INSULTHIN TM HT INSTALLATION GUIDE

Transcription

1 INSULTHIN TM HT INSTALLATION GUIDE Industrial Insulation IND- 08/11/ Johns Manville

2 CONTENTS INTRODUCTION 3 Installation & Safety Information 4 Installation Instructions 5 Material Details 5 Installation Techniques 5 QC/QA Requirements 6 Appendix A Stretch-Out Tables 7 Appendix B Thickness Tables 9 Figure 1 Identification Protocol for Pre-Cut Elbows 13 Figure 2 InsulThin HT Butterfly Two-Piece Elbow 14 Figure 3 Collar Seal Around Protrusions 15 Figure 4 Example of Vessel Head Installation 16

3 Johns Manville Industrial Insulation Group offers numerous insulation solutions to meet the demanding needs of your industrial insulation applications. Our full product line has the versatility to meet your unique application specifications, and each insulation is designed to optimize installation, offer long-term thermal performance, and help improve jobsite logistics. This guide features InsulThinTM HT, a high-temperature, hydrophobic, microporous blanket manufactured for flexibility, resistance to corrosion under insulation (CUI), and superior thermal protection. InsulThin HT requires only a fraction of the space of traditional insulation and can be cut to shape for insulating piping, fittings, and equipment. INSTALLATION GUIDE 3

4 Installation & Safety Information REVIEW THESE IMPORTANT GUIDELINES PRIOR TO INSTALLING INSULTHIN HT Review InsulThin HT Safety Data Sheet. All Safety Data Sheets (SDS) are available at Confirm that pressure testing of piping and fittings has been completed. Ensure that all equipment worktables or surfaces are clean and dry prior to insulation installation. Check that InsulThin HT is clean, dry and in good condition. Dirty, wet or damaged InsulThin HT should not be installed. Inspect work areas to confirm that they are wellventilated, well-lit, and safe. Obtain and use proper personal protective equipment (PPE) during installations. Refer to Safety Data Sheet for appropriate PPE recommendations. Take special care when working with large pieces of InsulThin HT in windy conditions. Product Information Please refer to the InsulThin HT SDS as the microporous material may cause dryness of the skin. Gloves are recommended and a respirator is suggested depending upon jobsite conditions during the handling, cutting, and installation of the product. Although the microporous material is contained in the quilted blanket, take care to avoid loss of the microporous material along cut lines during installation. PREPARATION & STORAGE InsulThin HT should be stored in a clean, dry and protected environment. If the product must be stored in an outdoor setting, it should be placed on pallets and thoroughly covered with a waterproof tarp or plastic sheeting. Although the microporous material is hydrophobic, all necessary measures should be taken to protect it from the weather. RECOMMENDED TOOLS Gloves Hard hat Sharp knife, box cutter, or carpet shears Tape measure Marker or carpenter's pencil Straight-edge ruler Reinforced strapping tape Sealant edge tape (optional) NIOSH N-95 dust mask respirator (optional) INSULATION PLACEMENT Ensure that each section of InsulThin HT butts up tightly against neighboring pieces of insulation. The blanket material of each section must touch the blanket of its neighboring section(s). The glass cloth trimming on the material does not provide thermal insulation. Do not allow open gaps between InsulThin HT and the pipe or equipment being insulated. There should be no gaps where pipe is covered only by the fiberglass-cloth trimming. There should be no gaps between multiple layers of InsulThin HT. INSTALLATION GUIDE 4

