as specified in Division 9.

B. Flexible Elastomeric Thermal Insulation: After adhesive has fully cured, apply two coats of the insulation manufacturer's recommended protective coating.

3.9 PIPING SYSTEM APPLICATIONS

A. Insulation materials and thicknesses are specified in schedules at the end of this Section.

3.10 FIELD QUALITY CONTROL

A. Inspection:  Perform the following field quality-control inspections, after installing insulation materials, jackets, and finishes, to determine compliance with requirements:
1. Inspect fittings and valves randomly selected by Engineer.

B. Insulation applications will be considered defective if sample inspection reveals noncompliance with requirements.  Remove defective Work and replace with new materials according to these Specifications.

C. Reinstall insulation and covers on fittings and valves uncovered for inspection according to these Specifications.

3.11 INSULATION APPLICATION SCHEDULE, GENERAL

A. Refer to insulation application schedules for required insulation materials, vapor retarders, and field-applied jackets.

B. Application schedules identify piping system and indicate pipe size ranges and material, thickness, and jacket requirements.

3.12 INTERIOR INSULATION APPLICATION SCHEDULE

A. Service: Insulate all process piping indicated on pipe schedule drawing 100-M-1:
1. Operating Temperature:  As Scheduled (2 to 49 deg C).
2. Insulation Material: Mineral fiber.
3. Insulation Thickness:
a. For pipe sizes up to and including 1-inch: 1-inch minimum.
b. For all pipe sizes 1-1/4-inch and above: 1.5-inch thick minimum.
4. Jacket: Foil and Paper.
5. Vapor Retarder Required: Yes.
6. Finish:  Painted.

3.13 EXTERIOR INSULATION APPLICATION SCHEDULE

A. Service: Process piping indicated on pipe schedule drawing 100-M-1:
1. Operating Temperature:  As Scheduled (2 to 49 deg C).
2. Insulation Material: Mineral fiber.
3. Insulation Thickness:
a. For pipe sizes up to and including 1-inch: 1-inch minimum.
b. For all pipe sizes 1-1/4-inch and above: 1.5-inch thick minimum.
4. Jacket: Aluminum.
5. Vapor Retarder Required: No.
6. Finish:  None.

END OF SECTION