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UNION CARBIDE CORPORATION Chemicals and Plastics UCC 002600 .* ; '*> ` STANDARD CMUaCAL* AMD PLASTICS CONTENTS APPLICATOR TRAINING PAGE i APRIL 1970 CHAPTER I II III CONTENTS TITLE INTRODUCTION HISTORY OF THE INSULATION INDUSTRY Asbestos and 80% Magnesia Mineral Wool Cork Diatomaceous Silica Structural Insulating Board Metal Type Reflective insulation Expanded Silica Insulation Cellular Glass Polystyrene Insulation Rigid Polyurethane Insulation Glass Fiber Insulation Cryogenic Insulation FUNCTION Heat Transfer PURPOSE General Commercial Insulation Industrial insulation Hot Temperature Service Moderate Temperature Service Low Temperature Service Cryogenic Service Tracing Systems Hot Temperature Tracing Systems Moderate Temperature Tracing Systems Economics PAGE *1 10 11 14 16 18 19 20 22 23 24 24 25 25 28 28 51 51 51 52 52 53 53 54 54 54 55 55 UCC 002601 STANDARD ORWCMJlIWPUinCI CONTENTS APPLICATOR TRAINING PAGE ii APRIL 1970 CHAPTER IV V VI Vlf CONTENTS TITLE TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES Mass insulation Reflective Insulation Properties of Insulation Materials Tables of Properties of Various Insulations PAGE 65 65 67 69 79 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS 86 Function of Weather-Barriers, Vapor-Barriers, and Coverings Requirements Imposed on Weather-Barriers, Vapor-Barriers, and Coverings Properties of Weather-Barrier, Vapor-Barriers, and Coverings Properties of Jackets and Their Significance Properties of Mastics and Their Significance Properties of Accessories Used with Weather-Barrier, Vapor-Barriers, and Coverings Types of Weather-Barrier, Vapor-Barriers, and Coverings 86 91 94 94 101 no no INSTALLATION REQUIREMENTS Thermal Properties Physical Properties Physical Properties of Materials Which Are Not Rigid Chemical Requirements Moisture Requirements Fire Safety Requirements Summary 116 117 117 123 125 126 127 127 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS 128 Summary of Individual Specifications 133 UCC 002602 STANDARD CMCWCAU AID fUtTKJ CONTENTS APPLICATOR TRAINING PAGE III APRIL 1970 CHAPTER VIII IX X XI XII xm CONTENTS TITLE TOOLS REQUIRED Hand Tools Power Tools ESTIMATING THE INSTALLED COST Introduction Information for Estimate Basis Preparation of the Estimate Conclusion Responsibility SHOP AND FIELD FABRICATION Design of Fitting and Vessel Insulation Covers Shop and Shop Practices INSULATION SUPPORTS AND SECUREMENTS Supports Securements GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF HEAT TRACER SYSTEMS General Preparation of insulation Systems Heat Transfer Cemented Tracer Systems - Piping Heat Transfer Cemented Tracer Systems - Equipment APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE General Equipment Piping Weather Barrier UCC 002603 PAGE 152 152 160 161 161 161 165 183 183 185 190 193 224 224 244 251 251 255 266 274 274 274 276 286 STANDARD otmcMA aw pufno CONTENTS APPLICATOR TRAINING PAGE iv APRIL 1970 CHAPTER XIV XV XVI XVII -C--O--N--T--E--N---T--S- TITLE APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE General Equipment Piping Weather-Barriers APPLICATION OF SEMI-RIGID INSULATION MODERATE AND HOT TEMPERATURE SERVICE General Equipment Piping Weather-Barrier APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERATE TEMPERATURE SERVICE General Equipment Piping Finish and Weather-Barriers APPLICATION OF PREFABRICATED PANEL INSULATION MODERATE AND HIGH TEMPERATURE SERVICE General Installation of Ribbed Jacketed Panels to Vessels Application - Sidewall Insulation Installation of Smooth Jacket Panels to Vessels Application - Sidewalls PAGE 288 288 292 304 308 311 311 31 j 315 316 318 318 318 320 322 324 324 324 327 329 331 UCC 002604 i t L L L L L L L L L- STANDARD ommCMS AND RLASTO CONTENTS APPLICATOR TRAINING PAGE v APRIL 1970 CONTENTS CHAPTER XVIII TITLE PAGE APPLICATION OF PREFABRICATED REFLECTIVE INSULATION MODERATE AND HIGH TEMPERATURE SERVICE 336 General Application of Prefabricated Reflective Insulation 336 336 XIX APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE SERVICE 345 General Application of Sprayed Asbestos Insulation Application of Insulation to Flanges and Flange Bolts 345 345 352 XX APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE Application of Sprayed Urethane Equipment and Its Operation Application of Weather-Barrier XXI APPLICATION OF WEATHER-BARRIERS Application of Mastic Weather-Barrier Application of Metal Jacket Weather-Barrier Application - Equipment Application - Piping 355 355 256 365 367 367 380 381 384 XXII APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Field Applied Insulation Factory Insulated Pipe and Conduit Urethane Foam Insulation, PVC Jacket Conduit Insulated Metal Conduit Fill Type Insulation Preparation Application Trench Backfilling 386 38$ 394 394 397 404 404 404 407 UCC 002605 $ STANDARD CONTENTS APPLICATOR TRAINING PAGE vi APRIL 1970 CHAPTER XXIII CONTENTS TITLE SAFETY AND HEALTH Definition Safety Regulations Protection from Personal Injuries First Aid, Report of Accidents, and General Policy on Emergency Situations Health Problems Precautions in Application Fires and Explosion Hazards Prevention of Potential Fires by Use of Leak indicators Maintenance of Insulation List of Reactive Chemicals APPENDIX INDEX PAGE 408 408 408 409 416 417 417 426 429 431 432 434 499 UCC 002606 STANDARD CHtHCALS AtO fLUTIO INTRODUCTION APPLICATOR TRAINING PAGE 1 APRIL 1970 INTRODUCTION In Hie following chapters the theory of heat transfer is explained, the properties of materials will be discussed, the influence of requirements as affecting materials and their application will be presented. Complete understanding of these are essential to become a proficient insulator. However, additional knowledge and skills are also necessary. The training program has for its purpose the systematic training of craftsmen through a formal program. In order to develop well-trained craftsmen, related instruction courses and work experience are programmed for each trainee. One of the instruction courses presented is this course "Insulation Application." Two other courses are required to provide the theory and knowledge necessary for insulation applicator craftsmen. These are "Blueprint Reading and Sketching" and "Basic Mathematics." Some of the items covered in a course of Blueprint Reading and Sketching are as follows: I. Blueprint Reading 1. Meaning of standard drafting symbols 2. Types of lines (center lines, visible lines, invisible lines, dimension lines, extension lines) 3. Measuring and use of scale, i.e. 1/4" = 1 '0", 3/8" = 1 'O" and 1/2" * 1 '0" 4. Relation of plan and elevation views 5. Sections 6. Details 7. Reading and interpreting shop sketches II. Drawing 1. Drawing to scale 2. Drawing plans, elevations, sections, details 3. Making field sketches III. Interpretations of Drawings and Specifications 1. Read and interpret specification 2. Read and interpret fabrication manual 3. Make material take offs UCC 002607 STANDARD oieUMftAiina INTRODUCTION APPLICATOR TRAINING PAGE 2 APRIL 1970 INTRODUCTION Under "Basic Mathematics" I. Basic arithmetic II. Conversion of fractions to decimals and reverse III. Use of simple formulas IV. Geometric Math 1. Angles, planes 2. Geometric figures 3. Calculation of areas, surfaces, etc. In addition to the knowledge of these subjects, it is equally important to develop the skill of workmanship. This can only be accomplished by practice,doing a specific job or operation. To illustrate this point, consider a tight wire acrobat. We all know that an acrobat maintains his balance by the skillful changing of his weight above the wire. In spite of this common knowledge few become skilled enough to accomplish this feat. Basically this is because few take the necessary time to practice to develop such a skill. In similar manner, to become a skilled craftsman requires practice. To provide the practice needed by a trainee to become efficient in all phases of insulation application* the shop and field training program was developed. The shop and field training program attempts to provide sufficient time in each aspect of the craft so that the trainee has a broad knowledge and a skill for the entire craft. The shop and field training program attempts to providejeach trainee with the opportunity to gain experience in all aspects of his trade. A summarization of what this includes follows: Phases of Field Training of Insulation Craft |. Use and Maintenance of Tools A. Hand tools B. Power tools C. Riggings UCC 002608 STANDARD OftttCAU A* JVASTK4 INTRODUCTION APPLICATOR TRAINING PAGE 3 APRIL 1970 INTRODUCTION Phases of Field Training of Insulation Craft - Contd II. Use of Insulation Specifications, Schedules, Bills of Material and Drawings A. Thermal Insulation Specifications 1. General Specifications 2. Material Specifications 3. Individual Specifications B. Bills of Material 1. Insulation 2. Securements 3. Accessories 4. Weather Barrier or Jackets C. Insulation Schedules for Equipment and Pipe 1. Identification 2. Location 3. Specification 4. Thickness ill. Organization of Work A. Tools required B. Materials required C. Procurement of tools and materials 1. JobSite 2. Storage 3. Point of installation D. Work 1. Function 2. Time UCC 002609 STANDARD CHEMCAU AMD hJUTIC* INTRODUCTION APPLICATOR TRAINING PAGE 4 APRIL 1970 INTRODUCTION Phases of Field Training of Insulation Croft - Contd The previous is common to all of the insulators craft. However, over the past /ears some insulators have become shopmen whereas others became the field applicators. As there is considerable difference in the type of work performed^the training for each is different. As the shopmen fabricate the fittings and special shapes prior to its installation, this part of the insulation training program will be presented first. Training of Insulation Shopmen IV. Forming 1. Band saw operation 2. Grinding operation V. Assembly 1. Low temperature service 2. Moderate and high temperature service 3. Traced service VI. Finishes and jac kets 1. Spray finishing 2. Jacket forming and attachment VII. Packaging and marketing III. Safety practices IX. . Field application UCC 002610 STANDARD anmiiiouno INTRODUCTION Phases of Field Training of Insulation Craft - Contd Training of Insulation Applicators X. Installation of insulation to high temperature surfaces 1. Rigid insulation a. Cushion blanket (where required) b. Cutting and fitting c. Securement and supports d. Expansion joints e. Weather barrier (1) Mastic (2) Metal jacket (3) Flashings f. Coverings 2. Sprayed asbestos insulation a. Securements and supports b. Machine operation c. Spray gun operation d. Consolidation e. Finish f. Weather barrier (1) Mastic (2) Metal jacket (3) Flashings UCC 002611 INTRODUCTION APPLICATOR TRAINING PAGE 5 APRIL 1970 STANDARD owcu4 ruvixa INTRODUCTION APPUCATOR TRAINING PAGE 6 APRIL 1970 INTRODUCTION Phases of Field Training of Insulation Craft - Confd Training of Insulation Applicators - Contd 3. Panel insulation (factor jacketed panels) a. Cutting and fitting b. Securement and support c. Joints (weather tight) 4. Heat traced installation a. Application of tracer (1) Air convection system (2) High conduction cement bonded b. Application of insulation (Same as listed under X-l) XI. Installation of insulation to moderate temperature surfaces 1. Rigid insulation a. Cutting and fitting b. Securement c. Weather-barrier (1) Mastic (2) Jacket 2. Flexible insulation a. Cutting and fitting b. Securement c. Weather bamer or covering UCC 002612 STANDARD CMCMIC4LS M funio INTRODUCTION Phases of Field Training of Insulation Croft - Contd* 3 4 Training of Insulation Applicators - Contd 3. Sprayed urethane insulation a. Machine operation b. Spray operation c. Weather barrier 4. Heat traced installation a. Application of tracer (1) Air convection system (2) High conductive cement system b. Application of insulation (Same as X1-1) XU. Installation of insulation to low temperature surfaces 1. Rigid insulation a. Cushion blanket b. Cutting and fitting c. Anti-abrasive coating d. Joint sealing e. Securement and supports f. Contraction joints g. Terminations h. Weather barriers UCC 002613 INTRODUCTION APPLICATOR TRAINING PAGE 7 APRIL 1970 STANDARD OOOll M PUITD INTRODUCTION APPLICATOR TRAINING PAGE 8 APRIL 1970 INTRODUCTION Phases of Field Training of Insulation Craft - Contd Training of Insulation Applicators - Contd 2. Fill type insulation a. Double wall container b. Compacting c. Purging system d. Seal XIII. Underground insulation 1. Steel conduit, pre-insulated 2. PVC conduit, pre-insulated 3. Bituminous Fill XIV. Building Insulation 1. Walls, roofs and floors 2. Air conditioning ducts XV. Space Insulation 1. Coolers and refrigerated spaces 2. Constant temperature and humidity spaces <VI. - Shop fabrication of Insulation In all work It is vital that each one learn to perform his work safely and be familiar with the hazards related both to his work and his environment. These safety considera tions include: I. General safety consideration related to construction II. The safety considerations related to work in a chemical plant III. Specific hazards related to the insulation craft. UCC 002614 T STANDARD QMC*U INTRODUCTION APPLICATOR TRAINING PAGE 9 APRIL 1970 INTRODUCTION By the use of this manual to provide information and the field experience to provide practice of ski I Is,ft is the sincere desire that the trainees become fine and safe workmen who take justifiable pride in their craft. W. C. Turner April 1970 UCC 002615 I STANDARD oanu ue njtmc* CHAPTER I APPLICATOR TRAINING PAGE 10 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY Thermal insulation was one of man's earliest inventions. He found that by covering himself with dried animal skins he could retard the heat loss from his body and could stay warmer in cold weather. Later he learned to weave cloth to enclose his body to obtain the comfort he desired. As time passed, the wearing of clothes became so accepted that the fundamental purpose -- as thermal insulation -- became of less significance. Further development by man of his invention of thermal insulation made this true. At a very early age man discovered he could use fire to his advantage -- to cook food and to provide heat to make him more comfortable. He found that by putting rocks around a fire he could better control the fire and direct heat toward the food he was cooking. These simple rock enclosures he built around his fire were thermal insulation although, of course, he did not have them so named. Later he found that by building a larger enclosure of sufficient size to house both him and the fire he would stay more comfortable than if the fire was just out in the open. This simple enclosure was the beginning of the building of better enclosures from which has evolved our present day buildings and homes. Again we tend to forget that these buildings are thermal insulation type enclosures by which we isolate ourselves from weather and maintain the temperature inside for our comfort. As tends to be true of many old basic fundamentals, the importance begins to be lost with passing of time. The use of thermal insulation as clothes and as enclosures (houses, buildings) became universally used and accepted and further development stopped for many years. Not until the invention of the steam engine did the need for additional development of thermal insulation become apparent. In the early days of the steam engine when temperatures and pressures were low, coal cheap and plentiful, any old thing was used to caver the pipes. In one steam boat installation, for instance, it was found very economical to use old carpet from the saloon, which at that very time was being replaced by a new Brussels rug; thus, the old one, when used for pipe covering, was so much salvage. This was in 1858. Other mixtures were clay and cattle hair or other binding material; fire clay, charcoal and sawdust, ground fine, mixed with water, and cattle hair for a binder. Hair felt was used extensively, and one of the favorite binders was cattails. For boilers, plastic materials were used as early as 1865, but asbestos was not known in the business. One of the first installations of cement covering consisted of a layer of plaster of paris, covered with chicken wire, then a layer of fire clay held in place with chicken wire, the finishing being done with sand and plaster of paris. UCC 002616 STANDARD ottMon tm mw CHAPTER I APPLICATOR TRAINING PAGE 11 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY The indifference with which pipes were covered or left uncovered was traceable, of course, to the fact that the pressures were too low to prove troublesome, and also because little attention was paid to the conservation of heat or the saving of coal in those early days. In fact, it was considered more important to keep the heat out of the engine room than in the pipes. Appearance was also more important than either the conserving of coal or heat, if we are to believe the story told of the salesman who approached a quite noted engineer in New York and endeavored to sell him covering for the pipes of a fairly large job. "Why should we cover the pipes," said the engineer, they are very nicely painted." As steam power began to moke its importance felt in transportation and industry, it became necessary to control the heat loss from the pipe and equipment. A number of individuals recognized this problem and started to develop thermal insulation first for steam pipes and boilers then for the control of heat transfer in process industries, refrigeration industry, buildings and transportation. As would be expected, development started and continued for long periods in the various forms of insulation materials. To try to gi vea history of the entire industry based on time would be quite confusing. So this history is presented based on the development of a material or related class of materials. ASBESTOS AND 80% MAGNESIA The first insulation containing asbestos was used in 1866, in a material made by Robert F. Toope, and consisted of asbestos fiber and silicate of soda. Curiously enough this same insulation was also the first sectional insulation material to be made. Mr. Toope's place of business was on E. 79th Street, New York City, and he sold his patent rights in the United States to the Johns Company (now Johns-Manville). The first asbestos cement for use on boilers was tried about 1870, and contained of osbestos fiber. It was made by the Chalmers-Spence Company at the foot of E. 9th Street, New York City. Magnesia Sectional Covering appeared Sn 1885 while the first asbestos aircell covering was produced in Brooklyn in 1898. The discovery of the heat insulating properties of magnesia carbonate is credited to Hiram N. Hanmore, who had been in the pipe covering business for many years in a minor way. He was troubled with what the doctors then called a sour stomach and was recommended to carry with him a little piece of carbonate of magnesia and eat a small piece of it when he felt that his stomach was out of order. One night while UCC 002617 STANDARD DRMfOl AMI PLASTICS CHAPTER I APPLICATOR TRAINING PAGE 12 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY ASBESTOS AND 80% MAGNESIA - Contd sitting in a barroom in the coai mining region of Pennsylvania where he had a big job on hand, he took the magnesia from his pocket and while toying with it suddently realized its lightness, indicating to him that it might make a good non-conductor of heat. He walked over to the stove, which was very hot, and laid the piece of magnesia on the top. At the end of ten minutes he picked it up ond finding it was practically cool, remarked, "This is going to revolutionize the pipe covering business." Some tell the story differently, but there is little doubt that Hanmore got the idea of its insulating qualities from the very lightweight in proportion to the bulk of magnesia carbonate, and there is no doubt at all that his discovery did revolutionize the insulation business. Hanmore found that the Keasbey and Mattison Company made carbonate of magnesia, and bought a quantity in order to experiment with it as a substitute for the plaster of paris he was using in his cement. His first patent covered a non-heat-conducting covering made of magnesia and shredded rope. He found it very hard work, however, to chop up the second hand ship's rope, and also a very slow process. At that time he did not use enough of it to warrant putting in a machine to chew up the rope. So he tried out silk noils and found that these gave the mixture more strength than the rope. (Noils -- waste silk produced in the production of spun silk.) About this time someone told Dr. Mattison of the large orders for carbonate of magnesia coming from Mr. Hanmore. When one of Mr. Hanmore's workmen drove up to the Keasbey and Mattison Company's plant and asked for 1000 pounds of magnesia carbonate, the shipping clerk was astounded as the largest orders previously had been for a keg containing 30 pounds or sometimes a barrel of 60 pounds, but since the man had cash to pay for it, the men in the shipping deportment got busy and packed up as much as they had on hand which was about 500 pounds. Mr. Hanmore's man said he would call the next day for the balance. When he came back he said he needed five tons. The shipping clerk could hardly believe that he had heard correctly. "Do you know how much a ton of this stuff is?" he demanded. "Why you couldn't begin to get it in your wagon." The man said he did know and would make several trips to get the full amount, which he did, paying cash each time. The clerk finally asked him what in the world he was doing with the stuff, and was told that Mr. Hanmore had patented the.idea.of using.carbonate of magnesia as a pipe covering and was at that time covering the pipes of Uncle Sam's Navy vessels which then lay in the Philadelphia Navy Yard. This being a new idea it was promptly brought to the attention of Dr. Mattison with the final result that an arrangement was made with Mr. Hanmore for the manufacture of the covering. UCC 002618 STANDARD QtCMCALS AND PLASTICS CHAPTER I APPLICATOR TRAINING PAGE 13 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY ASBESTOS AND 80% MAGNESIA - Contd At that time the magnesia mixed with stile noils was simply put on the pipe in a plastic form but shortly afterwards Dr. Mattison took over the manufacture of the material, he formed the Magnesia Sectional Covering Company then molds were made for forming the mass into sections and blocks. Dr. Mattison, who had long been interested in asbestos as a mineral, suggested the use of the asbestos fiber instead of silk noils because the asbestos was fireproof, but it is not certain just when the change from silk noils to asbestos was made. The present Johns-Manville Corporation traces its origin to 1858, when H. W. Johns, roofing manufacturer and founder of the asbestos industry, started out as a jobber and manufacturer in a small basement shop at 78 William Street, New York City, under the name of the H. W. Johns Manufacturing Company. His first business was the production of a roofing made from rag felt and coal tar, together wilh paints and coatings for roofs and for preserving wood, metals and fabrics. }n 1868, the H. W. Johns Manufacturing Company first made known the results of long and continued research and experiment with asbestos fibers, and began the manufacture of numerous products composed wholly or in part of asbestos fibers, many of which came to be recognized as standard articles for mechanical, structural and electrical uses. By 1886, there were four departments in the company. Paints, Roofing, Insulations, and Asbestos Fiberizing and Textiles. While Mr. Johns was carrying on his experiments with asbestos, Charles B. Manville and his three sons were pioneering in other industrial fields and in 1886, they founded the Manville Covering Company in Milwaukee, Wisconsin. The early days of the Manville Company were largely occupied in determining the best materials for covering boilers and steam pipes. Mixtures of paper pulp and blue clay, common in the vicinity of Milwaukee, were tried successfully. Later, wool felt shoddy was used as a binder in the clay, instead of paper pulp, and failure from contraction and expansion of the metal surfaces as well as loss of temperature was considerably lessened. {Shoddy -- reclaimed wool.) Since production methods in industry were rapidly changing, corresponding demand for higher temperature insulations resulted. This led to an arrangement by which the Manville Covering took over the H. W. Johns Manufacturing Company branch in Chicago, handling the rapidly developing asbestos products for high temperature insulations. UCC 002619  STANDARD awcttiwruma CHAPTER I APPLICATOR TRAINING PAGE 14 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY ASBESTOS AND 80% MAGNESIA Mr. Johns died in 1898, ond three years later, in 1901, the ManviHe Covering Company of Milwaukee, in business since 1886, was merged with the H. W. Johns Manufacturing Company of New York, taking the firm name of H. W. Johns Manville Company, From the H. W. Johns-Manville Company the present Johns-Manville Corporation inherited the line of insulating cements, asbestos and asphalt roofings, asbestos paper, high and low temperature insulations and other specialities. When T. F. Manville, President, died in 1925, the company began a transition from limited to widespread public ownership, and in 1927, became known as Johns-Manville Corporation. MINERAL WOOL Mineral wool was first produced by nature during an eruption of the volcano of Kilauea, which native Hawaiian legend explained was the goddess, Pele, holding court. After the crater had cooled, natives would venture up the mountain and collect strands of wool-like substance which they reverenced as "Pole's Hair," thought to have been torn out by the goddess in a rage. Geological survey revealed this substance to be lava, blown into soft threads by the gigantic forces of the volcano. Mineral wool from blast furnace slag is supposed to have been in commercial production in Wales in 1840, and in Germany as early os 1870. Here in the United States production started in 1897. As far as the United States is concerned, experimental work was carried on several years before this commercial production date. A patent issued August 21, 1877, describes the fabrication of bonded products from bulk mineral wool using a bituminous binder.. This patent might be considered the forerunner of current batt and felt production as we know it today. A patent issued August 7, 1883, describes a thermal insulating cement composed of mineral wool, clay to give binding action and the addition of animal hair. Mineral wool insulation in block form was first described in a patent issued July 10, 1888. These blocks were made from mineral wool fiber that was dispersed in water and formed in a filter mold to remove the water, followed by a drying of the wet block. Mr. Charles C. Hall, founder of the commercial rock wool industry, moved to Alexandria, Indiana, in 1895 from Belleville, Illinois, to become Superintendent of Construction of a small steel plant then being built in Alexandria. The steel plant was UCC 002620 STANDARD OttKMi am putno CHAPTER l APPLICATOR TRAINING PAGE 15 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY MINERAL WOOL - Contd completed and ready for operation in the fall of 1896, but never operated because it was merged with other steel interests to form the original Republic Steel Company. Mr. Hall was a graduate chemical engineer from Worcester Polytechnic in the class of 1882. He had access to the chemistry laboratory of the steel plant and while the steel merger was pending his duties as Superintendent were so light that he utilized his time in making chemical analyses. Among the many things he tested was the peculiar formation of argillaceous limestone which was quarried in large quantities in Alexandria and used as building foundation stone. Mr. Hall's chemical analysis of this limestone showed that it had a low melting point and possessed a vary stable chemical composition before and after melting. He conceived of melting this rock in a furnace with heat supplied by gas, which was then abundant in Alexandria, and blowing the molten rock into rock wool by means of compressed air. He developed the process successfully then laid it aside. About six months after the merger of the steel interests, it was decided to move the steel plant from Alexandria. Mr. Hall did not care to leave Alexandria, so he turned to the {obof making rock wool in commercial quantities. In the spring of 1897, Mr. Hall borrowed $600 and built the original commercial rock wool plant. About $500 of the capital went toward building the furnace in which the rock had to be melted. The other $100 was spent erecting the make-shift building which housed the furnace. Early in November, 1897, the first run of commercial rock wool came out of the factory. Due to his limited working capital it was quite a struggle for Mr. Hall to keep the plant in operation, but by borrowing additional capital and selling out some interests in his company, managed to keep the plant on a profitable basis. About the time he had the gas furnace operating effectively, the supply of natural gas at Alexandria gave out and he was faced with the problem of melting rock with a different type of fuel. Mr. Hall then developed the water-jacketed cupola using coke to obtain the necessary temperature. This is the method used in almost all rock wool manufacturing plants. Since 1897, there were several corporations in which Mr. Hall was interested, that have manufactured rock wool at Alexandria. The last one, before Johns-Manville, was the Banner Rock Products Corporation organized In 1906. This corporation was acquired by Johns-Manville on February 1, 1929. UCC 002621 STANDARD OCMCALt AM> PU1TO CHAPTER J APPLICATOR TRAINING PAGE 16 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY MINERAL WOOL - Contd About fhls time, it became known that slags from the refining of non-ferrous metal would result in a suitable product. The resulting mineral wools were dark in color in contrast to the whiteness of the rock wools of the lime, and also the whiteness of the wools made from iron blost furnace slag. The dark wools, however, had the advantage of providing a composition that was more refractory and showed greater chemical stability. Eagle-Picher, due to their past experience in the smelting of lead and zinc ores, looked to these waste materials as a source of income and started investi gating the possibility of using their waste products to make mineral wool in 1927. Actual commercial Eagle-Picher production started in December of 1929, and by the end of 1930, had in production almost a full line of mineral wool products in the forms that they are known today. CORK The first mention of the use of cork as insulation appears to be by the elder Pliny in the first century of the Christian era, when he called attention to its use by women as winter footgear. Undoubtedly, it was utilized as sandals because of its insulating qualities and its freedom from capillarity. Pliny spoke of cork bark being used as a covering for roofs. John Evelyn, the English writer and diarist (1620-1706), mentions that cork was much used by old people for linings to the soles of their shoes. The poor of Spain laid planks of cork on the floor like tiles, to obviate the need for a floor covering that would be warm to the touch. They also lined the inside of their stone houses with cork bark, to make their homes easier to heat and to correct the precipitation of moisture on the walls. The primitive races of northern Africa used cork mixed with clay for the walls of their crude dwellings, and cork slabs as roof tiles. About the year 1890, the German firm of Grunzweig and Hartmann acquired patents in Germany and in the United States for a type of insulation known as "impregnated corkboard,11 and soon became the leaders in their own country in the manufacture of these " impregnated" cork slobs for insulating purposes, particularly for cold storage work. The United States patent rights for this new type of insulation were subsequently acquired by the Armstrong Cork Company of Pittsburgh, about the year 1900, following which a plant for its manufacture was established at Beaver Falls, Pennsylvania. This location was selected principally because the necessary clay for the preparation of the foreign binder to stick the granules of cork together was available there in generous quantity and at a point not far from Pittsburgh. UCC 002622 STANDARD CHEMICALS AMD FLASKS CHAPTER I APPLICATOR TRAINING PAGE 17 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY CORK - Contd The business grew rapidly, especially among the brewers, for the insulation of their cellars; but it was soon discovered that this impregnated corkboard was inferior in insulating quality, and in structural strength in service to a brand of "pure" corkboard being made under the patents of one John T. Smith, on American, and subsequently the manufacture and use of the impregnated, dr "composition", corkboard gave way entirely to the pure corkboard insulation. The manufacture of pure cork insulation was begun in 1893, in the United States, under the original John T. Smith patents by Messrs.Stone and Duryee. Cork covering was produced first, and then the manufacture of pure corkboard followed within a very few years. It is interesting to know that the discovery of the process of baking cork particles under pressure to bind them together, which later made pure cork insulation possible, was purely an accident; the process was not thought of in connection with cork covering and corkboard until Messrs.Stone and Duryee later applied it to that purpose. In the "Boat Works" of John T. 5mith on lower South Street, on the East River, in New York, was a large cast- iron kettle with a fire box under it. The kettle was used to steam oak framing for row boats that Smith manufactured there for many years. He also produced boat fenders, life preservers and ring buoys, in the manner common in those days, by pocking granulated cork in canvos jackets. Girls packed the cork in these jackets, using tin forms or cylinders to keep the canvas distended until filled. One of these cylinders became clogged in the hands of one of Smith's employees and was laid aside for the moment, but it inadvertently rolled into the dying embers of the fire box during clean-up late that evening. Early the next morning, Smith, owner and fireman, cleaned out the fire box and found his misplaced utensil. However, the hot ashes had not consumed the cork particles that had clogged it. The heat had been sufficient merely to bind the mass together in the form of a very substantial chocolatebrown cork cylinder. Smith noted this peculiar fact with much interest, if not with actual astonishment, and put the tin form and cork cylinder aside for future secret study and an investigation. He repeated the original and wholly unintentional experiment enough times to satisfy himself that for some good reason a certain degree of heat applied for a length of time served to glue cork particles together without the addtion of a foreign substance or binder of any kind or character, to produce what he later termed "Smith's Con solidated Cork." He thereupon applied for ond was granted basic patents in the United States, Germany, France, and England, covering the broad principles involved. UCC 002623 STANDARD M^puira CHAPTER [ APPLICATOR TRAINING PAGE 18 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY CORK - Contd In 1893, Messrs, Stone and Duryee purchased the Smith patent rights for the United States, France, and England, and began the manufacture, at No. 184 North Eighth Street, Brooklyn, New York, of asbestos-lined cork covering for steam pipes. This suggestion probably came to Junius H. Stone, who had previously been engaged in the steam pipe covering business, from the original Smith cork cylinder, which, incidentally. Smith hod failed to utilize to any good purpose what ever. Not long thereafter the patent rights on "85%magnesia" steam pipe covering expired, and the resultant competition so reduced prices as to seriously interfere with the further sale of the cork product. Then the Engineering Deportment of the United States Navy became interested in molded cork covering for cold pipes, to replace hair felt and such other fibrous materials as possessed a marked affinity for moisture. It was subsequently tried out os an insulation for brine lines on one of the large battleships being built. From here the material rapidly found favor in other governmental departments. Thus the real field of usefulness of Smith's Consolidated Cork -- as an insulating material for cold surfaces -- was discovered. Soon thereafter, the finn of Stone and Duryee began the manufacture of the very first pure corkboard that was ever produced, sold, or used. Mr. Harvey H. Duryee, of the firm Stone and Duryee, was of French Hugenot descent, and it please him to designate the products of his firm "Nonpareil," from the French words "non pareil," meaning no parallel, or no equal. The firm of Stone and Duryee subsequently became the Nonpareil Cork Works, and with the construction of a factory at Camden, New Jersy, it became the Nonpareil Cork Manufacturing Company. In June, 1904, the Armstrong Cork Company purchased the patents, plant and business of the Nonpareil Cork Manufacturing Company. By the time the patents expired, both pure corkboard insulation and cork pipe covering were known wherever the use of refrigeration had been scientifically introduced. DIATOMACEOUS SILICA For high temperature service, an insulating material to be of value must not only have a low conductivity, but also a high degree of refractoriness, a quality not ordinarily found in insulating materials. Less than forty-five years ago, there was no material available that possessed sufficient refractoriness to be of use in the high temperature ranges. UCC 002624 STANDARD OCMCAU PLASTO CHAPTER ! APPLICATOR TRAINING PAGE 19 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY DIATOMACEOUS SILICA - Contd At 1-hat time, with no suitable insulation available, the loss of valuable heat used in certain processes in manufacturing steel and metal products, glass, portland cement and lime, brick, tile and pottery was tremendous. Attempts were made fo curtail this loss by building furnace walls of brick several feet thick. This method was unsatisfactory because construction costs were exceedingly high, and such walls soaked up heat like a sponge, thus robbing the furnace of heat. In 1912, a new insulation was put on the market by the Celite Company. Composed of diatomaceous silica, it made available an insulation suitable for use at high temperatures. Diatomaceous silica is silica shells or skeletons of "diatoms" -- microscopic plants which lived in the rolling waters that swept over what is now California millions of years ago. Upon its death this minute organism sank to the ocean floor, leovtng as its only trace a silica shell built up during its life. Countless billions of other diatoms lived and died in these same waters and their tiny skeletons piled up in layer after layer, during some thirty thousand years, to form huge deposits of almost pure silica more than 1400 feet in thickness. Brick cut from these deposits contains myriads of tiny voids formed by these minute diatom skeletons. These voids represent as much as 85%of the volume of the brick. Thus loss of heat by conduction is reduced because of the small proportion of solid material present. In the manufacture of insulating brick for use at higher temperatures, this material is ground, pugged, pressed and fired in kilns. Calcined ground grades are used as an insulating conrete aggregate and as insulating fills. Diatomaceous silica can only be prepared in brick or powder form; therefore, in order to extend its range of usefulness it is necessary to combine it with other materials such as asbestos. STRUCTURAL INSULATING BOARD The first structural insulating board was manufactured in 1914, at International Falls, Minnesota, by the Minnesota and Ontario Paper Company. The product called insulite was made from ground wood and sulphite screenings. About the same time, in Penetaguishene, Ontario, a product called Ten-Test was made from coarse brown pulp and is now being produced by International Fiberboard Limited at Gatineau, Quebec. In 1915, the production of structural insulating board was approximately 2,750,000 square feet on a ^ inch thickness basis. UCC 002625 STANDARD CHEMICALS AM AJUTICI CHAPTER I APPLICATOR TRAINING PAGE 20 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY STRUCTURAL INSULATING BOARD - Contd In 1920, the Celotex Corporation at Marrero, Louisiana, started producing structural insulating board from sugar cane fiber called bagasse. The industry grew rapidly thereafter, and in 1955, there were 16 companies with 20 plants in the United States and 4 companies with 4 plants in Canada producing 3,280,000 square feet on a inch thickness basis. In the early days, structural insulating board was primarily one product being cut to size for various uses. It was first used to form partitions in buildings and in 1916, was used extensively in railroad refrigerator cars. During the First World War, the Army used large quantities to build barracks. In 1918, it was fabricated into insulating lath used in home building. By 1920, insulating board was being used extensively in home building and remodeling. In 1927, the automobile industry began to use it as a means of quieting automobile bodies. The following year it was used as an insulation in mechanical refrigerators. Also in that year it was used in the building of Hollywood sound stages with the development of sound movies. In 1929, it was used by Admiral Byrd on his Antarctic expedition as part of portable housing. In 1930, the aviation industry used it for sound deadening as did a large railroad in 1934. Roof insulation was developed as a special product in 1928, and the first ceiling tile was fabricated in the late 20's. In the late 30's, plank, thin board, and sheathing were special ly fabricated. In 1948, the board was fabricated into insulating roof deck slab used in post-and-beam construction. In 1950, shingle backer was developed which is used for undercoursing, wood shake or asbestos cement shingles. METAL TYPE REFLECTIVE INSULATION About the year 1800, history tells us that Count Benjamin Thompson Rumford, in England, conducted experiments in calorimeters which were polished metal containers to reduce the heat transfer to the surroundings. Likewise, James Prescott Joule, also in England, used polished metal calorimeters for his experiments. From this information, it is evident that these physicists recognized the effectiveness of a bright metallic surface as a barrier to heat transfer. In 1878, Jean Claude Peclet, in France, recognized the excellent insulating value of multiple sheets of tin separated by air spaces, and publicized it in his book, "Traite1 de la Chaleur." UCC 002626 STANDARD omou **> pvajticj CHAPTER f APPLICATOR TRAINING PAGE 21 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY METAL TYPE REFLECTIVE INSULATION - Contd However, credit for the first invention of reflective insulation having commercial significance must go to Sir James Dewar. In 1885, he conceived the "Dewar Flask," which is now known as the "Thermos" Bottle. Millions of "Thermos'1 Bottles are in daily use in the United States today. This invention employs two parallel heat reflective surfaces with a vacuum, i.e., a non-conductive space -- between them. Forty years later, in 1925, Ernst Schmidt and Eduard Dyckerhoff discovered that a number of crumpled tissue-thick aluminum foils separated by air spaces would insulate effectively -- without a vacuum. Furthermore, aluminum was now cheap enough to use for such a purpose. Hence, from this time on, substantial quantities of insulating materials of this type were manufactured and sold in Europe and the United States, principally for insulating houses and buildings. Such a product having substantial commercial use in this country was sold under the trade name "Alfol." In the second "World War,11 around 194Q the Germans used layers of tissue-thick aluminum foil insulation on steam lines of the pocket battleship "Deufchlond." The U. S. Navy subsequently obtained a piece of this insulation which had been in service for approximately 6 months. This piece was place on exhibit at the U.S. Naval Esperiment Station, Annapolis, Maryland. It had apparently served its purpose as effective insulation, when new. Yet, in its short service life, the foil hod become badly corroded away by the sea air, with holes big enough to put a man's hand clear through the insulation. Obviously , its value as insulation had been reduced. In the United States, during the "forties" a number of cold storage plants were built in which the walls were insulated by a field-fabricated assembly of aluminum sheets separated by wooden spacer strips. This construction was sold under the trade name "Alumiseol." However, the first significant reflective insulation for power and industrial plants was invented in 1949, In that year, George E. Gronemeyer, a U.S. Consulting Engineer, applied for patents on a new conept of reflective insulation for hot or cold service. This invention employed multiple sheets of reflective metal, such as aluminum separated by confined air spaces, supported by non-metal low-heatconductor material, and prefabricated into rigid insulation units. This product was manufactured and sold to industry from 1949-1953. However, it was found to be limited in application ond temperature range due to the non-metal spacer material. Union Carbide Corporation was the first large industrial concern to use this insulation. UCC 002627 STANDARD OttKALlMSflAma CHAPTER I APPLICATOR TRAINING PAGE 22 APRIL 1970 ===========^^ HISTORY OF THE INSULATION INDUSTRY METAL TYPE REFLECTIVE INSULATION - Contd Then, in 1955, George E. Gronemeyer made a major break-through in reflective insulation. He, at that time, placed on the market a more advanced concept of reflective insulation, suitable for heavy duty use in power and industrial plants. This invention employed multiple sheets of reflective metal separated by confined air spaces, supported by metal high-heat-conductor material, and prefabricated into rigid insulation units. Heat loss through the metallic supports was limited by an ingenious construction to the point that the all-metal insulation was more effective than conventional "mass-type" insulation. This sturdy structure overcame the limitations of his earlier invention. This product is patented, and is sold under the trade name "MIRROR('R') Insulation." It is factory prefabricated into units, or assemblies of units, to fit nuclear reactors, large and small vessels, pipes, ells, tees, valves, etc. However, this insulation is not sold as insulating material but as a system, engineered to fit the piping and equipment involved, with due allowance for expansion and contraction. This insulation has been and is being installed in most of the large nuclear power plants in the United States and abroad. It is in current usage at temperatures up to 1400F and is available for higher temperatures. Industrially, again. Union Carbide Corporation has led the way by making extensive use of this development in its plants. MIRROR has a unique combination of product characteristics which is not available in mass-type insulations. Being of all-metal construction, it is highly fire-resistant, clean, dustless, non-absorbent, chemically neutral, mechanically strong, durable, and maintenance-free. Furthermore, all insulation units are removable and reusable. This insulation has filled the need for dependable performance in continuous power and process service, year after year. Thus, it has achieved a leading position in the market for thermal insulation in the United States, and is presently expanding into foreign markets. EXPANDED SILICA INSULATION The Philip Carey Corporation started in the manufacture of 80% magnesia molded pipe insulation tn 1906. In the early 1950's, Carey, in conjunction with the Mellon Institute, developed a formula to produce expanded silica (Perlite) as a base material for rigid high temperature pipe and block insulation. This material was introduced on (R) Registered in the United States Patent Office UCC 002628 ! I i i i i L L STANDARD OnUMCALS AIO PtASTlO CHAPTER I APPLICATOR TRAINING PAGE 23 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY EXPANDED SILICA INSULATION - Contd the market under the tradename "Alltemp" in 1954. Improvements were made to the original product, the major improvement being that the material was made water repellent. This new product was named "Careytemp" and was put into production in 1958. Perlite in loose form has become an extremely useful insulation, as a poured-inplace insulation. It can be used as a high temperature insulation up to service temperatures of 1400F, and it can also be used for low temperature service when installed in vapor-tight container. CELLULAR GLASS Basic cellular glass patents date from 1934-1938 by St. Gabain in Frcn ce. Pittsburgh Plate Glass and Pittsburgh Corning Corporation research in cellular glass started in 1937. After material had been developed successfully in the laboratory, the question arose as to what to do with it. Market research revealed a need for a material of this type for use in curtain wall construction, refrigerating equipment, railroad and refrigerator cars, insulated truck bodies, marine field, and the cold storage field. A pilot plant for cellular glass was started in June 1941, using glass cullet from the gloss block tonk and lampblack. Actual manufacturing at Port Allegany, Pennsylvania, commenced June 29, 1942, using the same batch as the pilot plant used. In June 1943, batch cullet glass from Coming's Wellsboro Plant was used with lampblack until November 1943, then carbon black was used. During the latter part of 1947, a special field survey was made of some of the FOAMGLAS ' ' installations subjected to severe conditions, e.g., pulp mills, tobacco curing rooms, and dry kilns. As a result of this survey, the basic composition of the batch glass was altered from regular soda-lime batch to a modified borosilicate type to obtain better durability. This change occurred in January 1948, and is still the type batch used today. Modern FOAMGLAS ^ is 8 to 10 times as durable as the original. The big improvement in thermal conductivity values of FOAMGLAS^^ took place by the first of 1951, at which time the density was changed from an average of about 10 pounds per cubic foot to around 9 pounds. This, coupled with a stabilization of the UCC 002629 tilt11 STANDARD osieiuiniuiTa CHAPTER I APPLICATOR TRAINING PAGE 24 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY CELLULAR GLASS - Contd cell gases, brought the actual thermal conductivity value of FOAMGLAS('R)' from about .42 to .38 at a mean temperature of 50 C. Further research and refinements have brought the conductivity value of today's material down to .35 at a mean of 50F. POLYSTYRENE INSULATION STYROFOAM('R), polystyrene expanded by the Dow Chemical Company, was first produced in research laboratories in Midland, Michigan, in the early 1940's. Basically this material is comprised of a system of non-inferconnected cells providing numerous, minute air spaces. The extremely light weight of cellular polystyrene plus its sealed cell system immediately suggested it as a buoyance agent. Since at that time World War II was imminent, the material was brought to the attention of the Armed Forces wit?* ` s suggested use in mind. It proved of value to various branches^ of the Armed Set-1; os ana* it became necessary, because of this interest, to build production facility s. Paralleling the supply of material for the Armed Services, work toward improving the product and evaluating any other potential markets was being done at Dow. Research into the insulating ability of this material was conducted. This research resulted in a definite program of improvement looking to the day when the war would end. If was therefore in 1946, that the first commercial application of expanded polystyrene aiJow temperature insulation was made. Starting in 1946, the markets for STYROFOAM' ' grew rapidly. The florist found the material much more pleasant to handle than wet moss on frames, and STYROFOAM* ' began to be accepted for a basic floral material. Various fabricators for STYROFOAM' ' came into existence and developed a market in the novelty and display fields. The buoyoncy market was continued by small boat manufacturers and by the Armed Services, particularly the Navy. The growth in its use as low temperature and comfort insulation was steady into practically all fields recpiring this type of insulation. RIGID POLYURETHANE INSULATION Jn 1940, Schlack reacted polyesters with diisocyanates leading to chain extension and Increase in viscosity. This led Farenbabriken Bayer into an active research program to develop rigid foams, adhesives and coatings based on this principle. In 1945-1947, UCC 002630 STANDARD CMHULIUMUnO CHAPTER I APPLICATOR TRAINING PAGE 25 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY RIGID POLYURETHANE INSULATION - Contd scientific teams studying German developments issued a number of reports describing the uses of polyurethanes. Using chemicals produced by DuPont and Monsanto, Goodyear Aircraft Co. and Lockheed Aircraft Co. developed techniques for rigid polyurethane foam in 1946-1947. Since that time others, such as Union Carbide, Dow, Upjohn, and Hooker, have entered the field as producers of raw materials. Rigid urethane insulation is produced and sold nationally by Pittsburgh-Coming, Dow, National Gypsum and Unarco, and by numerous other formulators in smaller market areas. The major market for rigid polyurethane foam insulation is for insulating refrigerated railroad cars and truck trailers, and household refrigerators. Inudstrial uses, especially the spray application of the material to moderate temperature vessels, have developed since 1965. GLASS FIBER INSULATION In 1931, working independently, the Owens-Illinois Glass Co. and Coming Glass Works began research programs investigating the commercial possibilities of glass in fibrous form. These separate efforts were joined together when these two companies formed the Owens-Corning Fiberglass Corporation in 1938. The first commercial products of this new company were building insulation and furnace filters. In 1939, development of binders and application processes made possible the manufacture of rigid and semi-rigid insulation boards. Development of superfine light-weight glass fiber in 1949, opened up the use of glass fiber for thermal and acoustical insulation for aircraft and automobiles. In the early 1950's, other companies entered the glass fiber business. These were Johns-Manvitle, Pittsburgh Plate Glass, Gustin Bacon Manufacturing Co., Ferro Co., and Reichold Chemicals, Inc. Today glass fiber insulation is available in many shapes, densities, and properties to fulfill x'ny individual installation requirements. CRYOGENIC INSULATION The thermal performance of cryogenic insulations previously developed and currently in use covers four orders of magnitude, depending upon the performance requirements as a function of cost for a given application. UCC 002631 STANDARD CHtlttCALl MC PLASTIC* CHAPTER I APPLICATOR TRAINING PAGE 26 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY CRYOGENIC INSULATION - Contd Cryogenic insulations can be roughly divided into two types: gas filled and vaccuum. There are any number of gas filled insulations, including many types of fibers, mineral wool and powders. The most common are Perlite and Vermiculite powders. The use of gas filled insulation dates back to the infacy of the air separation business, but it is still important in many applications such as large storage reservoirs and li quefiers where the large volume does not justify the costs of the more expensive vacuum insulations and where the value of the products stored is low. Vacuum insulations date back to the original James Dewar work of the late Nineteenth Century. The original Dewar consisted of concentric glass jars with the annular space evacuated. Later, in order to cut down on the heat transport by radiation, these two surfaces were silvered, resulting in the common thermos bottle. Linde work in the 1940 s resulted in a practical means of interjecting a multiplicity of separate radiation shields or additional polished surfaces within this vacuum space, resulting in further improved performance. While James Dewar and a number of other investigators did do some work with evacuated powder insulations, it was not until the late 1930's and early 1940's that the concept of the evacuated powder insulation was applied to large scale cryogenic fluid storage containers by Dana. This concept is still widely employed, particularly with Perlite powder in large cryogenic tankage. At will be seen that improvement of two orders of magnitude is achieved over non-vacuum insulations (which have the thermal conductivity of the gas involved). In the early 1950's, development work was conducted in order to achieve another improvement in cryogenic insulations. In these powders, because of their small dimensions, gaseous conduction is essentially negligible and with the heavier powders, such as Perlite, solid conduction contributes about 70% of the heat transport. Thus, it was decided to use powders with lower solid conductivity, but essentially transparent, and to include copper flakes as an opacifying agent. Silica aerojet was chosen for the powder and the resultant formulation consisting of eqjal parts by weight of copper flakes and silica aerojet powder was designated Linde insulation C5-5, possessing an exceptionally low thermal conductivity. This made possible for the first time the economical distribution of low temperature fluids in small quantities. Early in the powder development program, it became apparent that an even better insulating material would be necessary for the economical storage and distribution of the lower temperature cryogens, hydrogen and helium. Initially, for this application, the concept of radiation shields and fibrous paper spacers was investigated, resulting in the Linde Super Insulation concept which became the cryogenic insulation of the 1960's. UCC 002632 STANDARD QOIfiCAtS AND PLA$7>C3 CHAPTER I APPLICATOR TRAINING PAGE 27 APRIL 1970 HISTORY OF THE INSULATION INDUSTRY CRYOGENIC INSULATION - Contd Many variations of the materials have been employed, depending upon the application, including aluminum foil and aluminized plastic radiation shields combined with fiber glass and rayon fiber papers ond mats to achieve varying degrees of performance and cost. More recently, the concept has been extended to extreme high temperature insulation systems by the use of copper, nickel and tantalum shields with quartz spacers. Currently, development work is under way for insulations up to 2000F. UCC 002633 STANDARD CMUOU tlDfUtTO CHAPTER (I APPLICATOR TRAINING PAGE 28 APRIL 1970 HEAT TRANSFER FUNCTION Heat To understand'the function of thermal insulation in controlling the transfer of heat, it is necessary to have an understanding of heat. Everyone knows what heat is, but to properly define it in words is not easy. To start, heat is a form of energy. What is energy? According to Webster's Seventh New Collegiate Dictionary, the definition of energy is: Energy l: Vitality of expression; 2; the capacity for action; 3: power forcefully exerted; 4: the capacity for doing work. Energy, as restricted to the field of science, is the capability of, or the causing of a moving force or work. Science further defines various forms of energy. These are: a. Mechanical Potential Energy is energy stored by virtue of the relative distance of a body above a horizontal reference plane. b. Mechanical Kinetic Energy Is energy stored by the relative motion between parts of a system. c. Internal Energy is energy stored within a body, such as a quantity of gas, liquid or solid, by relative motion of, and forces between the molecules or atoms composing the body. d. Work is a transient form of mechanical energy. Transformation of other forms of energy are brought about through the agency of force acting through distance (or work). The above is the definition of heat. As originally stated, it is one form of energy. It should be noted that it, and the other forms of energy, do conform to the dictionary defintion of energy. Definitions a, b, and c, relate to energy stored and d relates to energy being transferred or in transformation. This is in agreement with the dictionary definition of "the capacity for or doing." Energy can be measured. However, there are a number of units of measure, each of which is for the convenience of measuring a particular form of energy. The unit commonly used to measure heat energy It the British Thermal Unit. The definition of measurement of heat in terms of BTU's is as follows: UCC 002634 STANDARD OtfMCAU AM) PlASTlC* CHAPTER II APPLICATOR TRAINING PAGE 29 APRIL 1970____________ FUNCTION HEAT TRANSFER - Contd Heat - Contd British thermal unit (Btu) was defined in the early days of science as the quantity of energy (heat) required to raise the temperature of I pound of water 1F, from and at 32F. As the boundaries of knowledge expanded, the definition was changed to 1/180 of the quantity of energy (heat) required to change 1 pound of water from the ice point to the steam point at standard atmospheric pressure. The difficulty of setting up standards for such a definition, taking into account the now known variations of specific heat with both pressure and tempera ture, was so great that no standard was ever generally accepted. To relate the measurement of heat with other energies and to arrive at an acceptable standard for a Btu, the International Steam Table Conference in 1926 recommended that that the International Calorie be set at 1/860 of an International Watt-hour. By calculation, this established the Btu as 778.26 ft-lb. Other units used to measure energy are calorie, horsepower-hour, foot-lb, and kilowatt-hour. Each of these have a fixed relation with the other. 1 Btu = 252 calories I Btu - 0.000379 horsepower-hour 1 Btu = 778 foot-lb 1 Btu = 0.000298 kilowatt-hour Energy transfer from one body to another is by virtue of the existence of a temperature difference existing between the two bodies. Thus it is necessary to establish the definition of temperature: The temperature of a body is its thermal state in relation to communicating heat to other bodies. When two bodies are placed in thermal communication, the one that loses heat to the other is stated to be at the higher temperature. By definition, temperature is a level of hotness. Temperature, by itself, is not a measure of heat or energy. To illustrate this point, assume that there is a vessel containing water and that there is a hole in the bottom by which water could escape. This is shown in Figure 11-1. Consider the water to be heat and the height of the water in vessel to be temperature. Like heat, because of the difference in height between the hole and the top of the water, the water will flow out the hole and escape. However, measurement of this height will not determine the amount of UCC 002635 ridEQi STANDARD FUNCTION CHAPTER 11 APPLICATOR TRAINING PAGE 30 APRIL 1970_________ Knowing only the height of water level will not provide information necessary to determine amount of water escapting from hole. Difference In height between hole and water level determines amount of water which will escape from hole. ILLUSTRATION OF FLOW AS EFFECTED BV WATER LEVEL DIFFERENCE Figure ll-l UCC 002636 STANDARD oiEtfCtu At n>Jiia CHAPTER II applicator training PAGE 31 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Heat - Contd water which will escape. In a similar manner temperature measures the level of hotness/ but is no measure of quantity of heat. As shown in the illustration of the water in a vessel, the water flows only if the hole is at a lower level than the surface of the water inside the vessel. A difference of height causes the flow. Similarly, in transfering heat the energy transfer is by virtue of a difference in temperature. To measure temperature a number of temperature scales have been devised. These scales were devised in view of where certain definite physical phenomena occur. The two phenomen used as fixed points are the ice point and the steam point. The Fahrenheit temperature scale subdivides the temperature interval between ice point and steam point into 180 parts. Its 0 point was set by the lowest temperature attainable by means of a salt-ice mixture. From this the ice point was set at 32 and the steam point 212. In the Centigionde scale, which is now called "Celsius", the clean-water ice point was set at 0 and the steam point 100. Two other scales have been devised based on "absolute zero", the calculated level of complete absence of heat. The Rankine temperature scale was set with 0 being equal to absolute zero and with the same divisions of the Fahrenheit scale. This made the ice point 491.7 and the steam point 671.1 The other is the Kelvin tempera ture scale using starting point of absolute zero as 0, but using the same divisions os the "Celsius" scale, causing the ice point to be 273.16 and steam point to 373.16. These temperature scales have a relationship and knowing the temperature by degrees by one scale the degrees of any other can be determined. The relationship of these scales is as follows: From To Get From Fahrenheit From *Kelvir Celsius (Centigrade) From Ranktne F Fahrenheit |(K-273.16)+32 j C + 32 K Kelvin |(0F-32)+ 273.16 JC + 273.16 R - 439.67 5 on UCC 002637 STANDARD CHBDCAU AM> PUira CHAPTER !! APPLICATOR TRAINING PAGE 32 APRIL 1970 HEAT TRANSFER Contd Heat - Contd To Get C Celsius (Centigrade) o R Rankine From Fahrenheit |(F - 32) F+ 459.69 FUNCTION From Kelvin K -273.16 1 K 5K From Celsius (Centigrade) |C + 491.69 D From Rankine R - 273.16 The most commonly used scales are Fahrenheit and Celsius (Centigrade). At the temperature F of -40, Centigrade is also -40. Only at this point does the number of degrees on each of these scales designate the same level of hotness. For this reason, in stating the number of degrees it is essential that the temperature scale be given ^ otherwise the statement has no meaning. In the definition of heat the term bodies is used. Again, this term is used in its scientific sense. The meaning being as follows: Body is a mass of matter distinct from other masses; a sensible object in physical space. All the previously written matter was an attempt to provide a full understanding of heat. From the definitions of the terms used in the original defintion of heat, substitutions could be made so that the definition might be written as follows: Heat is force in transformation or transfer from one mass to another because of a difference in level of hotness existing between the two masses. Although this definition is not as scientifically correct as the first presented, the act of arriving at it may have clarified many points of question. UCC 002638 STANDARD CMCJMCAU AM) PLASTICS CHAPTER II APPLICATOR TRAINING PAGE 33 APRIL 1970 ___________ FUNCTION HEAT TRANSFER - Contd Effect of Heot on Substances All substances are made up of molecules in constant motion. Adding heat speeds up the motion of the molecules; removing heat slows them down. At the same time, molecules pull toward each other. This pull tends to restrict their movement and hold them together in a body. Speeding up motion by adding heat tends to overcome the attraction of molecu les; so substance expands. The temperature rises in a substance as heat is added unless there is a change in state of the substance. Substances may be solid, liquid or gas state depending on the attraction of molecules and rate of their rote of motion. The motion in these states are as follows: SOLID STATE. Energy of moving molecules is small as compared to attraction; so mole cules move as if on tethers. LIQUID STATE. Molecule movement and attraction are close to balance. Molecules will stick close together but can wander in any direction in the (liquid) substance. Surface tension is a result of molecular attraction. GAS STATE. Molecules are independent in their motion. Travel is limited only by collisions with other molecules or confining walls. A number of terms are used for particular actions of changes of state of substances. These are: melting, sublimation, evaporation, boiling and condensation. MELTING. When solid is heated to point where molecules move fast enough to break away from rigid pattern, temperature no longer rises with heatimput until all molecules have broken loose. SUBLIMATION. In breaking bonds of solid state, some molecules move fast enough to break away from all others to become a gas. To illustrate a typical example of this, carbon dioxide dry ice (solid) sublimes directly to gas. EVAPORATION. In heating liquid, some molecules speed up sufficiently to break through surface-tension layers, against attraction of other molecules in the liquid state to become a gas. In escaping gas molecules take away energy. This may cool the liquid. BOILING. Molecules in the liquid state gaining sufficient heat to accelerate and break away from each other to be in gas state. UCC 002639 STANDARD CMBMCAU AW RLASTKS CHAPTER If APPLICATOR TRAINING PAGE 34 APRIL 1970 FUNCTION HEAT TRANSFER - Contd CONDENSATION. Gas molecules losing heat slow down and pull together as a liquid. Molecules in gas state has relationship in respect to saturation, vapor pressure, and superheat. These relationships of molecules in gas state are as follows: SATURATION. To stay as gas, molecules must move fast enough to keep apart. Speed depends on temperature. For every temperature there is a maximum number of molecules that can exist as gas in a given volume. Adding more gas to a given volume of maximum density (minimum specific volume) without increasing temperature will increase mutual attraction of molecules to start condensation. This saturation always exist where gas and its liquid touch. VAPOR PRESSURE. Moving gas molecules exert a force in any confining surface, called vapor pressure. Vapor pressure goes up as the speed and number of molecules, or as temperature and density. SUPERHEAT. Saturated vapor not in contact with its liquid can be superheated in two ways: (1) increasing its temperature (adding heat) to expand it or (2) decreasing its pressure (throttling) over certain ranges. A graphic illustration of the relationship of substonce changes of state are shown in Figure 11-2. As heat has these effects on substances it becomes clear that its transfer from one substance to another must be carefully controlled in manufacture of chemicals. Control of heat trans fer is the function of thermal insulation. Heat Transfer Although the function of thermal insulation is to retard heat flow, to accomplish this it is necessary to know how heat is transferred. UCC 002640 rf I r r r i i f i i [ i L L L L L L STANDARD 4cmu"*u rutro FUNCTION CHAPTER II APPLICATOR TRAINING PAGE 35 APRIL 1970________________ WHEN A SUBSTANCE CHANGES STATE, ITS MOLECULES DO NOT CHANGE, ONLY THEIR RELATION lOUD'SIATI mobivlM ft (th to moao, but ara bapt bi rlfid pattora by "tatbort" I mutual attraction farm crystals JMILTINO AMO tUBUMftMG maintains both aaad amtra dasa af wrfy ("hrtyat boat") ta braab tbalr attraction tntfears UOilID SUMACS HNSION ium4 by urn t^tMl pull an malacula* at turfftta by tba mwlacula* bM liquid farms a barriar IVARORATION, CONDtNSATION af htdlvMvtl malaculas 9a aa at tun tlma but iwt affact is usually ana ar tba athar f IHI lttt V___________________________ s SATUJIATtOM IN CtOSlO VIS9U. Malaculu. rmtorln| liquid oquof Hiatt laoulnf liquid rban tamparatura b kapf (snitmt AOIUMO IN OMN VfSSIl tubas pbca trhon tba vapor prastura H nqoal ar grantor bon aatarnal prastura; bobbins farm FIGURE 11-2 UCC 002641 STANDARD OtBOCALt AM> MJUTKa CHAPTER II APPLICATOR TRAINING PAGE 36 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Heat Transfer - Contd Heat has two methods of transfer named conduction and radiation. Convection, fre uently called a method of heat transfer, is movement of mass from one position to another. However, for ease of discussion and understanding, although incorrect, it will be presented as if it were a method of heat transfer. As each of the above methods of heat or mass transfer ore n ernes for a phenomena, the definition of the terms describe the phenomena. Conduction, external is energy transferred from one body to another tody at a lower temperature by tangible contact. Conduction, interna) is energy transferred from one molecule to another at a lower temperature within a single body. Radiation is energy transmission through space from a hotter body to a colder body. Convection is the movement of a body, or bodies, with its, or their associated energy from one position to another without change or energy transformation. By this definition, convection is not a method of heat transfer. A typical example of convection is the movement of air from one part of a room to another. These are the methods by which heat is transferred or moved. To illustrate these factors again, let us use water to represent heat and two vessels to represent bodies. For the transfer method, the two vessels are connected by a pipe representing radiation and conduction. The height of water in each vessel represents the temperature of a body. The illustration of two vessels is shown in Figure 11-3. It is apparent that when the water in vessel (1) is at a higher level than vessel (2), water will flow to vessel (2). This flow will continue as long as a difference exists in the water level between the two vessels. When the water level in both vessels becomes the same, there is no flow of water between the vessels. Heat transfer is similar. A temperature difference must exist before heat flow occurs. When two bodies are at the same temperature, no heat will flow between the two, regardless of level of the temperature. To illustrate the methods of heat transfer, consider the example of a rod heated at one end. In the diagram shown in Figure 11-4, a metal rod is heated by a candle on the left end. The rod is initially at ambient temperature. UCC 002642 STANDARD **c putno FUNCTION CHAKItK II APPLICATOR TRAINING PAGE 37 APRIL 1970 Height Of Water Heighi Of Water Water will flow from vessel I to vessel 2 as long as vessel I has a greater height of water than vessel 2 in respect to common reference level. Water flow is result of existance of difference in height of water ILLUSTRATION OF WATER FLOW BETWEEN TWO VESSELS DUE TO DIFFERENCE IN WATER LEVEL Figure II-3 UCC 002643 STANDARD omuHtmtna FUNCTION CHAPTER II APPLICATOR TRAINING PAGE 38 APRIL 1970 _____ Heated Air HEAT TRANSFER FOR A HEATED ROD UCC 002644 Figure 11-4 STANDARD ocmcals njtfna CHAPTER II APPLICATOR TRAINING PAGE 39 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Heat Transfer - Contd After heating the rod a certain length of time, a rise in temperature can be felt at the right end and all along the rod. This occurs because of heat transfer by conduction along the rod from a region of high temperature at the left to a region of low temperature at the right. The rate of heat transfer depends on the thermal conductivity of the metal. For copper, with a high thermal conductivity, heat transfer will be quite rapid. However, convection heat transfer complicates the picture. Convection occurs when unheated air sweeps in around the heated rod. The air particles in intimate contact next to the rod are heated up by conduction from the rod to the air. The heated particles become less dense and therefore rise, thus carrying away the heat. More unheated air sweeps in and up to take its place and this process continues. If this happens of its own accord, the process is known as free convection. If air is forced across the rod, say by a fan, it is known as forced convection. The rod will also emit heat by radiation. The heat energy in the rod will be converted to radiant heat in the form of "batches" of energy called quanto. These will be propagated away from the rod to surroundings at a lower temperature in the form of electromagnetic waves. The transfer of heat in this manner is said to occur between two bodies that are different in temperature; the larger the difference, the more that is radiated. Electromagnetic waves travel at 186,000 miles per second and are characterized by their wavelength. Visible light, radio waves, radar, cosmic rays, and radiation are all electromagnetic waves; but they differ in wavelength -- the shorter the wavelength, the higher the energy. Electromagnetic waves need no medium, such as air, for their transmission. Therefore, unlike convection, radiation can occur through a vacuum; for instance, the energy that arrives to earth from the sun is radiant energy only. Restriction of Heat Transfer The purpose of thermal insulation is to retard or hinder the transfer of heat between bodies of different temperatures. Thermal insulations are materials or systems that are resistant to the flow of heat. UCC 002645 STANDARD m *oomcau a hmtk CHAPTER II APPUCATOR TRAINING PAGE 40 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Restriction of Heat Transfer - Contd To illustrate their function return to the illustration of the water flowing between two vessels, (f the pipe between two vessels was large and had little resistance to the flow of water, the flow of water between the two vessels would be large. If the pipe was very small, thus having large resistance to water flow, then the quantity of water flowing between the two vessels would be small. Thus, the higher the pipe resistance the smaller the quantity of water which will pass through the pipe in a given period of time. This is shown in Figure ||-3. In a similar manner, the greater the thermal resistance between two bodies of different temperature the lower the quantity of heat transfer between the bodies for a given period of time. This brings in a new variable which is time. In the water vessel illustration a valve could be put in the pipe, which would enable one to completely stop the flow of water. However, heat will be transferred through all materials if a temperature difference exists either within or between the surfaces of the material. There is no way to completely stop the flow of heat between bodies of different temperatures. By providing thermal resistance between bodies of different, temperatures the quantity of neat transferred in a given period of time con be reduced-. The relationship can be expressed as follows: ,, . . , ,Temperature difference between bodies Quantity' of heat prer rperiod of time = ------ E------- T=hr-e--r-m---a- li res:ist-a--n--c--e------------------- Note: The thermal resistance must be based on time and area units corresponding to that of quantity of heat. When Q = heat transfer per hour At = temperature difference R = thermal resistance Q = At (Equation 1) As stated, the relationship does require that units be of proper units of measurement. UCC 002646 STANDARD OtfiACALS M0 H.ASTKS CHAPTER II APPLICATOR TRAINING PAGE 41 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Restriction of Heat Transfer - Contd In the English System of measuring heat, the common unit is British thermal unit (Btu) and the common unit of measuring temperature is Fahrenheit (F). However, there was never a unit named for measuring thermal resistivity. This thermal resistivity is the reciprocal of conductance (C) or -L . The previously expressed relationship of heat flow in respect to time, area. Temperature difference and thermal conductivity can be written: .. . . r. Temperature difference in F Heat transfer in Btu per sq ft, hr = -- r | . .- Thermal conductiv ity in Btu per sq ft, hr To state in easily used terms: When Heat transfer = Q in Btu/sq ft, hr Temperature difference between surfaces = *1 " *2 if tj equals F of higher temperature surface and t2 equals F of lower temperature surface Thermal conductance of material = C in Btu/sq ft, hr, F Then 1" 2 Q= --x-- C (Equation 2) Thus, the basic equation for the calculation of heat transfer, through one material, is established. This equation shows that to obtain a low rote of heat transfer requires a material of high thermal resistance. It also shows that to obtain high thermal resistance requires materials or systems of low thermal conductance. Classes of Thermal Insulation Thermal insulation is material, or assemblies of material, having high thermal resistance and low thermal conductance. It is produced In many different forms. UCC 002647 STANDARD CKttCAU AND RtAfTW CHAPTER II APPLICATOR TRAINING PAGE 42 APRIL 1970 FUNCTION - Continued HEAT TRANSFER - Contd Classes of Thermal Insulation - Contd Basically there are two general classes. One is mass insulation and the other is reflective insulation. In some instances, the two are used together in a single installation. Mass Insulation Mass insulation is made of solids arranged to form finely divided spaces of oir or gas. An enlarged section of typical mass insulation is shown in Figure 11-5. As shown in the figure, when a temperature difference exists between the two sur faces of the material the heat will use all means to get from the hotter surface to the colder surface. The heat passes through the material by conduction, radiation, and convection. As it is impractical to separate each of the quantities of heat in regard to its mode of transfer, the total amount is stated to pass through the insulation by conduction. The measurement of the ability of a homogeneous material to transfer heat is conductivity (k). The definition is: Conductivity: the heat rate "per unit area per degree per unit length of heat travel." In English Units: Conductivity k 3 Btu/sq ft, hr,F, inch Notice that in English units the heat transfer is per one inch of thickness. Although the purpose of insulation is to provide thermal resistance, mass materials are tested and evaluated based on the heat that does transfer per inch of thickness. Naturally it is desirable that the conductivity be small. Knowing the conductivity it is easy to obtain the thermal resistance of flat materials, as thermal resistance R equals the thickness divided by the conductivity. When R is thermal resistance k is conductivity in Btu/sq ft, hr, F, inch I is thickness of insulation in inches. Then: I R3 I (Equation 3) UCC 002648 STANDARD owwc*n puma FUNCTION CHAPTER II APPLICATOR TRAINING PAGE 43 APRIL 1970 Lower Temperature Total -Heat Transferred(Q) SCHEMATIC ILLUSTRATION OF HEAT TRANSFER THROUGH MASS INSULATION FiAiirA lt_C UCC 002649 STANDARD ovouMfuino CHAPTER II APPLICATOR TRAINING PAGE 44 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Classes of Thermal Insulation - Contd It follows then from Equation (3), the heat transfer per hour (qg) through a single flat moss insulation, I inches thick with a higher temperature tj on one side and a lower temperature t2 on the other, is: C> {Equation 4) Reflective Insulation Reflective insulation is thermal insulation, depending for its efficacy in large part on reduction of radiant heat transfer across spaces by use of one or more surfaces of high reflectance or low emittance. In most instances reflective insulation is an assembly of materials, and more properiymay be called an insulation system. It is not a homogeneous material. For this reason the heat transfer must be measured as the conductance across the system. Heat transfer across the system is due to the temperature difference existing between the two sides of the syem. Like mass insulation the heat uses all methods to get from the hot side to the cold side. This illustrated in Figure 11-6. Again, like mass insulation the means by which heat is transferred from one side to the other are not separated into individual parts and the total of ail is measured as conductance across the reflective insulation system. In this case as the entire system must be measured as a single unit, the length of heat flow path is the entire unit. Thus the basic heat transfer equation is Equation (2). Q (Equation 5) Typical illustration of a reflective insulation system is the "thermos" bottle. UCC 002650 STANDARD nirrif puitkj FUNCTION CHAPTER II APPLICATOR TRAINING PAGE 45 APRIL 1970____________ SCHEMATIC ILLUSTRATION OF HEAT TRANSFER THROUGH REFLECTIVE INSULATION Figure 11-6 UCC 002651 STANDARD NDPUtm CHAPTER II APPLICATOR TRAINING PAGE 46 APRIL 1970 FUNCTION HEAT TRANSFER - Contd Surface Air Film Resistance to Heat Transfer In the use of insulation for conservation of energy in industrial installations, the resistance of the outer air film to the transfer of heat becomes important, as it directly influences the outer surface temperature of insulation. Under static conditions all heat transferred to, through, and from must be of equal quantity. This is illustrated in Figure Ilr7. As shown in Figure H-7, the heat transfer is from hot gas (air) on one side to cold gas (air) on the other. In most installations of insulation on industrial pipe and equipment, the inside surface is the pipe or equipment which is directly in contact with the insulation. Under these conditions, the inner surface temperature is essentially the same as the temperature of the pipe or vessel, and an inner air film resistance does not exist. The vessel or pipe may be hotter or colder than the outside air. These conditions are illustrated in Figure 11-8. The air film has an overall heat transfer conductance f. Or a resistance to heat flow A. . Thus, ' V'a a3 ' -7 t Equation 4 states that: t, - t2 Q a = --r~ lc as Qa = Qa| = Qq2 = Qa3 (As illustrated in Figure 11-7) In the case of one air film or k (Equation 6) (Illustrated in Figure II--8) UCC 002652 STANDARD Mc<u e nuta FUNCTION CHAPTER II APPLICATOR TRAINING PAGE 47 APRIL 1970 Direction of Heat Flow Hot Air Temperature t. Temperature of Hot Surface *1 Air Rim -- ,ya Insulation Heat Transfer To Insulation Q Heat Transfer __ Through Insulation A- ' AA /A. ^ A'/: Heat Transfer from insulation Q 3 t2 Temperature of Cold Surface -- It^Cold Air Temperature f4- Air Film All temperatures t., tj, t2, and t are held constant (static) Heat transfer Q equals Q equals Q l a2 03 HEAT TRANSFER THROUGH INSULATION UNDER STATIC CONDITIONS Figure II--7 UCC 002653 STANOARD CWMCM4 AW HASm FUNCTION CHAPTER II APPLICATOR TRAINING PAGE 48 APRIL 1970 L = thickness of insulation Temperature of pipe or vessel and inner t| surface of insulation Hot Pipe or Vessel Heat Transfer Insulation Heat conductivity of insulation is K AV VvVA, AIR tj = Temperature of Insulation _____ Outer Surface ,^ tQ = Temperature of,Air Air Film,,,-Gohductance, h. Direction of Heat Flow INSULATION ON HOT PIPE OR VESSELL y--L= thickness of insulation Air Film, Conductance h Cold Pipe or Vessel I Temperature of Pipe or Vessel and Inner Surface of insulation tj t - Temperature of Air t2 = Temperature of Insulation Outer Surface Heat Transfer q na AIR Heat conductivity of insulation is K insulation Direction of Heat Flow INSULATION ON COLD PIPE OR VESSEL SCHEMATIC ILLUSTRATION OF HEAT TRANSFER THROUGH INSULATION Figure 11-8 UCC 002654 STANDARD oukau ue ruuna CHAPTER II APPLICATOR TRAINING PAGE 49 APRIL 1970 l FUNCTION HEAT TRANSFER - Contd Surface Air Film Resistance to Heat Transfer - Contd Which is the basic formula to calculate heat transfer through one flat thickness of insu lation. The following examples will illustrate the use of this equation for the calculation of heat transfer. Example 1. Three inches of insulation is installed on a large hot vessel. The temperature of the vessel if 400F. The temperature of the air is 50F. The conductivity (k) of the insulation is 0.4 Btu/sq ft/ hr, F, in. The conductance of the air film is 2.2 Btu/sq ft, hr, F. What is the heat loss per square foot per hour? To find Qq in Btu/sq ft, hr Given: tj temperature of inner surface of insulation = 400F t temperature of air = 50F I thickness of insulation = 3 inches k conductivity of insulation = 0.4 Btu/sq ft, hr, F, in. f conductance of air film = 2.2 Btu/sq ft, hr, F Equation is Substituting in proper values = a 400 - 50 0 1j. _ 0.4 O 350 7.5 + .4 5 _ 350 7.95 = 44 Btu/sq ft. hr Answer UCC 002655 STANDARD OfMCUAIfUITKS CHAPTER II APPLICATOR TRAINING PAGE 50 APRIL 1970 HEAT TRANSFER - Contd FUNCTION Surface Air Film Resistance to Heot Transfer - Contd Example 2. Five inches of insulation is installed on a large diameter vessel/ operating at -100F (tj). The air temperature is 90 F (tQ). The conductivity (k) of the insulation is 0.33 Btu/sq ft, hr, F, in. The conductance (f) of the air film is 1.5. What is the heat transfer per square foot per hour? To find Qq in Btu/s-< ft, hr Given: tj temperature of inner surface = -100F t temperature of air = 90F I thickness of insulation = 5 inches k conductivity of insulation = 0.33 Btu/sq ft, hr, F, in. f conductance of air film Equation is Q= t.1 " *a I 4. I C7 Substituting proper values -- 1.5 Btu/sq ft, hr, F Q= a -W - 90 5+ I 03 T73 -190 15.15 + 0.66 _ -190 15.81 Qq = -12 Btu/sq ft, hr Note tlje minus quantity indicates the heat flow is from the air to the insulation. The theory of heat transfer and heat transfer through two simple cases of insulation has been established. Additional equations and data for solving more complex insulation problems are presented in Thermal Insulation Manual, Volume II, Design. UCC 002656 STANDARD otcttCAU Ate Kitna CHAPTER III APPLICATOR TRAINING PAGE 51 APRIL 1970 PURPOSE GENERAL All materials transfer heat. Thermal insulations are materials which transfer a small quantity as compared to others. This ability to retard heat flow makes these materials useful many places where control of heat is desirable or essential. The use of animal fur was one of man's first uses of a material as an insulation to conserve his own body heat. Over the passage of years we tend to forget that clothes are man's personal insulation to control the heat losses from his body. Yet, automatically in winter we use more effi :ient insulation -- heavier and thicker clothing -- than in summer. From the first cn'de lean-tos, today's office buildings, laboratories, industrial buildings and homes have evolved to provide a resistance to heat transfer so that the inside temperature could be maintained at a level necessary for human comfort. The increased use of refrigeration to keep the interior of buildings cool has further increased the importance of insulation and insulation-type material. In the preservation of food and its preparation, insulation is used in cold storage rooms, refrigerators, anJ stoves to control heat transfer. Likewise, in transportation insulation is used in automobiles, ships, airplanes, and railroad cars, and, of course, it is highly important in space craft. Thermal insulation is essential in the production of power and the processing of almost all materials. Thus there is hardly any phase of modern life which is not infljenced by thermal insulation. Many craftsmen, who are not called insulators or asbestos workers, use or install insulatingtype materials. For example, a man who makes clothes is a tailor. The insulator's craft has developed ar installers of materials having the prime function of providing resistance to heat transfer. Tnis craft is closely associated with the construction industry; hence, both material and labor for its installation are supplied by distributor-contractor companies. In the field of construction there has developed a loosely defined division of types of insulation services. One of these is called commercial and includes the use of insulation in building, such as duct insulation, hot and cold water piping insulation and insulation on low pressure steam piping and equipment. The other is industrial and includes the insulation of power plants, and the piping and equipment of process industries. COMMERCIAL INSULATION In general, commercial insulation is used to control heat flow so as to maintain the atmosphere in the enclosed space at the temperature and humidity as required by the occupants or contents of the building. In addition the insulation serves to reduce the UCC 002657 OOP --STANDARD CHAPTER III APPLICATOR TRAINING PAGE 52 APRIL 1970 PURPOSE COMMERICAL INSULATION - Contd cost of heating and cooling the structure. Although this is a large portion of the insulation industry these specific uses of insulation will not be further discussed as the major importance to our Company is in the field of industrial insulation. INDUSTRIAL INSULATION Insulations are used in the industrial field to control heat to conserve energy, control temperature, protect personnel and as fire protection. In all instances, from an economic view, it is used to save money or make possible the earning of money. The manner in which this is accomplished depends upon the individual installation. Some of the various services requiring insulation are presented to show where insulation is used to save money or make the earning of it possible. HOT TEMPERATURE SERVICE Hot service is commonly considered to be when the temperature of the surface on which the insulation is installed is above 212F. The temperature may be obtained from steam or other heating mediums, such as Dowtherm or electric heaters, or from process reaction. Insulating these hot service lines and equipment may be done for one or more of the following reasons: 1. When the heat in these lines or vessels is of value, they are insulated to conserve this heat. For any particular cost of steam (or other heating medium) and particular cost of installed insulation, it is possible to calculate the correct insulation thickness as determined by good economics. In this case the insulation saves money by saving heat. 2. When insulation is used to control temperature, it is a necessary component of the process system. In this case insulation makes the earning of money possible. 