1.0 SCOPE

2.0 INSTALLATION - SUBCONTRACTOR RESPONSIBILITY

3.0 DESIGN

3.1 Definitions

4.0 ADDITIONAL REQUIREMENTS

4.1 Surface Preparation and Painting

5.0 MATERIAL

5.1 Storage and Handling

5.2 Acceptable Materials

6.0 INSTALLATION

6.1 General

6.2 Application of Valve Insulation (Cold Service)

6.3 Application of Vapor Barrier Mastic

6.4 Application of Vapor Stops

6.5 Application of Joint Sealer

6.6 Application of Tape and Banding

6.7 Application of PVC Cladding (Indoor Service)

6.8 Application of Metal Cladding (Outdoor Service)

Extol of Ohio Inc. believes the information and recommendations herein to be accurate and reliable as of the date printed. HOWEVER, AS USE CONDITIONS ARE NOT WITHIN ITS CONTROL, EXTOL OF OHIO, INC. DOES NOT GUARANTEE RESULTS FROM USE OF ITS PRODUCTS NOR OTHER INFORMATION GIVEN HEREIN. NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTIES ARE GIVEN SINCE LAWS AND USE CONDITIONS MAY CHANGE. IT IS THE BUYER'S RESPONSIBILITY TO DETERMINE APPROPRIATENESS OF EXTOL OF OHIO, INC. PRODUCTS FOR BUYER'S SPECIFIC USES. © 1996, Extol of Ohio, Inc.. All rights reserved.

This document is the property of Extol of Ohio, Inc.. It may not be modified or changed by anyone other than Extol of Ohio, Inc.. Modifications and revisions to this document may be made only by attaching appropriate addendum sheet(s).
(C:WP/OFFICE/WPDOCS/XTOLSPEC\VALVINST.R01)

Extol Of Ohio, Inc. Specification: Valve Installation Practices - Cold Service

1.0 SCOPE

1.1 This guide covers the procedures for installation of EXTOL'S VALVE INSULATION SYSTEM for Styrofoam, Isocyanurate and Cellular Glass thermal insulation materials on above ground piping systems to be used in Cold Service; both indoors and outdoors.

2.0 INSTALLATION SUBCONTRACTOR RESPONSIBILITY

2.1 Any conflict between the requirements of this specification and related codes, standards, data sheets, drawings, attached commercial contract, etc., shall be referred to Owner for clarification/resolution. Subcontractor shall not make assumptions to replace information not furnished by owner. Subcontractor is required to obtain necessary information from Owner or other reliable sources. Any and all claims arising from lack of knowledge of required information may be rejected by Owner.

2.2 All insulation and finish shall be applied using the best modern practice and finished work shall display a neat appearance.

3.0 DESIGN

3.1 Definitions

3.1.1 The term "Cold Service" shall normally apply to below ambient operating temperatures. It includes anti-sweat which applies to operating temperatures below the ambient temperatures that can cause condensation. It does not relate to cryogenic applications.

3.1.2 The abbreviation OD when used without a description applies to outside diameter of the insulation and/or finish covering.

3.1.3 The term "Vapor Barrier" refers to a material which retards the passage of water vapor.

3.2 Extent of Insulation

3.2.1 General

3.2.1.1 All valves, fittings, vessel drains, and flanges on cold equipment and piping shall be fully insulated.

3.2.1.2 If insulation is unavailable in thickness shown, the next larger thickness commercially available shall be applied.

4.0 ADDITIONAL REQUIREMENTS

4.1 Surface Preparation and Painting

4.1.1 Before application of insulation, all surfaces shall be cleaned to remove loose rust and paint, dirt, grease or other foreign matter.

4.1.2 Stainless steel brushes only shall be used on stainless steel pipe.

4.1.3 All carbon steel piping operating below 250 ⁰F and stainless steel piping operating between 25 ⁰F and 250 ⁰F shall be painted with two coats of poly-amine cured epoxy or epoxy phenolic. Manufacturer's recommendation shall be followed for surface preparation of the steel.

4.1.4 Insulation shall not be installed until after field welds and other surfaces which requires painting but have not been leak tested and painted.

5.0 MATERIAL

5.1 Storage and Handling

5.1.1 Storage of insulation and accessory materials must provide adequate protection from damage due to moisture and temperature. All flammable materials must be stored away from ignition sources, such as welding operations.

5.1.2 Storage temperature for mastics, adhesives and sealers shall be within temperature ranges required by the material manufacturer. All materials which are improperly stored and exposed to temperatures outside the recommended temperature ranges should be removed from the site and replaced with new material.

5.1.3 All insulation material shall be kept dry and should be kept off the ground and provide adequate protection against moisture and inadequate drainage. Wet or damaged material should be replaced with new material.

