Vine INSULATION INSPECTORae ARL Insulation fo retain Insultion Imsulation 10 may also be nsed oie. Ths ope of ‘scaled acme 20 40 50 Ca 70 100 TPE IEE DSTO Marron ‘TYPES OF INSULATION Insulation is primarily used on piping and vessels to prevent excessive heat loss or to maintain temperatures at a low level. ‘The insulation used for either of these purposes )— may be referred to as thermal insulation. ‘Thermal insulation may bo required more specifically for the following TA, Safety (personal protection) i 12), Hot and cold conservation (precious resources) e |B. Operating costs (to maintain cost effectiveness). ‘There are four main types of insulation commonly used in the power, oil, gas and chemical industries each having a specific function: INSPECTION DUTIES 1tis the duty of an insulation inspector to check all insulation and associated operations ‘are carried out in accordance with the specification(s) for the work to be undertaken. Inspection is defined in BS 4778 : Part 1 (Quality Vocabulary) as, ‘activities such as measuring, examining, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity.’ Inspectors should not deviate from the specification requirements unless the client or supervisor gives permission to do so; this should preferably be written permission, The following list gives an overview of ities applicable to an inSation inspector: Obtain opin sens othe pecans) ena spesieon() Getto ly tapi ofr ta Getto know te perenne Check that al eouared uadestand te speciation Koop the eagoceuperiior inrmed oral tines of any departure ffm te | eenion Gondec sno stend ste mesings. Determine the days work programme wih he coos’ sexor prone Check the mera Determine wbeher the wrk mets the spexfeation requirement. Check for any appizton fe ake writen report at an agreed equency. nee Raine ie 208611 INSI-LARL 0 The heat copacty ofa body of eny kind s defined a he heat required to rae its temperate by IK. » o ” 0 100 ‘THERMAL INSULATION ‘Thermal insulation is defined in BS 3533 as "a material or system that has the property of resisting the transfer of heat", ‘The thickness of insulation required willbe primarily governed by the type of insulating satcrial used (especially its heat capacity), the heat capacity of the product, the heat capacity of the pipework etc., the low rate of the product in the system (vessels, pipework etc) and the temperature requirement for the product, ‘There are two types of thermal insulation: (1) hot insulation and (2) cold insulation. ‘Hot insulation Hot insulation, although not defined in BS 3533, is commen terminology used for insalaton tat will retard the transfer of eat energy from the insalated system when the temperature in the system is higher than ambient temperature. Therefore, hot insulation is used to Keep the product hot in a system. Hoot insulation may be used on extemal surface of pipework to keep the temperature of the product in the pipework high enough for the product to flow, of flow at a higher rate than it would at ambient temperatures for production cost ressons. Hot insulation may also be used to protect personnel or plant from high temperatures. ‘Common materials used for hot insulation systems include: Calcium silicate: <1000°C. Mineral wool: <850°C. ©. Foamglss: <430°C. 4 Polyisooyanurate: < 140°C. ‘Cold insulation Cold insulation, although not defined in BS 3533, is common terminology used for {insulation that wall retard the transfer of heat energy from the insulated system when the temperature in the system is lower thon ambicat temperature. Therefore, cold insulation is used to keep the product cold in a system. Cold insulation may also be used to protect personnel or plant ‘from very low ‘temperatures. ‘Common materials used for cold insulation systems include: Foam glass: >-270°C. b. Polyisocyanurate: >-145°C. Polyurethane: >-100°C. Protection against condensation ‘The application of the insulation can prevent condensction at the surface of a containing vessel, pipework etc., but it will not necessarily prevent moisture being <érawn through the insulation itself. The dew point may be reached within the insulation and it can become saturated if itis applied to a cold surface; this will affect the heat insulation properties and its mechanical strength. IF the cold surface is at a temperature lower than the freezing point, the moisture will freeze and the insulation will tend to rupture and break away (ablate). Factory made pre-formed bends and other fittings will minimise gaps in the insulation to reduce the susceptibility o rupture Yvapour barriers ace epplied to these insulation systems to prevent or reduce the ingress of moisture. Art ans Lit we S08 INS2-1Fd 0 50 o 0 %0 100 Bids protection Tr the outside temperature remain low enough for log enough, and the movement of product through the pipe or vessel is slow, then freezing cr excessive cooling may cour isolation may delay the onset of freezing or excessive cooling. The time taken for a liquid to reach ffeezing point under given conditions of temperature difference will depend on the heat capacity of the product, the heat capacity of the pipework, vessel etc. and the beat capacity ofthe insulation. ‘Small diameter pipes and other items are more vulnerable to freezing compared to larger items, therefore small diameter pipes etc. require a greater thickness of insulation for protection against frost conditions than do larger diameter pipes ete : 10 Baul? 0 Tromlatinn unm | Agousmic INSULATION vay ‘Acoustic insulation may be applied to piping, especially those pipes in which gases, ‘fluids or particle solids are transported at high velocities. This may be applied for environmental reasons to reduce noise pollution or to protect personnel from prolonged Sryenae tough mene wha ins ering The oe of cra ol of «gh destin te fom of pipe stn, ago ie a Sf elses be I Te lnc ot Eco wl een po te ing Lea viol shating uy bess over he mine woo it ten protected by metal cladain yl sheeting consists of glass cloth impregaated with loaded vinyl with an average thickness of ~ 1.4 mm. It is usually supplied in I m x I m sheets and usually operates within a service temperature of -50°C to +100°C. Other types of acoustic insulation may include perforated metal_or plastic sheeting, fabricated to form guards which can be fitted to machinery or compressors To reduce noise levels. Insulation may be applied to ventilation duots where quiet air conditioning is required. erent tion samen, INS?