3. When insulation is used to prevent personnel from being burned, it performs a function as a safety device. As such it serves to protect personnel from painful bums and reduces costly lost-time accidents. UCC 002658 STANDARD anmMi H-ajtio CHAPTER IN APPLICATOR TRAINING PAGE 53 APRIL 1970 PURPOSE HOT TEMPERATURE SERVICE - Contd 4. When insulation is used to protect piping and equipment from fire, it again performs a function of increasing plant safety. In this use it also minimizes financial damage in case of fire and also makes it possible to obtain more reasonable insurance rotes. In many instances the same insulation serves more than one of the above given functions on a single installation. Frequently an insulation is used to conserve energy and to control temperature in a process vessel. Also, very often an insulation is used to conserve energy loss from a oipe and act as fire protection for that same pipe. It quite often serves all four functions at the same time. MODERATE TEMPERATURE SERVICE Moderate service is most often considered to be in the temperature range of 35F to 212F. This temperature range includes such insulated items as field storage tanks, hot and cold water, moderate temperature vessels indoors, and air conditioning ducts. The reasons for insulating are the same as the four listed for hot service plus three others. These additional reasons are: 1. When a field storage vessel is insulated to minimize vapor loss caused by solar radiation, it is used to conserve product and by so doing saves money. 2. To control condensation of moisture on the surface. Condensation on outer surfaces causes rusting of steel and causes slippery, unsafe conditions. Preventing it reduces maintenance cost and cost due to accidents. 3. To retard (not prevent) freezing of contents of pipes or vessels in cold weather. Used in this manner the insulation is a necessary part of process control and contributes to the ability to produce a product to earn money. Again, the insulation may be used to accomplish more than one of these at the same time. LOW TEMPERATURE SERVICE Low temperature service is below 35F and extends down to approximately -240F. Although -150 down to -459.7F is low temperature, this range is given the special name of cryogenic. Service in the low temperature range includes insulation on equipment and pipe, and insulation of refrigerated spaces. UCC 002659 STANDARD CHAPTER 111 APPLICATOR TRAINING PAGE 54 APRIL 1970 PURPOSE LOW TEMPERATURE SERVICE - Contd The reasons for insulating is to conserve energy, control temperature, protect from fire, control vaporization, and prevent condensation on outer surfaces. Ail of these have been previously mentioned. CRYOGENIC SERVICE The temperatures encountered in liquifying gases require special insulation consideration. Below -240F the ordinary mass insulations require such bulk to control the heat transfer and temperature, that the insulation becomes impractical. The ideal cryogenic insulation must possess the ability to minimize heat transfer from radiation, conduction and convection. Vacuum assists in this, because a completely evacuated space has no gas to establish convection currents and no molecular contact to provide conduction paths. Radiant energy transfer can be retarded by the use of reflective surfaces. For this reason most cryogenic insulations are similar in principles to the Dewar flask. As this is a very special field of insulation, these systems are seldom installed in the field as ordinary insulation, but must be produced in manufacturing plants where it is possible to seal weld and produce vacuum spaces between the two walls containing the insulation. The Linde Division of Union Carbide Corporation hasdeveloped a number of cryogenic systems and named them Super Insulation. TRACING SYSTEMS The use of pipe or tubing externally attached to process lines or vessels to supply heat or refrigeration to them is called tracing. Tracing is used in high, moderate, and low temperature services. Steam, Dowtherm, hot water or electric tracers are used to supply heat to process lines and equipment. Brine or other refrigerants ore used to transfer heat from process lines and equipment. The major amount of tracing is used to supply heat rather than to remove it. HOT TEMPERATURE TRACING SYSTEMS In this temperature range, pipe and equipment tracers simply add heat, or supply heat to replace lost heat and so retard heat loss from the process liquids and gases. The heat is generally obtained from (1) steam or (2) electricity. UCC 002660 STANDARD (mhcau a* pusno CHAPTER III APPLICATOR TRAINING PAGE 55 APRIL 1970 PURPOSE HOT TEMPERATURE TRACING SYSTEMS - Contd 1. Steam heated systems consist of tubing to transmit steom, which is secured to the external surface of the process pipe or vessel, over which is installed insulation. Heat is transferred to the process pipe or equipment either by system (a) air convection, or (b) conduction through heat transfer cement. These two systems are shown in Figure 111-1. 2. Electric heated systems consist of electrically heated cable secured to the external surface of pipe or vessel, over which insulation is installed. At high temperatures the electric fracing must always be connected to the process pipe or vessel with heat transfer cement to prevent excessive temperature rise in the electric tracer. MODERATE TEMPERATURE TRACING SYSTEMS Within this temperature range steam or electricity may be used to add heat to the process line or equipment, or brine used to remove heat, depending upon the control of temperature required. When heat is added by steam, the air convection system is most frequently used as the temperature desired can be obtained without the use of heat transfer cement. When electric heating cable is used the transfer may be either by the air convection system or heat transfer cement system, depending upon design requirements. When heat is removed from the system by brine, in almost all instances, the heat transfer cement system should be used to obtain efficient cooling. In all cases the insulation over the tracer system is used to control the temperature of the process. In so doing if also conserves energy and provides personnel protection and fire protection. In these cases the insulation saves money and assists in the production process to earn money. It has been indicated that thermal insulation is used to obtain economical plant operation. Therefore, it is important to understand some of the economics involved. ECONOMICS Industrial insulation is used only when the saving, or earnings, justify the expenditure for it and its installation. The first consideration in any particular installation is whether UCC 002661 T STANDARD CHCMCMiAIOfUfna PURPOSE CHAPTER III APPLICATOR TRAINING PAGE 56 APRIL 1970 Process Pipe Direction of Heat Flow AIR CONVECTION SYSTEM Direction of Heat Flow HEAT TRANSFER CEMENT SYSTEM DIRECTION OF HEAT TRANSFER FOR THE TWO SYSTEMS OF HEAT TRACING Figure lll-l UCC 002662 T STANDARD cmukmj mb njktnct CHAPTER ill APPLICATOR TRAINING PAGE 57 APRIL 1970 PURPOSE ECONOMICS - Contd or not insulation is justified. The savings, or profit, must provide a sufficiently large return on the investment in insulation to warrant the expenditure. The decision as to when investment in insulation is justified is based on a number of factors such as the amount of heat the insulation will save, the capital investment to produce die heat, the operating cost of producing the heat, the cost of insulation investment, and the maintenance cost of insulation. At moderate temperatures the temperature difference between service and atmosphere is small; therefore, the heat loss would be small. In such circumstances the amount of money that could be invested in insulation to retard this heat loss would be small. Therefore, in this temperature range law cost insulation must be used, otherwise it could not be justified. To illustrate: low cost sprayed foam insulation is used in these services where higher investment insuiotions could not provide sufficient return to warrant their use. At higher temperatures, when there is no question that insulation is a good investment, the question then becomes one of how much (thickness) of insulation should be used to obtain the best economy. Heat energy is valuable in that it has monetary value. However, there is no direct conversion from Btu's into dollars, as the cost of heat depends upon many factors, such as its form, location and use. For example: the Btu's in gasoline are generally more costly than those from coal. Also Btu's obtainable from coal are less expensive at the mine than at some distant point to which coal must be moved to be used. Likewise, the cost of installed insulation varies with the materials used, location, labor rates and other factors. The simple statement that "the greater the thickness of insulation the smaller the loss of heat," may be restated as "the greater the cost of insulation the smaller the cost of heat." Depending upon the cost of installed insulation and the cost of heat, a definite thickness of insulation provides the lowest total cost. This basic truth has been recognized for years. At a meeting of the American Society of Mechanical Engineers in New York City, on December 6, 1926, Mr. L. B. McMillan presented a paper entitled "The Heat Transfer Through Insulation," in which he presented the formulas for calculating the economic thickness of insulation. For those interested in mathematics, the formula is shown on the following page. UCC 002663 STANDARD OWOU AND PlASTia CHAPTER III APPLICATOR TRAINING PAGE 58 APRIL 1970 PURPOSE ECONOMICS - Contd Mr. L. B. McMillan's Equation for Determining the Most Economical Thickness of Insulation - Cylindrical Surfaces When B - cost of insulation per year in dollars; including depreciation of capital investment, cost of money, return of investment and maintenance. k = conductivity of insulation in Btu/sq ft, hr, in, F. r1 = inside radius of insulation in inches. r2 -- outside radius of insulation in inches. *o = operating temperature of surface to be insulated, in. F 'a = temperature of air-mean average, in. F. M= value of heat in dollars per 1,000,000 Btu; including depreciation of capital investment of equipment to produce heat, cost of money, return on investment and maintenance. Rs = sum of thermal resistances, including surface resistance. Y = hours of operation per year. * ]p^. Y(tc - ta)Mx k Although the formula is complex, the physical laws upon which it is based are quite simple and can best be understood from graphs. To illustrate the first statement "the greater the thickness of insulation the lower the heat loss," see Graph No. 1. Notice that on a bare pipe or piece of equipment the heat loss curve runs completely off the chart. Also notice that after insulation is installed it becomes necessary to double the insulation thickness to cut the remaining heat loss in half. UCC 002664 STANDARD OCMCAU M RtAJTO PURPOSE CHAPTER IN APPLICATOR TRAINING PAGE 59 APRIL 1970 ECONOMIC THICKNESS OF INSULATION HEAT LOSS, H U 'S I 2345678$ 10 INSULATION THICKNESS, INCHES CIAPH 1 UCC 002665 STANDARD O910CALS AW RLASTtCS CHAPTER III APPLICATOR TRAINING PAGE 60 APRIL 1970 PURPOSE ECONOMICS - Contd As previously stated, Btu's have monetary value; therefore, the scale showing "&u's" can be replaced by dollars per year. This in no way affects the curve if the vertical scale is converted to the correct unit value. As shown in Graph 2, the heat loss-cost curve will include the following cost factors: (1) cost of fuel, (2) capital investment of heat producing equipment, (3) cost of moneyfor capital investment, (4) interest on investment, (5) depreciation period, (6) maintenance, (7) numberofhours of operation per year. In dollars per year the insulation cost can be plotted. Cost factors included in this curve are: (1) capital investment, (2) cost of money for capital investment, (3) interest on investment, (4) depreciation period, (5) maintenance cost. The sum of these two curves produces total cost curve. As would be expected, the most desirable condition is where the total cost per year is the lowest. The formula given by Mr. McMillan gives the method of determining this low point. As can be seen in Graph 3, each addition of inch of additional insulation saves less heat than the preceding inch. Therefore, it also saves less money. To illustrate the influence of economical insulation on the capital investment and operating cost of a typical actual installation, consider an 8-inch steam line operating at 425F. The average ambient temperature is 50F. With the following cost factors: Capital Investment in Steam Production is $12.00 per lb hour. Production Cost of Steam is $0.40 per 1000 lb. Capital Investment in Insulation is as follows: 1^ inch thickness $3.30/linear foot 2 inch thickness $4.10/linear foot 2% inch thickness $4.84/1 inear foot 3 inch thickness $5.90/!ineor foot Depreciation period -- 15 years With no insulation at all, the heat loss would be 2,841 Btu per hour, per linear foot of pipe. (The heat contained is 2,36 lb of steam per hour.) To produce this lost heat, a capital investment for steam production would have been $28.32. The cost to produce this heat would be $6.25 per year. By calculating costs based on the information given, the following table is obtained. UCC 002666 t I i l I k 1 L L L L L L L L L STANDARD OCUCI11 AMO PLASTICS PURPOSE CHAPTER III APPLICATOR TRAINING PAGE 61 APRIL 1970 COST FACTORS NUT: run cost CAPITAL INVESTMENT COST OF MONEY MTEREST MPKCUTMN MAINTENANCE NO. HRS. OF OPEN. ECONOMIC THICKNESS OF INSULATION 5 2 s e MSMATHM: CAPITAL INVESTMENT COST OF MOOT MTEKST ocmcMnoN MAINTENANCE MINIMUM C O n I 234 S67A9 INSULATION THICKNESS, INCHES UHI 2 UCC 002667 10 STANDARD OWHCALS AMD fLAITO PURPOSE CHAPTER Id APPLICATOR TRAINING PAGE 62 APRIL 1970 COST FACTONS HEAT: FUEL COST CAmu. mvEsraofr COST OF HOMEY INTEMST DEPRECIATION MAINTENANCE NO. HNS. Of OPEN. ECONOMIC THICKNESS OF INSULATION A -samm av nm i- insulation MINIMUM COST INSUIATKNI: CAfllXL WVESTMEMT COST Of MONET MTEKST DEPOECtATKM MAINTENANCE 1 234 56789 INSULATION THICKNESS, INCHES UCC 002668 CMPH 3 10 STANDARD OIUC1U A HJJTO CHAPTER ill APPLICATOR TRAINING PAGE 63 APRIL 1970 PURPOSE ECONOMICS - Contd Insulation Thickness Inches Bare 1* 2 2* 3 Capital Investment to Provide Steam for Heat Loss $ 28.32 2.57 2.10 1.74 1.52 Capita 1 Invest ment in Insula tion $ None 3.30 4.10 4.84 5.90 Total Capital Invest ment $ 28.32 5.87 6.20 6.50 7.42 Yearly Cost of Heat $ Additional Cost for Each Added ^ inch of Insulation $ 6.25 0.58 0.46 0.36 0.30 0.33 0.38 0.92 Fuel Savings for Each Added i inch of Insulation $/Year 0.12 0.10 0.03 The lowest capital investment would be if only inch insulation were used. But, with an additional investment of $0.33 to obtain 2-inch thickness, a saving of $0.12 per linear foot is obtained. The increased capital cost to obtain 2\ inch thickness over 2-inch thickness is $0.33 and a saving of $0.10 per linear foot is obtained. This is still a good investment. When the thickness is increased from 2^ inches to 3 inches, the capital cost increase is $0.92 and the savings if $0,003 per year. This is not considered a good investment. Thus, 2% inch thickness is the correct thickness. In the absence of compelling reasons otherwise, the economic thickness determines the insulation thickness. This is not always as easy as one might expect, as even within a single chemical unit the economic thickness may differ from one pipe to another, although all operate at the same temperature. The difference is ccused by difference in cost of heat to be conserved. For example: heat caused by chemical reaction may have little value and might even be required to be dissipated. The cost of high pressure steam might be different from low pressure steam. Heat from a Dowtherm boiler is more expensive than steam. Electric heat or electrically heated Dowtherm is very costly energy. Good ecoromy demands that each be insulated the correct thickness. UCC 002669 STANDARD cmemcals am Puurncs CHAPTER III APPLICATOR TRAINING PAGE 64 APRIL 1970 PURPOSE ECONOMICS - Contd Although the "economic thickness" was given for high temperature service it applies equally well when units of cost are based on cost of refrigeration. In both instances the calculations to determine economic thickness by McMillan's equation is quite time consuming. To make the determination simple, a manual of "How to Determine Economic Thickness of Insulation" was prepared by Union Carbide Corporation in cooperation with the Engineering Experiment Station, West Virginia University, This manual was later published by the National Insulation Manufacturers Association. The specification of the correct insulation thickness is properly an engineering function, and may be considered of no particular interest to the field applicators. However, even the most careful engineering design is of no value until the insulation is correctly instaljed by competent craftsmen. Poor workmanship can completely ruin the economics obtainable by insulation. The knowledge as to the importance of insulation in saving money makes one understand the importance of skilled workmanship. UCC 002670 i [ L b L L L L L STANDARD OtMCAU V* HJJTK* TYPES AND FORMS CHAPTER IV APPLICATOR TRAINING PAGE 65 APRIL 1970 PHYSICAL AND THERMAL PROPERTIES The two fundamental types of thermal insulation are mass and reflective. Each of these is produced in a number of forms. MASS INSULATION* 1 Mass insulation is made of numerous mass structures. These are: fibrous, granular, flake, cellular. Fibrous insulation is composed of fibers produced of many materials, some of which have similar characteristics and others possessing very different characteristics. Some of the fibers used in producing insulations are: 1 . Refractory fibers 2. Lime or slag fibers 3. Glass fibers 4. Asbestos fibers 5. Cattle hair The various fibers are bonded, felted, or woven together to produce various forms of materials. By variations in manufacturing methods and composition, o wide range of materials having different properties is produced. Granular insulation consists of small nodules which contain voids or hollow spaces. They ore not considered true cells, since gas (air) can be transferred between the individual spaces. The following materials fall within this classification: 1 . Calcium-silicate 2. Diatomaceous earth 3. Expanded silica 4. Open cell plastics 5. Vegetable cork In production of calcium-silicate, diatomaceous earth and expanded silica products, fibers are frequently added to improve the tensile strength of the material. However, the major amount of material resisting heat flow is thegranular material. UCC 002671 STANDARD OHUTAU JMO PLASTIC* TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES CHAPTER IV APPLICATOR TRAINING PAGE 66 APRIL 1970 ! ` MASS INSULATION - Contd -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- l Cellular insulation consists of small individual cells sealed from each other. Their major difference is that each cell is hermetically sealed from all others. The materials which fall within this classification are: 11 1. Cellular glass 2. Cellular plastics The fact that a material is cellular does not mean that no gas can pass from cell to cell. Gas will pass through many plastics; thus, there can be an interchange of gas through the walls of the cells of cellular plastic insulations. Flake insulation consists of small leaflike pieces. The material, of this description, most commonly used for insulation is vermiculite. Combination of these basic materials to produce an insulation of specific properties is quite common. Granular material is used as bonding agent for fibrous and flake material. Fibers ore added to granular material to increase tensile strength. Therefore, in many instances, a finished product can only be classified by the material which is its major component. Forms of Mass Insulotion These insulations are produced in many forms. Some of them are: 1. Rigid board, block, and pipe covering. 2. Semi-rigid board, block and pipe covering. 3. Flexible board and preformed pipe covering. 4. Blankets. 5. Felts. 6. Loose. 7. Tape. 8. Rope. 9. Cloth. 10. Paper. I l l L l L L L L UCC 002672 STANDARD QWflMI AJO PL4STCS CHAPTER IV APPLICATOR TRAINING PAGE 67 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES MASS INSULATION - Contd Other insulations are produced in one form and after application change into rigid material. These are: 1. Insulating or finishing cement made of fibers, grandules, or flakes with binders, in loose form. When mixed with water to proper consistency, it is applied to surfaces by trowel or palm. Sets to a rigid form after it has dried. 2. Fibers and binders made in bulk form. The fibrous mixture is applied to the surfaces to be insulated by spray gun, which adds water to the mixture. The sprayed plastic mix dries to form a rigid material. 3. Insulation mastics are fibers, flakes, or granules of insulation factory mixed with binders and liquids to a heavy plastic consistency. Application to surface is by trowel, palm, spray or brush. After the material has dried it becomes a firm semi rigid mass. 4. Sprayed organic foam consists of two (or more) liquids. When the components are mixed together by spray gun or mixer, then applied, the chemical reaction causes a foaming action. After reaction is complete the resultant mass is a cellular, organic, rigid insulation. 5. Bulk bituminous granules, which are poured into cavities, generally in trenches around underground pipe. After heat curing, the granules harden into a rigid mass. REFLECTIVE INSULATION Reflective insulation is composed of parallel thin sheets, or foil, of high thermal reflectance, spaced to direct radiant heat back toward the source. The spacing is also designed to provide restricted air (or gas) spaces. This reduces heat transfer by convection and conduction. In most instances, the thin metal sheets, or foil, are made of aluminum or stainless steel. Forms of Reflective Insulation Reflective insulation may be installed as part of building construction by the installation of sheets or foil in walls or ceilings. In this case the material comes in rolls or sheets and is field applied with other construction materials to form insulation. UCC 002673 STANDARD CHDBCMi AMD PLASTICS CHAPTER IV APPLICATOR TRAINING PAGE 68 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES REFLECTIVE INSULATION - Contd Reflective insolation is also obtainable in preformed pipe covering and panels to fit vessels and equipment. This is a rigid factory assembly. Because of the fact that these assemblies are factory produced to fit the pipe configuration and individual equipment, most are custom made to fit the piping or equipment to which they are installed. A third form of reflective insulation is flexible insulation. Although a few years ago one manufacturer devised a reflective lining for overcoats, there has been relatively little devel opment in flexible reflective insulations until very recently. However, the space agency has developed insulation suits using light-weight reflective insulation as the principal thermal resistance. This same development is also being used to make special suits for fire fighters. Combination of Types of Insulation Sheets of reflective insulation ore used with light density fiber insulation. In such an arrangement the fiber material acts as the spacer for the reflective insulation and also pro vides resistance to heat flow by its low conductivity and causes resistance to convective air movement. The amount of surface contact between the reflective insulation and the mass insulation must be kept to a minimum to ensure effectiveness of the reflector. Use of Vacuum in Insulation Both mass insulation and reflective insulation are much more effective if in a vacuum. This is due to the fact that air, and all other gases, does conduct heat. In the field of cryogenics, insulation in vacuum is commonplace. The use of vacuum to obtain effective insulation is not new. At the early part of this century. Sir James Dewar invented a container with an evacuated space between the two silvered walls. This is called the Dewar flask and is now commonly known as the "Thermos" bottle. Using this same principle, insulation for low temperature gases is installed in evacuated wall spaces. Sometimes the space is filled with powders and other times with reflective sheets separated by layers of glass mat or cloth. This latter system was devised by Linde and is named "Superinsulotion." UCC 002674 STANDARD OttflCALS AND RtAlTCt CHAPTER IV APPLICATOR TRAINING PAGE 69 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS From the number of types, forms ond vorieties of insulation material, it is evident that there must be considerable differences in the properties of these materials. This being so, it becomes important to understand the properties of these materials in order to select the one which will satisfactorily serve for a given installation. Some of the properties are of a nature which can be tested and numerically evaluated. Others, although no less important, cannot be so evaluated. Some of the latter are: 1. Availability. 2. Price. 3. Shape and sizes available. 4. Straightness and squareness, or trueness. 5. Smoothness of surface. 6. Cutting characteristics. 7. Dust hazard-health. 8. Compatibility with adhesive or cement. 9. Compatibility with coating (weather barrier). 10. Speed and cost of fabrication. 11. Speed and cost of installation. 12. Cost of shipping, handling and storage. 13. Efficiency of packaging. Some of the items will, in the future, have methods of testing by which they can be evaluated. These are straightness and squareness, trueness, smoothness, cutting characteristics, and com patibility with adhesives, cements or coatings. Other items such as availability, price, size and shape available are related to procurement ond are constantly changing, thus requiring periodic reevaluation. In addition, other factors such as cost and speed of fabrication must also be considered. The workability of material is a property which cannot be evaluated, at present, by technical test methods. Thus, these properties ond factors although difficult to measure or evaluate, ore important and must be considered. UCC 002675 STANDARD 4cHmcu ***> nutio CHAPTER IV APPLICATOR TRAINING PAGE 70 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd The physical, chemical; moisture and thermal properties are: 1. Abrasion resistance. 2. Alkalinity, pH 3. Capillarity. 4. Combustibility a. Flash point b. Flame point c. Self-ignition poi nt d. Flame spread index e. Smoke index f. Fuel contribution g. Melting point 5. Corrosion - rusting of carbon steel or other metals. 6. Corrosion - stress corrosion of stainless steel. 7. Cracking - hot surface. 8. Density. 9. Dimensional stability. 10. Dusting. 11. Drop resistance. 12. Elongation. 13. Expansion coefficient. 14. Hardness. UCC 002676 STANDARD OttMICAU AMD PLASTICS CHAPTER IV APPLICATOR TRAINING PAGE 71 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd15 16 17 18 19 20 21 22 23 24 25 26 27 15. Hydroscopicity. 16. Resistance to acids. 17. Resistance to caustics. 18. Resistance to solvents. 19. Shrinkage - heat. a. Linear b. Volumetric 20. Solvent absorption. 21. Specific gravity. a. Real b. Apparent 22. Strength. a. Breaking b. Compressive c. Flexural d. Shear e. Tensile 23. Temperature limits, minimum and maximum. a. Continuous b. Short periods c. Cyclic 24. Temperature rise - self internal heating. 25. Thermal conductivity. 26. Thermal diffusivity. 27. Thermal shock resistance. UCC 002677 STANDARD ooMctu rtATna CHAPTER IV APPLICATOR TRAINING PAGE 72 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd28 29 30 31 28. Vibration resistance. 29. Warpage - in service. 30. Water absorption. 31. Water vapor transmission. Materials which are installed in a wet state, such as cements or mastics, have all the above listed properties as dry materials, but in addition hove the following: 1. Adhesion a. Wet b. Dry 2. Shrinkage - wet to dry a. Linear b. Volumetric Organic foams applied in wet state have the property of swelling or as follows: 1. Expansion - wet to cured a. Linear b. Volumetric All these properties relate to the properties necessary for a material to be purchased, shipped, stored, fabricated, installed and ability to function properly in service. Because these terms are those which describe materials, it is essential that the meaning of each is clear and the significance of each is understood. In conversation, or written communication, problems related to materials must be discussed in these terms. For this reason the definition of each and the significance follows. UCC 002678 STANDARD odftCAi* *4> nJAva ac .......... . . .- CHAPTER IV APPLICATOR TRAINING PAGE 73 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd Abrasion resistance, the ability of a material to resist wearing away when rubbed by another material. Significance: Whenever insulation is installed on a pipe or vessel which vibrates or moves,the insulation must be able to withstand the rubbing of the metal without wearing away. On the other hand, many materials are formed by the use of abrasive materials which rapidly grind the surface to the desired contour. Almost all insulations can be abraded away. The problem is to obtain the degree of abrasion resistance desired. To illustrate: Wood can be abraded away relatively rapidly by sand or garnet paper, but is very satisfactory when used in floors or furniture, particularly when protected with a wear-resistant finish such as varnish. Alkalinity (pH), A relative value of soluble caustic contained in the material. Significance: A reference to indicate insulation materials which may be applied to metals without causing corrosion. Insulations slightly alkaline are suitable for carbon steel; whereas, they should be slightly acid when applied to aluminum. Capillar?ty, the action by which the surface of a liquid, where it is in contact with a solid, is elevated due to the relative attraction of the molecules of the liquid for each other and for those of the solid. Significance: This is a measure of liquid transfer through insulation. Should one water leak occur in installed insulation, a high rate of capillarity spreads the water damage. Combustibility, the capabiIity of burn!ng. Significance: This property is vital in determining fire hazard. Measurement of degree of combustibility is quite difficult as there are many aspects to fire, fire spread and release of gases and smoke. For this reason these various aspects of fire given below we re separated for tests and evaluation. Flash point is the temperature at which the vapors from a material at that temperature will flash into flame when ignited from an external fiTe source. Flame point is the temperature at which the vapors will flash and continue to burn when the ignition source is removed. UCC 002679 STANDARD OtCMCALi AND PLASTICS CHAPTER IV APPLICATOR TRAINING PAGE 74 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd Self ignition point is the temperature at which a material will begin to burn without an external ignition source. Flame spread index is the rate at which fire will spread from its original burning poi nt. Smoke index is the measurement of the density of smoke given off when a material burns. Fuel contribution is the amount of heat given off by a material when it is burned. Melting point is the temperature at which a material changes from a solid to a liquid state. Corrosion, rusting of carbon steel, or erosion of other metals by chemical action. Significance: If the insulation causes rusting or corrosion of metals to which it is applied, failure of the pipe or equipment may occur . Corrosion - stress, of austenitic stainless steel, is deterioration of austenitic stainless steel due to attack of chloride ions. Significance: The stress corrosion cracking takes place in the presence of concentrated chloride ions. Moisture absorbed by the insulation from the atmosphere, or from rain, will cause leaching of chloride contained in the insulation. To prevent this type of pipe or equip ment failure, either the stainless steel must be protected, or insulation used which does not cause the stress cracking. Insulation, when used on stainless steel, should be tested to determine if it will cause this corrosion. Cracking - hot surface, is the cracking of the insulation on its face next to a hot surface to which it is applied. Significance: Excessive hot cracking on the surface reduces the strength of insulation and causes a loss in its efficiency. Density is the weight per cubic foot. Significance: Must be known to figure loading of supports, etc. UCC 002680 STANDARD OltltfCALS AMO PLASTIC) CHAPTER )V APPLICATOR TRAINING PAGE 75 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd Dimensional stability, is the ability of a material not to change in dimension in respect to time or temperature. Significance: This is generally considered to be change beyond ordinary change due to expansion. Excessive shrinkage, swelling or warping, will cause excessive cracks and voids with resultant greater heat transfer. Dusting, is the release of particles from insulation material as it is handled or cut. Significance: Dust particles are an annoyance and may be a health hazard. Drop resistance, is the ability of a material to fall on a hard surface without chipping or cracking. Significance: In shipment, handling and application, this property affects the amount of rejected broken material. Elongation, the ability of a material to stretch without fracture. Significance: Insulation, especially in high temperature service, is applied to metal surfaces that expand and contract. The ability of insulation to elongate under tension reduces its tendency to fracture. Expansion coefficient is the unit change in dimension due to a unit change in temperature. Significance: This property of an insulation material establishes the relationship of its change in dimension in reference to other materials of construction. It is necessary to know the value of the coefficient of expansion to calculate problems related to spacing, and expansion joints. Hardness, the resistance of insulation penetration. Significance: This physical property is often ignored in the insulation industry because of wide range of surface hardnesses of various insulations. In some services a hard surface is needed, while in others a soft surface is desired. Hydroscopicity, the amount of moisture a material will absorb when exposed to damp air or gas. Significance: The amount of moisture contained in insulation affects many of its other properties including its thermal conductivity. UCC 002681 STANDARD CHIMCAli C H-kynCS CHAPTER IV APPLICATOR TRAINING PAGE 76 APRIL 1970_______________ TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd Resistance to acids. Resistance to caustics. Resistance to solvents, The ability to resist the chemical action, or destruction. Significance: All materials can be destroyed by various acids, caustics, or solvents. Thus when insulation may be subjected to any of these, it should be determined which insulation will resist the particular contaminate involved. Shrinkage - heat, the amount of dimensional change due to being subjected to maximum tem perature for which the insulation is used. This change is both linear and volumetric. Significance: Shrinkage is the major cause of cracks in high temperature insulation. Solvent absorption: The amount of solvent, (or acids or caustics) that a material will retain after being wetted and allowed to drain. The amount of these liquids which a material will retain may be quite different, especially as compared to water. Significance: The amount of liquid a material will take up or hold constitutes a safety hazard or fire hazard. Specific gravity, the weight of material as compared to water. As most insulations contain many voids of trapped air or gas, the apparent specific gravity is the weight of the insulation, including all voids, as compared to the same volume of water. The real specific gravity is the weight of the solids only as compared to the same volume of water. Significance: The differences of these indicate the amount of air or gas space contained in the insulation. It should be noted that from the apparent specific gravity given for most in sulations, it might be assumed that they would float on water. However, in mass cellular insulation water can replace the air and if the real specific gravity of the solids is greater than 1.0 the mass will sink. Strength, the ability of material to resist forces. Strength is a combination of abilities to resist many types of forces. These are breaking, compressive, flexural, shear and tensile. Breaking strength is the ability of a material to resist a transverse load. Compressive strength is the ability of a material to resist a pressing or squeezing load. Flexural strength is the ability of a material to resist a bending load. Conversely, flexibility is the property to be able to be bent without fracture. UCC 002682 STANDARD CX'WULl > WJJT1C1 CHAPTER IV APPLICATOR TRAINING PAGE 77 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Con Id Shear strength is the ability of a material to resist a slicing load. Tensile strength is ability of a material to resist a pulling load. Significance: The particular combination of these various strengths is what makes one material more suitable to fulfill a given set of physical requirements than another. Temperature limits, the minimum and maximum temperature beyond which the insulation will not give satisfactory service. These temperature limits are affected by the time of subjection to temperature and by the rate of change of temperature; therefore insulation temperature limits are rated as continuous temperature, short period temperature, cyclic temperature. Significance: When insulations are subjected to temperatures beyond their limit, they fail mechanically, thermally or chemically. Temperature rise - self internal heating, the characteristic of some materials, which when heated, experience an internal combustion reaction, with a resultant internal temperature rise well above that of the heat to which it was subjected. Significance: This most often ruins the insulation and might ruin the surface to which it is applied. In some instances it might cause serious accidental fire. Thermal conductivity, the heat flow rate per unit of area, per degree, unit of length and time. Significance: The basic measure of heat transfer, used in calculation of heat flow, economics and temperature determinations. The lower the conductivity the more efficient an insulation is in reducing heat flow. Thermal diffusivity, the temperature flow rate per unit of area per degree unit of time. Significance: This property is that which determines the rate of "heat-up" or "cool-down". Materials used in cyclic operation most generally require a material of high diffusivity; whereas, materials used for fire protection should be of very low diffusivity. Thermal shock resistance, the ability of a material to withstand rapid change in temperature without cracking or spalling. Significance: Very important property for materials subjected to thermal shock or direct fire impingement. UCC 002683 STANDARD CHUKCAU AND H.AJT1CS CHAPTER IV APPLICATOR TRAINING PAGE 78 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd Vibration resistance, the ability of a material to resist oscillating motion. Significance: Many applications of industrial insulation are to surfaces that vibrate, if the material breaks down, packs, or settles because of vibration, it becomes ineffective as a thermal insulator. Warpage resistance, the ability of a material to maintain its trueness of dimension after subjection to the effects of time, and high or low temperature. Significance: Warpage of insulation in service causes cracks and openings between the fitted insulation blocks or pipe covering. In addition it may cause failure in the weather barriers. Water absorption, the amount of water that a material will retain after being wetted and allowed to drain. Significance: The amount of water an insulation will take up and hold directly affects its conductivity. Water vapor transmission, the rate of water vapor (moisture in gaseous state) movement of a body between two specified parallel surfaces, under steady conditions, through unit area, for a unit time. Significance: This is the most important factor for insulations used in low temperature service. As vapor penetrates the insulation, it is likely to condense into liquid water and increase the conductivity of the insulation. In addition to the properties related to insulations installed in the dry state, the properties related to insulating cements that need to be defined are: Adhesion, the ability of a material to stick to a surface. In water-mixed cements and mastic, this ability to stick may be different when it is wet and plastic than when it is dry and in solid state. Significance: Good adhestion is necessary in the wet state for ease of application and sufficiently good adhestion is necessary in the dry state to keep the material from falling off or parting from the substrate. Shrinkage, wet to dry, the difference in volume and dimension from wet to dry state. Significance: The amount of shrinkage affects the amount of insulation applied to obtain that desired. Excessive shrinkage may cause cracks and loss of adhesion. UCC 002684 STANDARD CXMCALl UC PLASTOS CHAPTER IV APPLICATOR TRAINING PAGE 79 APRIL 1970 TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES PROPERTIES OF INSULATION MATERIALS - Contd The preceding items are the terms used to describe insulation materials and their properties. In many, test methods have been devised which are used to establish numerical values for these properties. An engineer must use these numerical values to design and specify insulation materials. However, these properties are frequently described in general terms. To illustrate, assume one rigid insulation was described as having a compressive strength of 50 psi and another of having a compressive strength of 125 psi. For design purposes, the numerical values must be used. For general communication, it could be stated that the first had fair compressive strength whereas the second had excellent compressive strength. To promote understanding between engineering and field erection, it is essential that both use these terms when describing materials. TABLES OF PROPERTIES OF VARIOUS INSULATIONS Each particular insulation has its individual physical and thermal properties. The difference in properties of one material as compared to others is what determines its particular usefulness in particular service requirements. There is no one material which is the best for all service requirements. Thus each set of service requirements must be evaluated and the material (or materials) most suitable should be selected. In most instances selection of the materials for a particular set of services is a responsibility of the design engineer. However, in some cases, such as emergencies, the insulation applicator may be forced to make a material selection. In this training course, it is impossible to present all the technical facts concerning all insulation materials but it is certainly desirable for the applicator to have some of the basic facts of the most commonly used insulations. For this reason tables presenting some of the basic physical and thermal properties of insulations commonly used in industrial insulation has been prepared. These tables have been tabulated in reference to the types and forms of the insulation. Included are Rigid and Semi-Rigid, Flexible, Blanket, Loose and Fill, Cements, Sprayed or Foamed In Place, Reflective, and Cryogenic Vacuum insulation. Such forms as Tape, Rope, Cloth, Paper has not been covered as it was felt that these were very specialized. UCC 002685 PROPERTIES OF THERMAE INSULATIONS STANDARD CMDUCMJ MI PLUTO TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES CHAPTER IV APPLICATOR TRAINING PAGE BO APRIL 1970 S >-< tz U. > zr3 Pv- 0 r 2<ui ^ g - ; uT ul. iC UlT Q 8 8 8 8 8 - ^ Z- 5 33 8 f*> >o o uo > rc*j in* *o- -Nc c>o O 5 38 ps. n ri ri uT sa 8 S 3 S44: q i2u^j9ui-nj I' t I I i i i i I i 1 I I I 1 l s I 1 s' I l ^ a -- < > .z DC l/ | -55 > - " > -& >s sr V >> >* C-D n ^o d --` oo 3I 2 d --' *or " Oo i<<2#> s $ IO o---- o O g o --> ~ *# *lO 8 5 Ut/1P 2 ga zI 2<UzSI\ 2 * VI a? * }> o ,, ~s o o *5 * to D 8 3 8 o3 i uwj! - - O r~ot o jS a m OO o g oi S8 <: a o I Ui O' oc p ^ g in 1 1 1 >% V V5 Z 5 0l_> =idi5u_ o Z * o Z o Z ee o Z 1Is VvO 1V 1V vi U _n " _d " .a * -Q -S o Y2 2 i sc o Z ee % . u. w z l z U % u t3 2 o 2 o zz% ooo O MO mO M" N Q -* N- -- -- r>* 5 CD o v> P *> pi - -- -- CD SO tol 8NM888'8O8e`8<N8<N8N 8 8 18 1 8 -- *0 -- CD ft V) O 22 s 5 y yy y o' oi a.' fij a. d 0 0 w6 5 y flu 0 1 5 =' J J 3 u y 4 U & rtoi U d aeo ol Ad y a! 0 u (k bA U di bs o m _]E m ji 2 to A _SE a A . Z in JS .= ~ z. UJ o I -<7 0u " 0u 0 3 J X< o' 3 6 ? ?1 J D UL. I* O = *C C jj .4 Ii |i ]4a JOS a 6 & 6 8 | I oas oa> I 3 5 =5 J 1 i 5 u. u- o V Jj ito O o "o iSff.? -- o (5 > O 5 S UCC 002686 3, | I . V g >, ^3 -^ o u ^ <5 s s! & O 8 > ^^ 8o - 3 3 8j if II 11 2J ae * ac *o s 1 r . L> 1 1 f! Sj 1= J'i H g JC 5 Z> ^ aM:l si o.-- v1ft ^5 IU.s} i I I I I l l l L L L L L L r STANDARD OtBKMJ PLASTIC! r TYPES AND FORMS nir;rA. AK.H THERMAL PROHRTIES F CHAPTER IV APPLICATOR TRAINING PAGE 81 APRIL 1970 100F ,24 io . 2B:300f .34 to 9 .0 to 96 less than 25 F IMi z r!" O tx z V UJ 3 E*^ F 2 sf ^ UL 8 & >< --> ou. h * ^O *z" u!j 5 ^ *F 6I 1 N di ^ < > .Z 25 lls -& x * > -ifs ia> >t9- 2 giz OrJ 8 00 8* S|-V:IU2) UJ ^ *T x 3-- i 1 i 8u> 8n Ss $ s I 1 1I 1 l *So 5ia> e"f ooc <a lti v> w> n v-i *o o. o* o* o o o o oo oo g s O O* O ) 00 CD to *> CD IO --* X u3 }* 5 OJS U l/T -* is Sg : si OO D a < pt ^ UJ 30 A v UJ 2 =3 0^5 <J Ik V z8 V zg E0 V i I s .3 VoC Z I V i v l Ij 2* CioN [ t/l > |? 'iSt| ISUAL i iS-j m& eg o Z I* "e i: 2 a >* 56 ro* >o t >- l t./Z> =U> uOZ>_j o 88 I N <M - - L S " l J! T> o0 ot Z 2 a 0 2 Iku iku Z7. 2O ?o ZZ IT1 o4k -0 ooc -i/C% aOe i c-- r oIk _- 4) i c--X 450 to 600 3 to 9 None blanket Minerol Fibers w ith binders L * cMa F 1 ut9o. > u eUZJ ZUJ fi o= o fo O A 5* jl Zo 6! a i is ik * 5 il ^c oe Ji -6 >3 JC Ik si J V U *2 Z' 5>f E 48 ese *wo> o < ik o s os k |L 2 u Q aUJ. >y TO I i j C 2 8, 6 i j c i > t z is z tMuS 2 * I ik E ZM o i < j i 8888t 555O s UCC 002687 o STANDARD oouuMifunio TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES CHAPTER IV APPLICATOR TRAINING PAGE 82 APRIL WO INSULATING AND FINISHING CEMENTS >o fj r oT 5Z5 A -- U z :*z Ouxoe Z< 8a> 800 8 8= Vk I 8g 8S -- 6s? r ss 8 > S3 s P O -J s? X 8 S3 O oo >n co C < _L Eo V <? V U VV c cc 8=2 i 1i V c i I YY C 1 . I/) *38- ii I 8 <oN O YY 88 o 6 a aa < << *& ? .? t 1" 0 ? o !c 5 5 -- 3 i Hi I i I? i E| 3E -E 51 4e 4 -8 J u. mx I ? jS ag J?E. 2v *1 U E _g 88 ll i < i! < < -?a < u * 1 .1 1 s |J g g -8 o8 O g -5- < s 1J <5 g U. I s 1 -s'? HII -- -- ^ "O 2 w -CO UCC 002688 L L L L L L L r STANDARD cmaCiu ruina f TYPES AND FORMS PHYSICAL ANQ THERMAL PROPERTIES f r CHAPTER IV APPLICATOR TRAINING PAGE 83 APRIL 1770 \ f f g: G 2 --3 *- RN cs cvi r. 8 B - 8a rs $ i 8 S5 Ul {& ^ ?2 ?a a - t. 3 5 viu i. i > H fe I -- -- V* i o ~0> < i wI oc J2Af> VVV O(J iRlA> c 2 1 YY CC 22 V | VY 22 si 2 g: 1 11 YYY i iO i >. VJ U > LT *-- o 5 5o 5 t4 -O N-- 8 2 > 00 -o o $ 8 IS88 -- TV -- n -- CNtDCD 8S Lc JS J! _S 1 5 o -8 i 5 I $ 8 (5 >.5s =O*. C=l. i]i figs U. ,5 O 3u. L L L ji 1 < U1 E < *i ^J o I ii su- &*> > 1 <3 s3 ? 6 <5 j =: I I 1 Ju. J J u l i 553 o ooo ? < "5 = 881 i tl UCC 002689 STANDARD cxracAU plutki TYPES AND FORMS PHYSICAL AND THERMAL PROPERTIES >o -- *. * I) o. 5Z 5 -o d *o d n -- uj 2oU^ l:<*UzZJ a soLLr $ 3 <K --CD | | 1 |52 y auj o juj X3 i^n 8 8 8 odo < > X? ><S>-fafi- > bc > "og ?< tz/i o 5 StiizOusr\j Ou 5 f o a ts> 0' 1=: oU =d)i;i tm3y V c 1 1 o o 8d V o o Vc I u 5 So s 8 CM 8 a> oK O a 16 s 'B s 5 1o s 0? 1 u- I"? u. *2 o 5 |J (D 1/1 2 < UCC 002690 CHAPTER (V APPLICATOR TRAINING PAGE B4 APRIL 1970 t l L L L L L L L r STANDARD r CMEMCAL5 A*0 PLAJTId TYPES AND FORMS r PHYSICAL AND THERMAL PROPERTIES r i CHAPTER IV APPLICATOR TRAINING PAGE 65 APRIL 1970 i 1- 5< a= 53 N M8 8 8 f >5C i e1/1 S< du ZS:> <3 o o S CD o tt i 3 /> & oiC1 i <> Ks o"r /> g5 z Iou ojaOy ~ o O i DC < 3 o ci CM 04 CM CM t 3zo" 5< K i *5 '6 Z? o o i ii O5Ci tS i 1 s e o 8 X _ .5- 5. u. w u. o c a. vi (zaHAc- 8. o o o,, OM 1U a. > _Ut> V>*- U, io_S .t p VO oo c o i c 1 '5 u UO XIO ii 3 IiJ oo o ? Ill a.' >-- o _O wo U </ I c Z UJ E3 6 _3 E3 E _3 j Jj o< < < < < UCC 002691 a. 4 E3 aI_ C 3I O <U s I cg STANDARD OCMCAU and plastics CHAPTER V APPLICATOR TRAINING PAGE 86 APRIL 1970_____________ WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS FUNCTION OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS* 1 2 3 4 Weother-borriers are materials which will resist the weather elements such as rain, sleet, snow, wind, solar radiation, and mechanical damage. Such materials are used to protect thermal insulation from these abuses. In addition, these materials may be required to assist in protecting insulation from fire and they also may be used to serve as pipe identification, color identification, or as a decorative surface. A listing of the fundamental functions which weather-barriers serve is: 1. Weather protection 2. Mechanical protection 3. Fire protection 4. Decoration As explained in Chapter I, thermal insulation (with exception of reflective types) depends upon finely divided air (or gas) spaces to retard the flow of heat. These small spaces are formed by the flakes, fibers, or nodules of solids in the insulation, or they ore formed by cells in the material itself. Each space must be sufficiently small to cause considerable resistance to air flow so that little heat can be transferred by air movement in the space it self. These small air spaces are essential to the ability of thermal insulation to effectively retard the flow of heat. When insulation becomes wet, or portly so, all or part of these air spaces become filled with water. Heat transmission through water-filled spaces will approach the rate of conductivity of water instead of air. The conductivity of water ot 70F means temperature is 4.7 Btu per sq ft per inch thickness, per degree temperature difference per hour as compored to 0.17 for air. Thus the increase of heat transmission through the spaces is increased by approximately 27 times. Therefore, from a completely dry to completely wet air, insulation will function at less than 5%of its thermal resistance efficiency. Besides lowering the effectiveness of the thermal insulation, on additional heat loss occurs in drying out insulation once it becomes wet. As most insulations are quite obsorptive, any water which does get into the insulation must be vaporized to drive it out. The heat required to vaporize one pound of water (at 212F) is approximately 1150 Btu. Expressed another way, each pint of water which may leak into insulation will require approximately 1200 Btu of heat to drive that water out of the insulation. Because water leaks in insulation cause both of these losses of heat, it is necessary to hove effective weather-barriers to keep the insulation dry. UCC 002692 STANDARD P<MCAU AW FUITIO CHAPTER V APPLICATOR TRAINING PAGE 88 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIER, COVERINGS AMBIENT CONDITIONS: Air Temperature = 90 F Relative Humidity = 80 % Dew Point Temperature = 83 F Vapor Pressure = 77.8 tbs/sq. ft. Dew Point in Insulation Vapor Barrier Insulation Pipe Ambient Air Temperature 90F Temperature Gradient in Insulation 80 F PIPE SURFACE CONDITIONS: Pipe Temperature 30 F Relative Humidity = lOO^b Vapor Pressure = 11.6 Ibs/sq.ft. Pipe Temperature VAPOR PRESSURE DIFFERENCE = 30 F Ambient vapor pressure minus pipe surface vapor pressure is 77.8 Ibs/sq.ft minus 11.6 ib$/$q. ft. equals 66.2 lb$/$q. ft. VAPOR PRESSURE DIAGRAM Figure V-l UCC 002693 r STANDARD r CMIMCALS AMD H.A*TS CHAPTER V APPLICATOR TRAINING PAGE 89 APRIL 1970 r WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS r f f i i i i i L [ l l ! I Table V-l l UCC 002694 STANDARD OtCMCAL* AMP FLASTO CHAPTER V APPLICATOR TRAINING PAGE 90 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PEW fO(NT TEMPERATURE F TABLE It MY BULB TEMP. F TC- 15 20 25 30 35 %*ELATIVE HUMIDITY 40 45 50 55 60 65 70 75 80 85 90 95 100 5 -35 -30 -25 -21 -17 -14 -12 -10 -8 -6 -5 -4 -2 -1 12 34 5 10 -31 -25 -20 -16 -13 -10 -7 -5 -3 -2 0 2 34 57 89 10 15 -28 -21 -16 -12 8 -5 -3 -1 13 s6 89 10 12 13 14 15 20 -24 -16 -11 -8 -4 -2 2 4 68 10 It 13 14 15 16 18 19 20 25 -20 -15 -8 -4 0 3 68 10 12 15 16 18 19 20 21 23 24 25 30 -15 -4 -3 2 58 II 13 15 17 20 22 23 24 25 27 28 29 30 35 -12 -5 l 5 9 12 15 18 20 2 24 26 27 28 30 32 33 34 35 40 -7 0 59 14 16 19 22 24 26 28 29 31 33 35 36 38 39 40 45 -4 3 9 13 17 20 23 25 28 30 32 34 36 38 39 41 43 44 45 50 -1 7 13 17 21 24 27 30 32 34 37 39 41 42 44 45 47 49 50 55 3 11 16 21 25 28 32 34 37 39 41 43 45 47 49 50 52 S3 55 50 4 14 20 25 29 32 35 39 42 44 46 48 50 52 54 55 57 59 60 55 to 18 24 28 33 38 40 43 46 49 51 53 55 57 59 60 62 63 65 70 13 21 28 33 37 41 45 48 50 53 55 57 60 62 64 65 67 68 70 75 17 25 32 37 42 46 49 52 55 57 60 62 64 66 69 70 72 74 75 50 20 29 35 41 46 50 54 57 60 62 65 67 69 72 74 75 77 78 80 55 23 32 40 45 50 54 58 61 64 67 69 72 74 76 78 80 82 83 85 50 27 36 44 49 54 58 62 66 69 72 74 77 79 81 83 85 87 89 90 55 30 40 48 54 59 63 67 70 73 76 79 82 84 86 88 90 91 93 95 100 34 44 52 58 63 68 71 75 78 81 84 86 88 91 92 94 96 98 100 105 38 48 56 62 67 72 76 79 82 85 B8 90 93 95 97 99 101 t03 105 110 41 52 60 66 71 77 80 84 87 90 92 95 98 100 102 104 106 108 no 115 45 56 64 70 75 80 84 88 91 94 97 100 102 105 107 109 111 113 115 120 48 60 68 74 79 85 88 92 96 99 102 105 107 109 112 114 116 118 120 125 Si 63 72 78 84 89 93 97 100 104 107 109 111 114 117 119 121 123 125 Problem: Given o "Dry-Bulb- te/nperofure of 60f and o relofive humidify of 25% Find the Dew Point Temperature. Solution.- From o ` Dry-Bulb' temperature of 60F in the loft column, rood acron the tool* to the right. Where thil line interucti the column of 25%relative humidity, we read o Dew Point Temperature of 25 F. Table V-2 UCC 002695 I I I I 1 I I 1 L L L L L L L STANDARD QlfMTM t AM> PLASTO CHAPTER V APPLICATOR TRAINING PAGE 91 APRIL 1970_____________ WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS FUNCTION OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd Coverings are materials used to protect insulation front mechanical damage. These may be also used as pipe identification and as decorative surface. They are used indoors, but may not have the qualities necessary to be classed as a weather-barrier. Weather-barriers can be used indoors as coverings, but coverings not possessing good weather-resistant qualities must not be used outdoors. In many instances, the difference between insulation weather-barrier and insulation covering is not the material itself but the manner in which it is installed. To illustrate, many jackets installed outdoors with sealed joints to resist rain are weather-barriers. The same jackets installed indoors with unsealed joints are coverings. In some instances, one single material may be used both as a weather-barrier and vaporbarrier or a covering and vapor-barrier. In other applications, two separate materials may be used where vapor control is required. REQUIREMENTS IMPOSED ON WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS To fulfill their function in protecting insulation, there are many demands imposed on weatherbarriers, vapor-barriers, and coverings. For successful protection of thermal insulation, the barriers and coverings must stay in place on the insulation and withstand movement caused by expansion and contraction without cracking or breaking. To accomplish this, the barriers, or coatings must possess mechanical strength. They must have sufficient flexibility and tensil strength to resist pulling action such as the expansion of surface transmits to the barrier. The barriers must have shear strength to resist pulling action such as the expansion the surface transmits to the barrier. The barriers must have shear strength to resist up and down motion of blocks and pipe insulation. These mechanical stresses imposed by internal sources to barriers are illustrated in Figure V-2. Other than forces from internal sources, barriers and coverings are exposed to external forces. Most insulations are relatively soft, thus any load applied to the surface must be transferred by the weather-barrier to the insulation without damage to the barrier. Mechanical abuse, such as a man walking on insulation, forces of wind involving impact, shear, compressive loading, and abrasion are abuses to which weather-barriers are subjected. The barriers or coverings must resist all of these, which are illustrated in Figure V-3. Of course, a weather-barrier's primary function is to resist the weather to which it is subjected. Weather is quite complex. In parts of the United States, the temperature may go as low as -40F and in other parts of the country it rises to 115F. The weather-barrier applied to thermal insulation may in winter be even colder than the cold winter air. Conversely, when weather-barriers are used on thermal insulations over hot surfaces, the effect of the heat from the pipe plus solar radiation will cause outer surfaces to be considerably higher than the ambient temperatures. UCC 002696 X STANDARD UB0CALS mc puma CHAPTER V APPLICATOR TRAINING PAGE 92 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS Im Vibration Weather-Barrier, Vapor-Barrier or Covering /// / S/s S/ // /)\ Expansion ------- Contraction Shear Insulation MECHANICAL STRESSES ON BARRIERS FROM INTERNAL SOURCES Figure V-2 UCC 002697 STANDARD OtfittCALS AW nJUTO CHAPTER V APPUCATOR TRAINING PAGE 93 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS Cutting or Shear Weather-Barrier, Vapor-Barrier or Covering Compression Insulation MECHANICAL STRESSES ON BARRIERS FROM EXTERNAL SOURCES Figure V-3 UCC 002698 STANDARD CMMOU ti TLMTKl CHAPTER V APPLICATOR TRAINING PAGE 94 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS REQUIREMENTS IMPOSED ON WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd In odditidn to weather, acid, caustics, and chemical fumes or spillage can damage weather barriers, vapor barriers, or coverings. It is of paramount importance that these be resistant to fumes and spillages to which they may be subjected. The barriers or coverings used in chemical plants must not increase the fire hazard within the plant. Fire hazard can be increased in several ways. One is that the barrier or covering could contribute to a fire or assist it to spread. Another is that It might create toxic smoke by its combustion. Still another is that it could react with chemical spillage or fumes to cause an accidental fire. A good weather-barrier, vapor-barrier, or covering should resist fire and help protect the insulation so as to provide a thermal shield between the fire and piping and equipment. These are the requirements imposed upon weather-barrier, vapor-barriers, and coverings. Each individual type of barrier or covering has its individual set of properties which make it more or less suitable to fulfill the requirements. Selection of materials to be used is based on its ability, including its associated economics. PROPERTIES OF WEATHER-BARRIER, VAPOR-BARRIERS, AND COVERINGS Many materials have been used as weather-barrier and coverings. In general, they fall into two classifications: jackets and mastics. Each of these has certain properties by which it is evaluated to fulfill the installation requirements. Evaluation of each material as to its properties is beyond the scope of this manual. However, it is well to establish the relation of properties with requirements. This relationship between property and requirements is stated to be the significance. These lists, one for jackets and one for mastics, of the properties of weather-barriers and coverings follow: PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE Application Properties Definition: The properties which influence or affect proper installation of the jacket. Cutting Characteristics Definition: The ability of the jacket to be secured. Significance: The ability of a materia! to be cut cleanly without ragged or jagged edges and without tearing. This property must be related to the use of proper tools and methods. UCC 002699 I STANDARD CHIMCALS tfC FI.ASTtO CHAPTER V APPLICATOR TRAINING PAGE 95 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE - Contd Application Properties - Contd Ductility Definition: The ability of the jacket to bend, flex, or be drawn. Significance: The ability of the material to conform to required shape without tearing , or being otherwise damaged. Service Properties Definition: Properties which govern performance of the jacket after installation. Abrasion Resistance Definition: Ability of a jacket to withstand scuffing or scratching without damage. Significance: This ability determines if a jacket is able to withstand mechanical abuses of scuffing or scratching or related abrasive action. Appearance Definition: The external view of the installed jacket. Significance: The ability of the jacket to be applied cleanly and neatly. Its ability to provide an even and pleasing surface, to harmonize with its surroundings, and 'remain that way in service. Conductivity, Thermal Definition: The ability of the jacket to transmit heat. Significance: When surface temperatures are high, the higher the thermal conductivity of a jacket the more likely it is to cause burns to anyone who comes in contact with it. Emittance Definition: The ability of a jacket to radiate energy due to its temperature being higher than the temperature of surrounding bodies. UCC 002700 STANDARD cmcmcau *m> elastics CHAPTER V APPLiCATOR TRAINING PAGE 96 APRIL 1970_____________ WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Emittance - Contd Significance: The ability of the jacket to transmit heat to ambient air and surrounding bodies affects the surface temperature. On high temperature installations, low surface emittance can cause surface temperatures to be sufficiently high to be hazardous to personnel. This is particularly true as the small amount of radiant heat causes no warning to a person that the surface is hot. Flash Point Definition: The temperature of the jacket, at which a spark will cause a flash flame. Burning will not continue unless the material is above fire point. Significance: This temperature is that at which sparks and fire must be kept from the material to prevent flash flame. Fire Point Definition: The temperature of the jacket at which, when ignited by spark or flame, the material will continue to burn. Significance: This is the critical temperature, at which a material is flammable. Fire point of a material affects the fire hazard to personnel and property. Fire Self-Ignition Point (Autogenous Ignition) Definition: The temperature of the jacket, at which, in presence of air, the jacket will burst into flame without being ignited by spark or flame. Significance: This is the temperature at which the material will automatically burst into flame. As such, it affects fire hazard. Flammability Definition: The ability of a material to support combustion. Significance: This is a general statement of the ability of material to support combustion. Flash point, fire point, fire self-ignition point, and flame travel are measures of degree of flammability. UCC 002701 STANDARD OICKCAIS ue PUUTK3 CHAPTER V APPLICATOR TRAINING PAGE 97 APRIL 1970____________ . WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Flame Travel Definition: The rate, in respect to distance and time, flame will spread over the jacket surface. Significance: High rate of flame spread is a contributing factor in accidental fire getting out of control. Flame Resistance Definition: The ability of the jacket to resist burning when subjected to flame. Significance: This is a general statement of the ability of a material to resist^combustion when subjected to a flame. Hardness Definition: The ability of a jacket to resist penetration. Significance: This property determines the ability to resist puncture. This property affects service life of the jacket. Heat Stability Definition: This is a combination of related properties which affect the overall stability of the material. Significance: High or low temperatures do cause change in the properties of the jacket. Either a peak temperature, or extended high or low temperature may adversely affect mechanical properties of the jacket. Impact Strength Definition: This, too, is a combination of other physical properties, including hard ness, ductility, shear and tensile strength. Significance: Although this is a combination of properties, comparative test methods have been devised to evaluate materials. The ability of a jacket to withstand a mechanical blow is one measure of its ability to remain water-tight . UCC 002702 STANDARD eCU A*C PU4Td CHAPTER V APPLICATOR TRAINING PAGE 98 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Low Temperature Embrittlement Definition: The temperature at which the jacket loses its flexibility. Significance: This is the temperature at which the jacket becomes brittle, when relative slight strain or impact can cause it to break. This temperature indicates the service suitability of the material. Melting Point Definition: The temperature above which the joint changes from the solid state to the liquid state. Significance: This temperature causes complete change of physical properties from those as a solid to those of a liquid. This temperature is important to fire hazards as molten drip may be source of secondary ignition. Puncture Resistance Definition: The ability of a material to resist penetration of a sharp object applied to its surface by mechanical force. Significance: This property is similar to impact resistance except that puncture is associated with a sharp object. Puncture resistance affects the service suitability and service life of jackets. Reflection Foctor - Light Definition: The ratio of Hie light reflected by a body to that incident on it. Significance: The amount of light reflected by a jacket affects the need for over coating with paint to obtain good lighting. Reflectance - Light Definition: The ratio of radiant light flux reflected by a body to that incident upon it. UCC 002703 STANDARD OtlMCAU *ND PLASTICS CHAPTER V APPLICATOR TRAINING PAGE 99 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Reflectonce - Light - Contd Significance: The amount of light reflected by a jacket affects the need for over coating with paint to obtain good lighting. Reflectance - Thermal Definition: The ratio of radiant heat flux reflected by a body to that incident upon it. For an opaque body, the sum of reflectance and absorptance for the incident radiation is unity. Significance: On low temperature applications located where they are subject to radiation, the reflectance greatly influences the amount of heat which reaches the insulation system. Resistance to Acids, Caustics, Solvents Definition: The ability of the jacket to resist deterioration when subjected to acids, caustics, or solvents in liquid or vapor state. Significance: The ability of the jacket to resist the action of acids, caustics, and solvents under service conditions determines its serviceability for various applications. Shear Strength Definition: The ability of the jacket to resist cutting action of forces acting upon it in parallef and opposite directions. Significance: The jacket must have the ability to resist shear in service. During high winds, the effects of lift cause high shearing action at securement bands. Conversely, the jacket must not be too difficult to cut; otherwise, installation cost becomes excessive. UCC 002704 STANDARD oomical* AW PLASTICS CHAPTER V APPLICATOR TRAINING PAGE 100 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Softening Point Definition: The temperature above which the jacket begins to soften, becomes tacky, or loses its physical strength. Significance: The softening point is one factor in setting the maximum service temperature to which a material should be subjected. Tear Strength Definition: The ability of a material to resist being pulled apart by externally applied force. Significance: This property determines the ability of the jacket to withstand ripping. Tensile Strength Definition: The ability of the jacket to resist being pulled apart by equal and opposite forces. Significance: This property determines the ability of the material to withstand the frictional pull imposed on it by the expansion of pipe and vessels upon which the insulation and jacket are installed. The ability of the jacket to enlongate under tension can assist in reducing the effect of the tension forces tending to pull it apart. Temperature Limits Definition: These are the high and low temperatures above and below which at least some of the properties of the jacket are so adversely affected that the jocket becomes unsatisfactory or unusable. Significance: These limits determine the temperature range of usability of the jacket. Thermal Shock Resistance Definition: This is the ability of the material to resist impairment of its properties caused by sudden change in temperature. Significance: A fast rate of change of temperature can have adverse effects on some types of plastic or laminated jackets. UCC 002705 STANDARD CHlMCAlS AND r: -STIC? CHAPTER V APPLICATOR TRAINING PAGE 101 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF JACKETS AND TH EIR SIGNIFICANCE - Confd Service Properties - Contd Woter Vapor Permeability Definition: The ability of the jacket to tronsmit moisture in the vopor state. Significance: The ability to transmit moisture is desirable in some applications, such as when the insulation and jacket are applied on hot surfaces. When the insulation and jacketing is on cool or cold surfaces, then a low water vapor permeability Is required. This water vapor permeability affects the selection of materials and the service life of the insulation. Water Resistance Definition: In most instances this is applied to two different properties. One, the ability of the jacket to retain its properties when subjected to water; two, the ability of the jacket to resist the passage of voter. Significance: This resistance to water determines and influences the life of the jacket when exposed to rain, sleet, snow, or water submersion. The resistance to water passage affects the efficiency of the insulation and its service life. Weather Resistance Definition: Is the ability of the jacket to withstand all of the ravages weather imposes on it. Significance: The ability to resist weather Is the basic function of the jacket when used in outdoor applications. Weather resistance affects both the performance and service life of the jacket. PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE Mastics have many identical or similar properties, particularly in service as jackets. However, some of these that are similar may be just sufficiently different that there will be some difference in the definition and the significance. Therefore, in spite of some duplication, thesesame properties which apply will be repeated in the list of properties for mastics. UCC 002706 STANDARD CHtactU no *laitics CHAPTER V APPLICATOR TRAINING PAGE 102 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Applicotion Properties Definition: Properties which influence or affect the proper installation of weather barriers or coverings. Build Definition: The thickness to which a coating or mastic finish can be applied without sagging, running, sliding, or dripping. Significance: Finishes for thermal insulation must be capable of application on vertical or overhead surfaces at specified coverage without subsequent reduction in thickness, caused by excessive flow or slump. Build also determines the number of coats required for optimum dry thickness. Consistency Definition: The resistance of a non-Newtonian material to deformation or flow. NOTE: Consistency is not a fundamental property but is made up of viscosity, plasticity, and other rheological phenomena. In non-Newtonian behavior, which is the usual case with mastics and coatings for thermal insulation, the ratio of shearing stress to the rate of shearing strain varies with the shearing stress. Significance: Consistency determines whether a mastic or coating can be troweled, gloved, brushed, or sprayed. It has a direct effect on application costs. Corrosion or Solvent Attack Definition: Harmful effect on metals or thermal insulation of contact with finishes. Significance: Finishes must not chemically attack insulation or adjacent metals to cause deterioration of the installation. Coverage Definition: The rate in square feet per gallon (coatings) or gallons per 100 square feet (mastics) at which finish must be applied to obtain satisfactory performance. UCC 002707 STANDARD CMCMICAU A* RVASTICS CHAPTER V APPLICATOR TRAINING PAGE 103 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Applicotion Properties - Contd Coverage - Contd Significance: The performance of finishesis directly reloted to the dry film thickness applied. Performance properties must be defined in terms of dry thickness, and this value must be established for application purposes in terms of coverage. Coverage data are essential for estimating quantities and cost. Drying Time or Curing Time Definition: Elapsed time required for a mastic or coating finish to dry or set after application before it may be placed in operating service. NOTE: Drying time implies time during which applied finish is sensitive to local damage by weather or personnel. Curing time implies time required to reach optimum service properties. Significance: Performance properties of finishes depend on adequate drying and curing. Premature service operation may lead to finish failure. Curing time data are needed to establish construction schedules. Flash Point Definition: The temperature of the jacket, at which a spark will cause a flash flame. Burning will not continue unless material is above fire point. Significance: This temperature is that at which sparks and fire must be kept from the material to prevent flash flame. Fire Point Definition: The temperature of the jacket at which, when ignited by spark or flame, the material will continue to burn. Significance: This is the critical temperature at which a material is flammable. Fire point of a material affects the fire hazard to personnel and property. Fire Self-Ignition Point (Autogenous Ignition) Definition: The temperature of the jacket, at which, in presence of air, the jacket will burst into flame without being ignited by spark or flame. UCC 002708 STANDARD CMtWCAU AMD AJkSiica CHAPTER V APPLICATOR TRAINING PAGE 104 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Applicotion Properties - Contd Ffre Self-Ignition Point (Autogenous Ignition) - Contd Significance: This is the temperature at which the material will automatically burst into flame. As such, it affects fire hazard. Flammability (during application) Definition: The ability of a material to support combustion. Significance: Finishes which contain volatile flammable solvents may ignite readily from a source such as welding sparks and spatter, electrical short circuits, open flames, or personnel smoking. Such a fire could spread very rapidly over freshly finished surfaces. Freeze-Thaw Resistance Definition: Resistance to change in application and performance properties caused by exposure to alternate cycles of freezing and thawing. Significance: Both application and performance properties can be affected by sub standard freeze-thaw stability in water-base products. Susceptibility to freeze damage affects shipping methods, storage facilities, and application schedules. Gap Filling and Bridging Definition: The ability to bridge, fill, and level joints and gaps in installed thermal insulation. Significance: Joints and gaps exist in installed block insulation. If these are not adequately filled or bridged, the protective value of the finish will be seriously impaired. Shrinkage Definition: Change in volume from wet to dry state observed after mastics and coatings have been applied and cured. Significance: While all finishes containing volatile solvents will show shrinkage during curing, it is important that the finish not crack or delaminate during this process. Shrinkage value must be known to establish coverage rate. UCC 002709 STANDARD CmCmCaL1 AND HastiO CHAPTER V APPLICATOR TRAINING PAGE 105 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Application Properties - Contd Sizing and Sealing Definition: The ability to prevent excessive absorption of finish into porous insulation. Significance: Excessive penetration of finishes into insulation will affect adversely the performance of the finish and the conductivity of the insulation. Storage Stability Definition: Resistance to change in application or performance properties caused by prolonged storage. Storage life is the time during which the product can be stored , under specified conditions and remain suitable for use. ^ Significance: Both application and service properties can be affected'by sub-standard storage stability. This property affects purchasing, storage facilities, and construction scheduling. Surface Wetting and Adhesion Definition: The mutual affinity of and bonding between finish and surface to which it is applied. Significance: Coatings and mastics must readily wet and bond to insulation surfaces without special treatments and/or application techniques. Ease of appli cation and cost of application require good surface wetting and adhesion. Temperature and Humidity Range {during application) Definition: The limiting temperatures and relative humidities between which practical application of finish can be made without harmful effect on properties. Significance: Application of finishes under extreme atmospheric temperature and humidity conditions can hinder or prevent attainment of necessary coverage and proper cure, thus significantly changing performance properties. The temperature of the sur face to which the finish is applied also must be considered. UCC 002710 STANDARD CKfMICAU UC HMTIC1 CHAPTER V APPLICATOR TRAINING PAGE 106 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Application Properties - Contd Toxicity Definition: Harmful physiological response to vapor inhalation or skin contact with finishes during application. Significance: Finishes should not adversely affect health of personnel making application. Container labels must legally and adequately describe any health hazard involved in using the product. Service Properties Definition: Properties which govern performance of finishes after installation. Abrasion Resistance Definition: Ability to withstand scuffing, scratching, rubbing, or wind-scouring without loss of protective properties. Significance: Abrasion resistance in severe service locations is essential to prevent water penetration through the finish. It affects service life and maintenance schedules. Adhesion Definition: The bonding of finish to insulation, usually by interfaciai forces of attraction. Significance: Mastics and coatings should bond strongly to insulation surfaces to afford maximum protection and resistance to delamination in service. This property is difficult to measure on insulation materials of low cohesive strength. Chemicals and Water Resistance Definition: Capability of withstanding exposure to designated acids, alkalies, salts, their vapors and solutions, and water, both pure and industrial. Significance: Attack by or absorption of chemicals arid water con materially reduce the performance and service life of finishes not resistant. Atmospheric contamination and spillage of chemicals are more common forms of chemical exposure of finishes. UCC 002711 STANDARD OtEMCAlt *X> ELASTICS CHAPTEK V APPLICATOR TRAINING PAGE 107 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Color Definition: The aspect of appearance dependent upon special composition of the incident light and the spectral response of the observer. Significance: Color of insulation finishes is dependent on incidence of area dirt and fallout, solar heat load, identification codes, and concealment, as well as aeathetic consideration. Color standards are to be established by agreement between buyer and seller. Elongation Definition: Extension produced by a tension force. Significance: This property determines the ability to withstand pulling stresses exerted during expansion of substrates to which the finish Is applied. Adequate elongation will ensure no cracking due to tension forces. Flash Point Definition: The temperature of the Jacket, at which a spark will cause a flash flame. Burning will not continue unless material is above fire point. Significance: This temperature is that at which sparks and fire must be kept from the material to prevent flash flame. Fire Point Definition: The temperature of the jacket at which, when ignited by spark or flame, the material will continue to burn. Significance: This is the critical temperature, at which a material is flammable. Fire point of a material affects the fire hazard to personnel and property. Fire Self-Ignition Point (Autogenous Ignition) Definition: The temperature of the jacket, at which, in presence of air, the jacket will burst into flame without being ignited by spark of flame. Significance: This is the temperature at which the material will spontaneously burst into flame. As such, it affects fire hazard. UCC 002712 STANDARD QffWtAl) AfcO PI.AfTICt CHAPTER V APPLICATOR TRAINING PAGE 108 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIF1CAM CE - Contd Service Properties - Contd Fire Hazard Definition: Susceptibility to ignition and consequent surface spread of flame. Significance: Low surface spread of flame is important to prevent fire growth away from an accidental fire. Fire hazard affects personnel safety, property values, and insurance rates. Flexure Definition: Ability of finishes to be deformed by bending or twisting without loss of protective properties. Significance: Flexibility of finishes changes with temperature, so temperature limits of use must be considered in establishing flexure limits. Finishes often are installed over relatively soft insulation, which requires that they have good flexibility to maintain protective properties. Impact Resistance Definiti on: Ability to withstand mechanical blows without loss of protective properties. Significance: The ability to resist mechanical blows is a measure of ability suit ability and service life. Mold and Mildew Resistance Definition: Capability of resisting deterioration by fungi. Significance: Growth of micro-organisms in the form of mildew or mold on the surface of fi nishes will cause unsightly appearance and can cause sub-standard performance. Odor Definition: Scent, emanation, effluvium, or smell from finish. Significance: Odor from finishes may be undesirable if it could contaminate foods or other materials exposed to it. UCC 002713 STANDARD cmcwcais and plastics CHAPTER V APPLICATOR TRAINING PAGE 10? APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF MASTICS AND THEIR SIGNIFICANCE - Contd Service Properties - Contd Temperature Limits Definition: The limiting temperatures between which finishes will perform satisfactorily. Significance: Temperature level, duration, and rate of change must be considered in evaluation. Temperature limits affect selection of finish, performance properties, and service life. Water Vapor Transmission Rote Definition: Between two specified parallel surfaces, the time rate of water vapor flow, normal to the surfaces, in a steady state, through unit area, under the specified conditions. Significance: The flow of water vapor through a permeable finish is a function of the difference of vapor pressures at its surfaces. If such a flow results in accumulation of water within insulation, serious changes in thermal conductivity and physical damage can result. In some installations, a relatively high rate is desirable to permit evaporation of water from heated insulation. Weather Resistance Definition: Resistance of finishes to deterioration by exposure to various weather conditions. Significance: Both physical and chemical changes can occur upon weather exposure and these changes con affect performance properties, service life, and maintenance schedules. UCC 002714 I STANDARD CHClMCAlS A*e >LA$TICS CHAPTER V APPLICATOR TRAINING PAGE no APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS PROPERTIES OF ACCESSORIES USED WITH WEATHER-BARRIER, VAPOR-BARRIERS, AND COVERINGS Other than jackets and the mastics, a number of accessories are used with or are a part of the weather-barrier and covering systems. Same of these are tapes, fabric reinforcings for mastics, adhesives, sealers, caulking compounds, overcoatings, and intumescent paints. In most instances, tapes would have the same list of properties as jackets, with the additional properties such as initial adhesion, service adhesion, slip, and peel resistance which would be of significance. Reinforcing fabrics as part of the mastic weather-barrier or covering system influence the in-service properties of the mastic, thus in-service properties of mastics are measured with the proper reinforcing cloth as port of the mastic system. Adhesives, sealers, caulking compounds, and overcoating also have approximately the same list of properties as listed for mastics, with emphasis placed on the individual property related to the function each performs. Intumescent paint is a special overcoating used for fire protection, thus its properties include that of fire resistance and heat retardation. TYPES OF WEATHER-BARRIER, VAPOR-BARRIERS, AND COVERINGS Many types of materials have been used as weather barriers, vapor barriers, and coverings. All of those listed are, to some degree, being used in the insulation industry. Those used by Union Carbide Corporation are those which are selected to best fulfill our needs, including our fire safety requirements. Jackets Almost all jackets can be applied around straight pipe with relative ease. As barriers over fittings, valves, irregular surfaces, jackets are difficult to apply. However, factoryfabricated jackets partly solved this difficulty. Unless considerable care is exercised, the joints between jackets are not water-tight. Some of the materials used for weather-barrier jackets are: UCC 002715 STANDARD CHEMCALi AND M.MTO CHAKItK V APPLICATOR TRAINING PAGE in APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS TYPES OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd Felt jackets are made of asbestos and asphalt, asbestos sheets, and asbestos-asphalt felt, and rag felt with asphalt. All of these have excellent weather-resistant char acteristics, but most are combustible, or have a high index of flame spread. Plastic jackets are made of heavy calendered plastics such as polyvinyl acetate, and Mylar. TKe properties of these cover a wide range, depending upon the plastic used. Composition jackets are made by the combination of two or more materials bonded together. There are numerous combinations of materials used in making up this type of jacket. Some of the most common are: Aluminum foil and craft paper Aluminum foil and glass cloth Aluminum foil and polyvinyl acetate Polyvinyl acetate and glass cloth Polyvinyl chloride and glass cloth Polyvinyl acetate, aluminum foil, and glass Fibers Asbestos and polyvinyl acetate Metal jackets are made of non-corrodable metal and/or metal treated to resist corrosion. In addition, especially for aluminum, an inner facing of treated craft paper may be bonded to the metal to reduce corrosion due to caustic action of the insulation. In some instances, these jackets are prerolled, precut, with preformed joints to reduce the difficulty of field installation. Some of the metals used for weather-barrier jackets are: Aluminum Aluminum with inner layer of craft paper Galvanized steel Galvanized and painted steel Stainless steel Tapes, which are a form of jackets, are also produced of many materials, such as rubber, fabric, aluminum foil, polyethylene, polyvinyl chloride, polyvinyl acetate, glass fabric, or glass fiber, or a combination of these materials. In most instances, they are produced with a pressure-sensiti ve adhesive on one or both sides. Presently, there are 400 to 500 different tapes on rhe market. UCC 002716 STANDARD CtfMCAU MO flASTCS CHAPTER V APPLICATOR TRAINING PAGE 112 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS TYPES OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd Mastics - Weather Barriers Similar to the jackets, there are many materials used as mastics for weather-barriers. In most instances, it is recommended that the mastics be reinforced with a membrane to provide higher tensile strength and tear resistance. For this reoson, the membrane most commonly used with each mastic will be mentioned. Cutback asphalt and fiber reinforced with 20 x 20 glass cloth is generally an excellent weather barrier and vapor barrier. However, due to high shrinkage and pinholing, it must be applied in two coats and heavy thickness. Recommended thickness is not less that 1/8 in. This coating is combustible in wet state. Additives are sometimes mixed into the material to reduce the burning rate after material has dried. Asphalt-Gilsonite cutback reinforced with 20 x 20 glass fabric has characteristics similar to aspholtic cutback, with the exception that the Gilsonite tends to increase weather resistance and flexibility of the dry film. Asphalt emulsion reinforced with one-inch hexagonaf wire netting is one of the oldest materials used as a weather barrier. Due to water content, they are fire safe during application but will support combustion after the emulsion has dried. Because of high shrinkage, they must be applied in two or more coats to cover shrink age cracks. Recommended dried thickness is 1/4 in. Dries to a hard, stiff, film with little flexibility. Polyvinyl Acetate emulsion reinforced with Dynel cloth is basically a breathingtype mastic, meaning that it has high vapor transmission rate and is an excellent weather-barrier but poor vapor-barrier. This mastic Is fire-safe during application, has a low rate of flame travel, and fire resistive. Because of its low shrinkage and good filming properties, it need only be 1/16 inch thick after it has dried. Polyvinyl-Acetate-Aery tic modified emulsion reinforced with Dynel cloth has similar characteristics to the polyvinyl acetate emulsion. Acrylic emulsion reinforced with Dynel cloth has similar characteristics to the polyvinyl acetate emulsion, with the exception that it has better elongation and flexibility than the PVA mastics at temperatures below 30F. UCC 002717 STANDARD CMtMCALS Am PLASTICS CHAPTER V APPLICATOR TRAINING PAGE 113 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS TYPES OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd Rubber lotex emulsions reinforced with glass fabric or Dynel cloth have excellent flexibility at temperatures above 50F. Their weather resistance is not as good as other coatings and most formulations of these will support combustion after they have dried. Vapor-Barrier mastics may be or may not be good weather-barriers. Various types of resins have been formulated as vapor-barriers. Some of these are vinyl chlorides, Hypolon, Monolar, acrylics, and other synthetic resins. In most instances when used outdoors in industrial applications, it is good practice to protect the vapor-barrier with a weather-barrier. Coverings Coverings are used over insulation installed indoors where it requires no weather-barrier.