INSULATION

INSPECTOR

IMechE Engineering Training Centre

4 Europa View
Sheffield Business Park T: +44 (0)114 399 5720
Sheffield E: [email protected]
W: trainingsolutions.imeche.org
S9 1XH
 NOTES TABLE OF CONTENTS

INTRODUCTION................................................................................................... INS1
Types of insulation ....................................................................................... INS1-1
Inspection duties ......................................................................................... INS1-1
INSULATION SYSTEMS ........................................................................................ INS2
Thermal insulation........................................................................................ INS2-1
Acoustic impedance ...................................................................................... INS2-2
CODING FOR INSULATION ............................................................................... INS2A
INSULATION MATERIALS .................................................................................... INS3
Insulation ................................................................................................... INS3-1
Protective coverings ..................................................................................... INS3-2
Fixing materials ........................................................................................... INS3-4
Storage of materials ..................................................................................... INS3-4
APPLICATION OF INSULATION ........................................................................... INS4
INSULATION INSPECTION................................................................................... INS5
Duties of an insulation inspector ..................................................................... INS5-1
REPORTING ......................................................................................................... INS6
HEALTH AND SAFETY (1) ..................................................................................... INS7
HEALTH AND SAFETY (2) ...................................................................................... P12
Scope ........................................................................................................... P12-1
Responsibilities .............................................................................................. P12-1
Occupational Exposure Limits (EH40 – January 2002).......................................... P12-1
Volatile organic compounds ............................................................................. P12-2
Health and safety data sheet ........................................................................... P12-3
QUALITY ASSURANCE ........................................................................................... QA1
Aim of quality assurance ................................................................................ QA1-1
Benefits of adopting quality assurance ............................................................. QA1-1
What is quality assurance? ............................................................................. QA1-1
Scope of quality assurance ............................................................................. QA1-2
Inspection vs quality assurance ....................................................................... QA1-2
Inspection vs quality control ........................................................................... QA1-2
Quality control vs quality assurance ................................................................. QA1-2
QA standards................................................................................................ QA1-2
NORMATIVE DOCUMENTS ..................................................................................... QA8

© Institution of Mechanical Engineers

Issue 2 30/01/03
 UNIT INS1  INTRODUCTION

NOTES 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
10 used for either of these purposes may be referred to as thermal
insulation.
Insulation may also be
Thermal insulation may be required more specifically for the following:
used to retain noise.
This type of insulation 1. Safety (personal protection).
is called acoustic
insulation. 20 2. Hot and cold conservation (precious resources).
3. 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:
1. Mineral wool.
30
2. Calcium silicate.
3. Rigid phenolic foams.
4. Cellular (foamed) glass.

40 INSPECTION DUTIES
It is 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,
50 '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
60 preferably be written permission.
The following list gives an overview of duties applicable to an insulation
inspector:
a. Obtain or gain access to the specification(s).
b. Learn the specification(s).
70
c. Get to know the plant.
d. Get to know the personnel.
e. Check that all concerned understand the specification.
f. Keep the engineer/supervisor informed at all times of any
departure from the specification.
80 g. Conduct and/or attend site meetings.
h. Determine the days work programme with the contractor's senior
personnel.
i. Check the materials.
j. Determine whether the work meets the specification
requirements.
90 k. Check for any application faults.
l. Make written reports at an agreed frequency.

100

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 UNIT INS2  INSULATION SYSTEMS

NOTES THERMAL INSULATION

Thermal insulation is defined in BS 3533 as "a material or system that
has the property of resisting the transfer of heat".
10
The thickness of insulation required will be primarily governed by the
The heat capacity of type of insulating material used (especially its heat capacity), the heat
a body of any kind
capacity of the product, the heat capacity of the pipework etc., the
is defined as the
heat required to flow rate of the product in the system (vessels, pipework etc.) and the
raise its temperature requirement for the product.
temperature by 1K. 20
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 common
terminology used for insulation that will retard the transfer of heat
30
energy from the insulated 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.
Hot insulation may be used on external surface of pipework to keep
the temperature of the product in the pipework high enough for the
40
product to flow, or flow at a higher rate than it would at ambient
temperatures for production cost reasons.
Hot insulation may also be used to protect personnel or plant from
high temperatures.

50
Common materials used for hot insulation systems include:
a. Calcium silicate:< 1000°C.
b. Mineral wool: < 850°C.
c. Foam glass: < 430°C.
d. Polyisocyanurate:< 140°C.
60

Cold insulation
Cold insulation, although not defined in BS 3533, is common
terminology used for insulation that will retard the transfer of heat
energy from the insulated system when the temperature in the system
70 is lower than ambient 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:
80
a. Foam glass: > -270°C.
b. Polyisocyanurate:> -145°C.
c. Polyurethane: > -100°C.

90
Protection against condensation
The application of the insulation can prevent condensation at the
surface of a containing vessel, pipework etc., but it will not necessarily
prevent moisture being drawn through the insulation itself. The dew
point may be reached within the insulation and it can become
100 saturated if it is applied to a cold surface; this will affect the heat
insulation properties and its mechanical strength.