5.2 Acceptable Materials

5.2.1 Valve Insulation and Accessories

5.2.1.1 Valve insulation material and accessories such as joint sealers, caulk, vapor barrier and cladding shall be per the main insulation specification for the cold service application. Insulation shall be fabricated in required shapes from bun stock/block by EXTOL of Ohio, Inc., in accordance with ASTM C 450 "Prefabrication and Field Fabrication of Thermal Insulating Fitting Covers for NPS Piping, Vessel Lagging, and Dished Head Segments" and C 585 "Inner and Outer Diameters of Rigid Thermal Insulation for Nominal Sizes of Pipe and Tubing (NPS System). The fittings such as valves, flanges, 90⁰ and 45⁰ elbows, and tees shall be two piece prefabricated flycut or routed for 9 5/8" outside diameter and smaller and shall be two piece mitered for 10 3/4" outside diameter and/or 4" IPS or larger

5.2.1.2.1 Where multi layer pipe covering is required, each layer shall be minimum 1" thick.

5.2.1.3 EXCEL-LAP precision fabricated ship-lap pipe covering, curved side wall segments and fitting system shall be fabricated by EXTOL of Ohio, Inc. It may be considered as an alternate to multiple layer construction.

5.2.1.3.1 The wall thickness of EXCEL-LAP fabricated items shall be minimum 2" and maximum 3".

5.2.1.3.2 Excel-Lap shall not be used on lines which cycle hot and cold on a regular basis and cryogenic systems. Cryogenic systems would be covered under separate specification.

6.0 INSTALLATION - APPLICATION OF VALVE INSULATION (COLD SERVICE)

6.1 General

6.1.1 Prior to installation of insulating material, its thickness shall be verified in accordance with the operating temperature and diameter of pipe and equipment. If thickness or material do not verify, Subcontractor shall contact Owner to resolve the conflict. The Subcontractor shall not in any case establish a new thickness or select different material without written approval.

6.1.2 All insulation sections shall be trimmed and tightly butted to eliminate voids, gaps or open joints. Joint sealer shall not be used to fill these imperfections. The insulation shall be fitted to achieve tight fit.

6.1.3 Insulation ends shall be rubbed against each other to achieve tight fit prior to application of joint sealer.

6.2 Application of Insulation for Elbows, Valves and Fittings

6.2.1 Insulation material for valve insulation shall be shop routed or fabricated in two piece prefabricated cover made from same insulation material and same thickness as for straight piping as manufactured by EXTOL of Ohio, Inc. in conformance with ASTM C450 and C585.

6.2.2 Insulation shall be cut back below packing glands, leaving packing glands exposed and joint between insulation and valve body at the packing gland shall be filled with the joint sealer (See 6.5) and termination sealed with vapor barrier mastic (See 6.3).

6.2.3 The terminations of piping insulation at each side of flanged joint or valve shall allow sufficient clearance space for bolt removal and shall incorporate reinforced vapor stop. (See 6.4)

6.2.4 If oversized flange insulation is required, voids between flange or valve body and the insulation cover shall be filled with 1.0 lb/cu. ft. resilient glass fiber and foam filled. Prior to injecting spray foam in large cavities, fiberglass shall be wrapped with aluminum foil.

6.3 Application of Vapor Barrier Mastic

6.3.1 A vapor barrier coating of mastic reinforced with glass cloth shall be applied to all outer surfaces of irregular surfaces and fittings such as elbows, valves, valve packing glands, vessel heads etc.

6.3.2 Vapor barrier mastic shall be applied to a minimum total dry (cured) film thickness of 0.038 in. or as recommend by the mastic manufacturer.

6.3.3 The first layer of mastic shall be applied evenly by suitable means as a tack coat over insulation or vapor barrier with an approximate 0.032 inch wet film thickness, or per Manufacturer's requirements.

6.3.4 Reinforcing cloth shall then be stretched tight, embedded into the still tacky first layer of mastic with minimum three inch overlap.

6.3.5 Apply second layer of mastic with 0.032 in. thick wet film thickness or as recommended by the mastic manufacturer.

6.3.6 Vapor barrier mastic shall be carried from outer surface of insulation to the uninsulated metal parts of the vessel or piping to provide continuous vapor seal at all terminations, projections, nozzles, and caps.

6.3.7 Vapor barrier on attachments shall be extended additional six inches over uninsulated surface.

6.3.8 The glass cloth shall be completely covered with mastic and there shall be absolutely no cracks, holes, thin spots or open joints in the vapor barrier.

6.3.9 The vapor barrier mastic shall be allowed to dry per Manufacturer's recommendation before application of metal jacketing.

6.3.10 Final dry thickness of vapor barrier shall be checked. The vapor barrier shall be continuous and shall be checked for cracks, thin spots and pinholes, etc. Unsatisfactory areas shall be repaired.

6.4 Application of Vapor Stops

6.4.1 The vapor stops shall be installed on either side of the valve insulation cover. This will allow access to the valve insulation without disturbing the line insulation.

6.4.2 Vapor stops shall be constructed using reinforced vapor barrier mastic. Start at the pipe with tack coat of vapor barrier mastic and embed mesh in the mastic back over the adjacent section of pipe insulation on either side of the valve. Carry mesh and mastic back over the O.D. of the pipe insulation. Apply additional finish coat of mastic over mesh.