^^ However, depending upon operating temperature, the insulation may or may not require vapor-barrier. Covering Over Insulation Requiring Vapor-Barrier Semivapor-resistant insulation which must be sealed with a vapor-barrier may use any of the previously mentioned types of vapor-barriers. The covering over this vapor-barrier may be needed to add strength, or simply to provide color to match surroundings. The covering may be a paint, jacket, or reinforced coating. Whichever type of finish is selected, it must be compatible with the vapor-barrier. Coverings Over Insulation Not requiring Weather-Barrier Insulated surfaces located indoors, where not subjected to washing down, need no weatherbarriers. Typical is insulation installed on commercial building piping, equipment, and duct work. As most insulation surfaces are not suitable as an exterior finish because of their softness, abrasiveness, or dustiness, a covering must be provided; A large number of finishes are available. Many pipe insulations are obtainable with factory-attached jackets suitable as an outer surface, or suitable as a base for a finish. Such outer surface jackets may be asbestos laminated jackets, foil faced jackets, composition fire retardant jackets, or metal jackets. When such jackets are suitable, they must be selected to fulfill the service and appearance requirements. UCC 002718 STANDARD Q4EB1CALS A> PLMT'CJ CHAPTER V APPLICATOR TRAINING PAGE 114 APRIL 1970 WEATHER-BARRIERS, vapor-barriers, coverings TYPES OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd Factory-attached canvas Is supplied with much pipe insulation as standard practice. It heips prevent damage to the insulation in shipping. In most instances this canvas is removed before the insulation is installed. However, the canvas can be repasted in place and provides a base for the surface finish. A polyvinyl acetate "lagging adhesive" or paint consistency is used as a paste to secure the canvas to the installed insulation. Additional coats of the polyvinyl acetate on the outside of the canvas provide the final surface or a base for an overcoating. Color can be added to the polyvinyl ccetate coating if desired. Where fire hazard is a consideration, glass cloth can be used Instead of canvas. It Is applied in the same manner as the canvas. Equipment insulated indoors, such as in machinery rooms or power plants, also requires an outer finish. Depending upon the insulation used, and the manner of application, this finish is obtained by using jackets or polyvinyl acetate finish. If a jacket is used, the surface to which it is applied must be smooth and even. The selection of a jacket is the same as stated for pipe covering. When equipment is Insulated with lags or a soft insulation, it must be given a 1/2 inch thick coating of insulating cement reinforced with one-inch hexagonal wire mesh. After this has dried to a 1/4 inch thickness, hard finish cement is troweled onto a smooth even surface. Canvas or glass cloth is then posted to this surface with polyvinyl acetate "lagging adhesive." An additional coat, or coats, of the polyvinyl acetate is then brushed over the cloth to provide the finished surface. The same procedure is followed when high temperature block is installed on flat surfaces such as boiler ducts. If cylindrical equipment is insulated with prefabricated curved segments and heads, the 1/2 inch insulation cement coating can be eliminated and the 1/4 inch finish cement can be applied directly to the insulation. The balance of the procedure will be identical to that previously stated. Overcoatings Overcoatings ere used for three main reasons: (]} protection from acids, caustics, or solvents that the finish, weofher-or vapor-barrier cannot withstand; (2) to provide an appearance not possible from the insulation finish; (3) to provide fire resistance. UCC 002718A STANDARD OVMCAL& AW RVAJTK3 CHAPTER V APPLICATOR TRAINING PAGE 115 APRIL 1970 WEATHER-BARRIERS, VAPOR-BARRIERS, COVERINGS TYPES OF WEATHER-BARRIERS, VAPOR-BARRIERS, AND COVERINGS - Contd Qvercootings for Acid, Caustic, or Solvent Protection Weather-barriers, vapor-barriers, and finishes used with insulation are designed to function with the insulation under ordinary environmental conditions. They may, or may not, resist acid, coustic, or solvent contamination. Where the Installation may be subjected to con tamination, the weather-vapor-barrier, or finish under consideration must be checked to determine if it will withstand the contamination. In some instances, it may be found that a properly selected weather-vapor-borrier will perform both functions. In other instances, it may be necessary to overcoat with a coating which resists the chemical contamination. In addition to resisting the chemicals, the overcoating must be compatible with the finish, or vapor-barrier. Overcoating for Appearance In most instances, the jacket or the mastic used for the finish or weather-barrier is suitable in appearance. When color is required, polyvinyl ocetate weather-barrier mastic can be obtained in most standard colors, or even special colors in quantity. However, in some in stances, such os insulation exposed in buildings, it is desirable to paint the outer surface to match walls or ceilings, or to provide high gloss light reflective surfaces. In these cases, because of the small areas involved, it is economical to have the insulated surfaces overcoated by the painters as they paint the interior of the buildings. UCC 002719 STANDARD CMHCA14 njkITIO CHAPTER VI APPLICATOR TRAINING PAGE 116 APRIL 1970________ INSTALLATION REQUIREMENTS The requirements that insulation materials must fulfill ore more than just the requirements of application and service. Starting at the point of manufacture, materials must have the capability of being packaged, shipped, stored, fabricated, and handled before their application. Each of these imposes certain requirements on the materials. After a material is manufactured, it must be packaged and shipped. During shipment it must resist movement, vibration, and mechanical abuses. The packages may be left out in the weather; thus, unless packages are weather-and water-resistant, the material may be exposed to water and moisture. During storage, insulation materials are also subjected to mechanical abuses and moisture and water damage. Another consideration, due to amount of bulk which is stored, is that the material should not be a fire hazard. Fabrication of materials imposes another set of requirements on the capabilities of materials. Some of the properties of material that influence the selection of material which must be fabricated are: 1. The ability to be cut, formed, or shaped. 2. The ability to provide smooth, even, and relatively dust-free surfaces. 3. The ability to be bonded to other surfaces with cement or adhesive. 4. The ability to stay straight, true, and dimensionally stable. 5. Sufficient physical strength to resist mechanical abuses to which it is subjected. During application, materials must hove most of these same properties, and they must be able to resist the cutting force of wire or bands used to secure them in place. Up to this point all the requirements that materials must have are those necessary to get them installed to perform their service function. To fulfill service requirements, the properties which insulation must have can be divided into the following basic divisions: 1. Thermal 2. Physical 3. Chemical 4. Moisture 5. Fire 6. Toxicity Each of these divisions will be discussed in relation to individual properties necessary to fulfill service requirements. UCC 002720 STANDARD OCMCAiS PLASTtQ CHAPTER VI APPLICATOR TRAINING PAGE 117 APRIL 1970 INSTALLATION REQUIREMENTS THERMAL PROPERTIES Temperature of pipe or equipment to which insulation is installed is one of the first considerations in the selection of an insulating material. Each insulation has a maximum service temperature and a minimum service temperature. The insulation used must have a temperature range suitoble for the service temperature to which it is subjected. If operating temperature is cyclic, the rate of this temperature change may cause some materials to crack or spall. For this reason, if change of temperature is rapid, or sudden, the thermal insulation must have sufficient thermal shock resistance to withstand the sudden temperature change without physical deterioration. Another service consideration is the rate of time that insulation takes to change temperature. Where fast adjustment to temperature change is desired, a high rate of thermal diffusivity is necessary. If slow rate of temperature change is desired, then a low rate of thermal diffusivity is required. In such installations where insulation is used to retard freezing or as fire protection, then a material of low thermal diffusivity is needed. In other words, thermol diffusivity is the measure of rate of temperature change. Specific heat is the measure of quantity of heat required to raise the temperature of a body. In cyclic temperature operations, it determines the amount of heat gain or loss necessary to raise or lower the temperature of the insulation. PHYSICAL PROPERTIES The type of installation is, most frequently, the deciding factor as to what form of insulation is most practical. In general, these forms of materials are used for the following broad types of installation: 1. Rigid insulation is used where structural strength is needed. Installations on pipe, vessels and equipment and ducts exposed to mechanical abuses are typical. 2. Semi-rigid or flexible insulations are used in ceilings and other areas where it has external support, or where flexibility is desired to conform to curvatures. 3. Blanket and felt insulation is used for wrapping of ducts and where compressibility and expansionability are necessary. Blankets are frequently used between vessel walls and rigid insulation to provide a thermal and mechanical cushion. 4. Sprayed fiber insulations are practical for large hot surfaces such as targe vessels and flue gas ducts. 5. Sprayed organic foams are useful for large moderate temperature surfoces such as storage vessels. UCC 002721 STANDARD CHCMCAU AM nUTO CHAPTER VI APPLICATOR TRAINING PAGE 118 APRIL 1970_____________ INSTALLATION REQUIREMENTS PHYSICAL PROPERTIES - Contd 6. Insulating cements are used to insulate small fittings, on contoured equipment, and in combination with rigid insulations to fill voids and as a leveling coat. 7. Poured or loose insulations are used for filling of cavities or tight enclosures. With these general guidelines as to type of installations, it is possible to consider the forces exerted on the insulation in service and the properties of the insulotion to withstand these forces. The forces imposed on rigid insulations are generally those caused by the following: 1 . Securements and supports. 2. Weight. 3. Movement from expansion and contraction. 4. Mechanical abuses. The forces caused by its installation using various securements and by its own weight on supports is illustrated in Figure Vl-I. In addition to being subjected to its own weight, insulation may be required to support the weight of pipe and its contents or the weight of some object resting on it. These are illustrated in Figure VI-2. When metal is heated, it expands (gets longer in length, width, and thickness) and when cooled it contracts (gets shorter in length, width, and thickness). This change in the dimensions of metal causes movement which, in tum, may impose tensile or compressive forces on the insulation. The growth of pipe due to being heated and the resultant tensile force, applied to insulation, is illustrated in Figure VI-3. Conversely, the compressive force applied to insulation when pipe contracts due to being lowered in temperature is shown in Figure VI-4. When operating temper ature cycles from high to cold and back again to high temperatures, both tensile and compressive force are imposed on the insulation in turn. To illustrate the amount of growth and shrinkage of pipe or vessels, the following table gives the expansion and contraction of various metals: UCC 002722 STANDARD INSTALLATION REQUIREMENTS CHAPTER VI APPLICATOR TRAINING PAGE 119 APRIL 1970 FORCES IMPOSED ON RIGID INSULATIONS BY SUPPORTS AND SECUREMENTS Figure VI-1 UCC 002723 STANDARD OlfUCAU AC> RUSTICS INSTALLATION REQUIREMENTS CHAPTER VI APPLICATOR TRAINING PAGE 120 APRIL 1970 ________ COMPRESSIVE FORCE ON INSULATION SUPPORTED ON CRADLE COMPRESSION OF INSULATION DUE TO WEIGHT Figure VI-2 UCC 002724 STANDARD 04CMCAU AW PLASTICS INSTALLATION REQUIREMENTS CHAPTER VI APPLICATOR TRAINING PAGE 121 APRIL 1970 Tensile Force Exerted On Insulation Due To Increased Length Of Pipe TENSIONAL FORCE APPLIED TO HIGH TEMPERATURE INSULATION Figure VI-3 UCC 002725 STANDARD ouciuwruira INSTALLATION REQUIREMENTS CHAPTER VJ APPLICATOR TRAINING PAGE 122 APRIL 1970 Length Of Pipe Change Doe To Contraction Compressive Force On The Insulation Compressive Force Exerted On Insulation Due To Decreased Length Of Pipe COMPRESSIVE FORCE APPLIED TO LOW TEMPERATURE INSULATION Figure VI-4 UCC 002726 STANDARD QUMCAU AMD ALAOTKS CHAPTER VI APPLICATOR TRAINING PAGE 123 APRIL 1970_____________ INSTALLATION REQUIREMENTS PHYSICAL PROPERTIES - Contd Inches of Linear Expansion Per 100 Feet For Various Metals from 0F Temperature o -200 -100 0 100 200 300 400 500 600 700 800 900 1000 Carbon Steel -1.28 -0.69 0 0.75 1.55 2.37 3.23 4.15 5.10 6.08 7.11 8.17 9.28 Cast Iron -1.06 -0.59 0 0.66 1.37 2.11 2.88 3.72 4.59 5.50 6.46 7.45 8.49 Stainless Steel -2.03 -1.09 0 1.12 2.23 3.38 4.56 5.80 7.04 8.31 9.61 10.93 12.26 Monel -1.49 -0.82 0 0.85 1.73 2.65 3.68 4.73 5.86 6.98 8.16 9.35 10.54 Aluminum -2.69 -1.40 0 1.50 3.08 4.74 6.48 8.27 10.10 11.95 13.83 Copper -1.96 -1.04 0 1.13 2.29 3.46 4.67 5.91 7.18 8.47 9.79 11.16 12.54 Vibration of pipe or vessels is another force that is transmitted from their surfaces to the insulation. In addition, at the interface surface, between the insulation and the vessel or pipe, the motion creates an abrasive action on the insulation. Insulation is also subject to external abuses such as objects being rested upon its impacts or external loads. External loads are of special consideration when the insulation is used as a structural member. Two examples of insulation used as structural member is shown in Figure VI-5. PHYSICAL PROPERTIES OF MATERIALS WHICH ARE NOT RIGID Flexible Insulations, including flexible board pipe covering, blankets, batts, etc., are for use where installations require that the insulation be fitted around unever contours and where change in dimensions of the pipe or vessel require material which can change its dimension without physical breakdown. For this reason, flexibility of the material and its degree of recovery are of importance. UCC 002727 STANDARD CHCMCALI AND PLASTICS INSTALLATION REQUIREMENTS CHAPTER VI APPLICATOR TRAINING PAGE 124 APRIL 1970 NOTE: Insulation must be sufficiently strong to withstand expected load without breaking. EXAMPLES OF INSULATION USED AS STRUCTURAL MEMBERS Figure Vl-5 UCC 002728 STANDARD otcificALS Att puma CHAPTER VI APPLICATOR TRAINING PAGE 125 APRIL 1970_____________ INSTALLATION REQUIREMENTS PHYSICAL PROPERTIES OF MATERIALS WHICH ARE NOT RIGID - Mastic, Plastic, Cements, and Formed in Place Insulation are used for a variety of reasons. Where the installation has uneven contour, or where large areas are to be covered, these materials may be used because of their ability to be economically installed. Regardless of whether it is an insulating cement, sprayed or fibrous insulation, insulating mastic, or sprayedon organic foam, they have physical properties to be considered in addition to their properties in their final form. These properties are: Adhesion -- wet Adhesion -- dry Build Expansion Ratio or Shrikage Most of these rely on dry-adhesion to the substrate for their support in service. Sometimes they are reinforced with netting or other securements, but basically, for ionglasting application, the bond between them and the substrate must remain unbroken. This means that the adhesion must be of sufficient strength to resist the forces imposed upon it by expansion and contraction, vibration and load, and the materials should have sufficient ability to elongate without shear ing the bond. During application, these materials must have sufficiently good wet adhesion to stay in place until dry or set. Shrinkage of insulation cemems, or expansion of foams, ore properties which affect the application and final properties of the materials. These also affect the density of final set insulation. CHEMICAL REQUIREMENTS The chemical requirements which affect the selection of material must be broken down into several divisions, these being: 1. Chemical effect on the metal to which the insulation is applied. 2. Possible react ion with atmospheric or spillage contamination. 3. Resistance to chemicals of contamination. The insulation should not cause rusting or corrosion to the metal to which it is applied. Various metals require different chemicol properties of the applied insulation to ensure no rusting or corrosion. For example, insulation applied to steel should be slightly caustic, whereas an insulation used on aluminum should be neutral or slightly acid. Stress corrosion of stainless steel can be caused by any insulation containing chloride ions. UCC 002729 STANDARD omou a#* ruim CHAPTER VI APPLICATOR TRAINING PAGE 126 APRI1 1970 INSTALLATION REQUIREMENTS CHEMICAL REQUIREMENTS - Contd When insulation becomes contaminated with chemical vapors or liquids, certain combinations can react. In some instances, this chemical reaction will produce sufficient heat to cause ignition with resultant dangerous fires. Highly absorbent and adsorbent insulations can and do provide a means whereby large quantities of chemicals may be trapped. If these trapped chemicals are combustible, the saturated insulation will act as a wick to give off these liquids during a fire with resultant high contribution of fuel to the fire and its spread. Another hazard to be considered is that of trapped toxic materials. An insulation may trap these for years. If moved or handled where it can contaminate an individual, it can prove very hazardous. In such cases, disposal of toxic-filled insulation is an almost unsolvable problem. Of course, it is expected that the insulation material will resist fumes and chemicals to which it is subjected without deterioration. MOISTURE REQUIREMENTS To be thermally efficient, mass insulation depends upon trapped air or gas. If this trapped air is replaced by liquid (or ice), the insulation is no longer efficient. Insulation indoors on hot lines or equipment with little or no chance of being wetted requires little concern for its efficient operation. When insulation is located outdoors, or where it might be saturated with water or other liquids, then the insulation itself must be non-absorbent or be protected from water. This becomes a function of the weather-barrier, but in cose of water leaks, then the properties of insulation which influence the extent of water damage are: (1) absorptivity, (2) capillarity. Insulation installed on low-temperature pipe or vessel can become saturated with water from vapor in the ambient air. Water vapor transmission is the amount of moisture in vapor phase which can pass through the insulation due to vapor pressure difference between its two sides. When the temperature of a surface is lower than that of the outside air, the moisture travel is to the cold surface. Where vapor is prevented from further travel by the cold surface, it becomes trapped and condenses. For this reason, when insulation is used on cold vessels or pipe, the vapor transmission must be very low, or it must be protected with an absolutely tight vapor-barrier which has sufficiently high resistance that graduoi filling up of moisture Is retarded long enough to obtain economic service. UCC 002730 STANDARD fjtftfjxt uo puna CHAPTER VI APPLICATOR TRAINING PAGE 127 APRIL 1970 INSTALLATION REQUIREMENTS FIRE SAFETY REQUIREMENTS The safest of all insolations and weather-barriers are those which are non-combustible and fire-restant. As there is no clear definition as to what is required of insulation to meet these requirements in this manual, these terms are expected to mean the following: The insulation shall contribute no fuel to the fire. The insulation shall emit very little smoke. The insulation shall emit no toxic gases. The insulation shall have a melting point above 1600F. Other than contributing to the hazard of a fire, an insulation may be expected to protect the vessel or pipe on which it is installed. In these cases the insulation shall have a high resistance to temperature change. It should not shrink or spall or deform when subjected to fire. SUMMARY There is no one insulation which fulfills all various requirements better than all others. For this reason, if is essentail that the insulation selected is the one that better serves all the essential needs. This means that all the requirements must be evaluated to select this material. It might not be apparent to one not making a complete evaluation as to why a particular material was selected. Thus, if that individual substitutes a material for another, he may, without realizing it, be causing a failure or a hazard. For this reason, any substitution of materials should not be done without approval of those responsible for design. UCC 002731 STANDARD CNPOCAl l AMD PIA9T1CS CHAPTER VI! APPLICATOR TRAINING PAGE 128 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS Thermal insulation installed, with its weather barrier or covering becomes an insulation system. The insulation system must fulfill its function and have satisfactory service life. As there is no one insulation or combination of insulations which will operate satisfactorily under all sets of conditions, each system must be designed to serve its particular set of service requirements. Each insulation system and its group of accessory materials must also be compatible with the other materials of the system. As the temperature range of services requiring insulation is from -300F to 1800F, the first major factor to be considered in selecting an insulation system is the temperatures to which it will be subjected. It should be noted that the system must be suitable for the temperature imposed on it, for frequently the temperature limitation is not set by the basic insulation itself, but by some accessory component used in the system, or by the manner of application. This explains why it is necessary to have more than one specification for the some basic insulation used for different temperature ranges. Material and Application Specifications provide the information necessary to purchase the correct materials and how these are to be installed to provide a suitable insulation system for the service intended. Various thermal insulation systems in common use by Union Carbide Corporation, Group I, are described in the 'Thermal insulation Manual, Vol. I, Specifications". This publication is divided into three parts. Part GS, the General Specifications, provides information of a general nature essential to the use of the individual specifications. Part M is the Material Specification, which provides the necessary information needed for the purchase of insulation materials and the qualities required of these materials. The third part is made up of individual specifications containing essential information pertaining to the proper application of materials for the purpose intended. A list of these individual specifications giving the specification number, basic insulations to be used, the temperature range for which the specification is suitable and what it is to be used to insulate is presented in Table VI1--1. UCC 002732 STANDARD MEUIC*U M) PLASTICS CHAPTER VII APPLICATOR TRAINING PAGE 129 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS The system was devised so that the number would designate the insulation to be used and the letters the service or use. A specification number can only indicate the use of that particular specification in a general way. it is impossible to designate all the details and limitations of that specification. For this reason, a summary of each of the specifications and its use follows: SUMMARY OF INDIVIDUAL SPECIFICATIONS Specification 10-H, 10-HSS Insulation Materials: High temperature glass fiber insulation installed as inner layer cushion prior to installation of cellular glass. Protective Cover: Most installations are protected with mastic reinforced with"" Dyne! cloth. JrTsome cases, where required, treated steel or stainless steel jacket may be specified. Operating Temperature Range: 50F to 600F Service: For use in storage or process vessels, equipment, and process piping located indoors or outdoors. This system is especially useful for installations where the absorption of vapor or liquids in the outer insulation cannot be tolerated. As the cellular glass insulation cannot become saturated, its conductivity in service remains constant. The system is suitable for installation on stainless steel surfaces. When exposed to external fire it will provide protection for the metal, to which It is applied, for approximately one hour. Caution: To perform satisfactorily, proper installation of insulation expansion joints are essential. Specification 10-J, 10-JSS Insulation Materials: Cellular Glass Protective Cover: Most installations are protected with mastic reinforced with Dynel cToth! In some cases, where required, treated steel or stainless steel may be specified. Operating Temperature Range: 50F to 350F UCC 002733 STANDARD CXUUCAU AMO HAitlO CHAPTER VII APPLICATOR TRAINING PAGE 130 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 10-J, 10-JS5 - Contd Service: For use on storage or process vessels and equipment and process piping located indoors or outdoors. This is the most vapor and water resistant system in the ambient to 400F range. This system is suitoble for application where absorption of vapors or liquids in the insulation cannot be tolerated. The insulation is acid and caustic resistant; however, on outer covering must be selected which is resistant to the chemicals involved. The system is also suitable for use on electric traced lines operating below 212F where constant thermal conductivity is important. The system is suitable for installation on stainless steel surfaces. Caution: When exposed to rapid change in operating temperature, the insulation wilt stress crack. Specification 10-JU, 10-JUSS Insulation Materials: Cellular glass Protective Cover: Three coats of bituminous mastic and two layers of glass fiber reinforcing cloth. Operating Temperature Limits: 50F to 350F Service: Steam and process piping located underground. The only underground insulation system suitable for easy installation of steam or electric tracer systems. Caution: Care must be exercised in the application of outer anti-abrasive coating on the inner surface of the straight pipe covering so that movement of pipe does not cause excessive abrasion wear of the insulation. Also, expansion chambers must be carefully installed to prevent breakage of the insulation by pipe movement. Water proofing must be installed to be absolutely water tight. Positive drainage of seepage water is essential to prevent buildup of water that would cause flotation of the insulation system. Specification 10-L, 10-L5S Insulation Materials: One layer of compressed fiber glass cushion blanket installed on cylindrical vessels and equipment prior to the application of cellular glass insulation. On piping, the cellular glass is installed directly to the pipe. UCC 002734 STANDARD cmciucau *>* n.uTid CHAPTER VII APPLICATOR TRAINING PAGE 131 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 10-L, 10-LSS - Contd Protective Cover; Most installations are protected with mastic reinforced with Dynel cloth. In some instances, where required, treated steel jacket is used on the cylindrical section of vessels and on straight pipe covering. Operating Temperature Range: -300 to 400F Service: For low temperature refrigeration and process (with exception of oxygen) equipment located indoors or outdoors. Although high temperature limit is 400F this system is not recommended for service which is always above freezing. However, it is suitable for the high temperature caused by the thaw out system used with low temperature process lines. The system is suitable for use on stainless steel vessels and piping. This specification provides fire protection to the metal to which it is applied, for approximately one hour. If extended fire protection is required, specification 32-LFP should be used. Caution: Properly constructed insulation expansion and contraction joints are essential. Specification 10-LSP Insulation Materials: Cellular glass Protective Cover: Mastic reinforced with Dynel cloth Operating Temperature Range: -40 to 150F Service; A special system for the insulation of spheres in the -40 to 150F temperature range. Being non-combustible, the insulation will provide fire protection to the sphere to which it is applied for a period of approximately one hour. Caution: The surface of the steel must be sandblasted and coated with inorganic zincsilicate coating prior to the application of the insulation. Support of the insulation depends upon the bond betwee/> the steel, the coating, the adhesive and the cellular glass. Should this bond fail due to poor application of the coating or the adhesive, the installation will fail. Absolutely no other materials than those specified should be purchased or applied. UCC 002735 CHAPTER VII APPLICATOR TRAINING PAGE 132 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Soecification 10-OX Insulation Materials: Heat treated glass fiber cushion on blanket installed on vessels and equipment prior to the application of cellular glass insulation. On piping the cellular glass is installed directly to the pipe. Protective Cover: Mastic reinforced with Dyne! cloth or stainless steel jacket. Temperoture Range: -300F to Atmos. Service: Oxygen equipment and piping located indoors or outdoors. Note: This specification only for oxygen service. Caution; As oxygen can detonate when in contact with many different materials, all the materials used to insulate oxygen service must hove been tested by Linde as being safe for oxygen service. All materials listed in the specification have been so tested. For this reason, absolutely no other materials than those specified should be purchased or applied. Specification 12-H, 12-HSS Insulating Material: Rigid urethane foam. Protective Cover: Most frequently, equipment and fittings are protected with mastic reinforced with Dynel cloth. Straight pipe is more frequently weather protected with treated steel jacket. Operating Temperature Range: 50F to 220F Service: Process, hot water, and very low pressure steam equipment located outdoors and indoors. Caution: This system gives very little protection from external fire. Protective devices must be sized as if equipment or vessels were bare. Steam vapor will saturate the material very rapidly and it is combustible, and emits dense smoke when burned. Not suitable for applications or vessels or piping operating at temperatures below ambient air temperature. UCC 002736 STANDARD CMtMJCAU *LAWCS CHAPTER Vil APPLICATOR TRAINING PAGE 133 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 14-J Insulating Material: Flexible plastic foam. Protective Cover: Where located indoors and concealed from view, no protective cover Is required. Where located indoors and exposed to view the surface shall be painted with two coats of vinyl paint. Outdoor applications shall be protected w? th mastic reinforced with Dynel cloth. Operating Temperature Range: 50F to 180F Service: Particularly suitable for installation on tubing which might be bent to fit or installed after insulation is applied. Sheet insulation can be installed with adhesive to fit large flat or curved surfaces. For this reason it may be used to advantage on spheres or ducts operating at moderate temperatures. Caution: This system gives very little protection from external fire. Protective devices must be sized os if the equipment or pipe was bare. The flexible plastic foam is combustible and emits dense smoke when burned. Specification 15-H Insulation Materials: Semi-rigid fibrous glass. Protective Cover for Outdoor Service: Equipment is usually protected with mastic reinforced with Dynel cloth and straight pipe with treated steel jacket, or mastic reinforced with DyneJ. Fittings and irregular surfaces are protected with mastic reinforced with Dyne! cloth. For indoor Service: Glass cloth jacket finished with PVA coating on straight pipe. Mastic reinforced with Dynel cloth on fittings. Operating Temperature Range: 70F to 750F Service: For use on vessels and piping where abuses are moderate. Excellent for indoor applications. Fire spread and smoke index sufficiently low to pass most building codes. Caution: This system gives little protection from external fires. Protective devices must be sized as if equipment or vessels were bare. UCC 002737 STANDARD OUUKALS IMV fusm CHAPTER VII APPLICATOR TRAINING PAGE 134 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specificotion Nos. 17-RX (externol, 17-RY (Internal) Insulation Material: Semi-rigid glass fiber board. P rotective Cover: External, indoors: Where installed inside of duct, none when installed outside of duct and where concealed from view the foctory applied jacket shall have joints sealed with tape and fire resistant adhesive. Where exposed to view, factory applied canvas jacket shall be painted with PVC paint. External, outdoors: The factory applied, vapor barrier jacket shall be sealed the same as required for indoors application, then coated with mastic reinforced with Dynel cloth. Operating Temperature Range: 60F to 150F Service: Either external or internal insulation for air conditioning and heating ducts. Caution: When air conditioning duct operates at lower than ambient temperature, joints of factory applied vapor barrier jacketing must be vapor sealed with care to retard vapor from entering the insulation. Specification Nos. 18-FX (external), 18-FY (internal) Insulation Material; Flexible fibrous glass blanket Protective Cover: Internal: None External: This application is used only on indoors applications, concealed from view. The factory-applied vapor barrier facing should be odhered to insulation with adhesive and its laps sealed with joint tape. UCC 002738 STANDARD OHIWOtU M K-AITICt CHAPTER VII APPLICATOR TRAINING PAGE 135 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification Nos. 18-FX (external), 18-FY (internal) - Contd Operating Temperature Range: 60F to 150F. Service: Either external (FX) or internal (FY) insulation for air conditioning and heatingducts located where they are protected from physical abuses. Caution: Care must be token to obtain excellent sealing of jacket joints. Specification 19-H, 19-J Insulation Material: 19-J Fibrous glass side wall and roof insulation. 19-H Minerol Wool side wails, expended silica roof insulation. Protective Cover: Factory-attached aluminum panel. 19-H has corrugated aluminum jacket, whereas 19-J is supplied with smooth aluminum panel. Temperature Range: 60F to 450 F Service: For vessels 12 feet and larger in diameter - where used when high winds are expected the 19-J system should not be used as light weight glass fiber roof insulation tends to lift then blow off. Also, 19-J cannot be used on vessels on which the use of stud welding is prohibited. Caution: Both systems give little protection from external fire. Protection devices must be sized as if vessels were bare. Care must be taken in panel layout to obtain a neat, clean insulation application. Specification 21-H, 21-HSS Insulation Material: Preformed asbestos fiber. Protective Cover: Straight pipe, either metal jacket or mastic reinforced with Dynel cloth. Fittings, mastic reinforced with Dynel cloth. Temperature Range: 212F to 1000F UCC 002739 STANDARD QttMBCALl AMD CHAPTER VIJ APPLICATOR TRAINING PAGE 136 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 21-H, 21-HSS - Contd Service: For hot process and steam lines. Especially useful for high temperature steam traced fines. The material has high resistance to fracture, thus will not break into pieces when subjected to a blow or pressure between lines of support. Has good fire resistance for a limited time. Caution: Weather-barrier must be excellently sealed as material is very absorbent. For this reason this system is not recommended where material may become saturated from combustibles due to flange leakage, etc. Mechanics should exercise care and take all safety precautions to prevent breathing of the asbestos fibers which may be floating in the air when the material is cut. Specification 22-H, 22-HSS, and 22-H5P Insulation Materials: Bonded Expanded Silica. Note: On vessels over 400F or over 8*-0" in diameter the specified cushion blanket is to be installed prior to installation of the expanded silica. Protective Cover: Straight pipe, and cylindrical sections of vessels either metal, or mastic reinforced with Dynel cloth. Fittings, heads and irregular surfaces of vessel protected with mastic reinforced with Dynef cloth. Temperature Range: 50F to 1400F Service: Steam and process equipment and piping. Used where fire protection is of importance. The only specification which should be used on traced lines operating below 212F. Also, this specification or 32-HFP are the specifications to be used on Ethylene Oxide and Acetylene services. Special specification 22-HSP is for insulating of hot spheres. The temperature limitations on this specification, however, is 70F to 500F. Caution: As bonded expanded silica is water repellent it requires special solvent type adhesive for cementing it together. Likewise ordinary insulating cements will not bond to its surface. UCC 002740 STANDARD CHtMCALS U*> HAJTCS CHAPTER VII APPLICATOR TRAINING PAGE 137 APRIL 1970 SELECTION OF INSULATION MATERIAL And application specification TO FULFILL installation requirements SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 23-H, 23-HSS Insulation Material: Calcium Silicate. Note: On vessels over 4Q0F or 8'-0M in diameter, specified cushion blanket is to be installed prior to application of the calcium silicate. Protective Cover: Straight pipe, and cylindrical sections of vessels either metal or mastic reinforced with Dynel cloth. Fittings, heads of vessels, and irregular surfaces protected with mastic reinforced with Dynel cloth. Temperature Range: 212F to 950F Service: Weather-barriers must be excellently sealed as material is very absorbant. Material contains asbestos fibers so safety precautions should be taken to prevent breathing in of the insulation dust. Specification 25-H Insulation Materials: High temperature calcium silicate and regular calcium silicate. Note: On vessels high temperature cushion blanket should be installed prior to the installation of the two layers of calcium silicate. Protective Cover: Straight pipe, and cylindrical sections of vessel either metal or mastic reinforced with Dynel cloth. Fittings, heads of vessels, and irregular surfaces protected with mastic reinforced with Dynel cloth. Temperature Range: 1000F to I600F Service: Steam and process equipment in the 750F to 1200F range. Caution: in this temperature range the proper construction of expansion joints is of utmost importance. This specification should not be used for fire protection, nor is it suitable for application to surfaces of stainless steel. The calcium silicate contains asbestos so safety precautions should be taken to prevent breathing in of the dust. UCC 002741 STANDARD 0*U)C*U AW PLAST10 CHAPTER VII APPLICATOR TRAINING PAGE 138 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION _ TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 31-H, 31-HSS Insulation Material: All metal, stainless steel case enclosing reflective sheets of aluminum. Protective Cover: Factory applied stainless steel jacket. Temperature Range: 33F to 1000F Service: For process pipe and equipment. For special installations where absorption of chemicals by insulation cannot be tolerated. Also very useful where fast removal or replace ment of insulation is of importance. Advantageously used on heads or flanges of vessels, which may be insulated, but which require frequent removal for process purposes. Caution: Reflective insulation is custom made to fit vessel or piping system. Does not lend itself for field cutting and fitting. Entire insulation, including its jacket, must be factory fabricated from vessel or piping drawings. Order of application of individual units must be in accordance with manufacturers recommendations. Specification 32-HFP & 32-HFPSS Insulation Materials: Inner and outer layer of expanded silica. Note: On vessels over 400F operating temperature or over S'-O" in diameter specified cushion blanket to be installed prior to application of the expanded silica. Protective Cover: Straight pipe, and cylindrical sections of vessels either metal or mastic reinforced with Dynel cloth. Fittings, heads of vessels and irregular surfaces protected by mastic reinforced with Dynel cloth. Temperature Range: 40F tol400F (operating) Service: For insulating and fire protection of vessels, equipment or piping operating at ambient air temperoture and above. This specification and 32-LFP are the only specifi cations to be used where the insulation is expected to serve as extended time fire protec tion. Specifically for use for protection of reactive chemicals. Caution: Insulation must be installed in double layer broken joint construction to retard exposure to fire at joints. UCC 002742 STANDARD 04DUCALI AND PLASTIC* CHAPTER VII APPLICATOR TRAINtNG PAGE 139 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 32-LFP, 32-LFPSS Insulation Materials: Inner layer cellular glass and outer layer expanded silica. Note: On all vessels, specified cushion blanket should be installed prior to application of the cellular glass and expanded silica insulations. Protective Cover: Straight pipe and cylindrical sections of vessels, either metal or mastic reinforced with Dynel cloth. Fittings, heads of vessels and irregular surfaces protected by mastic reinforced with Dynel cloth. Temperature Range: -300F to 400F (operating temperature) Service: For insulating and fire protection of vessels, equipment or piping operating at temperatures below ambient during at least part of the operating cycle. This specification and 32-HFParetheonly specifications to be used where the insulation is expected to serve as extended time fire protection specifically for use for protection of reactive chemicals. Caution: Insulations must be installed in double layer, broken joint construction to retard exposure to fire at joints. Specification 37-H Insulation Materials: This specification is one for factory conduit cased insulation. TKT insulation may be of any type, as required. Protective Cover: Steel conduit, galvanized and with factory applied water resistant heavy duty coating. Temperature Range: As determined by the insulation specified, up to and including 750. Service: For underground hot piping. Suitable for all ground conditions. Field instaliarion of insulation is only required where sections of the assembly are field connected. Caution: Water proofing of the field connected joints must be done with care as any leaks in these joints will adversely affect the entire system. UCC 002743 STANDARD CXEMCAU AND RLAiTCJ CHAPTER VII APPLICATOR TRAINING PAGE 140 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 38-H Insulation Material: Foamed urethane. Protective Cover: Heavy gauge PVC conduit. Temperature Range: 50F to 220F Service: For moderate temperature underground lines. Suitable for ail ground conditions. Field installation of insulation is only required where sections of the assembly is field connected. Caution: Waterproofing of the field connected joints must be done with care to prevent water seepage into the system. Specification 39-H Insulation Material: Bituminous Fill Protective Cover: None Temperature Range: Depending on type listed as follows: Type A Type B Type C 220F to 300F 330F to 385F 385F to 520F Service: For underground hot lines. Only recommended where soil drainage is excellent, and water table is considerably lower than the installation. In most installations corrosion protection and galvanic protection of lines are essential. Should be used only on lines operating at constant temperature. Caution: Packing of bituminous fill insulation around, particularly underneath, of line is essential. Line should be put into service to cure the material before backfilling. UCC 002744 STANDARD o<tMCiU uc purncs CHAPTER VM APPLICATOR TRAINING PAGE 141 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 40-J Insulation Material: Cork filled PVA mastic. Protective Cover: None Temperature Range: 34F to 180F Service: To retard condensate drip from vessel or piping operating at a temperature below ambient air dew point. Caution: Mastic to be sprayed or troweled to surface. The surface must be dry during application and be above ambient dew point temperature until mastic has dried. Specification 41-H and 42-H Insulation Material: Sprayable asbestos fibers and inorganic binders. Protective Cover: Cylindrical sections of vessel either metal or mastic reinforced with DyneJ cloth. Large flat surfaces and irregular surfaces to be protected with mastic re inforced with Dynel cloth. Temperature Range: 41-H, Amosite Asbestos Fibers 70F to 700F 42-H, Crocidolete Asbestos Fibers 70F to 1350F Service: For process vessels, flue gas ducts and fire protection of steel. Used advantageously for very large hot surfaces. Caution; Surface of steel must be clean and free of mill scale. During application all workmen in area should wear proper dust masks. UCC 002745 I STANDARD GMUttCALS AND PLASTICS CHAPTER VII APPLICATOR TRAINING PAGE 142 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS SUMMARY OF INDIVIDUAL SPECIFICATIONS - Contd Specification 43-H, 43-HSS Insulation Material: Urethane liquid sprayed and foamed on surface to be insulated. Protective Cover: Sprayed mastic. Temperature Range: 50F to 250F Service: For large area vessels, when fire protection by insulation is not important. Caution: Not to be used on any vessels containing reactive chemicals. All fire safety devices must be calculated os if vessel was bare. Correct mix of two component liquids is important. Should not be sprayed when ambient conditions ore less than 70F or when wind velocity is greater than 5 mph. Fresh air mask required when spraying indoors. Proper filtering mask essential when spraying outdoors. UCC 002746 STANDARD CMIMTCALS AMO PLASTICS CHAPTER VII APPLICATOR TRAINING PAGE 143 APRIL 1970 SPECIFICATION NUMBER 10-H, 10-HSS 10-J, 10-JSS 10-JU, 10-JUSS 10-L, 10-LSS 10-LSP 10-OX 12--H, 12-HSS 14-J 15-H I9-+I 19--J 21-H, 21-HSS 22-H, 22-HSS 23H, 23-HSS 25-H 31-H, 31-HSS 32-HFP, 32-HFPSS 32-LFP, 32-L 37-H 38-H 39-H 40-J 41-H 42-H 43-H, 43-HSS SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION feEQUlREMENTS TABLE Vll-I INSULATION Cellular Glass (with glass fiber inner cushion blanket) Cellular Glass Cellular Glou - Underground Cellular Gloss (with gloss fiber inner cushion blanket on equipment only) Cellular Glass Cellular Gian (with heat treated fiber inner cushion blanket) Rigid Urethane Foam Flexible Plastic Foam Fibrous Glass, Bonded Fibrous Glass Panels, Faced with Corrugated Aluminum Fibrous Glass Panels, Faced with Smooth Aluminum Asbestos Fibers, Bonded Bonded Expanded Silica Calcium Silicate High Temperature Calcium Silicate (inner layer). Calcium Silicate (outer layer) Reflective, Stainless Steel Cased Reflective Shields Bonded Expanded Silica (double loytr-broken joint construction) Cellular Glass (inner layer). Bonded Expanded Silica (outer layer) Steel Underground Conduit - Insulation as Selected - Underground Molded Urethone Foam on Pipe in PVC Conduit - Underground Bituminous Fill - Underground Cork Filled PVA Mastic Sprayed Amoiste Asbestos Sprayed Crocitol ite Asbestos Sprayed Urethane Foam OPERATING TEMPERATURE RANGE 7OF (21C) to 600F (316C) 50F (10C) to 400F (204C) 50F (10C) to 350F (177C) -300F (-I84C) to 400F (204C) -40F (-40C) ta )50F {66Q -300F (-IS4C) to Atmos. 50F (IOC) to 220F (104C) 50F {10C) to 1B0F (82C) 70F (2IC) to 400F (204C) 70F (21C) to 400F (204C) 70f (21C) to 400F (204C) 212F (100C) to 1000F (538C) 40F (4C) to 1400F (760C) 212F (100C) to 1000F (538C) 750F (399C) to HOOF (871C) 33F (1C) to 1000F (538C) 40F (4C) to HOOF (760C) -300F (-1&4C) to 400F (204Q 4OF (4C to 750F (399C) 50F (10C) to 22OF (4C) 220F (I04C) to 520F (271C) 34F (IC) to 180F (82C) 70F (2IC) to 7OOF (371C) 700F (371C) to 1350F (732C) 50F (10C) to 250F (12IC) Letters in Specificotions: H indicated Ambient to high temperature service. J indicates Ambient or cyclic temperature service. L indicates Low temperature service SS indicates suitable for application steel surface . Metal Jackets SP indicates for application to sphere. OX indicates for oxygen service. FP Indicates suitable for Fire Protection. U indicates for underground service. When metal Jocketi ore specified odd M to Spec. No. for stoinleu ileei or MT for treated steel. UCC 002747 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS STANDARD CMMCAU AMD H.AJTO o | zl 3s Uoiuci tQV> 5 -^ 400 o7Z wo<c W VTV <-r KUi aQ_: <ec < a1 o5 oo is- M.s Sill ` E .? o <LE UUi fUV vao- pu.i is ? 2 O1 s og PROTECTIVE COVER z UJ C `5 s *~ o c 'Z* <51 aIU> i oU_JJ fiD < H* Z J -g b _Tncxi fJ 5 w3> o --^ -o sa "o co Ic Z u Ja 10-lSS oz i-- U< QC 2S u5 4/t Z --oiJ oz -- 5c < II _J I! |X s2 ?< ^oc 3aO-* *o K u. or 8 l -L i&i ? S'? Ms _ D 8 5:2 i_ -2n-S-2 * Jj S S TS-OS *I Ilia. 5 II g 5.5 - E .? *E ii =||i -81s s . lull" S ? g * u .T fc E 5S22 JC m= 1& .- " E- iU u S> i? CHAPTER VII APPLICATOR TRAINING PAGE 144 APRIL 1970 i , S ill o .5 oX5 *!D 5cO S|X >r0i Ui U U V -- 5 - - * -o' g _*J: >. o* f"t --JSu >s. S"o 3 " -g |r SSO- Q>. gi 0w ^5 ^- *c0 < z z v> o o *5 S- 2 >. *acz*"--5g ~"an M3*e 5 ** c -:ini <_5 -* *t > to -VD J> BC ' v *Z li ? J "8 _* >- O ?8 1-0 - 3 9 8 4j J u .T5) .H. u VlAO oo oo O^ II 13 IfOX2i U u. --'D8 S LL. t 3 ST ill? ^ O-Q i 13 I ,32 j fct *u `S,, wjiiJ.-5 Q C ? 1.2 2 S " --O C -- .V2 s* nin * *D c -2ai-Scg_ j5^-*-c?- -di5 E^3 U_^Xi 1Hoj=-j^O>;xjeCo Uw. e Co U o -o -5 -o S2 S au.. o. u.vCr>iN .^ Nc*|> ^^O J Si !e 5 S' !c II II 21 21 5eD 2X. Is Xf *8 u. r>* Cl Iu S'S 8 5 31 M 0> c J 1 H= ? I ` f| . o 1 57 5 -SS -l o1 S |-g il"f5i| 8 1 Sea S.1 2 HI l2 iI l--lg UCC 002748 5 33-|e s 3< >C Bl^C Z U v - 5 z g = _8 -e ^ <t8i-s O7 t? g I l | o. 11 : iQ.t 5>^ a0!.>-*0:ft I I I I I I l [ [ L l L L L STANDARD omacui M0H.AJTK3 CHAPTER VII APPLICATOR TRAINING PAGE 145 APRIL 1970 SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION" TO FULFILL INSTALLATION REQUIREMENTS" o z *3 ^< oz < t-- if! Sa- 3a < "2 5 O. Z) G CD < S1 i J s* 8 r N^ T-i 53-T JS-t la-3 ~8 i& 1-:5 2ild* =E | 1 jo<i= lg | j 8i e Z *3 o o nni JsI i| ^ ;f s aU-o --i - S* < s * w >Uui oD 52 21o3> 3 |S -c .-o^f .s11 s sM 1 i-*i2 g S 2J u S 5 Sir > OK oc uj J2 2Q oz < U oC tu *5 X 9 x* S3i/ Z i 5 .- 2?I -O iJ- ll Hit 010 1= -? 8 =g yI JK _c -- .?{ f .S " ii | -- > . *S| S Jg =t 5 i?E! *!ls! 5-0 j! S 1i{fbc5u^ Z ' - - ? ei - s --Sslii2p:'s* Isii! c 3 _o O 8f'1 .o5iPu"i?D?je* .631 it- Jr9wS -->aI .u4 `I'STd-s* 1 o g * a *1 Sx- JO t> -5 ; i 8 i (SSj 2x "5 xx g 1 S S I -5 = n I s1 s fSjijos ^ 1= 1! 15 s' i? s=ii 1 ,t 4I&e e5 Sf =u -tO jov l 5 .S.-S s 8 u i <5-1 4 -J 4 V5|e? mu! e1 5 Ej1 rM* I -f s e J-f =.Si1 I O .c E u -- 4 i 4 . a8 ~a SI II e 8 Is II s* \h -u So.-, o2 5 5 `--' ug 55 ft Cl UCC 002749 n> -c C -5 POT ^Qn. ioc: -*>5iSE y SI II I IJ E5 'aj 5d ;u z-.i J ME H ~-5 S3 .S, eg ' ' u. si ';s? i> Jpc.=8 81 = - KJ *-- CD "g !S 5 _s> JE 0M L"B . 0---- u ^ 4 SsHli I o " .S II si -sils S^5i 6*2:5 g >5 ? 2 g> i e ? 0 11d. o. -- u STANDARD OCWCALS A* PLASTICS CHAPTER VI! APPLICATOR TRAINING PAGE 146 APRIL 1970 oz - i * il II Si I jJo2 .u2 UJ O' UJ > 50 7O*r U<oci --o X- 6,,--0 3-S -co x 2- 3O =! 2 2. g--s= j*i ;s ! !lil| a Mo 5| IJI s - S-i-5 ^jll re i-2 i5 la < =5 -8 .0 ! z sis.. UJ 0 s - 5 Q u _ *0 il 3 UJ UJ o IC sU iIlH co < "8 8?. Zo 5 <u < x uEBS S3 x1 5 r1 5 i/t Z. $ si 21 Ml -Si;? a E 2 lli ? o - ill ill J* JE 2c ic8u.8.g-3 .-5Sl3; si 3 u. o 3 O * *3 O Hi# ?y Jj. i -P s* wo i *S s* Sot5 it > Ji 2 -8 sis . = 1*1 IH^ t-- XJI51 1* ^ N OO 0J:^r4 w I8 o * *5 9 i-s 2t ||c 8 o x 5l - _D a -D S -g- a o 85 fi -o i s " Jt = 9- - a 5 J* 8 S 1* JSS 22i-o*2I ? ,* tie8 -8 22. .5t So- ge" >3 ^=.3 2-8 sis . si rl-5.a| o X c w nih s? X " V > m e3 ! O2 X^ P, c- si 5 x J) .i .1=1 .2 e O " C 2 8 48 C20> 9c -C5 -3D C *> O * N 0. o ?J < J S-S'S S o J_ iz 2. 8` |i 1o*i S *a 2g.?o | . J->i2l"lX1ta; iu?" tOiL&. -|ss>--olO 5 -g 85 5 1st O *, - . 111-I g>"S I i -9 ~ 3 O * J! ti ,, -- $ t "S o *S ^g c * sp 7 i s.! is.- sr jg ^e . 5 - a. n o .-- o - s si 11 g" < ou * O r!a1-1 Uu Sfc w t- Smoasr rl 5 4^ U. 88 O CD 4> o c d v e SB- S^-|s|-<j#" -. ^!* -?g>oo; 7a-oeLAs-Jsaout. 4XSr1g.) 8s. Il il ii II ? g S UCC 002750 2y 6aUa fl2i?5 til il t 12 # .o x4* o> * dsC Ji |8 5* iS IE r STANDARD r CM0UCM4 A* ^tkSTKJ r r r oZ V-- i< u u i LU o. CO J j 1S 0 sF.f 5S t8 Mills hnr liilll1 z ill 111 I <i t ] Ss UAJ 55 % V Vo O< UJ " Xtt O> 5< O4K-9 U4<AJ < 17 . .* J < a | Li S < jt; Mo S; 5*1 ae 5 .-fcf 2*1 i a SJ?*icx'i"f[ 1 Ic-l! asl^l fie ? 5 t|?c- Z o i h< u _1 i aa.. < o iZ < 5 o. _i < on 3 o S.S ?sf IIj-I. > O mu |sui 2: u i &ls ilM ^ i 2 fs I i II i CD i oZ < i zCO occ. i z o *-- u i LU CO ? is. z o 5& S. O 5 ts uS Z y/> 54 rr<t; nn* H<< II II <C u: *>5t /i O uHci ?>x M 1-5 k/1 D Ze li II o \ l5- <oc *o(e. A 5 i liO " :l c^ V u. 5* --N-Ur.>' o8 N* Tv X 7 -- K Ills St.-.T L-? 8 8 8> '; ifl O hc F to Z" to S K ? B t I a a8 '?-S-s6J7J-5!5 UCC 002751 CHAPTER VII APPLICATOR TRAINING PAGE 147 APRIL 1970 _________ SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION TO FULFILL INSTALLATION REQUIREMENTS STANDARD CMfMCAU AMO PLASTIC* CHAPTER VII APPLICATOR TRAINING PAGE 148 APRIL 1970 o II oc 5 o5< Ui OC /-J o <TZ. c^c L- L/\ u 3^< Ua;I -fc > oo 8a s 7o ^S - < S J i. yo 5 ? XO w i. _iEs-!Os!*i ;. > --< OU 0 m 3 <*u- -6P ^2 = fi a tj * u sis ?g s-55l| 18..? ii o. 2 3 2 J _ yI 5B 5 5,151 5-s.l g ~su 1 -= ip 61 8;..S?. -i iul* ii* . e -2 ^ 6 ? -111 Ii:5r J< itiSl*&0 0 lD 0c 1J 1 ! i ll I Jill |c L iSJ? P-g lQ.= --J 2 "IN5 s j*--11.1 j. <e2* D 55 " i = SO z 25 2 .r1 ~ .2g au.-* -III*: oJIz.2: :H JF c - _* 2f W ; -- .i -* g *5l=1| -1e-1*s5: I oil &JJ s- s -Sc 5-= : Jl h fl o j t; t* *s3 j*D `1 2 S c Si 5. L> - ~ -s* 23-l 1 <2 o . . "S-S_,j `S55 -5eoIop*r*-"*5S"C-7 S !i S 3 Z Z. u 3 c -o r> It s i.* a. 5o S a. Q 1 Z U < S ' ill <$: 8 z LU CL CL CO < oz - < Ot0oSc-'s5^*as7: vi z. 3Ou ^-_? =i> J 5 1. <O JHJ 1 . v oX oX s2 s v> .a Ii s5.-Df I ^^ tNI K^ roin< *c U s< 07o <*> U u. eo5 sa.' 28 a. y ^ "C eg 5 *(i U) . wXU a. O O II fX It is w r> Li. 82 o Si ii 2 W28U. ^n u. S2 Jill fiSll o ^ c._ = "O o 5-o? "Sg ss Iae *^ si II I8 c? Rf u. -S S III I J i i^ . fi * ro 2 S o. <S ;ff3 c 8 i. -" c -2 =Ui 1o 8 S .9- li-s -y a. i;s - - cn 111 UCC 002752 r r r r r r r r r \ oZ \ I-- < y i Li. u LU Ql/l. i oz t-- < y i D_ Q_ < Q iz <_I < i on i zo i-- i3 z> iO gz iu i STANDARD OCMOU AM) W.AJTIO CHAPTER VII APPLICATOR TRAINING PAGE 149 APRIL 1970 i ~8 -D = o .S ?. 5 = II o Ui So -= ? o2Z S</' < <* ~Zf a < UJ T3 S3 ao o^' ia5u. = *>-8 oL/ z =18 III Ill u. LU a. a. Q z < LU Q_ a. } < cj 5 If 2 * > s2 " 11 i I * ?3 it U. f o w 1u. 1* e s8 s i s-5-i-i s f iiO ioll*--?o = . o#E gj.? iO`i s -3-S* S IZ I fU j u--. ^S o- c it if SI _ 5i .a > 2 o "5 Sj!i BVt/Ii s: z 2L~ & C* T> IT J?S c *u2 t Ills a .2. * ft.*' co-c| % 5 Uil * t> 35 zz -J5L.Z*: -U= -2B f-.B _U3 ill .aD j So 2t; s-f ^ I ta J? . S' I 111 u. o u dll e 111 ? 8. ill * 1? 1I ^ 5. 5o oS ss Z i< 4 i 21 LLi So.' 5 O --e N. u. II o^ -o.?5 ? O -s 5 -S iliS = IE ?ll. 1u c1L4-o- 68 J* I s: 3c x^ 4 UCC 002753 a. -o -E IS 3o r .S 3 V* 0 5- = la? i %wOa. *oc 2 ji Si 3& . HIS65-E f? X >L-- *5 e -.& f "c 'E - 0-0 ' *x? i J53 > * till O sc ? SL 5'= 6 o j> *& Et < %J uta H*i z Soa 1-s X I5 I--*5f*.8]1' *6 .0ft* J si mf 1 s ^ Jz S i S' zs -o r= i5; 3E E O j) ft ? 3 yy oCfNN oCkMn I> iS . N0T6S: (1 ) W kr run o f pipe is short betw een fittin g s , v te Dyne I reinforced m astic. SELECTION OF INSULATION MATERIAL AND APPLICATION SPECIFICATION~ ~ TC> FULFILL INSTALLATION REQUIREMENTS STANDARD OffMfCALI AMO PIAITId CHAPTER VII APPLICATOR TRAINING PAGE T 50 APRIL 1970 fill o ;Z= IzOSSO- ^<2s so sB -SS -i--j1:S 1 3 ll 2 a2 22 J< -AO7 Uo<:i rz tu 3A i! = ! 5s < 1^2 s 2 ' Si ; X S 8 2 c HsJf S 5 2t t/i o z g"I* > 2ijU Q_ U t* o z sg 2P ifi?i 5 I S Sc < LL) Cl. o a'l f * --i l-jii-J;T CQ < -c"o _S> 5 nisi oz -- <U 5x Kg A e ' 2 u. J> 11-I * -4 iJ sg t S _ -5 1.54 5-54 2 llili!. flii HI I ll J ? 5 < 1 - S 8 2 o_ c Sf 2 E 4 i! sf jil * i5il5S41f? U M r* 11 i? s 3 - S | !i!Is . i r 5-5 4 n-iiL-il-S I. s ?`i| O5U --A8 -*Uoo =-IS _ a'v c #11-5 53 u> O* Q. O fi 3.. .t2 lt ? x 8 I8. f2 ! i. 4 -J5o8 5s J8*f 1:4.1 | -8 8 rsJ sH nV~ _ 0.-2 =" llifl 8 Ia "O 5P 8c li\ *V s l1 JS 2 "i J=1 * v* Jf 5 *2 III D * *- i3J5S1 4 J s il jo a> i i ?^.4 i 115 . l*o? u a c = is~a* -.Jv5. !2i34z; 4^J- .ill. = si 5 ??r 1 5^2 4 = i4 C " C!,O >. <*5 58 s> ji: 21 -I 3 I * .> .* 5 - o -^at *Oc> -25cc _ttooc .2 ui* E . ~&B5 2T .-f-l| . o i?l Uili"i,,: *5 NN oy 84 Is ? z< ya CM N to CQ oEp5; 84 14 ll U^ UN. OQ <-- ,,5* v -^2P -Z8SVO *-1*ur*-oua sa>ti.. . 5 ; S-o 8 -- ^ -O * C c o. * Ir. ^JcIIc ll 8 11; <j?l aS. rp UCC 002754 s| si 4? . B or*ct *?Moo ? 41 E J 8j = s sl B 8= 5 a l l L L L I, L L r r r f i Zo i <I-- u !u LU Q<>. oz <uI-- --I a. o. < zO < _l < CXL L LU I-- < 5 L oZ L z3in Lo oz k-- LU i i STANDARD MVCUl UC ELASTICS i 5-* o z_ 5z ..? * -s 9 S -- -o-s pi si o i Iis.5. SESjs*? UJ UJ ^ XO Z 2< si Sac H UJ y o si .' Jo E - ? u 5 O "F . C I; -8 3 I iiilj.tjst e ozCO > - z sstua. V 2a2c .2L o > ' 5 fillCL. a ilcsi < LU a. 3 8 1 s e 8. & cQ < z o u2 5 x vt 3Z .2 2 IS CHAPTER VI! APPLICATOR TRAINING PAGE 151 APRIL 1970 .3 | !-I9 S-*? -o 1 || 6 8 =5 I 8 i S - i0 2LE. S *9 ^11 Eu 2o --E UD i .*'S s "8 3u 11 U | 51 I?* Is HI & `ii i 5lS*1-2 =VD O 'Z T> . rs s s o.-- E V) 4- -- it J!.U1 ? - -8 J 3j 8 ofc '5c . --v Xu 1 if III! 4 . -- -C * X S'-- 3 io 2 e u .S _2 -c O * c BH 5 " . *S ?g S-2 o: -g 8.1 I .|-1 S I f? s. , 2 j: cUfjo c Ow -O "Sc- * 2Q 5 *C x 1:5? "S 9 .t z ic ^ *" o -D D S5|ts J5-8 ? *?1**t* fsiiifl s Ijc 514*1 llill uO A x A J.-JI 4 i_ S,, *,, iI!$ 4 11 li$ 2g< S0o5.- ~X x= ait so 8g ** I -n QU__CVJ S5 Ii j53 2% aS raS3 a sl ? . _ O - isii-j -5. >o 1 u/ u 2 w> ,5 as8CC --W3 T*J>" W c Crct v " g o. * 6 UCC 002755 S-i* * c j: " ^ go x-o'2-*8=8 2E E. " oS-jjl i ' * u -i 8W B..- O Vm X > as .-=8 27 s j g = ? 85..e-.S8-Zessiu jI; -si -*l I" BP 5 ? !-i ru ao I* kA S STANDARD cnewCALt plastics CHAPTER VIII APPLICATOR TRAINING PAGE 152 APRIL 1970 TOOLS REQUIRED In the application of thermal insulation a number of tools are required. Some are for very special purposes and others are commonly used. Some tools are hand tools and others are power tools. Where tools are used for a specific purpose such as in the spraying of fibrous insulation, their operation and use is described for that particular operation. The more commonly used tools will be discussed in this chapter. A good workman keeps his tools clean and in good working condition. He uses each tool only for the purpose it was intended. In general, tools are separated into two divisions; one division being hand tools and the other being power tools. HAND TOOLS The use and method of operating most hand tools are generally quite evident. For this reason, description of the purpose and method of using hand tools will not be covered in this chapter. For example, it is not necessary to state that a knife is a tool used to slice or cut materials. This is well known. Also, well known is that various types of knives have been designed to best cut particular types of materials. It is interesting to note that the insulator does have to become skilled in using a number of different tools to accomplish his task of installing insulation. The hand tools necessary to perform the various functions of installation are as follows: I. Marking Tools 1. Pencil 2. Ink Pencil 3. Crayon 4. Soapstone 5. Chalk line 6. Scratch Awl 7. Scribes 8. Divider 9. Trammel Points II. Guiding and Testing Tools 1. Straight edge 2. Mitre gauge 3. Mi tre box 4. Framing square 5. Templates for mitres 6. Steel square 7. Special patterns and guides 8. Level UCC 002756 STANDARD TOOLS REQUIRED HAND TOOLS - Contd III. Measuring Tools 1. 6--Ft folding rule 2. 6 or 8-Ft pocket rule 3. 50-Ft tape IV. Holding Tools 1. Clamps 2. Cutting frames 3. Springs 4. Rubber bands 5. Pressure sensitive tape 6. Wire 7. Rope V. Cutting Tools - Sharp Edge 1. Butcher knife 2. Boning knife 3. Hawk-bill linoleum knife 4. Rubber knife 5. Shears 6. Pliers 7. Snips 8. Aviation snips 9. Shears 10. Nippers 11. Hatchet (steel and brass) VI. Cutting Tools - Tooth 1. Hand saw 2. Key-hole (compass) saw 3. Hack saw 4. Rasps 5. Gritted paddles CHAPTER VIII APPLICATOR TRAINING PAGE 153 APRIL 1970 UCC 002757 STANDARD D<t*CAU D PLASTICS CHAPTER VIII APPLICATOR TRAINING PAGE 154 APRIL 1970 TOOLS REQUIRED HAND TOOLS - Contd VII. Hammer Type Tools 1. Masonry hammer 2. Mallet VIII. Fastening Tools 1. Stretcher (Banding Machine) 2. End nippers 3. Screw driver 4. Pliers 5. Wrenches (Allen, spud, crescent, end) 6. Blind rivet gun 7. Punch IX. Finishing and Coating Tools 1. Flat broad trowel 2. Pointing trowel 3. Margin trowel 4. Rubber palm 5. Rubber gloves 6. Paint brush X. Sharpening Tools 1. Files (various shapes) 2. Whetstone X). Tool Holders 1. Tool box 2. Tool pouch Most of the most common hand tools used by the insulators are illustrated on pages 155 thru 159. UCC 002758 f STANDARD r CHEUCAL3 AM) PLASTICS r r r i i i i y CHAPTER VIII APPLICATOR TRAINING PAGE 155 APRIL 1970 I measuring tools INSULATORS HAND TOOLS UCC 002759 STANDARD O4U0CALS AM) n.i)TCl SAW CHAPTER VIII APPLICATOR TRAINING PAGE 156 APRIL 1970 ALUMINUM COMPASS SAW HANDLE COMPASS SAW BLADE RASP TOOTH TYPE CUTTING TOOLS HAMMERING TOOLS SCREWDRIVER LOCKING ADJUSTABLE FASTENING TOOLS INSULATORS HAND TOOLS UCC 002760 STANDARD CHEMICALS AW PLASTICS BONING knife Rubber knife CHAPTER VIII APPLICATOR TRAINING PAGE 157 APRIL 1970 unoleum knife utility knife heavy duty shears METAL CUTTING SNIPS CLAUS5 SHEARS SIDE CUTTING PUER END CUTTING NIPPERS CUTTING TOOLS INSULATORS HAND TOOLS UCC 002761 AVIATION SNIPS STANDARD QMCAL3 MO PLASTICS CHAPTER VIII APPLICATOR TRAINING PAGE 158 I*TM STRETCHERS BROAD TROWEL CUTTER PIPING TROWEL FINISHING AND COATING TOOLS INSULATORS HAND TOOLS UCC 002762 STANDARD QtlMCALS A>C PUtfTICS CHAPTER VH( APPLICATOR TRAINING PAGE 159 APRIL 1970 INSULATORS HAND TOOLS UCC 002763 STANDARD OtENICAlS AND PLASTICS CHAPTER VIII APPLICATOR TRAINING PAGE 160 APRIL 1970 TOOLS REQUIRED POWER TOOLS During the past few years many more power tools have come into use in the insulation craft. Power tools of both common and special types ore used by the insulation shopman in the fabrication of insulation. Not all shops have the same fabrication equipment, as each obtains equipment most suitable for its production needs. However, the following tools are commonly used in insulation fabrication shops. 1. Band saw, horizontal or vertical 2. Inside and outside core grinders 3. Circular saw 4. Head grinder 5. Paint and mastic spray A shopman will be given detailed instruction in the use of these machines by his supervisor. For this reason, the operation of these machines will not be discussed further. The field applicator uses many power tools also. Some of the very common variety are power saws and others are more specialized power equipment, such as sprays for mastic stud guns, etc. A short discussion on the use and operation of these special tools is given in this or other chapters of this manual. Field applicators use the following power tools: 1. Circular saw 2. S ki 11 saw 3. Sabre saw 4. Band saw 5. Drill 6. Disc grinders 7. Spray asbestos machine and gun 8. Spray foam machine and gun 9. Mastic (and paint) pump and spray gun 10. Pin and stud welders The operation of power saws, drills and disc grinders are relatively simple and, with observation of safety precautions, a normal amount of practice con produce a skilled operator in their use. The operation of a machine and gun to apply asbestos is given in Chapter XIX. The operation of spray foam machine and gun is given in Chapter XX. The operation of most spray pumps and guns is given in Chapter XXI. UCC 002764 STANDARD onmcMi *e w-mtki CHAPTER IX APPLICATOR TRAINING PAGE 161 APRIL 1970 ESTIMATING THE INSTALLED COST INTRODUCTION The areas of thermal insulation usage are many, but can be generally placed into two main categories; namely, Industrial and Commercial. To further clarify these categories, the following examples are given: A. Industrial 1. Chemical Plants 2. Refineries 3. Steam Power Plants B. Commercial 1. Hotels 2. Hospitals 3. Department Stores For the purpose of this text, emphasis will be placed on the cost estimation of thermal insulation as it applies to the industrial category in general and to the insulation of piping, piping auxiliaries and major equipment items in particular. Although the insulation requirements of the commercial category may appear to be less sophisticated, the same basic principles of cost estimating will be applicable. The wide variety of insulation materials and installation techniques make full coverage of the subject at hand impracticable within the limits of this text; consequently the example estimate used will be confined to two basic specifications for purposes of demonstration. INFORMATION FOR ESTIMATE BASIS The type of information needed to develop the scope of work to be included in the cost estimate is derived from data listed below: . A. Process Flow Sheets and Plant Layout Drawings. B. Pipe Sketches and Piping Arrangement Drawings. C. Equipment Drawings. D. Assembly Drawings. E. Models. F. Insulation Design. G. Thermal Insulation Manual - Volume I - Specifications. H. Thermal Insulation Manual - Volume II - Design. UCC 002765 STANDARD CHEMCALS AMD Rl*$TIC$ CHAPTER !X APPLICATOR TRAINING PAGE 162 APRIL 1970 ESTIMATING THE INSTALLED COST INFORMATION FOR ESTIMATE BASIS - Contd I. Reference Data for Physical Characteristics of Insulation Materials and Accessories. J. Insulation Material and Accessory Prices. K. Field Measurement Surveys (where applicable). Items A, D, and E convey to the estimator a fairly composite picture of the overall project enabling him to obtain some insight into job conditions. For example, working heights above ground level, crowded or close work areas, and possible location of material storage zones relative to work areas can be assessed from this data. Items B, C, E, and K are tools necessary to accomplish an accurate, detailed material "take-off." Process Flow Sheets and Equipment Layout Drawings can be used to arrive at an estimate of cost; however, it is obvious such an estimate would be rather inaccurate. For example, an actual fitting and flange count is not possible; consequently, a factorial approach would be required to achieve a dollar value for this facet of the estimate. The use of factors to arrive at any estimate has a great tendency to dilute the estimate accuracy, and should be avoided where possible. Item F will convey to the estimator a listing of the physical components of the project which are to be insulated, the type and thickness of the base insulant to be used, and other pertinent data needed to prepare the cost estimate. (See Figure IX--1.) Item G supplemented by Item H will give the estimator the installation details plus greater detail on material specifications than indicated on the Insulation Design Schedule. Methods of attachment of base insulants, types of finishes, and other special application considerations are shown. Item I is necessary to provide the estimator with the size, weight, and physical make-up of the materials the craftsmen must handle. On pipe insulation of a particular diameter, the estimator may question, "Is the pipe insulation section manufactured as two pieces per section or several"? On flat surface work, he may ask, "Are the insulation blocks available in sizes other than 6" wide by 36" long"? It can be readily seen from these examples that differences in the physical make-up of materials can greatly affect the labor cost of installation. This data should also contain the coverage capabilities of insulating cements, adhesives, mastics, etc.; the weights per lineal foot of wire, bonding materials, etc. (See Figure IX-2.) Item J requires that a complete insulation and accessory material cost file be available. The file should be maintained and up-dated to reflect material price changes that frequently occur. Manufacturers* published price lists are used in developing the file and are usually available through the empoyers* purchasing department. The lists are usually supplemented with data that fulfills the requirements for Item ] also. UCC 002766 STANDARD CNtJUCALJ AND ELASTIC* CHAPTER IX APPLICATOR TRAINING PAGE 163 APRIL 1970 ESTIMATING THE INSTALLED COST Figure IX - 1 UCC 002767 STANDARD OtOKAUMCVUim CHAPTER IX APPLICATOR TRAINING PAGE 164 APRIL 1970 ESTIMATING THE INSTALLED COST .STtHfAT/tJ D a t a . /N rU ls )n o rJ A T rfitA lS A*je>/}rr/:srs>-/S `k Figure IX- UCC 002768 STANDARD otEWCAit amp plastics CHAPTER IX APPLICATOR TRAINING PAGE 165 APRIL 1970 ESTIMATING THE INSTALLED COST PREPARATION OF THE E5TIMATE General The most important function in the preparation of the cost estimate is the development of a Bill of Material by making a quantity survey. Using the best data available (such as, equip ment drawings, piping arrangement drawings and/or pipe sketches), the "take-off" should be done systematically. This can best be accomplished by using a prepared quantity survey form. (See Figure IX-3.) Work requiring the use of different base insulants should be "taken off" in order of material specification and thickness. For example, list Calcium Silicate 1" thick, 1-1/2" thick, etc.; then Cellular Glass 1" thick, 1-1/2" thick, etc. Procedure for Piping Insulation "Take-Off" Straight pipe insulation should be taken off in lineor feet, nearest to the next full section increment. For example, if the measurement is 29'-0" and the pipe insulation sections are in 3' long increments, the quantity should be noted as 30'-0" linear feet. Pipe insulation should be measured between fittings along the centerline of straight pipe only. (See Figure IX-4.) Since shop prefabricated fitting, flange, and valve covers will normally be used, flanges, valves, ells, or other fittings should not be included in this measurement. Where the application of mitered pipe insulation is possible, bent pipe should be calculated on the basis of insulated pipe measured on the outside radius. Units should be figured in linear feet. Elbows of standard manufacture should not be considered as bent pipe. Flanged valves and fittings should be counted as complete units only. For example, a flanged valve consisting of a valve body, bonnet flange, and two flanged connections should be taken as one unit, and not listed as a valve plus two (or three) pairs of flanges. Units should be counted as pieces. It is also important that all flanges, valves, and flanged fittings be identified as to pressure rating (150 lb, 300 lb, etc.) since the size of the prefabricated insulation cover varies as a function of the pressure rating. All other fittings should be counted as pieces and identified as to whether they are welded or screwed. During the "take-off", special items such as steam tracing should be indicated, noting tracer size and whether or not heat transfer cement Is to be used. Insulation requirements for hangers, supports, and special trim should also be listed. After completing the "take-off" of the basic pipe insulation materials, the next step is to calculate the quantity of pipe insulation finish materials. Depending on the specification, these materials might be canvas, metal jacketing, mastics, etc. The usual procedure is to calculate the surface area of the pipe insulation and fitting, flange, and valve covers in square feet. If the finish is UCC 002769 STANDARD CMIMICAU AW PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 166 APRIL 1970 ______ ESTIMATING THE INSTALLED COST Figure IX UCC 002770 STANDARD CHtWCALS AMO RtAITO ESTIMATING THE INSTALLED COST CHAPTER IX APPUCATOR TRAINING PAGE 167 APRIL 1970 _____ PIPING METHOD OF MEASURING Figure IX-4 Port 1 of 2 UCC 002771 'EM STANDARD MTU CMOKili AND fUSftO CHAPTER IX APPLICATOR TRAINING PAGE 168 APRIL 1970 ESTIMATING THE INSTALLED COST A - Bare Area - Measure Over Uninsulated Surface B - Insulated Area - Measure Over Insulation Surface EQUIPMENT METHOD OF MEASURING Figure IX-4 Part 2 of 2 UCC 002772 STANDARD CMJCALS AHO PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 169 APRIL 1970 ESTIMATING THE INSTALLED COST PREPARATION OF THE ESTIMATE - Contd Procedure for Piping Insulation "Take-Off* - Contd of the jacket type, this square footage plus an allowance for joint laps and waste fixes the quantity. In the case of mastic finishes, the coverage capability of the mastic must be considered and o conversion made to gallons, which is the common "norm" of purchase. Application labor for both jacket and mastic finishes is costed on a square foot basis. The accessory material requirement will be dictated by the specifications applying to the particular job at hand. These materials generally fall into one of the following categories: attachment devices (wire, bonding, clips, etc.), insulating cements, adhesives, mastic and cement reinforcing items (Dynel cloth, wire mesh, etc.). The need for the accessories must be quantitated in the standard "norm" for procurement to pounds, insulating cement in pounds and converted to standard size bags, reinforcing items in square feet, etc. (See Figure IX-5.) The Thermal Insulation Manual - Vol. I - Specification M - Article VI contains a listing of insulation fabrication and installation accessories. Reference must be made to the manufacturers' published data for a specific accessory in order to obtain purchase norms, covering capacities and other pertinent information. An invaluable aid in the calculation of the surface area of prefabricated fitting, flange, and valve covers is the publication "A5TM Recommended Dimensional Standards for Prefobrication and Field Fabrication of Thermallrisulotion Fitting Covers for N.P.S. Piping, Vessel Lagging and Dished Head Segments.'1 A table such as shown in Figure IX-4 aids in the determination of pipe insulation surface areas. Figure IX-5 shows the application of the preceding discussion in developing the pipe insulation and accessory Bill of Material using Figures1 IX--1, -2, and -3. The Bill of Material is then listed on the estimate sheet (Figure IX-7) and priced from the appropriate manufacturers' price lists maintained in the previously mentioned cost file. Note that an allowance for waste has been applied as a percentage factor to the cost of the base insulation material. The allowance for waste of finish materials and accessories has been built in by rounding-out the quantities to purchasing norms. For example, the actual requirement for weather-barrier mastic is 95 gallons, so two standard 55-gallon drums are billed for procurement. Allowances for waste are judgment items and must be based on job conditions, types of materials and experience. Estimating Installation Costs of Pipe Insulation The accuracy of the Bill of Material can be established to a very high degree; however, determining accurate labor and other costs of installation presents a more difficult problem. There are many variables involved in estimating these costs. Each job must be analyzed as to its individual UCC 002773 STANDARD chemicals am> Plastics CHAPTER IX APPLICATOR TRAINING PAGE 170 APRIL 1970 ESTIMATING THE INSTALLED COST mi X 3O) Part 1 of 2 UCC 002774 STANDARD fXfMICALl ANP PLASTIC* CHAPTER IX APPLICATOR TRAINING PAGE 171 APRIL 1970 ESTIMATING THE INSTALLED COST anTF Part 2 of 2 P/F 1HSULAT/&/J lA/Af. ! ' r./JZE T M k ~ / / 0r_C itC 3 3 a .i2 3 4 . / f ' / ' f t - r r > f j & /Z/ UCC 002775 STANDARD CMCMJCALS AND PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 172 APRIL 1970 ESTIMATING THE INSTALLED COST Figure IX- 6 UCC 002776 STANDARD 04E*UCAi.& A10 PtAJTICl CHAPTER IX APPLICATOR TRAINING PAGE 173 APRIL 1970________ ESTIMATING THE INSTALLED COST Part 1 of 5 Qc $ 8 10 5 Do \r, <co<o3 u h <8 14. -w Ir12 Q O2 sKfl. c vj ss UM wUI Q <o Ju. $ I *d o: 3ol Is v{- o c U"- (V vs VS 5*tv V8 V, * *0 Is 4 iJL 1 1 I t iVj Q -J P S$ P 1 <C I Uj *9 Cl v L<2 *C * 5 t/j kl u 5 <c 3 VI <S UCC 002777 IHa Sfc ir. Lf u h**% ig 5q i'O !" V >v fH o' <S fi I1 10 rx i X wDD) ui N >> V- oz UUj p "5 <tr $ wo^DJ is t- u to _* 5o5 u. MIT < OfUt.* Ui Qf--fi * 01< 2 5< K w"V^) < 5 zui Zo z kl 3 OZ <Uoi DC-IS STANDARD CHCWCAUS AND PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 174 APRIL 1970 ESTIMATING THE INSTALLED COST ft flOw jjIjI V0 TOTAL ft fl U o xR ft c0 ftLi h* :v -l a ' ft< :a U# <5 % eun k* fNt =s o ft a c offtt V < .j I VS vs s fr V v? V9 vs ! t 1 1 & N ty N V M 0 Aj Vj> v}< *> Cs N> > M i? M N tv <> *n N N VNN N % *) ^ *0 V N $ V-iS % --is . is & :ij: * v^: '. (5-1 I'Vi Jr-1 !=^ V) vm WL ^ S^s :q \TM\ : m ; Os s 6) J 6^1 h <p H > > 3 k c -1 <o $ ftu 1D p> a - iRHl-- *V $ W% 'aX 1 K V k NI <s* M >s v > u n > X i 1 V5 $ k s Ji V >ft k V V n -5 n * *> H VI s *i v ^ QJ. -1 s V V $ *o V L> vnc e $ i Vx $ * lo N N \ rs 'v , k ft. ft u J3 _ Vi v> s V A. n SJ 4 1* _sj N si > 1V V. %Oft i 4 a 1*1 1V -V, t V VV, >! -.5N? s V$ i T? V* k (f; z ? 5 2 * i **o s c* Q -s 1 vs V5 vs iCL 5 si ?hu ! s * 3? !viu $A ci j>ft*i *c*`; f8at s 2 11a `\5 V' Cl VI cs s X X >1 x ."V Cl X. ' Co V vVf?. s k? V V V v Hu Sft \> $ *o Vi i * X 'x ft .v M V) k V* X k Co V N X X X X >> V N v. .V \ s< s. VX .c > i*1 s V' V \ Xx < XV .V n .X ** N x s V -1 vv1 >, f? L<> o H0 S 39 -J < Lo H- J < lO H 53 S2?S0. * * ojja; nsS w^o 2 5 mwu< m H z > % > ft ft $ ? *? *1 ft A 4 ___ "|e*g|fs= iaww rT vo*CM D I3> UCC 002778 STANDARD CHtmCAL.% AND PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 175 APRIL 1970 ESTIMATING THE INSTALLED COST >e*#- t0M0y * 50a Hi 5! \ N> VA $ii<a-> :Sy i tKt a . iie j*aMJw w0 Mo 1 <CMn VS * 5* fti % $ ot.tj Swlw fawc k4 Jo0s rV * * * tf s r s 1 VV 51 3 <! $ *1 1 st! 1X % VV)j 1 1 I1 topXt I 11 1uowtt* 1 0 'Cd|NP-'SSti n n Vln\oi st c V. ts $ vc.: ] .J J3 * Is, 9 *1 v 0 1 if a N tQ NVi v V * >a to ^ ft to S N VX. * M !a ^ 5 V * 4 4vT5N; <2 \5 *? Us:l *v N v5 SM tNo <$ "3 aHs* i 5$ ?s * N ft. dV-I $'Hx \ vi ny '<5 %to *X 'v> * Vtv % >K `ft >V. > V*2 al Vi sp| vs> ft* ?S V X vS V s $> V V)V. * c Si X <Sl W iVK N N "S. 1 2 % > X X to % $%3 X vT 3 1 1V * * 5 * X > X ____ UCC 002779 II ,v>$. Vi. L:s"isjs: fsjWoy to 'o ID; fti . Vhi s0: VVMVs- LJ1 ifl s .*5 "\ 14 l U gIM9 S 4 <NSs *> f.Nx 1 1 t*t v cC wW* s< 12 - < o a 3l <PoVi*- 53 ,,5s?fo*uoc-jgj5-a.to3a: 2itS2w01ox sOisSu=uo<!wSW,,3S:i>Iui->UU$^3ji'i IX-17 Y tn ro> oD> *- ao* STANDARD CMtMCAU AMD FLA$T<S CHAPTER IX APPLICATOR TRAINING PAGE 176 APRIL 1970 ESTIMATING THE INSTALLED COST ,, * < sVft o * 2M0 N$ X <S> *n $ > >9 si X te X X X & i L X 7" b or 9 H O N <0 . 0Itf V* **- * -HSO* $ 5 o mwm a -i O nS ft S3 M * ft* N < \9 C-. \ i J Ml <c -Toa"1 * TT ft. ** X. $ "N A \ * i V, Vi c t 1 N V 1 vt \A K ft vi s X $j 5 N> $&a "A! N <s 2 l1 ft ** ft M V> 'C O N. X y X X * 1 I * ft -Iz .* * Va > V5 \0> V *N > \ . 1o 1ft. $ V: S: . Nv 4 s. 4 ft 1 1a \ v w o V % t ** Sj y 1 *1 * $ N "ft % S! V > 4j . ii K 'S .8 4 W 1VS UCC 002780 H- vS l t* -''*ISIs 2p|j 0 l4 l1^ M : |sms^T' =* <0 s^i r2* Vi o *> 1 t> fi i^i *s s ^ -4 IS S V a S <C ii <a X % 1 <: V5 1 c mw 1 w> t IX m X o<4. oL_ '* D k. a-Jl lL a -J ** Oe D i K O J < - Of I" 5* si .oey*4 x O Jjq; " uSo - ly^SV 2 202 IV BX o ex* t4 z WJ^ s= x 3r , n5X aIIuIu" STANDARD CxeMJCAtS AND MASTICS CHAPTER IX APPLICATOR TRAINING PAGE 177 APRIL 1970 ESTIMATING THE INSTALLED COST TOTAt j \ Figure IX-7 x Part 5 of 5 HVo a*m * vE> * N9 V * n\S Qv CM *> *1 --! a <* * 0 sa \ 3 N. N ill 3= -<> :cl <a . aitl :u k"ft J11 5H $ v. * >VS *3 tM ao0<a omu 1I Wo 111 HHa<I II SIS ill fe ft a \\ i *1 %V Ji * *1 J J i i| <( 1 qS|$ N3 -Si > \i m ft J 11 ? k 1s A oX $W 3 1ua ? 1 1 3jO Jg vj l \s 1 vt 0 %n VI Vi vi vi l i? *5 1 s 1J 1,N i & 1 *? *s 3 $3 K *Q 1 k k Si >j S Q s VS $ V3 i * M -si > 1V il i 5? V . * A< I Vi, ~>cs\ w -S 1 V 'a v, 11 k 13 N4 N*_ 1 .f I1 V * il _L Ij UCC 002781 J. >31p>** V\ s'1`1? :*ls 0 <0 5VS zu h'J Ki \i toll . *i >k Si i& vS H w b5 ^1 4X9 |S r s vs 1 1 5 .Q Kl E1 m<l HOm3% *O><1* g1 *- og SC< "x OuR3DoC ;-s:5 iSal g5 IS3S-xa|; IleSi STANDARD OCMCALS AMD rLAATTO CHAPTER IX APPLICATOR TRAINING PAGE 178 APRIL 1970 ESTIMATING THE INSTALLED COST PREPARATION OF THE ESTIMATE - Contd Estimating Installation Costs of Pipe Insulation - Contd characteristics; then the judgment and experience of the estimator become the prime factors in determining the accuracy of these facets of the estimate. Referring to the sample estimate (Figure IX-7) under INSTALLATION, the major work components have been listed and norms established that make it easier to envision production rates. For example, pipe insulation is listed in linear feet, prefabricated fitting covers as pieces, finish in square feet, etc. The components designated as "item" are difficult to quantitate and consequently are costed by special methods. These methods will be explained later in the text. Figure IX-8 should now be referred to for sample production rates established for the estimate at hand. From these production rates, a man-hour unit can be arrived at for the various components. Stated as a formula, man-hours per unit = where N equals the number of hours of work and P equals the production rate. For example. 