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 UNIT INS2  INSULATION SYSTEMS

NOTES 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
10 fittings will minimise gaps in the insulation to reduce the susceptibility
to rupture.
Vapour barriers are applied to these insulation systems to prevent or
reduce the ingress of moisture.
Frost protection
20
If the outside temperature remains low enough for long enough, and
the movement of product through the pipe or vessel is slow, then
freezing or excessive cooling may occur. Insulation may delay the
onset of freezing or excessive cooling.
The time taken for a liquid to reach freezing point under given
30 conditions of temperature difference will depend on the heat capacity
of the product, the heat capacity of the pipework, vessel etc. and the
heat capacity of the insulation.
Small diameter pipes and other items are more vulnerable to freezing
compared to larger items, therefore small diameter pipes etc. require
40 a greater thickness of insulation for protection against frost conditions
than do larger diameter pipes etc.

ACOUSTIC INSULATION
Acoustic insulation may be applied to piping, especially those pipes in
50
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 exposure to high
noise levels which can induce hearing loss.
The use of mineral wool of a high density in the form of pipe sections,
lags or mattresses is commonly used to considerably reduce noise
60
levels. The thickness of insulation will depend upon the dB rating.
Lead vinyl sheeting may be used over the mineral wool, it is then
protected by metal cladding. Lead vinyl sheeting consists of glass
cloth impregnated with loaded vinyl with an average thickness of ~
1.4 mm. It is usually supplied in 1 m x 1 m sheets and usually
70
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.

80 Insulation may be applied to ventilation ducts where quiet air

conditioning is required.

90

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 UNIT INS2A  CODING FOR INSULATION

NOTES 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 identification number, e.g. HC 40 P140361.
10 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
20
ED Electric trace - dual
EH Electric trace - hot
EHO Electric trace - hot oil
FP Frost protection
HC Heat conservation
HO Hot oil
30 HS Hot sour (gas)
MT Maintenance of temperature
PP Personnel protection

Cold insulation:
AC Acoustic cold or Anti-condensation?
40 C Cold
CB Cold burn
CC Cold conservation
CS Cold sour (gas)
EC Electric trace cold (below 100°C)
MC Maintenance of cold temperature
50
Heat conservation
(HC) insulation to surfaces of pipes and vessels normally operating at
temperatures greater than 60°C, where any leakage of heat is considered
to be loss of energy.

60
Cold conservation
(CC) insulation to surfaces of pipes and vessels normally operating at
temperatures less than -10°C, where any leakage is considered to be loss
of energy.
Personnel protection
70 (PP) insulation to surfaces normally operating at temperatures greater
than 55°C 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 at temperatures
80 less than -10°C, where any leakage of heat is 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.
90
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
100 (MC) insulation to surfaces of pipes and vessels containing fluids where
the need to maintain process temperatures is more important than CC.

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 UNIT INS3  INSULATION MATERIALS

NOTES The materials used in insulation may be divided into three types:
1. Insulation.

10
2. Protective coverings.
3. Fixings.

INSULATION
There are many types of insulation which exist, however, there are
20
four main types commonly used in industry:
1. Mineral wool.
2. Calcium silicate.
3. Rigid phenolic foams.
4. Cellular glass.
30
Mineral wool
This fibre is made from minerals such as rock, slag or glass, processed
from a molten state and bonded with an organic binder suitable for
the operational temperature ranges of most plant, it is non-
combustible and is in frequent use both onshore and offshore, it is
40
supplied as pre-formed pipe sections, lags and slabs and in a flexible
form 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 650°C.
Calcium silicate
50
This thermal insulation is composed principally of hydrous calcium
silicate and material fibres. Calcium silicate though extensively used
now tends to give way to mineral wool as it is relatively cheaper but
can perform the same tasks as calcium silicate, but not in the case of
super heated systems. By nature calcium silicate is more able to cope
60 over longer periods of maintenance before being replaced, it is for this
reason that the power industries favour this material. It is supplied
as pre formed pipe sections, lags and slabs. Calcium silicate displays
permanent shrinkage after exposure to high temperatures and may
require expansion joints to limit gaps. This material operates at a
temperature of 0°C to 982°C.
70
Rigid phenolic foams
The exceptionally high level of closed cell and the fine cell structure
gives this material excellent thermal properties. It is one of the most
efficient thermal insulation materials commercially available, being
based on a phenolic resin. This has been used throughout Europe,
80
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. It is available in pre-formed pipe
sections, lags and slabs, other uses for this material are to insulate
90 tankers for the road and rail industries.
Cellular glass (foamed glass)
This material consists of a glass composition that has been foamed or
cellulated under molten conditions, annealed and set to form a rigid
incombustible material with hermetically sealed cells.
100
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.

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 UNIT INS3  INSULATION MATERIALS