-210 20 30 «0 50 © 0 0 A coding system is normally used to identify the type of insulation. The coding normally consists of a simple abbreviation but may be used as part of the line idemification number, e.g. HC 40 P/40361. The following abbreviations are shown to give an idea of what may be expected, but the system may change depending on specification used. Hot insulation: A Acoustic ‘ E Electric trace i, #7604 ED Elects wace- dual EH Eletio trace bot EHO Electric trace het oil FP Frost protection HC Heatconsenvation shy ibe, fey, HO Hotoil uF ‘HS Hotisoun(gas) MT Maintenance of temperature PP Personne protection Cold insulation: AC Acoustic cold or Anti-condensation? Cc Cold CB Cold bun CC Cold conservation cs (ees) EC__ Electric trace cold (below 100°C) MC _— Maintenance of cold temperature Heat conservation, (EO) insulation to surfaces’ of pipes and vessels normally operating at temperatures seater than 60°C, where any leakage of heat i considered to be oss of nergy, Cold conservation (CC) insulation to surfaces of pipes and vessels normally operating at temperatures less han 10°C where any leakage js considered to be loss of ener. Personnel protection, @P) insulation to surfaces normally operating at temperatures greater than SSC and less than -10°C, which can come into contact with personnel under normal operating conditions. Anti condensation (AC) insulation to surfaces of pipes and vessels operating a: temperatures less than ~ 1OPC, where any leakage of heat ig not considered to be a Loss of energy. Frost protection (FP) insulation to surfaces containing fluids likely to freeze in cold weather under normal operating conditions. ‘Maintenance of operating temperatures (MT) insulation to surfaces of pipes and vessels containing fluids where the need to ‘maintain process temperatures is more important than HC. Maintenance of cold temperatures (MC) insulation to surfaces of pipes and vessels containing fluids where the need to ‘maintain process temperatures is more important than CC. awe 30004 INs74420 ” 0 100 INSULATION MATERIAL “The materials used in insulation may be divided into three typess 1. Insulation. Groupe 2. Protective coverings. 3. Fixings. INSULATION ‘There ere many types of insulation which exist, however, there are four main types commonly used in industry: 1, Mineral woot 2. Calcium silicate. 3. Rigid phenolic foams. 4. Cellular glass. 8 Dla he Be supplied as pre-formed pipe sections, lags and slabs as a ‘mattress. This material is non-hygroscopic, rot and vermin proof and is non-corrosive to ferrous and non-ferrous material. It has a temperature range of -0°C to 65 ‘has beea used throughout Europe, USA, the Middle East and the Far East where its properties are particularly suitable for conditions of high temperature and high relative humidities. ‘This material operates at a surface temperature of -180°C to a maximum of 120°C. [tis available in pre-formed pipe sections, lags and slabs, other uses for this materfat are to ‘insulate tankers forthe road and rail industries, Cellular glass is one of the best commercially available insulating materials and though ‘expensive can be used for (1) high temperatures and (2) its main function - for systems ‘operating at-0°C and below. Applied correctly this product will see out the life expectancy of the item it is covering, but if wrongly applied the cost implications are enormous. This material operates at tee 30003 INS3-10 “0 30 o ” » temperatures between -268°C and It is supplied in pre-formed pipe sections, lags and slabs available in two grades governed by compressive strength and density. Polyisocyanurate eae hams er sand gid wets ats eter an te Pen ee ioe peerage dren ad I ce uae Posamnte wae wilted tmpeta been a °C, Perlite savy ¢ /99 > ‘This therrhal insulation material has an additional property in that the binder used contains sodium silicate, long recognised as a corrosion ‘inhibitor. More than 50% of feevceutom silicate binder in the WRI200 eystem is used to protect metal surfaces weitat comesion This product i fly new to the United Kingdom construction Sins. Tk operates ata temperature of up to 1200°C and at present there are 10 Gnited Kingdom long term performance records available, however curent reports indicate a good performance at high temperatures. vermiculite (lini) ‘This thermal insulation material bas been used mainly as a fire proofing agent for structural sce in high fire rsk areas ofthe petrochemical industry. Vermiculite is a micaceous mineral which is mined and processed to produce a high purity concentrete. This concentrate in the form of flakes of varying size and thickness, fs expanded in a high temperature furnace to produce a slab form which is then cut and angled to suit any shape of angular freme work. A compound also exists to fill any ‘voids or gaps. ‘Austenitic stainless steel cladding is usually used to protect the vermiculite, ‘Vermiculite can withstand temperatures over 800°C. — Other insulation materials ‘There are many insulation materials available in many forms, others which may be ‘encountered include the following: Cork insulation (cold work). Fibreglass (heating systems). Polystyrene (chilled water). Polyurethane (process). Foil backed insulation (undercover process). Fibreboard (roofing). Lamellar mattress (industry). High temperature fibre blanket refractory) Spray applied fibrous thermal insulation for high temperatare (turbines). ‘Ceramic (furnaces). Glass rope (steam tracing). rrere mp eo ee Insulation compound is sometimes used with calcium silicate and is formed from @ ‘powder containing mineral fibres which, when mixed with water, is used for repairs and Sealing joints between sections, lags or slabs and where performed shapes are jmpracticable. Insulation compound has a temperature range up to ~800°C. PROTECTIVE COVERINGS Protective coverings are to protect the insulation and include: 1. Vapour seals. 2. Metal cladding. Seaecaat INS3-2 e ce e« c c a « a « a a e @ ¢ ax 50 © 0 % 100 3. Hard setting composition or self setting cement. Vapour seals ‘Vapour sealing compound is used for cryogenic applications, it is used to prevent the passage of water vapour from the exterior into the insulaticn system. Vapour sealer is ‘normally applied by gloved hand, trowel or float. ‘A umber of manufacturers have differing coating sealers which may consist of any of terse” flgi> Vigo Sea acrylic latex; solvent based vinyl polymer; polyvinyl acetat hypalin; 7 1p 1Fwe04 clastomefic polymers; basic mastio solutions. ‘Vapour sealer may have an interposed open weave glass cloth (10 x 10 mesh). ' Meta eladding pee dladdl “The reasons for applying metal cling to naulateg may be a5 follows: 1, To give appropriate protection agains meckanicel damage, 2. To protect against water, snow, srbore deposits, sunlight or ozone 3. To assist in identifying the pipe or vessel by either pa‘nting with a. teristic: colour by means of coloured beads a interme. Ths ideuifoaton sie ae Ee ted o inlets the dietion of proces flow. To pve protection aginst spillage of ils and other flammable uid. 5. ‘To improve appearence orto provide asurfice that canbe easily cleaned 6 Toretard ori posible to prevent the spread of ame, 7. Toprotectagninst chemical tack, vein and mould growth Metal cladding is available in aluminium, galvanised mild steel, aluzinc alloy and austenitic stainless stel. It is normally available in thicknesses: 0-5 mam, 0.7 mm and 09 mm. Metal cladding should be arranged to shed water, swaged and