8 hours of work .053 man-hours per linear foot 150 linear feet per 8-hour man-day Multiplying man-hours per unit of work by the hourly wage rate gives the unit dollar cost per unit of work. For example, if the wage rate used is $4.00 per hour, the unit cost becomes $4.00 x .053 = $0.21 per linear foot. For unit cost per unit of work, the formula now becomes bJ x R, where N and P are as heretofore stated and R is the wage rate per hour. This is the method P and wage rate used to arrive at the labor figures for the sample estimate. The labor unit for the pipe and fitting work includes placement of the base insulant and its securement. As previously mentioned, the installation part of the estimate includes several components of work that must be costed, but ore difficult to quantitate. These have been designated as item" and are as follows: 1. Haul, unload and store materials 2. Scaffolding 3. Construction Equipment Rental 4. Support labor Each of these items must be analyzed in relation to the job that i s being estimated. There.is no fixed rule that can be applied to arrive at these particular costs. Knowledge of the job requirements and the experience of the estimator are the keys to estimating a realistic cost for these items. ' 1 r F r i UCC 002782 STANDARD OiCtfCAlS PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 179 APRIL 1970 ESTIMATING THE INSTALLED COST Figure IX- 8 UCC 002783 STANDARD CH&MCAU CHAPTER IX APPLICATOR TRAINING PAGE 180 APRIL 1970 ESTIMATING THE INSTALLED COST PREPARATION OF THE ESTIMATE - Contd Estimating Installation Costs of Pipe Insulation - Contd The costs for hauling, unloading, and storage of materials ore dependent on the type of storage facilities required, size and weight of material containers to be handled, and the distance from storage areas to work areas. Scaffolding requirements are obviously a function of working heights and the type of scaffold to be used (timber, tubular steel or other}. Consultation with the Craft Foreman responsible for accomplish! ng this type of work is an invaluable aid in establishing costs for scaffolding needs. Construction equipment such as air compressors, spray pumps with auxiliaries and trucks for hauling materials must not be overlooked. Costing is based on class of equipment used, length of time required and proper application of rental rates to this usage. Support labor is that labor not directly involved in the application of insulation materials. Examples of this type of labor would be carpenters for scaffold erection, truck drivers, labor to keep "productive men" supplied with material, labor for clean-up, etc. The cost of this item can only be evolved through a study of the specific requirements of a particular job. Reference to historical data from jobs of a similar nature and magnitude furnishes the best tool to aid in deriving a cost for the aforementioned items; in fact, this aid applies to practically all facets of the estimate. For purposes of the sample estimate (Figure IX-7) arbitrary costs have been assumed for these work components. Equipment Insulation Within the confines of this text, the insulation of equipment is intended to be inclusive of such items as pumps, tanks, heat exchangers, ducting and other various forms of "flat work". "Flat work generally includes cylindrical shapes over 36" in diameter as well as flat surfaces. Guidelines and reference data which have been previously discussed have been generalized and are applicable as well to (most of) this section of the text. For purposes of demonstration of "take-off" procedure and estimate format. Item 201-A, listed on the Insulation Design Schedule (Figure IX-- 1) will be used. Its size and configuration, which normally would be provided by equipment drawings, is as shown on the sketch incorporated as a part of the material take-off sheet. Figure IX-9^ UCC 002784 STANDARD *lUCAU AND PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 181 APRIL 1970 ESTIMATING THE INSTALLED COST 3~I~C9 S>2. xtfaeaL&M* ^ i s s f . JPATZ LQ/KT-L6fJ, un^dLLLL. l5 o r Figure IX-9 &&t*L..Fae l /rtS U L/lT ieyfiJ 4 3H 3<i UCC 002785 STANDARD OilMKALi 4M0 RLASTI& CHAPTER IX APPLICATOR TRAINING PAGE 182 APRIL 1970 ESTIMATING THE INSTALLED COST PREPARATION OF THE ESTIMATE - Contd Equipment Insulation - Contd The take-off norm for most equipment, or "flat work" items, is the square foot. Special appurtenances, such as head covers or other items which may be furnished prefabricated, might be listed os pieces and costed accordingly. The method of measurement for quantitating purposes is as shown on Figure 1X-4. The quantities are generally estimated by increasing the bare vessel dimensions to the insulated dimensions. For example, if the bare vessel diameter is S'-O" and the insulation thickness is 3", the area of the surface is calculated as if the diameter were 8'-6". Study of Figure IX-9 will show the basis for development of the equipment insulation cost estimate for the case at hand. Production rates and man-hour conversions are required for labor costing following the principles as previously outlined. The final step in the preparation of the total insulation cost estimate is the summarizing of the direct cost of the pipe and equipment components. To these direct costs will be added certain indirect costs to complete the estimate. (See Summary Sheet of Figure IX-7.) Indirect Costs The aforementioned indirect costs consist of the following items: 1. Location Expense 2. General Administration Expense 3. Engineering 4. Contingencies Location expense is mode up of costs incurred at the construction site. These costs moy or may not be completely identified with a specific project, and are usually distributed to all active jobs at the site. The basis for distribution is the labor dollar flow per month per job. For example, the current rote used in the estimate is 70% of labor. Since the estimated total dollar flow for labor rn the estimate is $1875, this expense figure becomes $1312 (70% x $1875). There are many items that make up the location expense. A few examples ore as follows: 1. Supervision 2. Insurance, Payroll Taxes, Workmen's Compensation 3. Utility Costs (Construction lighting, heating, etc.) 4. Temporary Construction (Field offices, store rooms, etc.) 5. Maintenance of Construction Area. UCC 002786 STANDARD CMPRCM1 AMD PLASTICS CHAPTER IX APPLICATOR TRAINING PAGE 183 APRIL 1970 ESTIMATING THE INSTALLED COST PREPARATION OF THE ESTIMATE - Contd Indirect Costs - Contd The general administration overhead is also made up of costs which cannot be identified to a particular job. These costs are distributed as a standard percentage of total costs (labor, material, and location overhead). Examples of items included in this expense are as follows: 1. Procurement or Purchasing Costs. 2. Costs of Engineering Department, which are not purely engineering, or which cannot be identified to a specific project. 3. Home Office activities. 4. Vacation, Holidays, Illness, etc. Engineering costs are inclusive of Process Engineering and Project Engineering efforts. These costs are estimated from historical data and/or manpower requirements projected over a given length of time. The figure arrived at is usually depicted as a percent of total cost (labor, material, and expense). The contingency allowance is a judgment factor applied by the estimator. The amount to be used is dependent on the confidence that the estimator has in the information on which he has based the estimate. The allowance is also intended to include coverage of possible estimating errors, un foreseen construction problems, field changes, etc. CONCLUSION The purpose of this chapter has been to provide the Insulation Craftsman with an approach to insulation cost estimate preparation. The wide variety of specifications that exist for insulation work makes it impractical to cover the entire field within the limits of this text. Hopefully, the narrative and Figures contained in this chapter will have fulfilled the purpose. In the final analysis, the degree of success the estimator attains in his cost forecast will be a function of information quality and adequacy and the estimator's knowledge and experience. RESPONSIBILITY The insulation applicator might question why this information on selection of insulation specifica tion was contained in this manual, for in most instances the selection is the responsibility of the Engineering Department. However, in case of emergencies it might happen that the insulator UCC 002787 STANDARD OtCMCAU M fLASTtCS CHAPTER IX APPLICATOR TRAINING PAGE 184 APRIL 1970 ESTIMATING THE INSTALLED COST RESPONSIBILITY - Contd must make a selection of materials and Hie method of application. In addition, in any large organization there always exists a possibility of error. Should such occur and the insulation has a valid reason for questioning the selection it is his responsibility to question the correctness of the selection. Another reason for presenting this information to the insulator is to give him the basic reasons of why certain materials are selected and applied. No specification can be written that covers every detail of an application and when a craftsmen knows why such is done in general he can do much better in following this in each detail. UCC 002788 STANDARD CHCMCAU AND PLASTICS CHAPTER X APPLICATOR TRAINING PAGE 185 APRIL 1970 SHOP AND FIELD FABRICATION Prefabrication of thermal insulation provides a means to obtain more economical and more quickly installed insulation of better quality. In addition, for maintenance, it is possible to remove and replace fitting covers. In spite of these apparent advantages, development of prefabrication systems has been a relatively recent development. In the development of the insulation industry the major manufacturers produced their pipe insulation to their own system of thicknesses and sizes. By 1940 the industry was producing insulation using five different methods of sizing. These were: 1. Standard and double standard thicknesses. .2 Combination thickness, which was used for high temperatures using diatomaceous earth insulation inner layer and 85% magnesia outer layer. 3. The 1/2 in. increment system, wherein the thickness increased in even 1/2 in. increments. 4. Thicknesses based on the number of laminations or plies. 5. Ice water, brine, and heavy brine sizes, wherein the thickness was based orfspecific operating temperature and pipe size. Then, the existing practices of producing pipe insulation required stocking a total of 600 sizes to obtain thicknesses from one to three inches. Regardless of the great number of sizes then being produced, insulations could not be used in combination because they would not fit to each other. All factors pointed to the need for a better system of pipe insulation to eliminate the costly waste and confusion. The problem indicated that insulation must fit insulation as well as the pipe. It was reasonable to conclude that the only manner in which this could be accomplished was to make the outside diameter of each piece of insulation equal to the outside diameter of some standard nominal pipe size (NPS). On this basic premise, the writer developed the Dimensional Standard System of Thickness. This system has been adopted by the major producers of insulation, by the U. S. Military Services as Military Specification MIL-1-2781B, and by industry as ASTM Standard Practice for Determining Outside Diameter of Rigid Pipe Insulation C-521. The inner and outer diameters of pipe insulation and approximate thicknesses for both NPS pipe and tubes are shown in Tables X-l and X-2. The standardizing of pipe insulation made it possible to devise a practical method of prefabrication to improve over the old hand-applied method shown in Figure X-l. The total number of covers required for fittings, flanges, and valves, from 1 to 7-1/2 inches in thickness is approximately 9,000. If tracer systems are installed on the pipe system, each fitting is slightly different than when the insulation is installed snugly to the pipe. This increased the number of fittings to approximately 7,000. A manual of design of these fittings was compiled UCC 002789 STANDARD QIEMCAU aX> ELASTICS SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 186 APRIL 1970 OUTSIDE DIAMETERS AND AVERAGE THICKNESSES FOR PIPE INSULATION ASTM R*camMrf4 Prectic* NPS NOM SIZE O. D. Inches 1/7 Nonlnoi A 0.0. Thk. Inch** Inches Insulation ittickneu l" Nominal a*b. 0.0. Arg. Thk. lnd>M TSk. tndiM InckM 1 f Z 0.0. Inches l/ 0.405 0.45 1/4 0.540 0.55 3/8 0.675 0.49 1/2 0.840 0.S2 1.315 1.660 1.660 1.900 0.98 1.16 1.09 1.00 2.375 2.875 2.875 2.875 1.54 1.72 1.66 1.57 3.500 4.000 4.000 4.000 3/4 1.050 0.42 1.900 0.91 2.875 1.47 4.000 1 1.315 0.52 2.375 1.09 3.500 1.59 4.500 li 1.660 0.60 2.875 0.91 3.500 1.66 5.000 >* 1.900 0.48 2.875 1.04 4.000 1.54 5.000 2 7.375 0.55 3.500 1.0S 4.300 1.58 5.563 2.875 0.55 4.00 1.05 5.000 1.86 6.625 3 3.500 0.49 4.500 1.02 5.563 1.55 6.675 31 4.000 0.49 5.000 1.30 6.623 1.80 7.625 4 4.500 0.54 5.563 1.05 6.625 1.55 7.625 41 5.000 0.80 6.623 1.30 7.623 1.80 8.625 5 5.563 0.49 6.623 0.99 7.623 1.49 1.625 4 6.625 0.46 7.623 0.94 1.625 1.46 9.625 7 7.425 e 8.625 9 9.625 10 10.750 1.52 1.52 1.52 1.39 10.750 11.750 12.750 14.00 ii 11.750 12 12.750 U 14.000 IS 15.000 1.39 1.58 1.43 1.45 15.000 16.000 17.00 18.00 16 16.000 17 17.000 IS 18.000 19 IV.000 1.45 1.45 1.45 1.45 19.000 20.000 21.000 22.000 20 20.000 21 21.000 22 22.000 23 23.000 1.45 1.45 I-.45 1.45 23.000 24.000 23.000 26.000 24 24.000 25 75.000 26 26.000 27 27.000 2* 29.000 19 29.000 30 30.000 31 31.000 32 32.000 M 33.000 34 34.000 35 35.000 M 136.000 1.45 1.45 1.45 1.45 1.45 1.45 1.45 1.45 1.45 1.45 1.45 1.45 1.45 27.000 28.0i'.) 29.000 30.000 31.000 32.000 33.000 34.000 35.000 36.000 37.000 38.000 39.000 2' Nominal Avg. 0.0. Thk. Inches Inches 2.05 2.22 2.16 2.07 4.500 3.000 5.000 5.000 i .97 2.12 1.94 2.36 2.11 2.36 2.05 2.30 5.000 5.563 5.563 6.675 6.675 7.625 7.625 8.675 2.05 2.30 1.99 2.07 8.625 9.623 9.623 10.750 2.02 2.02 2.15 2.09 11.750 12.750 14.000 15.000 2.09 2-08 1.95 1.95 16.000 17.000 18.000 19.000 1.95 1.95 1.93 1.95 20.000 21.000 22.000 23.000 1.95 1.95 1.95 1.95 24.000 25.000 26.000 27.000 1.95 1 .'5 1.95 1.95 28.000 29.000 30.000 31.000 1.95 1.95 1.95 1.95 1.93 1.95 1.95 1.93 1.95 32.000 ! 33.000 34.000 35.000 36.000 37.000 38.000 39.000 40.000 Table X-l UCC 002790 STANDARD choiicm* matte* SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 187 APRIL 1970 OUTSIDE DIAMETEKS AND AVEIAGE THICKNESSES FOB PIPE INSUIAIION ASTM Mcowftiftdid hoclici NPS Pipe NOM O. D. SIZE Inches 7f'Nominol Avg. O.D. TV*. Inches Inchm Insulation Thickness 3* hloatlnol Nominal Avg. O.D, Avg. O.D. TMi. Inches 31*. Inches Inch*) lltctlM 4' Noninol Avg. TWt. O.D. Inches Inches l/B 0.405 2.57 1/4 0.340 2.50 3/S 0.375 2.44 /2 0.040 2.89 5.563 3.563 5.563 6.625 3.10 3.04 2.97 3.39 6.625 6.625 6.625 7.625 3.60 3.54 3147 3.89 7.625 7.625 7.625 8.625 4.10 4.04 3.97 4.39 8.625 8.625 8.625 9.625 V4 1.050 2.78 6.625 3.28 7.625 3.78 8.625 4.28 9.625 1 1.315 2.64 6.625 3.13 7.625 3.65 8.625 4.15 9.625 U 1 .M0 2.48 6.625 2.98 7.625 3.48 8.625 3.98 9.625 >4 1.900 2.86 7.625 3.36 8.625 3.86 9.625 4.42 10.750 7 2.375 2.61 7.625 3.11 8.625 3.61 9.425 4.17 10.750 21 2.B75 2.86 8.625 3.36 9.625 3.92 10.750 4.42 11.750 3 3.500 2.35 8.625 3.05 9.625 3.6) 10.750 4.11 11.750 4 4.000 2.80 9.625 3.36 10.750 3.86 11.750 4.36 12.750 4 4.500 2.55 9.623 3.11 10.750 3.61 11.750 4.11 12.750 41 5.000 2.86 10.750 3.36 11.750 3.86 12.750 4,4? 14.000 3 5.563 2.56 10.750 3.06 11.750 3.56 12.750 4.18 14.000 6 6.625 2.32 11.750 3.02 12.750 3.65 M.000 4.15 . 15,000 7 7.625 2.32 12.750 3.15 14.000 3.65 15.000 4.15 16.000 8.625 2.65 14.000 3.15 15.000 3.65 16.000 4.15 17.000 * 9.625 2.65 15.000 3.15 16.000 3.65 17.000 4.15 18.000 10 10.730 2.59 16.000 3.09 17.000 3.39 18.000 4.09 19.000 11 11.750 3.39 17.000 3. 18.000 3.59 19.000 4.09 20.000 12 12.750 2.58 18.000 3.0B 19.000 3.58 20.000 4.08 21.000 M 14.000 2.45 19.000 2.95 20.000 3.45 21.000 3.95 22.000 IS 15.000 2.45 20.000 2.95 21.000 3.45 22.000 3.95 23.000 16 16.000 2.45 21.000 2.95 22.000 3.45 23.000 3.95 24.000 17 17.000 2.45 22.000 2.95 23.000 3.45 24.000 3.95 25.000 IB 18.000 2.45 23.000 2.95 24.000 3.45 25.000 3.95 26.000 IP 19.000 2.45 24.000 2.95 25.000 3.45 26.000 3.95 27.000 20 20.000 2.45 25.000 2.95 26.000 3.45 27.000 3.95 28.000 21 21.000 2.45 26.000 2.95 27.000 3.45 28.000 3.95 29.000 22 22.000 2.45 27.000 2.95 28.000 3.45 79.000 3.95 30.000 23 23.000 2.45 28.000 2.95 29.000 3.45 30.000 3.95 31.000 24 24.000 2.45 29.000 2.93 30.000 3.45 31.000 3.95 32.000 23 23.000 2.45 30.000 2.95 31.000 3.45 37 000 3.95 33.000 26 26.000 2.45 31.000 7.93 32.000 3.45 33.000 3.?5 34 000 27 27.000 2.45 32.000 2.95 33.000 3.45 34.000 3.95 35.000 5798 28.000 2.45 29.000 2.45 33.000 2.95 34.000 7.95 34.000 3.45 35.000 3.45 35.000 3.95 36.000 3.95 36.000 37.000 30 30.000 2.45 35.000 7.95 36.000 3.45 37.000 3.95 78.000 31 31.000 2.45 36.000 2.95 37.000 3.45 38.000 3.95 39.000 32 32.000 2.45 37.000 2.95 38.000 3.45 39.000 3.95 40.000 33 33.000 2.45 38.000 2.95 39.000 3.45 40.000 3.95 41.000 34 34.000 2.45 39.000 2.95 40.000 3.45 41,000 3.95 42.000 33 35.000 2.45 40,000 2.95 41.000 3.45 42.000 3.95 43.000 3* 36.000 2.45 41.000 2.93 42.000 3.43 43.000 3.95 44.000 Table X~1 (Continued) UCC 002791 STANDARD CHEMICALS MC PLASTICS CHAPTER X APPLICATOR TRAINING PAGE 188 APRIL 1970 SHOP AND FIELD FABRICATION BASIC OUTSIDE DIAMETERS FOR TUBE INSULATION ASTM Recommended Practice Tube Size 1/4 3/B 1/2 1/2 3/4 `3/4 il J 11 4 4 2 2 i2* 24 3 3 3 5/6 4 14 i5 i5 i6 16 1 8 i8 |)0 |i !ru 16 18 20 24 O.D. 1/2 0.250 0.375 0.500 0.625 0.750 1.315 1.660 1.660 1.660 1.900 0.875 1.000 1.125 1.250 1.900 2.375 2.375 2.375 1.500 1.625 2.000 2.125 2.500 2.875 2.875 3.500 3.500 3.500 2.625 3.000 3.125 3.625 4.000 4.000 4.000 4.500 5.000 5.000 4.125 5.000 5.125 6.000 6.125 5.563 6.625 6.625 7.625 7.625 8.000 8.125 10.000 10.125 12.000 14.333 16.333 18.333 20.333 24.333 Nominal Thickness of Insulation 1 42 2i 3 2.875 2.875 2.875 2.875 2.875 3.500 3.500 3.500 3.500 4.000 4.500 4.500 4.500 4.500 5.000 5.625 5.625 5.625 5.625 5.625 6.625 6.625 6.625 6.625 7.625 3.500 3.500 3.500 3.500 4.000 4.000 4.000 4.500 5.000 5.000 5.000 5.563 6.625 6.625 6.625 6.625 7.625 7.625 7.625 7.625 4.000 4.000 4.000 4.500 4.500 4.500 4.500 5.000 5.563 5.563 5.563 5.563 6.625 6.625 6.625 6.625 6.625 7.625 7.625 7.625 7.625 7.625 8.625 8.625 8.625 5.000 5.000 5.563 6.625 6.625 5.563 6.625 6.625 7.625 7.625 6.625 7.625 7.625 8.625 8.625 7.625 8.625 8.625 9.625 9.625 8.625 9.625 9.625 10.750 10.750 6.625 7.625 7.625 8.625 8.625 7.625 8.625 8.625 9.625 9.625 8.625 9.625 9.625 10.750 10.750 9.625 10.750 10.750 11.750 11.750 10.750 11.750 11.750 12.750 12.750 11.750 11.750 12.750 14.000 15.000 12.750 12.750 14.000 14.000 16.000 14.000 14.000 15.000 15.000 17.000 15.000 15.000 16.000 16.000 18.000 18.000 20.000 22.000 24.000 28.000 19.000 21.000 23.000 25.000 29.000 20.000 22.000 24.000 26.000 30.000 21.000 23.000 25.000 27.000 31.000 3* 7.625 7.625 7.625 7.625 8.625 8.625 8.625 8.625 8.625 8.625 8.625 9.625 9.625 9.625 9.625 10.750 10.750 11.750 11.750 11.750 12.750 12.750 14.000 14.000 16.000 16.000 17.000 17.000 19.000 33.000 24.000 26.000 28.000 32.000 4 8.625 8.625 8.625 8.625 9.625 9.625 9.625 9.625 9.625 9.625 9.625 10.750 10.750 10.750 10.750 11.750 11.750 12.750 12.750 j 12.750 14.000 14.000 15.000 15.000 1 1 1 j 17.000 17.000 18.000 18.000 20.000 < | j i 23.000 25.000 27.000 29.000 33.000 j UCC 002792 STANDARD OfMCAJ * ELASTICS CHAPTER X APPLICATOR TRAINING PAGE 189 APRIL 1970 SHOP AND FIELD FABRICATION Old Method Of Insulati ng Fittings Figure X-l UCC 002793 STANDARD OtfMCAU AMD PLAXna CHAPTER X APPLICATOR TRAINING PAGE 190 APRIL'1970 SHOP AND FIELD FABRICATION by Mr. R. E. Estep and the writer. This manual was adopted by ASTM as Siandard Practice C-450. Later, Mr. K. B. Lanham revised and improved the manual and this revision was adopted os Standard Practice C-450-657 by ASTM in 1965. DESIGN OF FITTING AND VESSEL INSULATION COVERS Basically all Flanged fitting covers were designed to fit over the adjacent pipe insulation. In most installations, the straight pipe insulation is installed prior to the fitting covers being installed. Therefore, flange fitting covers which fit over the adjacent pipe covering adopt themselves to proper installation sequence. This type of installation has another advantage in that the overlapping insulation can be installed to function as a slip joint and act as an insulation expansion and contraction joint. Fitting Insulation, General 1. All insulation fittings are designed to use standard pipe insulation for the main body, but may be fabricated of flat block insulation cut into curved segments. 2. Due to difference in requirements, the method of fabrication for low temperature rigid insulation flanged fitting covers is different than the fabrication of high temperature fitting covers. The C-450 Manual is divided into sections with ail flanged fitting covers of each temperature range separated into their proper groups. 3. Likewise, covers that are dimensioned to fit snugly to standard NPS pipe are listed separately from fitting covers that are dimensioned to fit standard NPS with clearance for heat tracers. Fitting Fabrication - Design Details 1. Flanged Valve Bonnets Valves manufactured by various companies for the same pressure and nominal (NPS) size do not have standardized bonnet dimensions or height of bonnet flange above centerline of valve. Because of this, the valve insulation cover was designed to fit the largest valve of a size, type and pressure. For valves smaller than dimensions given it is necessary to make field cuts on the top of the insulation cover to produce a fit around the packing gland. For this reason, bonnet top is made with a removable broken joint dutchman, permitting cutting of bonnet length, and field fitting, and bonding of the dutchman around packing gland. UCC 002794 STANDARD CMCaaCAU AM> RtAJTJCS CHAPTER X APPLICATOR TRAINING PAGE 191 APRIL 1970 SHOP AND FIELD FABRICATION DESIGN OF FITTING AND VESSEL INSULATION COVERS - Contd Filling Fabrication - Design Detoils - Contd 1. Flanged Valve Bonnets - Contd To assist in field fitting and to add additional strength to top of valve cover, when bonnet dutchman is 2-1/2 inches thick, the two layers of the bonnet shall be made with 1 inch thickness on the bottom layer and 1-1/2 inches thickness on the top layer. A typical sheet which provides dimensions for a valve cover is shown in Figure X-2. 2. Elbow Covers The manual presents dimensions for both short and long radius ells. Thus, care must be taken that proper dimensions are used for the ell or ells to be covered. 3. Heat Traced Welded Ells and Tees Where single-layer welded ell and tee covers are to be used on heat traced piping the ends are to be "Broken joint Construction" as noted in the manual. This means that 3 inch long and 6 inch long cylindrical sections are placed on alternate and opposite ends of the two halves of the fitting cover. This permits offset tie-ins with the adjacent pipe insulation to obtain mechanical stability. The fittings are oversize in diameter to allow space for the tracer. 4. All Flanged Fittings The insulation thickness of all flanged fitting covers is no less than 1-1/2 inches to provide sufficient mechanical strength. Flanged covers of one inch thickness, or less, are too fragile. Vessel Insulation 1. Sidewalls Although curved sectorial segments are recommended for sidewall insulation, the economic fabrication of curved segments depends upon thickness and width of flat blocks available, from which the curved sectors may be cut with a minimum of waste. The number of possible combinations make recommended tables for this prefabrication impractical. Where flat lagging might be used satisfactorily, the dimension for cutting it are presented in the manual. UCC 002795 STANDARD ottaouAWfumt SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE. 192 APRIL 1970 300 LB. FLANGED GATE VALVES Figure X-2 UCC 002796 i f I 1 L l L L L STANDARD CHOUCU-> MO H.MTK3 CHAPTER X APPLICATOR TRAINING PAGE 193 APRIL 1970 SHOP AND FIELD FABRICATION DESIGN OF FITTING AND VESSEL INSULATION COVERS - Contd Vessel Insulation - Contd 2. Dished Heads The manual gives dimensions for segments of insulation for dished heads based on the dished head radius being equal to the diameter of the tank. The head insulation is not designed to fit the radius of the knuckle. The insulation should be fitted over the vessel wall insulation which was trimmed at the proper angle to butt to underside of the head segments. This leaves a slight void at the knuckle. The common practice for cutting dished head covers is to cut pie shaped segments as shown in Figure X-3. However, such arrangement requires that each ring be cut differently than the other rings. Also, when applied these rings must be installed in proper sequence. A different method which is very suitable for the cutting and application of cellular glass^or expanded silica is to shape the blocks in double curved beveled squares. This is, illustrated in Figure X-4. The instructions for cutting these are given in Figures X-5,and X-6. Applica tion of these square segments is similar to installation of tile floors. Storting at center segments are installed in a straight line in one direction and another line starting at center is installed 90 degrees from first line. The space between the lines are then installed starting at the apex. Such is shown in a picture shown in Figure X-7 which has cellular glass and calcium silicate fit on top a dished head. SHOP AND SHOP PRACTICES As would be expected, this depends on needs and materials to be fabricated. However there are some items of equipment which are common to most insulation shops. For ordinary cutting of many insulations, modified carpenter tools are used. Tools Band Saws The most essential piece of equipment is a band saw. Both vertical and horizontal band saws can be used advantageously. The minimum cutting depth should be 22 inches and saws with 40 inch cutting depth are used advantageously for fabrication of 36 inch sections Blade speed for fabrication of inorganic foams should be approximately )040 ft. per minute. A 1" blade, 3 pitch, raker tooth chrome plated blade is recommended for cutting inorganic foam, particularly when foam pieces have been bonded together with hot asphalt. For unbonded UCC 002797 STANDARD OCMCALS RUSTICS CHAPTER X APPLICATOR TRAINING PAGE. 194 APRIL 1970 DISHED HEAD SEGMENTS SHOP AND FIELD FABRICATION fT ITt| lll'l i i l 1 1 1 i T 1 1 1 1 1 1 nr id 1 i i i i 1 1 1 i i 1 1 Tfi i 1 1 T b 1 i i i l 1 1 1 i l 1 1 ill i 1 1 1 c? u | i i i l 1 1 1 i i 1 1 11 i 1 1 i * i 1 i i i i 1 1 1 i l 1 1 ill i 1 1 l 1i iii 111 i 1 ill i 1 , i c 1 i i i i 1 1 1 i i 1 1II i 1 1 i ft 1 i i i l! 1 1 1 i i 1 l i1 i 1 1 l fi 1 f i i I 1| 1 1 i i 1 1 ill I 7 A9 l! 1 i i i i 1 1 1 i i 1 1 ii i - - M !O u 1 i i i L 1 1 1 i 1 1 II 1 i i i l 1 1 1 i 1 1 1 ll l m i fS; m -- 1 i i i l 1 1 1 i 1 1 1 11 T 9 o; K 1 i i i i 1 1 1 i l 1 1 ill i *A*L** K 1 i i i l 1 1 1 i j 1 1 11 i ijt p ft J i i i i 1 ! 1 i I 1 1 i: i xp om 1 i i i i T 1 1 i l 1 X XX 3 MIX X U j i i i l 1 1 1 i 1 a -I- - 4- M G. 1 i i t i ; 1 1 i l 1 m "00t 4 A -L - t u U 1 i i i l i 1 1 i 1 1 *4 w A 0 1 i i i l i 1 T i 1 1 .4 l**i}-m# *4A?? ai T T4 1 iii 1 i i I 1 r[ 3* * V - 0 1 l i i i l 1 i iH I 1 at xU 2 8 r. 3 ft 1 1 i i l l 1 i i l 1 s "S; it * t ?! 1 i i ij i l 1 St s s 1 o dx tl oA O o & w 1 1 i i l 1 1 IN a A M A J. . A A T0 1liil 1 9 9 A -a A - A Tmm m U cm f< 1liii 11 Iil 1l ii i Tl 1 r* mZ 5 V 1 _ , V 9 j_ * a M 1 A > m ds ~ c A K 1 i i i T 1 0 V c s VJ5 1 f ar a t (X 1 1 i i l 1 1 s aa : s a3 II:? 1 #: |*sscc;t t x zlX kl 1 9 * . a. - - > ; - A M > b l a - - 9A 9 9 - -A K It u 80 1 i* a0n 9 -J i | .i * ` J* -* z* `.9 > c jt :a -- h< c a * a * M _ t ; XR M 5 w B `Jtii A o 5 N X DC t cr : A * A Z '=1'-- 5 A - J..L - - - - - *. - M - - - A-A o ao m :- ' - A A A m|a < A A A - t c u K0 * o m il > > < 5* > >A > 1 f >*x1*r*l:" h 1 9 a* j -s .* .1 .i 9 . .1 -X-t.* . .1 .1 J DC r r z -'- o z ? d- A - x ft - - - a - A - - - - *|e . m 9 V a r a m m * - - - - m|h ; 1 *N M B 3 -> * - -* s o o 0 o ole > o e o O 23 x m9 9 3 9 s * s 3 s i o A s a ?!?:x a $ 7 t O - r r i 1 oA;J Figure X-3 UCC 002798 r r r r f f { ! i i i i i i i } i STANDARD OOEMCALS AMD PLASTICS SHOP AND HELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 195 APRIL 1970 Figure X-4 UCC 002799 STANDARD otaaeAU a haito SHOP AND FIELD FABRICATION ONLY 16-2/3% CHAPTER X APPLICATOR TRAINING PAGE-196 APRIL 1970 Note; The radios of a dished head is equal to approx, the tank diameter. Figure X-5 UCC 002800 STANDARD ckmcalj we politics SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 197 APRIL 1970 Radius Point Note: To find the degree double the diameter of vessel multiply by P] , divide into 180 Example: To make 11 '6" tank head H'6" doubled =23' 23* x Pi =72* 72 p80l 2-1/2 degree Figure X-6 UCC 002801 STANDARD CHtMCALf AND PLASTICS SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE. 198 APRIL 1970 / Demonstration Application of Cellular Glass and Calcium Silicate Installed in Dished Head Figure X-7 UCC 002802 STANDARD OWUU >n runo CHAPTER X APPLICATOR TRAINING PAGE 199 APRIL 1970 SHOP AND FIELD FABRICATION SHOP AND SHOP PRACTICES - Contd Tools - Contd Band Saws - Contd inorganic foams, 3/16" or 1/2" carbide tipped blades provide means for cutting smaller radius cuts with less thickness of saw cut. For the cutting of calcium-silicate, diatomaceous and asbestos fiber block and pipe covering, blades 1/2" x 0.035" thick, skip tooth, five per inch, are used. Materials being cut by band saws are cut to line marked on the insulation, by cutting to jigs, or by placement on a swinging arm. A picture of craftsmen cutting insulation on a vertical bandsaw is shown in illustration Figure X-8. Grinders Grinders used are not standard carpenter tools and are therefore designed for particular uses. Inside grinders are made so that the mandrel is coated with a grit. This mandrel rotation grinds the inside diameter into a recentagular block of insulation. An outside grinder shapes the insulation by allowing the insulation to rotate against the spinning grit mandrel. Small to moderate size organic foam is shaped by this method. A grinder of this type is shown in illustration Figure X-9. Head segment grinder is a machine for shaping double curvature head segments. This machine consists of an O.D. and I.D. circular section grinding spool, whose axes are simultaneously orientable in a vertical plane through a vertical axis and a swinging block holder pivoted in the same axis so that the block can be swung through the two spools. A picture of grinding spools is shown in Figure X-10. The holder is shown in Figure X-l 1, and the block to be swung through the two spools is shown in Figure 12. Other special grinders are circular edge shapers and plane edge shapers for the shaping of circular and straight edges of block insulation. Grinders may use grinding stones, grit paper, or grit glued to mandrel. Where grit i$.glued to mandrels, grit sizes 16 to 24 are recommended. For relatively fast moving mandrels, the finer grit size is recommended. UCC 002803 1 STANDARD CMMtfCALJ AK> ELASTICS SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 200 APRIL 1970____________ BAND SAW OPERATION Figure X-8 UCC 002804 STANDARD cmwiM *>r *1 rrr-- SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 201 APRIL 1970_________ OUTSIDE GRINDER Figure X"9 UCC 002805 T STANDARD SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 202 APRIL 1970_____________ Grinding Spool Figure X -10 UCC 002806 STANDARD CMuou mc puura SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 203 APRII 1970_____________ Insulation Holder Figure X-l 1 UCC 002807 STANDARD 0MC*L1 AND PLASTICS SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 204 APRIL 1970____________ Insulation To Be Formed By Grinding Spools Figure X-I2 UCC 002808 STANDARD OdJtfCALS AMD W.AST*** CHAPTER X APPLICATOR TRAINING PAGE 205 APRIL 1970 SHOP AND FIELD FABRICATION SHOP AND SHOP PRACTICES - Contd Asphalt Rollers As rigid low temperature inorganic foams are cemented together with hot asphalt, a heated pot with rollers which extend into the liquid asphalt is o basic machine used in shop fabrication. Such o hot asphalt roller is shown in Figure X-13. Assembly Tables After pieces of insulation have been cut to form the parts of a fitting, these parts must be bonded together to complete the assembly. This operation requires assembly tables. Such assembly tables should be sufficient in size to permit efficient working by the craftsmen and be located for minimum handling of parts and finished item. Dust Collection Removal of dust around the saws is necessary for good fabrication and working conditions. The amount of air required to remove dust for each band saw is a minimum of 450 CFM, and for each inside or outside grinder a minimum of 1750 CFM, for asphalt pot hoods and block dust removal grills a minimum of 500 CFM. Dust is collected in a dust collector of sufficient size and capacity for the individual shop. Ventilation Where fine air borne dust is a problem, it should be vented away from workers by a separate ventilation system. Collectors should be located so that dust is drawn away from the workmen. The airborne dust concentration where workmen are present must be within allowable limits for asbestos and other pneumoconiosis-producing dusts as established by governmental and professional agencies. Should dust count exceed these limits, then the operator must wear approved respiratory equipment. Shop Fabrication t One typical method of shop operation is to have the clerk and timekeeper prepare orders for the fittings and fill in the dimensions for the parts and pieces from the C-450 Fabrication Manual. These can then be used to draw stock, provide detailed information for the cutting and assembly operatrons. Typical of such shop orders with the detailed information is shown in Fiqure X-14, X-15, X-16, and X-17. UCC 002809 STANDARD cxaucAU aao plastics SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 206 APRIL 1970____________ Figure X** 13 UCC 002810 STANDARD QttKAU AID MJTO SHOP AND FIELD FABRICATION 45 a 90 WELDED TUBE TURN SEGMENTS CHAPTER X APPLICATOR TRAINING PAGE 207 APRIL 1970 O.D. D. 0, D. D.O.D. 1.0. SEG.LEN. NO.SEG. DEGREE FAB. ORDER NO. 93655-06______ SIZETHICKNESS MATERIAISPEC NO. REQ'D_________________________ RADIUS____________________________ COATING__________________________ FOREMAN_________________________ BLDG. _____________________________ PLANT________________________ REF. CHARGE_____________________ * WHEN NEEDED Figure X-14 UCC 002811 STANDARD Maotiwunn SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 208 APRIL 19ZQ THKt-4 90 FLANGED ELL -150 LB. FOANIGLAS ____ B_____ C___ 5__D_____ E______ O.D. O LD BODY I.D. BODY L. BODY L. NOTE- FROM 12" THRU 24 7 PCSL D&E AT 7 LONG RAD. ONLY. FAB. ORDER NO. 93655-06- MATERIALSPEC. SIZETHICKNESS RADIUS__ COATING NO. REQD.. FOREMAN PLANT___ BLDG____ REF CHG. Figure X-15 UCC 002812 STANDARD omuu n-una SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 209 APRIL 1970 0.0 D.1.0. 80DY 1.0. BODY L. BON. HT. B0N.D.THK. FAB. ORDER NO. 93655-06-_____ MATER I AlSPEC_____ SIZETHICKNESS PRESSURECOATING _ NO. REQ'DTYPE_____ FOREMAN_________________:________ BLDG_______________________________ PLANT_____________________________ REF. CHARGE______________________ * DO NOT STICK Figure X-16 UCC 002813 STANDARD oMAUAieruino SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 210 APRIL 1970 D. BODY L. BON. HT. BON. D THK. I PC. __ 1 PC____ 2 PCS.'C 2 PCS. -______ I PC. PC-_____ 4 PCS. DUTCH.-. - X_ - X_ . X_ - X_ I. D. I.D.. _ X_ _X_ __ Xx__ .0. D.. .0. D. .THK. .THK. .THK. .THK. .LONG .LONG FAB. ORDER NO. 93655-06- MATERIAL .SPEC_______ SIZE THICKNESS. NO. REO'D., COATING___ FOREMAN. BLDG______ PLANT____ REF. CHG. DO NOT STICK Figure X-17 UCC 002814 STANDARD CMOMCALi Atf> PULftTKM CHAPTER X APPLICATOR TRAINING PAGE 211 APRIL 1970 SHOP AND FIELD FABRICATION SHOP AND SHOP PRACTICES - Contd Shop Fabrication - Contd Following the dimensions, pieces for fabrication are cut ready for assembly. Figure X-18 shows the pieces and assembly of a welded elbow cover. Figure X-19 shows the assembly and pieces of flange globe valve cover, and Figure X-20 shows the pieces and assembly of a flange gate valve cover. Figure X-21 shows the projected assembly of pieces to form the flanged gate valve cover. The assembly of pieces into a complete cover requires that the pieces be bonded together. The cements used for the assembly are determined by the insulation and its service requirements. Each cement must be applied by the proper method. Some of the most commonly used cements and their method of application follow: 1. Hot Asphalt Cement is appfied to insulation in hot liquid state. It is usually heated in a pot located near, or in the assembly work bench. The pot is equipped with rollers that pick up and deposit hot asphalt on the surfaces to be adhered, when these surfaces are passed over, and in contact with the rollers. Coated surfaces are pressed together while asphalt is in liquid state. The asphalt hardens to a bond when its temperature drops. The use of hot asphalt cement is restricted to foamed insulation which will not be attacked by the high temperature of the asphalt or by its chemical composition. Hot asphalt must not be used on piping or equipment that will operate at temperatures that will remelt the asphalt. 2. Catalyst Type - Vapor Resistant Cement is a two-part mixture, usually one part powder and the other part liquid. After the two parts are mixed together, the resultant mix will set up within a given time - called pot life. For this reason, only the amount of material that can be used within this pot life should be mixed. This catalyst-type cement is most frequently applied with a brush. It is used mostly with foamed insulation in service on surfaces which cycle from low temperatures to higher temperatures which are above the melting point of asphalt. Keene's Cement is a water mix hydraulic-setting cement. The cement powder is mixed with water. Being hydraulic setting, the mixed cement must be used before it begins to harden. This cement is applied by brush or trowel. It is generally used to bond cellular glass together when this insulation is to be used in high-temperature service. UCC 002815 STANDARD OWMCAH W WJtfTiq SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 212 APRIL 1970 r [ \ i i i i i Welded Elbow Cover figure X-18 UCC 002816 L {. L L L L r STANDARD CMBHC4U * M-AJTICJ CHAPTER X APPLICATOR TRAINING PAGE 213 r APRIL 1970 SHOP AND FIELD FABRICATION r r r i { 1 * 1 I ( i t t I Flanged Globe Valve Cover Figure X-19 UCC 002817 STANDARD omKtLt mo fumo SHOP AND FIELD FABRICATmu CHAPTER X APPLICATOR TRAINING PAGE 214 APRIL 1970 Flanged Gate Valve Cover Fiaore X-20 UCC 002818 r r r i L L U STANDARD CMtMCAU A> PLASTICS SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 215 APRIL 1970 Projected assembly Figure X-21 UCC 002819 STANDARD OGMtCMJ M* FUSTICS CHAPTER X APPLICATOR TRAINING PAGE 216 APRIL 1970 SHOP AND FIELD FABRICATION SHOP AND SHOP PRACTICES - Contd Shop Fabrication - Contd 4. Insulation Adhesive Cements are premixed cements of fire clays, binders, and silicates. These cements depend upon dissipation of moisture for their setting. They hove almost unlimited pot life and can be used as received from the manufacturer. They are best applied to insulation surfaces by trowel. They are generally used to bond high-temperature insulations such as calcium silicate, asbestos fibers, or similar absorbent insulations. 5. Insulation Adhesive Cements for Non-Absorbent Insulations are made of fire clays, binders, and special solvents. This type depends on slight dissipation of moisture, or solvents, for setting. It is best applied by trowel and is used to bond moisture-resistant, high-temperature insulation such as bonded expanded silica. 6. Resin Adhesive Cements are made of organic resins and solvents. They have almost unlimited pot life and can be used as received from the manufacturer. They can be applied by brush or trowel. They are used to bond glass fiber and foamed organic insulation. In most instances their upper temperature limit is approximately 350F. Typical application of an insulation adhesive cement to bond the pieces of a Flanged Globe Valve together is shown in Figure X-22. Field Installation of Prefabricated Fitting Covers Preformed fitting covers provide an efficient means of field installation. In general the practice should be to install all welded and screwed fitting covers prior to the application and installation of straight pipe insulation. The reason is that it is easier to cut the straight pipe covering to dimensions where the pipe and fitting covers butt together. With flanged fitting covers the opposite is true. The straight pipe covering is installed first, then the flanged fitting covers are installed. This is proper procedure because the flanged fitting covers are designed to fit over the adjacent pipe insulation. A picture of the manner in which a flanged globe valve cover fits over the valve and adjacent pipe insulation is shown in Figure X-23. The final securement of this valve cover in position is shown in Figure X-24. Precision cut and assembled fitting covers are much more effective than the loosely fitted and cemented covers of the past. Prefabrication is one of the most important steps taken in the insulation industry to keep pace with industrial advancement of other industries. UCC 002820 STANDARD OtfJttCALS AM) PLASTICS SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 217 APRIL 1970 Cementing Flanged Globe Valve Covers Figure X-22 UCC 002821 STANDARD OitMiCAU 4>fl> RtAfTO SHOP AND FIELD FABRICATION CHAPTER X APPLICATOR TRAINING PAGE 218 APRIL 1970 UCC 002822 r STANDARD r OKMICAU AND nASTlCS CHAPTER X APPLICATOR TRAINING PAGE 219 APRIL'1970 f SHOP AND FIELD FABRICATION r r i i i i i i i i i i i i r Flanged Globe Valve Cover Secured In Position Figure X-24 UCC 002823 STANDARD OCMCUi AMD PIAJT1CS CHAPTER X APPLICATOR TRAINING PAGE 220 APRIL 1970 SHOP AND FIELD FABRICATION SHOP AND SHOP PRACTICES - Contd Field Fabrication A prefabrication shop may well be set up on the job site. Preforming fittings in a shop with power equipment is shop fabrication regardless of the location of the shop. Field fabrication, in our use of the terminology, is where the cutting and fitting is done with hand tools. In some installations of small jobs or maintenance it is necessary to field hand cut fittings. Flange covers, tee covers and elbow covers can be field fabricated with relative accuracy. However, it is quite difficult to cut all the parts sufficiently accurate to make good fabricated globe and gate valve covers. Conversely, plug valve covers should always be made of pipe covering by hand method in the field. When tee or flange covers are hand made in the field, the dimensions in C-450 should be followed. Welded elbow covers, hand made, in the field can be made more efficiently in the field when slightly different set of dimensions are used. The set of dimensions for such hand cut welded elbow covers are given in Figure X-25 and X-26. Where cylindrical vessels are to be insulated with flat blocks, in mitered form, the outside maximum width of the mitered block should be in accordance with the following table: Diameter of Vessel Maximum Outside Width of Miter 14" to 24" 25" to 30" 31" to 36" 37" to 42" 43" to 48" 49" to 54" 55" and larger 3" 3-1/2" 4" 4-1/2" 5" 5-1/2" 6" To determine the angle of cut for the mitered blocks: 1. Add twice the thickness of the block to be used to the diameter of the vessel. Multiply this outside diameter of the insulation by 3.1416 to find the outside circumference of the insulation. 2. Divide circumference of insulation by width of miter from table above to determine number of miters; if this number is not whole, increase to next largest number. Multiply by two. UCC 002824 1 STANDARD OOMieAU M RlASTO I CHAPTER X APPLICATOR TRAINING PAGE 221 APRIL 1970 I SHOP AND FIELD FABRICATION DIMENSIONS FOR MITERED SEGMENTS FOR SHORT RADIUS ELLS I 1 nominal insulation thicknesses 114' 2- 2Vi' 1 Pipl SUt A B c 0 A 8 C P A 8 C 0 A ft C D 3" 3 3% It 232 3V4- 3 3H 1* 2.00 -- -- -- -- ---- -- -- -- *-- -- -- J 4' 3 3% 36 1.86 2 6Vi Vi 186 -- -- -- -- -- -- -- -- 414' 4 3* K 1.50 3 4% K 180 S' 4 314 Jf. 133 A 3% 14 1.33 3 5*6 K 1.33 -- -- -- -- 6' 7' 1 8' 6 _ 2% 3_6_ _ 9* _ _ 10' 11* 1 12- _ 14* __ __ _ -- _ 16* 18' _ _ ] 20' 22' _ _ _,, _ ._ _ _ 1.11 _ _ _ -- _ 6 2% 36 i.n 6 3Vt J6 1.00 6 3% % 88 8 3)6 vi .75 8 314 16 .66 8 3H 96 .68 8 3% % .58 8 4% IK ft 5 114 .50 .41 8 5H 1 Vi 33 s 6Vi Hi 38 8 6K Hi 38 4 4Vi 14 1.11 6 3* K LOO 6 3% K 88 8 3)6 H ft 3% 14 .75 .66 8 314 % .66 8 4)6 16 .58 a 4% 1)6 80 8 5Vi 1)6 .41 ft 5% 1H 33 8 614 1H .28 8 6% 114 38 3 6Vi K 1.11 4 36 14 1.00 6 3% 14 88 8 314 K .75 8 3K % 86 8 396 Vi .66 8 414 16 .58 8 <96 96 .50 8 5)6 lli .41 8 514 114 33 8 6V4 Hi 38 8 7 Hi .28 24' - - - - 8 7* 2Vi .25 8 71i 2 35 8 7Vi 1H 35 1 1 Pint 3* 3V4- 4- 414' 5* Sill A B C D A 8 C D A 8 C D A B C 0 A ft C 0 8' 3 6 K 88 _ _ . __ _ _ ___ _-- _ 9* 6 496 Vi .75 6 4Vi a .75 -- -- ---- -- -- ---- -- -- -- I 10' 8 3% % .66 8 314 K 66 8 314 Vi .66 -- -- -- -- -- -- -- 11* 8 3% !i .66 8 4 k .66 8 4Vi K .66 8 4% 14 .66 * ' _ -- -- -- 12* 8 4% Vi .58 8 4)6 % .58 8 4)6 K .58 8 4% K 38 8 4H 14 31 14- 8 496 96 .50 8 496 % .50 8 5)6 K .50 8 5)6 36 30 -- -- -- -- 1 16' 8 514 1 .41 8 5)6 96 ---- 18* 8 514 114 37 20' 8 614 Hi .29 22- 8 7 Hi .29 \ 24* 8 7H 114 30 A -- Numberof Miters 8 * Greater Dimension of outside face of pipe insulation I C -- Lesser or throat dimension on outside face of pipe insulation D -- Number of short radius eJIs available from a linear foot of pipe insulation, based on alternating the cuts and allowing for saw kerf and waste 1 Dimensions are to nearest )&* ' dh Reproduced with permission, from Heat insulation Manual, Pebco Industrial Product Division, Fiberboard Corp. Figure X-25 UCC 002825 STANDARD OfMCALi am) plastics CHAPTER X APPLICATOR TRAINING PAGE 222 APRIL 1970____________ SHOP AND FIELD FABRICATION DIMENSIONS FOR MITERED SEGMENTS FOR LONG RADIU5 ELLS NOMINAL INSULATION THICKNESSES i* \w 2' 2V,' r Sire A B c 0 AB C D AB c 0 AB c 0 A8 c D 4- 2 X. 2.33 4 216 X. 2.33 __ -- -- -- - - -- -- --- -- -- .. 4 2% % 2.00 4 2% % 1.66 4 3% ft 1.41 6 "A 1.20 6 2*4 % 1.03 6 2% % .93 s 3ft I ft .75 4 2% X, 2.00 43 % 1.66 4 3% % 1.41 6 2% 1.20 6 2!i V* 1.03 6 3X 96 .93 6 3% Hi .75 6 4Vi 1% .66 3 4% 96 1.66 4 396 Vi 1.41 6 2% X. 1.20 63 Vi 1.03 6 3>6 % .93 6 3ft 1 75 6 4ft 1*6 .66 3 4% X. 1.66 4 3% X. 1.41 6 2% X. 1.20 6 3Vi Vi 1.03 6 3% X. .93 o iv* Vi .75 6 4ft IX. .66 -- ---- 4 416 6 3ft 6 64 6 4V4 -- - ft 1.20 ft 1.03 A S3 ft .75 % .66 _ --_ __ _ _ __ 8 3Vi IX, 8 3'A 1% 8 4% 1% 3 4% 1ft 8 5X. 1% .53 .53 .50 .43 .41 8 3% 1ft 8 4 IS. 8 4% 1% 8 4% 1% 8 5X, lVi .58 .53 .50 .43 .41 8 3% 1 a 4X. 1% a 4ft 1ft 8 4Vi 1% 8 5% 1ft .58 .53 .50 .43 .41 8 396 % .58 8 4X. i* .53 8 4% i% .50 8 5 i% .43 8 5Vi i% .41 _ __ __ __ _ __ _. _ 3 Ml 2X. .33 8 5% 2% .33 8 5*4 2ft .33 8 6X. 2Xr .33 8 6% 2% .29 a 6% 2ft .29 8 6% 2V .29 8 6Vi 216 .29 8 7% 3%> .25 8 7% 3Vs .25 8 7ft 3X. 25 8 7% 3 .25 8 8tt 3% .20 8 8ft 3Vi .20 8 8Vi 3V4 .20 8 8Vi 3Vi .20 8 8ft 4 .20 8 9 4 20 8 9ft 3Vi .20 8 9ft 3V4 .20 >y - - - - 10 7V. 3Vi .166 10 Vh 3Vi .166 10 7Vi 3Vi .166 10 S 3V. .166 ! Pipe ^ Site ; ** ; 216' [3*- ! 4' 4V1' 5* 1 6' 7* ; 8' : 9ID* in* j)2' 14' I16' jl8' 3Vi- AB C DA 6 316 16 1.03 6 3H X. .93 4 6 4X. % .75 4 6 4% 96 .66 6 8 3% 96 SB 8 6 416 1 .53 8 8 496 116 .50 8 8 556 lVi .43 8 8 596 116 .41 8 8 616 2X. .33 8 8 696 2X. .29 4* BC 4Vi* DA B C 0A _SVi 56 .93 -- -- -- -- 6X. % .75 4 6% 96 .75 4 4% 96j .66 6 4% % .66 6 4 96 .53 8 4X, % .58 8 4% % .53 8 4'16 96 .53 8 4% IX, .50 a 4% 1 .50 8 5X, 156 .43 8 556- 1>6 .43 8 516 1% .41 8 5% lVi .41 8 6Vi 194 .33 a 6% 1% 33 -- 5' BC D _ __* 6% 16 .75 5)4 % .66 416 Vi .58 4% % .53 4% 96 .50 SVi 116 .43 5_% 156 ._41 !> Number of Miters 3 -Greater Dimension on outside face of pipe insulation C - Lesser or throat dimension on outside face of pipe insulation Number of long radius ells available from a linear foot of pipe insulation based on alternating the cuts and allowing for saw kerf and waste. Dimensions ere to nearest J6' Dimensions based on formuta--Chord length -- 2 r Sin Where r -- radius to outside of insulation (where segments are circular graphically) A*-90* Divided by number of segments used. Reproduced with permission, from Heat Insulation Manual, Pabco Industrial Product Division, Fiberboard Corp. Figure X-26 UCC 002826 STANDARD OtfMCAU Art) PLASTICS CHAPTER X APPLICATOR TRAINING PAGE 223 APRIL.1970 SHOP AND FIELD FABRICATION SHOP AND SHOP PRACTICES - Contd Field Fabricotion - Contd 3. Divide 360 degrees by above result, which will give angle of cut for miter. Example: a 48" diameter vessel is to be insulated with 2" thick flat blocks cut into lage or mitered form. Outside diameter of insulation = 48" + 2" + 2" = 52". Circumference of outside of insulation = 52" x 3.1416 = 163.36". From the above table the outside maximum width of miter for a 48" diameter vessel is 5". Increase to 33 pieces. J63.36"_ = 32.67 pieces 5 Outside width of miter =* 163.36" 33 61" = 4.95" = approximately 4 Angle of cut on each side of miter * 360 = 360 2 x 33 pcs 66 = 5.45 NOTE: Sectional pipe insulation, where available, may be used more economically for 18" and smaller diameter vessels. Curved equipment blocks are available to insure snug fit for equipment up to 54" in diameter. UCC 002827 STANDARD DtttOLS urn flAITO CHAPTER XI APPLICATOR TRAINING PAGE 224 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS Insulation supports ore the appendages, or objects which carry the weigh! of the insulation. Frequently supports are attached to vessel walls; thus, the insulation support acts to transmit the weight of the insulation to those walls. In other instances, such as horizontal pipe, the pipe itself is the insulation support. Insulation securements are accessories which attach insulation in position. Insulation securements are such items as wire and strapping. SUPPORTS Insulation supports are designed to fulfill the requirements of the weight of the insulation, strength of the insulation, operating temperatures, and configuration of the vessel or equipment. The insulation supports for the insulation installed on the cylindrical section of a vertical vessel is shown in Engineering Standard EQ-64 and horizontal vessels in EQ-65. These particular supports are welded to the vessel by the vendor and is a preferred method of attachment. Jn cases of vessels which are converted from one service to another, or which may have been purchased without supports, the supports may be bolted on as shown in EQ-68 and EQ-69. In both cases, the area of the support on which the insulation rests is such that ail the weight of the insulation above will not exceed the compressive strength of the insulation. This is illustrated in Figure XI-- 1. In both cases the lowest support ring and uppermost support ring are slotted so that bands can be inserted through the slots for fastening the head insulation in position. The weight of the bottom head insulation is supported by the bottom support ring. Where it is necessary to insulate the heads of vessels with a skirt, proper support rings are shown in EQ-64 and EQ-70. EQ-64 supplies the information to obtain welded-on supports, whereas EQ-70 provides the means of installing a ring in the field. Wherever possible, method presented in EQ-64 is preferred to the method given in EQ-70. The support shown In EQ-68 is an arrangement whereby the cylindrical insulation on a large diameter vessel is broken up into sections with each section being separately secured by bands fastened to vertical angles. This eliminates the difficulty of trying to space, install, and pull up bands all the way around a large vessel. On very large bottom heads the weight of the insulation makes it impractical to attempt to hold up the insulation by straps fastened to thesupports around the cylinder. In addition, even if it were practical, the expansion of a large vessel would exert such stresses on the strap that either UCC 002828 STANDARD CNtMCALS AnO n.AJTO. CHAPTER XI APPLICATOR TRAINING PAGE 225 APRIL 1970 WELDED-ON INSULATION SUPPORTS FOR VERTICAL INCLUDING TANKS. OVER 3-FT O.D. hr with im\(Dw^-to p>fonoed dfpM, pen#!, end blech fa* Mwltf VESSELS, Utittofen TUdutao, t| {-). I* f| i M/2 M/ < t| S >1/3 *->/* < S f lor $Im 1Nttoto> 1. Wlbh, UnJ V*4 a/i* 1/4 J IO/J 3 Weld Sl** t (in. x 45* ) vu Vi* /4 GfMfltAL NOTH All ufprt rinfi AmII be itoaf -K*i p*oto ottonaiae. Praia id* iMttow aucpoit ring or imImi igocorg ! ll-fr. $to*t* ^ocm itoll to rir;pl# tol*ft*-*n. Select tugpen ring tie* tar* Tebie A. Motorito lor wpporti dwN to to neTod on V*l ouiAl/ doling to in Ito *a--l aeectficoriena. WoWing prtcaewro reAw eincfclng a^fati e now v*>sel atoll to oewel * rtor to ito pfWitMto containing oclwf. Artecknant et tippedt to on al*Up (wind) ASM! Cod* Veate* ttoll to in wloHMti with rto eppl ieebfo Cod* regwiroraenr* including pwiweld toot (>wimw wto* r*gvtad Strlftrung ringi iNewld to r -- iftpoced btitosrlng twpert ring dul*, prectieebJe, end tmy to uaed In Iteu to dondotg ifwulering atppert flag* on <roM*h tubfrott to oatootto pr*Mwr. Do net dot atlffening r| SCWIC NOTtS. ' A. Awto imubticn mtppart.tingt'mth* tog end totwa to each itoll ttoasitien ***. Pot diitod log h*ed, prwrtde ring on rto atrwgfct fang* to tto h*ed on rto itoll odioroni to ito toad. B. Ptovtde support ring oho** thell oopeMl** joint, C. Provtd* on imulotlon tupporf ring abovo noth (fong*d itolJ joint. CI*oignco bo tween tto tag (toe* I el ito tong* and tto tap to tto ring atoll to sufficient to prwido cttu for tightening (long* belli but not Uu tton 9-icto. D. Pw**d* the following inauldtton upper* ring* aw void tbirt*; 1. One ting on tto etotido to tto ahif* et 4 a t{ mchoa mintoiw. below tto heed tongont (In*. 2. On* tin. * Wn. iletrd ring tnsid* drift. Locoto tbit ring to prerid* t. i*in. riooranco b+-o*r tto bcttoo, tood end tto inr2or edg* to tto ring. Wald on lew, aid* only. 3. On troutot dotlgnod for aervic* btoew 0* C <32* O, pre*id* larnad lienor) ting wniide rl> afcirt oppeait* rto ring to D.l.efcw*. Tto lower bitide ring atoll to to hi n*e tbictoon end width ea rto outaldo (appntito) ting. Slot* or* nto roquiwd in rto wild*, iow*r ring. f. W*id^w irOwfoticn ntpgnrt ring en tto ewtaido to diiit nrh doubio-rii^ typo bet* for we with proalrwiad one tor beta a*r* bo apoc*d of laatt >fr 2-in. atot rto togbeae ring. Inartol bolted-** inwletten wpgorT ring pet Sid 0*40 whoto rW* aiot bo toreinnd. f, For leg lug-juppertod veottot with ditto* betton toed*, erwride on biotidtlen support ting m Ito dreigh* tonga to tto bettan toad or on rto atoll djoc* to ito totton hood. G. Loo*** toga ond itoi te provida totoiowi efootone* to l->ncb towant foe ring et rad atmdrawer w*ld end tto vettel c ircmnfor*nt<el m toigtiudinel won iilpo. Ring w red ottoctowe neida itol) we crop won* in the rmal. N. Locate ri^> end rorfi te deer deH eenttocrtetH, itefaciwiwi to*. lifting #l*., Ttore geaarble. *rg feeetleni ebwe Aecito ore prefotted te the** toia*> rnerfti totow inpaaiible re ewtod inttforenc* bo*noon atoll ^amingt or oneetowr** and ring*, en zoning to niwtoii ptectieobl* l*ngfh atoll to loft in tto ring. Picwido i-nch, mriiionno, cieonmce todown ring or md oitochmo-- neMa end ite<lMn*nr wold to Ito rniarfotong toot. J. Pretrid* wppert rmg tolem fletferm Clip Altochreont. locate or anooiatt nndttgi* to 9-incto> bo,* rwot loner ring. (SEE OVER fOR TYPICAL DETAILS) ENGINEERING STANDARD EQ-64 PACE I UCC 002829 STANDARD Che*mcu.s a*b Plastics CHAPTER XI APPLICATOR TRAINING PAGE 226 APRIL 1970 WELDED-ON INSULATION SUPPORTS FOR VERTICAL VESSELS, INCLUDING TANKS, OVER 3-FT 0. D. TrfieolMCTION *-* SECTION Jypiaai OTEyTpAicfral A Arfitoeding dg* o,d. oi vmi TS'-Oiott'-Q 27*-l M 36 3fl*-i to scr-o cnt J0--0 No. $irop-Anchor J 8od Jtoovaod j J On* to* for aoch 1 y-fr of c>FCW*'f*r*r>C* I or frocrion thwaof ( VIEW C-C fjrpitAi tirVATIQN [>-P Typical TypicJSECTION f-C ENGINEERING STANDARD EQ-64 UCC 002830 PAGE 2 r r r r i i i i ! r i i i \ t i i STANDARD CMUCAI AMD PLASTO CHAPTER XI APPLICATOR TRAINING PAGE 227 APRIL 1970 WELDED-ON INSULATION SUPPORTS FOR HORIZONTAL VESSELS OVER 3-FT O.D. (S-- MU A 04 Nc*w I, }, oM 3 lowgfrudt--i toon Qonito of *oli DETAIL A gWD BLgVATION Utartoio* Tliidiwti, t. <to.) tor Slso IWduMM, r wtoit, w <!> * n.) ' Wold Sl*o, t (la. * 45* f t * t. < 1} >; i n 3J <t! 49 i i i 1 1* s i i i GCNCXAl NOTES I ton o* toMotoric for mpfoit rlnp end ttoll to ^oclfiod rto VomI Spocifiowtom. Soioct riry |bor) ila fw+m Ttoio A. Wo^inp prxodwri to owtSiig nfynrti to 0 now voomI toil to o^wol to ttof for fto ptntnrr lonrointoy mcImm . Arro<to*wtr of Mppom ro m* ontotod (u*od> ASM! Cod* vmI tholl to to eonfon*vnco w*rh *to oppficoblo Cato rnuimnmt toctodins pa*w*ld toot trootooro rtoa r9airod. 0(1AtL NOTES 1. Locoro torlxoniol tMppor* ton to provide ntotown clrenna pi I-inch Lrtwo^i rto tor owetlwwro wefd N Ai vml Ito'NNto wa ody--. 2. taawo tt*Qp aad ton re clear itofl canmoiom to retofarcononr podt. PiOvito ntotoyn dtoiooco of 1-tocA twin rtof or tor omctmar* IA end onocfaMf* rif of to tofocof* Upm. 3. Support oftechnont woto tool! rto <rom tonpttwdtooi or cnvotoorareM void* to to'ninl. ENGINEERING STANDARD EQ-65 UCC 002831 STANDARD OtfNCAU AMO PIASTI0 CHAPTER XI APPLICATOR TRAINING PAGE 228 APRIL 1970 BOLTED-ON1 INSULATION SUPPORTS FOR VERTICAL VESSELS OVER 3-FT 0.0. tDodpnod for ot* with pralwmad fropm. ppnpt, ond Modi form irulo>ert) v*r feu OCTAIL C OCTAJL l 'boltod-oo kiofefton mppom oro to fao m\y hr FIELD INSTALLATIONS an an wMch Wdirtg i> olfkor nor pam'mJUa without pwoold hop! KwimM or bocowao oi woo or obon -oldod-Wi toadorian oip|MiTi not tfWwiM procficobl*. ONUSS OTHERWISE INDICATED, AU 0(MANSIONS GIVEN IN INCHES, ENGINEERING STANDARD EQ-68 NOTE: lolrt *ol| bo dig ildnid nochin* Mil with iqwrt hoodi d Kw own, wotm otborwho lodlcorod. A)J #ool port* dwtl bo cootod, or orkorolao prortcNd *b* mm oa th* vumI o ohlcK tkoy Oro offockod, prior tha attochoHM*. Lb# noifdow Pool bond* end clvrwirwo clip* 0* olwoiinufo moll. REFERENCES: Beftod m Iwmlofioo Support An^l* lor taaldo of Ski* bo Vortkoi VMo<..................................$N EQ-70 StroyAaiabor A/tqloi for VoMofa Owat is-ft Oo .... StrOrrr PAGE I UCC 002832 STANDARD CHCN*C*LS AND PLASTICS CHAPTER XI APPLICATOR TRAINING PAGE 229 APRIL 1970 BOLTED-ON INSULATION SUPPORTS FOR VERTICAL VESSELS OVER 3-FT OP. STRAP-ANCHOR ANGLES FOR VESSELS OVER 15-FT O.D. circumference of vessel. PLAN - Insulation support Strop angles (7yp.) x 1$ x " Steel angles with i x j" slotted holes DETAIL F Strop angles SECTION A-A TABLE 1 Outside Diomefer Number of Vertical of Vessel Anoles Required 15'-0 to??"-!) 2T-1 to 36*-0 36'-T to 5ff-0 Over 50*-0 4 s 16 One angle for each 9-ft of circum ference, or fraction thereof ENGINEERING STANDARD EQ-48 PAGE Z UCC 002833 STANDARD CNIMCAU MD ALASTO CHAPTER XI APPLICATOR TRAINING PAGE 230 APRIL 1970 UCC 002834 r r r r i i i i 1 i i i i i i i i STANDARD D*tCAll PIASTO CHAPTER Xi APPLICATOR TRAINING PAGE 231 APRIL 1970 BOLTED-OIT INSULATION SUPPORT ANGLE FOR INSIDE OF SKIRT FOR VERTICAL VESSELS {Dotipnad lot m* *l*k Pralpn--^ Shop--, femi, and lldi kmrfattw} ti ia mi PIH.D INSTALLATIONS vowal* a* wHich araldiAg H iWiir met pw>lMlfrl --^hnrf { al UNUSS QTHtt*ISI INDICATtP, ALL DIMENSIONS GIVEN IN INCHES. ENGINEERING STANDARD EQ-70 All *aol party tfwll fco teee4, ofk*nrii* ptetmctmd Aw ibm * H* *mmI (a rKicA tkay at* attached, pin to Ilf OltOChMWt. Um alumm** onglos on 1ummwmi REFERENCES: Raltad'On lxMotion SpycRi la Vertical Voiwk Ovo* S-* CX>...................................*4 EQ-di UCC 002835 STANDARD OtSMtCALl AND fCWTO CHAPTER XI APPLICATOR TRAINING PAGE 232 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS INSULATION SUPPORT ON VERTICAL CYLINDRICAL VESSEL r STANDARD .r ORM<AU AM> PIASTIO CHAPTER XI APPUCATOR TRAINING PAGE 233 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS r SUPPORTS - Contd the insulation would be damaged or the strap would be pulled apart at the clips. For these * reasons large bottom head insulation is supported by rectangular welding pieces as shown in EQ-67. The insulation is secured in position by wires fastened to these welding pieces. l' Because ot its special shape the support rings for spheres require a special arrangement for support rings to secure insulation on spheres operating below 70C as shown in EQ~66. The insulation on spheres above this temperature is secured by pins and speed clips. Insulation installed on horizontal pipe is supported by the pipe. As shown in Figure Xl-2, s the upper section of insulation rests on the pipe and the lower section is held up snug by the securement wire or strap. f Where wire is used to secure insulation it should be drawn taut by twisting the two ends together with sufficient tension that the sections of insulation are tightly butted together. The twisted ends must be bent back or embedded in the insulation so that sharp cut ends are embedded in f the insulation. ' Straps should be installed in a similar manner, being drawn taut by banding tool so that insulation 3 is drawn tightly together. Cut end of strap must be bent back toward clip to prevent a sharp projection. 3 On low temperature installations and for some small size moderate and high temperatures the pipe and insulation are installed in cradles. Under these conditions the entire weight of the pipe, its contents and the insulation are supported directly by theinsulation. To prevent the 3 insulation from being crushed where the pipe crosses the beam, a metal cradle is inserted to spread the weight load over a large area of the insulation. Such an installation is shown in Engineering Standard P-82. 3 Vertical pipe presents a different support problem, in the case of short lines with a bottom welded elbow, the vertical pipe insulation is supported by the elbow insulation. On all long vertical lines and lines with flanged valves, flanges, or elbows, an insulation support should be provided. This is illustrated in Figure XI-3. The reasons for this is that, in the case of long vertical lines, the excessive weight of insulation on the elbow cover will attempt to push 1 it down and around the elbow with a resultant crack developing on the outer radius of the cover. In the case of flanged fittings, the insulation should always be secure so that fittings con be received without insulation slipping down the vertical pipe. "M* UCC 002837 STANDARD ohwcau um rutfwa CHAPTER XI APPLICATOR TRAINING PAGE 234 APRIL 1970 INSULATION SUPPORT PINS FOR WELDING TO CARBON STEEL BOTTOM MEADS OR TO FLAT SURFACES (Designed for u with preformed shop**, ponel, end Mock form insulation) ELEVATION A-A After Welding Front Eievettoni of Pin TYPICAL FLAT SURFACES NOTE: This standard applies to flat surfaces and to bottom hoods of carbon steel vessels over 16-ft OD for operating temperatures above 70F. Pins shall be os manufactured by KSM Products, Inc., Moaiestown, New Jersey, or other approved seewrement. Pint shall be welded to vessel with a K$M-CD~6Q Capacitor Discharge Stud Welding Unit (or approved equal) with accessory ebuek to suit pirn. Pins shown ore $-n. thick, Pins shall be welded to vessels subject to postweld hear treatment before the final heat treatment. Pins may be welded in the field to vessels ond other equipment not subject to postweId heot treatment. All dimenekn* clveij in fochee. ENGINEERING STANDARD EQ-67 UCC 002838 f r r r f \ i i l i i i i i i L l STANDARD CNtMTM.1 AMD PLASTICS CHAPTER XI APPLICATOR TRAINING PAGE 235 APRIL 1970 WELDED-ON INSULATION SUPPORTS FOR SPHERICAL VESSELS FOR OPERATING TEMPERATURES LOWER THAN 70FI2IC) (Pailor/ InmivMi palmamd ihap*i, pmarl, nd ktaak farm inmtkaiam) 3-9 (So* T*9k A) u*CKHTAmg A7 & 3 CTJOK* IamIkIm SfpaM Ikv |n*>Wion TMcLmm, 1. !*.> 1 t. i 1-1/7 l-l/i * l! i 3-1/2 2-1/7 t! A 9 bor iu TVcbtao, t Width, W W*W Sin, t (in.) ' (*) ' (l*..4S>)W i li 1 1'4 1 34 GENUAL NOTES 1Prov'd* och ^h*r* riwvrv am rbii two tlettad bwulr(a a . Orh** imul**k* aupporfi, ah*r* /gulrad. dial! b* a ipafiM In rha V*sa*l ipacHkartn. Stlacf avpport mm from TABLE A. Mot*r**1 to* mppnrtii aholi b* at etd m ttt* Vn*t Sp*il>cot>om. W*lding pa**dwt* fcH-*ttoehy *uppom to iphara holl km *QuoI to thot f rW |i>iw tofiaiwg DETAIL NOTES 1, Support ring* *1*11 k* pravidad far all tpAoro* f* W *iMA*r*d *o* op*Ming tawporotufi ball the** 7Cf (?IC). tinpi or* mat t* km conrfnuavt. Dpoti^p tp*w arijoeanf and* daif Mt aata*d 2. Adpnt ring locdion, if wac--aor>, fo ppr`d> arininn cfooJoaca W I--**eK baawaaa rh* ring wmbrn* w*fd **d ^hav* firth w*i<f arfgai. local ring! to cloor dtoM connecriar*nd ratnfanamaat pod*. Prpd* iMM cNo--nta at I-inch bpnaon ring oMacbaM aldr and uoclia^il wald at a**f od|acar* r*a*a. ENGINEERING STANDARD EQ-66 UCC 002839 1 STANDARD ckwou am plastic* CHAPTER XI APPLICATOR TRAINING PAGE 236 APRIL 1970 INSULATION SUPPORTS AND 5ECUREMENTS Securement wire, or strap, transfers weight of bottom section of pipe insulation to top section of insulation wire, or strap SUPPORT OF INSULATION INSTALLED ON HORIZONTAL PIPE Figure X1-2 UCC 002840 CHAPTER XI UCC 002841 _____________________________ CHAPTER XI APPLICATOR TRAINING PAGE 238 APRfL 1970 ENGINEERING STANDARD NO. P-82 NOTE: Dimensional insulation data is taken from standard Insulation tables. It should be noted that the insulation OD and ID are standardized to match the OD of standard nominal pipe sizes, and for thicknesses over 2 l/2-in., multilayer construction is used. Cradle design isbasedon a maximum bearing value of 20 lb per sq in. for cellular glass, with one percent allowable deformation without damage to the insulation. Other types of insulation will tolerate greater pressures and higher percentages of deformation without loss of insulation values. The bottom 120" arc has been estaDiished as the effective cross-sectional bearing area for insulation and supporting cradles, with the first inch of insulation next to the pipe absorbingthe greatest proportion of the load pressure. Cradle material beyond the 120* arc is useful for installation and retention only. The following equations are the results of complex formulae reduced to simplified ratios for ease of application. T " . 0125 Dj L - .0125 "-- or .15^>2 D2 Where: T = thickness of cradle in inches L = length of cradle in inches Dj - OD of bare pipe in inches Dj => OD of insulation in inches S = span between supports in feet w = unit wt per foot of pipe, water, and insu lation, plus 10% safety factor. f = (20 lb/sq in.) bearing value for insulation c - (1.5) coefficient of friction for longitudi nal movement. "T" and "L" have been adjusted to increments most suitable for practical application. "L" has been further controlled by the greater of three minimum values as follows: (1) ten inches (2) one pipe diameter (3) wcS Djf Cradles are Intended for use in straight run horizontal piping with flanges and fittings, short vertical runs less than S/2, and installations not subject to vibration. Runs including valves or long vertical portions shall be treated with special considera tion. Where severe vibration is anticipated, such as in compressor lines, the insulation between the cradle and the pipe shall be resistant to vibration. ooi ENGINEERING STANDARD P-82 UCC 002842 T r STANDARD OtPSCAU AW *.MT*Ci CHAPTER XI APPLICATOR TRAINING PAGE 239 APRIL 1970 r INSULATION SUPPORTS AND SECUREMENTS t r $ Pipe i * ( rv* Insulation Insulation Welded Elbow _Insulation Support .Weight of Vertical Pipe Insulation on Insulotion Support -Welded Elbow <r vTn ,--Insulation Support v 'i .--Weight of Vertical m Pipe insulation on Insulation Support Flange Insulation Cover Flange or Flanged Valve or Elbow .Weight of Vertical, on Insulation Elbow Cover Insulation Elbow Cover Short Vertical Insulated Pipe Long Vertical Insulated Pipe Flanged Fitting in Vertical Insulated Pipe SUPPORT OF INSULATION ON VERTICAL PIPE Figure XI--3 UCC 002843 STANDARD chwcui n*ino CHAPTER XI APPLICATOR TRAINING PAGE 240 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS SUPPORTS - Contd Horizontal equipment less than 4 feet in diameter is insulated the same as horizontal pipe. If horizontal equipment is greater than 4 feet in diameter, difficulty is experienced when it is attempted to pull up the bottom insulation by securement bands. Due to friction and weight, before the sag at the bottom is drawn out, the bands begin to crush into the top insulation. For this reason, support angles are located 60 from the vertical center on lower half of the vessel to which the bands can be attached. These angles carry the weight of the insulation. To provide supports for the head insulation, cylindrical supports are provided at each end of the vessel. The insulation supports for horizontal vessels are shown in Engineering Standard EQ-69. The support of insulation on large flat or curved surfoces such as ducts or spheres can be quite difficult. In these installations the insulation supports must be attached to the surface to be insulated. For this type of installation, rectangular welding pins, split pins, and regular welding pins are welded to the metal surface and become the insulation supports. The insulation is secured to these supports by wire, strap, or speed clips. A typical application, using rectangular pins for support of insulation installed on a large flat surface, is shown in Figure XI-4. As shown, this installation uses wire fastened to the pins for the insulation securement. The use of regular pins as supports and speed clips for the securement of insulation is shown in Figure XI-5. In some instances the insulation provides its own support by adhesion to the surface to which it is applied. Sprayed urethane foam has excellent adhesion and needs no additional supports. Sprayed asbestos insulation of thickness one-inch or less, like sprayed urethane, requires no additional supports. When the thickness is greater than one-inch, regular welding pins or split pins must be attached to the surface to support. Such an application to the bottom side of a turbine is shown in Figure XJ-6. Adhesives are used both for the support and the securement of insulation. On air conditioning ducts, they are used to support the insulation on installations in the interior of ducts or on applications where the insulation is installed in the exterior of the duct. Use of adhesives to install industrial insulation has been relatively limited; however, for the installation of cellular gloss or spheres the use of adhesives has proven to be the only satisfactory method. For such an application a special catolyst-type adhesive is necessary. Illustration of the use of adhesives to support insulation is shown in Figure XI-7. UCC 002844 r STANDARO r owaciu ue lurno CHAPTER XI APPLICATOR TRAINING PAGE 241 APRIL 1970 r INSULATION SUPPORTS AND SECUREMENTS i i i * i ( 1 Figure XI - 4 I Figure XI - 5 UCC 002845 STANDARD OCMeAUMfUITIO CHAPTER XI APPLICATOR TRAINING PAGE 242 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS Figure X1 - 6 UCC 002846 STANDARD OtBKJU AW PLAfTCS CHAPTER XI APPLICATOR TRAINING PAGE 243 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS Application of Cellular Glass Insulation to Shpere or Adhesive TYPICAL USE OF ADHESIVE ~ insulation support-- figure XI-7 UCC 002847 STANDARD QteaCALS AM> PLASTCS CHAPTER XI APPLICATOR TRAINING PAGE 244 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS SUPPORTS - Contd The angle insulation supports, and supports which require welding to equipment or pipe are most frequently installed by crafts other than the insulators. For this reason it might be questioned as to why this explanation of insulation supports is included in an insulation manual. The reason is that the insulators are responsible to make certain that the proper supports are furnished to facilitate the correct application of insulation. If insulation is installed without correct supports, the insulation application will fail, if such failures occur the insulator is blamed for the failure. SECUREMENTS Securements are fasteners to fix and hold insulation in position, either to itself, or its supports. An insulation securement may be strap, wire, tape, clips, screws, or adhesive. Equipment Insulation Securement Rigid insulation installed around the cylindricd section of columns and vessels is more frequently secured in position with straps. As shown in Figure Xf-8, the insulation on the cylindrical insulation is secured in place by straps on 9-inch centers. The top and bottom head insulation is securedto slotted support rings. Where vessel is of large diameter, strap shall be divided in lengths of not over T5 feet so that individual sections of the circumferential band can be tensioned without damaging the insulation. Strap should be installed to cylindrical insulation, stretching to suitable tightness with approved banding machine, and clamping in place at joint. Strap joint shall consist of double-pronged clip. Where shape of vessel or appendages prevent complete encirclement of strap, strop should be fastened to tie wire, wire cables or other devices. Such an application is shown in Figure XI-9. Where the bands completely encircle very large hot vessels such as over 20 feet in diameter, it is necessary to allow for expansion of the vessel. This is done by using expansion bands or expansion springs in each 30-foot section of strap. This is especially essential when factoryproduced insulated metal panel insulation is installed. Two typical installations are shown in Figure XI-10. Due to corrosion factors the securement strap used on these applications should be manufactured of stainless steel. Its size is ]/2-inch wide and 0.02 inches in thickness. On large flat surfaces, irregular surfaces, and the bottom heads of large diameter vessels, wire fastened to rectangular pins is used to secure the insulation in place. Wire is also used to secure insulation around projections. These are illustrated in Figures XI-5 and XI--11. UCC 002848 STANDARD 04CMCAU MP RLUT1C3 CHAPTER XI APPLICATOR TRAINING PAGE 245 APRIL 1970 INSULATICN SUPPORTS AND SECUREMENTS APPLICATION OF STRAP TO SECURE VESSEL INSULATION Figure XI-8 UCC 002849 STANDARD OC1IICAU AMD M1ASTK3 CHAPTER Xi APPLICATOR TRAINING PAGE 246 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS USE OF TWISTED WIRE CABLE FOR FASTENING OF STRAP Figure XI-9 UCC 002850 STANDARD 0MCALS A*C PLASTIC! CHAPTER XI APPLICATOR TRAINING PAGE 247 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS Figure XI-10 UCC 002851 T STANDARD CWOM.* AW PLASTICS CHAPTER XI APPLICATOR TRAINING PAGE 248 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS SECUREMENTS - Contd Equipment Insulation Securement - Contd Clips pressed on pins which extend through the insulation are another securement. These are used on large Flat or curved surfaces. Typical installation of the use of clips to secure insulation is shown in Figure XI-5 and Figure XI--12. Pipe Insulation Securement Wire is used for securement of inner layers of pipe insulation (with exception of low temperature cellular gloss installations), and outer layers up to and including 12-inch OD. Wire is also used to secure pipe insulation above 12-inch OD where the weather-barrier is specified to be metal jacket. Wire shall be applied at proper intervals, looped around the circumference of the in sulation, then drawn taut and ends twisted together. Twisted ends should be pressed into in sulation to prevent projection. Pipe insulation above 12-inch OD shall be secured with stain less steel strap. Cellular glass low temperature pipe installations up to 4-1/2 inches in outside diameter are secured in position with glass fiber strapping tape. Above this diameter, inner layers should be secured with wire and outer layers are secured with stainless steel strap. Stainless steel strap should be applied to pipe insulation at proper intervals, looped around the circumference and be stretched to correct tightness with banding machine. Joint shall be held together by double-pronged clip. Clips should be located on the vertical side of horizontal pipe insulation. Spacing of insulation strap anchor wire shall be based on lengths of insulation block or section for equipment or pipe. Where 36-inch lengths are applied in staggered arrangement, four loops will be required at approximately 9-inch intervals so that no loop is more than 4-1/2 inches from any end joint. Where 24-inch lengths ore applied in staggered arrangement, three loops per length will be required. Where 18-inch lengths are applied in staggered arrangement, two loops will be required. Spacing of wire and strap is shown in Figures XI--13 and XI--14. UCC 002852 STANDARD *M> PLASTICS CHAPTER XI APPLICATOR TRAINING PAGE 249 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS Application of Bonded Expanded Silica Iruulotion to Equipment Leg Figure XI - 11 -Waldlng pin factanon (Sect. VII.A.22) 4 pint par block minimum Application of ft-eformed Bonded Expanded Sillco Intolotion to 5phf Body Figure XI - 12 UCC 002853 STANDARD O--CILI Am PLAINS CHAPTER XI APPLICATOR TRAINING PAGE 250 APRIL 1970 INSULATION SUPPORTS AND SECUREMENTS All end joint* in outer ond Intermedlote layer* of insulation shall be lopped a minimum of 3-fn. over end joint* below. End joint* of inner layer lopped approximately $ the length of o stondord section of pipe insulation All longitudinal joint* in outer ond intermediate layer* of insulation shall be lapped o minimum of 2-inches over longitudinal joints below. NOTE: longitudinal joints In the inner layer may be pfoced on horizontal center line* If convenient for the Instal lation. Location of Fasteners Strop or wire, as specified Outer layer of pipe insulotian inner ioyer secured with wire, at specified Inner layer of pipe insulation Securemcnt of Multiple Loyer Insulotion to Pipe Figure XI-14 UCC 002854 STANDARD tCHfiTH mo rusna CHAPTER XII APPLICATOR TRAINING PAGE 251 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS '" AND APPLICATION OFWT TRACER SYSTEMS There are a number of things which must be done in preparation for the actual application of insulation. These are listed in order to assist the insulator in the organization of his work. GENERAL PREPARATION OF INSULATION SYSTEMS Materials From the insulation list, drawings, and specifications, it should be determined what materials are required. Based on this requirement, it should be determined if the correct quantities, sizes and thickness of insulation are at the job site and that the insulation is in good condition. Broken or wet material should be rejected and replaced. It should be further determined that fabricated valve, fitting and/or flange covers are of the right material, correct size and thickness and in good condition. Of utmost importance is to check to find out if all accessories supplied are as specified and of proper quantity to do the job. Lack of a single accessory can delay the application just as much as the lack of the primary insulation material. A listing of these accessories which might be required is as follows: 1. Wire 2. Strap 3. Strap springs or expansion bands 4. Clips 5. Tape 6. Wire Netting 7. Expansion joint sleeve metal 8. Welding pins and clips 9. Cushion blanket 10. Sheet metal screws 11. Adhesive UCC 002855 STANDARD OfBftCAU AMO PLASTICS CHAPTER XII APPLICATOR TRAINING PAGE 252 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF"hEAT TRACER SYSTEMS GENERAL PREPARATION OF INSULATION SYSTEMS - Contd Materials - Contd 12. Sealers 13. Caulking compounds 14. Anti-abrasive coatings 15. Insulating cements 16. Heat transfer cement 17. Flashing 18. Jacketing - metal or plastic 19. Weather-barrier plastics 20. Vapor-barrier 21. Fabric reinforcing for mastics It is well to inspect such items as weather-barrier mastics, sealers, and adhesives to make sure that their consistency, and other application characteristics are suitable. Likewise, it is well to check insulation cements or other materials mixed with water to determine that they have been kept dry and are in good condition. Scaffolding Although scaffolding is erected by others, the insulator should inspect the scaffolding in reference to his needs for safe and efficient working conditions. If there are areas which need scaffolding for application, he should request that scaffolding be erected. Surface Preparation The insulator should determine if surfoce to be insulated should be painted, or otherwise treated prior to the application of the insulation. When surface painting is required, the paint must be completely dry before insulation is installed. UCC 002856 STANDARD OffMCALl AMD PLASTICS CHAPTER XII APPLICATOR TRAINING PAGE 253 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OFTifST TRACER SYSTEMS GENERAL PREPARATION OF INSULATION SYSTEMS - Contd Surface Preparation - Contd Any dirt, oil, or other contamination must be removed from surface before insulation is applied. Masking for Spray Applications Where insulation or coatings are applied by spray, it is necessary to protect the surfaces that are not to be insulated. Prior to the spray application, flanges, manholes and all other surfaces not to be insulated shall be wrapped with suitable coverings secured in position with wire or tape. These coverings shall be removed after application. Instruments and all other areas which are to be kept free of insulation should be protected with suitable covering. All equipment and piping within 25 feet of spray application must be covered or screened against overspray, rebound and drift. Supports With the exception of insulation which depends completely on adhesion for its support, all insulation in vertical vessels, large horizontal vessels, and long vertical lines requires supports. The insulator should assure himself that proper insulation supports have been provided for his application of insulation. These have been discussed in Chapter XI; however, to summarize the support requirements, the following listing is presented: 1. Rigid insulation on vertical equipment exceeding 1'-5" OD by 10'-0" high shall have supports in accordance with Engineering Standard EQ-64 or EQ-68. 2. Rigid insulation or dished heads of vertical vessel shall have supports in accordance with Engineering Standard EQ-64 or EQ-68. 3. Rigid insulation installed on horizontal vessels shall be supported in accordance with Engineering Standard EQ-69. 4. Rigid insulation installed on dished heads inside of skirts shall be supported in accordance with Engineering Standard EQ-64 or EQ-70. UCC 002857 STANDARD CMCMCAU AMD IA*TICI CHAPTER XII APPLICATOR TRAINING PAGE 254 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF*H0?T TRACER SYSTEMS GENERAL PREPARATION OF INSULATION SYSTEMS - Contd Supports r Contd 5. Rigid insulation installed on bottom head of large high temperature vessels shall be supported by rectangular pins spaced as shown in Engineering Standard EQ-67. 6. Where sprayed asbestos insulation requires support, it shall be supported by straight pins and clips or split pins. These are shown on Figures XI-5 and XI-6, Chapter XI. 7. Rigid insulation installed on high temperature spheres shall be supported by straight pins and clips. 8. Rigid insulation installed on low temperature spheres shall be supported in accordance with Engineering Standard EQ-66. In most instances, supports are not installed by the insulators. The supports are the base from which insulation starts. If this base is not correct, the insulation application is not correct and the probability is that a failure will occur. Thus, it is essential that the insulator knows what supports are required and insists that these be provided so that he can install a good insulation system. Types of Tracing System Traci ng systems are systems using pipe, tubes, coils, or electric coble attached to the outside of equipment or pipe to heat or cool that equipment or pipe. These can be installed in several ways, and may employ various mediums to supply refrigeration or heat. Cooling medium to reduce temperature of coils, pipe or tubes may be brine or other refrigerant. Heating medium to raise temperature may be steam, hot vapor, hot liquid or electricity. In the case of where steam, vapor or liquids are used as the heating medium, the tracers used may be plate coils, tubes or pipes. Where electricity is used as the heating medium, the tracers are electric cables or electric strip attached to the equipment or pipe. Installation of these various tracers to the equipment, or pipe, is by various methods depending upon the need. UCC 002858 STANDARD Ot&ftCAU fLAJTO CHAPTER XII APPLICATOR TRAINING PAGE 255 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS ~------------------------- And APPLICATION OFTTEaT TRACER SYSTEMS GENERAL PREPARATION OF INSULATION SYSTEMS - Contd Air Convection Tracer System - Piping Tracers may be installed as a single or multiple system, however, multiple tracer air convection systems cannot be economically justified as a single system connected by heat transfer cement is less expensive to install. Thus, air convection systems are limited to one single parallel tracer. The air convection system functions by heating the air in the annulus space between the pipe and the inside of the insulation. This system is sufficiently effective to be used where it is only necessary to maintain the pipe temperature at a considerable lower temperature than the steam. There are two methods of installing air convection traced systems. One is to wire the tracer tubing to the pipe and the other is to hold the tracer from the process pipe with spacers then secure in position with straps directly over the tubing at the spacers. These two systems are shown in Figure XII--1. The use of spacers are necessary when the tracer line is at a temperature which might cauye degradation of the process material and direct contact to the process line might cause excessive spot temperatures. Another instance when the spacers are required are when tracers are applied to aluminum lines. When aluminum pipe it to be traced, the piping must be separated from the tracer assembly by not less than two wrappings of glass cloth tape applied to the line. Care must also be taken that the tracer line does not contact the aluminum process line at any point. Where a tracer may touch the aluminum line between supports, the line must be wrapped with glass to prevent this contact. Manner of installing steam tracers is shown in Standard P-140. Recommended numbers of feet of tubing for tracing valve bodies is shown in Table XII--1. HEAT TRANSFER CEMENTED TRACER SYSTEMS - PIPING Surface Preparation Where tracers are thermally connected to pipe with heat transfer cement, proper surface preparation of the surfaces, to which the tracer system is to be applied, is of utmost importance. The proper functioning of the systems depends completely upon the obtaining of a thermal and a mechanical bond between the surface and the heat transfer cement. For this reason the surface treatments of the metal surfaces as listed below must be followed with extreme care: Carbon Steel Pipe operating at temperature above 150 F shall be cleaned of all scale. UCC 002859 STANDARD OltWCAU AIO nASTO CHAPTER XII APPLICATOR TRAINING PAGE 256 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS End APPLICATION OF~HlAT TRACER SYSTEMS Spocers shell be locoted of top V'cireumftrerttlol butt joints 1 1 ' > ;3= "T Insulotlon strop Tracer Process line Spacer - Strop - -Thickness T, as specified L i i i - Thickness T, os specified * Pipe insolation Tracer with Spacer Tracer - i Qi i Wlre- Process fine N-------Pipe insulation Tracer without Spacer Application of Insulation to Steam Traced Lines Figure XIM UCC 002860 CHAPTER XII ENGINEERING STANDARD P-140 UCC 002861 STANDARD CHCJMCALS KASTO CHAPTER XII APPLICATOR TRAINING PAGE 258 APRIL 1970 XU aluminum tubing tracers shill be iMUlitwl from system componeotji of other materials by Inserting a stainless steel connector at all points where the alumi num tubing connects to components of other material!. NOTE: Slse of tracer (3/8-in. OD or 5/8-in. OD), material of tracer (copper, stainless steel, or aluminum), and type of tracing system (spaced or cemented) shall be as spec ified on the steam tracing drawings. Nominal size, thlclmess, end specification of insulation for traced line shall be as specified in the insulation schedule. Insulation for steam supply and condensate lines that do not have line numbers shall be as specified on the steam tracing drswings. All steam tracing is shown diagrammatical^ on steam tracing drawings with symbols having the following mooning*. 1 Steam Tracer Steam Feed -X------- > Steam Condensate fcl Connector (or coupling) 1/2-in. IPS to OD Tube 'Union Tee for OD Tube prl Steam Trap Shop-fabricated piping Is to be steam traced shall be supported as shown or specified on the piping draw ings. Field'fabricated piping that Lsto be steam traced, and for which supports are not detailed on tits piping drawings, >*!! be supported in accordance with Stand ards P-77 or P-81, or as otherwise necessitated by lob conditions, Lines less than3/4-in. ODmay be supported by cradles as shownon Standard P-82, Except for lines less than 3/4-in. OD, methods of support that would impofce a load on the insolation or tracer shall not be used. Steam tracer tubing shall extend beyond pipe Insulation only far enough to feed and condensate line con nections. Fittings shall be used only at beginning and end of tracer,, at branches, and at ends of standard lengths of tubing. Changes is direction shall be made by tending the tubing. Tracer *htny shall be Its,tailed parallel to, and along the top of the line being traced. REFERENCES: Steam Tracing System ---Insulation Sixes and Assembly Dimensions................. ............................. Std P-140A Spaced Tracer Data.................................. Std P-141 Cemented Tracer Data ........ Std P-142 *Dof not use aluminum tubing at direction changes of 00 degrees or more. Where such changes occur at intervals of 20 feet or less, use stainless steel throughout. For intervals greater than 20 feet, make the direction change with stainless steeltubing, and uaea stainless steel tubfogunion with analuminum elseveiteach joint, Idstailed so that aluminum connects to aluminum. MATERIALS FOR STEAM TRACING SYSTEM3 ITEM Tracer Tubing COPPER STAINLESS STEEL ALUMINUM* ASTM B88 Type L annealed copper tube ASTM AZSS TP304 Stainless Steel tube In 60-ft coils (3/8-tn. OD x .030-in. for use In steam service. Flaring Test thk. or 5/8-in. OD x .040-In. thk) (Section 8) it required and good bending properties nre necessary. (3/8-In. or S/B-ln. OD x . 835-in. thk) 5050-0 Aluminum Alloy, Alcoa "Uti11tube", or approved equal. [3/8-ln. OD x .035-In. thk or S/8-in. OD x .049-in. thk) Fittings for Tracer (Connectors, Unions, Tees, etc) Brass. Ferrule-type with cutting edge. (Imperial HI-Seel", Crawford "Swagekkn, or approved equal.) AISI Type 316 Stainless Steel, Ferruletype with cutting edge. (Imperial "Hi-Seal", Crawford "Swagelnk", Parker "Ferrulok", or approved equal) Ferrule-type with cutting edge (Imperial "Hi-Seal", Crawford "Swagelok", Parker ,rFemilok", or approved equal). Connectors (IPS to OD) shall be AISI Type 316 stainless steel, all other fittings shall be aluminum alloy. Spacers 1 Per this Standard Per this Standard Per this Standard Straps 11/2-ln. wide x .020-In. thk soft annealed stainless steel (any 18-8 type) straps B with double pronged clips. 1/2-ln. wide x . 034-in. thk aluminum alloy straps with double pronged clips. I stainless steel (any 18-8 type) wire. Steam Traps Size, manufacturer and model number as specified on steam tracing drawings. Steam Supply Header and Feed Lines, and Valve and Piping Specification as called for on steam tracing drawings. Steam Condensate Lines Heat Transfer Cement Thermon Manufacturing Company, Houston, Texas, or approved equal, PAGE 2 ENGINEERING STANDARD P-140 UCC 002862 r STANDARD r CHAPTER XII APPLICATOR TRAINING PAGE 259 APRIL 1970 r GENERAL PREPARATION OF INSULATION SYSTEMS AND r APPLICATION OF HEAT TRACER SYSTEMS r i COVERAGE FOR VALVES i FEET OF TUBING REQUIRED VALVE SIZE TUBING SIZE l/2 5/a i 2---------3 /------ 2 2" 3--------- S 2*2-3fe [ 3" 4--------- 7 3k-4k 4" 6------- 10 S------7 4`/2-sk 3,/2-4l/2 i 9---------IS 7------ II S------9 4 ------8 8" 12------20 9 -- IS 7----- 12 6 IQ to" IS-------25 10 -- 20 8----- 14 7----- 12 i 12" 13-------30 IS-----25 12--20 8----- 13 m" 2!-----3S 16 -- 28 12 -- 20 i 16" 24 -- 40 20--32 16--25 18" 27-- 4S 24 -- 35 20--30 l 20" 30 --SO 2S-40 20-35 24" 36 --GO 30--50 25 -- 40 30" 45 -- 7S 40--60 35--50 L 36" 54 -- 90 4S-- 70 40 -- 60 I Table XI1-1 f I I UCC 002863 T STANDARD CHAPTER XII APPLICATOR TRAINING PAGE 260 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS . AND APPLICATION OF HEAT TRACER SYSTEMS HEAT TRANSFER CEMENTED TRACER SYSTEMS - PIPING - Contd Surface Freporotion - Contd rust, dirt, or oil. These should be removed by wire brushing and suitable solvents. All mill varnish or protective organic coating shall be removed with suitable varnish strippers. Carbon Steel pipe operating at temperature below 150F must be sandblasted and coated with inorganic silica zinc coating in accordance with UCC Coating Specification. Exception is where existing pipe which has been previously painted, the area to which tracer is to be installed should be with varnish strippers. After tracing and cement is installed paint shall be touched up. Stainless Steel pipe at all operating temperatures shall be cleaned of all dirt and oil. Backs of flanges and six inches on either side of welds shall be coated with silicone graphite coating in accordance with UCC Coating Specification. Due to process or atmospheric conditions it is sometimes necessary to protect the entire line with the coating. Such shall be done where specifically specified. Aluminum piping should be cleaned of oil, dirt and grease. When water mix heat transfer cement is to be used, the surface in contact with the cement must be coated with an aluminum primer (ALP). Resin heat transfer cement requires no primer. The surfaces of galvanized steel pipe, copper pipe and tubing must be cleaned of dirt, grease, oil and other contaminates. Installation of Tracers The general installation of the tracer tubing is done by pipe fitters and the electric tracers by electricians. The final securement and thermal bonding is to be done by the insulators. Types of Heat Transfer Cement Heat transfer cements are a family of products designed to conduct heat from a source to a point of use. Each particular heat transfer cement is designed for a particular set of conditions. Some of the conditions affecting the selection are (1) Source temperature, (2) heat source medium, (3) type of tracer, (4) metal or surface coating on tracer and process pipe to which it is attached, (5) atmospheric or process contamination, (6) application temperature, required physical characteristics, (8) curing requirements, (9) differential expansion and e ongotion requirements, (10) method of application, (11) overall heat transfer characteristics. UCC 002864 STANDARD CMEMCAL AM) PLASTICS CHAPTER XII APPLICATOR TRAINING PAGE 261 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS - AND APPLICATION OFTTESt TRACER SYSTEMS HEAT TRANSFER CEMENTED TRACER SYSTEMS - PIPING - Confrd Types of Heot Transfer Cement - Contd As the material is selected to fulfill these requirements, care must be taken that the heat cement specified is the one used. Of this family of heat transfer cements, basically, there is the water mixed types and the resin types. These types of heat transfer cements and their basic properties and limitations are shown in Figure XII--2. Because of the differences in the cements and installation requirements, several systems of application are required. Two systems are used for the installation of water mixed heat transfer cements. One is by trowelling into position, completely covering the tracer and bonding it to the pipe. With this system care must be taken to press the cement tightly between the tracing tubing (or electrical tracer) and the process pipe. The cement must cover the tracer by 1/4", This 1/4" coverage is required to ensure that the mechanical strength is sufficient to withstand the force exerted by the expansion of the tracer tubing. Base of the cements in contact with the process pipe must be a minimum of three times the outside diameter of the tracer. This configuration is shown as Section 1 in Figure XII-2. The lineal feet per gallon, per tracer is given in Table XH-2. The other system is to install the water-mix heat transfer cements with metal channels. These channels may be factory filled or they may have to be filled by trowel at the time of installation. The filled channels are pressed over the tracer and secured in place by straps. This installation is shown in Figure XII--3. Application arrangement of multiple systems are shown in Figure XII-4. Lineal feet coverage of water mix cement is shown in Table XII-2. This system should be used where pipe cannot be properly cleaned. Both systems can be used for either steam or electric tracing however, it is advisable to use the metal channel system for all electrical traced systems and critical steam traced systems which are bonded to the process pipe or equipment with water-mix cement. Like the steam tracing which is installed by the pipe fitters, the electric tracing system is installed by the electricians but cement bonding and final securement is done by the insulators. The installation of electric tracing on pipe and fittings are shown in Figure XII-5. UCC 002865 STANDARD ohbocmj um nuro GENERAL PREPARATION OF INSULATION SYSTEMS XFfij -- APPLICATION OF HEAT TRACER SYSTEMS HEAT TRANSFER CEMENTS CHAPTER XII APPLICATOR TRAINING PAGE 262 APRIL 1770 GENERIC 1 TYPE 1 Emulsion Mastic NO. SHELF LIFE STORAGE "Std" 1 Yr Store Above 32F INSTALL. CROSS SECTION Sec. 4 or Channel APPLICATION MINIMUM AMBIENT TEMP F HAZARDS CURING Alkaline * Keep Away Heat 160 to 33F from Eyes 212 4 Hour* SOLVENTS FOR CLEAN UP SERVICE TEMPERATURE F CURED Continuous intermi ttent MATERIAL MIN. MAX. MIN. MAX. Soap and Water Hand Solid 32 600 -320 750 Emulsion Mastic Solvent | Rejin Solvent Resin T-63 1 Yr Store Above 32F T-B5 60 lo 90 Day. Refrig. Below 40F T-80 60 lo 90 Ooyj Rcfrig. Below 40F See. 1 or Channel Sec. 2 Sec. 2 33F 70F or With Heated Gun 40F Two-Component Resin T-802 1 Yr Ordinary Sec. 2 33F Resin T-5 1 Yr Ordinary Sec. 3 33F Alkaline Keep Away From Eyes Heat 160 to 212 4 Hour* Soap and Water Hard Solid 32 1250 -320 1250 Sticky Weor Gloves Sticky Wear Glove* Toxic to Skin Wear Glove* Sticky Wear Glovet None Protect From Rain MEK Toluene Turpentine None Protect From Roin MEK Toluene Turpentine 2-Part Mix Working Time to 2 Hr* TrichJococthane Toluene MEK None Req'd. MEK Toluene Toluene Elastic Solid -200 375 -200 375 Elastic Sol id -200 325 -200 325 Elastic Solid 275 275 Remoins Plastic -200 180 -200 180 * No curing procedure required when imtoiled by channel tyttem Heat Tram. CHANNEL SYSTEM FIGURE XI1-2 TRACER SIZE 3/8 OD 1/2 OD VBOO 3/4 OD 7/BOD CHANNEL DIMENSION ab 7/8 1-3/16 7/8 1-3/16 7/8 I-VI6 1-1/4 1-11/16 1-1/4 1-11/16 UCC 002866 STANDARD CMMCAU AND RtASTlO CHAPTER XII APPLICATOR TRAINING PAGE 263 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS --~ XND APPLICATION OFIhEAT TRACER SYSTEMS TRACER SIZE 1/4 OD 3/16 OD 3/8 OD 1/2 OD 5/8 OD 3/8 OD 1/2 OD 5/8 OD 3/4 OD CEMENT COVERAGE PER SINGLE PARALLEL TRACER WATER-MIXED HEAT TRANSFER CEMENT TROWELLED ON PROCESS LINE SIZE 1/2" through Flat 1/2" through Flat 1/2" through 1-1/4" 1-1/2" through Flat 1/2" through 1-1/4" 1-1/2" through Flat 1/2" through 1-1/4" 1-1/2" through Flat FEET OF TRACER PER GALLON 50 49 45 48 30 33 23 28 IN METAL CHANNELS 1/2" through 2" 2-1/2" through Flat 1-1/2" through 2" 2-1/2" through Flat 1-1/2" through 2" 2-1/2" through 2-1/2" 4" through Flat 37 to 41 34 to 37 43 to 47 40 to 43 44 to 48 39 to 32 28 to 30 TABLE XU-2 UCC 002867 STANDARD OCMKAL* AM) PlASTICS CHAPTER XJI APPLICATOR TRAINING PAGE 264 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF HEAT TRACER SYSTEMS CHANNEL SYSTEM FOR INSTALLING HEAT TRANSFER CEMENT Figure XII-3 UCC 002868 STANDARD CMEMCALft AM> PLASTO CHAPTER XII APPLICATOR TRAINING PAGE 265 APRIL 1970 ' ----gg. i i GENERAL PREPARATION OF INSULATION SYSTEMS ------- - And APPLICATION OF HEAT TRACER SYSTEMS SPACING OF MULTIPLE TRACERS ON STRAIGHT PIPE FIGURE XIl --4 UCC 002869 STANDARD OOliUUMDnilTO CHAPTER XII APPLICATOR TRAINING PAGE 266 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS And APPLICATION OFTIEAT TRACER SYSTEMS HEAT TRANSFER CEMENTED TRACER SYSTEMS - PIPING - Contd Types of Heat Transfer Cement - Contd Close attention to application of heat conductive cement to the electric and steam tracers on fittings and valves is of utmost importance. Electric traced elbows must have sufficient tracer length so that the equivalent length of traces to surface area is the same as the pipe. On elbows in vertical lines electric tracer must be installed as shown in top left illustration in Figure XII--5. In similar manner, additional tracing length must be installed on flanges as shown in Figure XII--6. Should parts of electric tracers not be thermally connected with heat transfer cement these spots cannot transfer the heat generated to the process pipe. In turn this will cause a tempera ture rise at that spot with the possibility that the temperature may exceed the limits of the cable and will result in a burn-out. Because of their large outside area as compared to pipe valves also require additional tracer length and very careful installation of the heat transfer cement. This additional length of electric tracing required is shown in Figure Xlf-5. The amount of heat transfer cement used to cement traces to the valve body is greater than would be used for equivalent lengths of pipe. The amount of water-mix type heat transfer cement required per valve is given in the Table XIF-3. In summary, insulation specification can only point out the intent. Specifications cannot describe in detail such as was done in this manual. The insulation craftsmen must know and be able to perform the detail installation. To illustrate this fact the manner in which the application of water-mix cement is specified is illustrated in Figure XII--7 and the resin type in Figure XI1--8- It is evident from the preceding that it is impractical to attempt to cover all installation details in an "Insulation" Specifications. HEAT TRANSFER CEMENTED TRACER SYSTEMS - EQUIPMENT Surface Preparation The surface preparation for vessels and equipment which are to have heat cemented tracer systems shall be the same as listed for piping with one exception. This exception is that stainless steel vessels shall be entirely coated with specified protective coating. UCC 002870 r STANDARD r OCMKALS AM) PUSTIO CHAPTER XII APPLICATOR TRAINING PAGE 267 APRIL 1970_________ r GENERAL PREPARATION OF INSULATION SYSTEMS AND r APPLICATION OF HEAT TRACER SYSTEMS r i i i i [ i i HZ' Ml ELECTRIC KEATER ON i PIPE RUN WITH 90* ELBOW f/ Form c loop and wrap if \ i! \\ Ml cable around at // CZ / \ Place bends.'; a* cIom to /: flange at possible v, (Sown ;/ V Place bands;/ os' close to flange at !> possible ! Ml ELECTRIC HEATER Ml ELECTRIC HEATER APPLIED Ml ELECTRIC HEATER * APPLIED TO CHECK VALVE TO GLOBE OR GATE VALVE APPLIED TO ROTAMETE r Ml ELECTRIC HEATER INSTALLATION DETAILS Figure XII-5 UCC 002871 STANDARD CMCJflCALA AMO PLAfTia CHAPTER XII APPLICATOR TRAINING PAGE 268 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF HEAT TRACER SYSTEMS Place bands as close Ml ELECTRIC HEATER ON PIPE FLANGE 2" AND SMALLER Ml ELECTRIC HEATER ON PIPE FLANGE LARGER THAN 2" APPLICATION OF HEAT TRANSFER CEMENT TO PIPE FLANGE ELECTRIC HEATER FIGURE XII-6 UCC 002872 T STANDARD T OKWCAU MB n.UT*3 CHAPTER XII APPLICATOR TRAINING PAGE 269 APRIL 1970 w I GENERAL PREPARATION OF INSULATION SYSTEMS And T APPLICATION OFHEAT TRACER SYSTEMS 1 CEMENT COVERAGE FOR BODY OF VALVE 1 VALVE 1 SIZE NPS 1 1-1/2 2 3 14 6 8 1 10 12 14 1 16 18 20 1 24 30 36 1 GALLONS OF WATER-MIX HEAT TRANSFER CEMENT PER VALVE 0.36 0.43 0.71 1.00 1.43 2.00 2.50 3.00 3.50 4.00 4.50 5.00 6.00 7.50 9.00 1 1 i m 9 TABLE XII--3 9 m r UCC 002873 STANDARD OCMCAU AM> PLASTICS CHAPTER XII APPLICATOR TRAINING PAGE 270 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF HEAT TRACER SYSTEMS Scroll Process tine -1/4" min Heot transfer cement Large Process line Straight Pipe Tracer Heot transfer cement Close Wrapped Tracing Application Of Water-Mix Heal Transfer Cements To Pipe Figure XI1-7 Figure XI1-8 UCC 002874 1 STANDARD cmbucals p\-*rna CHAPTER XII APPLICATOR TRAINING PAGE 271 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS ------------ - AND APPLICATION OF"hIXT TRACER SYSTEMS HEAT TRANSFER CEMENTED TRACER SYSTEMS - EQUIPMENT - Contd Installation of Tracers Tracers should always be installed in hair-pin fashion rather than completely encircle the vessel. Reason for this is that when tracers are in a complete circle the expansion causes the diameter of the circle to become larger. This enlargement of the circle cannot be restrained by the bond and tensile strength of the heat transfer cement. When installed in parallel hair-pin fashion the extensibility of the cement is sufficient to allow linear move ment without loss of bond. Proper installation is illustrated in Figure XII--9. Application of Heat Transfer Cement The application of both the water-mix and resin type cements in vessels and equipment shall be the same as given for piping. Plate Coils Plate coils are made for the heating and cooling of vessels. These also should be thermally attached by heat transfer cement. The surface preparation at the area of installation of plate coils should be identical with those already listed. Because of the area involved water-mix cements are not satisfactory for the application of plate coils. Moisture towards the center would be difficult to remove even after long periods of airing. For this reason a special heat transfer cement is used for the bond of plate coils to vessels. This is a resin type, named T-5. Pfate coils can be obtained with heat transfer cement already applied. In such installations clean properly treated surfaces to which the coil is securely attached by bands, straps, bolts or studs, is all that is required. Where plate must be coated with the heat transfer cement its surface must be cleaned and coated as previously described. The heat transfer cement should be 1/16" to 1/8" thickness between the two surfaces, with no voids. Installation of plate coil to vessel is shown in Figure XII-10. UCC 002875 STANDARD oiEMCAU M> n.una CHAPTER XII APPLICATOR TRAINING PAGE 272 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS ARd APPLICATION OF HEAT TRACER SYSTEMS CEMENTING DETAIL Figure XII-9 UCC 002876 STANDARD HglfYll 1 AND hJkJTC CHAPTER XII APPLICATOR TRAINING PAGE 273 APRIL 1970 GENERAL PREPARATION OF INSULATION SYSTEMS AND APPLICATION OF HEAT TRACER SYSTEMS INSTALLATION OF PLATE COIL TO VESSEL Figure XII -- 10 UCC 002877 STANDARD CHUCAU AMO PLASTICS CHAPTER XIII APPLICATOR TRAINING PAGE 274 APRIL 1970 APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVED GENERAL Application procedure of Insulation for hot service depends upon the type of insulation. Soft flexible materials are installed in a different manner than rigid materials. For this reason it is necessary to discuss the installation as it applies to each particular type of insulation. EQUIPMENT Supports This type of insulation is supported by rings attached to the vessels. The only exception is where rigid insulation is installedon spheres it is secured by pins and speed clips. Surface Preparation Surfaces to be insulated should be properly cleaned. Painting of carbon steel vessels under the insulation is only required where vessel temperature is less than I50F or where it might be expected to be out of operation for relatively long periods of time. Stainless steel vessels and equipment should be coated with Thermalox No. 70 in accordance with UCC Coating Specifications prior to application of the insulation. The surfaces of vessels or equipment of aluminum, copper, or galvanized steel must be cleaned of all dirt, grease, oil and other contamination prior to application of the insulation. Application of Insulation The temperature, size, and shape of the equipment also affects the manner of installation. The service temperature of equipment dictates the amount of dimensional change which will occur when the vessel is placed in service. Size and shape affects the method of supporting and securing of insulation so that it remains in position, and intact. On cylindrical vessels less than 400 F service temperature and less than 8 feet in diameter, rigid block insulation can be applied directly to the vessel surface. Insulation block should be properly shaped to curved sectors to fit contour of the vessel. Base on first course of block should rest firmly on support so that all lateral joints run in parallel line with center of the vessel. The first course shall have alternate half blocks so that end joints are in staggered position. The blocks shall be secured in position with strap, pulled taut and fastened together with two-pronged dip. This installation is illuetrated in Figures Xlll-l and XIII-2. Where the cylindrical vessel is greater than 400F service temperature or greater than 8'-0" in diameter, a 1" thick cushioning blanket must be installed over the entire surface of the vessel prior to the installation of the rigid block. The rigid block should be formed to be two inches UCC 002878 STANDARD naTnii urn n imn APPLICATION - RIGID INSULATION ----- high TEMPERATURE s'ERVtcg CHAPTER XIII APPLICATOR TRAINING PAGE 275 APRIL 1970 Block Insvlotion fitted Id heod end secured with strops. P/wide o coble ring of twisted SfainUw Steel wire around top center nozzle, when required, to onehor strops. Finish os specified Expansion joint in occordonce with Figure 23-HS5-9 Curved Sector Insulotion Support in occordonce with UCC Std EQ-64 or EQ-A8, Block Insolation fitted to head ond secured with strops ottoched to Insoiotion Support, or by wires secured to pins installed in accordance with UCC Std EQ~67, Figure XIII--1 Stainless Steel Insulation strop os specified insulation applied with tightly butted joints Insulation Support in occordonce with UCC Std EQ~d4 or EQ-68. Squor* Insulation Slocks NOTE: A floating ring shall be installed around bottom nozzle to provide anchorage far insulation straps* Figure XIII--2 UCC 002879 STANDARD OieMlCALS ftASTICS CHAPTER XIII APPLICATOR TRAINING PAGE 276 APRIL 1970 EQUIPMENT - Contd APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE Application of Insulation - Contd greater in inside diameter than the outside diameter of the vessel shell to allow for the increase in vessel diameter when it is heated. When vessel is heated and expands, the cushion blanket is compressed, allowing the outer diameter of the rigid insulation to stay the same. This is illustrated in Figure XJII-3. The vessel also grows in length as it is heated. For this reason, it is necessary to allow for this change in dimension by providing slip joints in the insulation on vertical vessels. Slip joints at a vessel flange and Insulation supports are shown in Figures X f 11 --4 and Xllt-5. When the vessel expands, its change in dimensions causes the nozzles and pipe connections, on the cylindrical sides, to change location in relation to the cylindrical side wall insulation. If the insulation is secured tightly to the nozzle and to the side wall, a break must occur. For this reason, it is necessary to allow for this differential change. This is accomplished by the use of oversize flange covers which will allow movement. These are shown in Figures XUI-6 XIII-7. Flat surfaces such as large ducts which operate at high temperature present a major problem of support and securement of insulation to prevent expansion caused opening of joints. No truly good manner of installation has ever been developed. On these flat surfaces the insulation must be secured to the surface itself. As this surface expands, the movement is transmitted to the insulation block and will cause opening of the butt joints. On very high temperatures it is desirable to use multi-layer broken joint construction to minimize heat leak. On the outer surface of either single or multiple layer block, wire netting should be installed, over which 1/2 inch thick insulation cement is troweled to a smooth, even surface. The insulation cement reinforced with wire netting has more elasticity than rigid block; therefore, it has a tendency to elongate as the metal surface elongates. Such an application is illustrated in Figure XJII-8. Block insulation which terminates at any location should be tapered to provide water shed, or, where it terminates at a fire-proofing or base of equipment, it must be sealed off to prevent the entry of water. Such terminations are shown in Figures XI1I-9, XIH-10, and Xlll-01. PIPING Surface Preparation Surface preparation of piping shall be identical to insulation except stainless steel pipe shall be coated only behind flanges and elsewhere as specifically specified. UCC 002880 STANDARD oACiU u*m APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER Xlll APPLICATOR TRAINING PAGE 277 APRIL 1970 Difference is taken up by compressing cushion blanket USE OF CUSHION BLANKET UNDER RIGID INSULATION Figure Xlll--3 UCC 002881 Si STANDARD li euuuaiepunia APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE Finish, as specified Vessel woil - PVA mastic Stainless steel skewers Stainless steel pins 2-in. min CHAPTER XIII APPLICATOR TRAINING PAGE 278 APRIL !970 Slip joint Insulation support, (see UCC $td EQ-64 or EQ-68) Stainless steel skewersInhibited calcium siticote insulation 4-In. min Insulation strop (tight fit) ) T min Stoinless Meet sheet (0.010-in. thick) Insulation strap (snug fit) Stainless steel sheet. (0.010-in. thick) Insulation strop (tight fit) PVA moStic under SS sheet Heavy fillet of mostie Thickness UT" os specified Application of Slip Joint ot Vessel Fionge Figure XI11-4 Stainless steel pins Insulation support (UCC Standard EQ-64 or EQ-6&) Vessel shell Fill joint with white glass wool Stainless steel pint NOTE: Slip joint not required ot support directly obove the bottom head. Weather barrier, os specified Insolation strap over pins Weather borrier seal to sleeve Slip joint, stainless steel sleeves (O.OHMn. thick x 12-in. wide) Weother borrier teal to sleeve Insulation strap over pins Thickness "7" as specified Application of Slip Joint to Vessel Wall ot Insulotion Supports Figure XIII-5 UCC 002882 " STANDARD 04JKAU A* nUTTCS APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER XIII APPLICATOR TRAINING PAGE 279 APRIL 1970 Stainless steel skewers Insuioliort strop Strip of white gloss wool blanket wrapped oround pipe Figure XIII - 6 Insulating cement Stainless steel skewersInsulotlon strap Oversize elbow cover - AVvW ESS Oversize pipe insulotlon- Strap---/ Skewers NOTE: Finish not shown. Nozzle Connected to Straight Pipe Insulating cement- Strip of white glass wool blanket wrapped , aroung pipe----------------S *%- Nozzle Connected to Elbow Application of Slock Insulation to tine Nozzles an Vessel Figure XIII - 7 UCC 002883 STANDARD CMDVCM4 Am PLAITKt APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER XIII APPLICATOR TRAINING PAGE 280 APRIL 1970 end 24-In, centers diempnd poftern lor lop . Figure XII1--8. Figure XIII--9 UCC 002884 ECB STANDARD ^^9 ogucn* aw nuna APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER XIII APPLICATOR TRAINING PAGE 281 APRIL 1970 Figure XIII-10 Figure Xlll-Il UCC 002885 a STANDARD OOMCALI AND PlACTt& CHAPTER XIII APPLICATOR TRAINING PAGE 282 APRIL 1970 APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVI& PIPING - Contd Applieotion of Insulation The service temperature of piping not only influences the thickness of insulation to be used but it also dictates the method of installation. As in the case of equipment, the higher the tempera ture the greater the dimensional change of the pipe. For that reason, the manner of supporting the insulotion and the use of insulation covers as slip joints and the proper location of insulation expansion joints are important. With the exception of ball and plug valves and welded fittings on piping 3" NPS and under, all fitting insulation covers should be shop preformed wherever possible. Covers should be fabricated or modeled in accordance with dimensional standards as given in ASTM Recommended Practice C-450. Prefabricated fittings for welded fittings should be installed prior to installation of a straight pipe insulation. Such a prefabricated elbow cover is shown in Figure XIII--1 On vertical pipe lines, 4" NPS and larger, extending more than 15 feet above the bottom elbow, the insulation shall be supported by an insulation support located directly above the elbow. Typical installation is shown in Figure XIII-13. A pipe insulation support shall also be Installed above each pair of flanges or flanged valve in vertical lines. In addition, if vertical pipe extends more than 15 feet, additional supports shall be installed on approximately 15-foot centers to provide for installation of insulation expansion joint. This is also illustrated in Figure XIII-13. Installation of proper insulation expansion joints directly below top elbow of long vertical lines is essential for proper performance of insulation. These expansion joints are formed by leaving a 1-inch open void between the butt ends of the insulation. Depending upon the temperature, this void is packed tight with mineral wool or fiber glass. Over this joint, a slip-type sleeve of 0.010" thick stainless steel jacketing is installed so that when the pipe expands, this void will further open, but will remain insulated by the fibrous insulation which expands as the pressure against it is released. Construction of these expansion joints is shown in Figures XIII-13 and XIII-14. Securement of pipe insulation and fitting covers shall be by stainless steel wire or strap asstated in Chapter XI - Pages 23, 24, 25 and 26. On horizontal piping, an expansion joint shall be installed in each 21 feet of straight piping not interrupted by flanges or flanged valves and insulated with multiple-layer insulation, and each 42 feet of insulated lines with single-layer insulation. These distances should be measured from pipe anchor. UCC 002886 STANDARD OCIKALI MO PLAfTCft APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER XIII APPLICATOR TRAINING PAGE 283 APRIL 1970 ____________ Figure XIII - 12 UCC 002887 STANDARD CMMOU AH> PlAJTiO APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER XIU APPLICATOR TRAINING PAGE 284 APRIL 1970 Pipe ineiletton Thickness "T* os tpeelfii Weather barrier sea! to sleeve Fill joint with white gloss woof Weather barrier seal to sleeve Preformed ell ewer Thickness T os specified finish os specified Stainless steel pins Insulotion strop over pins Slip joint 'Stem less steel sleeves 0.010 in. thick Weather borrier, as specified Pipe insulation Application of Bonded Expended Insulotion to Welded EH with Slip Joint of Top of Verticol Line * Finish as specified Stainless steel pint ' Insulation strop over pins Slip joint * Stainless steel sleeves 0.010 in. thick f r i r r r F r F r l r r r r r Application of Bonded Expended Sflico Insulation to Vertiool tines at Insulotion Supports and Expansion Joints Figure XIII--13 UCC 002888 r STANDARD CHEMICALS AIO PLASTIC APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE CHAPTER XIII APPLICATOR TRAINING PAGE 285 APRIL 1970 Insulation (trap over sleeve Finish os specified...... v Pipe iwulotion- Weather borrier seal to sleeve Insulation strop over sleeve Application of Expansion and Contraction Joint to Bonded Exported Silica Insulation on Horizontal Piping Figure XII1-14 UCC 002889 T STANDARD QCMCM1 AM> ft.Amci CHAPTER XIII APPLICATOR TRAINING PAGE 286 APRIL 1970 APPLICATION - RIGID INSULATION HIGH TEMPERATURE SERVICE PIPING - Contd Application of Insolation - Contd A Flanged fitting insulation cover is installed over adjacent insulation; these too act as expansion joints. A preformed insulation flange cover and flanged valve cover are shown in Figure XIII--15. WEATHER-BARRIER Weather-barrier fittings and irregular surfaces shall be mastic reinforced with Dynel fabric installed in the manner as described in Chapter XXI "Application of Weather-Barriers". Straight pipe and cylindrical sections of vessels should be insulated with mastic reinforced with Dynel or metal jackets whichever is specified. Installation of each should be In the manner described in Chapter XXI. UCC 002890 STANDARD OCMCAU A* H-UTICS APPLICATION - RIGID INSULATION RlGH TEMPERATURE SERVICE1 CHAPTER XIII APPLICATOR TRAINING PAGE 287 APRIL 1970 Application of Bondod Expondod Sillco Inwtotlon to t)n Hong* Figure XIII--15 UCC 002891 STANDARD CMIMOUJ MA PLASTICS CHAPTER XIV APPLICATOR TRAINING PAGE 288 APRIL 1970 APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE GENERAL Application of rigid insulation on low-temperature service is different from that for hightemperature service in that the installation must be constructed to resist vapor migration. This creates a particularly difficult problem because of movement of the surfaces which are insulated. As previously discussed, the migration of moisture vapor to a cold surface where it condenses to water or freezes to ice is difficult to control. If an insulation is not almost completely vapor resistant, then control of the moisture vapor inward depends almost completely upon a vapor-barrier on the hot side (outer surface). Such a vapor-barrier is almost impossible to construct sufficiently tight under field conditions. For these reasons, an insulation which is almost completely vapor resistant in itself is essential to obtain long-lasting low-temperature insulation installations in our type of industrial usage. Cellular glass is the only insulation that does have almost perfect resistance to vapor migration. Thus this discussion is limited to the application of cellular glass for low-temperature service. Although cellular glass is highly vapor resistant, it is important to prevent vapor from migrating through the joints and getting to the inner surfaces of the insulation, particularly where tempera ture alternates between freezing and thawing. This freezing and thawing action will eventually break from cell to cell, causing failure of the insulation. Such action is illustrated in Figure XIV-1. If the exposed layers of cells are filled with mastic which does not freeze, then this action cannot occur. Such mastic-filled cells are illustrated in Figure XIV-2, Such an approach to vopor sealing cellular glass installations on low-temperature surfaces is much more effective than depending upon a thin vapor-barrier on the outer surface. As almost all materials do have some vapor transmission, the greater the thickness of the vapor resistant material, the smaller the amount of vapor migration. To illustrate this, on Figure XIV-3 is shown an external vapor-barrier and a joint seal vapor-borrier. In the case of an external vapor passage of moisture through the 1/8" vapor-barrier allows the vapor to enter the insula tion. However, with cellular glass being a vapor-barrier in itself, the total thickness of vapor-barrier, as illustrated, is 2". When temperatures are sufficiently low to warrant multi-layer construction, the problem of the proper use of sealing mastics becomes very important. Most mastics containing asphalt freeze at -50F. If such a mastic is used below this temperature, it can damage the cellular glass just as much as water freezing into ice. Thus it is necessary to use sealers which do not freeze ot the temperature to which they are subjected. Unfortunately, the sealers which can be used at very low temperatures are most often not as vapor resistant as those which freeze at a somewhat higher temperature. This is why different sealers are used on different layers of cellular glass insulation. UCC 002892 STANDARD Q<Q#CALI AM> PLASTICS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 289 APRIL 1970 CELLS VAPOR MIGRATION THROUGH JOINT BREAK IN CELLS CAUSED BY EXPANSION OF ICE TEMPERATURE OF PIPE OR VESSEL BELOW FREEZING MICROSCOPIC SECTION OF CELLULAR GLASS INSULATION INSTALLED ON PIPE OR VESSEL Figure XIV-1 UCC 002893 STANDARD oonuMUxa APPLICATION - RIGID INSULATION LOW-TEMPERATURE SERVICE CHAPTER XIV applicator TRAINING PAGE 290 APRIL 1970 CELLS OF CELLULAR GLASS INSULATION EXPOSED ON SURFACE- MICROSCOPIC SECTION OF CELLULAR GLASS INSULATION SURFACE PROTECTED BY SURFACE COATING Figure XIV-2 UCC 002894 STANDARD OffiMCAU AW nnUTlO APPLICATION - RIGID INSULATION l6w Temperature SerVic^ CHAPTER XIV applicator training PAGE 291 APRIL 1970 COMPARISON OF LENGTH OF VAPOR TRAVEL THROUGH SURFACE VAPOR BARRIER AND JOINT SEAL Figure XIV-3 UCC 002895 STANDARD CMCtfJCA* * *0 RLASTCS CHAPTER XIV APPLICATOR TRAINING PAGE 292 APRIL 1970 APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE GENERAL - Contd Cellular glass is rigid; thus, it is most important that it be fitted closely and joints made just as thin as possible. Butt ends of insulation should be coated with just sufficient sealer mastic to provide complete seal. Pieces of cellular glass should be installed with all sealed joints pressed tightly together. Cellular glass is more vapor resistant than any available mastic or plastic film; thus, when its joints are sealed; it requires no external vapor-barrier. For this reason, it requires only a weather-barrier for its outer protective cover. The mastic effectively fills the outer layer of cut cells and retards freeze and thaw from weather and serves to protect the insulation from mechanical abuses and ravages of weather. An additional consideration in many items of our Company's process equipment and lines is that these are subject to thawout by the use of hot gas. In most instances, hot nitrogen gas, over 212F, is used to thaw out and clean the equipment and pipe. This heating process causes equipment and pipe to expand. For this reason, the systems designed for our services are designed with insulation contraction and expansion joints. Where metpl^projects through insulation installed on low-temperature surfaces, it will provide a joint^of entry of ice - called ice creep. The formation of ice on the metal will crush any insulation. This is shown in Figure XIV-4. Where it is necessary to have metal projecting through the insulation, such as supports, hanger rods, etc., these must be insulated for a distance outward to protect the main body of insulation. It has been found that if these were insulated out four times the Insulation thickness with one half the thickness of the main insulation, this frost creep would be restricted to practical limits. This is shown in Figure X1V-5. However, when atmospheric temperature is near or lower than freezing, frost will be present where the metal projection extends its protective insulation. EQUIPMENT Supports Rigid low temperature insulation is supported by rings attached to vessels in accordance with the Engineering Standards. Surface Preparation Carbon steel surfaces operating below 0F continuously need not be painted or coated. The surfaces should be clean of mill scale, rust, dirt or other contamination prior to application of the insulation. UCC 002896 STANDARD CMWCAUM9 PU1TO APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 293 APRIL 1970 LOW TEMPERATURE SURFACE NSULATION WEATHER-VAPOR BARRIFR BROKEN BY ICE ZMETAL PROJECTION FROST FORMATION ICE CREEP FORCING BETWEEN PROJECTION AND INSULATION WEATHER-VAPOR BARRIER ICE CREEP ALONG METAL PROJECTION THROUGH INSULATION Figure XIV-4 UCC 002897 STANDARD otaacui mb rutro APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 294 APRIL J970 LOW TEMPERATURE SURFACE INSULATION THICKNESS OF INSULATION, T METAL PROJECTION WEATHER-VAPOR BARRIER APPLICATION OF INSULATION TO METAL PROJECTION ATTACHED TO LOW TEMPERATURE SURFACE Figure XIV-5 UCC 002898 STANDARD gawMwumo APPLICATION - RIGID INSULATION LOW TEMPERATURE Service CHAPTER XIV APPLICATOR TRAINING PAGE 295 APRIL 1970 EQUIPMENT - Contd Surface Preparation - Contd Carbon steel vessels operating above 0F temperature which cycle (hot thawout, etc.) or that are expected to be out of operation for relatively long periods of time should be corrosion protected as called for in UCC Coating Specifications. Stainless steel surfaces should be coated with Thermalax No. 70 in accordance with UCC Coating Specifications. The surfaces of vessels or equipment of aluminum, copper, or galvanized steel must be cleaned of all dirt, grit, oil or other contamination prior to application of the insulation. Preparation for Installation Similar to hot service, the temperature, size and shape of equipment affects the manner of installation. The service temperature (low and high) dictate the amount of dimensional change which will occur. Unless equipment is less than 20 inches in diameter, cushion blanket should be installed prior to the application of the cellular glass insulation. On all equipment operating with a top temperature lower than 350F, a 1/2-inch cushioning blanket shall be applied over the entire surface before application of the cellular gloss insulation. Blanket shall be held in place with a minimum amount of stainless steel wire. Blanket is required under rigid block installed on low temperature to provide a cushion spacer between the vessel that contracts and the cylinder of rigid insulation. The need for the cushion blanket is illustrated in Figure XIV-6 and 6A. On all equipment where top temperature might exceed 350F, a 1-inch-thlck cushioning blanket shall be installed over the entire surface. The cellular glass insulation shall be shop fabricated and fitted to allow 1/2-inch space for the cushion blanket between the insulation and vessel on equipment with top operating temperature less than 350F. A 1-inch space shall be allowed on equipment which has peak temperature above 350F. The base of first course of cellular glass side wall curved sectors should rest firmly on insulation support so that all lateral joints run parallel with center of vessel. The first course shall have alternate half-length blocks so that end joints are in staggered position. All butt edges and ends of formed insulation shall be sealed with a buttered coat of the specified sealer. This coating shall be of sufficient thickness to provide proper adhesion and seal between the individual tightly fitted block. UCC 002899 STANDARD owucau amd h-aitics CHAPTER XIV APPLICATOR TRAINING PAGE 296 APRIL 1970 APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE EQUIPMENT - Contd Preparation of Installation - Contd Multiple layers of insulation should be applied so that the butt joints of one layer do not coincide with those of any other layer- Care must be exercised to make sure that correct sealer is used with each layer. Application is illustrated in Figure XIV-6. Where the contour of vessel permits firm and effective attachment, all layers of cellular glass shall be secured in place with stainless steel strap. Where required, insulation strap shall be anchored to strap anchor angles. Where insulation is applied to dished or elliptical heads in multiple layers, the inner layers shall be held in place with stainless steel strap fastened to the insulation support. Outer layer of bottom head insulation on vertical vessels or heads on horizontal equipment shall be secured by strap to special anchor clips as illustrated in Figure XIV-7. Installation of insulation on flat heads requires that cellular glass flat insulation be used directly on the surface to the thickness required to bring the surface of the insulation flush to the top of the stud bolts. This is followed with the application of the cushion blanket and specified thickness of the insulation. This is illustrated in Figure XIV-8. Expansion-contraction joints must be installed over each insulation support and vessel flange. When the movement occurs where one area of insulation overlaps the other, non-setting sealer should be applied to these over-lapping surfaces. Application of insulation expansion-contraction joint at vessel flange is shown in Figure XIV-9, and joint at insulation support is shown in Figure XIV-10. The change in dimension of a vessel as it expands or contracts changes the relative position of nozzles or pipe connections in reference to the cylindrical insulation of the sides. Space must be provided by the use of oversize flange covers and pipe insulations at the point of connection to the vessel to prevent this movement from breaking the insulation or its seal. The proper applica tion of cellular glass insulation at nozzles or connecting piping is shown in Figure XIV-- 11. Wherever the insulation terminates on low-temperature equipment or vessels, such as on a skirt, leg, support, or cradle, the projecting metal of these should be insulated for not less than four times the specified insulation thickness. The recommended procedures for insulating these are shown in Figures XIV-12, XIV-13, XIV-14, and XIV-15. It is essential that all insulation terminating points be sealed to prevent entry of moisture. UCC 002900 STANDARD Q4CMCAU AW FLAJIK7 APPLICATION - RIGID INSULATION ------- LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 297 APRILJ970____________ _ Vessel Wall Cellular Glass Fits snug at atmospheric temperature Seated Joints Vessel Wall Cushion Blanket Compressed Cellular Glass Seoled Joints Without Cushion Blanket With Cushion Blanket AS INSTALLED AT ATMOSPHERIC TEMPERATURE Vessel Wall Shrinks from insulatioi when reduced in temperature Cellular Glass Pressure causes joint to be broken Pressure from Exterior Without Cushion Blanket Vessel Wall Shrink Cushion Blanket expands in thickness Cellular Glass still equally supported to resist outside pressure Pressure With Cushion Blanket INSTALLATION AFTER VESSEL HAS CONTRACTED DUE TO REDUCTION IN TEMPERATURE Figure XIV-6 UCC 002901 STANOARD --* m.uTO APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 298 APRIL 1970 Figure XIV-6A See Detail "A", anchor clips on J2*n. canton around vassal circumference. Insulation strop (under anchor dip) Insulation strap (o/er anchor clip) CaJIulor glass insulation Double prong clips i-in. dio stainless steel ring around bottom nozxle Preformed insulation cover Cushioning blanket Double prong clip Insulation support (UCC Std EQ-64 or EQ-68) Hord drawn stainless peel onchof clip------s. /--4" x } dotted hole Double prang clip* 0.035" DETAIL "ASecufcment for Cellulor Gloii Iniulotion on Bottom Vettel Head Figure XIV-7 UCC 002902 STANDARD OWtfCAU AM RUSTICS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 299 APRIL 1970 Figure XIV-8 UCC 002903 STANDARD ottmcMS pusna APPLICATION - RIGID INSULATION low Temperature service CHAPTER XIV APPUCATOR TRAINING PAGE 300 APRIL 1970 Figure XIV- 9 Figure XIV-IO UCC 002904 STANDARD CMUNCAS MB PiASTICS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 301 APRIL 1970 UCC 002905 STANDARD C1*CiLI AMO PLASTICS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPUCATOR TRAINING PAGE 302 APRIL 1970 _________ Figure XIV-12 Applicotion of Cellulor Gloss Inflation to Equipmonf Sicirt Figure XIV- 13 UCC 002906 r r r r r i \ \ i L L i i L l l l f STANDARD OtCMtCALS AMO PLAiTO APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 303 APRIL 1970 Weather harrier, as specified Support fug Support beam--/ Heavy fillet of mottle Thickness **F as specified I ^--i-m. dk> red* tack-welded to lugs on oil sides. Insulation to be attached to rods with wire or Insulation itrapi Coat oil joints around steel support with non setting sealer Vessel !' / n/~m **b 5poc* -ah: with Insulation Thickness MF as specified Support Beam eo/er, 4 * T measured from vessel wall Bottom View Section Application of Cellular Gloss Insulation to equipment Lugs and Supporting Steel Figure XIV-14 Weather barrier/ as specified Celtulor glass Insulation Thickness **F as specified- . Coat all joints around steel cradle with non setting seoler Longitudinql Section Section B-B Heavy fillet of mastic Steel cradle Insulate to concrete or four *F min. -- Wood block when specified --A' Coat top of concrete with vapor seol mastic ------------- Section A*A Application of Cellular Gloss Insulation to Equipment Cradle and Concrete Support Figure XIV- 15 UCC 002907 STANDARD awuu in n.wa CHAPTER XIV APPLICATOR TRAINING PAGE 304 APRIL 1970 APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE PIPING Surface Preparation Surface preparation of pipe surfaces shall be same as for vessels except stainless steel pipe shall be coated only behind flanges and elsewhere where specifically specified. Application of Insulation As with equipment, the maximum and minimum service temperatures of the piping, besides influencing the thickness of insulation to be used, also dictates the method of application. The dimensional change of pipe must be considered in design of its support and anchorage. As low-temperature service piping must be insulated to retard the migration of vapor moisture inward, all piping, wherever possible, should be supported by cradles outside the insulation.' Metal connections to the pipe which extend straight through the insulation should be avoided. As the pipe, in most instances, is supported by the insulation and as the change of dimension of insulation, due to expansion and contraction, is different than the pipe, the correct use of insulation expansion-contraction joints is vital to the efficient operation of the insulation. Location and distances between these expansion joints depend upon service temperature and configuration of the piping. Where pipe is subjected to sudden change in temperature or excessive vibration, a cushion blanket should be applied to bare pipe before installation of the cellular glass. Fittings and pipe insulation must be oversized to allow for this cushion where it is required. All fitting, flange, and volve covers should be prefabricated before installation on pipe. These should be of dimensions as given in ASTM Recommended Practice C-450. Prefabricated welded fittings should be installed prior to the application of straight pipe insulation. Typical welded insulation covers are shown in Figures XIV-6 and XIV-17. On vertical lines 4-inch NPS and over, and over 15 feet above the bottom elbow, an insulation support should be installed to prevent all the weight of the pipe insulation from resting on this elbow. A pipe insulation support shall also be installed above each pair of flanges or flanged valve located in the vertical line. Pipe insulation shall be installed in staggered position. All butt edges and ends of both layers (or single layer) of cellular glass insulation should be buttered with joint sealer before application. The joints shall be drawn together when insulation is applied so that only a very thin, vapor-tight, vapor seal coat separates the sections of the insulation. Insulation should be applied with all UCC 002908 STANDARD QWSMCAIS AW) PLASTICS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 305 APRIL 1970 UCC 002909 STANDARD owou ***> hawks CHAPTER XIV APPLICATOR TRAINING PAGE 306 APRIL 1970 APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE PIPING - Contd Application of Insulation joints tightly butted and fitted, to eliminate voids. Large voids shall not be filled with sealer, but should be eliminated by either refitting or replacing the insulation. Any rounded corners on the insulation surfaces shall be trued up before the insulation is installed. Inner layers and outer layers of cellular glass pipe insulation up to 4-1/2-inch outside diameter shall be secured in position with strapping tape. Outer layers of straight pipe insulation, welded fitting covers over 4-1/2-inch outside diameter and all flange (and flanged valve) covers shall be secured in position with 3/8-Fnch stainless steel strap. Location of securement tape and strap on the pipe insulation shall be as shown in Figures XI--13 and XI--14 in Chapter XI. Insulation expansion and contraction joints shall be constructed with the straight pipe insulation so cut and fitted that a 1/2-inch void is left between the butt ends of adjoining runs of pipe coverings. Over this void, a section of pipe insulation shall be installed of equal thickness to the specified thickness. The outer layer of the pipe covering and inner surface of the expansion joint cover shall be coated with non-setting sealer. The expansion joint cover should be installed over the pipe covering sufficiently tight that the non-setting sealer fills the void between the two, but not tight enough to bind. These joints shall be installed in both horizontal and vertical straight run at intervals, as follows: Up to 2-1/2 inches thick insulation - one for each 60 feet. Up to 5 inches thick insulation - one for each 45 feet. Up to 7-1/2 inches thick insulation - one for each 30 feet. These expansion joints shall be located one-half the distance between pipe supports, one-half the distance between points where pipe changes direction, or at the specified distances starting measurement from a pipe onchor. Typical construction of expansion joints for vertical and horizontal lines are shown in Figures XIV-18 and XIV-19. Flange, fitting and valve covers shall be installed over the adjacent pipe insulation. The joint between the pipe covering and these covers shall be buttered and sealed with non-setting sealer to form a slip joint os called for in expansion joints. Where these covers occur where expansioncontraction joints are required, they serve as the expansion-contraction joint. The two halves of UCC 002910 STANDARD 04CMICALS PLUTO APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 307 APRIL 1970 CelMor gloss Insulotion . Figure XIV-18 Surfaces coaled with non-setting sealer before installation Round outside corners Weother borrier, os specified ' Heovy fillet of mottic Application of Cellular Gloss Insulotion to Expansion and Contraction Joint in Horizontal Piping Figure XIV-19 UCC 002911 STANDARD cwcau njatp CHAPTER XIV APPLICATOR TRAINING PAGE 308 APRIL 1970 APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE PIPING - Contd Application of Insulation - Contd the cover shall be cemented together with joint sealer and secured in position with 3/8-inch stainless steel strap. Alt valves shall be packed and filled around valve stem and packing gland assembly with joint sealer to avoid water and vapor entry. A typical flange, flanged elbow, and flanged valve cover are illustrated in Figures XIV-20, XIV-21, and XIV-22. Where pipe must be supported by hangers, the rod should be insulated up to four times the specified insulation thickness to prevent ice creep. This is shown in Figure XIV-23. WEATHER-BARRIERS The cellular glass insulation shall be weather protected with specified mastic reinforced with Dynel fabric in the manner as described in the Chapter on Weather-Barrier application. UCC 002912 STANDARD OOMGAU A* PLASTICS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 309 APRIL 1970 Figure XIV-20 Figure XIV-21 UCC 002913 STANDARD OUMCALS AMD *LMTtCS APPLICATION - RIGID INSULATION LOW TEMPERATURE SERVICE CHAPTER XIV APPLICATOR TRAINING PAGE 310 APRIL 1970 Figure XIV-22 Figure XIV-23 UCC 002914 STANDARD exfuCAift Anna CHAPTER XV APPLICATOR TRAINING PAGE 311 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION MODERATE AND HOT TEMPERATURE SERVICE GENERAL Semi-rigid insulation is most generally mineral fibers bonded together into panels, boards, or pipe insulation. The density and amount of bonding material controls the rigidity. In this Chapter, the method of installation is concerned with a type of material which is semi-rigid, i.e. it is somewhat flexible but does have sufficient strength to maintain its form without support. EQUIPMENT Supports With this type of insulation it may be supported either by support rings, or by pins and speed clips. Where welding is permitted, the insulation may be supported by a flat bar or angle welded to the vessel. Where welding is not permitted, insulation supports must be bolted on as shown in Chapter IX, "Supports and Securements. '* On surfaces where welding is permitted, insulation is frequently secured in position by pins as illustrated in Figure XV-4. Surfaces to be insulated should be properly cleaned and where required should be coated with proper paint or coating material prior to installation of the insulation. Surface Preparation Carbon steel surfaces operating at temperatures below 150F must be blast cleaned and coated with inorganic zinc coating in accordance with UCC Coating Specifications. Stainless steel surfaces shall be coated with Thermalox No. 70 in accordance with UCC Coating Specifications. The surfaces of vessels or equipment of aluminum, copper, or galvanized steel must be cleaned of all grit, oil, dirt or other contamination prior to application of the insulation. Application of Insulation On cylindrical equipment less than 30 inches in diameter, preformed glass pipe insulation of a size to fit the vessel surface is used in place of block. This is installed in the same manner as pipe insulation, discussed later in this Chapter. UCC 002915 STANDARD oicau **> n-mio CHAPTER XV APPLICATOR TRAINING PAGE 312 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION MODERATE AND HOT TEMPERATURE SERVICE EQUIPMENT Cr -:d Application o" Insulation - Contd On vessels larger than 30 inches and up to 30 feet in diameter, the glass block or board should be cut to proper size lagging or curved sectors to fit vessel surface. Vessels above 30 feet in diameter may be insulated by flat board pulled to curvature of vessel by the securement strap. Fibrous glass block for vessel heads should be precut to fit contour of the head. The block or lagging should be applied in staggered position with all joints tightly butted. Multiple layers should be applied so that butt joints of one layer do not coincide with those of any other layer. Application is similar to rigid insulation with the exception that the expansion cushion blanket is not used under the semi-fibrous glass insulation as the insulation is sufficiently flexible to compensate for the circumferential expansion of the vessel. The installation of the semi-rigid insulation is the same as rigid insulation illustrated in Figure XIII--1 and XI11--2 in preceding chapter. Slip joints to compensate for lateral expansion must be installed as shown in Figure XV-1. The insulation should be secured in position by stainless steel straps on 9-inch centers, pulled just sufficiently taut to hold insulation snug to the vessel. Where vessel exceeds 25 feet in diameter, the strap should be "expanded bands" or should have one expander spring installed for every 30 feet of strap. The vessel flanges and manholes, or nozzles, should be insulated with precut covers unless specifically stated to be left uninsulated. The insulation manhole or nozzle covers are illustrated in Figure XV-2. Where block or lagging insulation terminates at any location, it should be tapered to provide water shed and to provide for its proper seal off to prevent entry of water. This taper and seal off Is shown in Figure XV-3. Application - Flat Surfaces Block or board insulation is installed by impaling it on pins welded to the surface to be insulated. The blocks or boards should be installed in staggered position with all joints tightly butted. Multiple layers should be installed so that the butt joints of one layer do not coincide with those of any other layer. UCC 002916 STANDARD OOMCALI AM> PLASTIC* CHAPTER XV APPLICATOR TRAINING PAGE 313 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION MODERATE AND HOT TEMPERATURE SERVICE Stainless steel pirn Insulotfon Jopport --- (UCC Standard EQ-64 or EQ-68) Vessel shell Fill joint with white plow wool Stainless steel pins ------ NOTE; Slip joint not required of support directly above the bottom heod. Weather barrier, as specified fnsufotlon strop ever pins Weather barrier seel to sleeve Slip joint, stainless steel sleeves (0.010-in. thick x I2~in, wide) Weather berrier seal to sleeve Insulation strop over pins H Thickness MT" os specified Application of Slip Joint to Vessel Wall ot Insulation Supports Figure XV-1 Thickness "T" a* specified Heavy fillet of vapor seal mostic Heovy fillet of vapor seal mastic Line Nozzle Finish, os specified Round outside corners /S \ Preformed insulation cover, miter cut ond fitted to vessel covering blind Nozzle Applicotion of Fibrous Glass Insulotion to Horizontal Vestel Notzles Figure XV-2 UCC 002917 STANDARD <CM4 MO RLMTO CHAPTER XV APPLICATOR TRAINING PAGE 314 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION MODERATE AND HOT TEMPERATURE SERVICE Application of Fibrcm Glou Inflation Adjocont fa Uninailoted Flongot Figure XV-3 Figure XV-4 UCC 002918 STANDARD CMMICALS M0 PLASTIC CHAPTER XV APPLICATOR TRAINING PAGE 315 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION MODERATE AND hGt TEMPERATURE SERVICE EQUIPMENT - Contd Application - Flat Surfaces - Contd Pins should be 1/4-inch longer than total thickness of insulation. The pins should be placed so as to provide a minimum of five attachments per block. The insulation should be secured in position by pressing the pin clips over the pins. Clips should be pressed into the insulation just sufficiently to allow pins to be cut off below adjacent uncompressed insulation surface. These depressions at pin and clips should be pointed up flush with insulation cement. This in stallation is illustrated in Figure XV-4. Vessel legs and vessel skirts should be insulated in the same manner as discussed In Chapter XIII and as shown in Figures XIII-10 and Xlll-l 1. The weather-barrier for outdoor service should be either mastic reinforced with fabric or metal jacket for cylindrical section of vessels. Flat surfaces, irregular surfaces, flanges and other fittings, should be protected with mastic reinforced with fabric. Application of these materials is given in Chapter XXI "Weather-Barriers." For indoor applications not subject to wash down by hose or liquid spillage, the equipment and vessels may be coated with bonding adhesive in which glass cloth is imbedded. After this has dried, the entire surface should be coated with PVA finish coating of specified color. PIPING Surface Preparation Pipe surfaces shall be coated and cleaned the same as called for equipment except that stainless steel pipe shall only be coated behind flanges and elsewhere where specifically specified. Application of Insulation The application of straight pipe insulation depends upon the type of outer jacketing or coating which is to be applied as a weather-barrier or indoor covering. When the jacketing is installed separately, the straight pipe insulation should be installed in staggered joint construction. All joints should be tightly butted to eliminate voids. When in sulation with factory applied jacketing is used, it should be installed with each cylindrical section butted tightly against adjacent sections. UCC 002919 T STANDARD qodoli Af puma CHAPTER XV APPLICATOR TRAINING PAGE 316 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION mqderAtTAnp hOt Temperature service PIPING - Contd Applicotion of Insulation Insulation on 4-inch NPS pipe and larger on vertical lines shall be supported by a pipe insulation support located directly above the elbow. A pipe insulation support should be located above each pair of flanges or flanged valve in a line. These are shown in Figure XV-5. With the exception of ball and plug valves and welded and screwed fittings below 3" NPS, all fitting covers should be prefabricated or premolded. These fitting covers should be in accordance with the description given in ASTM Recommended Practice C-450. Prefabricated fittings for welded pipe fittings should be installed prior to installation of the straight pipe insulation. Flanged fittings should be installed after the installation of the straight pipe. Welded and screwed fittings on 3-inch NPS pipe and smaller may be insulated by troweling or palming insulation cement over the fitting flush to the adjacent straight pipe insulation. Pipe covering on piping^jbove 212F and installed in staggered position should have expansion joints installedJn'uninterrupted straight runs exceeding 21 feet in length. Such an expansion joint andjts"details of construction are shown in Figure XV-6. In some instances, a large crack will develop in the pipe insulation after one line is in service, indicating the need for an expansion joint at that location. When this occurs, an expansion joint should be built into the system at that location. Securement of pipe insulation installed in staggered joint construction should be by stainless steel wire on 9-inch centers. Fitting covers should also be secured in position with stainless steel wire. WEATHER-BARRIER Straight pipe insulation indoors with a plastic, glass fiber reinforced, factory applied, fire resistant jacket should be secured in position by adhering the lap down over the adjoining edge of the jacket. In some instances these laps require a lap adhesive; in others, the adhesive is factory installed with release paper over the adhesive. Where this self-sealing adhesive is furnished, the paper should be stripped off the adhesive, the lop set in place at the center, and the lap sealed toward either end by pressing the head with the blunt edge of a knife. The circumferential joints are sealed with butt joint strips furnished with the pipe insulation. Fittings, indoors where no liquid exposure is expected, are finished with bonding adhesive, glass cloth, and PVA finish coatings. UCC 002920 STANDARD CHtWCALS PLAJTH3 CHAPTER XV APPLICATOR TRAINING PAGE 317 APRIL 1970 APPLICATION OF SEMI-RIGID INSULATION MODERATE AND HOT TEMPERATURE SERVICE Finish os specified Stainless Peel pins Inflation strop over pins Slip joint Stainless steel sleeves 0.010 in. thick Application of Bonded Exported Silica Insulation to Veitlcol Lines ot Insulation Supports ond Expansion Joints Figure XV-5 Figure XV-6 UCC 002921 STANDARD otaoCALS amd plastics CHAPTER XVI APPLICATOR TRAINING PAGE 318 APRIL 1970 APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERATE TEMPERATURE SERVICE GENERAL Flexible cellular insulation is a compressible elastic material. Because of these properties it must be installed in a different manner than the rigid or semi-rigid insulations. Because of its flexible nature it can be installed over tubing before the tubing is installed; and where tubing is deflected to fit, the insulation will also deflect without cracking or breaking. When it is secured in position to another surface or to itself, the major means of securement is with contact adhesive. EQUIPMENT Surface Preparation Surface preparation of equipment, vessels, or ducts to which flexible cellular insulation is to be applied is of utmost importance, as satisfactory installation and service depend upon the adhesion bond between the surface and the insulation. Carbon steel equipment, vessels, and ducts must be sandblasted and coated with zinc-silicate inorganic coating in accordance with Coatings Specifications prior to application of the insulation. Stainless steel vessels and equipment must be coated with Thermalox No. 70 in accordance with UCC Coating Specifications prior to application of the insulation. The surfaces of vessels or equipment of aluminum, copper, or galvanized steel must be cleaned of all dirt, grease, oil, and other contaminants prior to application of the insulation. Application of Insulotion Each sheet should be cut to be approximately 1/8-inch longer in each direction than the surface to be covered. The surface to be insulated and the inner surface of the insulation (cut cell side) should be completely coated with contact adhesives. The coated surface should be allowed to dry until it is non-tacky to the touch. The length of drying time will change with ambient temperature conditions. Basically, the lower the ambient temperature, the longer will be the time required for the adhesive to dry to a non-tacky state. UCC 002922 STANDARD AND FUkSTO CHAPTER XVI APPLICATOR TRAINING PAGE 319 APRIL 1970 APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERATE TEMPERATURE SERVICE EQUIPMENT - Contd Application of Insulation - Contd The insulation is positioned so that its edges overlap butting surfaces, or previously installed sheets, by 1/8 inch. The center of the insulation sheet is then pressed to the surface. Working outward, to avoid trapping air, the sheet is pressed firmly to the coated surface. The edges are compressed to take up for the 1/8-inch overlap; the expansion of the sheet will then assure tight butt joints. The joint should then be spread open and, by means of a small brush, contact adhesive applied to the two edges of the butt joint. This will assure that the joint will be firmly bonded with adhesive when the sheet is released to expand back in position. The sheets are then pressed into final complete contact by firmly pressing with a small hand roller. When a double layer of insulation is required, the outer surface of the inner layer and the inner surface of the outer layer of flexible insulation should be coated with contact adhesive then applied as described above. However, the outer layer should be applied so that the butt joints of the second layer do not coincide with those of the first layer. At the termination points and where the insulation butts to metal, exposed cut edges of cut insulation should be coated with flexible sealer and inside corners caulked with this sealer. On square or rectangular ducts, the application method of installing the flexible insulation is the same as described; however, the sequence of installation should be as follows: 1. The insulation should first be applied to the bottom surface,.neatly fitting the width of the duct. 2. The sides of the duct should be insulated next, with insulation extending from the top edge of the duct down over the edges of the bottom insulation to the flat outer surface of the bottom insulation. 3. The insulation should then be applied to the top surface of the duct, extending from outer surface to outer surface of side insulation. The insulation over standing duct seams should be the same as the thickness of that applied to the duct. Illustration of this application is shown in Figure XVI-1. UCC 002923 STANDARD OVUtOkU MOFLASTIO CHAPTER XVI APPLICATOR TRAINING PAGE 320 APRIL 1970 APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERATE TEMPERATURE SERVICE PIPING Surface Preparation Carbon steel pipe in the temperature range up to 150F shall be coated in accordance with the UCC Coating Specifications. Stainless steel piping shall be coated only behind flanges and elsewhere when specifically specified. Aluminum, copper, or galvanized steel pipe must be cleared of all dirt, grease, oil and other contaminants prior to application of the insulation. Application of Insulation on Straight Pipe Flexible foam insulation is furnished in slit or unslit cylindrical shapes to fit NPS pipe up to 5-inch NPS and tubes up to 4-1/8-inch OD. When piping is already erected, the slit insulation is installed by applying the insulation on the pipe. The butt edges are then coated with contact adhesive and held open until the adhesive had dried tack-free to touch. Then the edges are pressed together to form a bond. Around curves in the pipe where the butt joint may hove a tendency to gap, the seam may be pulled tight by a wrapping of pressure sensitive tape until the contact adhesive has an opportunity to set to final bond. All butt end joints should be cemented together in a similarly manner to the longitudinal edge joints. Pipe or tubing above the sizes of available cylindrical sections are insulated with sheet insula tion. The sheet insulation should be cut to fit around the pipe loosely, i.e., without stretching. The pipe and cut side of the insulation should be coated with adhesive and installed in the same manner as described in the "Equipment" section. All butt edges should be carefully sealed. When insulation is installed on pipe prior to erection, the unslit sections are slipped over the pipe. Open ends of the pipe or tube should be closed with plugs prior to slipping the insulation over to prevent mica dust from the insulation from entering the pipe or tube. The insulation should be slightly longer than the pipe or tube surface it is to cover. When the pipe or tube is erected, the insulation should be pushed back 6 to 8 inches from the ends to allow for connection." This is illustrated in Figure XVI-2. After erection, afl butt joints and joints to fitting covers should be cement bonded together. UCC 002924 STANDARD cwmcALi sm rukirta CHAPTER XVI APPLICATOR TRAINING PAGE 321 APRIL 1970 APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERA'tTTEMPERATURE SERVICE Figure XVI-1 Figure XVI-2 UCC 002925 STANDARD OttmCtU AMD PLASTICS CHAPTER XVI APPLICATOR TRAINING PAGE 322 APRIL 1970 APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERATE TEMPERATURE SERVICE PIPING - Contd Application of Insulation on Piping Fitting and Votve Covers As insulation for cylindrical pipe is only available up to 5 NPS and 4-1/8 tube sizes, the number of fittings which can be fabricated from pipe insulation is limited. Those that can be produced from pipe insulation should be in accordance with ASTM Recommended Practice C-450, latest revision. The material is most easily cut by a sharp knife, rather than by a saw. The fitting parts can be cut by a sharp knife, as illustrated in Figure XVI-3. Individual pieces are cemented together with contact cement. Large size fitting cavers shall be fabricated out of sheet insulation cut to fit the valve, elbows, or flanges. The sheet material is installed on the fittings in the same manner as described in the "Equipment" section. Sheets are cemented to the fitting with contact cement and all butt joints bonded together with contact cement. Dimensions for cutting sheet insulation for 90 degree long and short radius elbows are given in Figure XV-4. Supports and Hangers Because of the flexible nature of the insulation, it compresses with load. For this reason when horizontal pipe is supported by cradles, another insulation must be used to support the pipe at the cradles. Rigid urethane foam insulation should be installed between the cradle and the pipe at beam crossings. The rigid urethane should be of sufficient length to extend a minimum of 2 inches beyond both ends of the cradle. Joints between the rigid insulation and the flexible insulation should be bonded with contact adhesive. Pipe hangerswhich connect directly to the pipe should be insulated with pipe insulation for a distance of 6 inches beyond where they project through the insulation. FINISH AND WEATHER-BARRIERS Indoors Where the pipe or ductwork in buildings are concealed in pipe chases or suspended ceilings, the insulation requires no finish or coating. Where exposed indoors, ail equipment should be painted with two coats of vinyl finish of the color specified. Also, ductwork or piping which ore located where subject to mechanical abuse or washing down with water shall be painted with two coats of vinyl finish. Piping and ductwork exposed to view, but not subject to wash down or mechanical abuse, are to be finish painted with two coats of water emulsion PVA paint of color specified. Equipment and piping located outdoors sholl be protected outdoors with mastic reinforced with Dynel cloth of type specified and applied in accordance with instruction given in "WeatherBarrier" Chapter XXI. UCC 002926 T r t i r t T 1 1 l 1 1 1 1 1 * f STANDARD wucnj mo mino CHAPTER XVI APPLICATOR TRAINING PAGE 323 APRIL 1970 APPLICATION OF FLEXIBLE CELLULAR INSULATION MODERATE TEMPERATURE SERVICE Dimension ''A1* is a jab-site measure of the elbow circumference. Nomino! Pip* Six* 5 6 8 10 12 16 IB 20 24 l TABLE FOR DIMENSIONS B AND C Number of Lena Radius 90 ELL Short Radius 90 ELL Segments "B", In. "C\ In. "B", In. -C, In. 3 2-5/32 5-21/32 29/32 4-9/16 4 1-19/32 4-1/4 1/2 3-5/16 3 2-21/32 6-27/32 1-5/32 5-13/32 42 5-5/32 iyi6 3-27/32 6 1-5/16 3-7/16 9/16 2-19/32 8 15/16 2-5/16 13/32 i 1-31/32 6 1-13/16 4-1/2 8 15/16 2-5/16 13/16 3-13/32 19/32 2-19/32 6 2-11/32 5-19/32 1-1/16 4-1/4 8 1-3/4 4-3/32 13/16 3*3/16 8 2-27/32 6-19/32 1-5/16 I 5-1/16 10 2-3/32 4-31/32 1 3-13/16 83 6-13/32 1-29/32 6-1/2 10 2-13/32 5-5/32 1-13/32 4-27/32 B 3-13/32 7-3/16 2-5/32 7-1/4 10 2-11/16 5-13/16 1-19/32 5-7/16 s 3-3/4 B 2-13/32 8-1/14. 10 3 6-13/32 1-13/16 6-1/16 8 4-9/16 9-21/32 2-31/32 9-21/32 10 3-21/32 7-11/16 2-3/16 7-1/4 Dimensions for Opting Flexible Sheet Insulation Figure XVI - 4 UCC 002927 STANDARD OOMfCAL* RUUTKt CHAPTER XVII APPLICATOR TRAINING PAGE 324 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION MODERATE AND HIGH TEMPERATURE SERVICE GENERAL Prefabricated panel insulation is insulation which is affixed to metal panels by the manufacturer. The insulation is semi-rigid fibrous glass and the panels are either smooth or ribbed aluminum sheet. This type of insulation is useful for insulation of vessels over 12 ft 0 in. in diameter, and on flat surfaces, operating above ambient temperatures up to approximately 450F. Due to their construction, the insulation and the weather-barrier must be installed at the same time. For this reason the installation layout, providing proper overlapping of the aluminum facing, or the installation of bottom strips, for rain shield is of upmost importance. The panels can be installed by the use of insulation supports and securement straps, or by the use of studs, nuts and pins. Where welding to vessel is not permitted, securement straps must be used as the method of installation. The ribbed panel facing is furnished in a different size than the smooth panel. Thus, ribbed are made to dimensions to permit overlap of the ribs to form a water barrier and still form standard size insulation dimension of 96 in. x 48 in. The smooth panels are made to a 96 in. x 48 in. dimension and the butt joints are covered with a batten strip. Because of these differences, spacing of securements is also different, thus details of installation of these panels on vessel sidewalls must be described separately. In addition, the panels are installed differently when installed by straps than if installed by studs and nuts. INSTALLATION OF RIBBED JACKETED PANELS TO VESSELS Supports 1. Flat and cone head vessels should have an angle or plate continuously welded to the intersection of vessel head and sidewalls, to provide for insulation securement and water shed. This is shown in Figure XVII-1. Where welding is not permitted, bolted-on support and flashing should be installed as shown in Figure XVII-3. 2. If panel insulation on the sidewall of vessel does not extend to the base of the vessel, an angle or flat bar extending 1/2-inch greater in width than the insulation thickness should be installed around the vessel at the level where the panel insulation is to terminate. 3. Where welding to the vessel is permitted, the panels shall be fastened to the cylindrical section of the vessel by studs, welded to the vessel, that extend through factory-punched holes in the aluminum facing. Dimensions of panel and stud arrangement are shown in Figure XVJI-2. UCC 002928 STANDARD 0<CMCAU ** RtUTO CHAPTER XVII APPLICATOR TRAINING PAGE 325 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION MODERATE AND HIGH TEMPERATURE SERVICE Figure XVIf-l 48" 2i" rr JII i i *Tl- itire -- i -------- H i - 3 -- X" x 3" slotted holes Insulation Threoded stud, Hypolon washer, and nut. Stud Securement t S' ! --4-iM dia hales 1 1 Fastening Sequence 1 1 1* 1 (D Weld middle stud and 1 1 place nut - Panel No. 1 r (5) Weld center top and i 1 L /I /. :--^4--L- ^.. ,, bottom studs and ploce nuts " Panel No. 1 (5) Weld side studs, no nuts Panel No. 1 (4^ Position fonel No. 2 and mcrmnTIT " ! -- Factory mode cuts for remo/ol at facing lops place nuts on side studs (T) Weld rhree center studs and ploce nuts - Panel No. 2 Factory Prepored Panel Weld side studs, no nuts Panel No. 2 Panel Positioning (7) Continue with Panel No. 3 Shell Focing r Arrangement, Positioning ond Securement of Factory Prepared Ponels Figure XVII-2 UCC 002929 STANDARD CHAPTER XVII APPLICATOR TRAINING PAGE 326. APRIL 1970 ______ APPLICATION OF PREFABRICATED PANEL INSULATION MODERATE AND HIGH TEMPERATURE SERVICE Iruuloflon Stcuriwcit ofr Tcp and Sidawoll Wawctioci fWatdfnq ma^p+fmUted) Figure XVII - 3 UCC 002930 STANDARD CHEMICALS AMD flASTlO CHAPTER XVII APPLICATOR TRAINING PAGE 327 APRIL 1970 _________ APPLICATION OF PREFABRICATED PANEL INSULATION ------ MODERAtg AND HIGH TEMPERATURE SERVI^F INSTALLATION OF RIBBED JACKETED PANELS TO VESSELS - Contd Supports - Contd 4. Where welding to the vessel is not permitted, insulation supports must be bolted on as shown in Chapter IX "Supports and Securements." Surface Preparation Due to the type of construction involved this installation is restricted to the insulation of carbon steel vessels. Vessel operating above 0F up to 150F must be painted in accordance with UCC Coating Specifications. APPLICATION - SIDEWALL INSULATION Panels must be installed in vertical position so that their edges are parallel with the center line of the cylindrical section of the tank. If vessel foundation is sloped for drainage, where the panels abut the vessel foundation, their bottom edges shall be cut to the slope of the foundation so that the top edges form a continuous horizontal line around the circumference of vessel. This is illustrated in Figure XVII-4. The arrangement of panels shall be as follows: 1. Cutouts for nozzles, located at the same elevation may be simplified by arranging for horizontal lap to occur at this elevation. 2. The vertical laps between panels should be arranged, where possible, to fall on center lines of nozzles which do not occur at horizontal laps. When the vessel is on a low pad, where the level of rain or water can reach the bottom of the panel, the fibrous insulation should be cut and stripped from the bottom of the first course to an elevation greater than the highest expected water level. In no cose should this be less than 9 inches. This amount of stripped-out fibrous insulation should be replaced with cellular glass insulation of equal thickness and preformed to fit the diameter of the vessel. Where welding is permitted and the panels are to be secured to the vessel by studs, the panels must be positioned in accordance with predetermined reference lines. After positioning the panel in place, a stud shall be welded in the middle hole. The panel should then be secured UCC 002931 STANDARD OftmCALt tJ9 mono CHAPTER XVII APPLICATOR TRAINING PAGE 328 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION MODERATE AND HIGH TEMPERATURE SERVICE APPLICATION - SIDEWALL INSULATION - Contd to the vessel by washers and nuts. After final positioning, additional studs should be welded to the vessel and the panel secured in position. Before the second panel is installed, 2 to 3 inches of insulation should be removed from the panel edge to allow overlapping of the aluminum sheet. A bead of sealer should be applied to the first panel edge at this overlap. The second panel should be positioned, then secured in position as previously described. This procedure is followed around the vessel until first course of panels is installed. "S" clips should be installed on the top edge of the bottom course of panels to support the next course of panels. "S" clips should have sufficient length to provide 2 to 4 inches of overlap, depending upon the panel layout. A strip of insulation, of a width equal to that of the overlap, must be removed from the bottom of the second course panel. The second course panel is positioned with edges lined up with edges of the first course, then secured as previously described. Special care should be taken that no studs go through both sheets of overlapping ends of two courses of panels, as each course of panels must be free of other courses so as to provide a slip expansion joint. Fastening sequence for additional courses is the same as described for the first two courses. Fastening sequence and stud details are illustrated in Figure XVII-2. Where welding is not permitted the panels must be secured to the vessel by strap. These panels should be without factory-punched holes for studs. The first panel should be located and positioned in the same manner as described in the welded stud secured section. Insulation on overlap edge (2 to.3 inches) shall be removed before the panel is installed. As each panel is installed a bead of lap sealer shall be placed between the overlapping faces of the aluminum. Panels are to be held in position by temporary rubber or nylon bands until permanent straps can be installed. The straps should be installed on 24-Inch centers and at various intervals sheet metal screws should be set below the straps, with heads slightly protruding to prevent strap from slipping downward. Vessels over 12 feet in diameter should be strapped with expander strap or with expansion springs installed in each strap. Where springs are used, a spring should be installed in 30 ft of strap. Straps should be tightened to stretch each spring approximately 3 inches. The overlapped rib sections are to be joined together with sheet metal screws on approximately 24-inch centers. On vertical side wall panels "S" clips should be installed on 24-inch centers along top edge of each course of panels to support the next course of panels. Two to four inches of insulation should be removed from the bottom of second, and subsequent courses of panels to provide for overlap. The second course should be positioned, with edges lined up with first course, and UCC 002932 STANDARD oiihcau uc pura CHAPTER XVII APPLICATOR TRAINING PAGE 329 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION ------ MODERATE AND HIGH TEMPERATURE servicT APPLICATION - SIDEWALL INSULATION - Contd with the aluminum jheet supported by the "S" clips. A strap should be Installed at each horizontal overlap, positioned so as to ride behind the front leg of the "S" clip. Straps at mid sections of the panel should be installed as previously described. The overlapped rib sections are joined together with sheet metal screws, but care must be taken that sheet metal screws do not fasten two courses of panels together. Details of installation is shown in Figure XVII-4 and XVII-7. As mentioned, cutouts for manholes and nozzles should be located at the intersection of two panels where panel arrangement makes this possible. Where it is necessary to cut out to fit over a manhole or nozzle, the opening should be closed by one or two sections of panel cut to fit around the nozzle or manhole. These sections should be sealed to the panel facing and secured with sheet metal screws. Cutouts should be cut to fit tightly around base pipe nozzle or the insulation cover on insulated nozzles or piping. The junction must be sealed with mastic to prevent water entry. Details of the application are shown in Figure XVII-5. Roof Application As ribbed panels do not lend themselves for most roof or head applications, these are most frequently insulated with rigid block insulation. On the cylindrical part at the junction of a roof or head with the panel, the thickness of the rigid insulation should be increased to the thickness of the panel insulation plus the depth of the ribs in the aluminum so that a metal flashing can be installed to shed water. This is shown in Figure XVII-3. The installation of the rigid insulation is as described in Chapter XIII - Rigid Insulation. INSTALLATION OF SMOOTH JACKET PANELS TO VESSELS Preparation The preparation for installing smooth panels on vessels is similar to that of ribbed panels except that the dimensions for stud welding are different because battens strips are used on the vertical joints, and that the panels are installed with the long dimension in vertical position. Because it is necessary that battens be stud welded in position and roof or head insulation is secured in position with welded pins and clips, this application is restricted to vessels to which this welding is permitted as indicated in Figure XVII-6. UCC 002933 STANDARD CMCMCAU n^AilO CHAPTER XVII APPLICATOR TRAINING PAGE 330 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION MOdERATE'AND HIGH TEMPERATURE SERVICE Figure XVII-4 UCC 002934 STANDARD Q4WCALS AMD PLASTIC* CHAPTER XVII APPLICATOR TRAINING PAGE 331 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION ------ MODERATE ANd HIGH TEMPERATURE SERVICE" INSTALLATION OF SMOOTH JACKET PANELS TO VESSELS - Contd Preparation - Contd The studs to attach the batten strips should be installed in vertical rows, spaced to circum ferential dimensions of 96 inches- The vertical spacing should be as follows: First row - three inches above base or support. Additional rows - as shown in Figure XVII-7. Top row - three inches from top angle or support. These should be arranged to have centers of largest number of nozzles fall on edges or ends of panels. Details of stud spacing is shown in Figure XVII-7. APPLICATION - SIDEWALLS Panels must be installed in a horizontal position so that their end edges are parallel with the centerline of the vessel. If vessel foundation is sloped for drainage, where the panels abut the vessel foundation, the bottom edge should be cut to slope off the foundation. Where vessel is on a low pad where level of rain or drainage water con reach bottom edge of panel, the fibrous glass insulation should be removed from the first course of panels to an elevation greater than the highest expected water level. In no case should this be less than nine inches. The stripped out fibrous glass insulation is replaced with cellular glass insulation of the same thickness preformed to fit the shape of vessel. The fibrous glass aluminum panels are to be positioned so that alternate rows of studs are between ends of panels and other rows are at approximate centerline of the panel. The first course of panels should rest on vessel base or foundation or on lower support ring. After the panels are in position, they are impaled on the centerline studs. They are then secured with grooved caps or nuts, depending upon the type of stud assembly. Insulation straps shall be installed on a vertical spacing as shown in Figure XVIJ-7. Insulation straps shall be in stalled on the batten and over the top of the bottom and second stud. Vessels 12 to 20 feet in diameter should have one expansion spring installed in each band. Vessels over 20 ft in diameter should have on expansion spring installed at approximately 30 feet intervals. The batten strip, over the first course, should be cut two inches less than the height of the top edge of the panel, then should be installed by impaling it over the studs. "S" clips shall be installed along the top edge of first course of panels to support the second course. A clip should be placed four inches from each end, and three others should be spaced equally from the end clips. Two inches of the fibrous glass insulation (which is not adhered to the aluminum facing) should be removed from the bottom of each panel which is used on the UCC 002935 Figure XVfl-7 UCC 002936 f STANDARDCMCMCALS A*> PLASTICS OPCAATIOKS WtSfCnt AMD OMOt CAAiOI CANADA LNMTID r STEAM TRACING SYSTEM DETAILS AND MATERIALS r IHH f f [ lieVATlON OF TYPICAL STRAIGHT RUN i i i i i i i i i P-140 PIPING-DETAIL 6-15-67 i NOTC; l*/#r lo SrrfP-WOA for TobW 1, II ere) III. SUPPORTS ATTACHED TO PROCESS PIPE PETALS Of STEAM TRACER ATTACHMENT Ur>fc cotAaIkI*^ llnm wtrfc W$S fr*Ating po**n dwU b tomtoi Special tAfluirwwwtt, 7>**# Hnw dwvtd 6* f)vm q<iol InaNutiian by tho Preet t^tnMr lot twtroT* Otofh lor tbit CotOrai ibauld b Aimn on tb* # n tree*f tfa>gn drewlrtp. f kWw ofhorwj-- UtAiztfwd, alT dk lore in inchm. PAGE I UCC 002937 STANDARD oeacui mo rune omtAnoM mo uwom cmsoc CMuru lwtko NOTE: Site of tracer (3/8-in. OD or 5/8-in. OD), material of tracer (copper, stainless steel, or aluminum), and type of traoing system (Bpaced or cemented) shall beta spec* tiled on the steam tracing drawings. Nominal site, thickness, and specification of Insolation for traced line shall be as specified in the Insulation schedule. Insulation for steam supply and condensate limes dial do not have line numbers shall be an specified on the steam tracing drawings. All steam tracing is shown {Ungrammatically on steam tracing drawings with symbols having the following meanings* Steam Tracer -- Steam Feed X X----------X----------X------Steam Condensate I C | Connector (or coupling) 1/2-in. IPS to OD Tube Union Tee for OD Tube [~T~) steam Trap p-140 PIPING -DETAIL 6-15-67 AH ahiTTiiimm tubing tracers shall be insulated from system components of other materials by Inserting a stainless steel connector at all points where the alumi num mMng connects to components of other materials. Shop-fabricated piping that is to be steam traced shall be supported as shown or specified on the piping draw ings. Field-fabricated piping that is to be steam traoed, sod for which supports are not detailed on the piping drawings, h*U be supported in accordance with Stand ards P-77 or P-81, or as otherwise necessitated by job conditions. Lines less than 3/4-In. OD may be supported by cradles as shown on Standard P-82. Except for lines less than 3/4-in. OD, methods of support that would Impose a iii on the Insulation or tracer shall not be used. Steam tracer tubing shall extend beyond pipe Insulation only far enough to make feed and condensate line con nections. Fittings shall be used only at beginning and end of tracer,, at branches, and at ends of standard lengths of tubing. Changes in direction shall be made by bending the tubing. Tracer tubing shall be installed parallel to, andalongthe top of the line being traced. REFERENCES: Steam Tracing Syetem-----Insulation Sizes and Assembly Dimensions.....................................................Std P-140A Spaced Tracer Data........................................... Std P-141 Cemented Tracer Data...................................Std P-X42 *Dd not use aluminum tubing at direction changes of 90 degrees or more. Where such changes occur at intervals of 20 feet or less, use stainless steel throughout. For intervals greater, than 20 feet, make the direction change with stainless steel tubing, and uses stainless steel tub ing union with analumlaumaleeve at each Joint, installed so that aluminum connects to aluminum. ITEM Tracer Tubing Fittings for Tracer (Connectors, Unions, TeeB, etc) MATERIALS FOR STEAM TRACING SYSTEMS COPPER STAINLESS STEEL ALUMINUM* ASTM B88 Type L annealed copper tube in 60-ft colls (3/8-in. OD x .030-to. thk, or 5/8-in. OD x .040-In. thk) ASTM A269 TP304 Stainless Steel tube for use to steam service. Flaring Test (Section 8) is required and good bending properties are necessary. (3/8-in. or 5/8-In. OD x .035-in. thk) 5050-0 Aluminum Alloy, Alcoa "Utill tube", or approved equal, (3/8-in. OD x .035-in. thk or 5/8-in. OD x .049-in. thk) Brass, Ferrule-type with cutting edge. (Imperial Hi-Seal", Crawford "Swagelok", or approved equal.) AISI Type 316 Stainless Steel, Ferruletype wttb cutting edge. (Imperial Hi-Seal", Crawford "Swagelok", Parker "Ferruiok", or approved equal) Ferrule-type with cutting edge (Imperial "Hl-Seal", Crawford "Swage lok", Parker "Ferruiok", or approved equal). Connectors (IPS to OD) shall be AISI Type 315 stainless steel, all other fittings shall be aluminum alloy. Spacers I Per this Standard Per this Standard Per this Standard Straps 1/2-In. wide x . 