NOTES 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 temperatures between -268°C
10 and 427°C. It is supplied in pre-formed pipe sections, lags and slabs
available in two grades governed by compressive strength and
density.
Polyisocyanurate
Polyisocyanurate foam is similar to standard rigid urethane but is
20 denser and has better fire proofing and insulation properties, whilst
maintaining all the characteristics and advantages of rigid urethane.
Polyisocyanurate is able to withstand temperatures between -140°C
and 140°C.
Perlite
30 This thermal insulation material has an additional property in that the
binder used contains sodium silicate, long recognised as a corrosion
inhibitor. More than 50% of the sodium silicate binder in the WR1200
system is used to protect metal surfaces against corrosion. This
product is fairly new to the United Kingdom construction industry. It
operates at a temperature of up to 1200°C and at present there are
40
no United Kingdom long term performance records available, however
current reports indicate a good performance at high temperatures.
Vermiculite
This thermal insulation material has been used mainly as a fire
proofing agent for structural steel in high fire risk areas of the
50
petrochemical industry.
Vermiculite is a micaceous mineral which is mined and processed to
produce a high purity concentrate. This concentrate in the form of
flakes of varying size and thickness, is expanded in a high temperature
furnace to produce a slab form which is then cut and angled to suit
60
any shape of angular frame work. A compound also exists to fill any
voids or gaps.
Austenitic stainless steel cladding is usually used to protect the
vermiculite.
70 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:
a. Cork insulation (cold work).
80
b. Fibreglass (heating systems).
c. Polystyrene (chilled water).
d. Polyurethane (process).
e. Foil backed insulation (undercover process).
f. Fibreboard (roofing).
90 g. Lamellar mattress (industry).
h. High temperature fibre blanket (refractory).
i. Spray applied fibrous thermal insulation for high temperature
(turbines).
j. Ceramic (furnaces).
k. Glass rope (steam tracing).
100
Insulation compound is sometimes used with calcium silicate and is
formed from a powder containing mineral fibres which, when mixed
with water, is used for repairs and sealing joints between sections,

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 UNIT INS3  INSULATION MATERIALS

NOTES lags or slabs and where performed shapes are impracticable.

Insulation compound has a temperature range up to ~800°C.
PROTECTIVE COVERINGS
10
Protective coverings are to protect the insulation and include:
1. Vapour seals.
2. Metal cladding.
3. Hard setting composition or self setting cement.
20
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
insulation system. Vapour sealer is normally applied by gloved hand,
trowel or float.
30
A number of manufacturers have differing coating sealers which may
consist of any of the following:
a. acrylic latex;
b. solvent based vinyl polymer;
c. polyvinyl acetate;
40
d. hypalon;
e. elastomeric polymers;
f. basic mastic solutions.
Vapour sealer may have an interposed open weave glass cloth (10 x
10 mesh).
50
Metal cladding
The reasons for applying metal cladding to insulation may be as
follows:
1. To give appropriate protection against mechanical damage.
60
2. To protect against water, snow, airborne deposits, sunlight or
ozone.
3. To assist in identifying the pipe or vessel by either painting with a
characteristic colour by means of coloured bands at intervals. This
identification also may be used to indicate the direction of a
70 process flow.
4. To give protection against spillage of oils and other flammable
liquids.
5. To improve appearance or to provide a surface that can be easily
cleaned.
80
6. To retard or if possible to prevent the spread of flame.
7. To protect against chemical attack, vermin and mould growth.
Metal cladding is available in aluminium, galvanised mild steel, aluzinc
alloy and austenitic stainless steel. It is normally available in
thicknesses: 0.5 mm, 0.7 mm and 0.9 mm.
90
Metal cladding should be arranged to shed water, swaged and mastic
sealed at overlaps both circumferencially and longitudinally, screwed
or banded at the correct size and pitches.
Metal cladding is usually supplied in flat sheet form in various sizes,
100 e.g. 2 m x 1 m or 2.4 m x 1 m. Coiled sheeting is not normally used
on sites but restricted to large metal shops at home office bases.

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 UNIT INS3  INSULATION MATERIALS

NOTES Fabrication of cladding for fittings is usually carried out on site.

Materials used are in the form of general pipe cladding, bends, tees,
dome ends, valve and flange boxes. These are arranged to shed water
10 at the job face and are mastic sealed after fitting.
Hard setting composition & self setting cement
Hard-setting composition is defined in BS 3533 as 'Clay-bound
finishing material that is supplied in loose dry form, prepared for
application by mixing with water and dried by the application of heat.'
20
Self setting cement is defined in BS 3533 as 'Finishing material, based
on Portland, cement that is supplied as a dry powder and, when mixed
with water in suitable proportions, will set without the application of
heat.'
Self-setting cement is used to protect calcium silicate insulation which,
30
when mixed with clean water, affords a smooth surface as a final finish
for heated surfaces up to a temperature of 650°C.
Self-setting cement is composed of mineral fibres and fillers mixed
with a water based binder which will set between two and four hours.
It is applied wet by either gloved hand, trowel or float and is smoothed
40 using insulator steels.
These coatings may be used over a wire mesh reinforcement.
May also be used as protective coverings as an alternative to metal
cladding in certain circumstances.
50
FIXING MATERIALS
Fixing materials are used to hold down insulating materials and
protective coverings, the following may be used:
Wire netting - used to hold down insulation but only used with hard
60 setting or self setting cement as a protective covering.
a. Binding wire.
b. Binding tape.
c. Fixing bands.
d. Self-tapping screws.
70
e. Nuts, bolts and other fastenings.
f. Adhesives.
g. Anti-abrasion compound.
h. Joint sealant.
Note: Self tapping screws should never be used on a cold work
system. Penetration of the vapour barrier may in time lead to the
80
ingress of moisture and water particularly on columns and vessels at
high elevations; the situation could be worsened by fog/mist in high
winds.

STORAGE OF MATERIALS
90 Insulating materials should be stored in weather proof buildings or
enclosures.
Ensure boxes containing sections or segments of insulation are stored
end up. Cartons or packs of mattresses or slabs should be laid flat.