5 Installation Instructions The installation technique of InsulThin HT blanket is the same as that of other flexible, roll-type blanket insulations. MATERIAL DETAILS Material: Johns Manville s microporous InsulThin HT 5 mm and 10 mm. Maximum continuous use temp: 1200 F (650 C) 1. Material A. Factory precut elbows are available from Johns Manville. 2. Jacketing A. Jacketing materials shall be as specified by the owner/ engineer. 3. Pre-formed metal elbows sized for various thickness combinations of Johns Manville s microporous blanket are commonly available from metal fitting manufacturers. 4. Caulk/sealant to seal around protrusions: Caulk materials must be able to withstand high temperatures (400 F 500 F) and must be approved by owner/engineer. 5. Pins. Where pins are attached to equipment, they should match the metallurgy of the vessel. Contact owner/ engineer for heat treat requirements for all applications where welding pins are to be used. A. Peel and stick pins. Owner/engineer must approve and verify that the glue used does not contain chlorides. B. Glue-on style w/ perforated base. Owner/engineer must approve and verify that the glue used does not contain chlorides. INSTALLATION TECHNIQUES 1. Cutting A. Manual Cutting I. The microporous blanket may be cut manually with scissors or another sharp cutting blade. It is recommended that the cutting blade be as sharp as possible and in good condition, without nicks or burrs (which may catch and pull on the fabric threads). For best results, cut on a hard surface covered with card board to allow the knife to cut completely through the insulation material. (Cutting the blanket with a dull blade is more laborious, creates more dust, and tends to damage the material. The use of a dull knife is not recommended.) II. Using metal, Masonite, cardboard, or templates of other construction can be effective for manual cutting. III. When using sharp tools or instruments, use caution and the appropriate PPE. B. Machine Cutting I. Some distributors offer pre-cut lengths and shapes. 2. Application A. General I. Tape: Spiral wrapped, ½ or ¾ inch fiberglass reinforced strapping tape can be an efficient method for securing the InsulThin HT blanket. II. Staples: Outward clinch stainless steel staples may be used to secure either butt joints or overlap type joints on InsulThin HT blanket. III. Banding: Stainless steel banding may be used to secure InsulThin HT blanket to the pipe. IV. Wire: Stainless steel tie wire may be used to secure InsulThin HT blanket. V. InsulThin HT should be terminated a safe distance from the flange to allow for access to and removal of the bolts. VI. Appendix A1 shows the InsulThin HT stretch-out table with a ¼ overlap. B Small bore pipe (<2 in / 50mm diameter) I. Wrap layers of 5 mm thick InsulThin HT up to the desired thickness (Appendix B), staggering all joints. Appendix B includes thickness tables for both flat and pipe geometries as well as shiny and dull jacketing surfaces. C Pipe greater than 2 in / 50mm diameter I. Wrap layers of 5mm or 10mm thick InsulThin HT up to the desired thickness (Appendix B), staggering all joints. II. InsulThin HT blanket may be secured with the following options prior to installing the jacketing: 1. Fiber reinforced tape 2. Outward-clinch stainless steel stapling 3. Wire 4. Bands III. Application aids such as bungee cords or Velcro bands may improve efficiency and help increase productivity. INSTALLATION GUIDE 5

6 INSTALLATION INSTRUCTIONS IV. Multi-wrap application utilizing a single, long piece of InsulThin HT is acceptable for a maximum of 2 wraps. V. For multi-layer applications greater than 2 layers, the circumferential joints must be staggered. VI. If an open gap occurs at a circumferential joint due to uneven edges of blanket on a multi- wrap application, a bandage filler strip of InsulThin HT should be used to cover the butt joint. VII. Overlap the strip 1 (25 mm) minimum on each side of the gap, and secure with tape or wire. VIII. Either overlap or butt joint longitudinal seams are acceptable. Overlap seams should always be positioned to shed water on horizontal pipes. D. Valves I. Insulate valves only when specified by owner/ engineer. E. Flanges I. Insulate flanges only when specified by owner/ engineer. F. Elbows (See Figure 1 & Figure 2) I. Insulation for elbows should be pre-cut butterfly design. II. For multi-layer installations, butterflies must be sized to allow for nesting. Multilayer precut elbows are available from Johns Manville. G. Vessels (See Figure 3 & Figure 4) I. Options for heads: a. Pre-cut (in a shop) InsulThin HT gore sections are preferred and the most efficient. b. Radial seams may be butt-joined or lapped. Joints on multi-layer applications should always be staggered. c. Head-to-shell tangent seam may be butt joint or overlap seam. d. Metal bands or wire are the most common methods for securing the InsulThin HT prior to the jacketing. H. Horizontal Shells I. For single layer applications, cut a length of blanket equal to the circumference. A butt joint is acceptable, however, it must be a tight joint. An overlap of up to 1 (25mm) is acceptable. II. For multi-layer applications, circumferential joints for each layer may be butted or overlapped. III. For multi-layer applications, circumferential and longitudinal joints should always be staggered. IV. Rubber bands, bungee cords, Velcro straps, pins, stainless steel wire may be used for temporary securement until metal bands can be installed. I. Vertical Shells I. Provide a minimum 1 (25 mm) overlap on longitudinal seams. II. Bungee cords, Velcro straps, stainless steel wire, or pins may be used for temporary securement until metal bands can be installed. III. Circumferential lap joints shall be shingled to shed water. IV. Circumferential lap joints shall be overlapped a minimum of 2 inches (50 mm). V. Stagger all longitudinal seams. VI. All seams shall be staggered on multi-layer installations. 3. Jacketing General A. The method for installing jacketing over microporous blanket is similar to that of other industrial insulations. B. For piping, a minimum of three (3) stainless steel bands per jacket course is required. C. Molded metal elbow covers should be used wherever available. D. See InsulThin HT jacketing stretch-outs in Appendix A2. QC/QA REQUIREMENTS 1. Prior to jacketing. Visually inspect the insulation and banding prior to jacketing installation (required). The inspector must verify: A. Insulation material is as specified B. Correct number and thickness (Appendix B) of layers C. Proper intermediate banding and spacing D. Correct use of permanent sealing of topside protrusions where required 2. After jacketing. Visually inspect the jacketing and sealing (required). Inspector must verify: A. Proper means of permanent sealing around protrusions where required B. Proper band and spring spacing C. Proper jacketing material INSTALLATION GUIDE 6

