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Flexible Fire Protection Jackets
www.aisplc.com
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Overview
Many applications in the oil, gas and petrochemical industries require flexible, user-friendly fire
protection systems that can be easily fitted without specialist tools. For ease of maintenance such
systems should be simple to remove and refit, yet be of durable construction and able to withstand
the rigours of service duty.
ContraFlex® is a range of tailor-made flexible protection jackets developed by Advanced Insulation.
ContraFlex® is designed to provide high performance thermal insulation and protection from jet
and / or hydrocarbon fire to equipment which requires frequent maintenance access.
ContraFlex®
Flexible Protection Jackets
Contents
Overview...........................................2
Design Criteria...................................4
Typical Applications...........................5
Jet Fire Performance..........................6
Hydrocarbon Fire Performance.........8
Blast Performance...........................10
Insulation Performance...................11
Rating Description
J120 Jet fire rated ≤ 120 min
H30/H60 – Assemblies Hydrocarbon rated ≤ 60 min
H60/H120 – Structures Hydrocarbon rated ≤ 120 min
IS Static insulation jacket for temperatures from -36°C to +260°C
IS HT Vibration insulation jacket for temperatures from -36°C to +650°C
Blast Resistance Up to 2.15 bar
ContraFlex® Performance
Bespoke Service
To meet the requirements of the client,
Advanced Insulation offers a full bespoke
service, which includes survey, design,
manufacture and installation.
Survey
Advanced Insulation provides a total
environmental lifecycle support for ContraFlex®
from design to disposal. As a part of the initial
survey we offer to dismantle and dispose
of any existing fire protection in order to fit
ContraFlex®.
Design
The ContraFlex® design team utilises Lectra
software integrated with Carlson proprietary
software for 3D product realisation and the
operation of 32’ cutting table installed in a
mobile production unit.
Manufacture
ContraFlex® is manufactured in the form of a
jacket, usually 50-61 mm thick. The thickness of
the jacket can vary to suit the requirements of
the application. Manufacture can be undertaken
either at Advanced Insulation’s facilities or,
where appropriate, at a project site anywhere in
the world.
The ContraFlex® team is headed up by a
principal fabrics engineer who has over ten
years experience in the manufacture of the
flexible jackets and an understanding of their
applications within the oil and gas industry.
Installation
Full installation instructions are supplied with
each jacket, detailing how the components fit
together around the protected structure. The
jackets are held in place by simple fastening
systems, such as stainless steel fixings and
/ or Velcro straps. Both ContraFlex® and the
fixings are designed to be easily removable
for maintenance, yet are suitable to withstand
exposure at the site.
Contraflex® Mobile Production Unit
Fabric cutting table
Stainless Steel I.D Plates
Production Centre
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ContraFlex® flexible protection jackets can be readily adapted for use in a variety of applications,
such as:
Valves and actuators
Welding nodes
Manways
Cable trays, conduits and instrument lines
Motorised actuators
Junction boxes
Air receivers
Process vessels
Hot equipment exhausts
Localised protection
Design Criteria
The maximum surface temperatures given in the table below are widely used in upstream offshore installations
as default values in determining the passive fire proofing (PFP) requirements for critical equipment which requires
protection in order to allow it to fulfil its function in an emergency. These PFP requirements form an integral part of
fire and explosion and mitigation philosophy.
Process equipment and piping (vessels, columns, heat exchangers, etc.)
likely to contain gaseous, liquid or liquefied hydrocarbon< 350
Riser sections, pipelines and ESDV’s, flanges < 200Riser supports < 400Fire pumps, essential generator < 200
Processing Equipment
Structural Elements
Welding Nodes < 400Bulkhead < 400Vessel Skirt /Vessel Support < 400Deadweight support < 400
Junction boxes and motorised actuators < 100
Cable trays, conduits and instrument lines Umbilical Breakout < 100
TUTU (i.e. Topside Umbilical Termination Unit) < 100
Electrical & Instrumentation
ContraFlex® capability
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ContraFlex®
Design Criteria
Type of equipment Maximum Surface Temperature (°C)
J120 H30
H60
H60
H120
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Process Equipment
While the individual operators’ standards vary, the manufacturers specify that the maximum operating temperature of
pneumatic and hydraulic valve actuators is 130°C and of motor operated valve actuators 110°C. The ContraFlex® jackets
have H30 temperature rise of 11°C and J30 temperature rise of only 30°C. This allows for ambient temperature of
equipment of over 55°C and the maximum temperature of equipment in direct sunlight can reach 85°C.