100
Metal cladding on pallets are stored inside a building or are fully
covered over with weather proof material; this will help prevent any
water entering the ends of the rolls by capillary action which could
otherwise cause water staining.

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 UNIT INS3  INSULATION MATERIALS

NOTES Jointing compounds, mastics, etc. should be stored in accordance with

the manufacturer's recommendations which is typically at a
temperature not less than 5°C.
10
Banding and lacing wires, clips, screws and pop rivets should be stored
in clean containers.

20

30

40

50

60

70

80

90

100

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 UNIT INS4  APPLICATION OF INSULATION

NOTES APPLICATION
The following sequences of operation are typical of those that may be
encountered:
10
Heat conservation and protection
1. Preparation.
2. Insulation plus fixing.
3. Repeat insulation plus fixing if required.
20 4. Metal cladding plus fixing, or self setting compound or hard setting
cement.
Cold conservation and cryogenic service
1. Preparation.
2. Insulation plus fixing.
30
3. Repeat insulation plus fixing if required.
4. Vapour seal.
5. Metal cladding.
Acoustic insulation
40 1. Preparation.
2. Insulation plus fixing.
3. Repeat insulation plus fixing if required.
4. Metal cladding plus fixing
50 Heat conservation and protection
The values given in Preparation
the text are typical Prior to any work taking place, the insulation inspector should check to
specified requirements
and are intended to
ensure that foulings do not interfere with the application of insulation
give the reader an or create a hot path. Foulings can include hand rails, cable trays,
instant view of how 60 adjacent piping, plant and equipment and structural steel.
insulation is applied.
Always consult the The substrate should be inspected to ensure it is free of oil, grease,
specification for soils, splashes or spillage and free of moist or wet areas.
precise requirements.
Where required, support clamps should be fitted.
70 The insulation material should be thoroughly dry and free of any
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
80 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 at the correct size and pitches in
accordance with the specification requirements.
90
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 which is then
arranged to shed water. A circumferentially male swaged seam is fitted
100
50 mm to one end of the cladding with a half folded lipped edge to the
longitudinal seam. Banding is secured to the cladding and drawn tight.

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 UNIT INS4  APPLICATION OF INSULATION

NOTES provide a continuous seal ensuring that the reinforcing membrane is

completely covered.
The insulation inspector should inspect the single layer application and
10 the vapour sealer separately (stage inspections).
Multi-layer applications
For multi-layer applications the inner layer can be applied dry and
secured by tape of 25 mm wide glass reinforced polyester self adhesive
tape at 100 mm centres. Oversized sections or radiused and bevelled
20
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).
30 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 cryogenic service.
Screws will not be used as they will penetrate the vapour sealer.
40
Acoustic insulation
Preparation
This is the same as for heat conservation insulation.
Insulation plus fixing
50 The thickness of insulation required to control noise pollution will be laid
down in 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, lead vinyl sheeting is often used.
The application of the acoustic insulation is the same as for heat
60 conservation, then a lead vinyl sheet is applied over the mineral wool
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.
70 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.
80 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.
90

100

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 UNIT INS4  APPLICATION OF INSULATION

NOTES The overlapping seam should be not less than 50 mm when secured by
either the banding or screws in accordance with the specification
requirements.
10 Overlaps are normally placed in position of pitches at either two o'clock
or ten o'clock on 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 mm bead
20
minimum thickness.
Fittings such as bends, tees and metal segments of dome ends shall be
weather proofed in the same manner. Valve and flange boxes shall
have all seamed joints fully sealed, particular care should be taken at
exit points such as valve spindles, where water entry poses many
problems. Valve boxes should have a sloping roof design to the top
30
section of the 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 as an alternative to metal cladding.
40 Hard setting composition is normally applied in two layers to give a final
thickness of approximately 10 mm. The first layer is left rough to act
as a key for the second layer. The final coat is trowelled to a smooth
finish.
Self setting cement is normally applied in one layer to give a final
50 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 use.
Cold conservation and cryogenic service
60 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
70 For single layer applications a staggered joint (>150 mm) should be cut
from one half of the insulation, the remaining section will have a bead
of joint sealer fitted to the circumferential and longitudinal joints.
The two sections are then fitted to the pipe, bands are secured to the
correct size and pitches in accordance with the specification
80 requirements. The joint sealer should partially ooze out of the external
joints after tensioning of the banding. Vapour sealer should then be
placed over the clip area of the banding to fully seal any damage caused
to the insulation by the compressive strength of the banding clip.
Vapour seal
90 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 a 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.
100 A second coat of 1 mm thickness vapour barrier may be applied not less
than 6-8 hours after the first coat and smoothed to a uniform finish to

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Issue 2 15/01/10 INS4-2
 UNIT INS4a  CORROSION UNDER INSULATION

NOTES For any insulation system to be considered effective at resisting the

transfer of heat, it is accepted that this not only comes from the
correct selection of insulation material, but also on the assumption it
10 remains dry.
Once an insulation system becomes saturated a number of issues arise
notably:
 Corrosion under insulation (CUI) can start and remain un-
detected.
20
 Thermal characteristics are compromised.
Both of which could lead to loss of efficiency and catastrophic failure.
Sources of water can be quite varied but in the main can be identified
as:
30
 Precipitation
 Use of deluge and sprinkler systems
 Condensation
 Wash down activities
40
 Steam discharge
The point of water ingress is usually at one or more breaks within the
weather proofing of the system as a result of one or more of the
following:
50  Inadequate design
 Mechanical damage
 Incorrect installation
 Poor maintenance
60
Areas most susceptible 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.
The highest rates of corrosion have been found between +50° to
+120°C, for operating temperatures sub-zero, the corrosion rate is
70
slow, however, special attention needs to be paid to protrusions or
where there is a transition to ambient temperature. Stainless steel
pipework and vessels are often insulated, unfortunately these are not
immune to corrosion and in fact are susceptible to external stress
corrosion cracking (ESCC).
80

External stress corrosion cracking.