mastic sealed at overlaps both circumferencially and longitudinally, screwed or banded at the comrect size and pitches. Metal cladding i usually supplied in flat sheet form in various sizes, eg. 2m x 1 mor 24 mx 1m. Coiled sheeting is not normally used on sites bat restricted to large metal shops at home office bases. Fabrication of cladding for fittings is usually caried out on site. Materials used are in the form of general pipe cladding, bends, tes, dome ends, valve and flange boxes, ‘These are arranged to shed water at the job face and are masti> sealed after fitting Hard setting composition & self setting cement defined in BS 3533 a8 Clay-bound fishing matecal that is supplied in Toose Drei fr spon by ming with Water nd id by the application oF heat"— fomy fou (SGPReing|BSReHE desined in BS 3533 a5 ‘Finishing material, based on Portland cement, that is supplied as a dry powder and, when mixed with water in suitable proportions, will st without the application of het! 4s Eyer SoeFy 0 “0 50 0 | 100 Selfiting cement is used to protect calcium silicate insulation which, when mixed seth lean water, affords a smooth surface a a final nish for heated surftees p10 @ temperature of 650°C. Seltsciting cement is composed of mineral ibres and fillers mined with a Weta: based sae voich will set between wo and four hous. Tes applied wet by either gloved and, trowel or float and is smoothed using insulator steels ‘These coatings may be used over a wire mesh reinforcement May also be used as protective coverings as an altemative to metal cladding in certzin circumstances. FIXING MATERIALS Fixing materials are wed to bold down insulating materials and protective coverings, the following may be used: ‘Wire netting ~ used to hold down insulation but only used with hard sing oF seif setting cement as a protective covering Binding wie. Binding tape. Fixing bands. Self-tapping screws. ‘Nuts, bolts and other fastenings. Adhesives. ‘Anti-abrasion compound, Joint sealant. Note: Self tapping serewe should never be used ona coid work system. Penetration of the vapour barrier may in time lead to the ingress of moisture end water particularly on a eared vessels at high elevations; the situation could be worsened by fog/mis in high winds. remo eo sP STORAGE OF MATERIALS Inulating waterils should be stored in weather proof baldings or enclosores ‘Ensure boxes containing sections or segments of insulation ae stored end up. Cartons cr packs of mattresses or slabs should be laid flat Metal cladding on pallets are stored inside a building or ao filly covered over wilt wrether proof tata; this wil help prevent any water entering the ends ofthe rll by ‘capillary action which could otherwise cause water staining. Seinting compounds, mastics, ets. should be stored in accordance with, the sae war's recommendations which is typically ate temperature not less than 5°C. Banding and lacing wire, clips, serews and pop rivets should be stored in clean containers. cama nsec INS3-430 0 ‘The valves given inthe text are typical specified ‘requlrements and are Intended to give the reader ‘on instant view of ow Insulin s applied. gp (\4 q Heat conservation and protection Preparation Prior to any work taking place, the insulation inspector should check to ensure that -foulings do not interfere with the application of insulation or create a hot path Foulings can include hand rails, cable trays, adjacent piping, plant and equipment and structural steel. ‘The substrate should be inspected to ensure it i free of oi, grease, soils, splashes or spillage and free of moist or wet area. ‘Where required, support clamps should be fitted. ‘The insulation material should be thoroughly dry and free of auy defects. Insulation plus fixing, For single layer applications a staggered joint (150 mm) should be cut from the insulation. The two sections should be fitted together, tightly butted and secured by lacing wire or bands at the correct size and pitches in accordance with the specification requirements. For multi-layer applications, oversize sections or radiused and bevelled lags may be used, secured by bands af the correct size and pitches in accordance with the specification requirements. ‘The insulation inspector should inspect the first and second layers separately (stage inspections). “Metal cladding fixing Rolled metal cladding is applied to protect the insulation whichis then arranged to shed water. A circumferentially male swaged seam is fitted SO mm to one end of the cladding with a half folded lipped edge to the longitudinal scam. Banding is secured 10 the cladding and dram tight. The overlapping seam shovld be not less than $0. mm eonmpanaeeiet ae INS4-120 30 0 7 » 100 when secured by either the banding or sorews in accordance with the specification requirements COverlaps are nonmnally placed in position of pitches at either two o'clock or ten o'clock fon horizontal runs. Metal cladding on vertical runs are supported by S clips at each joint to prevent slippage. ‘The cladding is then weather proofed by applying a mastic Seal to the circumferential and longitudinal seams using a cartridge gun applying a 5 ‘am bead minimum thickness. Fittings such as bends, tees and metal segments of dome ends shell be weather proofed in the same manner. Valve and flange boxes shall have all seamed joins fally sealed, particular care should be taken at ext points such as valve spindles, where water entry poses many problems, Valve boxes should have a sloping roof design tothe top section ofthe two halves. Hard setting composition or self setting cement May be used if the specification or the engineer deems this practical, which can be used an alternative to metal cladding. Hard setting composition is normally applied in two layers to give a final thickness of approximately 10 mm, The frst layer is left rough to act as a key for the second layer. ‘The final coat is rowelled to a smooth finish. Self setting cement is normally applied in one layer to give a final thickness of approximately 5 mm and is trowelled to a smooth finish. When dry these two materials may be painted with a variety of coatings for indoor or outdoor se. ‘Cold conservation and eryogenie service Preparation ‘This is the same as for heat conservation insulation except in the case of an application of foam glass where checks should be made to ensure the inside layer has been anti abrasive coated. Insulation plus fixing For single layer applications a staggered joint (+150 mm) should be cut fom one half of the insulation, the remaining section will have a bead of joint sealer fitted to the ‘cireunsferential and longitudinal joints. ‘The two sections are then fitted to the pipe, bands are seotred to the correct size and pitches in accordance with the specification requirements. The joint sealer should partially ooze out of the external joints after tensioning of tie banding. Vapour sealer should then be placed over the clip area of the banding to fuily seal any damage caused to the