7 Appendix A: Stretch-Outs Appendix A1: InsulThin HT INSULATION STRETCH-OUTS (inches) (.25" OVERLAP) Pipe Size Actual 5 mm InsulThin HT Thickness 10 mm InsulThin HT Thickness Inches OD 1 Layer 2 Layer 3 Layer 1 Layer 2 Layer 3 Layer INSTALLATION GUIDE 7

8 Appendix A2: JACKETING STRETCH-OUTS (inches) for InsulThin HT 2" Overlap Pipe Size Actual 5 mm InsulThin HT Thickness 10 mm InsulThin HT Thickness Inches OD 1 Layer 2 Layer 3 Layer 1 Layer 2 Layer 3 Layer INSTALLATION GUIDE 8

9 Appendix B: Thickness Tables Appendix B1: InsulThin FLAT Geometries Shiny Jacketing Surfaces (e=0.15) in(mm) 200 F (93 C) 300 F (149 C) 400 F (204 C) 500 F (260 C) 600 F (316 C) 700 F (371 C) 800 F (427 C) 900 F (482 C) 1000 F (538 C) 1100 F (593 C) 1200 F (649 C) 0.5 (13) 5mm 5mm 10mm 10mm 15mm 15mm 20mm 20mm 25mm 30mm 35mm 0.75 (19) 5mm 5mm 10mm 10mm 15mm 15mm 20mm 25mm 25mm 30mm 35mm 1 (25) 5mm 5mm 10mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 40mm 1.5 (38) 5mm 5mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 40mm 45mm 2 (51) 5mm 10mm 10mm 15mm 20mm 25mm 30mm 30mm 40mm 45mm 50mm 3 (76) 5mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 45mm 50mm 55mm 4 (102) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 50mm 55mm 65mm 6 (152) 5mm 10mm 15mm 20mm 30mm 35mm 40mm 45mm 55mm 65mm 75mm 8 (203) 5mm 10mm 20mm 25mm 30mm 35mm 45mm 50mm 60mm 70mm 80mm 10 (254) 5mm 10mm 20mm 25mm 30mm 40mm 45mm 55mm 65mm 75mm 85mm 12 (305) 5mm 15mm 20mm 25mm 35mm 40mm 50mm 60mm 70mm 80mm 90mm 14 (356) 5mm 15mm 20mm 25mm 35mm 45mm 50mm 60mm 70mm 80mm 95mm 16 (406) 5mm 15mm 20mm 30mm 35mm 45mm 55mm 60mm 75mm 85mm 95mm 18 (457) 5mm 15mm 20mm 30mm 35mm 45mm 55mm 65mm 80mm 80mm 100mm 20 (508) 5mm 15mm 20mm 30mm 40mm 45mm 55mm 65mm 80mm 90mm 105mm 24 (610) 5mm 15mm 25mm 30mm 40mm 50mm 60mm 70mm 85mm 100mm 110mm 30 (762) 5mm 15mm 25mm 35mm 40mm 50mm 60mm 70mm 90mm 95mm 115mm 36 (914) 10mm 15mm 25mm 35mm 45mm 55mm 65mm 75mm 90mm 105mm 120mm 48 (1219) 10mm 15mm 25mm 35mm 45mm 55mm 65mm 80mm 95mm 110mm 125mm Flat 10mm 20mm 30mm 40mm 55mm 65mm 80mm 95mm 110mm 125mm 145mm Ambient temperature = 86 F (30 C) Wind speed = 2.2 mph Surface emissivity = 0.15 Max touch temp = 140 F (60 C) INSTALLATION GUIDE 9