Usually occurs as a result of transportation of halides such as chlorides
through to the steel surface, where they can concentrate due to
repeated water evaporation.
90

Protective coatings.
It has been recognised that prevention of water into the insulation
system has mostly been unsuccessful, therefore the resistance to
100
corrosion is related to the effectiveness of any protective coatings
applied.

© Institution of Mechanical Engineers

Issue 3 30/06/11 INS4a-1
 UNIT INS4a  CORROSION UNDER INSULATION

NOTES Specification requirements for coating of carbon steels varies

considerably through-out the industry. With any number of paint
coatings specified such as:
10  Epoxy/phenolic paints
 Epoxy high build paints
 Siloxanes
 Inorganic zinc silicates
20
 Urethanes
 Thermally sprayed Aluminium.

Stainless steels
30
These can also be protected by a number of products such as those
listed above, however, those containing low melting point metals
should be avoided due to the increased risk of liquid metal assisted
cracking, (LMAC).

40 Aluminium foil is often used to prevent the occurrence of ESCC.

Whilst great improvements have been made in CUI awareness and the
importance of effective weather proofing for new and remedial
insulation work. There is still a huge amount of in-service pipework
50 and vessels that requires inspecting, on many sites however this would
be impractical.

Risk Based Inspection

60

Risk = Probability of failure x consequence of failure.

where:
Probability of failure is a score system based on key factors such as;
70 operating temperature, location, time in service etc.
Consequence of failure is a score system based on factors such as;
likelihood of loss of life, environmental impact, cost of loss of product
etc.

80

90

100

© Institution of Mechanical Engineers

Issue 3 30/06/11 INS4a-2
 UNIT INS5  INSULATION INSPECTION

NOTES DUTIES OF AN INSULATION INSPECTOR

The duties of inspection personnel are essentially those inspection
duties which the client or employer wants them to perform. A
10 significant problem in industry is that different organisations use
inspection personnel in different ways, or use inspectors for functions
additional to inspection. For some, this has led to a misunderstanding
as to the defined role of inspection.
The definition of inspection to BS EN 28402: 1991 : Quality Vocabulary
20 - "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."
The definition of inspection to BS EN 45020: 1993: Standardization
and Related Activities - "Evaluation for conformity by measuring,
observing, testing or gauging the relevant characteristics."...
30
"Evaluation for conformity" is defined in the standard as: "Systematic
examination of the extent to which a product, process or service fulfils
specified requirements."
Inspection may be performed for fitness for purpose or quality control
purposes, and may be carried out by the contractor, the client or a
40 third party.
Inspection is not supervision and inspection is not a substitute for
supervision.
It is not the duty of an inspector to deviate from specified
The agreed
specification(s) for the 50
requirements; generally speaking, if the specification is inadequate
contract may consist of the work will be inadequate. Inspector qualification schemes do not
a combination of one or require, or test for, a sufficient depth of engineering or design
more of the following: knowledge which would enable an inspector to pass judgement on the
 national/international correctness of an application specification. It could be argued that
specification(s)
experienced inspectors may be in a position to take certain
 client specification(s)
 job specification(s) 60 engineering decisions, but it is dangerous to generalise on this point.
 procedure
specification(s)
Accurate reporting is an important duty for any inspector, but what
constitutes an accurate report can differ between organisations and
projects. Who the inspector actually reports to is also an important
consideration.
70 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
80 competent to perform the work and providing it has been made clear
what is required from the outset.
Ideally, inspection personnel should be issued with relevant
procedures and work instructions to enable them to carry out
inspection and associated activities in accordance with the client's or
organisation's requirements. The procedures should leave the
90
inspector in no doubt as to what is to be done. Unfortunately, this
documentation rarely exists!
An insulation inspector may be requested to carry out the following:
a. Participate in the implementation and control of the field
100 construction strategies as they apply to the insulation contractor.

© Institution of Mechanical Engineers

Issue 3 15/10/09 INS5-1
 UNIT INS5  INSULATION INSPECTION

NOTES b. Participate with the planning staff in approving the insulation

contractor's schedules and associated progress measurement.
c. Monitor and inspect the quality performance against specification
10 requirements including applicable drawings.
d. Monitor the progress of the works against the schedule and plan.
e. Provide technical liaison and clarification, provide solutions to
technical queries raised by the contractor with approval of the
engineering department.
f. Participate in the field in the management approach for
20 construction safety, industrial relations and any other special
request.
g. Establish meaningful working relationships with other
departments and develop the necessary level of understanding of
their operating procedures, programmes and plans, as they apply
to the insulation activities.
30 h. Ensure that all support facilities, services and materials required
in the field by the contractor are available on a timely basis and
are maintained to the specified standards.