020-tn. thk soft annealed stainless steel (any 18-8 type) straps with double pronged clips. 1/2-in. wide x ,034-ln. thk aluminum alloy straps with double pronged clips. Steam Traps I Size, manufacturer and model Dumber as specified on steam tracing drawings. Steam Supply Header and Feed Lines, and Steam Condensate Line Valve and Piping Specification as called for on steam tracing drawings. Heat Transfer Cement Thermon Manufacturing Company, Houston, Texas, or approved equal. PAGE 2 UCC 002938 STANDARD OVtfiCALS *> ELASTICS CHAPTER XVII APPLICATOR TRAINING PAGE 333 APRIL 1970 APPLICATION OP PREFABRICATED PANEL INSULATION ------ MbDERATE AND HIGH TEMPERATURE SERVICE APPLICATION - SIDEWALLS - Contd second and successive courses. This provides for two inches overlap of facing. The second and subsequent courses shall be installed in same manner as first course. Details of stud layout and panel installation are shown in Figure XVII-7 and XVII-8. Cutouts for manholes and nozzles should, wherever possible, be located at the intersection of two panels. Where it is necessary to cut out a panel to fit around a nozzle, the opening should be closed up by one or two sections of panel cut to fit around the nozzle, then sealed to panel facing with non-setting sealer and secured in place with sheet metal screws. All cutouts should be cut to fit around the bare nozzle, or around the insulation cover of insulated nozzles or flanges. Junction shall be sealed with caulking mastic. Details of application are shown in Figure XVII-9. Roof Application The roof insulation consists of two layers of fibrous glass insulation installed in broken joint construction. If vessels have a maximum operating temperature below 220F the roof is insulated with roof panels as received. If vessel has a maximum temperature above 250F the roof panels used on the first layer shall have the wrap around weather-barrier at edges of panels field trimmed from the board before the board is Installed. The first layer of fibrous glass should be full specified thickness. It should be impaled on pins welded to the vessel roof. These pins should be located four inches from the edges and corners of the insulation, using no less than three pins on each of the sides and the ends. After insula tion is impal ed, it should be secured tightly to vessel roof by pin clips forced on the welded pins. The outer "cap" layer of one-half inch thick fibrous glass roof insulation shall be installed in broken joint construction by embedding it in non-combustible adhesive spread over first layer of insulation at a uniform rate of two and one-half gallons per 100 square feet. On roofs with curvature such that top insulation does not bed firmly with the first layer, it may be necessary to cut through the asphalt cap sheet in straight lines to allow insulation board to bend. Joints must be tightly butted. The joints and cuts in the cap sheet should be covered with roof tape embedded in adhesive. Tape end joints should be lapped a minimum of four inches. The insulation on the roof and side wall must be carefully flashed to prevent entry of water. The edge of exposed cut roof insulation where it extends over the side walls should be flashed with formed aluminum sheet to fit the circumference and curvature of the roof. Drip leg shall extend a minimum of one inch below shed angle or plate. It should extend a minimum of six inches up over the roof insulation. This flashing is impaled on studs then secured in position with caps or nuts. The junction of the flashing with underside of shell angle or plate should be caulked with caulking mastic. Tape embedded in adhesive shall be applied over junction of insulation and edge flashing. UCC 002939 STANDARD (MRMCALS A* PLASTICS CHAPTER XVII APPLICATOR TRAINING PAGE 334 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION MODERATE AND HIGH TEMPERATURE SERVICE FI gure XVII-8 Fi gure XVII-9 UCC 002940 STANDARD CHONCU.I PtASTtCI CHAPTER XVII APPLICATOR TRAINING PAGE 335 APRIL 1970 APPLICATION OF PREFABRICATED PANEL INSULATION MODERATFAND HIGH TEMPERATURE SERVICE APPLICATION - SIDEWALLS - Contd Roof Application - Contd The roof Insulation should be covered with weather-barrier mastic reinforced with Dynel fabric as described in Chapter XXI - "Weather-Barriers." UCC 002941 STANDARD oteMCAU ahd puona CHAPTER XVIH APPLICATOR TRAINING PAGE 336 APRIL 1970 APPLICATION OF PREFABRICATED REFLECTIVE INSULATION MODERATE AND HIGH TEMPERATURE SERVICE GENERAL Reflective insulation is thermal insulation which depends for its efficacy largely on reduction of radiant heat transfer across its thickness by use of surfaces of high reflectance and low emittance. The insulation is composed of units containing heat reflective sheets separated by low conductive supports, end enclosures, and outer cosing arranged to form isolated gas (air) chambers between the sheets and the end closures. Although reflective insulation is used in applications, particularly buildings, where the sheets are field cut and erected, the application discussed here will be restricted to factory prefabricated panels, pipe covering, and fitting covers. Flat and curved panel reflective insulation for equipment is shown in Figure XVIII--1, and pipe insulation and typical fitting insulation are shown in Figure XVIII--2. APPLICATION OF PREFABRICATED REFLECTIVE INSULATION Supports and Securement Reflective insulation is furnished in prefabricated units to be installed by straps and clips, hinges and snap-lock, buckles, and occasionally by sheet metal screws. The buckle-secured insulation is most often used where fast removal and replacement of the insulation is a require ment of the installation. Insulation support rings shall be installed in accordance with manufacturer's requirements. Insulation supports should be checked to determine that they are in accordance with the drawings. Surface Preparation Surfaces of equipment to be insulated must be clean, protective requirement is same as listed in Chapter XIII, Rigid Insulation High Temperature Service. Because this insulation is custom-made to fit the vessel or the piping system, the applicator should familiarize himself with the drawings and installation instructions prior to starting erection. The sequence of application of the custom-made insulation units is of prime importance. If the installation is started with the wrong unit, it is likely that the final assemblies cannot be in stalled as designed. In general, installation is started at the bottom of pipe or vessel and pro ceeds upward. The manufacturer provides a drawing showing each insulation unit and its identification mark number plus packaging list identifying units in each shipment. Also, the manufacturer furnishes installation instructions which provide the installation sequence by insulation unit mark numbers. UCC 002942 f STANDARD r CHMCttt AW FUSTICS CHAPTER XVIII APPLICATOR TRAINING PAGE 337 APRIL 1970 r APPLICATION OF PREFABRICATED REFLECTIVE INSULATION MODERATE AND HIGH TEMPERATURE SERVICE f f i i i i i 1 i i i Flat Panel ? Curved Panel T Figure XVI11-1 UCC 002943 STANDARD CMCMALS U9 ROITO CHAPTER XVIII APPLICATOR TRAINING PAGE 338 APRIL 1970 APPLICATION OF PREFABRICATED REFLECTIVE INSULATION moderate And high Temperature service" Figure XVI11-2 UCC 002944 STANDARD (XIMCALS AMO PLASTICS CHAPltR XVIII APPLICATOR TRAINING PAGE 339 APRIL 1970 APPLICATION OF PREFABRICATED REFLECTIVE INSULATION ---------- moderate And hiOh temperature SERVICE APPLICATION OF PREFABRICATED REFLECTIVE INSULATION - Contd Application of Insulation The panels for curved equipment surfaces should be applied with edges and ends closely abutted and with outer casing laps, or trim strips arranged to shed water. Where stainless steel straps are provided for securement, strap supports are installed on the panels (by the manufacturer) to position the straps. Straps should be installed to draw up the cylindrical panels snug but care should be taken not to tension the band too tight and cause deformation of the panel. Where stainless steel screws are provided for the securement, the screws should fit the two screw holes provided by the manufacturer. The proper screws and lock washers are provided by the manufacturer. As the panels are erected the screws should be pulled snug, but not tight. After the entire assembly is complete then all screws should be tightened. Fast removal insulation should be placed in position and secured in position by fastening the buckle. A typical installation using strap and screws is shown in Figure XVIII-3. Fast removal and replacement insulation cover for vessel is shown in Figure XVIII-4. Piping The installation and sequence of installation instructions furnished by the manufacturer must be followed so that all pieces fit together as designed, A typical sketch showing sequence of installation is shown in Figure XVIJI-5. Insulation supports, where required, should be located as indicated on the manufacturers' sketches. The insulation should be applied with the overlapping end of each section placed over the flush separator end of abutting section. The extended longitudinal edges of each section shall be lapped over flush edges of opposing half section so that all joints are tightly butted. In general, these lapped edges of the outer shell shall be placed so as to shed water. The fittings, flanges, valves, and bent piping.should be insulated in a manner similar to that for straight piping. The fitting covers should be applied with telescoping joint connections to the adjacent piping. UCC 002945 STANDARD extiftCALS Art tlfcSTIO CHAPTER XVIII APPLICATOR TRAINING PAGE 340 APRIL 1970 APPLICATION OF PREFABRICATED REFLECTIVE INSULATION MODERATE AND HIGH TEMPERATURE SERVICE I r r r r r r r r UCC 002946 L r STANDARD r CMPirmi and ruksno CHAPTER XVIII APPLICATOR TRAINING PAGE 341 APRIL 1970 r APPLICATION OF PREFABRICATED REFLECTIVE INSULATION MODERATE AND HIGH TEMPERATURE SERVICE r r i i i i i i i i i i i i Figure XVI ||--4 UCC 002947 STANDARD CHCMCAU mA PtAiTO CHAPTER XVIII APPLICATOR TRAINING PAGE 342 APRIL 1970 00 4Nm ;. i: l ' $ \ 1 1 <! $ APPLICATION OF PREFABRICATED REFLECTIVE INSULATION MODERATE AND HIGH TEMPERATURE SERVICE 1>^*1 * i 1 .... ,> I ,.>3> i iw m*2 | 1 55s * X Sf i \> > ir,N * Ns V N 2 >1 fr) Tz- So --<f sr/c2-iz^ 1_ ,K*_ .v 2 k; ,;i i i V. ^1 }' ----------- -p~ 7Ui^ V r v ^ .... -3>T4 z-s/'* .;^slA* Sr/cz-/$3 // z :tfz '/f3 /A/STAti. frr--C-/--E- T -F t &0 l**,#*' * ja >: ** 4^` T' L tl 2~SO Figure XVIII-5 UCC 002948 T STANDARD OCMCALS AND NUJ7X3 CHAPTER XVIII APPLICATOR TRAINING PAGE 343 APRIL 1970 APPLICATION OF PREFABRICATED REFLECTIVE INSULATION ---------- MODERATE AND HIGH TEMPERATURE SERVICE APPLICATION OF PREFABRICATED REFLECTIVE INSULATION - Contd Piping - Contd The securement of the insulation should be by strap, snap-lock, buckles, or screws, depending upon service requirements. During application and securement, care should be taken to pre vent crushing or other abuses to the insulation. Where any field cutting or fitting around supports or nozzles is required, the fitting should be clean, neat, and tight with a closure installed to provide seal of the individual air chambers in the insulation. Provision should be mode in the assembly of the insulation of the units to allow for expansion and contraction of the surfaces insulated without damage to the insulation. Screws should not be used to secure telescoping sections together where the movement between the adjacent sections is needed for allowance of expansion and contraction. Where equipment or piping is located outdoors, or where otherwise required, joints or openings in outer shell of insulation shall be flashed to form a water shed. A completed installation of reflective insulated piping is shown in Figure XVIII-6. UCC 002949 STANDARD OffMCALJ tJ0 PLASTICS CHAPTER XVIII APPLICATOR TRAINING PAGE 344 APRIL 1970 APPLICATION OF PREFABRICATED REFLECTIVE INSULATION ---------- MODERATE AND HIGH TEMPERATURE SERVICE Figure XVI11-6 UCC 002950 STANDARD odMAUJJC^una CHAPTER XIX APPLICATOR TRAINING PAGE 345 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE SERVICE GENERAL Asbestos insulation for spraying is a mixture of asbestos fibers and inorganic binders supplied in dry bulk form. The insulation is packaged in bags. Application to the surfaces is by spray apparatus which pneumatically delivers the dry blend through a hose to a spray gun where the asbestos and binders are mixed with a fine water spray before it strikes the surface to which it adheres. To obtain a good application of sprayed asbestos insulation one must have a complete understanding of the spray machine and the proper application techniques. APPLICATION OF SPRAYED ASBESTOS INSULATION Supports Supports and securements are necessary for large surfaces and for insulation over two inches in applied thickness. The insulator should inspect the surfaces to be insulated to assure himself that all cylindrical vessels over 24 inches in diameter, square ducts and equipment to be in sulated with two inches or greater thickness have 10 gage pins welded to the surfaces to be insulated. These pins should be spaced 18 inches on center on sides and 12 inches on centers on bottom surfaces and edges, as illustrated in Figure XIX-1. The sides and bottom of vessels and equipment, such as turbine casings, insulated with 2-1/2 inches thickness and over should have split pins welded 18 inches on centers on sides, 12 inch centers on bottom with additional pins around the edges on 12 inch centers for attachment of wires for fastening of hexagonal wire netting. This is shown in Figure XIX-2. If the insulation on the side walls of vessels or equipment does not extend down to base of vessel, an angle or flat bar with an outstanding leg equal to that of the thickness of the insulation should be welded around the base of the vessel to provide a termination and water seal barrier at the bottom. Surface Preparation Surfaces to be insulated must be clean and where protective coating is required, the coating should be dry, before the installation is started. As adhesion to the surface is of paramount importance, the insulator should assure himself that the sprayed asbestos insulation will bond with the coating on the metal surface. An applied test patch is recommended. Should there be any question as to the ability of the coating to with stand the temperature to which it will be subjected, such question should be referred back to the Engineering Group for decision. It should be pointed out that where metal is coated or painted, if the coating or paint fails then the bond between the sprayed insulation and the metal surface is lost. UCC 002951 STANDARD OCWCALI AW fiAtna CHAPTER XIX APPLICATOR TRAINING PAGE 346 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS H IGH TEMPERATURE SERVICE Finishing cement Normcl insulation layer High density insulation layer Dry asbestos fiber packing Asbestos paper (wired in place) Normal Insulation layer Asbestos poper (cemented in place) Tooled groove Split pins, or TO gage welding pins with speed clips Wire netting Weother barrier, as specified Application of Sprayed Asbestos Insulation to Steam Turbine Figure XIX-1 UCC 002952 STANDARD OOwCAU MC H.A1T10 CHAPTER XIX APPLICATOR TRAINING PAGE 347 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE SERVICE APPLICATION OF SPRAYED ASBESTOS INSULATION - Contd Operation of the Sproy Machine The machine serves to transfer the fiber mixture from the hopper to gun nozzle where it is mixed with water spray before it strikes surface being insulated. A typical sproy machine and list of parts are shown in Figures XIX-3 and XIX-4. The basic components of the machine are: 1. Hopper to hold the fiber mixture. 2. Automatic Feeder to control the fiber mixture flow. 3. Cording Brushes, which comb out the fibers just before they enter the impeller chute. 4. Fiber Impeller System, which pushes the fiber mixture through the blowing hose at required speed and density. The machine functions as follows: The fiber mixture in the hopper is fed to a screw conveyor which carries the mixture to the carding brushes which comb out the fibers and drop them into the impeller chute. The fibrous mixture is picked up by the impeller and carried by air through the blowing hose where, after leaving the spray gun, is wetted in mid-air with atomized water. The wet mix material Is deposited in wet form on the surface being insulated. The amount deposited depends upon the insulation mechanic handling the spray gun. Before starting application an inspection should be made of the machine to determine if it is in good operating condition and is properly connected with air, water and electric power. The inspection procedure should be as follows: 1. Inspect the spray gun to see that all three valves are operating properly. Disassemble and repack with water pump grease when necessary. 2. Make sure the air and fluid hose connections are secure and not broken. 3. Check to see whether there are any breaks in the air, fiber and fluid hoses. 4. Check the voltage in the machine to make sure that the machine is wired to coincide with the voltage supplied. UCC 002953 STANDARD oaMiMuna CHAPTER XIX APPLICATOR TRAINING PAGE 348 APRIL 1970____________ i > in UCC 002954 *> T3 C STANDARD CMMCAU AND PlAITCS CHAPTER XIX APPLICATOR TRAINING PAGE 349 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS hi Oh TEmPIRaTUre serViCE tnuv QUN 29. Spray Gun Head 30. Water Line Connection & Control Valve 31- 2V4" Fiber Blowing Hose 32. Air Control Valve for Air Switch No. 28 33. Air Supply Connection 34. Atomizing Air Valve Figure XlX-4 UCC 002955 STANDARD oiscu * n*mo CHAPTER XIX applicator training PAGE 350 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE SERVICE APPLICATION OF SPRAYED ASBESTOS INSULATION - Contd Operation of the Spray Machine - Contd 5. Inspect the brushes, and impeller to see they are not excessively worn. 6. Check machine while empty to see that all moving parts are functioning properly. This can be done by pressing the master switch starting up the blower mechanism and then turning on the test feed switch which starts the feed mechanism. However, machine should be run only a short period of time when air is not on. 7. The 1/4" air hose should be connected to the air switch to test the switch for proper function. 8. Moving parts should be lubricated as noted on Maintenance Instruction Sheet. Connecting the Machine to Required Services Air is required at a volume of at least 5.5 C.F.M. at 60 psi. This can be obtained by the use of plant air or an air compressor. Air supply must be supplied with an air filter and pressure regulator. The air supply hose is connected to air connection on spray gun and the air line from gun is connected to the air switch located on the panel. The air is turned on and the regulator adjusted to 40 psi. Water is required at a delivery rate of at least 0.5 gallon per minute. The water supply must be supplied with fluid filter and pressure regulator. The water hose is connected to water supply connection. The water is turned on and the regulator adjusted to 25 to 30 psi. Electricity may be either 115 or 230 volts as machine is equipped for both voltages. Electric supply cord is attached to proper voltage connection. However, care must be exercised to see that correct voltage is supplied to the machine. Low voltage will damage the electrical system. Where question exists, an electrician should be called in to test the voltage supplied to the machine. Fiber Hose is connected to the machine, where it is secured in place by tie wire, and to spray gun at other end. UCC 002956 STANDARD CMtucuj we plMites CHAPTER XIX APPLICATOR TRAINING PAGE 351 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE SERVICE APPLICATION OF SPRAYED ASBESTOS INSULATION - Contd Operotion of the Machine: 1. The hopper of the machine is filled with the fiber mixture. It should not be pushed or tamped causing a compression of the mixture. 2. The machine is activated by pushing the master switch to "ON" position. 3. The air supply is turned on to atomize the water. 4. At the gun, the water valve is turned on. The spray pattern of water should be even and smooth. 5. Aiso at the gun, the air feed switch is turned in counter-clockwise direction. This starts the fiber flow. Spraying of Fiber The fibrous insulation is sprayed by the operator onto the surface to be insulated. The build up in insulation thickness is controlled by the operators use of the gun. The operator should hold the gun at least 12 inches from the surface being insulated. The optimum distance is approximately 18 inches. The insulation should be sproyed on at an angle between 60 to 40 degrees. Spray angle should not be perpendicular to the surface. Proper quantity and atom*? ization of water to make the applied insulation damp is essential to obtain good consolidation of the insulation and to give it good surface adhesion. The operator and those in immediate spray area should wear masks capable of removing asbestos particles from the air. Vessels and Equipment Petal I s When a vessel is on a low pad where the level of rain or drainage water can reach the bottom of the insulation, a course of water repellent insulation, preformed to the diameter of the vessel, and of specified thickness, shall be installed to an elevation greater than the highest expected water level. In no case shall this be less than nine inches. On vessels below 212F, cellular glass shall be used as the water repellent insulation and on vessel above 250F expanded silica insulation shall be used. Thickness up to one and one-half inches should be applied in sufficient quantity so that, when consolidated to specified thickness, the density of the insulation, after drying, will be between 8 and 13 lbs. per cubic foot. Consolidation is accomplished by tamping the sprayed insulation with flat trowels or other flat surface. Where necessary to consolidate the insulation where pins project, the use of 1/2-inch thick organic rigid insulation fastened to board will allow pin to penetrote the organic foam which presses the damp fibrous mixture down around the pin. UCC 002957 STANDARD CM8MCAIS AMD PLASTICS CHAPTER XIX APPLICATOR TRAINING PAGE 352 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE service APPLICATION OF SPRAYED ASBESTOS INSULATION - Contd Vessels and Equipment Detoils - Contd When insulation exceeds 1-1/2 inches in thickness the sprayed insulation shall be applied in two layers. First layer should be applied and consolidated with edge of flat trowel, forming a criss-cross pattern , to 55 percent of its applied thickness. The split pins used for reinforce ment should be pulled apart to form a V prior to application of second layer. The last layer is applied as described for single layer application. This last layer must be applied within 30 minutes of the application of the first layer. This is shown in Figure XIX-1. On the top heads of vertical vessels and the top quadrant of horizontal cylindrical vessels the sprayed insulation should be consolidated to approximate 20 lb. density, when dry, so rhat its compressive strength is sufficient to permit it to be walked upon without mechanical damage. The reinforcing of the insulation should be 4 by 4 inch squares of hardware cloth inserted over *he pin and pressed into the surface of the insulation for a distance of 1/4 inch. A speed clip should be forced over the pin and pressed down to firmly secure the hardware cloth in position. Pin should then be clipped off so Its top will be lower than the finished insulation surface. Fibrous insulation should then be troweled over the hardware cloth, flush with adjacent sur faces. Application is shown in Figure XJX-5. APPLICATION OF INSULATION TO FLANGES AND FLANGE BOLTS Flange bolts or studs should be wrapped with asbestos paper secured in position with stainless steel wire. The space between the bolts or studs should be packed with dry asbestos fiber. The sprayed insulation should be applied with a taper inward to vessel surface at the flange. Over these tapered edges asbestos paper should be installed, adhered to the insulation with asbestos paper adhesive. The asbestos paper should then be applied over the entire bolt and flange area to the tapered insulation asbestos paper. Sprayed insulation should then be installed as described in preceding section. This application is shown in Figure XIX-6. Finish Where the insulation is to be covered with metal jacket it requires no finish cement. Where the insulation is to be covered with fabric reinforced mastic it should be covered with a hard finish cement sprayed or troweled to a thickness of 1/4 inch over hexagonal wire mesh. This cement is to be scored with a cement finisher's tool in squares approximately 4 feet by 4 inches to allow for expansion and contraction. It is important that scoring is through the cement finish to the surface of the sprayed fibrous insulation. UCC 002958 STANDARD Aje PLUTO CHAPTER XIX APPLICATOR TRAINING PAGE 353 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS -----High TEMPERAtURE'SERViCF Speed Clip 4" 5q. Hardware Cloth___ Welded Pin of Specified Gauge shown in place ^,Pin to be snipped at top of clip 11* "7 Insulation as Sprayed Insula ion ) /as tamped h/;//;////,,/frn/7. SECTION Left Center Right Insulation as Sprayed Support Detail Insulation as Tamped SECTION Finished Application Figure XJX-5 UCC 002959 STANDARD OOtfCAU PtASne* CHAPTER XIX APPLICATOR TRAINING PAGE 354 APRIL 1970 APPLICATION OF SPRAYED ASBESTOS HIGH TEMPERATURE SERVICE Pack With Dry Asbestos Fiber Wrap With Asbestos Paper Secure With Stainless Steel Wire Q, Sprayed Asbestos Insulation Glue Asbestos Paper To Sprayed Insulotion With Adhesive APPLICATION OF INSULATION TO FLANGES AND FLANGE BOLTS Figure XIX-6 UCC 002960 STANDARD CHEMICALS Att PLASTICS CHAPTER XX APPLICATOR TRAINING PAGE 355 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE Sprayed urethane insulation is supplied as two liquids; the resin component and the activator component. These, when mixed together in equal proportions, expand to approximately thirty times their original volume due to generation of gas filled cells entrapped in the mixture. Application to the surfaces to be insulated is by spray equipment which delivers the two components to the gun in proper proportions, at which point the two liquids are mixed to gether and sprayed on the surface. The liquid on the surface expands to foam the thermal insulation. APPLICATION OF SPRAYED URETHAbE Preparation of Surfaces To Be Insulated Surfaces to be insuloted must be clean, and where coating is required, the coating must be completely dry before application is started. Unpainted carbon steel should be cleaned of rust, mill scale, dirt, grease or other contamina tions. If steel is pointed with long oil red lead primers or long oil oleoresinous paints the urethane may cause softening of the paint with resultant poor bonding of the sprayed insulation. When such is suspected, a test patch should be installed and inspected prior to spray application of the vessel or equipment. Most other paint systems are compatible with the urethane if they are fully dry and free of dirt, grease and oil. Stainless steel surfaces should be coated with Thermalox No. 70 in accordance with UCC Coating Manual prior to application of urethane foam. This coating must be completely dry before installa tion is started. Heavy aluminum may be coated with sprayed urethane provided it is clean. However, thin gage aluminum (less than 1/16" thick) requires special coating treatment before application of the urethane foam insulation. Copper and brass need no special surface treatment other than that they be clean and dry. Protection of Surfaces Not To Be Insulated Urethane spray, like all sprayed liquids, has a certain amount of drift and rebound particles which drift in the air from the point of spraying. For this reason areas not to be insulated must be protected from these drift particles which have excellent adhesion to surfaces in which they come in contact. UCC 002961 STANDARD CHfMCAU AMO PlASTO CHAPTER XX APPLICATOR TRAINING PAGE 356 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE APPLICATION OF SPRAYED URETHANE - Contd Protection of Surfaces Not To Be Insulated - Contd All flanges, manholes and all other surfaces on the vessel not to be insulated should be wrapped with suitable coverings and secured in place with suitable wire or tape. This covering is removed ofter the application of the sprayed insulation. Instruments and all other areas which are to be kept free of insulation or overspray should be protected in like manner. Piping and equipment within 25 feet of spraying operation should be covered or screened for protection from overspray or drift. Material The urethane liquid and the activator liquid should be of the UCC type as specified. EQUIPMENT AND ITS OPERATION Application of Sprayed Urethane Insulation Whenever possible, spraying should be done when ambient air temperature is above 50F, in dry weather, at moderate relative humidity conditions and when wind velocity is less than 15 mph. Wind shields should be used if wind velocities exceed 15 mph. For best results the temperature of the surfoce being insulated should be between 70F and 120F. When ambient air temperature is less than 5QF the feed tanks and the hose to spray gun should be heated. Generally, the spray gun should be held approximately 36 inches from the surface being coated. Surface ripples will occur when gun is held too close to the surface, when gun movement is too slow for the speed of foam rise, or when spray material throughput is too high. The liquid should be sprayed onto the surface using a 50 percent overlap pattern and fast aim movement. To obtain even distribution of film requires gun triggering and feathering on the overlap. Operation of Pumps and Spray Gun I Equipment Required The proportioning pump should consist of an air motor and two volume balanced cylinders to insure an accurate 1:1 ratio. The air motor should have sufficient capacity to insure adequate air pressure to atomize the materials properly. UCC 002962 STANDARD CMCMiCAU *W FLA)?*? CHAPTER XX APPLICATOR TRAINING PAGE 357 APRIL 1970 APPLICATION OF SPRAYED URETHANE --MODERATE TEMPERATURE SERVICE EQUIPMENT AND ITS OPERATION - Contd Operation of Pumps and Spray Gun - Contd I. Equipment Required - Contd The feed system should be defined in terms of size of material supply containers, either 5-gallon pail feed or 55-gallon drum feed. If a gravity feed system is used, the supply drums should be elevated to insure positive flow. If the feed pumps are to be used, the distance from the supply drum to the proportioning pump will influence feed pump selec tion. Longer distances require higher pressure pumps. The feed pump used on the "A" or isocyanate side should be divorced above the bung to prevent moisture contaminating the material. The heating system should include high pressure heaters capable of handling 3/4 gpm of each material at normal operating temperatures of 100-110 . The desired material tempera ture may vary between foam systems. Insulated hoses equipped with a heating wire or tape should be specified to maintain the material temperature at the gun. The length of hose required will vary depending on the type of application. Spray gun should be an infernal mix airless spray gun for best results. The gun should be capable of delivering 10-12 lbs. per minute of mixed materials. The gun should be easily flushed and be of a design to permit quick and easy disassembly. Check valves should be included on both material inlet ports to prevent materials from crossing over to one another. Solvent pump should be constructed of materials which are resistant to the common solvents used, such os methylene chloride and butyl celiusolve. Pump packings should be Teflon. A nitrogen pressurization kit should be included to supply a nitrogen head to both material supply drums. This will prevent loss of the blowing agent on the "B" side and moisture contamination of the "A" side. A pressure relief valve should be included to prevent overpressurization. If the unit is to be used for spraying outdoors at ambient temperature below 50F, a freon injector should be included. This is necessary to get good quality foam at low temperatures. This device adds on additional blowing agent, normally UCON or equivalent, to the "B" side. This is necessary because Freon 11 or equivalent, the normal blowing agent contained on the B side, turns from a liquid to a gas at 75F. At ambient temperatures below 50F, additional freon is required to initiate the foaming action. UCC 002963 STANDARD 04M1CAL5 AND PLASTIC CHAPTER XX APPLICATOR TRAINING PAGE 358 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE EQUIPMENT AND ITS OPERATION - Contd Operation of Pumps and Spray Gun - Contd 2. Operating Instructions The first step in installing the machine is to hook up the air supply hose from the compressor. Twenty CFM is required and 1/2" air hose should be used. Solvent should be pumped through the system to clean out the oil and to check for leaks. The solvent pump itself should be checked for leaks. The check valves on the static mix gun inlet parts should be checked to insure that they seat properly. This can be done by first connecting the solvent hose to one material inlet port and turning the gun to spray position. Start the solvent pump and spray solvent. Check for leakage at the other material port. Repeat this procedure with the other material inlet. Protective clothing should be worn, including goggles. If the spraying is being done in doors, an air mask or respirator should be used. If isocyanate gets on your skin, wash Immediately. The inbound air pressure on the proportioning pump should be set at 40 psi and adjusted upward depending on the tip being used, the output desired, etc. The maximum limit is 120 psi. The heaters should be set at mid-range initially and adjusted from there, depending on the spraying temperature recommended by the material supply. The heaters should be allowed to warm up for approximately 20 minutes prior to spraying. We are now ready to begin spraying. The substrate being sprayed on should be dry and free of drit and grease. Any rust or foreign matter should be removed by wire brushing or sandblasting. Foam can be applied directly to wood or clean steel surfaces. It should not be applied directly to untreated aluminum surfaces. Foam should not be sprayed outdoors if the wind velocity is more than 15 mph. High winds will result in overspray, which can cause contamination on painted surfaces or glass windows in the area. Parked cars are a particularly good target for overspray. Overspray will also cause a lack of good thickness control and can produce poor foam because of loss of exotherm. UCC 002964 STANDARD CHEMICALS A*C PLASTIC* CHAPTER XX APPLICATOR TRAINING PAGE 359 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE EQUIPMENT AND ITS OPERATION - Contd Operation of Pumps ond Spray Gun - Contd 2. Operating Instructions - Contd Urethane foam sprays best when the ambient temperature is between 65F and 100F. Below 60F, it is a good idea to spray a light coat of foam first as a flash coat. This will insulate the surface you are spraying. The lower the ambient temperature, the more difficult it is to produce good controllable foam. Exothermic heat is lost and the UCON blowing agent is hard to handle. The combination of these causes the foam density to increase from the 2 Ib/cu ft level normally desired. If the ambient temperature is below 40F, drum heaters should be used to heat the material before entering the proportioning machine. The 208-036 freon injector will help in cold weather spraying. The spray gun should be held approximately 18 inches from the surface being sprayed and moved perpendicular to the surface. If the operator is too close to the work surface, ripples wil j result. If the operator is too far away, he will get overspray and poor thickness control^ A good operator should cover 15-20 board ft. per minute. An area 3* to 4' wide can be covered in one pass. The height of the area that can be covered depends on the spray tip used.and the distance from the surface. Normally, 8 inch to 12 inch band can be covered. The foam should be put on 3/4 inch to I inch thick per pass. If thicknesses greater than 1 inch are required, multiple passes can be made. Urethane foam will bond to itself nicely. You should not spray into rising foam. If the spray gun starts spitting, flush and check for a plugged tip by unscrewing the tip holder and removing the tip. An important point to remember in troubleshooting is to shut the air off and remove the pressure from the system. If no material Is discharging from the gun, first check the material level in the supply containers. If material supply is all right, then check the ball valves on the pump inlets to insure they are open and passing material to the proportioning pump. If the material is feeding into the proportioning pump properly, disconnect the gun at the inlet ports and check material blow. If material is flowing from the hoses, the gun is jammed. If no material is flowing out of the hoses, disconnect them from the pump outlet. If material flows from the pump outlet, your hose is plugged. If no material is coming out of the pump outlet, your problem is probably in the pump ball check or packings. UCC 002965 STANDARD OtCMCAU AND PLASTICS CHAPTER XX APPLICATOR TRAINING PAGE 360 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE EQUIPMENT AND ITS OPERATION - Contd Operotion of Pumps ond Sproy Gun - Contd 2. Operating Instructions - Contd If you are spraying poor quality foam, the first thing to check is the heaters and heated hose to insure the proper temperatures are being maintained. The next thing to check is the ratio of the materials, which may be incorrect. The characteristics of the foam will give you a good ideo as to which component is off ratio. If too little of the "A" or isocyanate side is being delivered, the foam will be lighter in color, will rise fast, display larger cells and lower density, and hove poor adhesion. If too little of the "B" or resin side is being delivered, the foam will be dark in color, have a slow rise, and be higher in density. Once you have determined which component is short, check that side starting with the material drum, suction hose or feed pump, pump inlet boll valve, gun inlet check valve, heated hose, etc., until the restriction is located. At the end of the day, the pumping unit should be flushed thoroughly with solvent. The pumps should always be stopped at the bottom of a downstroke. This will prevent any buildup of isocyanate on the displacement rod. The spray tip should be removed and immersed in DMF to remove foam particles. A good methodpreventing foam buildup on the gun is to coat with a mold release such as silicone prior to use. Under no circumstances get DMF on the skin as it can be quite harmful. For longer shutdown periods, the entire unit should be flushed with a 50/50 mixture of methylene chloride and DOP. Then a light preservative oil should be pumped through and left in the system. Film thickness applied should be approximately 35 mils per inch of required insulation thickness. This requires approximately 0.18 to 0.2 lbs of material per square foot, per inch thick insulation. Liquids up to approximately 70 mils thick can be applied in one coat. This will produce about 2 inches thickness of insulation. If greater thickness of insulation is required ft is necessary to apply additional coats. In such cases the preceding coating should be completely foamed, dry, and tack-free to touch before another coat is applied. UCC 002966 STANDARD CNfMCAU AM Puma CHAPTER XX APPLICATOR TRAINING PAGE 361 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE ~ EQUIPMENT AND ITS OPERATION - Contd Operation of Pumps and Sproy Gun - Contd Should spray equipment apply liquid which does not react to produce foam, the application should be stopped and unreacted liquid removed. After the difficulty is corrected, this area should be resprayed. Surfaces To Be Insulated Cylindrical, flat, and irregular surfaces of vessels and equipment to be insulated with "foamed in place" urethane should be sprayed in manner described. The final insulation thickness should be as specified. The installation should be performed as described above. Flanges In most cases manhole flanges, blind flanges and vessel flanges are not insulated on moderate temperature vessels insulated with "foamed in place" urethane. The body insulation should be tapered down to the vessel around these flanges to permit removal of bolts and to allow the application of weather-barrier mastic. This is illustrated in Figure XX-1 and XX-3. Where blind flanges and vessel flanges are required to be insulated, the spray insulation should be the same as if they were not to be insulated. After the spray application is completed these should be insulated with preformed flange covers of urethane insulation. This application is illustrated in Figure XX-2 and XX-4. Vessel Legs If a vessel is equipped with concrete-filled structural tubing legs, the legs should be insulated the some as and os part of the vessel. If, however, the vessel is equipped with channel legs and these legs require fire protection, as would be indicated by the concrete encasement around their lower section, then these legs must be insulated with fire-resistant high temperature insula tion. The fire resistant insulation should be installed completely around the legs as shown in Figure XX-5. Vessel Skirts The bottom head of vessels with skirts should be insulated same as the main body of the vessel. The inside of the skirt should not be insulated unless so specified. The spray application of foam urethane applied to the vessel shall extend down the outside of the skirt for a distance not less than eight times the specified insulation thickness, or to the concrete pad, whichever is nearer. This application detail is shown in Figure XX-6. UCC 002967 STANDARD OftWCALS PLASTICS CHAPTER XX APPLICATOR TRAINING PAGE 362 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE Vessel Application of Sprayed Urcthone Foom Adjoccnt to Uninsuloted Nozzle V*n*l Figure XX-1 Sprayed urethane foam Insulation Thickness *T* as specified db Manhole or blind flange Preformed urethane foam Insulation cover Wrap with suitable catering prior to application of sprayed urethane foam. Remove the covering prior to application of preformed insulation cover. Conrocf Adhesive Weother - border os specified Sprayed urethane foom insulation Application of Sprayed Urethane Foom to Insulated Nozzle Figure XX-2 UCC 002968 STANDARD ptCWCALS A* PLASTICS CHAPTER XX APPLICATOR TRAINING PAGE 363 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE teMPErATure service VmI Figure XX-3 Sprayed urethane foam Insulation Thickness "T" at specified MonKola or blind flange - Preformed urethone foam Insulation coyer -- Wrap with suitable covering prior to opplfcotion of sprayed urethane foam. Remove the covering prior to application of preformed insulation cover. Contact Adhesive Weother - barrier as specified Sprayed urethane foam insulation Application of Sprayed Urethane Foam to Insulated Nozzle Figure XX-4 UCC 002969 STANDARD ociacui ue njuno CHAPTER XX APPLICATOR TRAINING PACE 364 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE- Figure XX-5 TMcknMi -f iptclflid Application of Sproyd Urfbono Foam Imuloflon <o f^ulprmrtt Sfcltf Figure XX-6 UCC 002970 STANDARD OtlMCALS A* PLASTICS CHAPTER XX APPLICATOR TRAINING PAGE 365 APRIL 1970 APPLICATION OF SPRAYED URETHANE --MODERATE TEMPERATURE SERVICE EQUIPMENT AND ITS OPERATION - Contd Surface Finishing Where there may be excessive buildup or irregularities of insulation surface these should be cut off to be flush with the adjacent surfaces. If a smooth surface is required for sake of appearance the insulation should be smoothed off by sanding the surface with a power sander. Safety Precautions The spraying of urethane foam releases fumes and minute particles into the air. The spray operator, and anyone close to the operation of the spray, must wear masks capable of protection against isocyanate vapors and atomized particles. Cannister and cartridge masks for use with solvent vapors are recommended. These should be worn where ventilation is good. When spraying in enclosed or confined areas a full fresh air face mask must be used by the applicator. The foaming of urethane is caused by a chemical reaction which produces heat. Because of the insulating properties of the foam this heat can develop excessive temperature rise on the inner masses if the heat cannot dissipate to the surroundings. For this reason no more than one inch of insulation should be applied at one time over a combustible material such as wood, nor should over four inches be installed at one time over incombustible surfaces, such as steel. APPLICATION OF WEATHER-BARRIER After the foam application is completed and the insulation is cured to tack free consistency the weather-barrier mastic may be installed. The application of the weather-barrier mastic should be done as soon as practical to protect the foam from the weather. Weather-barrier material should be weather-barrier mastic, of specified color, and be spray grade. The mastic should be water-emulsion type as described in Weather-Barrier Chapter of this Manual. Surfaces not insulated should be protected by suitable covering the same as described in Preparation Section of this Chapter. UCC 002971 STANDARD otewou.* a* Mjure CHAPTER XX APPLICATOR TRAINING PAGE 366 APRIL 1970 APPLICATION OF SPRAYED URETHANE MODERATE TEMPERATURE SERVICE APPLICATIONS OF WEATHER-BARRIER - Contd The spray application of mastic over the urethane foam is to be done in two coats. After the first coat has taken its set, a second coat should be applied. The combined thickness of the two coats should be not less than 50 mils when dry. Details of application of weather-barrier mastic is discussed in Weather-Barrier Chapter XXI. It should be noted, however, that no re- inforcing cloth is required in the application of the mastic. . NOTE: Additional instructions for spray equipment can be obtained in the following: 1. Graco Equipment - Instruction Manual Set No. 306991 Gray Company Inc. Minneapolis, Minnesota 55413 2. Manual Gusmer Coatings Inc. Old Bridge, N. J. 08857 UCC 002972 STANDARD OfCMCALI **C RUOTtO CHAPTER XXr APPLICATOR TRAINING PAGE 367 APRIL 1970 APPLICATION OF WEATHER-BARRIERS Weather-barriers, to fulfill their function in protecting insulation, must have strength, flexibility, and resistance to weather. There are two basic forms of weather-barriers used to protect insula tion; one is mastics and the other is jackets. Because of their complete difference in form, they must be applied differently. APPLICATION OF MASTIC WEATHER-BARRIER There are numerous types of weather-barrier mastics, each of which may require some differences in the method of application. However, as we specify only the heavy body resin-type mastic, this application discussion will be limited to that particular type of mastic. Preparation The first item is to check materials to determine if all materials required are aval lable. For the installation of a mastic weather-barrier, the following are needed: 1. Weather-barrier mastic. 2. Reinforcing cloth. 3. Cauljking mastic. 4.,Heat resistance sealer (for high-temperature service). ^ ^5. Lap sealer (for low-temperature service). 6. Expansion strip (for high-temperature service). The mastic itself should be inspected to determine if it is in good condition and suitable for use. Also, it should be determined that the proper grade of mastic was delivered. If several grades are available, trowel grade is required when material is to be palmed or troweled. Where it is to be sprayed -- spray grade is required. As these mastics are water-base materials, after they are delivered to the job site they must be kept from freezing if the atmospheric temperature falls below 32F. The insulation should be installed as specified prior to the application of the mastic. During the period between its application and until it is weather protected, all absorbent insulation shall be protected from rain, snow, or other liquids by temporary wrapping with protective coverings. Should absorbent insulation get wet due to circumstances beyond control of the insulator, it is necessary for it to be dried out before the final weather-barrier mastic is applied. This should be done by keeping the insulation covered with the temporary protective plastic sheet or tarp until the line or vessel is heated for a sufficiently long time to drive out the moisture. The installed insulation should be smooth, even, and free of voids. UCC 002973 1 STANDARD CMtMCAU AND ^410 CHAPTER XXI APPLICATOR TRAINING PAGE 368 APRIL 1970 APPLICATION OF WEATHER-BARRIERS APPLICATION OF MASTIC WEATHER-BARRIER - Contd Preparation - Contd On outside installations, any insulation in relatively horizontal positron shall be sloped for water drainage. Sharp outside corners of insulation should all be rounded off. This is illustrated in Figure XXJ-1. A heavy fillet of caulking mastic should be installed to all inside corners of insulation and to the inside corners where metal projects through moderate and low-temperature insulation. Caulking shall be allowed to dry and set before the application of the weather-barrier mastic. The application of caulking to inside corners is illustrated in Figure XXI-1. A heavy fillet of heat resistant sealer should be applied around all metal projection which will be above 180PF in service. The sealer shall be applied outward from the junction of the projection for a distance six inches over the metal and six inches over the surface of the insulation. As the mastic is a water-base material, it cannot be applied when air temperatures are low. As most manufacturers make a special winter grade, it is possible to spray this special grade below freezing. The limitation for its application is as follows: ^ Standard grade should not be applied when ambient air temperature is less than . 32F nor when the temperature is expected to be as low as 20F within the next j 24 hours. J Winter grade should not be applied when ambient air is less than 20F nor when 1 the temperature is expected to be less than 15 within the next 24 hours. i Troweled or Palmed Application 1 ! Troweled or palmed application of mastic should be done by first bonding the reinforcing cloth to the insulation surface with the weather-barrier mastic. In some instances trowel ! grade mastic requires slight thinning with water to obtain a first coat into which the cloth will embed for good adhesion. The cloth shall be pulled taut with all joints overlapped two inches. All inside corners, rounded off with caulking as previously described, and out side rounded-off corners shall be reinforcing cloth pverlapped as illustrated in Figure XXI-1. The trowel grode weather-barrier mastic shall be troweled or palmed over the cloth, pressing UCC 002974 i < t f f I r t r r STANDARD CXtMICALS A*C PLASTIC CHAPTER XXI APPLICATOR TRAINING PAGE 369 APRIL 19ZP_. APPLICATION OF WEATHER-BARRIERS Figure XXI - 1 UCC 002975 STANDARD OtftfCiU ^LUTK* CHAPTER XXI APPLICATOR TRAINING PAGE 370 APRIL 1970 APPLICATION OF WEATHER-BARRIERS APPLICATION OF MASTIC WEATHER-BARRIERS - Contd Troweled or Polmed Application - Contd it through the mesh to bond it to surface and mastic underneath. Care shall be exercised that the mastic is troweled or palmed over the cloth in a manner to completely seal all the openings in the weave of the cloth. After the mastic has partly set, it should be softly brushed by brush wet with water to produce an even, smooth surface. The combined wet thickness of the weather-barrier coating and mastic when wet should be between 3/32 and 1/8 inch in thickness. To achieve this thickness, for each 15 to 16 sq ft of surface covered one gallon of mastic must be applied. The dried thickness of the material should nor be less than 1/16 inch thick. This weather-barrier shall be carried out six inches onto metal beyond termination of insulation at supports, skirts, or other projections, and shall be sealed from the metal. Spray Application Prior to spray application, adjacent areas not to be coated such as structural steel, floors or walls shall be meshed or screened to protect them from overspray or drip. Valve stems, handles, gauge glasses, instruments, and other such items shall be wrapped with plastic sheet to protect them from splatter. Operation of Spray Equipment Mastic to be sprayed must be of spray consistency. Spray equipment is to be 30:1 ratio airless pump and airless mastic gun. In most instances a .837 reverse-a-clean tip will give most satisfactory results. The first step is to properly hook up the compressors, pump hose and gun. The compressor should be located well away from overspray. Instructions for connecting operating and maintaining pump is given in following instruction sheets 1, 2, 3, and 4. The instructions for operating and maintaining the spray gun is given in instruction sheets 5, 6, and 7. The spray application shall be used only on equipment or large piping over 30 inches in diameter, of sufficient surface area to warrant the use of spray. The insulation surface is covered with a smooth, even coat of mastic of just sufficient thickness to embed the fabric. The fabric shall be applied to the wet mastic, pulled taut, then smoothed and passed by gloved hand to embed it into the mastic. Joints in cloth shall be not less than 2 inches in width and be bonded together by the mastic. All inside and outside corners, previously rounded out, shall be overlapped with two layers UCC 002976 STANDARD OtfWCALS A#C ^VAJTO CHAPTER XXI APPLICATOR TRAINING PAGE 37? APRIL 1970 APPLICATION OF WEATHER-BARRIERS AIR REQUIREMENTS Air input pryiiuiv required Id eptRltl puwp it 20 N 120 p.k.i. Use lowttl oir prtltuN r4tdtd lO oiloio desired IW* oromizotion end coverage. DO NOT eeceed the 120 p.i.i. moaimum. For average sproying o I g.p.m., the pump supplying motertol to onf \oray pv<i will rtquii* opproi. 30 c.f<m. of free oir. Alt comurfwtion wtd Mow rot# figures foe this unit spraying a 56,000 centipoist fhiaofrapic apparent viscosity mastic with 50, 60, and 80 p.i.i. air tupoiy pressure, using Up >*> .029 In. through .07?, art given in Form 306*737 supplied with the Reverie-ACIpoh toav noi J*. INSTALLATION NOTE Pump delivers ? got. ol swltriei tvtry 21 eydit or 3 pal. par minute a* 63 cycles per minute. (63 cycles per minute is the recommended maximum for continuous pump CAUTION Pump develops materiel pressure appro*. 30 times tho In* hound Orf pressure. The working pressure of marterfol ho0 supplied with this unit is strong enough to provide and adequate safety margin e* long as pump ii operating at not mar# than 120 p.s.1. air pressure. PREPARING UNIT FOR USE 01 Place unit in tiesired wadi oao, melting suro that unit otf controls are accessible to the operator and sufficient overhead clearance 18* ft. min.) is available to raise pump completely* '?> Insert two stabilizing legs through stabilizing plate tubes and install legs in sievetar base as shown in Fig. I. Install the other two stabilizing legs in elevator base and secure all le^ with setscrews. (!) Connect material hose to swivel union at outlet manifold and to spray gun as shown in Fig. 1. Attach Reverse~A-Clean to spray gun. (5. Connect o 1 {t, i.d. (min.) or supply hose to l-ln. np.t. (f) oir inlet union. Refer to Fig. 1. Main air line should in clude O Meed type matter oir valve. Instruction Sheet 1 UCC 002977 STANDARD CXtWCAU AMO FlASTITt CHAPTER XXI APPLICATOR TRAINING PAGE 372 APRIL 1970 APPLICATION OF WEATHER-BARRIERS OPERATION 22 CHECKS BEfOPf STARTING (1) Lfnir is factory trtred wi'h o light, rust-inhibiting Ort. The first fe cycles during initial pumping will nonnelly remove this ail. However, to prevent eoominolion of any materiel, th# system should be solvent flushed prior to use. Rotor to para graph 7 ond fallow the iratrvetlora that eppfy, (2) See that motorfol pump vetting cup is rilled with e compat ible solvent or light oil. See Fig. 2. O) Check the dun* reive of outlet manifold to see that It it closed. Refer to Fig. Z* (1) Check the material for heavy fillers, dirt or other toon# particles that might clog spray Up in Reverse-A-Clear*. (5) Rrf>rm the necessary Ivbiicotioo services as indicated us teporoio pump, spray gun ond elevator instruction forms. 3 REMOVING Alt TRAWED UNDER INDUCTOR ELATE (l I Cine pump ON-OFF air uefve. Ihon open master olr valve to eneigixe unit. Refer to Fig. 7. (2) Open oir wnt voire of inductor plote. Refer to Fig, 7. (3) Full knob of push-pull volv* to raise .nit. Refer to Fig. 7. {<| Place on opened 5S-gol. drum of material on itobllirer pfoie under the raised unit, so drum bottom touches elevator bos*. (5) Smooth the top surface of the material until nearly level to lessen th* omount of or that will be trapped under inductor plate. (6) Push knob of puih-pulI vofve to lower unit -- guide in* doctor plot* '"to d*um. (7) Rock ot jiggle pump o firmly seot nduc*or p'o** on top of motoricl ond to ekhoust or tfoppnc/ under plot*. (8) Continue ocfion until moteriol opprsm ot vent opening in ploto then clou o*r went volve. Retor to fig. 7. 4 STARTING 4 ADJUSTING fUMR FO SWAYING CAUTION HANOIt GUN WITH CAC. NOZZIE VELOCITY OANOCROUS. At close range, the prastvra releosod con penetrate the *Wn end causa other injuries* Re* for to separate gun Instruction form 306-771 fur other safely precaution*. (1) Open pump ON-OFF olr value Mly. (?) Tom lever of Revee-A-Oeo into spray position (point* Jng toword fear of gun) end turn toftljr Ittch of spray gun Into "OFf-SAF" petition. Refer to Fig. I. (3) Aim ond (rigger pm info a waste container. Tom ngdeter T" hoodie adjusting hi*w clock*** to Hart pump -* run iIm* ly until obout one-quart of matenof h sprayed or until clean nob/iel ft spraying from gun. Refer to Fig. 7. (4) Set on regulator at a trio! totting of obout 60 pa.l, ond ipray on a tost panel, holding gun about 12 rr*. away, Vory the dittonce to suit the bind of moteiiol being sprayed. (5) If spray oottera H not fully otomtxed, grodvoHy increase the pomp materia) pressure with gif regulator until full otemixotion Is attained. instruction Sheet 2 UCC 002978 STANDARD cxtmuu ut> riMTid CHAPTER XXI APPLICATOR TRAINING PAGE 373 APRIL 1970 APPLICATION OF WEATHER-BARRIERS CAUTION Always gw lowest air prriiure necessary to otormxo A* material. DO NOT e*eed the morimvm recommended oir preurre of 170 PJt.S, ______________ (61 1f io*Oy poMfrn becomes ragged or if spraying stops, swing lerarof Revent-A-Cleon 100* to front ond remove obstruction * by using line prvitu'C. f7> Follow the instruction* given in spray gun literature for pro per ipreying rochmpue. 5 OPE SATING PE CAUTIC.N5 & CAR Of THE UNIT (11 Always slop pump of the bottom of It* stroke and be Wf* wotting cup it filled, to prevent materiel drying on ditplMt* men' rod. (71 Keep pump, hot# end gun filled with material Ip minimize Iha iwciuity lor flulhirg * N(V!I leave unit with olr puoptd nto the system, (3> When gun h not in um, Loop Revone-A-Clean immersed In cloon. compatible solvent. Do not remove gun or Mlvitol haee k.nin to service or to clean. (4)Wh*n unit temporarily shutdown, relieve pWWP In System by doting pump ON-OFF oit volve ond triggering gun Open. 131 Drain surge tank whenever there b MCful* 0 surge at ipwjf gn, R*lov prmn in system (see step (4) obove) before OpOft* ing dump voi-e at outlet monifoldi (6)M spraying a water bote moterial be itirl to (luiH out with mineral ipiritt solvent, doily. Refer to paragraph 7. 6 REMOVING EMPTIED OtUM (I) tftn end bold in knob of air-assist volve to fro# Inductor plot# end rail# it to top of drum. NOTE If while roiling, inductor plot# slop* ot o drum rolling hoop, vt# etevstor to roiie plot pent hoop, then reIrose elevator end continue using oir-ossHt volva. (2) When inductor plot# reaches top of drum, simultaneously, release oir-ouiii knob and pull #i#vetor pushful I knob to rah# plot# above drum. Refer to Fg, 2. flushing procedure NOTE Unit il'OjId be flushed according to general operating con ditions ond !nd of mottrlol pumped -- water base material oi solvent* (such oi k.-tone) Shot ore harmful to rubber hose o> packings vKnt be liushed out with o mineral spirit solvent, daily. Also flush when changing to on incompatible material. The lost working day of the week it o good time to flush unit, (I) Remove drum at explained in paragraph 6, (7) Push knob of pushravf! volv# to lower unit. Refer to Fig.2. (3) Disconnect moterioi orain bock hose from outlet manifold and air-assist hose from inductor plot#, loosen setscrews fn inA(for plot* collar and remove plot# from pump intake. Refer to Fig. 2. (4) Turn solely taleh a*1 2sp3r4ay gun into "ON-SAFE* position. Remove teverse-A-Cleon from gun ond soak in cleon, compat ible solvent. (SI Aim ond trigger open gun Into o materiel container, de*moss pump to O slow speed with elr regulator and pump oir to force moteriof front lythn. Clot# gun end open dump volve to drain materiel from (urge tor*. Close dump value offer took h drained. See Fig. 3. (6) loise unit ond lower pump intoko Into o poll contoining about 2 gal, of clean, compatible lolvent. Open dump volve ond pump solvent through dump valve into a wait# container until solvent is fairly cleon. Then close dump volve, trigger gun ond pump solvent through gun into woste contoinor until clean solvent comes from gun. Refer to fig. 3. Increase pump to high speed ond circulott solvent through gun bock into sol vent container, for several minutes. Cleon inductor plot# and drain bock hose, white solvent is circulating. (7) Stop pump with ON-OFF oir vol ve, drain surge tonk with dump valve, close dump volve ond start pump to refill dump volve with solvent. Drain ond refill several times. (8) Release solvent pressure by dosing pump oir volve and hold ing gun trigger open or opening dump volve. Then remove Surge tor* ond spray gun, ond dean with new solvent. Check smell hole near top of surge tonk body ond cleon, if plugged. Rein stall surge tonk. See separate Instruction Form 306-721 for gun cleaning procedure ond Fonn 306-73? for Reverse-A-Cloon clean ing procedure. (9) Rotihms pump from solvent container ond then pump air to remove sol vent from system. (10) Shut off oir to pump ond reconnect gun to hose, Place pump intake Into o container of dean solvent. Start pump and operate slowly, with gun closed, until pump stalls out, then reiooio pressure in the filled System. Leave solvent In system intii reedy to resume ipreying. ~ NOTE If may bo necessary to repeat slap 7 (61 sovoral times us ing clean solvent, before system is clean enough Ip be stared. DO NOT stare with solvents (such as Ketotra) harmful to rubber. Instruction Sheet 3 UCC 002979 STANDARD 04MCALS AMO ftATTIC CHAPTER XXI APPLICATOR TRAINING PAGE 374 APRIL 1970 APPLICATION OF WEATHER-BARRIERS (11) Remove solvent container, pump oi r through tyttom *9 mmove solvent, ond drain solvent from surge fork ond from lappi In moteriol hose, (121 lilnloll inductor plate, ond drain bock hoM end airratiil hose. Rechorge unit with roteriol (refee to per. 3 & 4) and ihoa pump about dnr^uOfl ef material to woste or until adterlal hoe forced oil rejoining tolvffit from ipire, Reimteil lever*#-AClrun, perform ntcetsory checks before storting (refer to per. 3) ond return spraying.- MAINTENANCE CAUTION ALWAYS RELEASE Alt AND MATERIAL RRESSURES lEFOtE SERVICING UNITS C> TROUBLESHOOTING CHART listed below are trovUtt which mey occur during the use el fhb unit and their probable comet ond possible mem die l. Service retraction* ore given Here or In the teeorote Instruction Fome for the spray pm, pump, regulator, etc. foe the lass common trouble* only. The operator ihould be obfo to ramedy the more common troubles with the efd of the traubtathoofinp chert. Check ell ether possible remedies before disouembling TROUBLES: Pump foils to operate p.eperly- Insufficient pressure or volume with pump operating Excessive surge at spray gum Insufficient moteriof breakup . Too heavy a cooling thickness- Tolls or finger* in spray pattern- Spitting ot spray gun .-- PROBABLE CAUSES: Restricted air supply line Air capacity insufficient Closed or clogged oir volve, regulator, etc. --1 1 Air regulator setting too low or inoperative A* regulator setting too high (120 p4.i. mpv.) -- Material too viscous or cold 111 -- ...... Clogged Reverse-A-Cleon, gun or mat. hoses Material hose too long (pressure drop result*) Dried mottriol seizure of displacement rad 1 ------ Worn packings ar abstracted pump volves " Inoperative pump oir motor Material suuply inwfficient- Nigh flow rate Surge tank oir head lct Improper or worn spray gun tip ...... Worn, damaged pr obstructed gun port* - Improper spraying technique POSSIBLE REMEDIES: Cl rot trapttf lr l*ol, AIR REQUIREMENTS Open or clean Adjust or service Adjust Warm the materiel Oeor, service (Form 306-771 & 306*737) Remove odded hose ($Cf mo*.} Fill wetting cup, clean rod Clear, service (Form 306-735) Service (Form 306-735) Change to full dram Change tip (Form 306-737) Check top plug, relieve pressure6 replace "0" ring teol or drain Change, replace (Form 306-737) Service (Form 306-731) See Farm 306-721 9 PUMT ON-Off AIR VALVE REPLACEMENT Install new or serviced valve at shown in fig, 4 >0 Hw* valve will relieve pr .nun in air motor when closed.70 * * * 70 ruSM-fLILL OR AIR-ASSIST VALVE SERVICE Ta reploce air seals or pocking*, shut off air supply, remove valve end disassemble a* shown in port* illustrations on poge 7. Inspect pom for damoge or wear ond replace o necessary. Instruction Sheet 4 UCC 002980 T STANDARD CHOKMiMOKAfTIO CHAPTER XXI applicator training PAGE 375 APRIL 1970 APPLICATION OF WEATHER-BARRIERS OPERATION CONNECTING HOSE, FLUSHING & INSTALLING TIP (1) Connect a grounded material hose (i in. 10 min.) to gun inlet (j in. NPSM). See Fig. I. NOTE Flush system with a suitable solvent to remove lubri cant. Check system under pressure for leoks at con nections. (2) Relieve pressure (slap pump and trigger gun) and install tip (see Fig. 1) and/or accessory RE VERSE-A-CLEAN TIP or Filter assy. (See poge 3). NOTE, tighten tip retainer nut with moderate tension only. HOW TO USE GUN CAUTION 1. BE,SURE BOTH object being sprayed and the spraying ^/'equipment are grounded. 2. KEEP AWAY from high pressure lpray fo prevent seri ous injury. 3. ALWAYS RELIEVE PRESSURE before removing tip or disconnecting gun ... stop pump and trigger gun. (1) Check tightness of spray tip retainer nut. (2) Check material to be sprayed for particles that could clog spray tip. (3) Stort pump and set oir regulator ot obout 60 psi. Release trigger safety (see Fig. )) and test spray a small area. GASKET TIP _ RETAINER (4) Adjust fluid pressure until proper atomization is obtained use lowest possible oir pressure. NOTE The fluid pressure and spray tip (orifice size and spray ongle) control atomization and pattern length, os well os the flow rote -- which in t.u.r.n...d.e..te..rmines the sprayin g spee d. --- '-4 (5) Use a FULL-OPEN, FULL-CLOSE triggering action. Hold gun about 12 in. away and perpendicular to surface -- do not arc gun. See Fig. 2. A short practice period is odvisable to determine proper distance and speed of strokes. (6) When spraying complex shaped objects, use gun movements that will prevent material build-up and sags. (7) Whenever gun is left unattended, engage trigger safety to prevent accidental triggering. Refer to Fig. I. (8) Clean tip often (at leost twice daily during continuous spraying). Remove ond clean tip ond tip filter (if used) in a clean, compatible solvent and blow dry with air. NOTE A clogged tip may be cleaned by blowing out obstruc tion with air from the front of tip ... this prevents forcing obstruction deeper into tip orifice. If obstruction cannot be dislodged, soak in solvent overnight then blow out with oir. USE EXTREME CARE to prevent damage to knife-like edge of tip orifice. When spraying materials thot dry, harden or set up quick ly, be sure to clean tip often ond keep nozzle immersed in suitable solvent during shutdown periods. Fig. 1. IGROUNDED MATERIAL HOSE 7" NPSM INLET Instruction Sheet 5 UCC 002981 CHAPTER XXI APPLICATOR TRAINING APPLICATION OF WEATHER-BARRIERS ^9 SHUTDOWN & CARE OF GUN (?) Relieve pressure in system and remove and clean spray tip and tip fitter (if used). See (8), par. ?. --------------------NOTE ------ ------------ Check valve seat tightness before reinstalling tip--use from 190 to 210 in.-ib of torque. (2) With gun connected to hose, immerse nozzle in solvent until ready to start spraying again. This will keep air from drying the materiol and lessen cleaning of hose and gun. (3) Flush out gun whenever rest of system or unit (pump, hose, etc.) is being flushed. (4) Gun passageways, needle, diffuser , and spring should be thoroughly cleaned and Inspected regularly -- depending on usoge and type of materiol being- sprayed. Disassemble parts, soak and scrub clean (use supplied brushes) in clean compatible solvent. Inspect ports, replace if worn or damaged, ond reasr rmble on gun. See Fig. 3. CAUTION Handle diffuser and needle carefully, to prevent domage to the Hard carbide portions.______ __ DO NOT change position of adjusting nut on needle. If needle is to be replaced, refer to por. 6 for trigger stroke adjustment. (5) To clean trigger safety latch, remove trigger hand grip (see Fig. 3) ond scrub lotch clean. HYDRA-SPRAY TECHNIQUE HOLD GUN APPROX. 12' to 14* FROM SURFACE KEEP GUN PERPENDiCUlARTO SURFACE , HAVE GUN IN MOTION BEFORE TRIGGERING MAINTAIN EVEN SPEED ALL THROUGH STROKE RELEASE TRIGGER WITH GUN STIbl MOVING Fig. 2 MAINTENANCE CAUTION ALWAYS relieve pressures before servicing gun or tip 4 troubleshooting chart TROUBLES: Trolls at fingers in spray pattern-----Gun will not stop spraying ---------- Spurting from spray tip . Gun will not spray ............. Distorted or uneven spray pattern ---- PROBABLE CAUSES AND REMEDIES i Materiol pressure too low (Increase)--------------------------------------- - -- i V Materiol too viscous or supply low (Thin, refill)--------------------------- Tip orifice too smalt for moterial (Change)----------------------------------- Triggering not positive (use full-opan, or full-close action)---------- Broken or weakened spring (See por. 6)------------------------------ --------- Clogged or worn needle or seat (See por. 3 ond por, 6)------------- - Clogged, worn or wrong tip (clean out or replace)--------------------- 1t- Driod materiol seizure of com shaft packings (Sea por, 5) - No fluid pressure (check pump operation) - Plugged ipray tip or needle seot (clear)---------------------------------- it--tv it 4. it Instruction Sheet 6 UCC 002982 STANDARD OfMCAU AMI RlAlTICS APPLICATION OF WEATHER-BARRIERS CHAPTER XXI APPLICATOR TRAINING PAGE 377 APRIL 1970 5 IF gun leaks at trigger packing nut Reoloce com shaft peeking* os follows: (t) Remove trigger. (2) Unscrew packing nuts and remove packings, glands, and com shaft. See Fig. 4. If com shaft is tight, loosen spring retainer to relieve tension. Refer to Fig, 3. (3) Cleon and inspect parts. Soak new leather packings in light oil until pliable. Assemble parts reverse from disas sembly. NOTE: When assembling trigger, insert cam shaft into cam lever so flats on shaft ends will fit into the forked clamps of trigger. Reclomp trigger fa shaft, tightening the bottom screws first. Refer to Fig. 3. 1 I J 1 ) 1 1 1 D IF GUN LEAKS AT NOZZLE (1) Tighten vofveseafttorque from 190 to 210in. lbs. If leakage (3) When installing needle and spring in gun body, check continues, replace needle, orvalve seat -SEE STEPS (3) & (4) Par. 3. trigger stroke for approx, 5/16 in, travel as shown in Fig. 5. 1 Turn adjusting nut in or out as needed, ond lock in ploce. (2) If needle is worn or damaged, remove lock and adjusting Reassemble ports reverse from disassembly. nuts and using same number of turns, install on a new needle. ] ACCESSORIES (Must be purchased separately) 1 205-614 Reverse-A-Cleon Tip stoppages cfeared with paint pressure by reversing ] tip in nozzle. Includes tip of choice. 164-121 162-863 164-120 164-075 1- 205-265 207-012 Filler Adapter Kit Permanent edge-typ. filter with ,009 in. spacing and mounting parts. Instruction Sheet 7 1 UCC 002983 STANDARD 0CMICALS RtASflO CHAPTER XXI APPLICATOR TRAINING PAGE 378 APRIL 1970 APPLICATION OF WEATHER-BARRIERS APPLICATION OF MASTIC WEATHER-BARRIERS - Contd Operation of Spray Equipment - Contd of cloth as shown in Figure XXI-1. After the first coat has taken its set, a second coat shall be spray applied. This second coat must completely fill all the voids in the cloth and cover it from view. The total combined thickness of the reinforcing cloth and the wet mastic should measure 3/32 to 1/8 inch in thickness. If the sprayed surface is pebbled or unsmooth, it should be smoothed down by water brushing. The weather-barrier shall be carried out six inches onto metal beyond termination of insulation at supports, skirts, or other projections, and shall be sealed to the metal. The heavy-build mastic used for trowel, palm, or spray application requires 4 to 8 hours to dry to touch. During this period of time it should be protected from being washed off by rain or other liquid water. As the material requires approximately 48 hours to cure, it should be protected from mechanical abuses while it is still soft. After curing, any shrinkage cracks which might appear, particularly at inside corners and at projections, should be pointed up with mastic to ensure a water-tight installation. Flashing After trowel or spray application of weather-barrier additional flashing of a cant of mastic over which a trowel coat of mastic, reinforcing cloth and second coat of mostic should be installed around the projections such as nozzles. This is illustrated in Figure XXI-2. Expansion-Contraction Joints Expansion joints in weather-barrier in high-temperature insulations should be constructed with an expansion strip as shown in Figure XXJ-3. Joints installed in vertical position shall be constructed to shed water. Joints in horizontal position shall be constructed in a similar manner except that a bed of non-setting sealer shall be placed between the two layers of expansion strip so as to prevent entry of water, but not restrict the movement between the sheets. The metal strips shall be of 0.008- to 0.010-inch thick stainless steel. Each strip should be sealed to the insulation beneath it by embedding it in the mastic and securing it in position by stainless steel strap. The weather-barrier mastic, with its reinforcing cloth, should be extended over each of the strips but must not be extended over the sheets where they overlap. UCC 002984 r STANDARD QICMCAL* r CHAPTER XXI APPLICATOR TRAINING PAGE 379 APRIL 1970 APPLICATION OF WEATHER-BARRIERS i i i i i i i Floshtng o* Top Nozxfet of Equipment i Figure XX1-2 i 1 i i i i i Figure XXf-3 UCC 002985 STANDARD oewCAU ao puoto CHAPTER XXI APPLICATOR TRAINING PAGE 380 APRIL 1970 APPLICATION OF WEATHER-BARRIERS APPLICATION OF MASTIC WEATHER-BARRIERS - Contd Expansion-Contraction Joints - Contd Expansion joints in low-temperature insulation are constructed with the insulation as described in Chapter XIV - Application of Rigid Insulation - Low Temperature. APPLICATION OF METAL JACKET WEATHER-BARRIER Jackets may be of plastics, laminates, or metal. The specified metal weather-barrier jacketing used in our installations are treated steel and stainless steel, with the exception that aluminum may be used in areas of little fire hazard. When factory aluminum prejacketed insulation is specified, the entire panel is installed as a unit; thus, this is described in the insulation application and will not be described in this chapter. Preparation The materials required for application of metal weather-barriers on equipment are as follows: 1. Metal jacket as specified. 2. Steel metal screws. 3. Equipment insulation strap. 4. Clips for equipment insulation strap. 5. "S" clips. 6. Jacket support clips. 7. Stainless steel wire. 8. Flashing strip. 9. Lap sealer. 10. Non-setting lap sealer. 11. Heat-resistant sealer. The materials required to install metal weather-barriers on straight pipe are: 1. Preformed metal jacket. 2. Pipe insulation strap. 3. Clips for pipe insulation strap. 4. Closure bands, with factory installed sealer. 