insulation by the compressive strength of the banding clip. ‘Vapour seal Depending upon the specification, a coating of vapour sealer should be applied of a 1 ‘mm thickness to seal the insulation surface, followed immediately by @ layer of open weave, 10 x 10, mesh glass cloth embedded into the vapour sealer ensuring that the overlap is >75 mm. Any wrinkles should be smoothed out ‘A second coat of I mm thickness vapour barrier may be applied not less than 6-8 hours after the first coat and smoothed to a uniform finish to provide a continuous seal ensuring thatthe reinforcing membrane is completely covered, ‘The insulation inspector should inspect the single layer application and the vapour INS4-2 ec e ec ec e ec e€ ec e€ e ecARL 20 co 50 0 0 %0 %0 UNIT INS4+ APPLICATION OF INSULATION Multi-layer applications For multilayer applications the inner layer can be applicd dry and secured by tape of 25 mm wide glass reinforced polyester self adhesive tape st 100 mm centres Oversized sections or radiused and bevelled lags are fitted with a staggered joint, jointing compound, vapour sealer and scrim cloth which are applied in the same manner as for the application of a single layer (on no account should wood or metal skewers be used that will penetrate the insulation as this may cause a cold path). ‘Metal cladding fixing, ‘The application of metal cladding to a cold system is basically the same as a heat conservation system except that the secured system will be banding throughout the cold conservation and eryogenic service. Screws will not be used as they will penetrate the ‘vapour sealer. Acoustic insulation Preparation This isthe same as for heat conservation insulation. Tasulation plus fixing The thickness of insulation required to contol noise pollution will be laid down ia the specification. The choice of insulation in nearly all cases will be mineral wool in the form of section, radiused and bevelled lags or mattress. In addition, lea vinyl sheeting is offen used. ‘The application of the acoustic insulation is the same as for heat conservation, then a lead vinyl sheet is applied over the mineral woo! insulation and overlapped by 75 mm, both circumferentially and longitudinally. The overlaps are then sealed with adhesive and are allowed a tack period of 2-3 minutes before joining, depending upon conditions. Lead vinyl sheeting applied over insulated bends or elbows are installed in overlapping segments cut from templates. ‘The overlaps are as large as is practical but need not exceed 75 mm. Bands are used to draw and tension the vinyl sheets and are removed prior to the metal cladding being fitted ‘Metal cladding fixing For the protection of an acoustic system, the metal cladding application is the same as for a cold conservation system. The securing system is banding throughout. The use of screws for bends, tees etc. may be permitted depending upon the specification. Arye Rncetttay 20 20 30 © days game: firosgua ey ‘ORROSION UNDER IN: ATION For any insulation system to be considered effective at resisting the transfer of heat, itis accepted that this not only comes from the correct selection of insulation material, but also on the assumption it remains dry. (Once an insulation system becomes saturated a number of issues arise notably: ‘*Corrosion under insulation (CUD can start and remain un-detected, ‘Thermal characteristics are compromised, Both of which could lead to loss of efficiency and catastrophie failure. Sources of water can be quite varied but in the main can be identified as: ‘Precipitation ‘sUse of deluge and sprinkler systems ‘*Condensation ‘*Wash down activities steam discharge The point of water: inde 5% usually at one or more breaks within the weather proofing of the xgtem as gresulf of one or more of the following: irons Inadequate design ‘*Mechanical damage ‘incorrect installation ‘Poor maintenance 0 ‘Areas most susceytiffe to CUI will be those operating at temperatures -5° to +200°C and in areas where water is either held in or trapped beneath the insulation. “Te highest rates of corrosion have been found Between +50° to +120°C, for operating temperatures subg, the corosion rats is slow, however opecal attention needs tobe rao prouill @e nebavnton ab Capen Sapa Pipework and vestel: are often insulated, anforhmaely these ae not corrosion and in fact are susceptible to extemal stress corrosion cracking (ESCC). whe Sibu tS p60 sneton External stress corrosion cracking. Usually occurs as a result of transportation of halides such es chlorides through to the steel surface, where they can concentrate due to repeated water evaporation, Protective coatings, It has been recognised that prevention of water into the insulation system has mostly ‘been unsuccessftl, therefore the resistance to corrosion is related to the effectiveness of any protective coatings applied. Specification requirements for coating of carbon stels varies considerably through-out the industry. With any number of paint coatings specified such as: ‘*Epoxyphenolic paints ‘Epoxy high build paints ‘Siloxanes ‘Inorganic zine silicates *Urethanes ‘*Thermally sprayed Aluminium, carmen Boal ntARL Stainless ste! to | These cam also be protected by a numberof products such those listed above, however, those containing low melting point metals should be avoided due to the increased rik of liquid metal assisted cracking, MAC). ee = Ma age Aluminium foils often used to prevent the occurrenes of ESCC, hrs 20 | Whilst great improvements have been made in CUI avaretess and the importance of effective weather proofing for new and remedial insulation work. There is stil a huge amount of in-service pipework and vescels that requires inspecting, on many sites however this would be impractical. Risk Based Inspec » 2 of wp , brink ‘Risk = Probability of faire x consequesce of failure. where: Probability of failure is a score system based on key factors such as; operating 40 | temperature, location, time in servi et. “yw hay Consequence of failure i a score system based on factors such as; likelihood of loss of life, environmental impact, cost of loss of product etc. oe 0 « 0 so * 109 DRROSION te 298631 INS4a-2NEN aen ARL POST NCoea "DUTIES OF AN INSULATION INSPECTOR | ‘The duties of inspection personnel ate gssentially, those inspection duties which the client or employer wants them to A significa problem in industry is that 10 | different organisations use inspection personnel in different ways, or use inspectors for fimctions additional to inspection. For some, this has led to @ misunderstanding as to the defined role of inspection ‘The definition of inspection to BS EN 28402 : 1991 : Quality Vocabulary - "Aetivites such as measuring, examining, testing, geuging one or more characteristics of a 20 | product or service and comparing these with specified requirements to determine p}.re4a) conformity." Kaanbey ‘he definition of inspection to BS EN 45020 : 1993 : Standardization and Related Activities - "Evaluation for conformity by measuring, observing, testing or gauging the relevant characteristics." .. "Evaluation for conformity” is defined in the standard ‘a8: "Systematic examination of the extent to which a product, process or service fulfils Specified requirements.” Inspection may be performed for fimness for purpose or quality control purposes, and ‘may be carried cut by the contractor, the client ora third party. 