40
Typical inspector's duties
Before work commences
1. Determine your duties and responsibilities. Duties may include
those which relate to health and safety aspects taking into
consideration mandatory requirements. You may also be required
to check that unused materials are disposed of correctly or
50
quarantined.
2. Ensure the contractor's supervisor is aware of your duties and
authority.
3. Ensure you have the correct applicable specification(s) and any
data sheets. Also ensure you at least have access to relevant
60
referenced normative documents.
4. Determine the order of precedence for normative documents if the
specification does not make it clear.
5. Learn the specification, procedures, work instructions etc.
6. Approach your supervisor if you are not sure what is intended of
70
any requirement.
7. Ensure you have copies of any applicable documentation, e.g.
correspondence, minutes from meetings, concessions etc.
8. Liaise with the contractor's supervisor to determine whether the
contractor's personnel are familiar with the work requirements.
80
9. When required, confirm that the contractor's operators are
properly trained and conversant with the equipment, materials and
application techniques being used.
10. Agree with the client/supervisor the level of liaison that is required
and determine reporting/recording requirements.
90
11. Ensure you have test instruments etc. that are required and that
they are properly calibrated and in correct working order.
Insulation application
1. Inspect the substrate surface for any damage or faults. Inspection
would be performed to the degree required by specification/client.
100

© Institution of Mechanical Engineers

Issue 3 15/10/09 INS5-2
 UNIT INS5  INSULATION INSPECTION

NOTES 2. Inspect the substrate surface for any contamination such as grease
or oil. Inspection would be performed to the degree required by
specification/client.
10 3. Check that the pipe or vessel surfaces are free from moisture prior
to any work being carried out and after any inclement weather.
4. Check that the correct materials are being used - correct type, size
and condition.
5. Check that pipe or vessel single layer insulation joints are correctly
20 staggered and tightly butted, wired or banded to the correct size
and pitches.
6. Check multi-layer pipe or vessel insulation joints are correctly
staggered and tightly butted with no voids or gaps.
7. Check that bands are correctly pitched.
30 8. Check that hold points are observed for stage inspection, e.g. pipe
or vessel supports; first layer application of multi-layer systems.
9. Ensure that any metal cladding applied does not make contact with
the clad item and ensure minimum clearances are observed.
10. Check that minimum overlap requirements are being observed.
40 11. Ensure that any metal cladding applied allows for the shedding of
water.
12. Check for sufficient bolt clearance at valves and flanges. The
minimum clearance is equal to the stud length +25 mm or as
otherwise specified.
50 13. Inspect for damage.
14. Check at the end of the day that unprotected insulation is covered
over and is secure.

Inspection specific to cold insulation

60
1. Check that single layer pipe or vessel insulation (if foam glass) has
been coated 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 cloth applied and vapour sealed.
70 2. Check that multi-layer pipe and vessel insulation joints are
correctly staggered and tightly butted with jointing compound,
banded to the correct size and pitches, scrim clothed and vapour
sealed. First layer of multi-layer insulation can be applied dry.
3. Scrim cloth should be open weave cloth 10 × 10 mesh. It should
be overlapped by 75 mm both circumferentially and longitudinally
80
and sealed in place with a vapour barrier in either one or two coats.
Minimum thickness 2 mm. (Size requirements are typical of those
required).
4. Check that nozzles and protrusions are fully insulated, joints
correctly staggered and tightly butted with jointing compound
90 taped or banded to the correct size and pitches. Scrim clothed and
vapour sealed (ensure they are insulated to their fullest extent).
5. Ensure hold points are strictly observed for stage inspection, i.e.
are pipe or vessel supports fitted, first and/or second stage
applications of multi-layer insulation, scrim clothed and mastic
100 sealed.

© Institution of Mechanical Engineers

Issue 3 15/10/09 INS5-3
 UNIT INS5  INSULATION INSPECTION

NOTES Miscellaneous
1. When required, attend appropriate meetings, such as periodic on-
site meetings or those meetings called to provide solutions to a
10 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.
2. 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 for the inspector to carry out
20
inspection".
3. Check the work area housekeeping. For example, equipment and
consumables should be cared for (correctly handled, stored and
maintained) and the site should be tidy.
4. On completion of the work/contract, ensure that all records
30
(specifications, procedures, work instruction, permits,
concessions, plans, report sheets etc.) are collated and filed in the
appropriate location. This is only required when it is your
designated responsibility.
5. Do not seek confrontation. Try and avoid arguments. Never be
40 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 from the supervisor or client. Do not
accept or reject work based on your opinion alone. Be objective
at all times.
50

60

70

80

90

100

© Institution of Mechanical Engineers

Issue 3 15/10/09 INS5-4
 UNIT INS6  REPORTING

NOTES The reporting requirements of quality control associated with

insulation work and the actual information recorded can differ
considerably from job to job. The daily inspection report is common
10 to most jobs and is often written out on a Daily Inspection Report Form
which has 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 plain paper or on specially designed forms.
20 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
30 make a detailed log of work performed, observations, relevant
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 that may exist on a project
40 involving insulation inspection and that which the insulation inspector
may be responsible for collating and controlling effectively until final
completion of the work.
The applicable specification(s).
1. Procedures and related work instructions.
50
2. Quality plans.
3. Method statements.
4. Concessions (waiver or variation orders).
5. Daily inspection report forms.
60 6. A daily log (this may be stand-alone document or one in addition
to a daily inspection report).
7. Lists of remedial action.
8. Progress reports.
9. Minutes of meetings.
70
10. Correspondence.
11. Calibration certificates.
12. Copies of work permits.
13. Site instructions.
80 14. Mechanical completion certificates (hold-point release forms or
inspection request forms).
15. Audit reports
16. Internal.
17. External.
90 18. Non-conformance reports.
19. Certificates of conformity.