Structures
ContraFlex® is typically used to protect riser clamps, pipe supports and pipelines to ensure that the surface temperature
is maintained below 400°C during a J60/J120 event. The bespoke design and fixings enable ContraFlex® jackets to
be secured to large structures when required. Each segment of a jacket is designed to be easily handled by one or
two people and incorporates lift points to enable individual segments to be lowered to the ground. Weight of each
segment is clearly marked on it.
3. Electrical & Instrumentation
ContraFlex® fire protection for electrical junction boxes is designed to restrict internal temperature rise and to protect
the junction box from overheating. ContraFlex® has world leading ΔT of 11°C for H30 rating.
Riser ESDV Check Valves
Vessel Protection Pipe Support
Junction Box Mounting Actuator with access panel
Large Diameter Structure
Control panel protection
ContraFlex®
Typical Applications
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Key Features
Tested to International Standard ISO 22899-1
Third party certified by Lloyds Register, ABS
Approved by State Fire Department of the Republic of Kazakhstan
Proven capable of withstanding temperatures of 1,350°C for two hours with the back face temperature rising by only 123°C
Proven capable of withstanding blast overpressures resistance of 2.15 bar
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ContraFlex®
Jet Fire Performance
ContraFlex® is tested to both the International Standard ISO 22899-1 “Determination of the Resistance to Jet Fires of
Passive Fire Protection Materials, Part 1: General Requirements” and to the guidance criteria of the Health and Safety
Executive, Offshore Technology Report OIT 95 634 “Jet Fire Resistance Test of Passive Fire Protection Materials”.
The test specimen, which was 61 mm thick, was subjected to a propane jet fire with an average mass flow rate of
0.296 kg/s1 with a heat flux equivalent to 350 kW/m2 and maximum temperature of 1,350°C (2,462°F). The average
temperature rise above ambient (ΔT) was:
Property Value
Jet fire resistance (ISO 22899-1) J120
Back face temperature rise (J120) 123°C
Temperature resistance From -50°C to 1,350°C
Blast overpressure resistance 2.15 bar
Standard thickness 61mm
U Value 0.061 W/m K
Mass 12 kg/m2
Lloyds Register certificate SAS F090134
ABS Certificate (PDA) 12-LD843417A-PDA
ContraFlex® Jet Fire Performance
Jet Fire Duration Average Temperature RiseJ30 ΔT 17°C
J60 ΔT 37.5°C
J90 ΔT 68.5°C
J120 ΔT 123°C
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ContraFlex® has undergone a series of jet
fire resistance tests lasting in excess of
120 minutes. These tests were applied
to both tubular and planar test specimens
made of carbon steel and protected with
ContraFlex® passive fire protection system.
The test was undertaken in accordance
with the International Standard ISO 22899-
1 “Determination of the Resistance to Jet
Fires of Passive Fire Protection Materials,
Part 1: General Requirements”. The
thermal and mechanical loads applied to
the material by the jet fire as defined in
this standard are similar to those created
in large-scale jet fires resulting from high-
pressure releases of natural gas.
The facility used for this test is
independently certified by Lloyds
Register for compliance with BS EN ISO/
IEC 17025:2000. The ContraFlex® jet fire
test was witnessed by representatives of
Lloyds Register.
Key Results
ContraFlex® J120 test specimen was
subjected to a propane jet fire with
an average mass flow rate of 0.297
kg/s-1
The maximum temperature rise
recorded in the specimen by the end
of the test was 123°C.
After the test, ContraFlex® jacket
appeared to have suffered only
minimal damage to the outermost
layer of material. Each of the two
circumferential joints and the axial
joint remained intact.
ContraFlex® J120 – Pre test
ContraFlex® J120 – During jet fire impingement
ContraFlex® J120 – Post 120 minutes of jet fire
ContraFlex®
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Jet Fire Performance
ContraFlex® has been tested and certified to the International Standard UL1709:2005 thermal
programme and has been proven to withstand hydrocarbon fire temperatures of 1,100°C for up
to one hour, therefore ideal for the protection of junction boxes, actuators and similar assemblies
which include corners, edges and openings.