30 Inspection is not supervision and inspection is not a substitcte for supervision, 40 | It is not the duty of an inspector to deviate from specified requirements; generally ‘The agreed specifections) | Speaking, if the specification is inadequate the work will be inadequate. Inspector Jorthe contact may consist | qualification schemes do not require, or tes: for, a sufficient depth of engineering or ‘sfa combination afeneor | design knowledge which would coable an inspector to pass judgement on the more of ke following: correctness of an application specification. Tt could be argued that experienced + natoneinternationat it it " inspectors may be in a position to take certain engineering decisions, but it is dangerous specication’) 0 Tria rtianeen + ellent specications) See + Job specifications) Accurate reporting is an important duty for any inspecter, but what constitutes an procedure spacification(a) ‘accurate report can differ between organisations and projects. Who the inspector actually reports to is also an important consideration. It should be made clear to all workers, including inspectors, as to what is expected from © | them for the activities they are to perform - this is a basic quality assurance requirement. This is not to say an inspector should not perform duties outside the scope of inspection, this may be acceptable providing the person is competent to perform the work and providing it has been made clear what is required from the outset. Ideally, inspection personel should be issued with relevant procedures and work instuctions to enable them to cary out inépection and associated activities in accordance with the client's or organisation's requirements. The procedures should eave the inspector in no doubt as to what is to be done. Unfortunately, this documentation rarely exists! 80 | An insulation inspector may be requested to carry out the following: a. Participate in the implementation and control of the field construction strategies as they apply to the insulation contractor. b. Participate with the planning staff ia approving the insulation contractor's schedules and associated progress measurement. ©. Monitor and inspect the quality performance against specification requirements including applicable drawings. ‘Monitor the progress of the works against the schedule and plan. ©. Provide technical liaison and clarification, provide solutions to technical queries raised by the contractor with approval ofthe engineering department, £ Participate in the field in the management approach for construction safety, 7 industrial relations and any other special request. n * ‘Art Ruane Lat tee 382 INSS-10 30 0 0 © ” g Establish meaningful working relationships with other departments and develop the necessary level of understanding of their operating procedures, programmes and plans, a8 they apply to the insulation activities. th. Ensure that all suppor facilities, services and materials required in the field by the Contactor are available on a timely basis and are maintained to the specified standards. “Typleal inspector's dues ‘Defoe work commences Determine your duties and responsibilities. Daties may include those which relate to heatth and safety aspects taking into consideration mandatory requirements. ‘You may also be required to check that unused materials are disposed of correctly cor quarantined. Ensue the contractor's supervisor is aware of your duties and authority. Engare you have the correct applicable specification(s) and any data sheets. Also censure you atleast have access to relevant referenced normative documents. Determine the order of precedence for normative documents if the specification does not make it clear. Lear the specification, procedures, work instructions etc. ‘Approach your supervisor if you ae not sure what is insended of any requirement. Ensure you have copies of any applicable documentation, e.g, correspondence, ‘minutes from meetings, concessions et Liaise with the contractor's supervisor to determine whether the contractor's personnel are familiar with the work requirements. “When required, confirm that the contractor's operators are properly trained and conversant with the equipment, materials and application techniques being used. “Agree withthe client/supervsor the level of lisson that is required and determine seporting/recording requirements. Ensure you have test instruments to. that are required and that they are properly calibrated and in correct working order. Inspect the substrate surface for any damage or faults. Inspection would be performed to the degree required by specification/lient. Inspect the substrate surface for any contamination such as grease oF oil Inspection would be performed to the degree required by specification/client. Check that the pipe or vessel surfaces are fiee from moisture prior to any work being carried out and after any inclement weather. | Check that the correct materials are being used - correct type, size and condition. Check that pipe or vessel single layer insulation join's are correcly staggered and tilly buted, wed or banded te te comet size and pitches. ‘Check multi-layer pipe or vessel insulation joints are correctly staggered and tightly butted with no voids or geps. ‘Cheek that bands are correctly pitched, | Check that hold points are observed for stage inspection, e.g. pipe or vessel supports; fist layer application of multi-layer systems. Ensure that any metal cladding applied does not make contact with the clad item and ensure minimum clearances are observed. (Check that minimum overlap requirements are being observed. — INSS-2 aaseeceseeaam naan ae Ar &30 100 UNIT INSS - INSULATION INSPECTI Ensure that any metal cladding applied allows for the shedding of water. Check for sufficient bolt clearance at valves and flanges. The minimum clearance is equal to the stud length +25 mm or as otherwise specified. Inspect for damage. at the end of the day that unprotected insulation is covered over and is Check that single layer pipe or vessel insulation (if foam glass) has been costed with anti-abrasive material, joints correctly staggered and tightly butted with Jointing compound, tape or bands securing the insulation correctly taped or banded to the correct size and pitches, scrim oloth applied end vapour sealed. Check that multi-layer pipe and vessel insulation joints are correctly staggered and tightly butted with jointing compound, banded tothe correct size and pitches, scrim clothed and vapour sealed. First layer of multi-layer insulation can be applied dry. Scrim cloth should be