100

© Institution of Mechanical Engineers

Issue 3 17/03/08 INS6-1
 UNIT INS7  HEALTH AND SAFETY

NOTES Careful consideration is required when handling or storing thermal

insulation materials especially when confined spaces are involved.
Some thermal insulation materials have combustible components that
10 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 materials is of a biochemical
20 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
difficulties or nerve disturbances.
30
Loose particulate matter especially in the form of fibres may be
harmful if inhaled and may cause respiratory and skin irritation and
itching.
Cellular glass, isocyanurates, polyurethanes, phenolic foams, calcium
silicate, mineral wool on contact may abrade or puncture skin, sheet
40
metal, banding, fasteners or foil backed insulations may cause cuts,
tears or punctures.
Isocyanurates, polystyrenes, polyurethanes, phenolic foams are
combustible at elevated temperatures producing toxic smoke and
fumes.
50

60

70

80

90

100

© Institution of Mechanical Engineers

Issue 3 30/06/10 INS7-1
 UNIT P12  COSHH REGULATIONS

NOTES SCOPE
The Control of Substances Hazardous to Health Regulations,
10 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, irritant,
20 toxic or very toxic.

30

40
Corrosive Harmful Irritant

50

60 Toxic Very Toxic

 Any preparation (mixture) that is dangerous for supply, as

above.
 Any substance which has a Workplace Exposure Limit (WEL).
 Any biological agents used at work.
70  Any dust other than one with a WEL at a concentration in air
above 10 mg/m3 averaged over 8 hours, or any such respirable
dust above 4 mg/m3 over 8 hours.
 Any other substance that creates a risk to health because of its
properties and the way it is used or is present in the workplace.
80
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
90
substances because these have their own specific regulations.

100

© Institution of Mechanical Engineers

Issue 10 15/02/11 P12-1
 UNIT P12  COSHH REGULATIONS

NOTES New International symbols

10

20

30

40

50

60
New International symbols were introduced in 2009 via the Regualtion
on Classification, Labelling and Packaging of Substances and Mixtures
(CLP Regulation) and will replace the European symbols during a
transtional 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 the Globally Harmonised System webpages.
70
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
full in the UK when the new CLP Regulation is fully in force (1 June
2015), it is also necessary to amend CHIP and its supporting guidance
80
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’ (i.e. the costs
90 in reducing exposure would not be grossly disproportionate to the
benefits).

This can be achieved by:

 changing the process so that the substance is no longer
100 used/produced;
 replacing it with a safer alternative; or
 completely enclosing the process.

© Institution of Mechanical Engineers

Issue 10 15/02/11 P12-2
 UNIT P12  COSHH REGULATIONS

NOTES Workplace Exposure Limits (EH40/2005)

10 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
20 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.
30
WELs are occupational exposure limits (OELs) 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).
40 Short-term exposure limits (STELs) are set to help prevent effects,
such as eye irritation, which may occur following exposure for a few
minutes.

The changes came about as a result of concerns expressed by HSC's

50
Advisory Committee on Toxic Substances (ACTS) about how well
employers and other stakeholders understood OELs, and about how
widely these were being used in industry.

Research carried out for HSE showed that those concerns were
justified. As a result, an ACTS Working Group was given the task of
60 considering a new approach to the setting and use of OELs.

EH40/2005 Contents: Foreword; Introduction; List of workplace

exposure limits (WELs); Tables 1: List of approved workplace
exposure limits; Table 2: Biological monitoring guidance values;
70
Supplementary information for table 1; Setting exposure limits;
Applying occupational exposure limits; Calculation methods;
Monitoring exposure; Mixed exposures; List of synonyms; References.

Supplement to EH40/2005 New and revised WELs in force from

80 October 2007

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.

90
This directive requires Member States of the 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).
100

The Health and Safety Commission has approved new and revised
Workplace Exposure limits (WELs) required to implement the 2nd
IOELV Directive that came into force on 1 October 2007

© Institution of Mechanical Engineers

Issue 10 15/02/11 P12-3
 UNIT P12  COSHH REGULATIONS

NOTES Responsibilities

10 The COSHH Regulations aim to protect 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.
20
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
30
guidance.

The eight principles are reproduced below:

(a) design and operate processes and activities to minimise emission,

40 release and spread of substances hazardous to health;
(b) take into account all relevant routes of exposure – inhalation, skin
absorption and ingestion – when developing control measures;
(c) control exposure by measures that are proportionate to the health
risk;
(d) choose the most effective and reliable control options which
50
minimise the escape and spread of substances hazardous to
health;
(e) where adequate control of exposure cannot be achieved by other
means, provide, in combination with other control measures,
suitable personal protective equipment;
60 (f) check and review regularly all elements of control measures for
their continuing effectiveness;
(g) inform and train all employees on the hazards and risks from the
substances with which they work and the use of control measures
developed to minimise the risks;
(h) ensure that the introduction of control measures does not increase
70 the overall risk to health and safety.