Stahl 316 SS junction box was encased in ContraFlex® jacket with removable panel to enable
access to the front panel of the junction box. The design included elements such as corners,
edges and openings. The test specimen, which was 60 mm thick, was subjected to hydrocarbon
fire for 60 minutes. The average back face temperature rise above ambient (ΔT) was:
Property Value
Hydrocarbon fire resistance (UL1709) H30 / H60
Back face temperature rise H30 ΔT 11°C
Back face temperature rise H60 ΔT 58°C
Temperature resistance From -50°C to 1,100°C
Standard thickness 60mm
U Value 0.061 W/m K
Mass 18.4 kg/m2
ABS 12-LD890376A-PDA
ContraFlex® Hydrocarbon Fire Performance – H30 / H60
ContraFlex® Hydrocarbon Fire Performance – H30 / H60
Hydrocarbon Fire Duration (Min.) Temperature Rise
H30 ΔT 11°C
H60 ΔT 58°C
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ContraFlex® has been tested and certified to the International Standard UL1709:2005 thermal
programme and has been proven to withstand hydrocarbon fire temperatures of 1,100°C for up to
two hours, therefore ideal for the protection of structural steel members in panel sections, large
construction vessels, supports, pipework and large valves which include corners and edges.
Unloaded SHS column (200 x 200 x 10 mm) was protected by ContraFlex® jacket. The vertical
joint was banded at 200 mm centres with 316 SS Ω straps. The test specimen, which was 50 mm
thick, was subjected to hydrocarbon fire for 120 minutes. The average back face temperature rise
above ambient (ΔT) was:
Property Value
Hydrocarbon fire resistance (UL1709) H60 / H120
Back face temperature rise – H30 ΔT 70°C
Back face temperature rise – H60 ΔT 300°C
Temperature resistance From -50°C to 1,100°C
Standard thickness 61mm
U Value 0.061 W/m K
Mass 11.2 kg/m2
ABS 12-LD890376B-PDA
ContraFlex® Hydrocarbon Fire Performance – H60 / H120
ContraFlex® Hydrocarbon Fire Performance – H60 / H120
Hydrocarbon Fire Duration (Min.) Temperature Rise
H60 ΔT 70°C
H120 ΔT 300°C
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In the event of an accidental release of
flammable gas on an offshore installation,
if an ignition of the released gas occurs, it is
likely that a vapour cloud explosion would
occur. Should the release continue after the
initial explosion, a jet fire might result.
Any damage caused by the initial vapour
cloud explosion would increase the severity
of the resulting fire. It is, therefore, necessary
to demonstrate that materials used for fire
protection of structural and other components
are not degraded by the effects of a vapour
cloud explosion and so continue to provide
the required level of fire protection.
Two tests were conducted in the explosion
chamber at the Spadeadam test site to
demonstrate the ability of ContraFlex®
jackets manufactured by Advanced Insulation
to withstand the effects of gas explosions
generating overpressures in excess of
1.5 barg.
Test Results - Vessel
Average peak overpressure of
1.55 barg
ContraFlex® jacket remained in position
Only the protective Velcro covering
over the lacing was removed or torn
in some places
Test Results – Tubular Sample
Average peak overpressures of
2.15 barg
ContraFlex® jacket remained in place
Only the protective covering of the
vertical lacing was torn or removed
in some places
The horizontal weather protection
remained intact
Some lacing was exposed but note
was removed
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ContraFlex® J120 – Pre Blast
ContraFlex® J120 – Post Blast
ContraFlex® J120 – Post Blast
ContraFlex® Blast Performance
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Enhanced personnel protection
Thermal insulation and protection
Heat / cold conservation
Winterisation
Available in a range of thicknesses
Lightweight
Range of fixings, e.g. lacing wire is used for high temperature applications and fire proof Velcro for standard temperatures
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ContraFlex® IS HT ContraFlex® IS
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ContraFlex® Insulation Features
ContraFlex® jackets can be tailored to provide thermal insulation commonly used in the offshore
and petrochemical industries. The typical thickness of these jackets is 50, 75mm, and weight
from 6kg /m2 at 50mm thickness.
ContraFlex® Insulation Performance
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ContraFlex® Insulation Service Temperature Range
ContraFlex® IS – Static Application From -36°C to +260°C
ContraFlex® IS HT – Vibration Resistant From -36°C to +650°C
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CONTACT INFORMATION
Advanced Insulation Limited offers a full
technical support service for all our products,
regardless of location or application. For
further details, please contact your nearest
management office and let us know how we
can help.
www.aisplc.com
Angola:
+244 923 364 273
Brazil:
+55 19 41417117
Kazakhstan:
+7 707 600 4452
Korea:
+82 51 921 6367
Malaysia:
+60 3 5121 3886
United Arab Emirates:
+971 4 8813567
United Kingdom:
+44 (0)1452 880880
United States:
+1 (281) 600 0022
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