open weave clott: 10 x 10 mesh. It should be overlapped by 75 mm both circumferential and longitudinally and sealed in place with @ vapour barrier in either one or two coats. Min:mum thickness 2 mm. (Size requirements are typical of those required). (Check that nozzles and protrusions are fully insulated, joints correctly staggered and tightly butted with jointing compound taped or bended to the correct size and (ensure they are insulated to their fullest Ensure hold points are strictly observed for stage inspection, ie. are pipe or vessel supports fited, first and/or second stage applicatiors of multi-layer insulation, ‘serim clothed and mastic sealed. When required, attend appropriate meetings, such as periodic on-site meetings or those meetings called to provide solutions t0 a particular problem that has arisen. ‘You may also be in a position where you need to arrange a meeting to resolve problems that have arisen. Ensure that you effectively organise your time so that you are available for inspections when required. Do not give the contractor an excuse to say, "we were ‘waiting forthe inspector to carry out inspection". Check the work area housekeeping. For example, equipment and consumables should be cared for (correctly handled, stored and ma:ntained) and the site should be tidy. ‘On completion of the work/contract, ensure that all records (specifications, procedures, work instruction, permits, concessions, pans, report sheets ete.) are collated and filed in the appropriate location. This is only required when itis your {designated responsibility Do not seek confrontation. Try and avoid arguments. Never be condescending, patronising or arrogant. Remember the main duty of an inspector is to inspect against specified requirements and report findings. If the specification is not clear on a particular requirement, seek advice ffom the scpervisor or client. Do not accept or reject work based on your opinion alone. Be objective at all times. arenas Lat2» 30 0 0 UNIT “The reporting requirements of quality control associaied with insulation work and the actual information recorded can differ considerably from job to job. The datly inspection report is common to most jobs and is often written out on a Daily Inspection ‘Report Form wich bas a format designed by the organisation that you are representing, i.e. the inspection agency, contractor or client. Progress reports are often required and these may have to be produced on plein peper cor on specially designed forms. Ideally, the exact reporting and recording requirements should be specified in a procedure or in the job specification itself. Always liaise with the supervisor or client ‘verify what is required to be recorded or reported. Regardless of specification requirements, the inspector should always make a detailed log. of work performed, observations, selevant conversations and similar; include applicable times, dates, people involved etc.. You may find this information very ‘useful in future disputes. ‘The following list shows the documentation thet may ex'st on a project involving insulation inspection and that which the insulation inspector may be responsible for collating end controlling effectively until inal completion of the work. “The applicable specifications). Procedures and related work instructions. Quality plans. Method statements. Concessions (waiver or variation orders). Daily inspection report forms ‘A daily log (this may be stand-alone document or one in addition 10 a daily inspection report). Lists of remedial action. 3. Progress reports. 9. Minutes of meetings. 10. Correspondence. 11. Calibration certificates. 12. Copies of work permits. 13, Site instructions. 14, Mechanical completion certificates (hold-point release forms or inspection request forms). 15. Audit reports a. Intemal . Extemal. 16. Non-conformance reports. 17. Certificates of conformity. INS6-1ARL 0 3» 0 0 Co 0 0 VB Tea) Tay Careful consideration is required when han¢ling or storing thermal insulation materials ‘especially when confined spaces are involved. Some thermal insulation materials have combustible components that may constitute a fire hazard, therefore these types should not be left exposed or inadequately protected. ‘Thermal insulation materials should always be handled and stored as directed by the specific instructions accompanying the product. ‘The usual risk involved in health hazard meterils is of a biochemical nature in which ‘vapours such as organic solvent fumes and solids may react with body tissues or fluids changing their characteristics and resulting in body malfunction, e.g. vapour sealers ‘may, on skin contact, cause irritation and remove natural body oils from the skin area Fumes may cause ‘dizziness, impaired vision, respiratory difficultics or nerve disturbances. Loose particulate matter especially in the form of fibres may be harmful if inated and ‘may cause respiratory and skin iritation and itching, Cellular glass, isocyanurates, polyurethanes. phenolic foams, calcium silicate, mineral ‘wool on contact may abrade or puncture skin, sheet metal, banding, fasteners or foil backed insulations may cause cus, tears or punctures. Isocyanurates, polystyrenes, polyurethanes, phenolic foams are combustible at elevated temperatures producing toxic smoke and furces. AbaratARE 0 0 0 100 Scope ‘The Control of Substances Hazardous to Health Regulations, 2002, referred to as the COSHH Regulations, define a substance hazardous to health as: + Any substance which is listed in Part 1 of the Approved Supply List as dangerous for supply because it is corrosive, harmful, iritant, toxic or very toxic. Irvitant Toxic Very Toxic + Any preparation (mixture) that is dangerous for supply, as above. + Any substance which has a Workplace Exposure Limit (WEL). + Anybiological agents used at work + Any dust other than one with a WEL at a concentration in air above 10 mg/m? averaged over 8 hours, or any such respirable dust above 4 mg/m? over 8 hours, © Any other substance that ereates a risk to health because of its properties and the way it is used or is present in the workplace. If the packaging has any of the hazard symbols above then it is classed as a hazardous substance. COSHH also covers asphyxiating gases as well as germs that cause diseases such as leptospirosis or legionnaires disease and germs used in laboratories. COSHH however, does not cover lead, asbestos or radioactive substances because these have their own specific regulations. toe} 200601 PI2120 © 80 0 100 NIT P ew International symbols ce Cc Cc e to Dorie. Goo wide. (icomuanetaes = ec ce ce Pimmbl. e e e Loos Tnrm Helth btazuadex caution Oxcdizin New Intemational symbols were introduce in 2009 vie the Regulation on Classification, Labelling and Packaging of Substances and Mtures (CLP Regulation) Sod will replace the European symbols during a tanstionl period. Some of them are Similar to the European symbols but there is no single word describing the hazard Information