Download - 1.4 Advanced PFP Seminar 11 2011.pdf
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Advanced insulation & fire protection systems to the oil and gas industry
Asaf Hisherik – Upstream Surface Engineering Bill Rivers – General Manager USA
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• Introduction
• Part 1 - Technical background
• Part 2 - Passive Fire Protection systems
• Part 3 – Site Application
• Q & A Session
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Advanced Insulation Systems , formerly known as Alderley Materials Ltd, specialises in the manufacture and supply of unique phenolic resin based syntactic foam insulation and flexible Passive Fire Protection (PFP) systems.
AIS is a single source for insulation and fire protection systems to the oil and gas industry and represents one of the most respected and progressive names in topside and subsea insulation worldwide. AIS offers a wide range of products to meet the growing demand for fire protection systems adaptable for elevated service temperatures and pressures.
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AIS provides a complete ‘supply and apply’ service for
all passive fire protection and insulation needs:
• Sourcing and supply of materials
• Shipping and site logistics
• Worldwide application and manpower supply using own pool of qualified certified applicators
• Verifiable audited performance records for the entire contract
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Gloucester
(UK)
Leeds
(UK)
Abu Dhabi & Dubai
(UAE)
Aktau
(Kazakhstan)
Houston
(USA)
Singapore
(Asia)
• Head Office
Gloucester (UK)
• Research & Development Gloucester (UK) •Manufacturing Gloucester (UK) Leeds (UK) Dubai (UAE)
• Sales Gloucester (UK) Abu Dhabi & Dubai (UAE) Singapore Houston (US) Aktau (KZ)
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• Quality Management LRQA ISO9001 - 2008
• Environmental Management LRQA ISO 14001
• Occupational Health and Safety BS OHSAS 18001
The above ISO certification include the manufacture, supply and apply of insulation and fire proofing products and services.
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AIS qualified products are now used worldwide by major oil and gas companies and by their contractors.
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Offshore
Platforms/ Vessels
Subsea
LNG
Onshore
Market Segments
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Vessel Insulation/ Protection
Deck Insulation/ Protection
Valves/ ESDV/ Flange Insulation /Protection
Process Pipe Work Pipe Support
Offshore Applications
Hot Riser Insulation/ Protection
Blast Wall & Blast wall Coating
Cold Splash/ Thermal Shock Insulation Protection
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Cable Tray Protection
Storage Tank Protection
Process Pipe work
Onshore Facilities
Junction Box Insulation/ Protection
Valves/ ESDV/ Flange Insulation Protection
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Structural Thermal Shock Insulation Protection
Jetty
Storage Tank Protection
Process Pipe Work
LNG
Spill Reservoir / Tranches Insulation Protection
Tranches/ spill reservoir PFP
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Demonstrate the benefits of utilizing integrated thermal
insulation and PFP system on structural, processing and
Civil applications
My Aim…..
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Part 1 – Technical Background
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The purpose of applying fireproofing is to provide temporary
protection until such time when fire fighting systems and loss control measures may be employed.
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Loss control systems measures may include:
• Depressurization of vessels
• De-inventory of vessels
• Isolating fuel flow/limiting fuel availability shutting down units
• Actuating suppression/exposure
• Active cooling systems
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BS EN ISO 13702: 1999, Petroleum and Natural Gas
Industries – Control and mitigation of fires and
explosions on offshore production installations –
Requirements and guidelines
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API RP 14C - Safety Analysis for Production
Platforms
Specifies the requirements for the analysis, design, installation and testing of surface safety systems for offshore production platforms.
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• Valve will be limited to a maximum surface temperature of
200°C for the duration of a 60 minute jet fire.
• Actuator will be limited to a maximum surface temperature of
100°C for the duration of a 60 minute jet fire.
• The protection will be provided up to and including the
conductor hang-off flange and seal arrangements.
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• BS EN ISO 13702 indicates that a typical critical temperature for structural steel is 400°C.
• PFP systems shall resist a blast overpressure of 800mbar and provide the full specified fire performance after the blast.