10 Appendix B2: InsulThin FLAT Geometries Dull Jacketing Surfaces (e=0.80) in(mm) 200 F (93 C) 300 F (149 C) 400 F (204 C) 500 F (260 C) 600 F (316 C) 700 F (371 C) 800 F (427 C) 900 F (482 C) 1000 F (538 C) 1100 F (593 C) 1200 F (649 C) 0.5 (13) 5mm 5mm 5mm 10mm 10mm 15mm 15mm 15mm 20mm 20mm 25mm 0.75 (19) 5mm 5mm 10mm 10mm 10mm 15mm 15mm 20mm 20mm 25mm 25mm 1 (25) 5mm 5mm 10mm 10mm 10mm 15mm 15mm 20mm 25mm 25mm 30mm 1.5 (38) 5mm 5mm 10mm 10mm 15mm 15mm 20mm 20mm 25mm 30mm 30mm 2 (51) 5mm 5mm 10mm 10mm 15mm 20mm 20mm 25mm 25mm 30mm 35mm 3 (76) 5mm 5mm 10mm 15mm 15mm 20mm 25mm 25mm 30mm 35mm 40mm 4 (102) 5mm 10mm 10mm 15mm 15mm 20mm 25mm 30mm 35mm 35mm 40mm 6 (152) 5mm 10mm 10mm 15mm 20mm 25mm 25mm 30mm 35mm 40mm 45mm 8 (203) 5mm 10mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 10 (254) 5mm 10mm 15mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 12 (305) 5mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 40mm 50mm 55mm 14 (356) 5mm 10mm 15mm 20mm 20mm 25mm 30mm 40mm 45mm 50mm 55mm 16 (406) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 55mm 18 (457) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 60mm 20 (508) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 55mm 60mm 24 (610) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 50mm 55mm 60mm 30 (762) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 45mm 50mm 55mm 65mm 36 (914) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 45mm 50mm 55mm 65mm 48 (1219) 5mm 10mm 15mm 20mm 25mm 30mm 40mm 45mm 50mm 60mm 65mm Flat 5mm 10mm 15mm 20mm 30mm 35mm 40mm 50mm 55mm 65mm 75mm Ambient temperature = 86 F (30 C) Wind speed = 2.2 mph Surface emissivity = 0.80 Max touch temp = 140 F (60 C) INSTALLATION GUIDE 10

11 Appendix B3: InsulThin PIPE Geometries Shiny Jacketing Surfaces (e=0.15) in(mm) 200 F (93 C) 300 F (149 C) 400 F (204 C) 500 F (260 C) 600 F (316 C) 700 F (371 C) 800 F (427 C) 900 F (482 C) 1000 F (538 C) 1100 F (593 C) 1200 F (649 C) 0.5 (13) 5mm 5mm 10mm 10mm 15mm 15mm 20mm 25mm 25mm 30mm 35mm 0.75 (19) 5mm 5mm 10mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 40mm 1 (25) 5mm 5mm 10mm 10mm 15mm 20mm 25mm 25mm 30mm 35mm 40mm 1.5 (38) 5mm 5mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 40mm 50mm 2 (51) 5mm 10mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 3 (76) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 55mm 60mm 4 (102) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 45mm 50mm 60mm 65mm 6 (152) 5mm 10mm 15mm 20mm 30mm 35mm 40mm 50mm 60mm 65mm 75mm 8 (203) 5mm 10mm 15mm 25mm 30mm 40mm 45mm 55mm 65mm 75mm 80mm 10 (254) 5mm 10mm 20mm 25mm 35mm 40mm 50mm 60mm 70mm 75mm 90mm 12 (305) 5mm 10mm 20mm 25mm 35mm 45mm 50mm 60mm 70mm 80mm 95mm 14 (356) 5mm 15mm 20mm 30mm 35mm 45mm 55mm 65mm 75mm 85mm 95mm 16 (406) 5mm 15mm 20mm 30mm 35mm 45mm 55mm 65mm 75mm 90mm 100mm 18 (457) 5mm 15mm 20mm 30mm 40mm 50mm 60mm 70mm 80mm 90mm 100mm 20 (508) 5mm 15mm 20mm 30mm 40mm 50mm 60mm 70mm 80mm 95mm 105mm 24 (610) 5mm 15mm 25mm 30mm 40mm 50mm 60mm 75mm 85mm 100mm 110mm 30 (762) 5mm 15mm 25mm 35mm 45mm 55mm 65mm 75mm 90mm 105mm 115mm 36 (914) 5mm 15mm 25mm 35mm 45mm 55mm 70mm 80mm 95mm 105mm 120mm 48 (1219) 10mm 15mm 25mm 35mm 45mm 60mm 70mm 85mm 100mm 110mm 130mm Flat 10mm 15mm 40mm 40mm 50mm 65mm 80mm 95mm 110mm 130mm 145mm Ambient temperature = 86 F (30 C) Wind speed = 2.2 mph Surface emissivity = 0.15 Max touch temp = 140 F (60 C) INSTALLATION GUIDE 11