on these is available on thc Globally larmnonised System webpages. In Great Britain , the implementing legislation is the Chemicals (Hazard Information and Packaging for Supply) Regulations 2009 (known as CHIP or CHIP 4). Although the CHIP Regulations will be repealed in fell in the UK when the new CLP Regulation i fully in force (I Jane 2015), it is also necessary to amend CHIP and its supporting ‘guidance as the transitional period progresses and the new Regulation begins to apply the new Globally Harmonised System regime. ‘The first requirement of COSHH is to prevent exposure to substances hazardous to health where it is ‘reasonably practicable’ (ie. the costs in reducing exposure would not bbe grossly disproportionate to the benefits). This can be achieved by: ‘+ changing the process so that the substance is no longer used/produced; ‘© replacing it with a safer alternative; or © completely enclosing the process. Ant aaneLat see) 30061 PI22 annnonannannnannannann» ’ , , ’ ’ ’ » ’ ’ » » ’ » » » » a + MEL/OES values were quantified in poo (oar ermilion) 0 30 0 30 7 » ” Workplace Exposure Limits EH40/2005 Second Edition 2011 The Guidance note EH40/2005, entitled Workplace Exposure Limits, is a document published by the Health and Safety Executive which gives legally binding workplace exposure limits for substances hazardous to health, ‘The latest edition of EH40 represents a new departure for the setting of, and compliance with, occupational exposure limits (OELs). The previous system, setting OELs as maximum exposure limits (MELs)* and occupational exposure standards (OESs) has been discontinued in favour of a single type of OEL known as the ‘workplace exposure limit (WEL). This new system was introduced on 6 April 2005. WELs are occupational exposure limits (O3Ls) set under COSHH, in order to help protect the health of workers. WELs are concentrations of hazardous substances in the air, averaged over a specified period of time referred to as a time-weighted average (TWA). Two time periods are used: long term (8 hours) and short term (15 minutes). Short-term exposure limits (STELs) are set to help prevent effects, such a8 eye invitation, which may occur following exposure for a few minutes. ‘The changes came about as a result of concerns expressed by HSC's Advisory Committee on Toxic Substances (ACTS) about how well employers and other stakeholders understood OFLs, and about how widely these were being used in industry. Research carried out for HSE showed that those concems were justified. As a result, an ‘ACTS Working Group was given the task of considering a new approach to the setting ‘and use of OELs. FH40/2005 Contents: Foreword; Introduction; List of workplace exposure limits (WELS); Tables 1: List of approved workplace exposure limits; (as consolidated with amendments, December 2011); Supplementary information for table 1; Applying ‘occupational exposure limits; Calculation methods; Monitoring exposure; Mixed ‘exposures; Table 2: Biological Monitorirg Guidance Values; List of synonyms; References, further information. Supplement to EH40/2005 New and revised WELs in force from October 2007, further revision December 2011 On 1 October 2007, the European Commission's 2nd Directive on Indicative Occupational Exposure Limit Values (2006/15/EC) was implemented in Great Britain and Northern Ireland. ‘This directive requires Member States of te European Union to introduce domestic occupational exposure limits for the substances listed in the Annex to the directive ‘Additionally, the level of the domestic limit must take account of the Indicative Occupational Exposure Limit Value (IOELV). ‘The Health and Safety Commission has approved new and revised Workplace Exposure limits (WELs) required to implement the 2nd IOELV Directive that came into foree on 1 October 2007. The second edition of EH40/ 2005 was published in 2011 and has been updated to include new and revised workplace exposure limits introduced by the 3 IOELV Directives in force from 18* December 2C11 and implemented in Great Britain and ‘Northern Ireland. tenes sat PI232 20 0 ” 80 100 Responsibilities ‘The COSHH Regulations aim to protec: workers (and others who may be affected) from the adverse health effects of substances used at work. COSHH obligates employers to assess the risks arising from their use of substances hazardous to health and to take steps to prevent or adequately control exposure. A training organisation is responsible for exposure by trainees. The existing requirements to follow good practice have been brought together by the introduction of eight principles of good practice for the control of exposure to substances hazardous to health and are set out in Schedule 2A of The Control of Substances Hazardous to Health Regulations 2002 (as amended) Approved Code of Practice and guidance. ‘The eight principles are reproduced below: (@ design and operate processes and activites to minimise emission, releese and spread of substances hazardous to health; (©) take into account all relevant routes of exposure — inhalation, skin absorption and ingestion - when developing control measures; (©) control exposure by measures that are proportionate to the bealth @ choose the most effective and reliable control options which minimise the escape and spread of substances hazardous to health; (©) where adequate control of exposure cannot be achieved by other means, provide, in combination with other control measures, suitable personal protective equipment; (® check and review regularly all elements of control measures for their continuing effectiveness; (8) inform and train all employees on she hazards and risks from the substances with which they work and the use of control measures developed to minimise the risks; () ensure thatthe introduction of control measures does not increase the overall risk to health and safety, IE employers apply the principles correctly, exposure should be below any relevant WEL. Control by personal protective equipment shculd only be used when other ‘measures are not reasonably practicable. The list of WELs applies to concentrations of hazardous substances breathed in by the worker and are used to determine the adequacy of control measures. There are several publications which give advice and guidance on ‘what is required under the COSHH Regulations. some Pizepewweerewrwvrewer eee er eee ee ee ee ee ee eee ee He ARE 2» » 0 30 Eo 0 0 AIM OF QUALITY ASSURANCE. ‘The aim of quality assurance is to improve quality whilst keeping costs to an acceptable level. ‘The objective of a system used to implement quality assurance, ie. a quality system, is to determine and rectify the root cause(s) of any problems, thereby reducing faults and wastage. This will in tun, improve quality and reduce costs. The emphasis is on prevention rather than detection and care. BENEFITS OF ADOPTING QUALITY ASSURANCE, A properly implemented and managed quality system shoulé: help to ensure thatthe company fecuses on market