Document No.

CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

QAFAC

EPIC FOR MTBE TANKS AND PIPE LINE BETWEEN

QAFAC & QP REFINERY

METHOD STATEMENT FOR COLD INSULATION WORKS

A0 16-Dec -19 Issued for Review NP AC

Reviewed&
Prepared By Approved by
Rev Date Description Approved By Approved by
CAPE QAFAC
CAPE FERNAS

INDEX
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

1. PURPOSE

2. REFERENCES

3. RESPONSIBILITIES

4. ACCESS

5. ENVIRONMENTAL PROTECTION

6. MATERIAL STORAGE

7. PROCEDURE

8. FINAL ACCEPTANCE

9. SPECIFICATION CONTROL
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

1. PURPOSE

1.1. The purpose of this Method Statement is to ensure a detailed control of the
application of cold insulation to piping for the project EPIC for mtbe tanks and
pipe line between QAFAC & QP as referenced in the requirements of
specification QMM-RP-000-PAT-00004 .

2. REFERENCES

2.1 QMM-RP-000-PAT-00004 - Specification for thermal insulation of cold

services
2.2 DRW. NO. 4006-00-13-61-0099

3. RESPONSIBILITIES

3.1. The Site Supervisor shall be responsible for ensuring the correct application
of this procedure.

3.2. The Supervisor shall be responsible for confirming the insulation type and the
extent of insulation, also that the materials used are in strict accordance with
the specification.

3.3. The Site supervisor shall be responsible for material receiving inspections
prior to installation. Also, he is responsible for achieving the final acceptance
/ sign off Inspection control sheet and completion certificate.

4. ACCESS

4.1. All work will be carried out within the MIC area. When work is carried in
elevated locations, the access will be provided by others :

4.1.1. Proprietary Tube, Board and Clip Scaffold assemblies erected and
inspected by qualified and competent scaffolders. Personnel will
ensure that prior to using scaffolds that they will check the validity
and status of the scafftag.

4.1.2. Mobile Access Towers, Steps and Equipment operated or erected

by personnel trained in the manufacturers recommended manner.

4.2. All access will be kept tidy and free from obstruction at all times.

5. ENVIRONMENTAL PROTECTION

5.1. All works will be carried out under dry and atmospherically correct condition.

5.2. Materials will be stored neatly at the ground level within designated area. Any
surplus insulation material shall not be permitted to store on the scaffolding.

5.3. It will be mandatory for all personnel to keep all work areas clean continuously
throughout the working shift.
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

5.4. Spillage / scattered materials will be cleaned immediately to prevent wind

borne debris throughout the site.

5.5. During inclement weather all insulation work shall be protected.

6. MATERIAL STORAGE

5.1 Insulation and ancillary Products shall be handled, stored, packaged and
delivered in a manner which prevents damage, deterioration, abuse, misuse or
loss and, where applicable, in accordance with the client instructions or as
specified in the contract.
5.2 Storage areas shall provide adequate protection against harmful
environments. Procedures shall ensure that product is controlled, identifiable
and stored in a manner as to prevent damage and/or deterioration.
5.3 Materials that exceed the shelf life shall be discarded or the same shall be
used after shelf life extension letter from manufacturer.
5.4 All materials shall be checked to ensure that they are within their shelf life and
that a valid letter of conformity is held.
5.5 Consumables like selanats etc. shall be stored in accordance with
manufacturer’s recommendations.
5.6 Coating materials shall be used on "First in-First out Basis"; no coating
materials shall be used after expiration of their shelf life.
5.7 Each batch of wet products used shall be accompanied by a material
certificate from the respective manufacturer.
5.8 The storage temperature of the materials shall be recorded in Daily record of
material storage temperature form CMS GF 084.
5.9 material receiving inspection shall be carried out upon receipt to verify that all
products are approved for the activity specified and is stored correctly with
batch certificate and expiry dates valid.

7. PROCEDURES

7.1. Ensure the substrate released for insulation is in a satisfactory condition to

be insulated and is clean, dry and the area surrounding is free of obstacles
and debris, as per specification.
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

7.2. It shall be the responsibility of the Supervisor to ensure the materials are
applied in correct order of layering and all the adhesives and sealant are
applied correctly.

7.3. The materials shall be applied in the following manner and will be monitored
by the Site supervisor.

7.4. Application of insulation to Piping

7.4.1. Pre-formed PIR of 45kg/m³ density with a thickness 25& 50 mm

shall be carefully cut & adjusted to follow the exact shape of
surfaces, pipes, nozzles, elbows, rings, supports etc. The
insulation thickness shall be as per the specifications.

7.4.2. Circumferential joints of pipe sections shall be offset by half

section length in successive layers or with offset at least 75mm
where it cannot be obtained.

7.4.3. For the single layer application, the circumferential and

longitudinal joints of the pre-formed PIR insulation shall be glued
together using joint sealant.

7.4.4. For single layer and outer layer of multiple layer up to 762mm OD,
the securement of insulation shall be by means of 13 X 0.5mm
thick SS Banding spaced at 50mm from each end of the section
and at intermediate intervals of not more than 300mm.