5. Stainless steel wire. 6. Heat-resistant sealer. UCC 002986 STANDARD otoiCAU mb fuava CHAPTER XXI APPLICATOR TRAINING PAGE 381 APRIL 1970 APPLICATION OF WEATHER-BARRIERS APPLICATION - EQUIPMENT The equipment insulation strap clips shall be embedded into the insulation to provide a smooth, even surfoce for application of the jacket. On vertical vessels, the metal jacket is installed, starting at the bottom. The first course Is supported by jacket support clips, attached to the insulation support. Each vertical joint must be lapped a minimum of three inches or in the case of deep corrugations the metal should be lapped two corrugations. A bead of lap sealer should be placed between the layers of metal on all vertical joints before the joint is fastened together with screws on six-inch centers. Care should be taken to prevent screws being installed in a manner that two courses of metal are fastened together. It is essential that relative movement be allowed between each two courses of metal to provide for the expansion and contraction dimension change of the vessel. The jacket shall be held in position by insulation strap, which should be tightened just sufficiently to secure the jacket. Second and subsequent courses of jacket shall be supported by "S" clips. Each subsequent course of metal jacketing should overlap the preceding layer 3 inches to shed water. At top of vessel, a six-inch-wide stainless steel flashing strip should be installed. This should be bonded in place, overlapping the last course of metal jacket. It should not be attached to the metal jacket so as to form a slip expansion and contraction joint. The mastic weather-barrier used over the vessel head shall be applied down over the flashing to provide water shed. Details of this construction are illustrated in Detail A, Figure XXI-4. Horizontal vessels should always be jacketed with smooth metal jacket. This is because it is practically impossible to water-seal circumferential joints of corrugated metal. The smooth metal jacket shall be installed around the vessel with each course of jacketing overlapped a minimum of three inches with the preceding one. Each circumferential joint should be sealed with a bead of non-setting lap sealer which was placed on the lap area of the installed metal prior to application of the overlapping next course. The circumferential joint should be secured by strap placed directly over the joint. Intermediate straps shall be installed between circum ferential joints and shall be on centers not greater than 18 inches. Horizontal joints shall also have a minimum 3-inch overlap. They should be located on sides of vessel so as to shed water. They shall be secured with screws on six-inch centers. All sharp edges shall be bent under to prevent a hazard. Details of construction are shown in Figure XXI-5. On either horizontal or vertical vessels, if heads or special contours are covered with metal jacketing, the jacketing must be preformed to properly fit. All joints of preformed jackets shall be so formed and fastened together to form a water-tight assembly. Where these jackets fit UCC 002987 STANDARD n-ASTO APPLICATION CF WEATHER-BARRIERS CHAPTER XXI APPLICATOR TRAINING PAGE 382 APRIL 1970_____________ PVA mosfic S Clips Do not place screws /p which will bind two / to coven of jocket together------ / 1 Seal vertical laps wirh lop seoler Detail A Insulation Details 9 and E Mastic weather barrier level with insulating cement. Flashing strip, secure with insulation strop Jacket 3"n. lop Screws on 6-in. centerj Details C and f Details D and E Corrugated Metol Jacket on Vertical Vessel Jacket insulation support per 0-44 Or 0-46 {with slotted holes) us--Jocket support clip K attached to insulation support, see Detail E Jocket Detail $ Jocket Insulation rr~~ J5L i i Detail F $ Clip -Insulation thickness Vessel wall Detoil E Jocket Support Clip Jacket Detail D Jocket support clip ottoched to insulation support, see Detail E. Mastic weather bonier on heod lopped over shell insulation to Insulation support or 3-in, min Figure XXI - 4 UCC 002988 STANDARD PtfMtfAll AMD PLASTICS CHAPTER XXI APPLICATOR TRAINING PAGE 383 APRIL 1970 APPLICATION CF WEATHER-BARRIERS Metal Jacket on Horizontal Vessel Figure XXI - 5 UCC 002989 T STANDARD CMIICALS AMD FUITIO CHAPTER XXI APPLICATOR TRAINING PAGE 384 APRIL 1970 APPLICATION OF WEATHER-BARRIERS APPLICATION - EQUIPMENT - Contd together to the cylindrical jacketing the laps should all be sealed with lap sealer. All projections through the jacket must be suitably fastened and sealed with sealer suitable For the temperature to which it is to be subjected. APPLICATION - PIPING Straight piping insulated with metal jacketing should be weather-protected with preformed jacketing with longitudinal "Z" joint. The metal jacket may be supplied factory applied to the insulation, if the jacketing is not factory applied, the pipe insulation should be secured with stainless steel wire. Ends of wire shall be twisted and embedded in surface of insulation so as to provide a smooth, even surface for application of the jacket. Jacket (or pipe insulation with jacket attached) should be installed by placing the jacketing in position and engaging the "Z" joint. Longitudinal joint on horizontal pipe shall be located on horizontal centerline of pipe with open end down to ensure runoff of water. The jacketing (or pipe insulation and jacketing) should be secured by strap drawn tight and fastened with clip. On diameters of pipe insulation 6-5/8 inches and under, one strap shall be used at center of assembly. Larger diameters should be secured with two straps, each approximately 12 inches from end of assembly. The butt joint between adjacent assemblies shall be sealed with a closure band. These bands shall befurnished with sealing compound on each of the edges, so as to make a water-tight joint. Some of the excess sealing compound should be located between the strips of compound directly at the closure of the "Z" joint to provide a seal at the closure overlap. The closure bands shall be tightly secured in position with pipe insulation strap. This assembly is shown in Figure XXI-6. Where the straight pipe is metal jacketed and fittings weather-protected with mastic, the mastic should be installed in the manner described in the first part of this chapter. The weather-barrier mastic and fabric reinforcing should be lapped over the metal jacket for a minimum of one inch. UCC 002990 STANDARD 0CMC4U AND PLASTIC! CHAPTER XXI applicator training PAGE 385 APRIL 1970 APPLICATION OF WEATHER-BARRJERS Figure XXI - 6 UCC 002991 STANDARD fWtMTALt 4X> njJtTO CHAPTER XXII APPLICATOR TRAINING PAGE 386 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND Hi6h TEMPERATURE SERVICE There are three basically different systems used to insulate warm and hot lines underground. One is the field applied insulation; another is the factory insulated piping conduit systems; and the third is the fill type of applications. Whenever it is necessary to provide heat tracing for a line the field applied insulation is most frequently used due to the complex problems of securing properly designed traced piping from the manufacturer of preinsuloted conduit enclosed pipe. FIELD APPLIED INSULATION General As all underground lines are subjected to ground pressure and water, the insulation must have high compressive strength and be water and vapor resistant. These requirements restrict the choice of insulation down to one-cellular glass. Preparation The trench in which the insulated pipe is used must be properly prepared, otherwise the finished installation may be damaged by any sharp projection or uneven contours when the assembly is placed in position. A typical trench is shown in Figure XXII-1. The sand bed at the bottom of the trench is essential to spread the compressive load imposed on the bottom of the cellular glass when the insulated pipe is lowered into the trench. The digging of the trench and its preparation is not done by the insulators, however, the insulator should make sure that this work is done in accordance with the specification. The pipe to be insulated should be cleaned of all oil, grease, dirt, rust, or scale. Where coating is required, it must be coated in accordance with the coating schedule and specifica tions. The coating should be completely dry before insulation application is started. If the pipe is to be steam traced or electric traced, the tracing should be installed in accordance with the specifications and in the manner described in Chapter XII - Application - General. All of the cellular glass insulation pipe covering and fitting covers should be prefabricated to dimensions required. All the insides of the pipe covering should be coated with anti-abrasive coating to prevent pipe movement from wearing away the insulation. This coating applied on the inner bore and edges of the pipe covering must be dry before the insulation is installed. If the insulation is to be installed on stainless steel pipe, the bore coating should be a silicon-graphite, anti-abrasive coating. Installed on pipe of other metals, the anti-abrasive coating should be formed of a water solution of Keene's cement. UCC 002992 T STANDARD OtfNCMi UDKAinO CHAPTER XXM APPLICATOR TRAINING PAGE 387 APRIL 1970 __________ APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Figure XXII - 1 UCC 002993 STANDARD OtCMCAU AND PLASTICS CHAPTER XXII APPLICATOR TRAINING PAGE 388 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE FIELD APPLIED INSULATION - Contd Preparation - Contd The accessory materials required for an application of cellular glass to pipe which is to be located underground is as follows: 1. Stainless steel wire 2. Pipe insulation strap 3. Clips for pipe insulation strap 4. Anti-abrasive coating 5. Anti-abrasive coating (for application to stainless steel) 6. Concrete support pads (field poured) 7. High temperature fabrication cement 8. Joint sealer 9. Reinforcing cloth (g lass fabric) 10. Water-barrier coating 11. Graphite pipe slides for support pads Application Being installed underground, the cellular glass insulation on the outside of the pipe cannot move. Any movement of the insulation would cause cracks in the water barrier which would allow entry of liquid water from the soil. For these reasons the pipe movement, due to expansion and con traction, must befree to take place without hindrance inside of the insulation. Thus, expansion chambers must be built into the insulation to provide space for the movement of the pipe. In this application, its water barrier must be so constructed as to a water-tight conduit as well as an insulation. Thus, every joint must be water tight and the system so constructed that pipe movement will not exert forces on the insulation to break it and cause it to lose its water tightness. Straight Pipe Insulation up to 2-1/2 inches in thickness is to be installed in single layers. Installations of 3 inches thickness and greater is to be installed in multiple layers. This pipe insulation is to be applied in staggered positions. Where multiple layer insulation is used, butt joints of one layer must not coincide with those of any other layer. The cellular glass insulation must be fitted with very tight joints. Large voids should not be filled with coating or cement, but the insulation should be recut and refitted to eliminate voids. UCC 002994 STANDARD OtCilfCALS WO RLAJT*CJ CHAPTER XXII APPLICATOR TRAINING PAGE 389 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE FIELD APPLIED INSULATION - Contd Straight Pipe - Contd All installations where installation of insulation is on piping whose service temperature is less than 212F shall have all longitudinal and circumferential butt edges buttered with joint sealer before application. These joints should be drawn together when the insulation is applied so that only a thin, vapor-tight and water-tight seal separates the sections of insulation. Insulation installed on piping operating above 212F should be installed without sealer in butt joints, however all butt edges and joints should have been previously coated with abrasive resistant cement. Wherever it is necessary to field cut and immediately install pieces, the field cut butt edges should be buttered with sealing compound to prevent abrasion of these butt joints. All inner and outer layers up to and including 12 inch OD shall be secured with stainless steel wires. All single, or outer layers of cellular glass over 12 inch OD shall be secured by stainless steel strap and double pronged clips. Spacing of the wire or the strap should be as shown in Chapter XI - Figure XI-14. Expansion Chamber An expansion chamber, constructed of insulation of larger inside diameter than the outside diameter of the pipe, shall be provided to allow for pipe movement at lead-off lines, expansion loops, and where pipe direction changes at elbows. The inside diameter of these expansion chambers must be sufficiently large to accommodate all the movement of the pipe without the exerting of forces on the cellular glass. The inside diameter of the insulation for the expansion chamber should never be less than four inches greater than the outside diameter of the pipe. However, if pipe movement is greater than two inches in either direction, this inside diameter must be increased to allow for free movement of the pipe. Expansion chambers should never be constructed of cellular glass insulation less than 2 inches in thickness. If, for temperature consideration, the cellular glass requires greater thickness than 2 inches then, of course, this greater thickness shall be used. The expansion chambers shall be constructed in such a manner that concrete pad supports molded to fit the bottom of the expansion chamber will support the bare pipe. Between the concrete pods and the bare pipe, graphite pipe slides shall be installed to permit free movement of the pipe. UCC 002995 STANDARD CHtMCAU u*> HMlia CHAPTER XXII APPLICATOR TRAINING PAGE 390 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH temperature^ ervice FIELD APPLIED INSULATION - Contd Expansion Chamber - Contd A table for determining the lengths and spacing of these concrete pads is given in Figure XXH-2. Detail of installation of the graphite slides is shown in Figure XXII-3. A general assembly of an expansion chamber at lead-off pipe is shown in Figure XXII-4 and at elbows (or expansion loop) is shown in Figure XXII-5. In all cases, the oversized pipe insulation used to construct the expansion chamber should overlap the pipe covering on the straight pipe at least 6 inches. This overlapping joint shall be sealed with lap sealer. Water-Barrier Application Being underground, the assembly of the insulation plus the water-barrier must be a water tight conduit which keeps the pipe dry. Thus, the outer finish over the insulation must be installed with different materials and methods than ordinary weather-barriers. The outer surface of the insulation shall be sprayed, brushed, or gloved with water-barrier mastic to a thickness not less than 1/8-inch in thickness. While the coating is still tacky, tar impregnated glass fabric reinforcing cloth shall be laid smooth and embedded in the mastic. Ail edges of cloth shall be overlapped a minimum of three inches to provide a joint of equal strength to that elsewhere. While the first coat is still tacky, a second coat of 1/8-inch thickness should be applied in the same manner as the first coot. A second layer of the glass reinforcing cloth shall be installed in the second coat of mastic in the manner described for the installation of the first cloth reinforcing. Finally, before the second coat is completely dry to touch, the third coat of water-barrier of 1/8-inch thickness should be applied. The coating and layers of cloth shall be installed in a uniform manner to prevent uneven contraction and a tendency toward surface cracks. Installation in Trenches After the water-barrier mastic has dried the assembly should be carefully laid in the trench on the sand bed. During the moving of the assembly, care must be taken to prevent bending of ihe assembly which would crack the insulation and water-barrier. Should the assembly be inadvertently cracked, the insulation and the water-barrier finish should be carefully repaired to be as crack free as all other parts. Care must be taken to prevent trenches from filling with water, and if so, located so that its water level could not rise above lower third of assembly. The trenches should be equipped with drain tile to drain water away. It must be remembered that hot gas or steam lines insulated with cellular glass might be lighter than their displacement of water; and if the trench became filled with water, might float to the surface. UCC 002996 STANDARD CXGWCAU AM> PLASTta CHAPTER XXM APPLICATOR TRAINING PAGE 391 APRIL 1970____________ APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Nominol Pipe Size | length of Concrete Pod (Inches) | Dim nfi" (Inches) 3 ond smoKer 4 5 6 8 10 12 | 6 6 12 12 12 12 Continuous Max C-'to-C Spacing (feet) a 5 8 6 4 3 -- Size and Spacing of Concrete Support Pods Figure XXII - 2 UCC 002997 STANDARD CXXCUI AHDEIASDQ CHAPTER XXII APPLICATOR TRAINING PAGE 392 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE ss insulation INSTALLATION OF GRAPHITE CRADLE AND SLIDE PLATE BETWEEN PIPE AND CONCRETE PAD Figure XXII-3 UCC 002998 STANDARD CKtMOU U9 ^.AJTO CHAPTER XXII APPLICATOR TRAINING PAGE 393 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Figure XXII-4 Woter-feorrier finish -- Cellular glass, oversize pipe insulation -- 9c Concrete support pad and slide plates Concrete chamber cover Straight pipe insulatiorn >,v^ See Figure 10-JU-6 for Section A-A j Distance to be sufficient to olio* for free pipe movement Joint sealer- 6-in. min Insulation overlap Plon Expansion Chamber fear Elbows oncf Exponsion loops Figure XXU-5 UCC 002999 STANDARD CMCMtGtU AMD ^LAJTCS CHAPTER XXII APPLICATOR TRAINING PAGE 394 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE FIELD APPLIED INSULATION - Contd Installation in Trenches - Contd Backfill over the assembly shall be with a minimum of three inches of sand around the outside of the insulation. For one foot above the assembly, the backfill should be rock free earth. Above that the trench may be filled with any fill material available. A section of completed straight pipe so insulated and installed in a trench is shown in Figure XXU-7. A section of the expansion chamber is shown in Figure XXII-6. FACTORY INSULATED PIPE AND CONDUIT General Factory insulated pipe includes the pipe, insulation, outer conduit and accessories for the joining together of the pipe, insulation, and conduit sections. As such, the pipe insulation and conduit must be ordered as a ``package" to comply with the piping design. One type of preinsulated pipe and conduit is pipe insulated with urethone foam in PVC jackets. Another type is pipe insulated with any specified insulation, factory installed in steel conduit. As each of these must be installed in a particular manner, the presentation regarding their installation is separated. URETHANE FOAM INSULATION, PVC JACKET CONDUIT This type of preinsulated pipe conduit is used on systems normally operating at temperatures from 50F to 250F. As the insulation itself is water-resistant, it is particularly advantageous when used on piping operating at less than 2I2F, but at a higher temperature than the ground in which it is buried. As a factory insulated system, the insulator is responsible for application of the insulation at the connections between the individual sections and fittings. Preparation The trench in which the insulated pipe conduit is to be laid must be in accordance with the drawings. The bottom of the trench should be uniform and smooth. It is essential to determine that all straight insulated conduit, all factory insulation fittings, insulation stock, and compression couplings are available at start of installation as these are custom made and not readily available. Types of fittings are shown in Figures XXII-8 and XXII-9. UCC 003000 STANDARD CMDnCAlS AMO PLASTICS CHAPTER XXII APPLICATOR TRAINING PAGE 395 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND Hl6H TEMPERATURE SERVICE Concrete cover Celluior gloss (oversize) Woter-berrier finish Sand Bockfill Graphite Slide Plates tile if required) Expansion Loop Cross Section with Installation Completed Figure XXI1-6 Rock-free FackfTH Sor>d Cellular glass Backfill moteriol to suit Woter-barrier finish Grovel (odd drain file if required) Trench Cross Section with Installation Completed Figure XXI1-7 UCC 003001 STANDARD CHAPTER XXII APPLICATOR TRAINING PAGE 396 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Figure XXIf-8 Typical Prnl<rtd Pipe ood Tubing Fitting* Figure XXIf-9 UCC 003002 STANDARD oiku.>n.tn>c CHAPTER XXII APPLICATOR TRAINING PAGE 397 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE URETHANE FOAM INSULATION, PVC JACKET CONDUIT - Contd Preparation - Contd Prior to installation of any pipe or fittings, the compression coupling and its components must be placed around the conduit adjacent to the section or fittings to be jointed. This is of utmost importance as after the pipe is welded together, there is no way in which these can be put in position around the conduit. Application After the piping has been welded together, the loose scale, paint, dirt, grease, and other con taminate materials should be removed from the exposed ends of the pipe. Pipe should then be tested. The urethane insulation stock furnished to cover the exposed pipe ends should be fitted in between adjacent factory installed insulation. This pipe insulation shall be secured in position with stain less steel wire. The joining sleeve should then be slid into position over the joint insulation. When in position, the stainless steel clamp rings shall be pulled tight by the bolts compressing the rubber seal around the PVC conduit. Assembled coupling around joint is shown in Figure XXII-10. Anchors and terminals require special treatment. The anchors are supplied with steel welded directly to the pipe. The insulation is installed around the pipe butted up to anchor steel. The sections of preinsulated pipe conduit are installed to this anchor as previously described. However, as the outer sleeve coupling must also butt up to the anchor steel, it is furnished in two sections which after being placed in position are solvent welded to obtain its outer seal. After the insula tion and sleeve are installed th- concrete anchor is poured around the assembly. INSULATED METAL CONDUIT This type of preinsulated pipe is used for systems normally operating at elevated temperatures. The top limit of operation is determined by the insulation specified. The preinsulated conduit con be obtained with glass fiber insulation having a maximum temperature of 450F, calcium silicate with a maximum temperature of 1000F, expanded silica with a maximum temperature of 1400F, or with high-temperature calcium silicate with a maximum temperature of 1800F, However, generally, the ordinary usoge is up to 750F, as special design is required for the higher temperature. Similar to other factory-applied conduit systems, the field insulator is responsible for application of the insulation and water proofing at the field-connected junction between individual sections and fittings. A typical anchor assembly is shown in Figure XX11--11 and a conduit terminator assembly is shown in Figure XXII-12. UCC 003003 STANDARD CMCMCALS AM> n.ASttO CHAPTER XXII APPLICATOR TRAINING PAGE 398 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Typical Urthan CompT>sion Coupling - Field Applied Figure XXII - 10 UCC 003004 STANDARD OXBGALi H.MTO CHAPTER XXII APPLICATOR TRAINING PAGE 399 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Figure XXII-12 UCC 003005 STANDARD CHIMCAL) AND PUASTICS CHAPTER XXII APPLICATOR TRAINING PAGE 400 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE INSULATED METAL CONDUIT - Contd Preparation The trench In which the insulated pipe conduit is to be laid must be in accordance with the drawings. The bottom of the trench should be uniform and smooth. As the insulated pipe conduit is custom made, it is essential to check to determine that all of the sections and fittings specified are available before the installation is started. After the lines are welded and tested, all loose paint, dirt, rust, scale, or other extraneous materials should be removed from the exposed ends of the pipe before the insulation and water proofing is installed. Application The connections between sections of preinsulated conduit are water sealed in two different ways depending upon the particular conduit obtained from the manufacturer. Insulation Installation 1. The specified insulation is fitted to the exposed pipe ends which were welded together, shown in Figure XXII-13. The sectional insulation ts secured in position by insulation straps and clips. This operation is shown in Figure XXII-14 and XXII-15. 2. The welder positions the cylindrical conduit closure and then seam-welds it to the conduit. This operation is shown in Figure XXII-16. Water Sealing of Bituminous Covered Conduit 1. All metal surfaces should be covered with a brush coat of water proofing coating furnished by the manufacturer. 2. The areas between the connection band and the shop coating should be wrapped with impregnated blanket, embedded in the water proofing coating to bring the surface of this equal in height to the connection band. 3. Over the area between the ends of the shop coating in the conduit, cover with the water proofing coating. One side of the impregnated blanket should be covered with the coating, then with coated side of the blanket inward. The blanket should be firmly pressed in position. After blanket has set in place, its entire surface should be covered with the water-proofing coating to obtain a minimum thickness of the field |Oint of not less than 1/8 inch. UCC 003006 STANDARD OtfMCAU NO PLASTICS CHAPTER XXII APPLICATOR TRAINING PAGE 401 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Figure XX11--13 Figure XXII-14 UCC 003007 STANDARD OtgMCALS *M> PLUTO CHAPTER XXII APPLICATOR TRAINING PAGE 402 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND H|GH TEMPERATURE SEWlCE Figure XXII-15 Figure XXII-16 UCC 003008 [ STANDARD GHtMOLS rk-4iTlG I CHAPTER XXII APPLICATOR TRAINING PAGE 403 APRIL 1970 APPLICATION TO UNDERGROUND PIPING I MODERATE AND HIGH'TEMPERATURE SERVICE I INSULATED METAL CONDUIT - Contd 1 Water Sealing of Bituminous Covered Conduit - Contd 4. Drape the top and sides of these field joints with 15-lb asbestos pipe line felt before backfilling. I Water Sealing of Epoxy Coated Conduit I 1. All high spots of welds and burned coating should be removed by grinding or filing. The entire joint surface should then be cleaned with acetone, methyl 1 ethyl ketone, or xylol. 2. The epoxy coatings furnished, for this water and corrosion sealing, are a two- ] part-mix catalyst type. The contents of the catalyst should be added to the epoxy coating, then stirred for four or five minutes. 1 3. The mixed coating should be applied to the entire joint area and over the factorycooted conduit. This must be allowed to dry for a minimum of eight hours before proceeding with next coat. 1 4. The second coat of epoxy should be applied while the first coat is still soft. Two layers of 6-inch-wide glass cloth, overlapping 2 inches on each wrap, should be I spiral-wrapped over the joint, and 6 inches over the adjacent factory-applied conduit wrapping. Each layer should be wrapped in opposite directions, and each layer should be brush-coated with the epoxy coating. After thirty minutes, when coating over last 1 layer of glass cloth has set tack-free a final heavy coat of epoxy coating should be applied giving a completely smooth outer surface. Backfilling should not be started t before coating is hard. 1 Note: The curing time of epoxy coatings is affected by temperature and humidity. As temperature goes down, the curing time of the epoxy is increased. Also, when humidity increases, the 1 time af curing is increased. At ambient temperatures of 60F or above, no heat need be applied to accelerate the cure of the epoxy coating. If ambient temperature below 60F is encountered and it is necessary to backfill trenches with a minimum delay, heat may be I applied to the joints to accelerate the cure. This may be accomplished by the use of infra-red electric bulbs or radiant heaters. Care must be taken that the coating is not heated above 150F, as temperatures above this will burn or deteriorate the coating. 1 Trench Backfilling 1 The backfilling material should be free of rocks ond concrete debris. No backfilling should be done on both sides of the conduit simultaneously. The soil should be deposited in uniform layers, X not over six inches in thickness and tamped. m UCC 003009 STANDARD oichcau tm PiA*ra CHAPTER XXII APPLICATOR TRAINING PAGE 404 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE FILL TYPE INSULATION This type of insulation is a bituminous fill which is poured and tamped around the pipe in the trench. When heated it fuses around the pipe to form a protective envelope. Proper grade of material, depending upon temperature of pipe, must be used to obtain this fushion. PREPARATION The trench must be properly prepared to allow sufficient space for installation of the insulation. The pipe installed in the trench must be supported to allow for sufficient insulation between the bottom of pipe and bottom of trench. Minimum dimension for trench to accommodate various sizes of pipe is shown in Figure XXII-17. Where width of trench Is greater than required, a leap frog form should be constructed for side walls. Special trenching is required at expansion loops with allowance provided for pipe movement. Dimensions of trenches at loops are given in Figure XXII-18. Process lines must be completely welded and tested before installation of the fill insulation. Also, all loose paint, rust, dirt, and scale must be removed prior to application of insulation. All standing water in the trench shall be removed before commencing application. APPLICATION The fill insulation should be removed from the bags with a minimum of free fall, in order to reduce the dust. Generally it is installed most efficiently by placing unopened bag on the pipe, then slitting it, then carefully pouring the insulation out of the bag around the pipe. The fill insulation shall be installed in successive layers approximately six inches in thickness. Each layer must be thoroughly consolidated by knifing vigorously with a round shovel point or similar tool. Care must be taken to compact the material solidly against the bottom and around sides of pipe. When the top layer has been knifed thoroughly it should be leveled and tamped. Tamping should be done with 8" x 8", 1/4" thick steel plate attached to handle of suitable length. This application may be made in the trench cavity or be in side wall forms. Where the bituminous fill insulation system emerged above the surface, a transition consisting of a 20 gauge galvanized steel jacket shall be provided for the fill insulation to extend above the ground surface. The junction of the bituminous fill insulation and the above-grade insulation shall be sealed with a weather-barrier coating. This is illustrated in Figure XXII-19. UCC 003010 STANDARD OtfitfCALS *> MJTO CHAPTER XXII APPLICATOR TRAINING PAGE 405 APRIL 1970 APPLICATION TO UNDERGROUND PIPING MODERATE AKid high temperature servo RECOMMENDED NOMINAL NN SIZE INCHES ENVELOPS DIMENSION MIN. INCHES I TO 4 a AMOS 10 AND 12 ! 4 9 0 a 41 -- Pipe support NOTE: Lines burled closely, as shown, must be at approximately the same temperature* Lines of dissimilar temperatures should not be in the some trench, and wherever possible should be 6'-(T apart. ApplicoHpn of Bituminous Fill losuiotion to Underground Piping Figure XXII-17 Plon View Application of Bituminous Fill Insufotion to Urderground Expansion Loops Figure XXII-18 UCC 003011 STANDARD me fuma CHAPTER XXII APPLICATOR TRAINING PAGE 406 APRIL 1770 APPLICATION TO UNDERGROUND PIPING MODERATE AND HIGH TEMPERATURE SERVICE Preformed insulotion, m specified Weather barrier seal over fill and metal joefcet JO^goge golvonTzed iteel jacket, outside surface coated with two coots of corrosion-resistant coating before Installation* Bituminous fill insulation RECOMMENDED ENVELOPS NOMINAL PIPE $J2E, INCHES DIMENSION "A" MIN. INCHES 1 TO 4 4 S AND ft s 5 ft 10 AN0 12 tft S 11 transition and Termination of Bituminous Fill Insulation Figure XXIM 9 UCC 003012 STANDARD APPLICATION ~0 UNDERGROUND P1f*|NG MODERATE AND fgv^5RATjgSiVgs ^PLICATION - Contd /here lines insulated 4.1*1 with bituminous . * fill enter c raertnoie ^ ___it *ftfyy woll| tfi ptpM |M| e inserted in a sleeve projecting rnroogn me wail. Sooce ^cw t]ctkr% Qn^ J7 be packed with asbestos rope or leod Docking. P*P* "*** Vhen application is completed the Insularion racer Oe -- tr--~ m r specified by the manufacturer. RENCH BACKFILLING he backfilling material should be free of race at c." oeoris. The soil should be esoei n uniform layers not over six inches in rhicxness snc *p. tar cam xidetioA. tecUili ndl not be less than 12 inches over the too of me oinjaunous Trs^arion. UCC 003013 STANDARD ftoBUCALS AW PLASTIC) CHAPTER XXIII APPLICATOR TRAINING PAGE 408 APRIL 1970 SAFETY AND HEALTH DEFINITION The dictionary definition of safety is: The condition of being safe from undergoing or causing hurt, injury or loss. In this sense safety covers more than just the prevention of personal injuries but also covers pre vention of damage to personal health, and prevention of property and production loss. Safety means the prevention of accidents, the definition of accident being: an accident is an unintentional interruption to an orderly process - a turning aside of an intended procedure. Thus, safety is the orderly manner to achieve desired results free of loss due to injuries, health, time, or property. To accomplish safety in our complex construction of plants and their operation requires highly intelligent craftsmen. SAFETY REGULATIONS City and State Construction Laws and Regulations The laws and regulations of cities and states governing construction differ in each community, thus it is impossible to present in this chapter any reasonable summory of these laws. However, even though there may be differences, these laws were passed for the protection of the individual and they should be followed. Recommended safety practices for construction have been set forth in a manual "Manual of Accident Prevention in Construction" by the Associated General Contractors of America, Inc. All Union Carbide Corporation construction personnel or contractors are expected to abide by the practices set forth in this manual. Company Regulations and Safety Practices Each plant has developed safety practices for its particular set of conditions. These too were developed for the protection of the individual and it is of extreme importance that each individual abide by these for his own protection and those of his fellow employees. These following statements are made to further establish the company's safety policy for construc tion and maintenance craftsmen. The more particular circumstances in which the insulator must take precautions are presented in this chapter. UCC 003014 STANDARD OUMCALS JLA5TO CHAPTER XXIII APPLICATOR TRAINING PAGE 409 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES Protection from Falls To install insolation on equipment, on columns, vessels and pipes at elevations above ground level requires that the applicator work from scaffolding and ladders. Ladders Falls from ladders ore one of the most common construction accidents. Intelligent use of ladders is necessary to prevent accidents. Use of Ladders 1 . The ladder selected for a particular job must be one intended for that use, and in good safe condition. 2. The foot of the ladder should be placed approximately 1/4 of its length from the vertical plane of its top support. 3. Ladder feet should be placed on substantial, level base. 4. Both top and bottom of the ladder must be secured to prevent movement. Securement should be as shown in Figure XXIII-1. 5. Ladders leading to platforms, or walkways, must extend at least 36" above that level. 6. Long ladders must be braced at intermediate points as necessary to prevent spring. 7. Ladders must be climbed or descended properly, by facing the ladder and using both hands to hold onto rungs. 8. Objects should not be carried In hands while climbing or descending a ladder. 9. Metal ladders must not be used around electrical circuits, because if they accidentally come in contact with a "hot" wire they become a conductor of electricity. Scaffolds Other than falls, the use of scaffolds has one other potential hazard; that is, objects laid on scaffold boards falling off causing damage or injury. UCC 003015 STANDARD OtfMCALS AW ^LAStCS CHAPTER XXlli APPUCATOR TRAINING PAGE 411 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES - Contd Protection from Falls - Contd Scaffolds - Contd Although it is not the responsibility of the insulation applicator to build scaffolds, he should make it his responsibility not to work on any scaffold that is unsafe. To help him judge scaffolds the following is presented. 1. The scaffolding must be on firm footing. Footing should be secured against movement by recessing, staking or other means. 2. All uprights must be plumb. For steel scaffolds less than 75 ft. high, 2" diameter tubing* is recommended. For scaffolding above this height, 2-1/2" diameter tubing is minimum. 3. Platform of wood planks must be firm and steady. All lap joints should be at ledgers, minimum 6" drop lap on each side of ledger. All planks should be secured by wire and/or nails to provide solid footing and prevent them being blown off by wind. 4. Guardrails and toe boards are recommended. 5. Install overhead danger signs. Use of Scaffolds 1. Scaffold working platforms should be free of ice, snow, oil, slick dust, or other debris while being used. 2. No open fire should be permitted upon or near wooden scaffolds, or flammable components such as canvas or polyethylene covers. 3. Scaffold structures should be protected from trucks or other vehicles. 4. No materials should be stockpiled on scaffolds. 5. Swing stage scaffolds should be tested with four times the load before being used. All suspension ropes or cables, blocks and sheaves should be frequently inspected. No more than two workmen should be permitted on a swinging scaffold. Workman should be equipped with safety harness with harness snaps attached to "edge" in 1/4" steel rope every 5 ft. which is anchored to a secure overhead attachment. UCC 003017 STANDARD otfuicAU t*o PLAsna CHAPTER XXIII APPLICATOR TRAINING PAGE 412 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES - Contd Protection from Bums Applicators of insulation must be careful to prevent burns to themselves and others. There are three major hazards contributing to accidental bums; these are: (1) fire, (2) hot surfaces, and (3) chemicals or solvents. Protection from Burns by Fires Everyone knows that fire can cause serious burns, and no one attempts to come in contact with fire or flame. The important factor is preventing accidental fires. As this is such a broad and important subject it will be discussed later in this chapter as a separate subject. Protection from Burns by Hot Surfaces Many burns are caused by an individual coming into contact with a hot surface. Our safety requirements state that hot piping or vessels operating at high temperatures shall be insulated 6'0" above grade or operating levels to prevent burns. Unfortunately for the con struction and maintenance insulation workers, they must apply insulation at levels where hot pipe or vessels are not insulated. For this reason, no bare pipe or projection should be used for hand support or for climbing until it is determined that it is not too hot. Any blackened copper tube or pipe is most likely hot. Aluminum pipe or aluminum jacketed insulation can be very deceptive. Because of its low emittonce, aluminum radiates very little heat, thus gives little warning that the surface is hot. However, where in direct contact, its high conductivity will transmit heat to the skin rapidly, causing severe burns. Protection from Exposure to Solvents or Chemicals Many chemicals, such as acids or caustics can cause burns, or be very toxic. Care must be taken not to come into contact with liquids or vapors of unknown chemicals. Take extreme caution in working near a leaky flange, valve and any vent valves. Vent valves are dangerous as they might be discharged unexpectedly. When removing insulation, do not handle any saturated insulation with unprotected hands unless it has been previously determined that the liquid is nontoxic and nonburning to the skin. In cases where a person inadvertently does come into contact with chemicals he should immediately wash in a safety shower ond use nearest eye bath. Foreign matter in the eye should be flushed out with water. The eye should not be rubbed under any circumstance. As soon as possible report to the Medical Department fora checkup. UCC 003018 STANDARD CHAPTER XXIII APPLICATOR TRAINING PAGE 413 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES - Contd Protection from Exposure to Solvents or Chemicals -- Contd Before storting work in a chemical unit, the applicator or his foreman should check with unit head operator to determine location and nature of hazard in that unit. Each insulator must be advised of these hazards. In all cases, when working in areas of toxic chemicals, proper protective clothing, safety glasses and masks must be worn to prevent injuries. Many materials used such as adhesives, sealers and insulation contain compounds which will burn the skin, are toxic, or cause eye irritation. When these are hand mixed, applied, or sprayed, the first most important step is to read the instructions and warnings on the can or container. These instructions must be followed. Prevention from Exposure to Excessive Noise Extended exposure to loud noise can cause reduction in hearing ability. When work must be performed in noisy locations proper ear protection devices as recommended by plant safety group must be worn. Prevention of Cuts and Electrical Shock Cuts are most generally caused by the improper use of power tools, hand tools, or from coming into contact with a sharp projection. All insulators must use tools which can cause bad cuts. Power Tools Other than cuts, electric power tools may cause an electric shock to the user if a tool is improperly connected or grounded. Most permanently placed electric-driven equipment, properly connected by the electricians, is free of electrical hazard. The major cause of electrical shock is in the use of portable electrically driven equipment in improper condition. Some of the main points to be remembered are: 1. Check Operating Department to be sure that electrical tools are suitable for use in the area. (Hazardous Work Permit) 2. If extension cords are used, make connections at the tool and then toward the power source. An improper connection, or short, then will blow the fuse rather than shock the user, 3. Check frequently for cable insulation breaks, especially at the socket and at the point of attachment to the tool. 4. Make sure that oil tools are properly third-wire grounded or are of the double grounded type. UCC 003019 STANDARD Of&KALSAfC PLASTICS CHAPTER XXIII APPLICATOR TRAINING PAGE 414 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES - Contd Prevention of Cuts and Electrical Shock - Contd Power Tools - Contd 5. When electric tools are used in wet areas, an insulated platform and rubber gloves should be used. Use of Power Tools Other than cuts, proper precautions from eye injuries must be taken when using power saws, drills or other cutting equipment. 1. Damaged or worn tools should not be used. They must be repaired or replaced before use. 2. Safety equipment, such as guards, must be used. 3. Proper eye protection must be worn. 4. Saw blades must be regularly checked and kept in good condition. 5. Blade used must be as recommended for material being cut. 6. Approved type respirators must be worn when operator is exposed to harmful dust. Use of Hand Tools 1. The weight, size and type of tool should be selected to fit the job. 2. All cutting tools should be kept sharp, as sharp tools improve accuracy and are safer to use than dull tools. 3. All tools should be protected against damage from corrosion. Keep adjustable parts lubricated to prevent wear and for efficient operation. 4. All tools should be placed in tool holders, or secured in proper manner so that they cannot fall from scaffold. 5. When required, such as when sheet metal is being installed, proper protective gloves must be worn. UCC 003020 STANDARD 04NCAU AM> AJJTO CHAPTER XXIII APPLfCATOR TRAINING PAGE 415 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES - Contd Prevention of Cuts and Electrical Shock - Contd Sharp Projections 1. Care should be taken at all times not to fall, slip, or walk against any projection which can cause injury. 2. Wire, with ends twisted to secure insulation, should have twisted ends bent back and embedded in insulation. 3. Sharp, cut ends of straps, or clips, should be enddown and back to prevent sharp projection. 4. Any sharp corners of metal jackets should be rounded off. 4. Sharp edges of metal jackets should either be folded or bent back so as not to be a hazard. Protection-from Eye Injuries 1. Care must be taken to prevent any splashing, drip, or vapor of chemicals coming into contact with the eyes. 2. Care must be taken to prevent particles of solids from getting into the eyes. 3. Approved eye protection must be worn at all times. Protection from Falling Objects 1. Before entering any construction area observe what hazards may exist overhead. Do not stand or work where there is danger of falling objects. 2. Wear hard hat at all times in plant or construction areas. 3. Remove all loose objects from ledges or scaffold platforms prior to performing work in that area. UCC 003021 STANDARD CXfttCALS AND RVAJTtC' CHAPTER XXIII APPLICATOR TRAINING PAGE 416 APRIL 1970 SAFETY AND HEALTH PROTECTION FROM PERSONAL INJURIES - Contd Protection from Moving Equipment I. When necessary to work near or over moving or rotating equipment, it is necessary that when working above this equipment a deck must be provided, and when close to the sides a barricade should be erected. Protection from High Pressure Spray Equipment If not handled carefully, any compressed air operated pump or spray gun can be dangerous. Loosened jets or tips can be ejected under pressure, hose or container can be split by pressure, thus thorough knowledge of equipment being used is important. Unfortunately, due to all the types and manufactures of pumps and equipment, it is impossible to give detailed instructions in this manual and only the fundamental precautions can be given. 1. Never exceed the recommended air pressure of the equipment being used. 2. Even though unit is stopped and air to pump is shut off, there still remains dangerous pressure in the system. This pressure must be relieved to prevent accidents while servicing or handling. 3. Handle gun with care. Nozzle velocity is dangerous. At close range the pressure stream CAN PENETRATE THE SKIN TO CAUSE SERIOUS INJURY. 4. Always use extreme care when removing hose from gun. A plugged line contains liquid paint, mastic or chemicals under pressure. Always release pressure in system by closing pump air valve and opening dump valve or spray gun. 5. Precautions for handling gun is given in following chart. Protection from Compressed Air 1. Hose and equipment must be in good safe condition. 2. Plant air must never be used to clean dust off clothes. FIRST AID, REPORT OF ACCIDENTS, AND GENERAL POLICY ON EMERGENCY SITUATIONS It is important to all craftsmen to know what to do in case of an accident or emergency. Each Plant and each Department within a Plant have different rules covering such safety items. The training covering these safety items should be given all employees in General Craft Training. Most Plant Training Programs will include: UCC 003022 STANDARD OtCMOLS AM) PUlSTiCI CHAPTER XXIII APPLICATOR TRAINING PAGE 417 APRIL 1970 SAFETY AND HEALTH FIRST AID, REPORT OF ACCIDENTS, AND GENERAL POLICY ON EMERGENCY SITUATIONS -Cont, 1. Emergency reporting procedure using emergency alarm boxes to provide emergency aids such as Fire Protection, First Aid Rescue Squads, Operating Supervision, and Doctors when on duty. 2. Dispensary reporting system for injuries other than emergency. 3. Unsafe working condition reporting system. 4. Job Hazardous Analysis system. 5. First Aid general instructions. HEALTH PROBLEMS Health problems can be caused by the materials being produced in the plant (or unit) in which work is being done by the applicator. Likewise, health problems can be caused by the materials (insulation or accessories) being applied by the applicator. Chemical plants produce liquids and gases which are toxic. For this reason care must be taken in working in a chemical plant not to come into contact with toxic liquids, nor breath toxic fumes. As eoch unit within a plant is probably different from others within that plant, safety precautions not only differ from plant to plant, but also unit to unit. For this reason the craftsman must become familiar with the safety precautions necessary in each unit where he is working. These safety precautions must be followed. During application of some insulation materials and accessories the installation itself may be a health hazard unless proper precautions are taken. PRECAUTIONS IN APPLICATION Spraying of Urethane Foam Insulation Where urethane systems are sprayed to produce foam insulation, the fumes and droplets in the surrounding air are toxic and hazardous. When sprayed indoors or a confined area, fresh air masks must be worn, in all cases eyes should be protected by safety glasses. When mastics or other coatings mixed wi th toxic solvents are sprayed, safety precautions stated above should be followed. Various solvents are toxic, so in mixing, spray or brush application, care must be taken. Epoxy compounds are an example of such materials that might cause skin rashes, severe itching, eye irritation and respiratory ailments. Materials of this type must never be used without adequate UCC 003023 STANDARD OCHKALI AID FUSTICS CHAPTER XXIII APPLICATOR TRAINING PAGE 418 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Sproying of Urethane Foom Insulation - Contd ventilation. Confined fumes and solvent vapors can seriously irritate the eyes, lungs and respiratory tract. Likewise confined fumes may be a fire and explosion hazard, in cases where fumes or solvents come into contact with the skin they should be immediately washed off with soap, water and scrubbing brush. Protection from Dust Hazards Dints of various kinds cause respiratory and lung ailments. In the past few years considerable attention has been given to dust associated with insulation materials. It has been shown that excessive exposure to dust containing asbestos has a detrimental effect. The lungs of workers of excessive exposure to the inhalation of asbestos contain small microscopic size structures composed of fiber coated with layers of protein and iron. This non-malignant lung disease is called asbestosis. The risk of asbestosis can be eliminated by proper protective measures and use of proper breathing equipment. Safety Practices for Handling and Applying Thermal Insulation Products Containing Asbestos Pipe and Block Insulation Warehousing, Storage and Handling Under normal conditions, the handling, storage and warehousing of undamaged cartons of pipe and block insulations, containing asbestos, present no health safety problems. If cartons are broken or materials damaged while insulation is being handled, the following steps should taken: 1. Core should be taken to avoid generating dust when piling, stacking or placing pieces into containers. 2. If spillage occurs, debris should be cleaned up immediately. Repack usable materials. 3. When cleaning spillage, vacuum equipment is recommended for picking up dust and small particles. 4. If large quantities of spillage occurs and cleaning involves sweeping and/or shoveling that could create excessive airborne dust, the waste should be wet down with water and should this not be possible or dust still occurs, approved breathing equipment should be worn. UCC 003024 STANDARD ooucAis ano plastics CHAPTER XXIII APPLICATOR TRAINING PAGE 419 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Safety Practices for Handling and Applying Thermal Insulation Products Containing Asbestos - Contd Pipe and Block Insulation - Contd Warehousing, Storage and Handling - Contd 5. Only usable material should be returned from the job site to the warehouse. 6. When returning material from the job site, clean dust and debris off cartons. Repack odd lot pieces. Close cartons. Fabrication in Warehouse and Job Site Shops 1. Open and remove the material from cartons with care. 2. Handle and stack pieces of material in a manner that will avoid breakage and generating dust. 3. Mechanical dust collecting systems adequately designed to remove dust at the source should be installed on power-operated, fixed and portable equipment in the warehouse shop and/or in the job site shop. 4. All machines should be furnished with suitable waste containers for the collection of scrap and waste to prevent the material from failing on the floor and generating dust. 5. Shop-fabricated pieces of Thermal Insulation such as fittings, segments, etc., should be placed in containers. Care should be taken when handling these pieces during piling, stacking and packing. 6. Containers should be closed after packing and remain closed until the materiol is used. Application Procedures 1. Unpacking and application of the material should be cone in a manner that will minimize airborne dust. 2. Avoid dropping, throwing or unnecessary rough handling of insulation materials. 3. Keep floors and surfaces clean of scrap, shavings and debris. Put unusable material into waste containers immediately. UCC 003025 STANDARD OtCMCALS AND PLASTIC CHAPTER XXIII APPLICATOR TRAINING PAGE 420 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Safety Practices for Handling and Applying Thermo! Insulation Products Containing Asbestos - Contd Application Procedures - Contd 4. Hand sawing, cutting, jacket stripping, etc. should be done in a manner that will create minimal airborne dust. Use of proper methods and tools will help considerably towards dust abatement. 5. When working in confined spaces, portable dust collectors or exhaust blowers should be provided to remove dust from the source. 6. If conditions prevent collecting or exhausting dust from the source, use exhaust blowers to provide general room air changes. 7. Avoid exhausting into other working areas. 8. In confined spaces, if mechanical exhaust equipment cannot be used, approved breathing equipment should be worn. 9. When wiring or banding insulation and applying jackets or facings, care should be taken to avoid generating excessive dust, using the precautionary measures described above. 10. Surplus usable materials should be placed in cartons, which should be closed and returned to the warehouse. Cements Warehousing, Storage and Handling Handling and storage of closed bags containing cements do not present health safety hazards, provided bags are unopened and not broken. 1. When unloading railroad cars and trucks, if there is excessive loose material resulting from opened or broken bags, respirators should be worn during clean-up and unloading. 2. Spillage should be cleaned up and open or broken bags repacked, resealed or discarded immediately to prevent distribution of dust into other areas. 3. If bags are damaged and spillage occurs in the warehouse, material should be cleaned up immediately to prevent distribution into other areas. Vacuum equipment is recommended for this cleaning. UCC 003026 STANDARD CHEMICALS AM> nJUTO CHAPTER XXIII APPLICATOR TRAINING PAGE 421 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Cements - Contd Warehousing, Storage and Handling - Contd 4. If large quantities of spillage occurs and cleaning involves sweeping and/or shoveling that could create excessive dust, respirators should be worn. Application of Cements Opening, dumping and discarding of bags should be done with the utmost care to avoid generating excessive dust. 1. Open the bag wide enough to empty without shaking. 2. When dumping, keep bag on the mortar box mixing level to avoid dropping. 3. Do not shake bags. 4. Place empty bags in a container, wet down contents, and discard. 5. Mixing area should be well ventilated, but free from heavy drafts that will cause dry material to become airborne. 6. Material should be mixed In a mortar box, pail or tub and not on the floor. 7. Wet the material and mix into a slurry as quickly as possible. 8. When mixing cement in a confined space where proper ventilation is inadequate, respirators should be worn. Cleaning 1. Bag breakage, cleaning up dry cement and discarding bags at the mixing area should be handled in the same manner as recommended under Warehousing, Storage and Handling. 2. Wet down tools, mortar boxes, wheelbarrows, mixing containers, and any spillage before scraping ond cleaning. 3. Cements should be handled wet whenever possible. Wet material will create no dust problem. UCC 003027 STANDARD chemicals mc PLAJDO CHAPTER XXIII APPLICATOR TRAINING PAGE 422 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Cements - Contd Spraying of Thermal Insulation Spraying Areas Spraying of Thermal Insulation Products containing asbestos requires special precautionary measures. Refer to the Sprayed Mineral Fiber Manufacturers Association for Sprayed Fiber Application Practices. 1. The equipment and machinery to be sprayed should be shielded by adequate wind breaks and, where practicable, drop cloths to prevent excessive dust and contamina tion in adjacent areas. 2. Workers not engaged in the spraying operations should wear respirators when entering an area within 15 feet of the spraying machine, nozzle or equipment. 3. Where Sprayed Fiber Application Practices cannot be followed and excessive airborne dust is generated, it is recommended that portable mechanical exhaust ventilation be used to remove airborne dust. Exhaust must be located to avoid contamination of other occupied areas. Application 1. All personnel in the immediate area engaged in the machine feeding and spraying operation should wear respirators, whether in confined or open areas, ventilated or not ventilated. 2. Respirators should be worn after the spraying operation has been concluded and until the generated dust concentration has cleared. Other Workmen All personnel not involved with the machine feeding and spraying operation should be kpet from the spraying area until the generated dust concentration has cleared. Cleaning 1. Spillage and excess spraying materials should be cleaned up immediately after spraying operations have been completed. UCC 003028 STANDARD OtWUU AK> PUiTId CHAPTER XXIH APPLICATOR TRAINING PAGE 423 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Cements - Contd Spraying of Thermal Insulation - Contd Cleaning - Contd 2. Settled dust and fly material should be removed from all surfaces to avoid airborne contamination. Vacuum cleaning is recommended for this purpose. 3. Scrap spray material should be wet down and placed in closed containers for disposal. 4. Tools, ladders, etc. should be cleaned wet. 5. Avoid brushing, sweeping and shoveling dry material whenever possible. 6. Respirators should be worn during clean-up. Stripping^of-Thermal Insulation Stripping Area Careful work methods, use of proper tools, and wetting down will minimize excessive dusts in stripping operations. 1. The area in whichstripping takes place should be confined by means of curtains, portable partitions, etc., to prevent excessive dust contamination in adjacent areas. 2. If area cannot be confined, only workmen engaged in stripping should be permitted in the work location. Stripping and Tearing Off 1. All personnel in the stripping area engaged in tearing off, handling, cleaning and disposing of material should wear respirators. 2. Where circumstances permit, materials should be wetted down prior to and during removal. 3. Where applicable, portable mechanical exhaust ventilation should be used to remove airborne dust. 4. Avoid unnecessary re-handling of scrap. UCC 003029 STANDARD OttttfCALS AND M.AITO CHAPTER XXItl APPLICATOR TRAINING PAGE 424 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Cements - Contd Stripping of Thermal Insulation - Contd Stripping and Tearing Off - Contd 5. Locate truck, "Dumpster" bucket or final disposal equipment as close to stripping site as possible. 6. Wet down scrap material before shoveling, hauling or dumping. 7. Do not permit accumulation of scrap and debris on floor and other surfaces. 8. Vacuum equipment is recommended for cleaning up during and after stripping. Other Workmen 1. Personnel not involved in the stripping and tearing off operation should not be permitted in the stripping area. 2. If it is essential for other workmen to be in the work area, respirators should be worn by them. Safety Practices for Handling and Applying Thermal Insulation Products Containing Mineral Fibers Tests indicate that mineral fibers can cause respiratory difficulties and skin irritation. For this reason they should also be handled in a manner not to generate dust. Listed below are the protective measures to follow when these materials are used. Housekeeping An organized housekeeping program should be maintained in all areas and on all operations at all times. A major source of excessive airborne dust is from loose materials, scrap, and debris distributed throughout the job area and disintegrated by trampling on, running over, etc. Much of the airborne contamination can be eliminated by exercising simple good housekeeping practices. UCC 003030 STANDARD 04CWCAL5 A*0 WjtfTO CHAPTER XXIII APPLICATOR TRAINING PAGE 425 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Safety Practices for Handling and Applying Thermal Insulation Products Containing Mineral Fibers - Contd Housekeeping - Contd Specific standords and practices designed for providing safe, clean and orderly working conditions should be defined. Efficient supervisory control, planning of systematic cleaning plus day to day follow-up are the basic requirements for dust control and health protection. Physical Contact with Mineral Fibers 1. If particles accumulate on exposed skin areas, do not rub or scratch. Remove the particles by washing thoroughly with soap and warm water. If water is not available, use dry wash materials (waterless soap and paper towels). 2. Long-sleeve shirts, long trousers and caps should be worn to cover maximum skin areas to ovoid contact with the mineral fibers. Clothing should be loose fitting at collars, wrist bands and waist bands and waist to eliminate skin irritation. 3. Barrier creams applied to exposed skin areas will provide protection against skin irritation. They should be used prior to handling the material and applied according to instructions. 4. Good personal hygiene practices are essential. Thoroughly wash exposed skin areas periodically and shower at end of the work day. Change and launder work clothing frequently, separately from other articles. 5. Proper work methods and practices that will eliminate the creation of excessive dust should be adhered to at all times. 6. Suitable gloves should be worri when handling abrasive materials. 7. Mineral fiber slivers that superficially penetrate the skin should be removed by thorough washing. Those embedded in the skin should be removed immediately and medical treatment administered. 8. Safety glasses, goggles or face shields should be worn when applying materials overhead, or in areas where airborne particles may get into the eyes. UCC 003031 STANDARD chemicals and plait CHAPTER XXIII APPLICATOR TRAINING PAGE 426 APRIL 1970 SAFETY AND HEALTH PRECAUTIONS IN APPLICATION - Contd Sofety Practices for Handling and Applying Thermal Insulation Products Containing Mineral Fibers - Contd Exposure to Excessive Mineral Fiber Dusts 1. When mineral fiber materials are machine sawed, die cut, slit, etc., mechanical dust collecting systems adequately designed to remove dust at the source should be installed. 2. Hand cutting, jacket stripping, etc., should be done in a manner that will create minimal airborne dust. Proper methods and tools will help considerably to abate dust. 3. When working in confined spaces, dust collecting systems adequately designed should be provided to remove dust from the source. If conditions prevent collecting dust, use exhaust blowers to provide general room air changes. Avoid exhausting into other work areas. If mechanical exhaust equipment cannot be used to remove excessive dusts, respirators should be worn. 4. When applying mineral fiber insulation overhead, workers should be clothed as described under "Physical Contact with Mineral Fibers", wear eye protection and respirators if excessive dust is generated. 5. When mineral fiber thermal insulations are stripped from piping or other surfaces, the area in which stripping takes place should be confined by means of curtains, portable partitions, etc., to prevent excessive dust concentrations in adjacent areas. All workers i n the stripping area engaged in tearing off, handling, cleaning and disposing of material should be clothed as described under "Physical Contact with Mineral Fibers", wear eye protection and respirators. Where circumstances permit, materials should be wetted down prior to and during removal. Where applicable, portable mechanical exhaust ventilation should be used to remove airborne dusts from the area. 6. Avoid unnecessary rehandling of scrap by locating disposal equipment as close to working area as possible. Do not permit accumulation of scrap and debris on floor and other surfaces. FIRES AND EXPLOSION HAZARDS Similar to other hazards previously mentioned, the hazard of fire and explosion involving insulation may be during the period of installation, or possibly after the installation is completed. In the first instance, the preventing fires or explosions during the time of application can generally UCC 003032 STANDARD QMCAU AIC fLASTO CHAPTER XXIII APPLICATOR TRAINING PAGE 427 APRIL 1970 SAFETY AND HEALTH FIRES AND EXPLOSION HAZARDS - Contd be controlled by safe installation practices. All plant safety regulations must be followed, such as wearing of hard hats, safety glasses and no smoking. Fires caused by coatings or insulations after installation may be the fault of incorrect design, or selection of materials over which the applicator has no control. However, when an applicator substitutes a material from that specified, he may, without knowing it, be the cause of a fire or explosion. Safety Practices to Prevent Fires and Explosions During Application Welding Whenever welding is required, such as for the attachment of securement pins, when in an operating plant a hazardous work permit must be obtained and all precautions taken as required by the plant. The following are some of the fundamental safe practices which should be followed: 1. Frame of ail welding machines should be grounded. 2. Remove all loose combustible materials from area of welding. 3. Remove all volatile materials such as solvents or paint from area of welding. 4. Wet down any combustible material with water and have standby water hose. 5. Shield all wood scaffold planking with asbestos felt or metal. 6. Provide metal bucket for disposal of hot electrode stubs. 7. Wear proper protective clothing such as eye shields, flame-resistant gauntlet gloves, flame-resistant aprons and caps. Handling and Application of Combustible Coatings and Solvents Coatings and solvents should be carefully handled to prevent damage to the cans and their identification. Care should be exercised to prevent contamination. All drums should be grounded in accordance with Standard EL-64, to make them safe from static build-up when material is poured from drum into smaller containers. Adequate fire extinguishing equipment should be provided at storage locations. UCC 003033 STANDARD OdUTN 1 Af0 PLASTICS CHAPTER XXIII APPLICATOR TRAINING PAGE 428 APRIL 1970 SAFETY AND HEALTH FIRES AND EXPLOSION HAZARDS - Contd Handling and Application of Combustible Coatings and Solvents - Contd When any combustible insulation, coating, sealer or adhesive is used, care must be taken that none is installed or spilled on hot surfaces which might cause ignition. Particular care must be used in the installation of materials in units, pipes, or vessels already in operation. Fire and Explosion Hazards of Insulations and Coatings in Service Chemical leakage and atmospheric contamination may be absorbed by many insulations. Insulation saturated by chemicals can be a hazard in two ways: One, due to the large amount of liquid it can absorb, saturated insulation is capable of holding up to five times its own weight of a liquid. With the amount of insulation used on vessels and pipes it thus, when saturated with a combustible, can provide large quantities of fuel for a fire, and be responsible for fire spread. Two, many chemicals react (such as oxide) in the presence of insulation to cause fires, or their flash point and flame point temperature is so reduced by the chemical contamination that they are easily ignited. In one year the Process Safety Department, in one plant, reported 35 fires caused by flammable chemicals in insulation. This resulted in initiating tests to determine self-ignition of chemicals in contact with insulation. From this program certain guidelines for the use of insulation been developed. ]. Vessels and pipe containing ethylene oxide should be insulated with expanded silica insulation. For ordinary temperature control Spec. 22-H, or where longer term fire protection is necessary 32-HFP, should be used. 2. Acetylene lines and vessels operating above ambient temperature should be insulated with expanded silica insulation Spec. 32 HFP, and below ambient temperature should be insulated with a combination of inner layer (or layers of cellular glass and outer layer of expanded silica in accordance with Spec. 32 LFP. 3. No copper wire or tracing are to be used where there is acetylene or acetone present. 4. Combustible insulations, such as urethane, should never be installed on reactive or toxic service vessels or lines. (See attached recommendation from Fire Protection Department.) 5. When urethane insulation is used on any vessels or fines containing combustibles, all safety devices or spray protection must be calculated as for a base (uninsulated) vessel or pipe. UCC 003034 f STANDARD otnou ** mjhiric: r CHAPTER XXIII APPLICATOR TRAINING PAGE 429 APRIL 1970 r SAFETY AND HEALTH r FIRES AND EXPLOSION HAZARDS - Contd Fire ond Explosion Hazards of Insulations and Coatings in Service - Contd i 6. Because of water channeling and other problems, any vessel insulated with urethane insulation requires special placement of spray heads. f 7. Urethane insulation should only be used in accordance with fire protection regulations that follow. i In addition to the insulation the weather-barrier may be a potential fire hazard. If the weather-barrier is of mastic it may be of a material which reacts with other chemicals, or it i may not resist chemical attack, allowing the chemical to saturate the insulation. In addition, any mastic which has high surface burning rate can spread fire. i Aluminum jacketing melts very rapidly in a fire, thus will not protect insulation from direct fire exposure. As the hot molten metal drips, it can be a secondary ignition source for combustibles which may be below. i Treated steel and stainless steel jackets and fire-resistant mastic have been found to be the most satisfactory of weather-barriers. However, treated steel jacket should never be used i on Ethylene Oxide lines because iron oxide reduces the self-ignition temperature of the material. i Hot surfaces may cause the ignition of chemicals from pressure relief valves or leaks. Where such hazards exist, it is of utmost importance that ail surfaces which might be so contaminated be insulated so as to have a safe surface temperature. This necessitates that the correct thickness i of insulation and the correct weather-barrier be used. In such applications the installation of aluminum jacketing can be very dangerous as it will raise the surface temperature on the insulation on hot lines or vessels 75F to I25F, i PREVENTION OF POTENTIAL FIRES BY USE OF LEAK INDICATORS i Leaks of certain chemicals from flanges are very hazardous, particularly where these are hidden and can be absorbed by the insulatipn. These chemicals require that a leak indicator be in stalled around the flanges before the insulation is installed. At present leak detectors are to be i installed in accordance with IC4 Piping Specification. When insulation is installed care must be taken to prevent any insulation getting into the tube. i A Piping Standard is being developed and will be issued at a later date to cover in more detail the fabrication and installation of these indicators. i r UCC 003035 STANDARD ocuaouj mo funo CHAPTER XXIII APPLICATOR TRAINING PAGE 430 APRIL 1970 SAFETY AND HEALTH FIRE PROTECTION RECOMMENDATIONS FOR USE OF RIGID POLYURETHANE INSULATION The following recommendation* are intended as o guide from a fire protection standpoint, for the use of setf-^oitinguishing type rigid polyurethane foam Insulation on chemical processing and storage equipment. Eoch case should be engineered separately as there are "gray areas'* between each of the definitions shown. 11/6^67 - The self-extinguishing type is no longer required on outdoor piping only. SERVICE OR USE Ethylene Oxide, Acetylene, Peracetic Acid, and Other Unstables LPG, Olefins Plants, etc. Stable (Ordinary) Flammable* Aluminum Line* and Equipment with Stable Flammable* Aluminum Line* and Equipment with Unstable Flammable* FIRE RETARDANT NONCOMBUSTIBLE OUTER COVER OUTER LAYER INSUL. WATER SPRAY (Wrtthtr-Barrle,)_________ (Min. 1" Thick)___________________ PROTECTION___________ OTHER Required Required Required Full 0.24 gpey^ft^ Standard Water Water Spray Appl icotion rate. Required Required Required Required Not Required Not Required Required (1-1/2" When LPG) No Polyurethane. Full Fire Resistive Insulation Required. Required Not Required Not Required Required No allowance for insulation in SV sizing. Full .24 gprq/ft with reduced allowance for rundown, requiring odditionol spray nozzles* No allowance for tnsulotion SV sizing. Water spray ordlnorilyp not required. However, if needed, use full .24 gpm/ft^ and additional spray nozzles as for LPG and Olefins Plante Full .24 gptq/ft^ water spray application rate. UCC 003036 STANDARD OQMCMi AMD PlAlTICi CHAPTER XXIII APPLICATOR TRAINING PAGE 431 APRIL 1970 SAFETY AND HEALTH MAINTENANCE OF INSULATION In addition to safety practices already recommended, there are two additional recommendations which should be followed. 1. In repair or replacement of insulation installed on vessels or lines containing combustible and reactive chemicals, the Engineering Standard Specification recommendation was developed for safe installation and operation. If deviation from the standard or substitution of materials is felt desirable, the proper engineering representative responsible for insulation should be consulted before such deviation or substitution is made. 2. Weather-barriers should be kept in excellent repair, not only to keep insulation efficient, but also to prevent entry of toxic fumes or flammables into the insulation, the result of which may be quite hazardous. UCC 003037 I STANDARD OeMCALS AfO JOTC SAFETY AND HEALTH CHAPTER XXIII APPLICATOR TRAINING PAGE 432 APRIL 1970 LIST OF REACTIVE CHEMICALS Acetaldehyde Acetaldehyde monoperacetate Acetal do! Acetic anhydride Acetone Acetyl chloride Acetylene Acrolein Acrolein dimer Acrylic acid Acrylonitrile Ally! chloride Aluminum chloride Amyl aldehydes, primary Vntimony trichloride 'is(2-cyclopentenyl) ether oron trifluoride ethyl etherate ,3-Butadiene utadiene peroxide utyl acrylate ,2-Butylene oxide utyl peroxide utyraldehyde utyric anhydride alcium carbide olcium hexammoniate alcium hypochlorite afcium metal alcium oxide -Chioropropiona I dehyde alorosulfonic acid ilorotrifluoroethylene apper acetyl ide otonaldehyde, 91% oton oil otylidene dicrotonate 3-Cyclopentadiene Cyclopentadiene Cyclopentenyl chloride cyl acrylate, primary acetylene Diacetyf peroxide Dibenzoyi peroxide Dibutyl fumarate Dibutyl maleate 2.3-Dichloropropionaldehyde Dicyclopentadiene, 92% Diethyl acetal Di(2-ethyI hexyl )fumarate Di(2-ethylhexyl)maleate Diethyl maleate Diethyl sulfate Dihexyl maleate 2.4-Dihydroxy-3,3-dimethy Ibutyroni tri le Diisobuty(aluminum chloride Diisopropyl maleate Diisopropyl peroxydicarbonate Diketene Dilauroyl peroxide Di(methylamyl)maleate Di(methyl CELLOSOLVE) maleate Dimethyl maleate Dipropionyl peroxide Dipropyl peroxide Di(tert-butyl) peroxide Dripolene "C" Epichlorohydrin 2-Ethyoxy-3,4-dihydro-2H-pyron 3-Ethyoxyprop iona Idehyde Ethyl acetoacetate Ethyl acrylate 2-Ethyl butyl acrylate Ethylene cyanohydrin Ethylene oxide 2-Ethylhexyl acrylate Ethyl l-propenyl ether 2-{5-Ethylpyrid-2-y 1 )ethyI acrylate Formaldehyde GIutaraIdehyde, 25% in water Glycidyl ocrylote Glyoxal, 30% in water 2.4-Hexadienal UCC 003038 STANDARD Ottoii mo Fumo CHAPTER XXIII APPLICATOR TRAINING PAGE 433 APRIL 1970 - SAFETY AND HEALTH r LIST OF REACTIVE CHEMICALS- Contd* * 3 4 Hexaldehyde Hydrazine Hydrogen cyanide, 96% Hydrogen fluoride Hydrogen peroxide N-(2-Hydroxyethyl)ethylenimine o-HydroxyodipaI dehyde, 25% in water Isobutyraldehyde Sodium crotonate Sodium hydroxide Sodium metal Sodium methylate Sodium sorbate Styrene Styrene oxide Sulfuric acid Isoprene Isopropyl peroxide Isopropyl sulfate Ketene Maleic anhydride Tetraisopropyl titanate Toiylerte diisocyanate Tridecyl aldehyde (mixed isomers) Triisobutyialuminum Valeraldehyde Methacrolein Vinyl acetate 3-Methoxybutyraldehyde Methylacetylene Vinyl butoxyethyl ether Vinyl butyl ether Methyl acrylate Vinyl 5-butylmercaptoethyl ether 2 -Methyl butyraIdehyde Vinyl butyrate Methyl isocyanate Vinyl chloride Methyl isopropenyl ketone Vinyl 2-chloroethyl ether Methyl methacrylate Vinyl cyclohexene monoxide 2-MethyIpental dehyde Vinyl ethyl CARBITOL Nickel carbonyl Vinyl ethyl ether Nitric acid Vinyl 2-ethylhexanoate Paraldehyde Vinyl 2-ethylhexyl ether 4-Pentenal Vinyl S-ethylmercaptoethyl ether Peracetic acid Vinylidene chloride, 1% phenol and Peracetic acid (25% in ethyl acetate) 3.2% acetone Perchlorfde acid Vinylidene chloride monomer 2-Phenoxyethyl methacrylate Vinyl isobutyl ether Phosgene Vinyl isopropyl ether Phosphorous oxychloride Vinyl methoxyethyl ether POLYOX catalyst Vinyl methyl ether Potassium hydroxide Vinyl propionate Potassium persulfate Vinyl 2,6,8-trimethyl-4-nonyl ether Potassium sorbate 1 Propadiene Propionaldehyde t Propylene oxide Pyruvic aldehyde, 40% in water Silicon tetrachloride Silver acetylide J Sodium aryl(2-methacryloxyethaxy)benzene sulfonate UCC 003039 STANDARD 0--011 M nTKl APPENDIX APPLICATOR TRAINING PAGE 434 APRIL 1970 APPENDIX TEMPERATURE AND HEAT TFMPERATURE CONVERSION TABLE FAHRENHEIT SCALE LISTED IN EVEN NUMBERS . Cl 9 --r1 A rr 4*1* ilT . II 7 tt.T tJ 1 257 7) oo 1*7 >9 9 31 0 37.1 72 t 333 71. .251 7j. *330.t|. 3J I* r *3. 3.. -34? t.. -20.} . 9> *10 4 7 tt 2 *7*.'*,- 31 3 -741 7!. a. u)i it- at W7 1) 3 -7 Ol. 39 -399 *<- *0/ .29 ol. tt 9 TV* -tv.*1. 7X7 3-. *3.7 k.l -9* 7;. 37 1 726 H. 303 M T IT.I )14 9 2 -714 0,. 91 M.7 9 1 *7)4 39.3 -323 9 . 9.* .713 > - 0.4 *737 t . 4>.0 *1,1 47 1 43 t 49.2 on I . 3* 321 7 . 95 0)1 i!. 3 -?S ttl -IX O'. 2 nt 7* 7 75 7 7* 7 Tt 7 9 -m * . 39 > 79 7 HJ nt * * J 79 7 M -729 ) . 379 7 *3 * -nr i. 37) > 7 4t 0 nt i - 377 93 t i -726 7.. 9) 0 7 47 1 -77* > * 37J *4 7 47 t -7?l 4 . Si to r 2 -171 0 . in U 7 -77* * . 37? 7 7 0 3 -779 * . VI M.7 m -m \ . 9 tt 7 30 4 -m 91* M 7 11 0 -373 7i. 50 91 t It i -27' 7 - 967 ft.7 V 1 *37> H* 93 7 Vt S3 2 33 1 M3 * 55 -3N l . 2t3 -22 0 . 96* -il* 9*3 I t . 93 -2'l 2 . 2t> -TIT t.. 9 *4 7 99 7 H7 97 7 tt 7 *9 7 )* 0 |*3<7 09 TO > 3* 3 1-7'* 04 01 7 17 1 1-31* 1- 07 <n > 37 3-J.l}- 99* 09 > tt J 111 9'* 9tt 10* 7 to t mw (IM IIM 01*16 SMTOxl" R . icTv- n K c 10) 7 It*.9 15) 3 2 -319 * tt) 106 7 U0.4 -IS.) -20 tt) 107 7 III.* -103.2 a 21) - ttl in / III.) 1)2.2 -ttl -111.) - DO <0 7 m i 151.1 -a 61 3 -211 7 - 54* HO 7 m IJ0,6 -09 *3 1 -Oil > 540 VI! 7 113.) -1X.0 43) *2 6 *3 64 9 210 * . 3*3 -JMO - tt* -209 4 ttl 20*1 . 54* 112.7 M9 7 114 7 m.7 12).0 IB.* >14.) I-IM.9 1)4 9 .1.] m *1-147 -tv -Itt -135 754 . 54) >16.7 Itt.dl-UT.l 40 *5-4 -107.1 - ) 117.7 1)6 )M.7 -IS *6.0 201.7 - 5*1 110.7 m i -1 1 -321 3 20* * - 3* IlT.7 IV *M4) * *7 1 206 1 9 IX. 7 130 2 -145.01 -72* 7 4 -30) * - Itt m.7 Itt U4 an 205 Q 337 m.7 129.) -10.9 M t t-2tt * . 596 1)5.7 IV 9 -40 ] at - 5 194.7 1X.fHS 1 23) 4* .9 -209 I - Jtt m 7 1)1 0 -rn.r a* 4 -20 - 333 136.7 191.5 Ml .7 122 71 0 r-IQ.2 . IV 7 Itt.l 141.1 rl 7 - > 120 7 19 * 140.6 -201 1 . 930 IV 7 135 3 >140.0 -350 -TOD.* . n* IX 7 IttOMtt4 7 0 Xtt I3> 7 154.9 -190.9 316 1.199 4 XV IV.7 >94.9 `-Itt.l -317 7* 3 -1 9 tt* 19) 7 !35.4hlV.*l -216 74 ) M 1 - tt) 154.7 -IV.2 ais n * -197 t|- V4 19S.7 Itt.) -Itt > 76 0 ytff 7l - S3 19*. 7 >V I Mtt.l -91) 76 5 -im.71 . m IV.7 IV * 130 6 413 77 1 -TO 11 SI 1917 Itt.) m.e 111 77 t -TO.6 . so IX.7 !. rl56 4 40 7 ) TO.OI - )> I 7 IV ) 1)).? -TV 76 0 .9*4 141 7 IV.9 >1X5.3 4BI 79 9 -TO 9 .31/ 1*3.7 >40.4 ->32.1 -207 79 * .<2 3 - 91* 141.0 19.) -306 0.6 TO.) - ) 1.7 1*1.5 M31.7 903 01 0 -TO.) . tt* 145.7 1B.I 1)1.1 9 11.3 ttl 7 . 91)11 7 142* -IV.9 -10) Vi.r 7<6 7 210.7 tt*. 7 330.7 231.7 zn.7 224.7 ns.? 294 7 237 f ztt.r 7X7 38.7 38.7 3)6.7 Itt.7 241.2 M.7 20,7 50.7 20.7 >47 7 24.7 2B.7 7X0.7 m.7 ar 7X6.7 756.7 255.7 296.7 t 0 - 92.7 MM 91.7 18.1 18.6 > ltt.2 - 8 01 `22 >64,9 ST '2? IM ) l22 \Zi - M 01 rr -j 194.9 19$ * 196 0 1*6.5 197 l 1*7 6 199 2 >99.9 199.9 199.9 -7)1 300 4 201.0 -ni X>.) TO.6 205 2 709 9 0 > -191.1 0.6 hi.6 0 2 r> a 0.1 -Itt 4 t* 9 hi 9 0 1 I 1 0 4 -10.1 163.3 6 5 -1 7 to 1 -`*9.1 0 * 1 6 M2 itt e M 0 .1 4 m 3 10 9 ) 1*7.7 >0 2 MX.O -TO III 1 7 10 H.1V.4 -TO . 0 1 7 1 3 -Itt.* 900 - 20* IB 7 1 9 no 3 -m . 30* 1)1.7 l * ->n. i 307 Itt 7 1 0 H127.3 -it? . 30*1159.7 l.3 >116 7 1*6 - tt) )* 7 1*7 1 -136.1) .19) . 04 Itt.7 1*7.6 -125 6 -1*4 - X) 156.7 1 1 -415.0 >195 S3 1)7 7 1 -124.1 -tfi . XI l Itt 7 IB.) -122 > .191 . 200 159 7 149.9 -129.3 -> - 7*9 1M.7 IS. * in i -IV 237 7 290.3 2M.7 204.9 JV 7 2l0 7 TQt 0 XI .7 906 5 5*2.7 309 1 20 7 202.6 30 7 TO 7 ttS 7 209.6 - 96.6 2*6 7 TO 9 367.7 909.9 90 7 3.* 20? 211.0 - 0.2 370.7 7M.5 tt 10.3 - J90 > 14! 7 151 0 ->22.2 IM 271 7 312.1 .4 -itt.a - 797 l.7 1)1.5 -171.7 XT 77? 7 2 6 0 I tt e -IB 2 - 7* 1*3 7 l > 7I >tt 275 7 313 3 91 ) l1 7 3*51 *64.7 152* -190.6 it) 274.7 319 9 - 59.4. ft 1 -Ml > - 7*9 1*5 7 >52.3 -l.0 -It# 773 7 2/4 ) - 59.91 97 6 -I 6 - m 7 155 1 .119 4 -i 7717 ? 9 -M.3I 92.3 Itt.O . m 1*7 7 15*.3 -lit.* itt 777.7 215 * - V 91 ft t -179 4 - Tti 1*0.7 154.9 -m.l -101 220 7 2M 0 l.! 94 9 -170 9 - 7 14* 7 > 4 -117 DO 779.7 7H 3 - 5* 7! *4 9 ITt.3 . 7 1 7 ltt.0 -117 3 TO 2 3 *5 4 -177.1 > TM 171 7 114.5 -116.7 -171 3* 7 217.6 96 0 177.2 - 7*7 172 7 tit > L>H. 1 -IV 3V 7 ?* 3 -4)9 96 5 rl74 7 - 706 m 7 ltt.6 r9.6 -IT* 20)7 20.6 .54* 97 1 -176,1} . 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I ITS) It* 51) 7 /) 9 67? 7 994 l >730 )>4 7 5*7 I 72 9 )1) 7 5*7 74 4 5>*. 7 M 2 73 e 16) 624 7 10 0) ? 1*7 *26 7 m 5 71V ' mo >2)0 1 IT 517.7 9B 734 >49 07 7 7*6 1 IT 5>9 7 tt* ] 76 1 >49 09 7 77? 519 T tt* * 7* T 1 *7* T , 1X0 1)10 rv530 7 80 4 77 2 171 6X 7 739 at.7 J5> 0 77 9 172 6)1 7 523.7 U> 3 71 3 175 6)2 7 7 S3.7 a* 7 5)5.7 52* 7 ?337.7 at. 53* 7 IB 7 S3I 7 397.1 912 * 8) 2 8? 9 TO5)4 V 4 >XM 6 96* 769 7m>9..o4t> 9> 7 69 9 97 93 3 <74 *2? 7 7? 4)4 7 ?76 655 *tt>77 7 78 733 7*1 7 176 437 7 77) 179 *8.7 777 > ?*V Ml TO00 7 197 01 7 SB 7 157 1 93 9 597 7 9)7 4 0 4 tt / TO? 15 0 m 60 7 >0 >0)7 m 40 7 TO TO 9>1 ns./ fit 6 1 i 05 7 9M )3 7 XV 3 m i V 0* 7 an JV 7 B* * 6* 7 169 07.7 677 UO T 3*0 V 9 t ft 7 5V 7 ttt 0 V 09 7 V 540 7 ttl s M.) T9I 430 7 90 ttl 7 341 1 M 9 m 01 7 5*2 7 5*2 * m 4 9) 02 7 9)5 54? 7 9*3 2 0 10 0) 7 > 565 K 4 >* 04 7 60 M I l ! WD *7> I nm i uoo *77 j tt TlO *a I , <mo` nn i>mr tn it < it *X*** \' 1<X20 `I I1T7 7 j DMI 1m 71* I <B0 I IT 100) I Tj? it; m72* 1 LUO ' IT ?B . two I MM ion ; I9M (022 1 nor; VMJXJ*) jI 730 I 13 ; >00 ?*) . in | it rm | it. it 734 I 1X0 I MS lll)M ; u i : 1430: M 777 } 14 If *07) ; M77 ; M l J is; MM 21 t 1)10 IWD ' nos 07 100 U . 1)0 mi I 98 13 ob im.tut. M I) > : lJ7 | 1170 II ' II 1139 <0 V> ' MfiO JO >1 i 67? MM 20 110 MB >*30 K 11)1 1 rn MX X si um )> m * I* 10 2 <20 M It 2>8 31 31 nt ITCB X *9 >71* ?> f 1770 * >m >*r *4* 17 tm 954 I7M 22 M HO >7 2920 m tm 228 73* 7750 77 71 77 72 2X0 Ml* 100 7)10 Ml* >6*0 2SO 1011 < ) >07 >1 73 10V if 7200 KUO >P 22a0 too Bra 23)0 10 < to TOO 1*8 >* 32 32 20 xm too ?*>0 1071 3*20 >077 If Ii 100 19 2M0 M I* 7 1C*> 3000 7MO UCC 003040 STANDARD cmmcmj rLUritx APPENDIX TEMPERATURE AND HEAT APPENDIX APPLICATOR TRAINING PAGE 435 APRIL 1970 TEMPERATURE CONVERSION TABLE (Centigrade Scale Listed in Even Numbers) i.. 1 Im1 IlM letM Cf (MitM ft**** "7 4M* C***4>MI IM*. i**a IrM e u f J____i---------- it. i m .-*57 4 | 2 i -- -tTf-nt i ). .vo nr Til 6 li ,.j*r \ 1*1 1U illL i\i 435 4 < J_9_ -43* nl y> 64 Hi 169 301 0 >-4*0 4 i 9 3 O 16 H3-- .jj/.i i-4J| l 1 111 9( 16 'll W* 44** 1 t? 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IS 1559 1400 I* TO IS. 75 1690 1449 15.40 14.40 1050 1700 10.00 17.90 1700 >749 10. 79 17. 70 1750 1490 17. >0 I#.3> 1990 Dlrirtil imuMnMvkM* rilf tmr ateilMtH W)*m1w yet*m4N Par ratemet tHttiUl m4 to AU *ee* fOa--l ii j nit flle MH0,9luM- Hr UCC 003042 STANDARD rvctuCAU urn ft**no APPENDIX APPLICATOR TRAINING PAGE 437 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIAL THERMAL, CONDUCTIVITY OF MATERIALS k 3 Btu in/ hr, sq ft, in, *F Miscellaneous Solid Materials Asbestos, 36 lb density Asbestos, wool, 25 lb density Asbestos paper, 61 lb density Asbestos millboard, 60 lb density Ashes, soft wood, 12 lb density Ashes, volcanic, 51 lb density Asphalt, 132 lb density Bricks Building Refractory, average Basalt Carbon black, 1 2 lb density Cardboard, corrugated Celluloid, 87 lb density Concrete, sand and gravel 142 lb density Concrete, cinder 97 lb density Charcoal, powder, 1 2 lb density Cotton wool, 5 lb density Earth plus 42% water, frozen, 108 lb density Glass Glass, pyrex, 139 lb density Glass, soda lime Gravel, 116 lb density Mean Temp *F 200 212 212 86 68 300 68 70 1000 32-210 133 86 75 75 63 100 0 200 200 68 k I. 32 0. 696 1.089 0. 84 0, 216 1.476 5.16 5. 0 9.0 8. 88-19. 32 0.144 0. 444 1.44 12. 6 4. 92 0. 348 0. 420 7. 44 3. 6-7. 32 7. 08 7.08 2. 64 UCC 003043 STANDARD OfUTil t 4Nn m Arno APPENDIX APPLICATOR TRAINING PAGE 438 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS THERMAL CONDUCTIVITY OF MATERIALS - Continued k = Btu in/hr, sq ft, in, *F Miscellaneous Solid Materials Gypsum plaster, sand aggregate Gypsum plaster, light wt aggregate Gypsum board, 51 lb density Ice, 57.5 lb density Leather, sole, 62. 4 lb density Mica, 122 lb density Rubber, hard, 74. 3 lb density Rubber, soft, 68 lb density Sand, dry, 94. 8 lb density Sawdust, dry, 13. 4 lb density Soil, dry Soil, dry, including stones, 127 lb density Soil, wet Snow, 7 to 31 lb density Titonium oxide, 52 lb density Wool, pure, 5. 6 lb density Wood, average Mean Temp *F 99 100 86 68 68 68 68 32 1000 86 k 5. 55 1. 56 0. 744 15. 12 1. 104 3.0 1.104 0. 96 2. 26 0. 504 0. 90 3. 6 to 12. 0 4. 08-15. 6 0. 492 0. 252 1. 2 UCC 003044 STANDARD omaoLi m Ruano APPENDIX APPLICATOR TRAINING PAGE 439 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS THERMAL CONDUCTIVITY OF MATERIALS k = Btu in/hr, sq ft, in, *F Metals Aluminum Mean Temp F 64 212 930 k -- 1404 1428 1855 Antimony 32 127 212 116 Bismuth 64 56 212 47 Brass (20% Cu, 30% Zn) 32 672 212 720 Bronze 1308 Cadmium- 64 644 212 626 Copper, pure 64 2688 212 2616 Gold 64 2028 212 2040 Iron, pure 64 468 212 439 Iron, wrought 64 419 212 415 Iron, cast 129 332 216 322 Lead 64 241 212 238 Magnesium 32-212 1104 Mercury 32 58 Nickel 64 432 UCC 003045 STANDARD APPENDIX APPLICATOR TRAINING PAGE 440 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS THERMAL CONDUCTIVITY OF MATERIALS - Continued k = Btu in/hr. sq ft, in, *F Metals Mean Temp *F k Platinum 64 482 212 503 Silver 64 2904 2856 Sodium 32 384 Steel, 1% carbon content 64 314 212 311 Steel, mild 212 312 Steel, 13% Cr, 0. 2% Ni 932 199 Steel, 18% Cr, 8% Ni 932 149 Steel. 23% Cr, 1 2% Ni 932 130 Steel Wool, density 6. 3 lbs/cu ft 50-212 0. 607 Tantalium 64 384 Tm 64 432 Zinc 212 64 212 308 780 768 UCC 003046 STANDARD oicmcals mo njUTia APPENDIX APPLICATOR TRAINING PAGE 441 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS Gases Air Ammonia Argon Carbon dioxide Carbon monoxide Chlorine Ethane Ethylene Helium Hydrogen Methane Neon Nitrogen Oxygen Steam THERMAL CONDUCTIVITY OF MATERIALS k = Btu in/hr, sq ft, in, F Mean Temp *F 32 32 32 k -- 0. 168 0. 151 o. no 32 0. 101 212 0. 154 32 0. 162 32 0. 052 32 0. 127 32 0. 121 32 0. 982 32 1. 159 122 1.488 32 0. 210 32 0. 0307 32 0. 168 32 0. 170 32 0. 117 Liquids Acetone Ammonia Ethyl alcohol Methyl alcohol Petroleum oil (Average) Sulphur dioxide Water Mean Temp F 68 45 68 68 68 68 68 k 1. 236 3. 480 1. 260 1.488 1.00 2. 34 4. 10 UCC 003047 aa STANDARD lUll owoutwiuna APPENDIX APPLICATOR TRAINING RAGE 442 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS THERMAL CONDUCTIVITY OF MATERIALS k = Btu in/hr, sq ft, in, *F Woods, Oven Dried (heat flow across grain) Aspen Bald cypress Balsa Balsam wool Boxwood Basswood Douglas fir Elm rock Elm, soft Fir, white Hemlock Larch, western Maple, sugar Maple, soft Oak, red Pine, southe rn yellow Pine, white Red cedar, western Redwood Redwood, California Spruce Density lb/cu ft 26 24 10 2. 2 56 24 29 48 34 26 29 36 43 36 42 35 25 21 25 22 21 Mean Temp *F 85 85 85 90 68 85 85 65 75 85 85 85 85 75 85 85 85 85 85 75 85 k 0. 828 0. 756 0. 408 0. 27 10.45 0. 696 0.756 1. 164 0. 88 0. 828 0. 792 0. 936 1. 128 0. 089 1. 188 0. 936 0. 72 0. 636 0. 744 0. 66 0. 624 UCC 003048 STANDARD cwywirAii and rutno APPENDIX APPLICATOR TRAINING PAGE 443 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS THERMAL CONDUCTANCES OF AIR SPACES Btu/hr, sq ft, P MEAN TEMPERATURE F 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Width of Air Spa ce. Inches 0.128 " 6.256 0.364 0.493 0.713 "05 1.50 2.300 2.385 2.470 2.560 1.370 1.425 1.480 1.535 1.180 1.234 1.288 1.340 1.100 1.148 1.193 1.242 1.040 1.080 1.125 1.168 1.030 1.070 1.112 1.152 1.022 1.065 1.105 1.149 2.650 2.730 2.819 2.908 1.590 1.648 1.702 1.757 1.390 1.440 1.492 1.547 1.295 1.340 1.390 1.433 1.210 1.250 1.295 1.340 1.195 1.240 1.280 1,320 1.188 1.228 1.270 1.310 2.990 3.078 3.167 1.813 1.870 1.928 1.600 1.650 1.700 1.486 1.534 1.580 1.380 1.425 1.467 1.362 1.402 1.445 1.350 1.392 1.435 3.250 3.340 3.425 1.980 2.035 2.090 1.750 1.800 1.852 1.630 1.680 1.728 1.510 1.550 1.592 1.485 1.530 1.569 1.475 1.519 1.559 UCC 003049 STANDARD cwhhcm t mo n-unc* APPENDIX APPLICATOR TRAINING PAGE 444 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS SPECIFIC HEATS AND WEIGHTS OF MATERIALS Material Aluminum Asbestos Bakelite - Phenolic Brass, yellow Brass, red Bronze Brick Carbon Chalk Charcoal Cinders Coal Concrete Cork Coke Copper Glass Graphite Gold Granite Gypsum Humus (soil) Ice Ice Iron, cast Iron, wrought Iron, wrought Iron, at high temperatures Lead Limestone Temperature F 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32-212 32 32-212 32-572 1382-1832 Mean Specific Heat 0. 215 0. 20 0. 3-0. 4 0. 088 0. 09 0. 014 0. 20-0. 22 0. 165 0. 215 0. 20 0.18 0. 24-0. 3 0. 156 0. 485 0. 203 0. 094 0.12-0.19 0. 201 0. 031 0.195 0.259 0. 44 0. 465 0. 487 0.130 0. 110 0.122 0. 213 0. 031 0. 217 Weight Ibs/cu ft 168 150 * 534 534 509-554 125-143 139 143 25 81-94 137 75 556 162 135 1205 168 155 76-100 56 64 442 485 485 485 710 155-162 r r r r r i i i i L L t L t, L L L UCC 003050 T STANDARD ORMCill MO PLASTlCf APPENDIX APPLICATOR TRAINING PAGE 445 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS SPECIFIC HEATS AND WEIGHTS OF MATERIALS - Continued Material Temperature F Mean Specific Heat Weight lbs/cu ft Ma rbl e Mercury Masonry, brick 32-212 32-212 32-212 0. 210 0. 033 0. 20-0. 22 170 850 Nickel 0. 109 537 Oil, machine 0. 0. 400 Porcelain 32-212 0. 22 Quartz 32-212 0. 17-0. 28 165 Sand Sandstone Silver Silica Steel, mild Steel, high carbon Stone, average 32-212 32-212 0. 195 0. 22 0. 056 0. 191 0. 116 0. 117 0. 200 100-125 143 655 485 485 150 Tin Water Wood, fir Wood, oak Wood, pine Zinc 0. 056 1. 000 0. 650 0. 570 0. 67 0. 095 459 62. 4 25-32 42-54 27-42 440 UCC 003051 STANDARD H3MCHT mb nutria APPENDIX APPLICATOR TRAINING PAGE 446 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS HEAT UNITS FOR WATER AT VARIOUS TEMPERATURES Temp., Lb. p*r deg.F Cu. ft. 32 62.41 33 62.41 34 62.42 35 62.42 36 62.42 37 62.42 38 62.42 39 62.42 40 62.42 41 62.42 42 62.42 43 62.42 44 62.42 45 62.42 46 62.41 47 62-41 48 62.41 49 62.41 50 62.40 51 62.40 52 62.40 53 62.39 54 62.39 55 62.38 56 62.38 57 62.38 58 62.37 59 62.37 60 62.36 61 62.35 62 62.35 63 62.34 64 62.34 65 62.33 66 62.32 67 62.32 68 62.31 69 62.30 70 62.30 71 62.29 72 62.28 73 62.27 74 62.26 75 62.25 76 62.25 77 62.24 78 62.23 79 62.22 80 62.21 81 62.20 82 62.19 83 62.18 84 62.17 85 62.16 66 62.15 B.t.u. per 1b. 0. 1.01 2.01 3.02 4.03 5.03 6.04 7.04 8.05 9.05 10.05 11.05 12.05 13.05 14.06 15.06 16.06 17.06 18.06 19.06 20.06 21.06 22.06 23.06 24.05 25.05 26.05 27.05 28.05 29.05 30.05 31.05 32.04 33.04 34.04 35.04 36.03 37.03 38.03 39.03 40.02 41.02 42.02 43.01 44.01 45.01 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 Temp-, deg.F 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 14? 143 h44 jl45 Lb. per fl.r.u. cu. ft- per 1b- 62.10 62.08 62.07 62.06 62.05 62.04 62.02 62.01 62.00 61.99 61.98 61.96 61.95 61.94 61.93 61.91 61.90 61.89 61.87 61.86 61.84 61.83 61.81 61.80 61.78 61.77 61.75 61.74 61-72 61.71 61.69 61.68 61.66 61.64 61.63 61.61 61.60 61.58 61.56 61.55 61.53 61.51 61.50 61.48 61.46 61.44 61.43 61.41 61.39 61.37 61.36 61.34 61.32 61.30 61.28 58.99 59.98 60.98 61.97 62.96 63.96 64.95 56.94 66.94 67.93 68.92 69.92 70.91 71.91 72.91 73.90 74.90 75.90 76.89 77.89 78.89 79.89 80.89 81.89 82.89 83.88 84.88 85.88 86.88 87.88 88.88 89.88 90.88 91.88 92.87 93.87 94.87 95.87 96.86 97.86 98.86 99.86 100.86 101.85 102.85 103.85 104.85 105.84 106.84 107.84 106.84 109.84 110.84 111.84 112.84 Temp., Lb- per B.t.u. Temp., Lb. p* <fg.F cu. it. P*' tb-,._ J*B:L cu. ft. 150 61.19 117.84 208 59.92 151 61.17 118.85 209 59 on 152 61.15 119.85 210 59.87 153 61.13 120.85 211 59.85 154 61.11 121.85 212 59.82 155 61.09 122.85 214 59.81 156 61.07 123.85 216 59.77 157 61.05 124.85 218 59.70 156 61.03 125.85 220 59.67 159 61.01 126.85 230 59.42 160 60.99 127.85 240 59.17 161 60.97 128.8S 250 58.89 162 60.95 129.85 260 58.62 163 60.93 130.85 270 58.34 164 60.91 131.85 280 58.04 165 60.89 132.85 290 57.74 166 60.87 133.85 300 57.41 167 60.85 134.85 310 57.08 168 60.83 135.85 320 56.75 169 60.81 136.85 330 56.40 170 60.79 137.85 340 56.02 171 60.77 138.85 350 55.65 172 60.75 139.85 360 55.25 173 60.73 140.85 370 54.85 174 60.71 141.85 380 54.47 175 60.68 142.86 390 54.05 176 60.66 143.86 400 53.62 177 60.64 144.86 410 53.19 178 60.62 145.86 420 52.74 179 60.60 146.87 430 52.33 180 60.57 147.87 440 51.87 181 60.55 148.87 450 51.28 182 60.53 149.87 460 51.02 183 60.51 150.87 470 50.51 184 60.49 151.87 480 50.00 185 60.46 152.87 490 49.50 186 60.44 153.88 500 48.7B 187 60.42 154.88 510 48.31 188 60.40 155.88 520 47.62 189 60.37 156.89 530 46 9 5 190 60.35 157.89 540 46.30 191 60.33 158.90 550 45.66 192 60.30 159.90 560 44.84 193 60.28 160.90 570 44.05 194 60.26 161.91 560 43.29 195 60.23 162.91 590 42.37 196 60.21 163.92 600 41.49 197 60.19 164.92 610 40.49 198 60.16 165.93 620 39.37 199 60.14 166.93 630 38.31 200 60.11 167.94 640 37.17 201 60.09 168.95 650 35.97 202 60.07 169.95 660 34.48 203 60 04 170.96 670 32.89 204 60.02 171.96 680 31.06 B.t.u. per lb. 175.98 176.99 177.99 179.00 180.00 182.02 184.03 186.04 188.06 196.15 208.26 218.39 228.55 238.74 248.95 259.20 269.48 279.80 290.17 300.39 311.05 321.55 332.10 342.71 353.39 364.14 374.96 385.86 396.84 407.91 419.07 430.3 441.7 453.2 465.0 477.0 489.1 501.6 514.2 527.0 540.0 553.2 566.7 580.4 594.4 608.7 623.2 638.0 653.4 669.5 686.6 705 2 725.3 747.5 772.6 UCC 003052 T STANDARD ORMOU MD Fund APPENDIX APPLICATOR TRAINING PAGE 447 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS STEAM TABLES 1-SAT PRESSURES 2-SAT TEMPERATURES Aft* pm Pu ou 10 i.o I.l 1.0 VtoO 7.0 1.0 ID 1t0o u 70 ft 30 40 50 /-'TO B 00 ntooo 120 uo 141 uo 10 170 10 10 200 SO xc so 0 10 00 00 no 0 no M00 m 106 TM r n.0 101.74 Ift-U 111.0 IU.47 107.24 I7Q.H 170.0 laz.K 10.71 S.71 717 00 713.03 777.90 710.07 Sfl.D 7S7.7J 7!1X) 25JJ1 307 0 JWJB JftXT I77J1 MXMi..7a7 w.n X3JB2 sa.ii JQ.VJ SMI 373.01 177X1 SIKJl co.e 417.11 431.77 444.0 40.71 407.02 400.21 005U11...1J030 04.03 sun 00.71 044*4 M Sal Sal li4 * 0.01001 Mil 0.01(14 SB.I 0XIC& 173.73 0.0100 111.71 0.01 B! Nil OXWO 0.01(41 0.01(49 0.0101 0.01454 tia ILB SVM 4734 12.40 0.010! 0.01(77 0X1*7* {L01(I3 0.0107 0.0170) 001713 210 2130 26.29 20.a> u.m Iis3..7aHn 0.01727 oxim 0XI? 0.0)737 0X171* SSW 7.175 S2 sail ana 0X1774 DX1707 DXI7D 0X170 0.0)0} a.au a.049 i.ra law un 0XUD9 o.oun 0.01122 00107 0.1)10 ISIS >.na 7.135 7.532 Z.4H 0.0183! OX IKS 0X110 0X1113 oxtn 0.010 3.281 L.M3I LMW 1320 LIUS 1.0020 0.0117 0X01 0.020 QX20 0X212 ISIS 0.7690 flebnm ItUM (MBit 0.0223 0X2A SsUxM tern bttft*nM~) tel Sal lt$4 Eaap *404* 47.1 nasi 00.4 0.7 auMdt muNL< BK.J IBS! mu 1122.1 usi acsa ISM au130.1 nu IULI mu 11343 iuj mi IULI 1503 ms 1DS3 1513 v2 IULI. itu mi navi 103 nsa 11SS4 111.1 mi 11MJ nu 20.1 mi mu 952.1 no.! Jut WJ lita.1 23SS 930.7 110.7 Till 20.1 222.1 2H.S nst nti m.) nta jisi au saa MVS WJ 01.1 04.7 USI mi 177,1 172.1 US2 1174.1 1177.1 110.1 UOI 110.1 107.2 IULI I1S.I ll.7 tms 330J WSJ 3*1.1 MSI KOI KU B12 04.1 HU mj 1154.1 115VI 11913 1191.5 107.1 au 3713 mi n aja.o 112.2 MVS 110.4 Oil UILI BS0 nu 1m20v2.s1 1WS 1204.1 a.