12 Appendix B4: InsulThin PIPE Geometries Dull Jacketing (e=0.80) in(mm) 200 F (93 C) 300 F (149 C) 400 F (204 C) 500 F (260 C) 600 F (316 C) 700 F (371 C) 800 F (427 C) 900 F (482 C) 1000 F (538 C) 1100 F (593 C) 1200 F (649 C) 0.5 (13) 5mm 5mm 5mm 10mm 10mm 15mm 15mm 20mm 20mm 25mm 25mm 0.75 (19) 5mm 5mm 5mm 10mm 10mm 15mm 15mm 20mm 20mm 25mm 30mm 1 (25) 5mm 5mm 10mm 10mm 15mm 15mm 20mm 20mm 25mm 25mm 30mm 1.5 (38) 5mm 5mm 10mm 10mm 15mm 15mm 20mm 25mm 25mm 30mm 35mm 2 (51) 5mm 5mm 10mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 35mm 3 (76) 5mm 5mm 10mm 15mm 15mm 20mm 25mm 30mm 35mm 35mm 40mm 4 (102) 5mm 5mm 10mm 15mm 20mm 20mm 25mm 30mm 35mm 40mm 45mm 6 (152) 5mm 10mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 8 (203) 5mm 10mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 55mm 10 (254) 5mm 10mm 15mm 15mm 20mm 25mm 30mm 40mm 45mm 50mm 55mm 12 (305) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 60mm 14 (356) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 55mm 60mm 16 (406) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 50mm 55mm 60mm 18 (457) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 50mm 55mm 65mm 20 (508) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 45mm 50mm 55mm 65mm 24 (610) 5mm 10mm 15mm 20mm 25mm 30mm 35mm 45mm 50mm 60mm 65mm 30 (762) 5mm 10mm 15mm 20mm 25mm 30mm 40mm 45mm 55mm 60mm 70mm 36 (914) 5mm 10mm 15mm 20mm 25mm 35mm 40mm 45mm 55mm 60mm 70mm 48 (1219) 5mm 10mm 15mm 20mm 25mm 35mm 40mm 50mm 55mm 65mm 75mm Flat 5mm 10mm 15mm 20mm 30mm 35mm 45mm 50mm 60mm 70mm 80mm Ambient temperature = 86 F (30 C) Wind speed = 2.2 mph Surface emissivity = 0.80 Max touch temp = 140 F (60 C) INSTALLATION GUIDE 12

13 Figure 1: JM Identification Protocol for Pre-Cut Elbows Each elbow piece will be factory marked for easy identification as follows: Pipe Size Total Thickness Layer Number Example: = 6 IPS - 30mm Insulation Thickness Layer INSTALLATION GUIDE 13

14 Figure 2: Installed Butterfly Two-Piece Elbow Example of installed InsulThin HT butterfly two-piece elbow INSTALLATION GUIDE 14

15 Figure 3: Collar Seal Around Protrusions Permanent Sealing Method INSTALLATION GUIDE 15

16 Figure 4: Example of Vessel Head Installation Single gore banded Multiple gores banded Second layer staggered joints InsulThin HT 1/2" or 3/4" Stainless Steel Band INSTALLATION GUIDE 16

17 717 17th St. Denver, CO The InsulThin HT Installation Guide is intended as a guide only; actual conditions encountered during installation may vary from jobsite to jobsite. By providing this guidance, Johns Manville assumes no responsibility for quality of installation, field workmanship, building code compliance, or job safety. Johns Manville Safety Data Sheets (SDS) are available with specific product safety information. For information on other Johns Manville thermal insulations and systems, call the number listed below or visit JM.com. For Customer Service and Technical Information IND- 10/16/ Johns Manville. All Rights Reserved.