Typical Design Requirements – Offshore
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• The liquefied petroleum gases exist as gases at normal temperatures and pressures but can be liquefied under moderate pressure.
• If the pressure is subsequently released, the LPG again becomes gaseous. If an LPG vessel is involved in a fire, it may overheat and rupture violently giving an intensely hot fireball and may project pieces of the vessel over considerable distances.
• Such a rupture is commonly termed a Boiling Liquid Expanding Vapour Explosion (BLEVE)
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Fire tests are performed on fireproofing materials to measure the level of
Protection provided by a particular fireproofing system (including material,
thickness, application method, etc.).
The fireproofing material aimed at protecting steel structures and supports from reaching 538 C for a period of 3 hours based on a fire exposure as defined by UL 1709.
Underwriters Laboratories has developed a test protocol to simulate hydrocarbon fire exposures. This test protocol is UL 1709 and is intended to approximate fire exposures that may be expected in a process plant.
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Industry Design Fire Curves
Cellulosic Curve
* Max Temp. ** Erosive Force
“A” Category – ISO834 1000 C° at 90-100 min
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H - Curve
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“H” Category – UL1709 1000 C° at 7 min
* Max Temp. ** Erosive Force
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Pool Fire
Image from Sandia National Laborites
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Cellulosic Curve
“J” Category – 1350 C° at 2-5 min
* Max Temp. ** Erosive Force
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Jet Fire Testing - ContraFlex®
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Part 2 – Passive Fire Protection Systems
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• An intumescent is a substance which undergoes a chemical reactions as a result of heat exposure, thus increasing in volume, and decreasing in density
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Stage 1
• HEAT Source > React to heat > chemical reaction will start at around 65-80°C.
Stage 2
• Reaction > Material turns soft > emits gases and intumesce & expand into carbonaceous char
Stage 3
• Protection /Insulation > The char provide insulation that restrict the rate of temp rise of the steel. Char has to resist jet fire erosion when exposed to JF.
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ContraFlame® is a multifunctional composite system based on
unique phenolic syntactic foam and phenolic glass reinforced
laminate.
Truly passive fire protection
• No chemical reaction • No change in physical dimension • No change in density • No change in material micro-structure
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Diameter = 40 - 177µm
Glass or ceramic microspheres
Actual microspheres at 200x magnification
non porous
excellent water and vapour resistance
chemically stable
can be surface modified
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Property Value
Compressive Strength @ 20oC 18.3 MPa
Expansion Co-efficient 20.7 x 10-6
Temperature resistance From -196°C to 185°C
Blast overpressure resistance 4.2 bar
Standard thickness 34mm
Thermal Conductivity @ 20oC 0.054 Wm-1K-1
Flammability Zero (No spread of flame)
Smoke Generation Negligible
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Features Epoxy Intumescent ContraFlame
Jet Fire Protection Certified Certified
Thermal Insulation Low High
Thermal Conductivity 0.213 W/mK 0.05 W/mK
Service Temp Range -30°C to +80°C -196°C to +185°C
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ContraFlame® Lloyds certification JF120
1. LR Certificate of Fire Approval JF120 SAS F100180 M1.pdf 2. ContraFlame report v2 pdf.pdf
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ContraFlame Blast Testing 4.2 bar
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Key Features • Lloyds certify Jet Fire (J120) Rated phenolic syntactic foam • Lloyds certify Blast Protection (4.2 bar) • Superior Thermal insulation/protection (0.05WmK) • Wide service temp. (-196°C to +185°C) • Close Cell structure (i.e no water absorption) • Durable and impact resistance • Proven to eliminate CUI
JF120 Lightweight Fire Protection & Insulation
Uses:
• Hot risers • Hot three phase separators • Hot slug catchers • Under decks insulation/protection • Top deck spill /blast protection • Flare stacks • Steel structures that are subject to thermal shock, e.g. LNG plants, jetty • Process pipework and equipment
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Jet Fire Rated Precast Shells