* 1204.1 ana 4)1.1 491.S sou SSI RLS 120.1 731.1 12033 m.7 0S1 1U2O0UI BU 1104 UI.I S11711..71 45.4 itu !SM4 1U1J llttl 117.9 Tr tt & 0 ft SO ss a n n ft 0 ft ft 00 MB no its 19 tft UO US 1ft US ISO 1ft 1(0 165 170 ITS 10 1ft in 200 2)0 212 29 240 2ft 20 300 350 400 450 500 550 MPumm O.OUS4 03950 1.12170 L141U 1.17111 L2141 USD 13051 UOI OSU412M0 0O3.905C9 UU1 0J492 I.UK U7U L470 Lt924 IJ420 23229 73370 2JMS Ull 1.711 1.201 4.741 1.335 5.912 L71S 7310 LUO 5339 11.521 14.12J 14.191 17.111 24.919 H.425 49.2(0 17.011 134.13 747.11 40.1 ini 1003 10Mad he nl Sal IlHl ' 0M 0.0102 wot 0.0102 0.0101 OJ102 2947 2441 203S4 0.0103 0.0101 SisOuliOat QlO10( 1)012 1430.7 120*7 1021.4 U7J OJO107 UUN 03109 03KB 031112 74Q.0 01.1 MVS .4113 4043 S0U13 SOltli O.OU17 0.91119 o.oua 350.4 304.5 20.4 L9 20177 0L3O1W12S7 03107 0.0109 SOI02 1711) 07.34 I3S0 72101 mis 031114 031117 .0.0109 031142 031145 9737 MJ2 77.3 HtJ 62.01 S01M 0.01161 0.01154 0.0107 MTS 5S23 45.31 40.91 03110 03100 S01172 0.01177 0.0102 0.01709 LG172S 3114 27J2 2S0 a 15 1U23 11.70 SMS 03170 S0L799 0.01U4 03194 03204 03711 1461 3341 1303 1.0993 0370 0.4240 UMtrt EatMt* ** 0.00 1975.1 332 B7SI 1.0 13.01 B10C7SL11 ISO! aa.ww 330 3104 1903 1003 HMJ BS7.1 1014.3 410 4107 5330 S02.9.919 USLS 1041.1 100.1 1042J 1040.1 17J7 720 27.94 12.97 17.52 10373 10343 101.4 M2I.7 10253 92.91 97.n 102.9 107.9 112.9 1022.9 100.0 1017.0 BI4.I 1911.7 117.0 177.9 527.9 U2.9 137J 1001.2 100V? 10023 999 3 99S3 142.9 147.1 1S2.9 1S7.9 9911 9903 997.1 994.1 USO 171.1 11I0L.10 2003 7213 2411 177.9 97LS 920.4 99V2 902.2 939.7 134.7 20.1 3213 3753 430.1 4173 9493 9UL1 170.7 92L0 nu 71V9 MSI M4 1075.1 SI 77.1 1079.3 1011.5 1093.7 B0.I 1003 1990.3 1093.3 Bn9uU B9S9 1U0J 1BV1 179V? 11173 110.5 111 LI 11117 1111.3 1117.9 IIB.9 11233 1174.1 1101 117SI U3S1 110.7 1134.7 11313 11311 1140.1 11473 1341.9 IMS 7 1150.1 IB3-1 1103 11173 11711 1179.7 11923 12013 13043 1201.7 11903 UCC 003053 STANDARD DUMOU AMD PlAfTtCS APPENDIX APPLICATOR TRAINING PAGE 448 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS STEAM TABLES 3 -- SUPERHEATED STEAM AD) PttuM Pn h <?a(m 70 I777.lt) <JUJ <290.711 OI7J&) |HMI) 1354.47) <3IL2)) 710 (. IS ins> 400 4444.10) SO (4(7.0!) SB (nut) BUJll MOO (M4.U) 1500 (MUM noo <(3412) 7500 (Hill) 3000 I615.3M 370.7 < 70S.40) U lipri MM 0.07 I*.? Oftl? 751.0 5*17 xm Omftsll 1411 2M4 0.014 >304 0411 JSS.4 0411? mj MU) nsi 0.9153 <74.0 0.01)7 44)4 031 <71.1 0.0701 501.7 0.M S42.4 0.0735 SIU IJt2i5u7 tsai m QftXK 1)2.5 0.0501 507.7 5* MRS 7b.n 11504 3.09 1156.3 n.49 ! lift 7 7.175 1177.4 1.477 IIILI 4.4X7 I107J 11)5 11)4.1 i.m HIM 14438 131.1 IMJl 132.0 1.KI1 1204.5 0.1271 134.4 o.Ttn uou 0.54)7 imi 0.4955 inti 0.2716 1107.1 0.1071 1135.1 1)37 mu 0u.0n05.10 i.eu 107.1 m 719) nv.i ini.t 11440 1IKI 7.259 tui.i 400 11.9/ 1739.9 177514*23 12.421 17)05 1.34? i23)J 073 173.7 m4.1i)s7 im 1719.4 ?.3i) iiioj 500 1/.)) 17.) 7190 UM.i H.IU I714J ).4n US3J 7420 tzu.i 4.48) 17711 Jill 1774.1 7.771 ITttJ 2.B1 itui 1.7(75 17)71 1.7)51 1745.1 1)777 1731.3 0.7947 1715.3 .... * Ttavtiaw*. 4rm F ilO 41.99 13341 n.4i 1134.4 am 17X3,1 10.427 1331.0 7.797 1330J Ml) 11711 1.117 1125.7 ijoa IBM 2.477 MILS 7.W 1314.7 1.4770 1305.) l.BII 17)14 0)443 171). 0.5779 1270.7 0.5 U0 I74U 03115 1174.5 44)0 I30U 1*47 1307.) 17.14) 131.9 11.441 I3MJ till un.9 1075 1378.5 4.5): 13/03 1.3 1)73.4 7oa 1771.0 2.277 ITtU M500 11C.7 1.3044 1357J) L0737 IBM L7U) 1331.0 0.(004 1775.1 1371) 1707.2 03489 1740.0 0.KK 117L8 00904 1040.) HI 4)37 1437.5 1J 45 14.1M 11)07 UJIJ 12.449 14)03 9372 147ft) 7.445 14705 4.944 I47S.9 3.59) 14244 2.947 1477.7 7.447 Uffl.i t.Mit 141(4 1.4405 1412.1 1.109) M07.7 OJlil U515 0.5070 1389.2 0.4357 I353J a30)4 13315 03791 im c 0m.1Xu0 O.Bt) 12503 900 -.i* W7 1 45 107.1 7030 him 11.457 mot 10.077 1410.1 UE7 147*4 5457 1477.0 4407 1475.7 i.nz 1474.5 7.02 1472.5 1.57(7 1459.4 1.5715 IK60 1.3013 14(1.5 0.303 14554 0.KM 14483 0.489) 11793 9.3532 14093 3J710 33174 0.715) 130.0 1.1)11 13517 1000 \/1l 1MU 41.44 Vill.D :i.m 1532.4 14.454 1511.9 10.910 15)13 .6i6 US.) 5.251 1323.4 4.309 1520ft 1.439 1575.6 7J59 15253 2.114 1572.4 11995 151*6 I.40H 1515.; 1.0470 1511ft 0.934 1505.1 0.5)90 1190.1 0.3VB 1*74.5 0.10(1 1451.4 03475 1441.1 0.2710 104.7 10 4\ R*l Mi/1. 49.91 :*. U4/.0 14.451 16)5.6 i:jj7 1(34.7 9310 1(35.2 65*4 1434.7 4.312 1(33.7 1.37) 1617.7 1.2W 1(31.7 2.441 1(78.6 1 3504 1CJ.6 1.(20* 15! 1..WI 1617 J 0 5)19 1606.S 0.4558 1595.1 0.3(71 BI5.3 0.30U 1574.3 0.2105 1559.1 UCC 003054 r STANDARD r chueCais plastics APPENDIX APPLICATOR TRAINING PAGE 449 APRIL 1970 r APPENDIX r THERMAL PROPERTIES OF MATERIALS PSYCHOMETRIC INFORMATION r i i i i i i L l l l l l UCC 003055 STANDARD AM> PLASTICS APPENDIX APPLICATOR TRAINING PAGE 450 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS PSYCHOMETRIC INFORMATION DEW P O IN T TEMPERATURE -4 2 6 11 16 24 30 28 35 33 40 38 45 42 50 8 OtftOtA A - N N AOAOfl lA'O'DNN O AOA8 o CD o* A O AO A O -- N CN o- oo </) CD O CO fs o IS. /S *o o t o a 2 u> ift X vu > S5 is U0i n * o 9 5 101 100 106 105 111 109 116 114 121 t O' T **V 0- -- -- CN p- V O* V o. 04 P) P) ^ V sssss oo o> <o n a > o> n co cd n o O - - 'N o co fO CO -- -- CN CNPsrSK.CN rs cv rs -- - (AA-44N K cd a> o. N WN -N Ps CN 0 -- W> nn t t OAO A O *A A -O A N A AON Ps cO 0> <N .3s:2 <n - <A----------CN cOn On folOr>>T^ o* y a* y > Y A A A <0 T CO P) IN IS N (S cn rs <n rs NOO- -- VO1^0.-- N N N vN A N A - 'Oy y> *r> > -o fs PS a> oo O' n o a> i no---------- Is. -- -O'-- n nnn w*) o ^ A A <0 a O' ^ O' ^ eo ANNA CNN -- noo -- O' CN -- -- -- M m <0 n 9* n ^ d >n o n is <n ^?AA A K tN N (N A ANN o v* 8 o ft > o -- ---------- n in i *o -- -- OtQMN W IN (N P)rt - A -* A O AAA *0 O' y O* y A ANN (N PS CO CN Ps O' l> -- -- * CM i.=c-2a-Z2Q |eo &l i Jo s*5 vc c fli 2 i;" i i- 3*g1-T0PTJ -- uu 5 1.1! - w V iIt -oiiijl o M ry l IP)- NN^O^ - - <n n n STS35? MNNAAAN N o o y O', o <D O O' O' -- co n o i i -- ^-- u*> O -y co cn -- IN (N (N n NN AQA n ^ ^ AA o t o> a a A AANN 8iN N CD CD --On A O* -- II 1 t 0} n cn *o o N CO IN --MNP) AOTT A N - A O V) aaann o y (n n Ps oo to O' o> N -- is. cn 1 I i <n --- *--0 --d> P) cn K CN M A O A Ov nn^ A AA s A o y p> Ps CO 00 co o> -2 2 DRY TEMI F -25 -2 0 -16 -1 1 -8 u- r> o r> oCY O CN /> 3 (0 2 ^-------*n <n i i i in Pv TTTo CO C--N ---D CN < CN *0 O' -< -hk -- N SSSt A O' O N IN N N P)P> ^ 8 S 3?3 S NKO AO> N N CD CD 00 n -- a i> y 'O IS Ps Is CO CN -- ~ CO N" 11 11 cn *n o* --O P--s -- N *0 ap r> n Ps n - A O' ^ ^ N1 A A N'OOTffl AANNS <*> 1 -- 40 -- 6 O t m in - IN N N n A O N fN P) 'V " A A A o y q i> A A A AN O A - -o >A rj r4 CS---------- 11 1 1 1 * iA i * ok -- y CO -- *-- -- -- CN CN fcSSS? OfN^OP) y AAa A ni ni flf5t 8r n cn -- -- IN ^ -- ii i i* OrtK O ------------ On n o y M<NNp)P) a n -y Ay ym .N a 822SSooo*n O -- p- <N (N 0*AO<AQ f->n tt3S AO AO A A A AN K oaoa8 CP CO O' O' -- I 'O c 1V 8S *D fjJ'-cn ?o 0 . ise 01 8 UCC 003056 STANDARD CUBICALS MB K.AS1IQ APPENDIX applicator TRAINING PAGE 451 APRIL 1970 APPENDIX THERMAL PROPERTIES OF MATERIALS PSYCHROMETRIC INFORMATION PERCENT RELATIVE HUMIDITY ABOVE WHICH CONDENSATION WILL OCCUR ON SURFACE OF EQUIPMENT OR PIPE NOT INSULATED EQUIP. AMBIENT AIR TEMPERATURE F OR PIPE 40 45 50 55 60 65 70 75 80 85 90 95 100 TEMP. F 35 82 68 57 48 39 33 28 24 20 17 15 13 11 40 82 68 57 48 40 33 28 24 20 17 15 14 45 82 69 57 48 41 34 29 25 21 18 16 50 82 69 57 49 41 35 30 26 22 19 55 83 70 59 50 42 36 31 27 23 60 84 70 60 51 43 37 32 27 65 84 71 60 52 44 38 33 70 84 71 61 52 45 38 75 84 72 62 53 46 80 85 73 63 54 85 85 73 63 90 86 74 95 86 UCC 003057 STANDARD QtntTffll \ AMD FLASTICS APPENDIX APPENDIX APPLICATOR TRAINING PAGE 452 APRIL 1970 WATER VAPOR PERMEABILITY TABLE MISCELLANEOUS MATERIALS MATERIAL PERMEABILITY, perms Aluminum foil, 0.0025 inch thickness Aluminum foil, 0.001 inch thickness Aluminum foil, cloth backed Aluminum tape, paper backed Asphalt-saturated 15 lb felt, coated with 25 lb asphalt per 100 sq. ft. Calcium-silicate insulation, one inch thickness Cellular glass insulation, one-half inch thickness Cork, one inch thickness Duplex laminated kraft paper (30-30-30 ) Duplex laminated kraft paper, reinforced Fiberboard, 3/4 inch thickness Foil-faced kraft paper Foil-faced reflective insulation, double faced Friction tape, single layer double layer Gypsum lath, metallic aluminum backing Laminated paper and foil Mineral wool, unprotected, 4 inch thickness Piaster, fiberboaid or gypsum lath Plywood, 2 coats aluminum point Plywood, 2 coats asphalt paint Polyethylene, 0.004 inch thickness Polyethylene, 0.03 inch thickness Roll roofing, smooth 40-65 lb per 108 sq. ft. Sheating paper, asphalt-impregnated, glossy Vinyl membrane, 0.004 inch thickness 0.005 to 0.01 0.01 to 0.05 0.004 0.006 0.05 21 to 35 0.00005 3 to 7 0.20 0.70 12.5 0.01 0.08 to 0.13 2.34 1,45 0.09 to 0.39 0.01 29.07 19.7 to 20.6 1.29 0.43 0.10 0.002 0.13 to 0.17 0.17 to 2.05 0.80 to 2.0 UCC 003058 STANDARD OBlOU AMD PUITIO APPENDIX APPLICATOR TRAINING PAGE 453 APRIL 1970 APPENDIX PIPE AND TUBE INSULATION DIMENSIONS OUTSIDE DIAMETERS AND AVERAGE THICKNESSES FOR PIPE INSULATION ASTM Recommended Proctice NPS Pipe NOM 0.0. SIZE Inches 1/2 Nominal Avg. O.D. Thk. Inches Inches 1/8 0.405 0.45 1/4 0.540 0.55 3/8 0.675 0.49 1/2 0.840 0.52 1.315 1.660 1.660 1..900 3/4 1.050 0.42 1 1.315 0.52 U 1.660 0.60 1* 1.900 0.48 2 2.375 0.55 2i 2.875 0.55 3 31500 0.49 3i 4.000 0.49 1.900 2.375 2.875 2.875 3.500 4.00 4.500 5.000 4 4.500 0.5c 5.563 4i 5.000 0.80 6.i625 5 5.563 0.49 6.625 6 6.625 0.46 7.625 7 7.625 8 8.625 9 9.625 10 10.750 u 11.750 12 12.750 14 14.000 15 15.000 16 16.000 17 17.000 18 18.000 19 19.000 20 20.000 21 21.000 22 22.000 23 23.000 24 24.000 25 25.000 26 26.000 27 27.000 28 28.000 29 29.000 30 30.000 31 31.000 32 32.000 33 33.000 34 34.000 35 35.000 36 36.000 Insulation Thickness k* Nominal l-' Nominal Avg. O.D. Avg. O.D. Thk. Inches Thk. Inches Inches Inches 0.98 1.16 1.09 1.00 2.375 2.875 2.875 2.875 1.54 1.72 1 .66 1.57 3.500 4.000 4.000 4.000 0.91 1.09 0.91 1.04 2.875 3.500 3.500 4.000 1.47 1.59 1.66 1.54 4.000 4.500 5.000 5.000 1.05 1.05 1.02 1.30 4.500 5.000 5.563 6.625 1.58 1.86 1.55 1.80 5.563 6.625 6.625 7.625 1.05 1.30 0.99 0.96 6.625 7.625 7.625 8.625 1.55 1.80 1.49 1.46 7.625 8.625 8.625 9.625 1.52 1.52 1.52 1.59 10.750 11.750 12.750 14.00 1.59 1.SB 1.45 1.45 15.000 16.000 17.00 18.00 1.45 1.45 1.45 1.45 19.000 20.000 21.000 22.000 1.45 1.45 1.45 1.45 23.000 24.000 25.000 26.000 1.45 1.45 1 .45 1.45 27.000 28.000 29.000 30.000 1.45 1.45 1.45 1.45 31.000 32.000 33.000 34.000 1.45 1.45 1.45 1.45 1.45 35.000 36.000 37.000 38.000 39.000 2` Nominal Avg. O.D. 7hfc. Inches Inches 2.05 2.22 2.16 2.07 4.500 5.000 5.000 5.000 1 .97 2.12 1.94 2.36 5.000 5.563 5.563 6.625 2.11 2.36 2.05 2.30 6.625 7.625 7.625 8.625 2.05 2.30 1.99 2.02 8.625 9.625 9.625 10.750 2.02 2.02 2.15 2.09 11.750 12.750 14.000 15.000 2.09 2.08 1.95 1.95 16.000 17.000 18.000 19.000 1.95 1.95 1.95 1.95 20.000 21.000 22.000 23.000 1.95 1.95 1.95 1.95 24.000 25.000 26.000 27.000 1.95 1.95 1.95 1.95 1.95 1.95 1.95 1.95 28.000 29.000 30.000 31.000 32.000 33.000 34.000 35.000 1.95 1.95 1.95 1.95 1.95 36.000 37.000 38.000 39.000 40.000 UCC 003059 STANDARD ocuou ue ruLgrta APPENDIX applicator training PAGE 454 APRIL 1970 APPENDIX PIPE AND TUBE INSULATION DIMENSIONS OUTSIDE DIAMETERS AND AVERAGE THICKNESSES FOR PIPE INSULATION ASTM Recommended Practice NPS Pipe NOM O.D. SIZE Inches ^`'Nominol Av$. O.D, Thk. Inches Inches Insulation Thickness J Nominal si- Nominal Avg. O.D. Avg. <5.6. Thk. Inches Thk. Inches Inches Inches 4" Nominal Avg. O.D. Thk. Inches Inches 1/H 0.405 2.57 5.563 3.10 6.625 3.60 7.625 4.10 8.625 1/4 0.540 2.50 5.563 3.04 6.625 3.54 7.625 4.04 8.625 3/8 0.675 2.44 5.563 2.97 6.625 3.47 7.625 3.97 8.625 1/2 0.840 2.89 6.625 3.39 7.625 3.89 8.625 4.39 9.625 3/4 1.050 2.78 6.625 3.28 7.625 3.78 8.625 4.28 9.625 T 1.315 2.64 6.625 3.15 7.625 3.65 8.625 4.15 9.625 li 1.660 2.48 6.625 2.98 7.625 3.48 8.625 3.98 9.625 1* 1.900 2.86 7.625 3.36 B.625 3.86 9.625 4.42 10.750 2 2.375 2.61 7.625 3.11 8.625 3.61 9.625 4.17 10.750 2| 2.875 2.86 8.625 3.36 9.625 3.92 10.750 4.42 11.750 3 3.500 2.55 8.625 3.05 9.625 3.61 10.750 4.11 11.750 3i 4.000 2.80 9.625 3.36 10.750 3.86 11.750 4.36 12.750 4 4.500 2.55 9.625 3.11 10:750 3.61 11.750 4.11 12.750 4 5.000 2.86 10.750 3.36 11.750 3.86 12.750 4.49 14.000 5 5.563 2.56 10.750 3.06 11.750 3L56 12.750 4.18 14.000 6 6.625 2.52 11.750 3.02 12.750 3.65 14.000 4.15 15.000 7 7.625 2.52 12.750 3.15 14.000 3.65 15.000 4.15 16.000 j8 8.625 2.65 14.000 3.15 15.000 3.65 16.000 4.15 17.000 9 9.625 2.65 15.000 3.15 16.000 3.65 17.000 4.15 18.000 10 10.750 2.59 16.000 3.09 17.000 3.59 18.000 4.09 19.000 In 11.750 2.59 17.000 3.W 18.000 3.59 19.000 4.09 20.000 ;i2 12.750 2.5B IB.000 3.CB 19.000 3.58 20.000 4.06 21.000 14 14.000 2.45 19.000 2.95 20.000 3.45 21.000 3.95 22.000 15 15.000 2.45 20.000 2.95 21.000 3.45 22.000 3.95 23.000 16 16.000 2.45 21.000 2.95 22.000 3.45 23.000 3.95 24.000 17 17.000 2.45 22.000 2.95 23.000 3.45 24.000 3.95 25.000 18 18.000 2.45 23.000 2.95 24.000 3.45 25.000 3.95 26.000 19 19.000 2.45 24.000 2.95 25.000 3.45 26.000 3.95 27.000 20 20.000 2.45 25.000 2.95 26.000 3.45 27.000 3.95 28.000 21 21.000 2.45 26.000 2.95 27.000 3.45 28.000 3.95 29.000 22 22.000 2.45 27.000 2.95 28.000 3.45 29.000 3.95 30.000 |23 23.000 2.45 28.000 2.95 29.000 3.45 30.000 3.95 31.000 24 24.000 2.45 29.000 2.95 30.000 3.45 31.000 3.95 32.000 '25 25.000 2.45 30.000 2.95 31.000 3.45 32.000 3.95 33.000 26 26.000 2.45 31.000 2.95 32.000 3.45 33.000 3.95 34.000 I27 27.000 2.45 32.000 2.95 33.000 3.45 34.000 3.95 35.000 i[22V8 28.000 2.45 29.000 2.45 33.000 2.95 34.000 2.95 34.000 3.45 35.000 3.45 35.000 3.95 36.000 3.95 36.000 37.000 .30 30.000 2.45 35.000 2.95 36-000 3.45 37.000 3.95 38.000 3. 31.000 2.45 36.000 2.95 37.000 3.45 38.000 3.95 39.000 32 32.000 2.45 33 33.000 2.45 34 ! 34.000 2.45 35 | 35.000 2.45 36 j 36.000 2.45 37.000 38.000 39.000 40,000 41.000 2.95 2.95 2.95 2.95 2.95 38.000 39.000 40.000 41.000 42.000 3.45 3.45 3.45 3.45 3.45 39.000 40.000 41,000 42.000 43.000 3.95 3.95 3.95 3.95 3.95 40.000 41.000 42.000 43.000 44.000 ' r r r r F I I I L L L L fc L t L L L UCC 003060 T STANDARD owcui ymno APPENDIX APPLICATOR TRAINING PAGE 455 APRIL 1970 APPENDIX PIPE AND TUBE INSULATION DIMENSIONS I~I?i32 j.5 32R2S ^ <Q N " o' o o o ^ SSJSgS P) N 0 " 0 ^J ri 33353 -O >"_ O -- rs ^ o i <o 4 'OM * . . . o 'ON# > " 8^^? 0> o (S IN IN -- n t >n ---- -- 88 OR fN nv ---- 88 W CN n O _^ 3 0-6 Ji-i p- < <-- -- 3 o 8 S 44440 4 040 4 f4444 rs K4R4S^S4Jfc . . ,O 4 N <S (K *- lv N N K N fc fc3 3 3 ^44 * NN NN S3 3 3 N(B *7 ~ --________rt I? !!t -- 4X 12* 44444 444fifS MCVC4NN ------------S o r> o n p> NW N N ooooo o o o NNNCNCI J *4 4" -4 t t >* ^. o* w rr h i*) co 33 n r? oJ !j . 8 S 3 o *6 Z JE-lS T444 O ooooo r) 4 P> T O' 38333 nW 444 aa 38332 4K- os *4 *4 *< S3SSS n-* n ^ d 4 S rC co "r SS * rn W 0- E-- Z Su, DON r 4 4 00 i OO -- 40044 --(NN sins n4444 assail* 4KttO>* ;$ ^n d4 4 1 --rC --oo 11 ' r>> >-- * (O m r> Jo * N ^ 4 4 S CO O' n 4N CO - -- -- -- -- -- -- <*V IN^ SIDE DIAMETERS FORiFIFE INSULATION ASTM RcomnondJ F re c tlt* \ \\ OUTER SIZE FOR FIFE IN S U LA TIO N ASTM R*cmnwndd Fracllc* EKpruMd In Nominal Iron Flp* S ix . UCC 003061 STANDARD OCMCALS AND At Unfit APPENDIX APPLICATOR TRAINING PAGE 456 APRIL 1970 APPENDIX PIPE AND TUBE INSULATION DIMENSIONS BASIC OUTSIDE DIAMETERS FOR TUBE INSULATION ASTM Recommended Ptactfce Tube Size 1/4 3/8 1/2 1/2 3/4 3/4 1 1 li l li 2 2 2 2i 3 3 3 5/8 4 4 5 5 6 6 8 8 10 10 12 14 16 18 20 24 O.D. 1/2 0.250 0.375 0.500 0.625 0.750 1.315 1.660 1.660 1.660 1.900 0.875 1.000 1.125 1.250 1.900 2.375 2.375 2.375 1.500 1.625 2.000 2.125 2.500 2.875 2.875 3.500 3.500 3.500 2.625 3.000 3.125 3.625 4.000 4.000 4.000 4.500 5.000 5.000 4.125 5.000 5.125 6.000 6.125 5.563 6.625 6.625 7.625 7.625 8.000 8.125 10.000 10.125 12.000 14.333 16.333 18.333 20.333 24.333 1 2.875 2.875 2.875 2.875 2.875 3.500 3.500 3.500 3.500 4.000 4.000 4.000 4.500 4.500 5.000 5.000 5.563 6.625 6.625 6.625 7.625 7.625 8.625 8.625 Nominal Thlckne* of Insulation li 2 2i 3 3.500 3.500 3.500 3.500 4.000 4.500 4.500 4.500 4.500 5.000 5.625 5.625 5.625 5.625 5.625 6.625 6.625 6.625 6.625 7.625 4.000 4.000 4.000 4.500 5.000 5.000 5.000 5.563 6.625 6.625 6.625 6.625 7.625 7.625 7.625 7.625 4.500 4.500 5.000 5.563 5.563 5.563 5.563 6.625 6.625 6.625 6.625 6.625 7.625 7.625 7.625 7.625 7.625 8.625 8.625 8.625 5.563 6.625 6.625 7.625 7.625 6.625 7.625 7.625 8.625 8.625 7.625 8.625 8.625 9.625 9.625 8.625 9.625 9.625 10.750 10.750 7.625 8.625 8.625 9.625 9.625 8.625 9.625 9.625 10.750 10.750 9.625 10.750 10.750 11.750 11.750 10.750 11.750 11.750 12.750 12.750 11.750 11.750 12.750 14.000 15.000 12.750 12.750 14.000 14.000 16.000 14.000 14.000 15.000 15.000 17.000 15.000 15.000 16.000 16.000 18.000 18.000 20.000 22.000 24.000 28.000 19.000 21.000 23.000 25.000 29.000 20.000 22.000 24.000 26.000 30.000 21.000 23.000 25.000 27.000 31.000 3i 7.625 7.625 7.625 7.625 8.625 8.625 8.625 8.625 8.625 8.625 8.625 9.625 9.625 9.625 9.625 10.750 10.750 11.750 11.750 11.750 12.750 12.750 14.000 14.000 16.000 16.000 17.000 17.000 19.000 33.000 24.000 26.000 28.000 32.000 4 8.625 8.625 8.625 8.625 9.625 9.625 9.625 9.625 9.625 9.625 9.625 10.750 10.750 10.750 10.750 11.750 11.750 12.750 12.750 12.750 14.000 14.000 15.000 15.000 17.000 17.000 18.000 18.000 20.000 23.000 25.000 27.000 29.000 33.000 UCC 003062 STANDARD cmwciu wo *ia*nc* APPENDIX APPLICATOR TRAINING PAGE 457 APRIL 1970 APPENDIX SURFACE AREAS OF NPS PIPE INSULATION SURFACE AREAS OF PIPE INSULATION Baaed on NPS Pipe and.ASTM Dimensional Standard Pipe Insulation - Square Feet per linear foot NOM. MW SIZE ftAJtE V* V* 3/1 1/2 3/4 1 1 1/4 1 1/2 2 21/2 3 3 1/2 4 4 1/2 5 6 7 8 9 10 11 12 14 14 18 20 22 24 26 28 30 0.106 0.141 0.177 0.220 0.275 0.344 0.435 0.498 0.622 0.753 0.917 1.047 1.178 1.309 1.456 1.734 1.996 2.238 2.520 2.814 3.076 3.338 2.665 4.189 4.712 5.236 5.759 6.283 6.807 7.331 7.854 0.62 0.75 0.75 0.75 0.75 0.92 0.92 1.05 1.18 1.31 1.46 1.73 1.73 2.00 2.00 2.26 Hi 0.92 1.05 1.05 1.05 1.05 1.18 1.31 1.31 1.46 1.73 1.73 2.00 2.00 2.26 2.26 2.52 2.81 3.08 3,34 3.67 3.93 4.19 4.45 4.97 5.50 6.02 6.54 7.07 7.59 8.12 8.64 1.18 1.30 1.30 1.30 1.30 1.46 1.46 1.74 1.73 2.00 2.00 2.26 2.26 2.52 2.52 2.81 3.08 -3.34 3.67 3.93 4.19 4.45 4.71 5.24 5.76 6.28 6.81 7.33 7.85 8.38 8.90 Nominal Insulation Thickness** 2? 3 34 4 1.46 1.46 1.46 1.73 1.73 1.74 1.74 2.00 2.00 2.26 2.26 2.52 2.52 2.81 2.81 3.08 3.34 3.67 3.93 4.19 4.45 4.71 4.97 5.50 6.02 6.54 7.07 7.59 8.12 8.64 9.16 1.73 1.73 1.73 2.00 2.00 2.00 2.00 2.76 2.26 2.52 2.52 2.81 2.81 3.08 3.OB 3.34 3.67 3.93 4.19 4.45 4.71 4.97 5.24 5.76 6.28 6.81 7.33 7.85 8.38 8.90 9.42 2.00 2.00 2.00 2.25 2.25 2.26 2.26 2.52 2.52 2,81 2.81 3.08 3.08 3.34 3.34 3.67 3.93 4.19 4.45 4.71 4.97 5.24 5.50 6.02 6.54 7.07 7.59 8.12 8.64 9.16 9.69 2.26 2.26 2.26 2.52 2.52 2.52 2.52 2.81 2.81 3.08 3.08 3.34 3.34 3.67 3.67 3.93 4.19 4.45 4.71 4.97 5.24 5.50 5.76 6.28 6.81 7.33 7.85 8.38 8.90 9.42 9.95 4* 5 5* 6 3.34 3.67 3.67 3.67 3.93 4.18 4.45 4.71 4.97 5.24 5.50 5.76 6.02 6.54 7.07 7.59 8.12 8.64 9.16 9.69 10.21 4.19 4.45 4.71 4.97 5.24 5.50 5.76 6.02 6.28 6.81 7.33 7.85 8.38 8.90 9.42 9.95 10.47 4.97 5.24 5.50 5.76 6.02 6.28 6.54 7.07 7.59 8.12 8.64 9.16 9.69 10.21 10.73 6.54 6.81 7.33 7.85 8.38 8.90 9.42 9.95 10.47 11.00 UCC 003063 STANDARD owm AMD KACTIQ APPENDIX APPLICATOR TRAINING PAGE 458 APRIL 1970 APPENDIX VOLUMES OF NPS PIPE INSULATION N o u : D r n .ity Of in u i tio n in lb /c u ft tim e i the cu ft p e t lin e a r f t a Ib i per lin e e r f t zo > UCC 003064 STANDARD O--CIU ** PIAITC APPENDIX APPENDIX APPLICATOR TRAINING PAGE 459 APRIL 1970 RECOMMENDED SIZES OF INSULATION LAYERS TO "SBTAIN TOTAL NOtaiNXI THINNESS NPS X NOMINAL LAYER THICKNESS M M 2-r n M M M N ""i? M M M a m m M M M 1 M M A n et m X -- II U a 1w !w i& * t ^ 2 s !o 2 -2 TO - -+t -M M TO aM MM M M a N N N N M N N N MAP) A M A * - - M a 22 * n mn A) A* AM A M N H M N N M H MA*M CM -a Ma -a MM n A c *" af Na M tt * m0e MA A MP N 2 M 2-2 a (4 MN a. m A# CM _ ,,-= <wa w - * * ** - -r M A) h n n *4 M M n m m N N N A M A ** D >4 <9 A - - A A * ' o a A A O ""3 A) a M N <4 n m 4NN ^ M - _22 AAA AN - - .r * -.A* # -a M .-* * A <0 -A-A -- M0 -- a * 4 0 A * a A II nT .1 -- -- -A-a -- S* -- -- -- __ -- ---- -A * o -- *o | -A -- M iWA * n -a -- -M -- jf - a* --* n r> NAnN - '** -- . a 4a AN w -- "* r* n m "to -- "*-1 aA "t o NN - CM fO CM _l TO N m n m UJ CD _N U3AV1 3NO s3avi O"1 SH3AV1 33MH1 SS3NX0IHJ. NOliVinSNI 1VNIW0N UCC 003065 STANDARD CMBKAU A.4ITJCI * APPENDIX APPENDIX APPLICATOR TRAINING PAGE 460 APRIL 1970 RECOMMENDED SIZES OF INSULATION LAYERS TO___ OBTAIN TOTAL NOMINAL THICKNESS NPS X NOMINAL, LAYER THICKNESS 1 #4 t* 01n; _ a --M M N ft -- CM X M N CM a CM a cm a a a a C* CSI #1SM s a x N v nm v r-. nn aa c a aa va CM M ; a a MSM i m n * H MOM a a a CM CM MM M a a a awn eg CVI a a N M CM M as i n WW wa a m as M *> OT M ass M O aan ae awn aa a aaa ass ss- M M V M M M n a M N N a CM CM X M a cm w cm a a o CM o eO M O e a O one- P a a pan oae ? 4 --W * X CM N N - _-== 00 mX MM x X X X X X X X X XXX XXX XXX XXX XXX A a A h n - <* a M M W < cc n A M W n m a a ri N M Sw N N -- a et N CM W CM a* H N N M a a cm a cm U w*w~ CM CM CM w to H X X X K X SI A A a a a aO A* ---- -W 1 aoa p a a MM N 25 - - --iw --- ul * [ % 2X a A r s a aa a a a. - 3-- wc aH M xM MSM H FI M aa aa aa a aa wa w CM < 0 2z M W 2 2N N CM C- w ^ cm a a a NP SS W - -- aAW xt( non aam s .a _ _ oo z 9 o o o v o a e a p a o a o p a p o a o m o r---- 4 t H o n N CM MAN (CNN WWW CM CM CM M M CM CO M M K H H M K X X X X X X XXX x x x XXX x x x XXX *2w r r, n 3-S -- W O* A M N CM aa CM CM CM WWW aac W CM W nnh| CD X K N M X X M X X X X X X X XXX XXX X X X x x x XXXI AA A to a aa aa ce o ** a aaa aea - a aa " *. w _r I a -- jf _ z M W m -- -- * -- a- | a* W a. __ N X M * MM MX XX XX XX XXX aw* - "Z -- CM -- CM o> r <M fO x* a M' aa CM a a a a -- ana 'I eg 1 m <0 ____ L a a "a a a "a a a eg s lO 3NO SM3AV1 0M1 SH3AV3 33HH1 SS3NX0IH1 NOIlVinSNI "IVNIWON UCC 003066 r r [ f r i i mm T STANDARD PQMCa* AM MJkITO APPENDIX APPLICATOR TRAINING PAGE 461 APRIL 1970 APPENDIX AREAS RADIATING AREA OF FLANGED fITTINGS (including occomponyfng flanges In square feet and in equivalent length of some size pipe standard weight fittings) Pipe size. In. 1 i v< I 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6 7 a ? 10 12 14 16 Flanged couplings Area, Pip* sq.ft. length, ft. 1 90* sill Area, sq.ft. Pip. flet.ngll* .32 .93 .79 2.31 3B .68 .96 2.20 .48 .95 1.19 2.35 .67 1.08 1.65 2.65 .84 1.12 2.09 2.78 .95 1.12 1.03 1.07 2.38 2.98 2.60 2.85 1.34 1.47 1.14 1.13 3.53 3.95 2.90 3.01 1.62 1.32 2.17 2.41 3.00 1.11 1.05 1.05 1.07 1.19 4.44 5.13 6.17 6.98 8.71 3.05 2.95 3.09 3.09 3.46 3.43 4.41 5.39 6.69 1.22 1.32 1.47 1.60 10.18 13.08 16.38 20.17 3.61 3.92 4.47 4.82 Long radius ells Area Pip. sq.ft. length, ft. .89 1.08 1.34 2.39 2.49 2.68 1.84 2.32 2.96 3.08 2.68 3.28 2.93 3.13 3.96 4.43 3.36 3.38 5.00 5.99 7.38 8.56 10.57 3.43 3.45 3.70 3.79 4.20 12.35 16.35 20.17 25.41 4.38 4.90 5.47 6.07 7^1--------------------- Crosses Area, tq. ft* 1.24 1.48 1.82 2.54 3.21 3.66 4.48 5.41 6.07 6.81 7.84 9.37 10.55 13.18 15.41 19.67 24.81 30.32 Pipe flet.ngth 3.59 3.40 3.64 4.08 4.26 3.99 4.28 4.59 4.63 4.67 4.53 4.69 4.67 5.23 5.47 5.89 6.78 7.23 Area, sq, ft. 1.62 1.94 2.38 3.32 4.19 4.77 5.83 7.03 7.87 8.82 10.0B 12.00 13.44 16.78 19.5B 24.87 31.48 38.34 Pip. length ft. 4.72 4.47 4.7B 5.34 5.56 5.70 5.56 5.97 6.01 6.06 5.81 6.01 5.96 6.66 6.95 7.45 8.60 9.15 AREAS, SIZES AND CAPACITIES OF STANDARD PIPE (All dimensions and weights ore nominal) Size, In. 1/4 3/8 >/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6 7 8 9 10 10 10 11 12 12 Diameter in* External (nterool 0.405 0.540 0.675 0.840 1.050 0.269 0.364 0.493 0.622 0.824 1.315 1.660 1.900 2.375 2.875 1.049 1.380 1.610 2.067 2.469 3.500 4.000 4.500 5.000 5.563 3.068 3.548 4.026 4.506 5.047 6.625 7.625 8.625 8.625 9.625 6.065 7.023 8.071 7.981 8.941 10.750 10.750 10.750 11.750 12.750 12.750 10.192 10.136 10.020 11.000 12.090 12.000 Thickness* Circumference, in. In. 0.068 0.088 0.091 0.109 0.113 0.133 0.140 0.145 0.154 0.203 0.216 0.226 0.237 0.247 0.25B 0.280 0.301 0.277 0.322 0.342 0.279 0.307 0.365 0.375 0.330 0.375 External Internal 1.272 1.696 2.121 2.639 3.299 0.845 1.144 1.549 1.954 2.589 4.131 5.215 5.969 7.461 9.032 3.296 4.335 5.058 6.494 7.7V 10.996 12.566 14.137 15.708 17.477 9.638 11.146 12.648 14.156 15.856 20.813 23.955 27.096 27.096 30.238 19.054 22.063 25.356 25.073 28.089 33.772 33.772 33.772 36,9t4 40.055 40.055 32.0)9 31.843 31.479 34.558 37.6J2 37.699 Transverse areas, sq, in. External Internal 0.129 0.229 0.358 0.554 0.866 0.057 0.104 0.191 0.304 0.533 1.358 2.164 2.835 4.430 6.492 0.861 1.495 2.036 3.355 4.788 9.621 12.566 15.904 19.635 24.306 7.393 9.886 12.730 15.947 20.006 34.472 45.664 58.426 58.426 72.760 28.891 38.738 51.161 50.027 62.786 90.763 90.763 90.763 108.434 127.676 127.676 8I.5B5 80.691 78.855 95,033 114.800 113.097 External surface area. sq.ft.tin ft. of pipe 0.1060 0.1414 0.1767 0.220 0.275 0.344 0.435 0.498 0.622 0.753 0.917 1.047 1.178 1.3009 1.45B6 1.7384 1.996 2.2350 2.2058 2.5220 2.8174 2.8104 2.8104 3.076 3.338 3.33B Length of pipe contain* ing co.ft. 2533.775 1383.739 754.360 473.906 270.034 166.618 96.275 70.733 42.913 30.077 19.479 14.565 11.312 9.030 7.198 4.984 3.717 2.815 2.878 2.294 1.765 1.826 1.826 1.515 1.254 1.273 Wt of water per foot, lb* 0.025 0.045 0.083 0.132 0.231 0.375 0.65 0.88 1.45 2.07 3.20 4.29 5.50 6.91 8.67 12.51 16.80 22.18 21.70 27.20 35.37 34.20 34.20 41.20 49.70 49.00 UCC 003067 STANDARD OfMCAU iM PLASTICS APPENDIX AREAS APPENDIX APPLICATOR TRAINING PAGE 462 APRIL 1970 [ r \ r r r i AREAS OF TANKS FOR INSULATION COVERAGE u s Li r? t OaR N a R a 5 T? J I *D 8 T -C *B S 8 8S ? < < UCC 003068 l I I l ! T STANOARD ojaALi n**rc> APPPKiruv AREAS APPENDIX APPLICATOR TRAINING PAGE 463 APRIL 1970____________ AREAS OF TANKS FOR INSULATION COVERAGE UCC 003069 STANDARD OCMCALS AMD PLASTICS APPENDIX APPENDIX APPLICATOR TRAINING PAGE 464 APRIL 1970 Dfomeler n*-A" 1 '-0" I*-6" 7-0" 7-6" V-fl" y-6" 4'-0" 4' -6" 5'-0* 5*-6* 6'-0" 6'-4" V-0" 7`--6" 8'-0" 8'-6" 9'-0" 9'-6" 10'-0" IO'-6" Il'-CT 11-6" 17-0" l3'-0" 13*-6" U'-0" 14'-A" I5'-0" 15'-A* lA'-O" 1A'-A" 17'--0" 17'-6" 18'-O'1 18'-6" 19'-0* ir-6" 2D'-O' 20'-6' 21 '-O' 21'-A" 77-0' 27-6" 23'-0" 23'-A'' 24'-0" 24'-A" 25'-0" 25'-A" 26'-0" 2A'-A" 27'-0' 27*-A" 28' -0" 28'-6" Surface Areo $q, Ft. Per Lineor Ft. 1.5708 3.1416 4,7*24 A. 2832 7.8540 9.4248 10.9956 12.5664 14.1372 15.7080 17,2788 18.8496 23.4204 21.9912 23.562D 25.132 26.7036 2.2744 29.8452 31.4160 32.9868 34.5576 36.124 37.6992 39.2700 40.8408 42.4116 43.9324 45.5532 47.1240 48.6948 50. 2656 51.8364 53.4072 54.9780 56.5488 58.1196 59.6904 61.2612 62.832 64.402 65.9736 67.5444 69.1152 70.6860 72.2568 73.8276 75.3984 76.9692 78.5400 80.1108 81.6816 83.2524 84.8232 86.3940 87.9648 89.5356 Volume Cu.Ft.Per Linear Ft. 0.1963 0.7854 1.7671 3.1416 4.9087 7.D686 9.6211 12.566 15.904 19.635 23.758 28.274 33.183 38.485 44.179 50.265 56.745 63.617 70.882 7B.540 86.590 95.033 103.87 113.10 122.72 132.73 143.14 153.94 165.13 176.71 188.69 21.06 213.82 226.98 240.53 254.47 268.80 283.53 298.65 314.16 330.06 346.36 363.05 380.13 397.61 415.48 433.74 452.39 471.44 490.87 510.71 530.93 551.55 572.56 593.96 615.75 637.94 AREAS AND VOLUMES - CYLINDERS Copocity Golf. Per Linear Ft. 1.4688 5.8752 13.219 23.501 36.72 52.B77 71.971 94.003 118.97 146.88 177.72 211.51 248.23 267.88 330.48 376.01 424.48 475.89 530.24 587.52 747.74 710.90 776.99 846.03 91B.OO 992.91 1070.8 1151.3 1235.3 1321.9 1411.5 1504.0 1599.5 1697.9 1799.3 1903.6 210.8 212.9 2234.0 2350.1 2469.0 2591.0 2715.8 2843.6 2974.3 3108.0 3244.6 3384.1 3526.6 3672.0 382.3 3971.6 4125.8 423.0 4443.1 4606. 1 4772.1 Diameter 29*-0" 29'-6" 30'-0" 30`-6" 31'-0" 31'-6" 32"-0" 37-6" 33'-O' 33'-6" 34'-0' 34'-6' 35'-0" SS'-A" 36'-0" 36'-6" 37'-0" 37'-6" 38'-0" 38'-6" 39'-0" 39'-6" 40'-0" 40'-6" 41'-0" 41 '4" 47-0" 47-6" 43'-0" 47-6" 44'-0" 44*-6" 45'-0" 45'-6" 46'-0" 46'-6" 47*-0" 47'-6" 48'-0" 48'-6" 49'-0" 49'-6" S0'-0" 60'-0' 70' -0" 80'-0' 90'-0" lOO'-O" )10'-0" 120' 0" 130`-0" 140'-0* 150'-0' 175'-0" 200'-0" Surface Area Sq.Ft.Per Linear Ft. 91.1064 92.6772 94.2480 95.8188 97.3896 98.9604 100.5312 102.102 103.672 105.2436 106.8144 108.3852 109.9560 111.5268 113.0976 114.6684 116.2392 117.8100 119.3806 12.9516 122.5224 124.0932 125.6640 127.2348 12.8056 130.3764 131.9472 133.5180 135.0888 136.6566 138.2364 139.8012 141.372 142.942 144.5136 146.0844 147.6552 149.2260 150.7968 152.3676 153.9384 155.5092 157.0800 188.50 219.91 251.33 22.74 314.16 345. SB 377.00 406.41 439.82 471.24 549.78 62.32 Vfetume Cu.Ft.Per Linear Ft, 660.52 683.49 706.86 730.62 744.77 779.31 804.25 829.58 855.30 881.41 907.92 934.82 962.11 989.80 1017.9 1046.3 1075.2 1104.5 1134.1 1164.2 1194. 6 1225.4 1256.6 12B8.2 1320.3 1352.7 1385.4 1418.6 1452.2 1486.2 1520.5 1555.3 1590.4 1626.0 1661.9 1698.2 1734.9 17721 1809.6 1847.5 1885.7 1924.4 1963,5 227.4 3848.5 5026.5 6361.7 7854.0 9503.3 11,309.7 13,273.2 15,393.6 17,671.5 24,0528 31,415.9 Capacity Galt. Pat Linear Ft. 4941.0 51129 527.7 5465.4 5646.1 5829.7 6016.2 6205.7 6398.1 6593.4 6791.7 69929 7197.1 7404.2 7614.2 7827.2 8043.1 82620 8483.8 8708.5 8936.2 9166.8 9400.3 9636.8 9876.2 10119 10364 10612 10663 11117 11374 11634 11897 12163 12432 12704 12978 13256 13536 1382 14106 14396 14683 21150 2789 3760! 47589 58752 71090 84602 99290 115154 132192 179927 235007 UCC 003070 STANDARD 04CMCALA M PLASTICS APPENDIX APPENDIX APPLICATOR TRAINING PAGE 465 APRIL 1970 Diomflftf O'-4" r-o** l*-4* ?-o2*-6" 3'-0" 3*-6` 4*-0" J'-O* 5**6d'-O" 6*-6" r-or-iS'-08'-V 9'-O' 9'-4* lO'-O* IO'-6* II'-oII '-4" I2--0" l?-4" 13'-0" 13*-6" U'-O" U'-4" 15'-O' IS'-4" l&'-O" 16'-4" i7*-o" !7'-4IB'-O" IB'-6" l9*-0` ir-6~ 20*-0' 20*-6* 2l'-0" 21'-4" 27-0" 27-4" 23'-0" 23*-4" ?4`-0* 24*-4" 25*-0" 2S'-4" 26*-0" 26*-4" 27'-O' 27'-6' 29'-0' 2B'-6* Surface Area in Sq.Ft. .7854 3.1414 7.0666 12.544 19.435 28.274 23.485 50.245 63.417 7B.540 95.033 113.1C 132.73 153.94 176.71 201.06 226.98 254. 47 233.53 314.16 346.36 380.13 415.48 452.39 490.87 530.93 572.56 615.75 440. 52 706.86 754.77 804.25 855.30 907.92 962.11 1017.9 1075.2 1134.) 1194.6 1256.6 I32D.3 1335.4 1452.2 152D.5 1590.4 1661.9 1734.9 1809.6 1885.7 1963.5 2042.8 ` 2123.7 2206.2 2290.2 2375.8 2463.0 2551.8 Volume In Cu.Ft. .0654 .5236 1.7671 4.1888 8.1812 14.137 22.449 33.510 47.713 65.450 B7.114 113.10 143.79 179.59 23.89 268.06 321.56 381.70 448.92 523.60 606.13 696.91 796.33 904.78 1022.7 1150.3 1288.2 1436.8 1596.3 1767.1 1949.8 2144.7 2352.1 2572.4 2B06.2 3053.6 3315.2 3591.4 3882.4 4168.8 45)0.9 4849.0 5203.7 5575.3 5964.1 6370.6 6795. 2 7238.2 7700.I 8181.2 8682.0 9202. B 9744.0 10306.0 10889.0 11494.0 12121.0 AREAS AND VOLUMES - SPHBtES Total Capacity in Go)Ions Diaaatar .4892 3.917 13.22 31.33 61.20 105.8 167.9 250.7 356.9 489.6 651.7 B46.1 1076 1343 1652 2005 2405 2855 3358 3917 4534 5213 5957 6768 7630 8605 9637 10748 I174T 13219 14586 16044 17595 19243 20992 22B43 24799 26866 29042 31334 33744 36273 38926 41706 44615 47655 50832 54146 57601 61200 64946 68842 72890 29'-0" 29'-6" 30'-0" 30*-6" 31*-0" 3I*-6" 32*-0" 37-6" 33'-0' 33*-6" 34*-0" 34*-6" 35*-0" 35*-6" 36*-0** 36*-6" 37* -0' 37*-6" 38*-0" 38*-6" 39*-0" 39*-6" 40*-0" 40*-6" 4!'-0" 41*-6" 47-0" 47-6" 43*-0" 43*-6" 44*-0" 44*-6" 45*-0" 45*-6" 46'-0" 46*-6" 47*-O'' 47* -6" 48*-0" 48*-6" 49'-0" 49*-6" 50'-0" 55*-0* 60*-0" 65*-0" 70*-0" 75*-O'* 80*-0" 85*-0" 90*-0" 95*-0" too*-o- 77094 81455 ! UCC 003071 Surface Ane in 2642.1 2734.0 2827.4 292Z5 3019.1 3117.2 3217.0 3318.3 3421.2 3525.7 3631.7 3739.3 3848.5 3959.2 4071.5 4185.4 4300.8 4417.9 4536.5 4656.6 4778.4 4901.7 5026.5 5153,0 52B1.0 5410.6 5541.8 5674.5 5808.8 5944.7 6082.1 6221.1 6361.7 6503.9 6647.6 6792.9 6939.8 7083.2 7238.2 7389.8 7543.0 7697.7 7854.0 9,503 11,310 13,273 15,394 17,672 20,106 22,698 25,447 2B,353 31,416 Volume in Cu, Ft. 12770.0 13442.0 14137.0 14856.0 15599.0 16366.0 17157.0 17974.0 1S818.0 19685.0 20580.0 21501.0 22449.0 23425.0 24429.0 25461.0 26522.0 276) 2.0 28731.0 29880.0 31059.0 32269.0 33510.0 34783.0 36087.0 37423.0 38792.0 40t94.0 41630.0 43099.0 44602.0 46140.0 47713.0 49321.0 50965.0 52645.0 54362.0 56115.0 57906.0 59734.0 61601.0 63506.0 65450.0 87,116 113,097 143,788 179,595 220,894 268,083 321,556 381,704 448.920 523,598 Total Capacity fn GoHorn 95526 100553 105752 111131 116689 122426 I2B343 134463 140760 147254 f53949 160839 167930 175231 182741 190462 198398 206552 214923 223518 232338 241389 250672 260195 269950 279944 290184 300672 31)414 322403 333646 345151 356918 368847 381245 393312 406656 419769 433167 44684! 460808 475058 489,600 651,673 846,024 t,075,609 1,343,464 1,652,402 2,005,400 2,405,406 2,855,344 3,358,155 3,916,785 STANDARD ORUUCAU AT MASTICS APPENDIX APPENDIX APPLICATOR TRAINING PAGE 466 APRIL 1970 BARE AREA OF PIPE FITTINGS (Including accompanying flanges in square feet ond in equivalent length of some size pipe standard weight fittings) Pipe lire In. i 14 * 2 2i 3 3i 4 4i 5 6 7 9 9 10 12 14 ,6 f longed couplings Areo Sq. Ft. Pipe length Ft. .32 .36 .46 .67 .64 .95 1.12 t.34 1.47 1.62 1.62 2.17 2.41 3.00 3.43 4.41 5.39 1 6.69 .93 .88 .95 1.08 1.12 1.03 1.07 1.14 1.13 1.11 1.05 1.05 1.07 1.19 1.22 1.32 1.47 1.60 90* ells Area Sq.Ft. Pipe length Ft .79 .96 1.17 1.65 2.09 2.38 2.98 3.53 3.95 4.44 5.13 6.17 6.98 8.71 10. 18 13.08 16.38 20.17 2.31 2.20 2.35 2.65 2.78 2.60 2.85 2.90 3.01 3.05 2.95 3.09 3.09 3.46 3.61 3.92 4.47 4.B2 Long radius ells Areo Sq. Ft. Pipe length Ft .89 1.08 1.34 1.84 2.32 2.66 3. 28 3.96 4.43 5.00 5.99 7.38 8.56 10.57 12.35 16.35 20. 17 25.4) 2.59 2.49 2.66 2.96 3.08 2.93 3.13 3.36 3.38 3.43 3.45 3.70 3.79 4.20 4.38 4.90 5.47 6.07 Tees Area Sq.Ft. 1.24 1.48 1.82 2.54 3.21 3.66 4.48 5.41 6.07 6.81 7.84 9.37 10.55 13. 18 15.41 19.67 24.81 30.32 Pipe length Ft. 3.59 3.40 3.64 4.08 4.26 3.99 4.28 4.59 4.63 4.67 4.53 4.69 4.67 5.23 5.47 5.89 6.78 7.23 Crosses Area Sq.Ft. 1.62 1.94 2.38 3.32 4.19 4.77 5. B3 7.03 7.87 8.82 10.08 12.00 13.44 6.78 19.58 24.87 31.48 38.34 Pipe length Ft. 4.72 4.47 4.78 5.34 5.56 5.70 5.56 5.97 6.01 6.06 5.81 6.01 5.96 6.66 6.95 7.45 8.60 9.15 UCC 003072 STANDARD OUKAU VC n.AiT<r APPENDIX applicator training PAGE 467 APRI1 1970 APPENDIX OUTSIDE SURFACE AREAS OF FITTING COVERS Fitting v9tm Lin* Flan* * - - * ~ r. * - - * - " - a m " - - * " " Line p*m pc* Nom PPC lin inch 1 ISO H 0.9 - % 0.9 - 1 1.2 - ix 1.8 - IX 1.8 3 1.9 2X ** 3 3* * 4 ~ -e - a. 10 - 12 - 14 - 16 - 18 - 20 - 24 300 H 11 * % 1.6 * i 1.6 IX 1.6 - IK 1.9 - 2 2.0 - 2X m3 a* J* -4 -s -a -B " 10 12 - 14 - i* 18 20 " 24 400 H 1.3 % 1.7 1 1.7 * IX 1.7 M 1H 2-4 as 2 2.4 2K -3 3K m4 a. S -6 8 s 10 - 12 - 14 IX 1.4 1.4 IB 2.1 2.1 2.6 3.0 3-0 3.3 3.8 4.3 4.6 5.4 8.2 7.7 9.2 iao ii.i 13.2 166 1.7 2.2 2.2 2.2 2.3 2.7 11 17 4.1 4.7 63 91 6.6 86 10.4 11.8 14.2 15.4 17.9 22.1 ii 2.3 2.3 2.3 2.7 2.7 3.2 3.7 4J2 4.7 5.4 5.B 69 8.8 109 12.4 2 11 2.1 2.4 2.7 2.7 3.1 31 3.6 3.9 43 60 5:3 6.1 7.0 8.6 10.2 11.9 12.2 14.4 16.8 2.6 2.7 2.7 2.7 3L1 3.3 3.7 63 4.8 5.4 69 6.3 7.5 9.5 11.4 12.9 164 16.2 19.2 23.6 2-5 2.9 2.9 2.9 3.2 33 3.7 4.3 60 5.6 6.1 6.1 7.8 9.7 12.2 13.5 2X 2.1 2.1 2.5 3.0 3.0 3.9 31 41 4.3 48 63 5.6 64 7.3 9.0 101 123 12.6 14.8 17.3 2.4 3.0 10 3.5 15 4.1 4.0 49 5-2 51 62 67 7.8 10.0 11.9 13.4 15.9 17.2 19.7 24.2 21 3.1 3.1 3.4 3.6 4.1 4.1 4.8 5.4 6.0 65 7.0 8.2 10.2 12.5 14.0 Outslda turfaca area in mm feat Nominal insulation thktnem-inchM 3 3X 4 4X 5 5X 23 2.3 2J3 3.3 3.3 19 41 41 5.2 51 62 6.7 7.5 8.4 9.4 11.2 121 111 15.2 171 2.7 3.2 3.2 31 4.3 4.3 5.0 5.7 SB 6.1 6.6 7.2 8.3 10.4 12.3 129 16.4 17.7 20.3 24.8 21 3.4 3.4 3.4 4.1 4.1 5.1 51 5.7 6.3 69 7.5 8.6 107 12.9 141 21 2.9 3.3 3.9 3.9 4B 4.9 4.9 53 5.9 6.4 6.7 IS 81 10.6 12.6 13.9 14.2 16.5 19.4 12 39 31 SB 4.4 4.7 5.1 5.8 7.0 7.7 8.2 8.7 9-9 11.4 13.4 15.1 17 7 19.0 21.7 264 3.3 4.0 4.0 4.0 4.6 4.7 5.2 59 6.7 7.5 85 9.0 10.3 11.7 14.0 167 14 14 3.9 4.6 4.6 5.1 SB 5.6 6.0 6.7 7.1 71 8.4 99 11-3 14.1 161 16.5 179 20.5 3.8 4.6 4.6 4.7 50 5.3 53 66 7.1 79 8.3 8.8 11.0 134 146 16.3 19.0 2D.4 23.2 28.0 3.9 4.7 4.7 49 5.3 5.4 5.9 6.7 7.3 8.0 8.6 9.2 10.4 13.7 15.2 17.0 4.6 4.0 49 5.3 5.3 5.8 6.3 6.4 6.7 7S 8.0 e.4 9.3 10.4 12.4 14.3 17.4 16.6 20.3 23.3 4.5 5.2 5.2 5.3 5.7 5.0 SB 7.4 71 a.6 9.2 9.7 11.1 13.5 169 17.5 20.4 213 24.7 29.7 4.6 5.4 5.4 5.5 60 6.1 6.7 7.5 8.0 83 9.5 10.1 11.5 13.9 17.5 18.2 4.7 4.7 5.3 5.0 6.0 6.6 7.0 7.1 73 83 83 9.3 10.2 11.4 13.5 15.4 171 18.5 20.5 23.4 91 5.9 S.9 6.3 6.5 6.7 7.3 8.1 8.7 93 10.1 10.7 123 14.7 17.0 20.0 21.7 23.2 263 31.4 5.3 6.1 6.1 6.2 6.7 6.9 7.4 8.3 8.9 93 10.5 10.6 12.5 15.0 17.7 20.7 5.4 5.4 6.0 8.8 61 7.3 73 8.0 8.3 9.2 9.8 10-2 10.8 12.3 14.6 163 181 191 21.9 241 51 6.7 6.7 61 71 7.5 8.1 91 9-6 103 hi 11.7 13.2 153 18.2 20.1 22.4 26.0 27.9 33.1 6.0 6.8 63 61 7.5 7.6 3.2 9.2 93 ia7 11.5 12.3 13.6 16.2 18.9 70.9 6 6.0 6.1 0.7 71 71 8.2 B.7 81 93 10.1 10.7 11.2 hi 13.6 15.7 19.3 20.2 20.2 2X4 26.5 6.5 7.4 7.4 7.5 83 8.4 9.0 10.0 103 113 12.1 123 14.3 17-t 19.5 21.5 22.7 26.3 30.9 343 6.7 7.6 7.6 7.7 8.3 8.5 9.1 10.1 103 11.7 12.5 13.2 14.7 17.4 20.7 22.3 ex 63 63 7.5 8.3 8.3 9.1 9.6 9.7 10.1 11.1 11.7 12.2 12.9 14.7 16.9 19.3 21.6 21.9 243 28.1 7.3 8.2 8.2 8.4 19 9.3 9.9 11.0 113 RS 13.2 133 15.4 18.3 20.9 223 24.9 271 31.2 38.3 7.5 8.4 8.4 8.6 9.2 9.4 TO-O 11.1 11.8 123 t3.7 14.3 15.9 18.7 21.7 23.7 7 7.6 71 8.4 9.2 91 iao 10.5 10.7 11.1 1X1 173 133 14.0 151 18.2 20.5 23.0 23.4 26.4 29.7 81 9.1 9.1 9.3 91 10.2 109 11.9 123 1X6 143 15.0 16.6 19.6 22.3 24.3 26.4 29.5 32.9 38.6 8.3 9.4 94 10.2 10.2 103 10.9 12.1 121 13.9 14.7 15.0 17.1 19.7 23.1 251 7X 81 85 9-2 10.1 10.1 103 113 11.6 12-1 13.2 133 14.4 15.1 17.0 19.5 313 24.5 241 28.0 31.4 9.3 10.4 10.4 10-4 101 11.2 11.9 130 13.6 14.7 15-5 163 179 21.0 23.7 25.8 23.0 31.1 34.5 40.5 9.5 10.2 10,2 10-4 11.1 11.3 13 0 1X8 1X9 15.0 159 16.7 18.4 21.3 24.5 261 UCC 003073 STANDARD OCMCAU A ELASTIC* APPENDIX APPLICATOR TRAINING PAGE 468 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Flttino covtr ,, - m *, r* ,, ,, ,, - m N ft ,, - M M ,, - ,, - M ~ ** - m ft* - Lit* pfS ** Norn P*P4 tin inch 1 400 16 ,, 16 * 20 - 24 600 ft 13 * % 1.7 ,, i 1.7 IX 1.7 ,, 1% 2.4 m 2 2.4 ,, 7X "3 3H 4 m6 -e 8 10 - 12 - i* . 16 m 18 ft. 20 - 24 000 X 18 .. X 18 t 23 ft* IX 2.3 IK ft* 2 ft* 2X -3 ft. 3X ft# 4 ft* s -> ft# 8 ft# 10 ft# 12 - 14 ft. 16 ft* 18 ft 20 - 24 1500 #. .. - .. .* - X 1.8 X 1.8 1 28 IX 2.3 IX 2 2K 3 3X 4 6 6 1H 2 14.7 169 18.6 23.0 156 17.1 20.0 24.5 16 26 29 29 2.3 29 2.3 29 2.7 36 2.7 3.3 12 17 3.7 4.3 4.2 5.0 6.1 5.7 66 7.7 66 7.7 66 ms 12.0 117. 8.7 116 111 149 16.3 19.0 21.1 26.6 17.8 20.4 226 286 2.4 26 2A 3.0 26 36 29 3.6 39 4.0 4.0 46 4.5 5.4 4.6 5.4 5.4 56 66 6.7 7.2 8.1 8.0 8.7 106 110 14.6 16.7 11.8 14.1 15.7 18.0 1B6 22.4 258 38.5 19.6 236 27.4 38.4 2.4 26 2.5 26 26 3.6 26 3.6 IS 4.0 4.1 4.6 46 5.4 5.6 ej 63 66 7.0 7.7 86 10.5 96 10.7 2X 16.4 17.7 206 26.1 2.5 3.1 11 16 16 4.1 4.7 46 B.4 61 B3 8.2 10.2 12.5 13.7 164 18. X 21.1 23.1 286 36 33 36 39 4.4 5.2 56 56 67 72 8.6 92 12.3 14.7 16.6 116 213 246 28.2 39.4 33 3.3 36 3.9 4.4 53 56 66 7.7 6.2 109 11.2 Outittt curtac* vm In tqu*r* f**t Nominal inoilfttioft thickrvftO-inchftft 3 3X 4 4K 5 SK 6 17.0 18.3 21.1 256 26 3.4 14 3.6 4.1 4.1 4.7 56 63 15 6.7 8.7 10.6 13.0 14.2 110 18.7 2t.7 236 29.7 4.0 49 49 49 5.4 5.6 63 63 73 76 9.1 9.7 92.8 153 166 193 206 253 28.9 403 3.5 43 4.9 4.9 5.4 5.6 12 73 8.1 8.7 10.9 11.9 183 196 22.6 273 33 49 4j0 4j0 46 4.7 5-3 59 6.5 B.1 96 B.6 10.7 143 153 173 20.1 23.1 2S3 39.4 43 46 $-8 59 6.2 69 7.0 7.6 7.7 IS 10.4 10.7 14.1 166 163 20.7 22.4 266 30.6 423 43 43 56 56 63 76 66 8.1 8.6 96 12.0 129 19.6 21.0 24.1 29.0 36 4*7 4.7 49 5.3 14 69 8.7 73 89 10.5 11.1 tl.7 156 16.6 1B.S 21.5 24.6 266 33.1 46 5.0 59 56 69 7.1 76 7.7 17 102 1 T.O 11.6 15.2 17.7 19.5 22.0 23.9 28.5 32.3 443 46 5.0 56 59 63 7*1 69 99 10.0 10.7 !3.0 14.0 206 22.4 25.6 30.7 4.6 14 5.4 5.5 6.0 11 17 76 B.O 9.1 11.4 11.4 126 168 176 196 226 26.2 28.5 34.9 56 5.7 6.5 6.5 7.1 76 8.7 8.7 9.5 10.3 126 117 16.4 19.1 206 236 256 30.0 34.1 46.3 5.6 6.7 6.5 6.6 7.1 79 8.7 10-0 11.9 12.5 14.1 153 223 218 27.1 32.4 53 6.1 6.1 6.2 66 66 7.4 83 86 106 12.4 12.4 14 8 19.0 203 213 24.4 27.7 30.1 36.7 69 14 73 73 76 86 96 93 103 119 14.1 13.9 17.7 20.4 223 256 279 316 356 48.4 63 04 73 73 79 84 9.6 104 114 12.7 163 114 25.1 217 298 34.1 253 266 314 354 10 17 69 7.8 64 76 69 7.7 79 7.6 8.2 9.2 94 11.0 136 136 89 8.5 9.1 10.1 104 12.0 14.6 144 16.0 199 20.4 239 113 20.5 214 24.1 259 29.3 314 384 28.9 31.0 33.6 40.5 7.2 73 11 11 8.7 9.7 10.5 10.6 116 123 110 15.0 7.9 74 96 9.0 86 10.7 11.5 116 12.6 13.4 163 163 206 21.7 217 216 203 246 26.6 283 289 309 334 35.3 37.7 394 604 526 7.1 76 73 10 8.1 9.0 11 94 97 9.7 104 116 16 117 119 117 12.7 13.7 116 17.7 134 156 174 169 6X 26.9 28.6 32.1 39.4 76 8.4 8.4 8.8 9.2 94 10.0 11.1 114 110 117 117 173 219 233 254 29.1 34.3 366 42.4 17 86 94 9.9 106 11.7 126 176 13.6 14.6 17.4 17.4 21.7 24.7 264 294 333 37.1 416 511 8.7 66 94 94 10.6 11.7 12.5 118 15.0 112 19.1 209 7 28.4 30.1 336 39.7 83 9.7 9*7 109 109 10.3 11.0 mi 124 14.1 164 166 204 239 24.7 273 30.7 344 373 412 94 9.7 104 104 114 124 134 134 14.6 15.7 18.7 18.7 211 263 28.4 316 334 416 434 57.1 94 9.7 104 106 114 124 139 110 163 179 206 214 7% 301 31.8 35.7 41.6 05 10.4 10.4 11.1 11.1 119 12.0 13.1 134 113 183 183 21.4 244 263 284 32.4 36.3 39.0 464 10.6 11.1 114 114 124 134 14.7 14.7 117 118 204 206 244 274 304 312 313 406 47.3 596 10.6 11.1 114 114 124 139 14.7 189 174 18.6 214 23.1 UCC 003074 STANDARD cmhkals puuncs APPENDIX APPLICATOR TRAINING PAGE 469 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Fittinf MV* Lina flanja a. * aa * 40 Scrmutd Globe Vclvt * a* a* m m Flangad Otoba Valya p* m - - ~ ^ 4b m m Lina 9* Nom ptp* liia inch | 1 1500 8 10 12 14 m 18 * IS <* 30 24 IX 2 12.5 16.6 21.4 25.8 29.9 34.8 399 52.6 13.6 178 229 279 31.7 38.5 41.0 949 14.2 la.s 23.7 28.1 32.6 37.0 43.0 661 Outtida turfaca aria in qua.a faat Nominal Insulation ttiicknau-indMa 3 3% 4 4Vfr . 5 SX 148 19.3 24.4 28.9 tai 20.7 260 30.6 17.3 22.0 27.6 32.3 ia.6 23.5 29.2 34.1 19.9 25.0 30.9 368 22.5 26.4 32.6 378 33.6 40.4 44.0 579 35.4 493 48.1 69.6 379 44.4 48.2 62.1 39.1 46.4 50.4 64.5 41.0 48.5 596 678 43.0 509 54.8 698 8 22.7 28.1 349 39.7 45.1 599 57.1 72.1 6% 7 7% 245 318 36.1 4t.6 47.2 55.1 59.4 74.7 25.7 31.4 38.0 43.7 *99 57.4 61 B 77.3 27.1 33.1 41.5 45.7 51.4 608 64.2 79.2 1.2 1.2 1.6 2.1 2.6 39 3.9 4.7 5.5 6.5 7.4 6.4 9.4 10.5 11 1.3 13 1.7 2.3 28 3.4 4.1 48 5.7 6.7 T9 8.6 9.7 10.6 1 19 2.1 2.7 3.0 36 48 59 6.0 7.0 8.0 98 108 118 12.4 IX 19 19 2.5 3.0 3.6 48 S.2 6.0 78 88 98 108 118 12.4 1* 2.6 2.9 3.1 3.4 4.1 5.1 56 68 78 8.8 9.7 10.6 t!8 13.4 2 2.6 29 3.2 3.8 48 5.4 6.2 7.3 8.2 9.3 10-4 119 125 142 2X 3.7 3.7 4.4 6.2 6.0 7.0 8.0 9.1 109 11.4 196 13.9 159 1S.9 3 39 3.9 4.7 5.6 6.4 7.4 8.4 9.6 10.6 119 13.1 14.4 15.7 178 3K 4 I a 10 12 14 16 ia 20 24 teo H 44 % 44 1 IK 4. IK 4V 2 5.6 M 7% m3 - 3K * 4 4 S 6 4 8 -4 10 a* 12 - 14 - 18 a. 18 20 44 24 30-0 XX - 1 2.9 - II U 58 68 7.2 $-1 98 118 128 168 218 248 39 4.0 a2 88 8.1 88 108 128 tw 188 23.2 268 4.5 4.8 6.7 68 88 9.6 118 13.4 14.3 19.7 248 27.2 5.2 5.3 7.7 9.5 98 108 12.7 14.7 15.6 20.7 35.3 298 59 59 aa 108 108 13.1 148 168 16.9 22.3 27.0 308 6.7 6.7 9.9 11.4 118 *4.3 15.2 178 186 240 29.0 328 79 7.9 11.0 12.6 t3.1 15.7 16.2 189 20.1 25.7 318 348 6.9 8.9 12.1 138 14.3 17.1 178 20.4 21.6 27.5 328 36.9 10.1 10.1 12.3 15.1 15.7 18.5 19.2 22.2 23.2 29.4 34.9 39.0 119 119 148 16.5 17.1 208 21.2 23.9 248 31.3 36.9 41.1 12.5 12.5 17.0 188 18.5 21.0 22.3 25.5 26.7 33.2 39.1 438 139 139 17.3 19.4 20.0 228 24.4 27.9 28.5 35.2 41.2 45.6 159 15.2 19.4 21.0 21.0 24.4 268 ?8.6 30.9 37.3 43.6 48.0 16.4 162 UCC 003075 STANDARD cmmcmj m0> n.tfnct APPENDIX APPLICATOR TRAINING PAGE 470 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Fitting cover Flwwd Globe Valve * * ** r * . * " * - M m " ~ m m m m - Nom Line pres s*ae psi inch 1 Outside surface area in square fart Nominal insulation thickness--inches 1X?2X33H44tt556 6%77* 300 1H 33 -2 - 2X ** 3 3% "4 6 Tt 6 8 ** to * 12 14 4.3 7.1 8.3 9.4 11.6 148 14.7 15.2 20.8 27.4 38.8 6.0 8.1 9.4 103 12.9 15.9 16.5 16.6 22.6 29.1 383 5.6 8.4 10.3 11.2 133 163 17.4 17.5 23.4 30.7 403 6.1 9.4 10.6 12-2 14.4 17.4 19.0 186 24.4 328 41.6 6.9 10.7 12.2 13.5 156 19.0 20.4 206 26-2 33.7 44.0 8.0 113 13.4 143 173 20.4 203 21.6 28.0 35.7 46.3 9.0 132 14.7 16.2 t8.7 22.0 21.6 23.3 30.0 378 48.9 10.1 15,7 16.1 17.6 203 23 6 24.9 243 313 40.0 513 118 15.7 17.5 19.1 218 2S.4 26.7 26.7 338 42.2 53.7 12.S 17.1 19.0 20.7 23.4 26.7 280 28.0 353 454 56.3 t3.8 18.5 203 22.1 25 2 29.7 30.4 30.4 38 0 463 563 158 20.0 22.0 23.8 268 308 32.3 328 40.1 49.2 61.6 168 218 217 256 28.7 328 34.0 343 42.4 51.7 64J - 16 18 20 24 400 X X H1 IK IX 6.5 68 73 78 63 8.7 108 118 12.6 138 158 168 130 19.5 2 .. 2K 78 83 9.6 10.6 11.6 138 148 158 17.0 18.5 20.0 213 232 9.3 10.3 118 12.7 138 148 15.9 178 188 208 218 233 25.3 "3 98 103 118 123 148 t5.4 168 188 198 21.4 23.0 24.7 26.4 - 3K * 4 s "e 11.9 138 158 20.4 123 TSlI 11.1 22.2 14.0 148 16.1 238 16.4 163 19.1 24.4 168 17.1 21.0 26.1 178 18.7 22.7 278 18.3 19.8 25.1 298 198 218 268 31.7 21.4 23.6 278 338 238 258 298 36.4 24.7 27.0 318 38.0 26.4 283 333 403 288 308 352 424 8 to - 12 - 14 26.0 263 28.0 28.1 31.2 338 358 37.4 396 418 436 430 488 - 16 ta 20 - 24 600 tt "X * 1 33 ** IK 33 1H 2 ~ 2X ** 3 - 3K * 4 -6 6 * B * 10 12 - 14 t* 16 - 16 - 24 48 42 68 7.7 8.9 102 11.7 122 18.0 202 30.0 82 5.4 73 8.7 11.1 11.7 123 143 J93 22.0 32.0 S2 6.6 88 9.4 11.7 126 126 15.3 20.8 211 33.3 63 73 9.4 103 123 133 14.6 163 213 24.1 343 7.6 7.6 10.5 116 132 14.6 16.0 176 238 258 36.6 83 9.4 11.7 12.7 153 163 173 19.1 25.0 273 383 9.8 10.5 122 14.0 16.7 172 182 20.6 26.7 29.6 412 11.1 113 143 TS.3 18.0 183 203 223 28.7 313 433 12.4 122 158 18.7 198 20.5 22.1 238 30.6 33.6 45.7 117 14.1 168 188 21.1 22.1 23.7 25.6 322 358 472 15.0 !S2 188 18.7 22.7 217 25.4 27.4 342 37.7 502 163 163 19.7 313 24.4 25.4 273 293 363 353 023 18.0 188 318 722 26.1 278 298 31.1 38.7 422 554 UCC 003076 r r r r r r i i i i [ i L L L L l STANDARD OMdMCALS AMO PLATOO APPENDIX APPLICATOR TRAINING PAGE 471 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Ftttfne OMT Flangad Glob* VmbM If a# tt * - ** ** - - " m tp - * Scrtwd GtttVah* < 4# M m M ~ - Nam Outtidt ftirfact ant in tqutn teat Lint Pk>t pn sUt Nominal Insulation thick Ml inch 1 IX 2 7X 3 3K 4 4K 5 5X 6 ex 7 ?K 900 to M M " * * a* a* H % t IX IX 3 ax 3 3H 4 6 e a 10 ia 14 10 is 30 34 1600 ~ X % 1 IK M IK M3 ax -3 3X 4 t# a - -8 10 - 12 14 - 10 * 19 20 24 0.7 13.7 1X7 16.7 16.9 17.5 21.0 35.4 35.4 100 1X1 16.9 IBS 1X0 19.1 229 27.3 37.4 11.9 1X1 18.0 18.0 19.0 30.2 24.0 28.5 38.9 12.7 17.1 19.0 19.0 19.9 31.3 24.6 29J3 40.8 14.0 1X8 19.7 198 22.6 23.1 27.1 31.7 429 15.3 20,3 22.4 223 23.2 24S 29.0 33.9 45.4 168 22-0 24.1 24.6 25.9 284 30.9 38.1 45.9 18.3 23.7 259 26.3 273 28.4 32.1 38.2 50.3 19.8 25.4 278 279 29.6 30.4 35.1 409 53 0 21.4 27.1 296 303 319 32.4 37.3 42.7 56.2 23.0 29.1 32.1 33.3 33.8 34.4 39.4 4X1 58.1 24.7 31.0 34.1 34.7 35.0 36.5 41.7 482 60.9 269 33.0 38.2 369 37.4 38.6 44 0 50.1 63.6 1X1 14.2 19.4 32.4 3441 31J 34 6 14.5 1X7 21.1 33J8 28.4 32.4 386 1X4 1X6 23.4 35.5 27.6 34.8 38.5 16.3 17.6 238 259 289 38-3 40O 170 19.1 25.6 27.2 308 38.7 42.3 19 5 20.8 27-2 31.0 33.0 40.9 448 2t.1 228 298 3X1 36.0 43.2 47.3 22.7 24.1 31.0 35.2 37.2 45.6 498 24.4 259 33.1 373 39.5 48.2 52.3 26-1 27.7 35.7 39.4 41.6 50.6 55.0 28.0 29.6 37.3 41.5 439 53.3 57.5 29.4 31.6 39.4 434 46.2 556 60.3 319 339 415 44.0 499 58.6 63.0 K K i IX IK 3 5.1 ax 8.2 X 7.3 3K 7.6 4 8.6 B a 5.1 6.2 7.3 7.8 8.6 11.2 1X2 6.3 76 8.6 8.9 10-2 13.6 1X4 7X 8.8 10.2 10.5 11.7 14.8 17.3 8.9 10.4 ItO 12.1 13.4 18.2 19.4 10.5 12.0 13.4 138 15-2 19.0 218 12.1 13.6 1X2 15-6 17.0 19.3 23.7 13.7 15.4 17.0 17.5 19.0 23.3 26.1 155 173 19.1 196 24.1 26-6 28-5 17.4 193 212 21.6 23.3 28.0 31.1 19.4 21.4 239 23.8 25.6 30.6 339 2U 23.6 25.7 26.1 28.0 33.2 36.6 23.7 26.0 280 289 30.6 365 39.4 260 283 30.6 31.1 33.2 39.4 42.4 UCC 003077 STANDARD CMMCALS AIO n.ASTKft APPENDIX APPLICATOR TRAINING PAGE 472 APRIL 1970 __________ APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Fitting cor Srnwd - - - Flanged GftUVafaw * m m m - * * - m ,, p. - m ,, m - p. - Nom Outx'dp uHM ar*p In qpa Iwt Lin* pip* pm iu Nominal Insulation tMckrw-lnehP* P>J inch 1 IK 2 2X 3 3X 4 4X 5 6X 6 6X 7 7X 8 17.6 19.7 21.7 24.1 264 29.0 31.6 345 37.1 40 0 43.0 483 *95 10 709 233 254 286 305 33.2 361 384 42.0 45.1 483 514 55 0 13 14 IB 18 20 24 ISO % M% m 1 4.1 pp IK 43 u IK 4.8 3 2% a. 3 4.4 44 43 50 54 7.0 3X Mpp 4 s -6 8pp a. 10 p. 12 - 14 pp 16 pp 18 .. 20 - 24 300 x % o 1 4.1 - IK 4.6 pp IK 66 p. 2 a. 2K -3 3X ,,4 a. 5 -6 m8 ap 10 ap 12 14 73 8.4 10.0 13.0 16.7 194 2S.S 26.7 394 414 48.1 600 5.2 5.6 64 73 8.2 9.7 98 12.2 14.7 164 304 27.1 35.1 404 p. IS 18 20 - 24 55.0 50.1 714 934 44 5-3 5.7 6.1 7.0 8.1 8.4 9.7 115 1X7 18.3 21.6 27.4 313 424 43.7 504 62.5 81 6.6 7.6 8.1 9.1 11.0 113 13.4 16.0 174 22.6 28.7 373 46.6 575 63.1 745 964 55 5.6 63 7.2 8.1 9.6 9.6 114 12.9 16.0 20.3 23.4 30.2 34.0 45.4 464 53.4 67.2 66 63 7.4 85 9.7 11.1 11.2 125 15.3 175 214 25.4 31.7 365 48.0 49.0 567 695 85 9.0 iai 103 115 12.7 124 145 163 194 24.1 27.5 33.9 393 504 515 595 72.6 95 10.4 115 114 13.0 144 14.7 16.2 17.2 225 26. t 303 36.6 415 53.7 54.7 62.4 76.1 10.4 112 12.4 13.4 145 16.5 16.5 1B.3 20.5 24.6 29.2 324 39.6 435 58.5 57.7 654 795 12.0 12.4 13.6 15.4 164 18.6 18.7 205 224 27.1 324 355 425 47.2 594 615 657 8X7 12.6 1X6 143 17.4 184 204 20.8 223 25.2 29.7 344 384 46.2 50.7 64.1 65.1 734 88 5 13.9 154 163 19-5 20-6 23.0 23.2 252 273 32.0 373 414 49.5 64.4 66.1 693 783 93.5 15.2 185 18.0 163 17.7 193 12.7 214 23.4 25.4 193 24.1 25.7 284 204 26.J 263 306 25.6 27.7 30.4 353 274 303 33.1 38-2 305 33.0 364 413 40.8 453 53.1 58-0 444 484 553 613 49.1 52.1 60.1 63.4 72.5 73.5 823 983 765 774 88.4 1033 81.1 823 893 1086 6.6 84 8.5 95 10.4 12.0 12.6 135 15-2 16.5 18 0 7.3 74 90 10.4 tt.2 12.4 13.6 15-0 16.3 17.7 19.2 6.2 8.7 100 114 9.0 9.6 10.7 125 10.1 10.7 114 134 115 115 13.1 15.1 12.4 13.0 145 164 13.6 143 15.7 185 144 16.0 17.1 19.7 163 17.1 186 21-4 17.7 18.5 20.0 224 19.2 20.0 215 24.8 203 21.5 233 264 114 14.2 16.6 19.2 125 144 175 194 134 16 4 19.2 213 1S.1 179 205 23.0 16.5 195 22.4 24.6 183 204 244 26.4 19.7 22.4 254 283 21.4 24.1 274 30.1 22.9 25.9 29.4 32.0 24.8 273 313 34.0 265 29.4 332 361 23.4 295 386 50.2 24.4 213 396 61.3 262 33.2 42.0 64.1 28.0 362 43.9 56.6 294 373 48.4 593 314 395 486 624 33.7 41.7 51.1 64.7 36.7 434 534 67.6 373 48.1 561 69.6 403 482 58.7 733 41.1 504 61.4 754 59.2 643 765 885 60.7 663 78.4 1005 636 684 816 1045 68.2 72.0 84.1 1074 695 745 875 111.5 72.1 78.1 915 1143 75.0 81.0 94.5 1194 783 842 98.1 1224 813 873 1013 126.6 843 904 1054 1303 874 943 1064 1343 400 X XPP MP. 43 6.7 67 73 76 9.0 10.1 lt5 12.4 tX7 15-0 16.3 17.7 19.2 IK 4.7 5.9 65 7.5 61 93 10.4 11.8 124 143 15.4 16.7 183 19.7 UCC 003078 r F F r r r i i i i L L t L i, L L L STANDARD cwHCiu Ate puisnes APPENDIX APPLICATOR TRAINING PAGE 473 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS fitting war Fianffd m - m - m . - m tm m m ,, m rt m m m m m m m m Norn Owtiid* fuffaca am In aquan fMt Lbw P<P* prm tfx NomM Ifttulftton tMcfcrww-mchw P* Ml 1 IX 2 3X a 3K 4 4K 6 SK 6 6K 7 7X 400 IK 4.9 XO 99 79 9.1 94 10.4 ns 1X8 14.0 154 18.7 1X2 1X6 . 3 XI 9.3 10.1 10.7 113 1X1 14S 153 17.2 189 20.1 21.6 23.3 m 2% 93 11.0 119 12.4 1X7 1X0 txs 17S 193 209 224 24.1 259 -3 1X3 119 173 133 14.6 169 17.5 1X9 219 23.1 2X7 2X4 27.2 m 3* 4 6 133 139 18.0 18.0 IXt 16.1 19.6 383 16.1 16.1 20.7 213 179 179 21.7 32.4 183 18.6 334 24.0 202 202 35.1 25S 213 219 26.9 273 23.4 23.4 288 29-5 25.3 25.2 303 313 259 369 32S 33.4 283 283 34.7 35.4 303 303 363 37.6 32.7 32.7 389 39.7 B m 10 m 13 - 14 m m 16 18 m 30 3 3X3 319 379 4X3 #7.4 axo 7X1 96.0 279 33.1 419 479 90.1 659 79.2 100.0 28.2 34.4 42.4 49J 618 67.5 80.0 102.0 394 36.7 439 51.7 63.5 693 819 1043 31.4 37 481 843 6X3 72.2 85.1 107.7 3X5 40.0 49.4 56S 693 7X2 883 111.4 3SS 423 510 ses 72.2 78.2 91.7 11X1 37.7 44.5 5X5 6X3 753 81.3 95.0 11BS 393 470 56.1 65,1 783 64.9 98S 122.4 42.1 493 58.7 673 813 87.7 101.9 t263 44.3 51.7 61.3 708 84.6 91.1 10S.4 129.6 463 54.2 84.1 7X7 87.7 94.4 109.0 1343 49.1 568 663 86.6 91.1 973 112.6 138.5 coo X MX f 1 4^ XI X9 99 7.2 6.1 9.4 t0.4 11.6 12.8 14.Q 15.4 1X7 183 IK XI X3 7.4 8.0 8.6 10.0 11.1 123 133 148 18.2 173 1X1 20.6 M IK M2 2H ** 3 79 105 119 119 89 11.7 1X6 149 as 12.6 133 1X0 9.7 133 14.1 1X9 10S 143 1X4 17.4 12.0 159 16.9 IB9 1X2 17.4 184 20.5 14.5 18.4 199 22.0 1X9 2X3 21.4 23S 17.3 213 233 2X4 18.7 233 243 27.2 203 259 2GS 29.0 213 27.0 28.3 3X9 JH 4 6 -6 M M a 10 12 - 14 ie ia M 20 P* 34 1X3 1X3 31.4 3X9 34.1 41.B 483 07.6 exo 79.1 80S 120.8 18.0 181 233 279 384 44.0 81.8 60.4 899 823 639 1243 193 21.1 24.4 389 379 4X4 639 63.0 787 84.2 S63 127.2 387 22.1 263 303 392 463 64.4 83.5 734 86.1 68.0 129.6 239 239 27-4 323 41.S 49.5 67.1 669 76.4 894 101.6 13X7 2X0 259 29.2 343 439 sis 59S 6X4 7X5 92.8 90X2 137S 273 273 313 36.5 463 54.4 62S 73.4 61.6 98.2 1083 141.9 29.7 29.3 33.3 389 48.7 57.0 653 75.4 848 99.6 112.5 1463 32.1 31.3 35.4 409 51.3 59.7 68.1 784 88.1 103.1 116.2 150.4 34.7 33.3 375 43.1 63.7 82.4 71.1 815 91A 106.7 119.2 154.9 374 35.3 39,7 45.4 56.3 66.2 74.0 84.7 94.7 110.4 123.9 15X2 4X1 37.4 419 489 69.0 880 770 88.0 98.1 114.0 1273 161.7 423 39.5 443 503 X17 703 80.1 91.2 101.5 ms 131.8 168.2 900 X % 1 IX IK 2 2K 3 3K 4 B m6 a to 13 ,, t4 18 m to m 30 - 34 8.7 9.3 99 13.3 16.7 17.1 179 30.6 287 31.1 36.2 47.6 69.1 89.6 81.7 9X9 9.7 187 114 123 139 15.2 16.7 1X2 19.6 219 22.7 243 10.4 11.4 12.2 133 14S 163 17.8 19.3 20.8 22.4 24.0 253 10.9 14.7 183 1X7 12-0 159 19.2 19.2 12.9 163 203 209 14,2 1X0 22.0 223 1X5 19.7 23.7 243 17.0 21.3 25S 2X1 18.5 23.0 27.2 27S 200 24.6 29.1 29.8 21.6 26.4 31.1 313 2X3 28.3 33.1 33.8 24.9 30.2 35.2 359 26.7 32.2 373 38.0 19.4 21.4 287 33.2 70S 22.5 29.7 34.6 219 233 31.1 36S 23.3 253 33.2 38.0 25.0 27.1 353 403 26.7 289 37.4 42.6 28.6 309 393 44.9 306 313 419 47.4 32.5 349 44.1 49.7 34.5 37.0 46.7 S2.2 36.6 392 48.9 543 38.7 41.3 51.4 67.4 40.5 602 613 723 419 519 63.6 743 43.3 63.6 65J 76.4 45.7 5X1 6X3 79.6 48 2 SB3 713 82.9 503 61.5 74.3 663 53.2 64.4 77.4 893 558 67.2 aio 92.9 59.5 702 83.8 963 61.2 73.1 87.0 999 64.0 76.2 90.4 103.4 663 793 93 7 107.1 85.1 97.1 89.1 929 96.0 96.6 103.1 106S 110.4 1143 118.0 1219 999 101.7 104.0 107.6 111.4 1153 1190 122.9 12X9 1309 1349 139.0 UCC 003079 STANDARD OCHOtli MO PLASTCI APPENDIX APPLICATOR TRAINING PAGE 474 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Fitting cover Flanged Gaia Valva a. .. M - ** .. - m * Wafdmg Tee a. m * m * a. flft m - " Screwed Tea " - - m ** m - m ** Mom Outside surface erta rn square fees Lino Orts Nominal insulation thickness--inch- Pt rMfl 1 i 2 n 3 3K 4 4* S 5K e ex 1 7V. 1500 X % 1 114 114 V 2 2% -3 3H ~4 M5 -0 rr 9 a. 10 w 12 " 14 a# 19 - 18 i 20 24 7.8 9.3 9.7 111 16.4 19.5 216 20.2 35.2 40.2 61.7 68.3 81.3 96.7 1160 88 106 108 14.4 178 21.1 23.6 216 37.4 43.0 646 71.6 86.7 100.4 120.0 9.6 11.6 128 14.6 186 22.4 24.9 25.1 39.0 44.0 56.3 716 69.1 103.0 123.8 10.6 121 126 16.3 198 23.6 260 28.6 40.5 465 678 758 911 1055 125.4 118 13.6 14.1 17.4 216 25.3 27.9 30.6 426 46.0 60.7 788 948 109.3 129.6 110 14.8 166 194 212 271 298 32.7 451 50.5 53.5 82.1 98.5 131 1338 14.3 16.3 16.9 21.0 256 29.1 31.8 346 476 531 66.4 85.5 102.1 1171 1386 167 17.9 184 22.6 26.7 31.0 33.9 369 50.2 SS8 69.4 88.9 1058 1211 142.4 17.2 19.4 200 24.3 266 311 36.0 39.1 52.9 58.5 72.4 821 109.0 1251 1469 18.6 20.9 21.6 266 306 351 381 41.4 55.4 611 75.4 956 1115 129.5 511 20.1 228 231 27 9 325 37.3 40.4 417 58.0 646 786 99.4 117.4 133.6 1S5.7 21.7 24.1 24.9 298 345 39.5 42.7 46.0 608 669 81.8 1036 121.4 1378 1801 213 259 26.7 31 7 36.6 41.7 44.9 486 616 696 93.0 106.7 125.3 1421 1048 X 14 .7 1a 114 a IK t.t 2 1.3 2% 1.6 3 1.8 334 21 4 2.4 S 10 6 3.7 8 10 12 14 16 18 20 24 X 16 % 1.1 1 1.3 IK 1.6 IK 1.6 2 1.6 2K 2.6 3 11 3K 3.1 4 11 0 9 8 10 13 14 1.1 1.3 16 16 16 26 2.6 3.0 3.0 17 4.4 61 9.2 11.6 126 156 186 21.9 29.3 18 1.6 16 2.6 26 26 3.2 38 38 38 4.6 61 76 10.4 11.7 16 18 16 28 2.5 31 31 3.8 36 4.4 63 7.1 10.3 128 14.1 17.1 201 23.7 31.3 18 26 26 13 31 31 38 48 48 48 51 61 8.7 11.4 136 2.6 2.6 2.6 31 31 38 38 4.6 4.6 63 62 81 11.5 14,1 15.6 18.6 218 258 33.4 21 12 31 4.0 46 4.0 48 6.7 67 67 86 7.0 8.3 12.6 14.7 31 31 31 46 46 4.7 4.7 5.6 6.6 58 7.1 91 128 15.6 17.1 201 23.7 271 35.5 2.7 48 46 48 48 48 58 6.7 6.7 67 68 78 106 136 158 4.0 4.0 46 46 48 5.7 5.7 66 66 6.7 81 10.5 14 1 17.1 16.6 21.9 25.5 29.3 37.7 13 46 46 58 58 58 6.8 76 76 76 86 8.7 111 14.7 17.1 48 *8 48 58 58 6.7 6.7 7.7 7.7 78. 91 11.7 15.6 186 201 23.7 27.3 311 398 38 58 69 68 68 68 76 61 9.1 9.1 9.1 9.6 12.7 158 18.4 5.9 5.9 58 68 68 78 78 9.1 9.1 9.1 106 t3.0 17.1 20.2 218 25.5 291 33.4 421 46 68 68 8.0 86 86 91 10.4 10.4 10.4 164 108 114 17.1 19.7 68 68 68 78 78 91 91 10.3 101 101 11.7 144 168 218 33.7 27.4 31.3 356 44.7 5.3 86 60 91 91 91 10,4 11.7 11.7 11.7 11.7 11.7 156 19.4 21.1 76 94 78 91 78 91 91 10.6 91 106 10.4 11.7 10.4 11.7 11.6 118 118 128 13.0 110 13.0 14.4 168 201 217 266 171 218 258 27.4 291 33.4 37.7 47.1 311 35.6 39.9 49.6 60 71 9.3 108 91 108 108 118 108 *08 11.7 136 118 118 111 1*8 110 110 136 *10 148 148 1*8 148 16.6 171 T9.7 21.1 228 238 11.3 13.1 13.1 t4.6 14.5 14.6 166 t88 217 27.4 291 33.4 37.7 42.3 521 1.7 118 116 131 112 131 148 16-1 *8.1 161 16.1 161 18.1 228 28.4 11.7 146 146 166 166 166 171 20.4 266 29.3 311 365 398 44.7 548 88 112 *31 *4.7 *4.7 *4.7 181 *7.7 17.7 17.7 *7.7 *7.7 206 219 268 128 161 61 174 178 174 188 72.1 27.4 311 33.4 37.7 421 47.1 576 96 141 14.7 162 161 161 17.7 19.4 *98 *98 *6* 198 208 264 288 UCC 003080 STANDARD ontfCM t am WAiria APPENDIX APPLICATOR TRAINING PAGE 475 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Fitting eowtr fliumri TM Flangad Tn - 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24 400 * 2D ft 3D 4.1 - IK 6.5 m 1H 5.5 m 2 6.7 2X -3 M M 3ft 4 5 -a 6.7 73 9.1 11.2 13.3 14D 18D 20.1 28.4 323 38.9 47.4 65.0 63.0 79.0 3A 4.1 62 5.7 fi.1 6.9 8.7 10.7 11.6 13.3 162 17.1 7D 9.0 10.5 12.5 14.1 153 17.7 27D 283 343 41.5 50.0 57.4 658 818 4.5 48 5.3 6.2 7.2 8-0 98 11.4 13.1 14.7 16.7 188 9.4 98 11.5 133 14D 160 18.7 23.0 29.4 36.2 430 51.6 69.0 67.4 B4D 4.6 6.1 SD 7.4 7.7 9.5 10.6 12.4 138 158 17.8 198 9.4 11.6 13.2 14.0 15D 17-7 19.4 24.1 30.7 37.5 43.8 53.0 606 69.4 852 53 6.4 7.1 7D 9.4 9.7 12.5 142 14.6 16.6 18.4 20D 103 11.7 13.6 1G.5 18.1 203 21.1 278 323 390 46.6 55.6 63.5 72.0 88.5 6.1 6.6 8.0 8.3 9.5 10.5 12.7 14J 17.1 18.7 213 233 11.7 13.0 143 16D 182 20.9 243 27.6 388 41.8 48.6 58.2 663 75.2 91.8 89 7.6 9.2 9.5 10.7 11.6 13.9 15.7 17.3 19.2 21.5 23.5 123 14.5 163 163 20.4 22.5 26.0 296 36.8 46.1 50.3 60.3 69.0 78 3 95.2 79 8.6 10.1 10.5 11.6 12.7 15.1 17.0 167 206 23.0 25.2 142 15.6 17.8 19.7 22.0 24.2 27D 15.5 17.1 19.2 21.4 23.7 2S.9 290 163 18.6 200 73.1 25.3 273 31.7 18.4 203 22.4 24.7 272 29-6 33.7 19.9 2t.B 24.1 36.7 293 31.4 36.6 21.5 23.2 250 28.4 31.0 33 5 37.7 31.5 39.0 48.7 56.4 33.4 4t.t 48.8 57.6 35D 4X4 513 59.5 37.5 45-8 53.8 622 39.8 480 56.4 653 41.8 SOX S8D 673 63.8 72.2 81.4 98.5 6S.6 77.5 84.4 102.0 69-2 79.6 90.5 1050 72-3 82.7 91.3 112 0 75.3 858 943 113.0 77.5 89.2 98.2 116.7 83 9.4 11 2 11.6 12.7 13.9 16.3 19.4 202 22.1 24.6 273 9.7 10.5 12.3 12.7 13.7 15.1 17.7 19.8 21.6 23.7 26.2 28.5 10.6 11.4 1X3 137 15 0 16.4 19.2 21.3 23.2 25.3 28.0 30-3 11.6 12.5 14.6 15.0 16.3 173 70.6 228 23-7 27.0 297 32.1 123 13.7 153 16.3 17.6 191 223 24X 26.3 28.7 31-5 33.9 13.9 14.9 17.1 173 18.8 20.5 23,5 25D 28.0 30.4 333 35 8 UCC 003081 STANDARD CMMC4L1 AMO FLAfTlO APPENDIX APPLICATOR TRAINING PAGE 476 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Frttmg cow Flanged To* ~ - 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% .7 & 1.0 1.4 1.7 31 36 3.0 36 4.1 421 X4 XO 6.7 % x 1J0 1.4 1.7 31 36 30 3.6 4.1 4X 5.4 XO 6.7 7.4 1 x 1.0 1.4 1.7 31 25 30 36 4.1 4.8 54 60 6.7 7.4 IX .6 1.4 32 33 2.7 34 4.0 4.6 5.5 6.3 7.1 8X 8.7 9.8 UCC 003083 STANDARD CT--CMI PLifTICl APPENDIX APPLICATOR TRAINING PAGE 478 APRIL 1970___________ _ APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS Fitting covtr Scrwd Eli 46* Lina pm P* Mom P*P siz inch i 1 8 2 1.3 2% 1.4 3 1.7 3* 1.7 4 2:3 5 6 e to 12 14 Ovtfcidt Surfact arH squara Hit Nominal insulation ihicknass--Inch** IX 2 2X 3 3K 4 414 5 5H 6 6X 7 7% 1.4 2.2 2.3 37 14 4.0 4.6 5.5 61 7,1 8.0 8.7 91 1.6 2.3 2.5 2.9 3.6 4.3 *9 5.7 6.6 7.5 8.3 9.2 9.1 1.8 2.4 2.7 12 39 4.5 5.3 6.0 68 7.7 8.6 9.6 10.5 2.3 2.6 32 37 4.3 82 5.8 6.7 7.4 8.4 9.4 10.3 11.4 2.3 2.6 32 17 4.3 4.8 5.7 6.7 7.4 8.4 9-4 101 11.4 21 13 3.8 4.3 4.8 17 6.4 7.1 7.5 8.7 9.5 10.4 11.6 13 3.8 43 5.7 6.4 6.4 7.1 7.6 8.7 9.5 10.4 11.4 12.4 3.8 4.3 6.2 58 84 7.1 7.9 8.8 87 >0.0 11.4 12.4 13.3 80 5.7 6.5 7.3 81 9.0 7.7 8.1 8.9 181 11.2 121 8.8 10.1 10.9 132 13-5 14.8 18 10 M 30 W 24 Flangad Ell Sheri Rad- >0* .. - - M ,, ,, Flanged EM Lee* Rad. 90 M dd m m m m ,, m - ISO m 1 2.4 12 - IX 3.3 3.9 aa IX 23 38 m 2 4.7 4.3 M 2X SL0 3 38 d. 3H d 4 -6 - dp a 10 a. 13 - 14 0.7 7.9 8.7 11.4 I1j8 16.4 201 28.4 pa 16 18 20 - 24 31.0 334 39.6 53.0 ISO % d % 0 1 2.4 3.2 - 1* 3.1 38 1H 3.1 38 d* 3 87 S.7 2X 6.7 a. 3 m 3X 80 87 4 78 pe 6 87 -A 11.4 a aa to ad 12 - 14 11.6 184 mi 264 16 ad 16 X - 74 31.0 334 401 610 18 43 4.3 6.0 5.9 5.0 7.6 9.0 10.0 1ZS 12.9 17.5 21.5 27.0 337 388 41.6 55.2 18 4.4 u 8.5 6.6 6.5 7.6 9.0 10.0 12.5 12.9 17.5 21.5 27.0 337 388 41.6 582 41 80 80 80 83 87 84 9.7 186 132 138 184 22.8 281 339 37.1 42.8 56.8 43 80 80 7j0 7.0 7.0 8-5 9.7 10.8 132 118 18.4 22.6 281 339 37.1 428 56,8 41 80 80 7.2 7.2 73 9.0 1Q.3 11.3 14.1 143 19.3 236 29.2 35.1 39.3 44.1 58.3 4.8 80 8.0 7.8 7.8 7.8 9.0 183 11.3 14.1 148 191 23.6 29.2 35.1 39.3 44.1 581 5.7 7.2 7.2 8.0 8.0 8.0 10.0 11.3 114 15.3 16.2 20.6 24.9 30.9 37.0 40.2 482 60.7 5.7 7.2 7.2 9.0 9.0 9.0 10.0 113 114 15.3 182 286 24.9 309 36.9 482 46.2 607 6.4 8.8 8.6 8.4 B.9 81 11.7 11.7 14.0 16.5 171 22.1 26.5 32.7 38.9 421 48.3 62.5 14 8.6 8.6 107 187 10.7 11.7 11.7 14.0 16.5 17.8 2X1 26.5 337 381 42.2 483 6X5 8.5 89 89 10.0 10.2 10.4 1X7 14.1 110 17.8 19.4 24.2 216 34.5 40.8 44.3 50.5 65.6 8.5 10.0 10.0 12.1 12.1 12.1 12.7 14.1 15.0 17.8 19-4 24.2 28.6 34.fi 40.8 44.3 50.5 656 84 11.2 11.2 11.4 11.6 11.8 14.2 15.8 17.0 19.4 21.2 26.7 301 361 421 46.3 57.6 8.2 9.4 11.2 in 13.6 13.6 13.6 14.2 161 17.0 185 21.2 287 301 36.3 47.S 46.3 62.6 681 10.8 12.6 12.6 12.B 13.1 13.3 15.9 17.4 168 21.6 231 27.3 3X7 382 44.9 48.4 65.0 701 toi 12.6 12.6 15.415.4 15.4 15.9 17.5 161 21.8 23.3 27.3 3X7 38.2 44.9 46.4 580 70.8 12.2 14.3 14.3 15.3 15.6 15.9 17.5 191 20.1 23.5 24.6 29.0 35.1 40.1 46.9 50.6 57.2 73.4 1X2 141 14.3 17.0 17.0 17.0 17.5 183 20.1 23.8 24.8 29.0 381 40.1 461 50.6 873 73.4 13.7 16.0 16.0 16.4 16.9 17.7 184 21.1 22-1 2S.7 27.6 30-6 37.7 42.0 49.0 521 59.6 780 13.8 180 180 181 189 18.0 19.4 21.2 22.1 287 271 30.6 37.7 42.0 49-0 526 sa.s 780 15.5 17.7 17.7 183 187 19.0 21.0 23.4 23.7 28.0 29* 32.7 40.5 44.4 519 56.0 62.0 788 185 17.7 17.7 20 3 20.3 20.3 21.0 23.4 2X7 28.0 29.8 3X7 405 44.4 511 560 62.0 788 173 193 19.3 187 203 701 731 254 251 303 32.2 351 43.4 47.4 53* 57.4 64.4 81-5 172 193 19.3 2X2 232 2X2 233 284 251 30.3 321 381 4X4 47.4 534 57.4 64.4 81-5 UCC 003084 STANDARD owacau we nutria APPENDIX APPLICATOR TRAINING PAGE 479 APRIL 1970 APPENDIX OUTSIDE SURFACE AREA OF FITTING COVERS FltUHf JttangrtEn 48' ~ ** m ,, - ,, - m m m Nam Pip* OoKIdt atrfic* iru In tquan ( til* Nominal imitation thicknm-lnehat 1* n 3 3H 4 4K 5 6tt 8* 75k ISO H * 1 IJ 1.6 1.9 11 2.4 21 12 40 4.7 5.4 9.1 6-9 7.7 6.6 ** 11 U 14 20 12 20 10 16 43 4.9 6.6 63 7.1 60 8.8 m 11 1.6 to 2.3 14 2.6 11 30 40 81 17 66 7.4 9.1 10 tt 2 1.6 tO 2.3 2.4 20 11 18 4.6 61 5.7 65 7A 8.1 9.0 m 2 lO 2.3 14 19 11 30 4.5 61 17 65 7.4 8.1 9.0 -3 20 20 13 10 4.0 4.4 63 69 16 7.9 6.7 15 10,4 *4 3St -4 9 6 14 16 4.2 4.6 60 19 14 7.1 so BJ 9.7 169 11.6 30 4.6 40 8.2 17 68 7.0 7.9 9.7 67 10.6 11.7 12.7 4.3 60 13 17 67 7.0 7.5 8.5 14 mi 11.1 11.8 12S 67 62 66 70 7.9 82 80 9.8 10.8 11-8 119 14.0 15.2 48 4 a 10 P 13 - 14 60 64 69 7.4 8.1 69 9.7 108 11.6 1X3 13.8 t4.9 16.1 7.7 66 9.2 90 103 tl.1 12.1 120 117 145 15.3 117 17.6 16t 167 11.2 IIO 115 113 14.4 162 113 17.6 18.9 263 21.7 12.7 115 14.0 14.5 114 143 17.2 182 19.1 20.0 21.0 22.2 217 16 18 PP 20 - 24 166 164 170 170 180 19.4 20.4 21.4 22.4 214 24.5 216 267 167 170 166 190 201 21.1 22.1 311 242 263 264 260 28.7 190 200 31.4 211 211 24.2 262 263 27.5 786 29.8 31.0 32.2 266 27.6 264 29-2 304 31.3 320 34.1 35.4 317 38X1 394 408 Table B-29 Square feet of insulation on duct work 1' limitation 2* limitation 1* IrtstHatiort 2* limitation Sami Sq ft Sml Sq ft Sami Sq It Sami Son ptrim (nail parbn Imul pvrin bmil parim tnaul Sami Sq ft Sami Sq It Semi Sqft Stmi partm tnaul parim trail parim imul parim a 1,97 65 11.17 8 2.00 66 11.50 t 1.83 66 11.34 9 117 66 11.66 10 2.00 97 11.60 10 134 97 11.83 ii 2.17 98 11.68 tl ISO 68 1100 12 2.34 68 11.63 12 167 99 1117 13 2.SO 70 13.00 t3 184 70 1134 14 2.69 71 12.17 14 100 71 12-50 15 2.83 73 12.34 16 117 72 tX68 t 100 73 17.80 16 134 73 1203 17 3.17 74 1388 17 ISO 74 1300 18 3.34 79 1283 16 166 75 1117 19 3L60 78 13.00 19 183 79 1134 70 166 77 1117 20 400 77 13.50 21 183 79 13.34 21 4t7 78 13.66 23 4.00 79 13.60 22 4.34 79 1303 23 4.17 SO 13.66 33 450 80 1400 24 4J4 81 1383 24 4,69 91 14.17 29 4 50 82 14.00 26 403 82 14.34 26 4.68 83 14.17 26 600 83 1450 27 4.63 64 1434 27 617 84 14.66 28 8.00 86 14.50 28 634 86 1403 28 9.17 89 1866 29 650 86 15.00 30 31 134 87 14.83 5.60 88 1800 30 31 666 87 1617 683 68 15.34 32 5.99 89 16.17 32 600 69 1650 33 34 110803 90 1834 91 1850 33 34 617 90 15,66 634 91 1863 38 817 92 1866 36 650 93 16.00 38 834 83 16B3 38 666 93 1617 37 650 94 1600 38 666 95 1617 39 1S3 96 16.34 40 7.00 97 16.50 41 7.17 98 18.66 42 7.34 99 16.63 43 7.50 100 17.00 44 7.66 101 17.17 45 703 102 1704 49 6.00 103 17.50 47 117 104 17.66 48 9.34 105 17.83 49 8.50 106 18.00 50 8.66 107 10.17 51 603 106 18.34 52 9 00 109 1850 53 9.17 110 18.66 54 9.34 111 1813 55 9.50 112 19.00 56 9.66 113 19.17 67 983 114 19.34 58 10.00 115 19.50 99 10.17 118 19.66 60 10.34 117 19.8! 61 10.50 119 20.00 62 10.66 119 20.17 63 10.83 120 20.34 64 n.oo 37 683 94 38 7.00 95 39 7.17 96 40 7.34 97 41 7.50 98 42 7.66 99 43 7.83 100 44 100 101 46 617 102 46 634 103 47 860 104 48 666 105 49 B83 106 50 9.00 107 51 9.17 109 52 9.34 109 53 9.50 110 54 9.66 111 55 983 112 56 10.00 113 57 10.17 114 59 10.34 115 59 10.50 tie 60 10.66 117 61 10 93 118 62 11.00 119 63 11.17 120 64 11.34 taml a*rlnw* l> tha mm f mn mm i4"i WOtn not **ampi*: A duct 4" a 6" hat a ufnltcifTHiu at >0 Inch**. Sqft insul 1134 16.50 16-68 1683 17.00 17.17 17.34 17.50 17.56 17.83 1600 16.17 18.34 18.50 18.66 18.83 19.00 19.17 19.34 19.50 19.66 19.83 20.00 20.17 20.34 20.50 20.66 UCC 003085 STANDARD CMMOUMPlUra APPENDIX APPLICATOR TRAINING PAGE 480 APRIL 1970______________ APPENDIX REQUIRED TO CEMENT IN POUNDS 1" THICK 'ffKULATIOVT FITTINGS 90 EO-T ws----535-- Slxe Mog.Cem. H.T.Cem. Asb.Cm. 1/2" 1" 1-1/4" 1-1/2" 2* 2-1/2" 3' 3-1/2" 4" 4-1/2" 5" 6" 7" 8" V" 10" 11" 12" .29 .34 .43 .65 .86 1.00 1.14 1.72 2.00 2.24 2.58 2.92 3.62 4.65 5.00 6.37 7.40 8.44 9.48 .42 .50 .63 .94 1.25 1.50 1.65 2.50 2.92 3.25 3.75 4.20 5.25 6.75 7.20 9.30 10.70 12.25 13.80 1.10 1.33 1.66 2.50 3.33 4.40 5.75 6.60 7.75 8.60 10.00 11.30 14.00 18.00 19.30 24.60 28.60 32.50 36.60 "45 ELLT 35 Mog.Cem. H.T.Cem. Asb.Cem. .15 .17 .22 .33 .43 .50 .57 .86 1.00 1.12 1.29 1.46 1.81 2.33 2.50 3.19 3.70 4.22 4.74 .21 .25 .32 .47 .63 .75 .63 1.25 1.46 1.62 1.82 2.10 2.62 3.37 3.60 4.65 5.35 6.12 6.90 .55 .66 .83 1.25 1.66 2.20 2.87 3.30 3.87 4.30 5.00 5.65 7.00 9.00 9.65 12.30 14.30 16.25 18.30 VAi.VE5 And!m------------- --CROSSE 85% BS5E Mog.Cem. H.T.Cem. Aib.Cam. Mog.Cem. H.T.Cem. Asb.Cem. .36 .43 .54 .81 1.07 1.25 1.42 2.15 2.50 2.80 3.23 3.66 4.53 5.82 6.25 8.00 9.25 10.52 11.80 .52 .62 .78 1.17 1.56 1.87 2.06 3.12 3.65 4.07 4.70 5.25 6.56 8.45 9.00 11.60 13.30 15.20 17.20 1.37 1.66 2.07 3.12 4.16 5.50 7.18 8.25 9.68 10.75 12.50 14.10 17.50 22.50 24.10 30.75 35.75 40.60 45.75 .38 .45 .57 .86 1.14 1.33 1.52 2.28 2.66 2.98 3.43 3.88 4.81 6.18 6.65 8.47 9.84 11.22 12.60 .56 .66 .84 1.25 1.66 2.00 2.20 3.33 3.88 4.32 5.00 5.58 6.98 8.98 9.57 12.36 14.23 16.29 18.35 1.46 1.77 2.20 3.33 4.43 5.85 7.65 8.77 10.30 11.40 13.30 15.00 18.60 24.00 25.70 32.70 38.00 43.20 48.70 The above quantities ore approxIm<*e for estimating purpose*. UCC 003086 7 STANDARD CtlttaCn I MB PUSTIO MATERIAL Galvanized or B. A. Wire 12 Gauge 14 Gauge 16 Gauge 18 Gouga Soft Copper Wire 12 Gauge 14 Gauge 16 Gouge 18 Gauge Galvaniiad Stool Bondi 1/2" Wida 1/2" Wida i/V Wida 1-1/4" Wida Stoinles Steel Bondi 18-8 Chrome 1/2" Wida 1/2* Wida 3/4" Wida 3/4" Wida MATERIAL Flat Black Sheet Metal 18 Gouge 20 Gouga 22 Gouga 24 Gouga 26 Gouge 28 Gouge 30 Gouge Plot Galvanized Sheet Metal 18 Gauge 20 Gouge 22 Gouge 24 Gouga 26 Gouge 28 Gouga 30 Gouga APPENDIX TABLE OF GAUGES AND WEIGHTS FOR WIRE, BANDS AND FLAT SHEET METAL GAUGE W&M DIAMETER OR thickness W&M W&M W&M W&M B& S 0.1055* Dia. 0.0600- Dia. 0.0625" Dia. 0.0475" Dia. B&S 8&S a&s B&S 0.0808" Dia. 0.0640" Dio. 0.0508* Dia. 0.0403* Dia. -- -- ---- -- .015" thk. .020" thk. .020" thk. .035" thk. -- -- -- " GAUGES U.S. Standard U.S. Standard U.S. Standard U.S. Standard U.S. Standard U.S. standard U.S. Standard U.S. Standard U.S. Standard U.S. Standard ;U.S. Standard U.S. Standard U.S. Standard U.S. Standard .015" thk. .020" thk. .015" thk. .020" thk. THICKNESS .05" .0375" .03125" .025" .01875" .015625" .0125" .0540* .0415" .03525" .0290" .02275" .019625" .0165" APPENDIX APPLICATOR TRAINING PAGE 48? APRIL 1970 LINEAR FOOT PER POUND 33.30 58. B2 95.23 166.66 52.63 83.33 142.85 250.00 39.26 29.45 19.63 6.73 39.26 29.45 26.18 19.63 WEIGHT IN PER SQ. FT. 2.00 1.50 1.25 1.00 0.75 0.625 0.50 2.1563 1.6563 1.4063 1.1563 .9063 .7813 .6563 UCC 003087 STANDARD ouauu * rvwtio INDEX applicator training PAGE 482 APRIL 1970 PAGE Accessories weorher-vcpor borriers, of. no Abrasion resistance Insulation moteriols. 106 jackets. mast i cs. 95 73 Absorption, wotar. 78 Adhesion cements. 78 mastics Adhesives for fabrication, 106 211 Alkalinity 73 Alumino-iUico blanket, properties. 81 Alumina-silica cements, properties. 82 Alumina-silica fibers, loose, properties. 83 Aluminum foil and glass material, vacuum properties, 85 Appeorance jackets. 94 Application, flexible insulation, 318 panel insulation. 324 reflective insulation. 336 rigid insulation, high temperature service. 274 rigid irtsulorion, low temperature service 288 semi-rigid Insulation, moderate temperature service 311 sprayed asbestos, 345 sprayed urethone foam. 355 Application specifications, table 143 asbestos fiber. 135 bituminous fill. 140 calcium silicate. 136,138 cel lu for glass, 131,132 chart 144 thru 151 conduit cased. 139,140 cork filled mastic. 14) expanded silica. 136,138 fibrous gloss, 133,134,135 plastic foam, 133 reflective. 138 sprayed osbertoi, 141 sprayed urethone. 142 foble 143 urethane foom. 132,140 Areas bore fitting areas. 466 bore pipe areas. 461 cylinders. 464 insulation fitting covers. 467 thru 479 pipe insulation. 457 spheres 465 tanks ^vessels 462,463 Asbestos ond binding cloy cements, properties. 82 Asbestos braided cloth with glass fibers, properties, 81 Albeitosis, definition of. 418 Asbestos fiber blanket, properties. 81 Asbestos fibers, loose, properties. 83 Asbestos fiber rigid insulation, properties. 80 Asbestos fiber, sprayed in place, properties. Asphalt rollers. 84 205 Autogeneous ignition See fire self Ignition or combustibility 95,103 Band sows (for fabrication). ftituminuous-coric filled mastic, properties, Blueprint reading course Body definition of. Boiling, definition. Breaking strength. British thermal unit (Btu) definition Build mastics 199 84 1 32 33 76 34 102 INDEX Bums protection from. Calcium sllico cements, preterites. Calcium silicate rigid insulation properties. Capillarity, Carbon-silica-vacuum, properties. Cellular gloss insulation properties. Cement coverage on fittings. Cements for fabrication. Ceramics fiber ond binders, sprayed In place, properties, Color mastics. Combustibility Rre point fockets. mastics. Fire self-ignition point jaekets. mastics, Florae travel. jackets. martlcs. Flammability, jackets. mastics. Flash point jackets. mastics Commerica! insulation. Compressive strength. Conduction or conductivity air spaces definition. fockets. significance. units. various moteriols Consistency mastics Convection definition Conversion factors, temperature Corrosion mastics. insulation. Coat estimating See estimating installed cost. Coverage mastics. Coverage, cement on fittings. Coverings, Cracking (hot surface), Cryogenic-vacuum insulations, properties. Cushion blanket used with rigid insolation. Cutting characteristics fockets, definition. Density, Dewpoint temperature surface condensation table. Diatomoceaws eorth rigid insulation properties. Diatomaceous silica cements, properties. Diatomacaous silica posdert, properties, Diatomaceous silica rigid insulations, properties, Diffuslvity, thermal. field cut elbows. shop fabricated cm/ers. pipe insulation tube insulation Dimensional stability. PAGE 411 82 80 73 83 80 480 211 84 107 73 98 103 98 103 87 108 96 104 96 103 51 76 443 34,36 95 77 42 437,442 102 36 434,435 102 74 161,165, 166,172175,178,182 102 480 113 74 85 276,282 94 74 450,451 80 82 83 80 77 190 221,222 453,454 456 75 UCC 003088 1 STANDARD cmnkmj mo njunci Drawing COOTSe, Int*--wetotinn, CVv reiiitonce. Dryirn or curing time mcntlcs. Ductility jackets, definition. Dust coiUcron (for fabrication shop). Dusting, Dust hazards safe practices insulation containing asbestos, warehousing storage and handling. fabrication of insolation. application of insulation. insulation containing mineral fibers. warehousing, storage and handling. application of insulation. Economics for most economic thickness. Economic Insulation thickness example. Electric shock, protection from. Elongation insulation mastics Embrittlement low temperature jackets. Emittance jockets. PAGE i i 70 103 95 205 70 418 418,420 419 419,421,422 424 424 426 52 55,57 60,61,62,63 413 75 107 98 95 Equipment insulation application flexible insulation. measuring of. panel insulation. reflective insulation. rigid-high temperature. rigid-low temperature. semi-rigid moderate temperature, sprayed asbestos. sprayed urethane foam. Equipment metal jackets. Estimating installed cost areas far estimates. components, estimate sheet. indirect cost, needed information. quantity survey. take off. types of usage Evaporation definition. Expansion-contraction joints weather-barriers. Expansion chomber underground Insulation, Expansion coefficient metals, table. metals, various Fibrous insulation asbestos cattle hair. glam fibers. lime or silica fiber. refractory fibers. 316 fhfu 323 165 324 Ihni 355 336 thru 274 thru 276 288 thro 310 311 thru 345 thru 354 355 thru 366 380 161 thru 184 172 165 173,174 182 162 166 165 161 33 378 389 70,75,118 123 436 65,345 65,311 65,311 65,311 65 INDEX APPLICATOR TRAINING PAGE 483 APRIL 1970 INDEX field fabrication elbows. mitered blocks. Field installation of preformed fitting covers. FTre point jockets. mastics. Fire, protection from handling of combustible coatings and solvents Fire-self Ignition point jackets. mastics, First aid. Fittings, fabrication of dimension of, Flame resistance jackets. Flame travel See combustibility. FlommoWllty See combustibility. Flash point jackets. mastics, Flexible insulation application moderate temperature service. Flexure mastics. Flexural strength. Forms of thermal insulation blankets ond barts. doth. felts. Flexible, loose. rigid. rape. semi-rigid. tape. Freeze-thaw resistance mastics. Gap filling and bridging mastics. Gas stote. Gouges end weights of wire bands and fft:k .Seat, PAGE 221 220 216 96 103 412,426 427 96 103 416 185 thru 191 191,192 96 103 318 thru 323 318 108 76 65 66 66 66 66 66 66 66 66 66 104 104 33 481 Glass-cellular, properties. Glass-cellular pellets, properties. Glass fiber mid binders, properties. Glass fiber blankets, properties. Glass fiber rigid Insulotions, properties, Glass fiber. bonded properties. unbonded properties. Granular insulation calcium silicate. dlatomaceous earth. expanded silica. open cell piastres. vegetable cork. Grinders (for fabrication). Gypsum pellets, properties. 80 83 80 81 80 83 83 80 80 80 81 83 199 83 UCC 003089 STANDARD owoUMiura INDEX APPLICATOR TRAINING PAGE 484 APRIL 1970 PAGE Hand tools - sm tools. Hardness jockets. Health - see safety and health health problems. Heat british thermal unit (bfu), conduction. convection, defini tion. effect, of energy. internal, kinetic, potential, radiation. transfer. transfer, restriction of. units of water work. Heof stability jackets. Heat tracers ~ see trocer systems. Heat transfer through insulation basic formula - equation 1, example; through one insulation and one air film. through one insulotion - equation 2, through one insulotion - equation 4, Heat units for water, table, High conductive cements coverage for valves, coverage on straight pipe. see tracer systems. tables of types of cements, types of cement. High temperature service panel insulation application. installation. supports. surface preparation. reflective insulotion equipment, piping. supports. surface preparation. rigid insulation application. equipment. cushion blanket. piping. supports* lurfoce preparation. spvoyed asbestos insulation equipment, Jupportj, surface preparation. underground systems field applied rigid insulation. metal conduit. p.v.c. conduit - urethane. History of insulation industry asbestos end magnesia. cellular glass. cork. cryogenic. diotomoceous silica. expanded silica. glass fiber. metal reflective, mineral wool polystyrene. polyurethane, Structural insulating board 75 97 417 28 29 36 36 28 33,35 28 28 28 68 36 36,38 36,37 446 28 97 40 46 41 44 446 260 269 263 262 260 324 thru 355 327 324 327 336 thru 344 336 339 336 336 274 thru 287 274 274 276 276 276 345 thru 354 345 345 345 386 thru 407 388 397 394 11 23 16 25 18 22 25 20 14 24 24 19 INDEX Hydroscopicity, Impact strength fackets. mastIei. Industrial insulation, purpose of. application of (see application specification). cryogenic. hot temperature service. low temperature service, moderate temperature service selection of (see selection of insulation). table of properties. tracing systems. Installation requirements. chemical, fire safety. physical moisture, thermal. Insulotion dimensions. multi-layer robin. Np* P*P outside diometeri surface areas. tub*. volume. Insulation fitting cavers area. Insulation schedules typical. Insulation supports ond securements see suppert*, securement. Insulation (thermal) application of, see application specifications, commercial, economics. flexible irauiotlons. industrial. cryogenic, hot temperature. law temperature, moderate temperature. tracing systems. physical ond thermal properties. properties of. purpose of. rigid insulation. selection of (sm selection of insulation). types and forms. Jockets felt, plastic composition, metal, Ladders, Lampblock powder. properties, Liquid state. Low temperature service. rigid insulotion application, equipment. cushion blanket. piping. supports. surface preparation. Magnesia corbenote-asbestos fiber, properties. Magnesia carbonate cements, properties, Moss insulotion, Mastic weother-borrier (see weather-barrier mojtics). application of, PAGE 75 97 108 52 52 S3 53 80 thnj 85 54-56, 251 116 125 116 117 126 117 459,460 461 453 thru 456 457 455 45B 467 thru 479 163 51 55 81 52 54 52 S3 53 54 80 thru 85 80 thru 85 5) 51 65 86 thru 101 409,410 83 33 288 thru 310 292 295 304 292,304 292 83 82 65 86 thru 11$ 367 thru 385 UCC 003090 m STANDARD CKZMCAU JUO AjUTD INDEX APPLICATOR 7RAINING PAGE 485 APRIL 1970 Mathematics cylinders, area &yplume spheres, aTeo &vo1ume PAGE 464 465 INDEX Melting defini tion, MelHng point [ockets. Metal conduit underground system. Metal jacket weather-barrier installation on equipment. Installation on pip'n9r materials required, preparation. 33 98 397 380 thru 385 380, thiu 383 383'384 380 380 Mineral fiber and binders cement, properties. Mineral fibers and binders, sprayed in place, properties, Mineral fiber blankets, properties, Mineral fibers, loose, properties, nodules, properties. Mineral fibers rigid insulation, properties. Moderate temperature service flexible insulation application, equipment - application, piping - application, surfoce preparation, panel insulation - equipment only, equipment - application, supports, surfoce preparation, reflective Insulation, equipment - application, piping - application, supports, surfoce preparation, semi-rigid insulation application, equipment - appllcotion, piping - application, supports, surface preparation, sprayed urethane foam, surface preparation. Mold and mildew resistance mastics. 82 84 81 83 83 80 318 thru 323 318 320 318 324 thru 355 324 324 320 335 rhiv 344 336 339 336 336 311 thru 317 311 315 311 311 345 thur 354 345 106 Noise, protection from, NFS pipe table. 413 461 Odor mastics. Overcoatings, 108,114,1)5 Panel Insulation application, moderate and high temperature service. Perlite - glass fibers rigid insulation, properties. Perlite, spheres, loose, properties. Perlite - vacuum, properties. Physical properties of thermal insulation, tobies. Pipe insulation application, flexible - moderate temperature, measuring of, reflective - moderate and high temperature, rigid - high Temperature, rigid - low temperature, semi-rigid - moderate temperature, 334 thru 355 324 thru 355 80 83 65 80 thru 85 320 165 339 276 304 315 Pipe'insulotlon dimensions. multi layer tables. Nps nominal (Astm C"521), outside diameter, obsolete. fitting co/ers surface areas. volumes. Pipe insulation metal jockets. Pipe, NPS circumference, temperature oreo. external surface area, length. fitting area per cu ft. table of diameters, thickness. Pipe tracer systems. Polystyrene cellular flexible foam, properties. Folysryrene, rigid properties. Polyurethane, rigid insulation properties. Polyurethane (2 part mix) sprayed in ploce, properties Polyvinyl acetate and cork mosric, properries. Power tools - see tools. Preparation, general masking. materials. scaffolding. supports. surface preparation. tracer systems (see tracer systems). Protection from bums, chemicois and solvents. cuts. electric shocks. eye injuries, foiling objects, fire. high pressure spray equipment. moving equipment. noise, sharp protections. Puncture resistance jackets, P.V.C. underground conduit system. Pycnometer data dew point temperatures, surface condensation table. vapor pressure tobies. PAGE 459,460 453 thru 456 453 thru 456 185 467 thiu G<> 457 458 3B4,385 461 461 461 466 461 46) 254 thru 270 81 80 80 84 84 251 253 251 252 253 252 412 412 415 413 415 415 412 416 416 413 415 98 466 90,450 451 39,449 Radiation definition. Reactive chemicals list of. Reflectance - thermo) jacksti. Reflection factor, tight jockets. Reflective insulation application of. {moderate and high temperature service) boric formula. Reflective, preformed, properties. Refractory - cellular foam, properties. Resistance to acids, caustics, solvents. Insulations, jockets. 29 432,433 99 98 336 thru 344 44 85 80 76 99 UCC 003091 STANDARD outau puunci Rigid insulation application high temperature service. low temperature service. underground systems. Rubber resin flexible foam, properties. Rubber resin rigid foam, properties. Safety and health bums, protection from. chemicals and solvents from. cuts. definition. falling objects, protection from. fires end explosion hazards. fires, protection from. fiat aid, report of Occidents, health problems dust (see dust hazards), spray (urethane). high pressure spray equipment, ladders, use of leak, indicators. moving equipment, protection from. noise. safety regulations. scaffolds, use of. sharp projections, protection from. Santocel - vacuum, properties, Santoeel - vacuum, opacified, properties. Saturation definition. Scaffolding general. use of. Securements odbesive. pins ond clips. strop, wire. Selection of insulotion systems to fulfill requirements. Semi-rigid insulotion application moderate and high temperature service. Sheor strength Insulotion, jackets. Shop fabrication design of fitting and vessel. insulation covers, practice, adhesives ond cements. equipment. bond taws, grinders. asphalt rollers. field installations Shrinkage, insulation, mastics, Silica aergel granules, properties. Silica fibers, properties. Sizing and sealing mastics. Solid state definition. Solvent absorption. Specifications interpretation of, INDEX APPLICATOR TRAINING PAGE 486 APRIL 1970 PAGE 274 thro 287 288 thru 310 386 thru 407 81 80 412 412 415 408 415 426 427 416 417 418 417 416 409 429 416 413 408 411 415 85 85 34 411 411 244 thro 250 240 224.240,244 224,244 248 128 thru 151 INDEX Specific gravity. Specific heot table. Spray application instruction sheets. mattici weather barrier. safe use of. spray equipment. Spray equipment - see tools asbestos. foom. mastics ond paint. safe use of. Sprayed asbestos insulation application. operation of spray machine, connection of machine, finish. pt of, cafe practices, spraying. Sprayed urethane foam insulation application operation of mochine. surface preparation, Stote of substances charge of, gas. liquid. solid. Steam tables saturated. superheated. Storage stability mrtttcs. Strop, Strength, Insulation breaking. compressive. flexural. shear. tensile. Supports angle-supports. 311 thro 317 77 99 185 thru 219 191 thro 199 191, 207 thro 210 193 211 160, 193 193 199 160 220,221,222 general. panel insulation. reflective insulotion. rigid insulation. Semi-rigid, stondards. Surface areas (see areas). Surface preparation for tracers. general. high temperature service. low temperarure service moderate temperature service. Surface wetting and adhesion mastics, 76 Topes, 104 Temperature 83 conversion table, 83 definition. scales. 105 Celsius (centigrade), fahrenheit, 33 kelvin, 76 ronkine, table. 1 PAGE 76 440 367 thro 378 371 thro 377 101,376 416 367 347 356 371 416 345 347 350 356 348 420 351 355 thro 366 356 356 355 33,34,35 33,34,35 33,34,35 33,34,35 447 448 105 224 71,76 71,76 71,76 71,76 71,76 224 thro 239 227,228,230 224 331 336 324 thru 240 225 thro 231 255 252 345 292 311,318,336 105 111 31,434,435 29 31,434,435 31,434,435 31,434,435 31,434,435 31,434,435 UCC 003092 uT? STANDARD Temperature limits Insulation, jockets, mastics. Temperature and humidity range application tolerance - macticv Temperature rim (self internal heating), Tamila strength, Tharmol conductivity air ipact definition, significances, units, Tharmol dlffustvity, Tharmat expansion of metali, table, Tharmol insulation classes of, moss, reflective, tables pi properties. Thermal properties of Insulation of various material, table. Thermal resistance equation 3, Thermal shock resistance insulation, jackets, Tools cutting, fastening, finishing, guiding, hammer, holding,' marking, ^/'measuring, ^ power tools, shop. Field, require, praying asbestos, foam, mastics and paints. Toxicity during application. Tracer systems air convection systems, equipment installation, surfoce preparation, heat pipe transfer cemented systems iratoilation, luffoce preparation, types of cements VP*/ Training applicators, phasos, programs, shopmen, Troweled (or pointed) applications weather-barrier mastics. Tube insulation dimensions. Types of thermal insulation cellular, fibrous, flake, granular. INDEX APPLICATOR TRAINING PAGE 487 APRIL 1970 ("AGE INDEX 71,77 too 10? 105 77 77 77 443 41,42 77 42 77 110,212,122 436 65 65 65,66 67 BOlhni 85 80 thru 85 437 thru 443 39,40,4 40 71,77 100 19 thro 160 IS 154 154 156 154 153 19 19 ISO 160 160 ia 347 356 370 106 255 262 255 29 255 260 29 260 254 2 2 1 4 367 456 65 6S 65 65 Underground Intuiarad piping conduit systems metol conduit, urethone foam - pvg conduit. field applied cellular glass expansion chambers. installation in trench. preparation. ttraighr pipe. Urethane foam underground conduit system, Vacuum - cryogenic insulation, properties. Vapor vapor migration. vapor pressure, Vapor barriers. definition. function, requirements (service), Vapor migration see water vapor permeability. Vapor pressure definition. tables. Verauculttes and binders cement, properties. Vermiculrte flakes, properties, Vibration resistance. Vinyl chloride foam, properties. Volumes NP5 pipe insulation. Warehousing sofe handling of insulation. Warpoge, Water, effect on conductivity. heat units of, table. Water absorption. Wofer resistance jackoti. Water vapor permeability. jockets. mastics. various moteriols. Weather-barriers application, of, decoration. fire protection. function. mechanical protection. properties. jockets. mastics. requirements (service). typetof. weather protection. Weather-barriers, application of. expansion contraction joint. flashing. metal jockets. preparation. sprayed mastics. instruction sheets. troweled or palmed mastic, Weather-vapor barrier accessories adhesions, sealers, etc.. Weather resistance jockets. mastics. Welding safe practice. Work organisation of, PAGE 386 riwv 407 397 thro 404 394 thru 397 386 thru 394 389 387 386 388 394 thro 404 85 87 87 87 87 87 91 452 87,88 89,449 82 83 78 80 450 418 78 86 446 78 101 106 101 101 452 367 94 86 91 94 thru 101 101 thro 109 91 111 94 367 thru 378 378 380 367 370 371 thru 375 368 113,367,380 101 109 427 3 UCC 003093