6.4.3 After vapor stop becomes dry, the valve insulation shall be installed using joint sealer applied full bed coverage on each butt end of the valve cover which will match the termination of the pipe insulation vapor stopped edge.

6.4.4 To complete, overlap the vapor stop on both sides of the valve with the vapor barrier of the line insulation.

6.5 Application of Joint Sealer

6.5.1 A vapor sealing joint sealer 1/16 inch thick shall be applied to all circumferential and longitudinal joints of outer layer in multi layer installation and to all circumferential and longitudinal joints of single layer insulation. Joint sealer shall completely fill full thickness of these joints.

6.5.2 Joint sealer is required on all indoor and outdoor insulation.

6.5.3 Layers of insulation shall not be bonded to each other. Excessive sealer in the joints should be avoided during application. Do not feather edge.

6.6 Application of Tape and Banding

6.6.1 Insulation shall be fastened circumferentially with 3/4 in. wide tape (2 inch from each end and one in the middle of pipe section and a minimum of two tapes per each section of equipment insulation. The tapes shall be pulled tight to seal all joints. Bands shall be used above 16 inch O.D. and on all curved wall segments where tapes do not close insulation joints tightly.

6.6.2 All tapes shall be lapped at least 50 percent on itself.

6.6.3 Tightening of tapes or bands shall not crush or crack the insulation. Cracked or broken insulation shall be replaced.

6.7 Application of Multiple Layers

6.7.1 Multiple layers shall be installed so the butt and longitudinal joints of one layer do not coincide with those of any other layer. The outer layer joints shall stagger inner layer joints by half sections. Minimum overlap shall be 18 inches.

6.7.2 Openings through the insulation shall be sealed vapor tight by applying joint sealer between protrusion and insulation.

6.8 Application of PVC Cladding (Indoor Service)

6.8.1 All insulated surfaces shall be covered with vapor barrier. Weatherproofing shall be installed as soon as practical after installation and sealing of reinforced mastic on the valve. The cladding shall be UVR PVC 25/50 one or two piece molded heavy gauge fitting covers with end caps. End caps shall reduce from insulation valve O.D. to O.D. of the pipe insulation with minimum ½" overlap. Fitting covers shall be minimum .028" thick.

6.8.2 The PVC fitting cover is applied over insulation and shall be sealed in the throat overlap with manufacturer's recommended solvent welding adhesive. Elastic cord or tape shall be used to hold the over in place for at least 10 minutes while the adhesive takes an initial set. Exposed adhesive in the lap area shall be feathered along the lap seam.

6.8.3 The PVC jacketing is then applied over the pipe insulation and shall overlap the fitting cover by approximately 1". Welding adhesive shall be applied in the circumferential lap between the jacket and the fitting cover as well as along the 1-1/2" to 2" longitudinal overlap of the jacket. Elastic cord or tape shall again be used to hold the jacket in place for at least 10 minutes.

6.8.4 Upon completion, all seams shall be visually checked for sealing and touched up with adhesive where necessary. No holes or voids are acceptable. Complete curing of the welding adhesive takes approximately 8 to 10 hours.

6.9 Application of Metal Cladding for Fittings (Outdoor Service)

6.9.1 All insulated surfaces shall be covered with vapor barrier. Vapor barrier and metal weatherproofing shall be installed as soon as practical after the insulation work has been completed. Vapor barrier shall be continuous on all surfaces including contraction joints, valves, flanges, etc.

6.9.2 All materials applied in one day shall have the vapor barrier applied the same day. Any exposed insulation shall be temporarily protected with a combination moisture and/or UV barrier such as black polyethylene film to keep rain water out. The film shall be sealed to pipe or equipment.

6.9.3 Mastics shall not be applied when ambient air temperature is below 40⁰F (4.4⁰C) or it is expected to be below 40⁰F (4.4⁰C) within 24 hours, unless manufacturer will specifically approve it's material for each individual application.

6.9.4 Two-piece smooth aluminum with a moisture barrier pre-formed valve covers with extensions are preferred. Minimum .020 thick aluminum.

6.9.5 The male half (no laps) of the valve cover shall be fitted to the insulation first and the female half (with laps) shall be applied with its laps on the outside of the male half.

6.9.6 Valve covers shall be secured by using stainless steel bands around the bonnet and on the body of both sides of the valve stem. No screws, pop rivets, etc. are to be used.

6.9.7 Where pop rivets are used to secure irregular shapes, all holes shall be drilled before metal is put in place over the insulation. A three inch wide by 0.020 in. thick aluminum strip shall be taped to the vapor barrier under the seam to prevent puncture of the vapor barrier.

6.9.8 The metal jacket for the straight runs of piping shall be tightly butted to the valve insulation cover and will be applied over the metal valve extensions. All laps should be positioned to shed water.

6.9.9 Caulk overlaps and any entrance holes with joint sealer as recommended in the materials specification section.

Related Links:

Extol's Valves & Jacketing
Extol's Insulation Valve System
Refrigeration Valves List
Other Specifications -Hot & Cold Service

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