Key Features • Closed cell structure, Pre-cast Insulation/Passive Fire Protection (PFP) for pipe work (size 1" - 36“) including bends, tees, reducers • Rapid, dry installation • Demountable and reusable • J120 Jet fire approved, blast resistance • Superior insulation properties (0.05 Wm-1 K-1) • Wide tolerance to elevated and low service temperatures, (+185°C to -196°C) • Designed to accommodate heat tracing on pipe work
• Flare Stacks • Risers • Insulated Pipe works size 1” - 36” • Pipe work which requires regular inspection • Pipe work requiring heat conservation /personal protection
Typical Application
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Jet Fire Rated Precast Enclosures
Key Features • Integrated Insulation and Passive Fire Protection to J60 or H Rating • Provision of bespoke Construction / configuration to suit protected element • Durable Construction to withstand service and environmental conditions • Complete onsite construction, world wide service • Wide tolerance to elevated and low service temperatures (+185°C to – 196°C) • Truly passive fire protection, material does not undergo any chemical change in the course of the fire • Tested at Spadeadam and verified by 3rd party technical consultancy • Self supported and do not require framing (no steel components) • Cable and pipe penetration can be installed post construction
Typical Application • Valves bodies • Actuators • ESDV • Flanges (short base / long base) • Riser Clamps • Pipe supports • Fire Pumps
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JF120-200 Riser Protection
Key Features Integrated Insulation and Passive Fire Protection to J120 High integrity corrosion protection with joint less corrosion barrier suitable for splash and tidal zone Long term resistance to wave action and debris impact Durable Construction to withstand service and environmental conditions Field joint application can be done on site or offshore Ambient Cure, no specialised curing procedures or equipment Low Heat Transfer Coefficient (U-Value) = 0.91 Wm-2K-1 at 96mm Wide tolerance to elevated & low service temperatures (+185°C to -196°C) • ContraFlame JF120-200 meets Total Specification GS SAF 337 • ContraFlame® JF120-200 system carries jet fire certification for • Use on process equipment, risers and pipework • Maximum temperature rise after 2 hour tubular jet fire = 64°C • Lloyds certification SAS F060240 • Tested on riser system with Hp/A up to 161m-1
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Deck Insulation / Protection
Key Features • Integrated Insulation and Passive Fire Protection to J120 or H rating • Provision of bespoke thermal insulation (e.g. control U value) for cellar decks, cantilever decks and associated structural components • Durable Construction to withstand service and environmental conditions • Complete onsite construction, world wide service including offshore • Ambient cure, no specialised curing procedures or equipment • Wide tolerance to elevated and low service temperatures (+185°C to – 196°C) • Truly passive fire protection, material does not undergo any chemical change in the course of the fire • Lloyds certification SAS F100180/M1 structural steel jet fire protection • Suitable for close proximity to accommodation blocks due to zero release of smoke and low spread of flame
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• Jet Fire (J120) Rated Flexible Protection Jackets • Blast Protection (2.57 bar overpressure) • Superior Thermal insulation/protection (back face temperature rise, following 120 min of 1350°C (jet fire) = 122.9°C
Jet Fire (J120) Rated Flexible Protection Jackets
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Designed for jet fire, hydrocarbon pool fire and simple insulation / personnel protection duties
Able to deal with gas cloud / flammable vapour issues
Jet fire resistance for two hours; back face temperature rise only 122.9°C
Blast overpressure resistance 2.57bar
Thermal conductivity 0.032W/m.K
Temperature resistance from -60°C to 1,350°C
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• Personal Protection Jackets (PP) • Typical Thickness of 50mm & 75mm • Superior Thermal insulation/protection • Weight range 9.0 -9.5 kg/m² at 50mm
ContraFlex® Light PP Insulation Jackets
Standard (-36° to +260° C)
High (-36° to +550° C)
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• Tested to ISO 22899-1 standard and certified by Lloyds Register (certificate number: SAS F090134)
• Thinner construction – two thirds thickness of conventional systems
• Weight reduction
• Tailor-made
• manufactured anywhere in the world
• Simplified installation technique
• Full technical support
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cover:
• Designed to withstand environmental exposure – temperature, weather, marine conditions
• Coated or impregnated silica and fibreglass fabrics finished according to operating temperature conditions
Insulation material:
• Different materials selected at thickness appropriate to thermal need, e.g. microporous silica (220-280kg/m3), needle mat
ContraFlex® – Construction