If employers apply the principles correctly, exposure should be below

any relevant WEL. Control by personal protective equipment should
only be used when other measures are not reasonably practicable. The
80 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.

90

100

© Institution of Mechanical Engineers

Issue 10 15/02/11 P12-4
 UNIT QA1  QUALITY ASSURANCE

NOTES AIM OF QUALITY ASSURANCE

The aim of quality assurance is to improve quality whilst keeping costs
to an acceptable level.
10
The objective of a system used to implement quality assurance, i.e. a
quality system, is to determine and rectify the root cause(s) of any
problems, thereby reducing faults and wastage. This will in turn,
improve quality and reduce costs. The emphasis is on prevention
rather than detection and cure.
20

BENEFITS OF ADOPTING QUALITY ASSURANCE

A properly implemented and managed quality system should:
a. help to ensure that the company focuses on market needs and
requirements;
30
b. make the company more 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;
c. lead to a reduction of costs due to a reduced number of faults and
40 wastage;
d. give a measure of performance which will enable any areas for
improvement to be identified;
e. induce a more organized way of thinking which makes management
more organized and effective;
50
f. provide motivation; motivated employees provide a better working
environment in addition to the product or service output benefits.

WHAT IS QUALITY ASSURANCE?

60 The definition for quality assurance given in the British Standard for
quality vocabulary (BS 4778: Part 1) is:
‘All those planned or systematic actions necessary to provide adequate
confidence that a produce or service will satisfy given requirements for
quality’.
70 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.
80
Quality assurance should be considered as a management tool when
used within an organization (internal quality assurance). A supplier who
implements and maintains a system for assuring quality, is providing
maximum confidence to a purchaser, or potential purchaser, that the
supplied product or service attains, or is going to attain, its fitness for
90 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
100
specifications should clearly define a company’s requirements for a
product or service. The quality of the product or service is deemed to

© Institution of Mechanical Engineers

Issue 2 30/01/03 QA1-1
 UNIT QA1  QUALITY ASSURANCE

NOTES have been achieved when the exact requirements have been met
completely and consistently.

10 SCOPE OF QUALITY ASSURANCE

Quality assurance should encompass all parts of an organization and all
phases of an activity, i.e. planning, design, production, maintenance,
administration etc. Collaboration with suppliers and purchasers should
also be part of an organization’s quality system.
20

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
evaluation in the same way as the other elements, e.g. planning,
30 design/specifications, production etc.
Inspection is defined in BS 4778: Part 1 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’.
40

INSPECTION VS QUALITY CONTROL

Quality control is defined in BS 4778: Part 1 as ‘the operational
techniques and activities that are used to fulfil requirements for quality’.
This definition can be vague, so modifying the term to be more specific
50 is advantageous, e.g. manufacturing quality control is more explanatory.
Quality control 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 control.
60

QUALITY CONTROL VS QUALITY ASSURANCE

The comparison between quality control and quality assurance is more
difficult to explain because of different beliefs between experts.
Assumptions are also made regarding the applicability of the term quality
70 control, e.g. is it referring to manufacturing 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
action is taken on the difference. Quality control is asking the question
80 “is the work/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 on quality
90 and asks the question, “has the work/action been performed correctly?”

QA STANDARDS
BS 5750 [ISO 9000 series] – Quality systems.
100 BS 4778 – Quality vocabulary.
BS 7229 – Quality systems auditing.

© Institution of Mechanical Engineers

Issue 2 30/01/03 QA1-2
 UNIT QA8  NORMATIVE DOCUMENTS

NOTES 1. Normative document: Document that provides rules, guidelines

or characteristics for activities or their results.
Note: The term normative document is a generic term that covers
10
such documents as standards, technical specifications, codes of
practice and regulations. [ISO GUIDE 2 & EN 45020]
2. Standard: Document, established by consensus and approved by
a recognized body, that provides, for common and repeated use,
rules, guidelines or characteristics for activities or their results,
20 aimed at the achievement of the optimum degree of order in a
given context. [ISO GUIDE 2 & EN 45020].
3. Code of practice: Document that recommends practices or
procedures for the design, manufacture, installation, maintenance
or utilization of equipment, structures or products.
30 Note: A code of practice may be a standard a part of a standard
or independent of a standard. [ISO GUIDE 2 & EN 45020].
4. Specification: The document that prescribes the requirements
with which the product or service has to conform.
A specification should refer to or include drawings, patterns or
40 other relevant documents and should also indicate the means and
the criteria whereby conformity can be checked [BS 4778: PART
1].
5. Technical specification: Document that prescribes technical
requirements to be fulfilled by a product, process or service.
50 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]
60 6. Regulation: Document providing binding legislative rules, this is
adopted by an authority.
Note: An authority is a body that has legal powers and rights [ISO
GUIDE 2 & EN 45020].
7. Procedure (1): Specified way to perform an activity [ISO 8402
70 & ISO 10005].
8. 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].
80 9. Instruction: Provision that conveys an action to be performed
[ISO GUIDE 2 & EN 45020].
10. Written instruction: A detailed written description of the
inspection(s) or test(s) to be performed [ICORR REQ DOC].

90

100

© Institution of Mechanical Engineers

Issue 2 30/01/03 QA8-1