Generally for all insulation materials

Packaging

• The material shall be packaged in such a way that it is not exposed to damage and/or moisture during It shall be stored dry and according to the manufacturer's guidelines.

The following information shall be on the packaging and packing slip:

• Supplier
• Material type
• Production date
• Expiry date
• Dimension
• Quantity
• Work order number if required

Properties of all insulation products

• All insulation shall have a neutral pH value and should not emit toxic or corrosive gases when exposed to fire.
• No asbestos or asbestos-containing products shall be used. Lead or lead-containing products shall not be used unless they have been accepted by the purchaser
• The insulation material should not contain flammable components

General recommendations

• For cold preservation: Diffusion tight material
• For heat preservation: Cellullar glass, materials that do not require cladding or polyurethane products
• For personnel protection: Perforated panels with spacers/rings. In some cases or projects, insulating coating is used instead
• For fire classes: Synthetic fiber, mineral fiber, Aerogel
• For acoustic classes: Cellular glass, mineral wool, approved soundproofing rubber mats.

The exact material description shall be stated in the IPS (Insulation Procedure Specification) or other relevant project specification.

Insulation types for pipes and equipment

Fiber material

• Mineral wool
• AES Fiber

Cellular materials

• Cellular glass
• Polyurethane
• Polystyrene
• Flexible elastomeric Foam (FEF)

• Mineral wool insulation is a common term for the materials stone wool and glass wool. Glass wool does not have the same fire properties as mineral wool and cannot normally be used at petrochemical/offshore facilities, where fire requirements are imposed, but are widely used in the building and shipping industry.
• The materials are prepared by melting the base material into liquid form. Liquid mass is spun into thin fibers
• Then binder is added to the fibers
• The contact surface between each fiber is minimal, while at the same time pockets of stagnant air is established between the fibers
  • Mineral wool material contains approximately 90% air and is produced from rock (diabas). Operating temperature is - 40°C - 750°C
  • Melting temperature > 1000°C

Uses

• Insulation normally at temperature > 180°C
• Soundproofing
• Distance insulation to avoid CUI (corrosion under insulation) or as second layer insulation with cellular glass as 1^st layer insulation
• Fire insulation on HVAC canals (heated ventilated air-conditioned), bulkheads and roofs.

Material properties

• Good thermal properties
• Low density
• Easy installation
• Absorbs moisture-up to 1% of own weight in moisture
• Creates dust under installation

Based on the fact that mineral wool materials absorbs moisture and CUI (corrosion under insulation) can occur in such cases, it is normally not used as 1^st layer insulation. In NORSOK M-004, mineral wool is permitted used at temperatures above 180°C, or be part of an insulation system where mineral wool is not in 1^st layer.

Can also be used with distance insulation.

Uses

• Glass wool is not permitted used in the offshore industry, but is still used by the shipping and construction industry
• Good thermal properties
• Low density
• Easy installation
• Absorbs moisture

• Operating temperature: approximately -40°C - 1100°C
• Melting temperature > 1330°C

Material properties

• Good thermal properties
• Can be used at high temperatures
• Absorbs moisture, up to 5% of its own weight
• Dust created under installation requires extensive use of PPE (personal Protection Equipment). By foiling the material the amount of dust is significantly reduced.

Uses

• Mainly used on systems requiring fire insulation and noise insulation

Challenges with AES fiber

Ceramic fiber vs. Synthetic AES-fiber

Ceramic fiber involve health risk and shall no be used. They have widely been replaced with AES fiber.

• Difficult to see the difference between ceramic fiber and synthetic AES fiber.
• To be sure, laboratory tests must be carried out
• Ceramic fiber is carcinogenic and requires protective equipment accordingly
• While the body easily breaks down synthetic AES fibers, it will not be able to do this with the long ceramic fibers
• Ceramic fiber is no longer an approved insulation material, but the product may be used at older facilities. When demolition of ceramic/synthetic fiber material, appropriate protective equipment shall be used, if there is uncertainty regarding the type of material.

• Made from glass
• Heating process in which carbon is added glass powder. The mixture expands and forms a closed cell structure
• Operating temperature: -260°C to 430°C
• Melting temperature > 1150°C
• Also available with factory-mounted spacers. (Foamglass Spacer system)

Uses

• Insulation for all insulation classes on equipment with operating temperature < 180°C
• First layer insulation in combination classes

Material properties

• Good thermal properties
• Low density
• High compressive strength
• Easy installation
• Does not absorb moisture- no water or humidity intrusion
• Porous material- low resistance to vibrations and rapid temperature fluctuations

Manufactured from polyurethane foam with external covering.

1. Stenca pipe

• Operating temperature: - 40°C - 140°C

Material properties

• Good thermal properties
• Low density
• Easy installation
• Absorbs moisture in surfaces that have been cut
• Flammable material
• Contains isocyanates (during production only)

Uses

• Cold and heat insulation

2. Polystyrene foam extruded from polystyrene

• Operating temperature: - 50°C - 75°C

Material properties

• Very good thermal properties within operating temperature
• Low density
• Absorbs moisture
• Flammable material
• Emits toxic fumes in the event of a fire

• Produced from synthetic rubber.

• 88% closed cell structure
• Operating temperature: - 40°C to 150°C
• Melting point > 120°C (varies and depends on producer and/or material)
• Can be supplied free of Halogens with prefabricated weather protection.

Material properties

• Very good thermal properties
• Low density
• Flexible-easy installation
• Absorbs moisture over time
• Flammable material that will emit toxic fumes in case of fire'

Uses

• Instrumentation and instrument pipes

KAEFER ENERGY Cryocover for extreme low temperatures, tested and certified for exposure in a temperature range of -196°C to 1180°C.

For cold insulation, Lambda CryoBox, is tested and certified for exposure in the temperature range -163 °C til 20 °C.

Fire Nuts are tested and certified in Jet and Hydrocarbon fire up to 2 hours.

Cold insulation

Mats e.g. Cryogel Z

Fire insulation

Prefabricated pipe segment and valve/flange boxes of cellular glass with Pitt-Char and Chartek e.g. Benarx XP and Energy Firecover. Tested for Jet fire (120 minutes) and hydrocarbon fire for up to 180 minutes.

Cellular glass with external coating

Foamglas Terostat and Benarx F XP makes cladding unnecessary and saves installation time.

Heat insulation

Mats e.g. Pyrogel

Favuseal, polymer based fire protection

Insulation types on valves and flanges

• Jackets
• Boxesasser
• Composite
• Expanding coating materials

End Cap Gasket: termination of pipe insulation is critical for water intrusion in the system. An End Cap Gasket can be a good solution to avoid water ingress and as a result avoid CUI.

A prefabricated FOAMGLAS® Terostat spacer system with distance holders.

• Glass wool is forbidden in petrochemical industry
• Ceramic fiber is forbidden in petrochemical industry
• Asbestos
• Silica
• Interam mats (contains ceramic fiber)
• Cork
• Foam insulation

Foam insulation can be XPS (Extruded Polystyrene). Often supplied in light blue panels with compressive properties. PUR (Polyurethane) is used for, among other things, joint sealer and core in building elements. In the event of a fire, PUR/PIR emits less smoke than Styrofoam, but the smoke is highly toxic. Both hydrocyanic acid gas and NOx can develop. PIR (Polyisocyanurate) is a further development of PUR and is similar, but it can withstand higher temperature than PUR. Some types may char and act as fire retardant.