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• Critical selection, vital to withstand temperature exposure, e.g. knitted stainless steel wire mesh, high temperature glass cloth
Fastenings:
• Easy to remove yet resistant to environmental exposure and tampering
• Inner jacket wired and riveted
• Outer jacket uses high temperature Velcro and stainless steel clips
ContraFlex® – Construction
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ContraFlex® - Key Features
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• Valves and Actuators
• Flanges
• Cable trays, conduits and instrument lines
• Electrical junction boxes and circuitry
• Air receivers
• Process vessels
• Hot Pipework
ContraFlex® – Typical Applications
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Jebel Ali, Dubai
Mussafah, Abu Dhabi
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Property Value
Jet fire resistance (ISO 22899-1) J120 (standard thickness)
Back face temperature rise 122.9°C
Temperature resistance From -60°C to 1,350°C
Blast overpressure resistance 2.57bar
Standard thickness 61mm
Thermal Conductivity 0.032W/m.K
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Client: Eastern Bechtel Co Ltd
Location: Abu Dhabi, UAE
Scope of supply: Flexible fireproofing solution to instrument junction boxes.
Minimum requirements: Fire proofing had to be designed and tested to be suitable for 1,100°C hydrocarbon fire for one hour with the internal junction box temperature not exceeding 120°C.
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Part 3 – Site Application
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Set up – Tools
Contraflame ® - Wet Application
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Set up – Steel Preparation
Contraflame ® - Wet Application
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Set up – Surface Preparation
Contraflame ® - Wet Application
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Stage 1 – Tie Coat
Contraflame ® - Wet Application
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Stage 1 – Tie Coat – 150 micron
Contraflame ® - Wet Application
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Stage 2 – C50
ContraFlame ® - Wet Application
C50 mixing process
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Stage 2 – Material Mixing
Contraflame ® - Wet Application
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Stage 2 – Material Applying
Contraflame ® - Wet Application
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Stage 2 – Material Applying
Contraflame ® - Wet Application
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Stage 2 – Material tampering
Contraflame ® - Wet Application
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Stage 2 – Material tampering
Contraflame ® - Wet Application
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Stage 2 – Material Curing
Contraflame ® - Wet Application
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Stage 3 – Multi Layer Outer Coat D2004
Contraflame ® - Wet Application
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Stage 3 – Multi Layer Outer Coat D2004 Contraflame ® - Wet Application
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Stage 3 – Multi Layer Outer Coat D2004
Contraflame ® - Wet Application
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The Finished System - Vessel
ContraFlame ® - Wet Application
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The Finished System - Risers
ContraFlame ® - Wet Application
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Leave surfaces rough
Old laminate ground back
Old C50
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Contraflame ® - Wet Application Sanha Processing Columns
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Client: PT McDermott
Operator: ConocoPhillips
Location: South Natuna Sea, Indonesia
Storage capacity: 1m barrels
Throughput: 500m ft2 gas and 100k barrels of oil and condensate, up to 24,140 barrels of LPG per day
Scope of supply: Passive fire protection for 25 process vessels; total area approx. 4,500m2 plus 1.2km of pipework. The tallest column is 175ft.
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Half Shells
Contraflame ® - Pre Cast Shells & Enclosures
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Half Shells Bands and Tees
Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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Contraflame ® - Pre Cast Shells & Enclosures
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For further details and support, please contact
Asaf Hisherik
Advanced Insulation Systems Ltd.
Mobile: + 44 (0) 7824 845 910
Office: + 44 (0) 1453 512 144
email: [email protected]
Web : www.aisplc.com
Advanced Insulation Systems Ltd
Registered office: Station Road, Berkeley, Gloucestershire GL13 9RL, UK
Registered in England: 02405903
Tel: ++44 (0)1453 511600 Fax: ++44 (0)1453 810108
Website: www.aisplc.com
Sales: [email protected]