needs and requirements; , make the company moro competitive in the market place due to an increased customer confidence in the company’s output, i.e. a product or service that a customer wants, this includes timing; {ead to a reduction of costs due to a reduced number of faults and wastage; 4. give a measure of performance which will enable any areas for improvement to be identified; induce a more organized way of thinking which makes management more organized and effective; £. provide motivation; motivated employees provide a better working environment in addition to the product or service outpu: benefits. ‘WHAT IS QUALITY ASSURANCE? ‘The definition for quality assurance given in the British Standard for quality vocabulary (BS 4778 : Part I)is: “All those planned or systematic acticns necessary to provide adequate confidence that a produce or service will satisfy given requirements for quality’ ‘The quality of a product or service is attained only by working in a controlled manner, following formalised procedures which are designed to eliminate the occurrence of problems. Quality assurance provides the objective evidence needed to give maximum confidence for quality. Quality assurance should be considered as a management foo! when used within an organization (intemal quality assurance). A supplier who implements and maintains a system for assuring quality, is providing maximam confidence to a purchaser, or poteatial purchaser, that the supplied product or service attains, or is going to attain, its ‘tness for purpose. Different people have different concepts for what is meant by a quality product or service, therefore it is very important to be aware of the customers’ requirements and/or expectations. In industrial contract situations, contract documents or purchasing specifications should clearly define a company's requirements fo- a product or service. ‘The quality of the product or service is deemed to have been achieved when the exact requirements have been met completely and consistently. (oars Rae at ‘aes sant Qart0 » 50 o oy SCOPE OF QUALITY ASSURANCE Quality assurance should encompass all parts of an organization and all phases of an activity, ie. planning, design, production, maintenance, administration etc. Collaboration with suppliers and purchasers should also be part of an organization's quality system. INSPECTION VS QUALITY ASSURANCE, Quality assurance is not inspection. Inspection is one of the important elements within a system for quality assurance which requires continuing eveluation in the same way as the other elements, eg. planning, design/specifications, production etc. Inspection is defined in BS 4778 : Part I as, ‘activities such as measuring, examining, testing, gauging one or more characteristics of a product or service and comparing these ‘with specified requirements to determine conformity’. INSPECTION VS QUALITY CONTROL Quality control is defined in BS 4778 : Part 1 as “the operational techniques and ‘ctivitis thet are used to fulfil requirements “or quality’. This definition can be vague, so modifying the term to be more specific is advantageous, e.g. manufacturing quality control is more explanatory. Quality contro is involved with the monitoring of a process and eliminating the causes of any deficient output with any process, or any phase during a contract, which has an effect on quality. The information obtained from inspection, as defined above, is used for quality contro. QUALITY CONTROL VS QUALITY ASSURANCE ‘The comparison between quality control aad quality assurance is more difficult to explain because of different beliefs between experts. Assumptions are also made regarding the applicability of the term quality control, eg. is it referring to manufactering quality control or company-wide quality control? Quality control deals with the actual measurement of quality performance, this performance is compared against what is required, and acticn is taken on the difference. ‘Quality control is asking the question “is the worl/action being performed correctly?” Quality control does not reach all elements which affect quality, e.g. quality control will rarely do anything to correct problems relating to management, documentation, training, and staff motivation. Quality assurance applies to all areas which have an affect cn quality and asks the ‘question, “has the work/ection been performed correctly?” QA STANDARDS BS 5750 [ISO 9000 series} — Quality systems. BS4778 — Quality vocabulary. BS 7229 ~ Quality systems auditing Arm nanetat ae S006 QaL2 SHMAHHMNANKRKMARARAAARAAAAAAARAAAE aaeaananmweewwewweewwewrwe ewe ewe we ewe ee we ew wo 10 » 30 100 |B Normative document: Document tht provides rules, guidelines or characterises foracaivites or thei reat, ‘Note: The term normative document is a generic term that covers such documents. ts standaris, taint. spectfeaions, codes of practice and. regulations [180 GUIDE 2 & EN 45020) g Standard: Document, established by consensus and approved by a recognized body, that provides, for common end repeated use, rules, guidelines or characteristics for activities or their results, aimed at the achievement of the optimum degre of order ina given context. (150 GUIDE 2 & EN 45020). Code of practice: Document tat recommends practices or procedure forthe deni, mamfacare, togalaton, malciennoe ‘or zation of equipment, structres or products, Note: A code of practice may'b standard apart of «standard or independent of standard, {ISO GUIDE 2 & EN 4502¢]. Specification: ‘The document that presoribes the requirements with which the product or service has to conform. as] Cm A specification should refer to or inckude drawings, pattems or other relevant documents and should also indicate the means and the criteria whereby conformity can be checked [BS 4778 : PART 1]. Technical specification: Document that prescribes technical requirements to be fulfilled by a product, process or service. Note: A technical specification should indicate, wherever appropriate, the procedure(s) by means of which it may be determined whether the requirements ‘given are fulfilled, A technical specification may be a standard or part of a standard or independent ‘of a standard (ISO GUIDE 2 & EN 45020] Regulation: Document providing bind:ng legislative rules, this is adopted by an authority. Note: An authority is a body that has Jegal powers and rights [ISO GUIDE 2 & EN 45020). Procedure (1): Specified way to perform an activity [ISO 8402 & ISO 10005}. Procedure (2): A written description of all essential parameters and precautions to be observed when applying inspection or a test method to a specific item or quantity of items, following an established standard, code or specification. [ICORR REQ DOC], Instruetion: Provision that conveys an action to be performed (ISO GUIDE 2 & EN 45020]. Written instruction: A detailed written description of the inspection(s) or test(s) to be performed [ICORR REQ DOC] wal =—wet Ge @ END Arpt Rane tat toed 200681 ast