7.4.5. Vapour barrier application shall be carried out either by weather

proofing mastic or by Butyl rubber self-adhesive VB membrane

7.4.6. Butyl rubber self-adhesive VB membrane shall be applied as per

the following procedures -

a) When applying Butyl rubber VB Membrane to substrate

surfaces, overlap each section of IWR 701 by a minimum
of 25mm.

b) Overlap adjoining sections of IWR-701 by a minimum of

25 mm. Use hand pressure or a roller to smooth tape and
ensure proper adhesion at overlap

c) On vertical runs of pipe, wrap from the lowest point to the

highest point to ensure rain shed. Wrapping uphill will
prevent any water from collecting at the seams.

7.4.7. Insulation installation to valves and flanges shall be as below.

➢ Flanged joints and valves have to be insulated, these shall be

provided with removable insulation (boxed type) to the
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

maximum Insulation applied to flanged joints and valves shall

be equal in nominal thickness to that applied to adjacent or
equivalent sized piping. The insulation of flanges and valves
shall be by preformed PIR and filled with resilient glass fiber
blanket inside the cavity.
➢ Spectacle blinds must not be totally enclosed by insulation
boxes, but must be left visible.
➢ Insulation on piping shall be stopped short of flanges, whether
they are separately insulated or not, and beveled back to allow
for bolt removal. Adequate protection shall be provided at these
points and at any termination of the insulation to prevent the
ingress of water.
➢ The PIR used for valves and flange insulation application shall
be of the density 45 kg/m³ & with a thickness of 25 or 40mm as
per re quirement.
➢ All insulation material shall be carefully cut & adjusted to follow
the exact shape of flanges & valves.
➢ Joints of the pre-formed Polyisocyanurate foam insulation shall
be glued together using suitable joint sealant Foster 81-33 .
➢ Stainless steel SS 316 (13X0.5mm) band shall be installed as
banding over PIR sections.
➢ Vapour barrier application shall be carried out by Butyl rubber
self-adhesive VB membrane as per section 7.4.8 of this Method
statments.

7.5. Application of Cladding to Piping & Valves/flanges

7.5.1. Flat cladding of aluminized steel shall be used to finish pipe

insulation. Cladding thickness shall be 0.6mm for insulation OD
up to 610mm.

7.5.2. The metal jacketing shall be done basically to prevent the

insulation from damage.

7.5.3. The orientation of metal jacket shall be so as prevent the ingress

of water and shall be tightly fitted over the vapour barrier.
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

7.5.4. S-clips shall be provided between individual lengths of metal

cladding on vertical piping to prevent the telescoping.

7.5.5. Metal jacket shall be fixed together with the help of SS banding of
13mm X 0.5 (for below 762mm OD) shall be put over a piping
positioned adjacent to the ball swage and at 250mm intermediate
centres. Pop rivets of 4.0mm dia shall be used to secure the
cladding without damaging the vapour barrier wherever banding is
impractical.

7.5.6. Cladding Laps shall be swaged to increase stiffness & seal

efficiency. Sheeting laps at circumferential seams between
adjacent sheets shall be 75 mm and shall incorporated a 10 mm(
Single groove) ball swage. While for longitudinal seams shall be
50 mm and shall incorporate a 10 mm (Single groove) ball
swage.

7.5.7. All metal joints over the cladding shall be sealed with the suitable
metal sealant mastic.

7.5.8. The cover/boxes shall be made in halves from metal sheets and
shall incorporate 25 mm cladding overlap between sections.

7.5.9. The vapor sealed insulation over flanged joints shall be encased
in 1.0 MM aluminized metal boxes. Boxes shall be constructed
from flat metal with circumferential locking seams. Metal boxes
shall be installed with removable, reusable construction.

7.5.10. The cladding shall be secured by means of stainless steel bands

positioned adjacent to the ball swage at circumferential laps, and
at 250 mm maximum intermediate centers, machine tensioned
and sealed.

7.5.11. Individual sections shall be lapped a minimum of 40 mm and shall

be secured with either stainless steel toggle fasteners or with slide
type fasteners fabricated from metal sheeting. Rivets used for
securing fasteners shall not damage vapor barrier.

7.5.12. The termination of the piping insulation at each side of the flanged
joint shall allow sufficient space for bolt withdrawal.
 Document No.
CEL-18663-UK-003-MS01

Date – 5-05-2019 Rev- A1

TITLE:
METHOD STATEMENT FOR COLD INSULATION WORKS

7.5.13. All metal joints over the cladding shall be sealed with the suitable
approved metal sealant mastic .

8. FINAL ACCEPTANCE

Upon final completion of the insulation and Metal Cladding, the Supervisor shall
complete inspection and issue an Inspection Control form for the relevant completed
work for client approval.

9. SPECIFICATION CONTROL

9.1. At all times the Supervisor will have access to:

Method Statement

Project Specification

Quality Documents

All employees, when in doubt will approach the Supervisor for assistance in
clarifying work requirements.