marathon field assessment daily log - terra millennium...

Field Fireproofing Assessment SummaryOwner: Marathon

Location: Texas City, TX

Page: 1

Platformer

StructuresThe fireproofing of structures within the Platformer unit has shown visible signs of distress most notably in the supporting structure of the Combined Feed & Platformer Effluent Exchangers. Figure 2 depicts consistent distress manifestations throughout the structure in which the fireproofing material has spalled from the Exchanger pedestal revealing corroded 2x2 wire mesh. Significant cracking, delamination and anchor failure has also been identified as distresses that are noticeable throughout the structure under both visual and hammer testing inspection. Due to the severity of distress, it is recommended that the fireproofing material be replaced for the entire structure supporting the Exchangers. The Reactor structure repairs however minor show noticeable cracking throughout multiple columns and beams. Hammer testing within arms-length inspection provided no signs of delamination. However, to prevent further damage to the fireproofing material it is recommended that all cracks throughout the structure be caulked to prevent water ingress. The Depentanizer structure is in very good condition and will require no recommended repairs. Figure 8 shows an example of the fireproofing condition as observed during inspection.

Pipe RacksThe fireproofing of the pipe racks have provided reasonable protection thus far however much of the fireproofing is old and will require substantial repairs. The Lightweight-Cementitious material of the pipe rack running N/S located east of the Depentanizer O.H. pumps show significant signs of distress. Figures 10-12 reveal evidence of deterioration as well as disintegration and corrosion of the anchoring system. Subsequently, the fireproofing material has separated from the steel substrate and wire mesh and should be considered a potential fall hazard in the near future. Therefore, given the degree of deterioration it is recommended that the existing fireproofing is removed and replaced. Figures 13-18 illustrate the severity of distresses observed within the E/W rack north of the Platformer/UDEX operator shelter. The extent of the defects observed within the rack include cracking of various types and range from insignificant to severe, spalling and hammer testing has also revealed signs of delamination at multiple locations. Previous repair plans to reseal various cracks have proven successful and should continue to provide reliable protection as Figure 16 illustrates. However, as Figure 18 depicts there are a number of locations in which the magnitude of the cracking has increased over time and require re-caulking or removal and replacement of the existing material. The condition of the E/W pipe rack south of the reactors is poor and Figure 20 represents common defects found throughout the rack in which significant cracking and delamination of fireproofing is seen thru the beam’s length. The severity of distress and the extent of which it occurs presents a prominent falling hazard and therefore is advised that the existing fireproofing material be removed and replaced. The N/S Rack West of Depentanizer Exchangers is in fair condition. It appears that larger repairs were deferred to removing only portions of concrete fireproofing and installing light-weight cementitious material. This repair has appeared successful however there are signs in which the two materials are separating from each other causing cracks within the fireproofing system as shown in Figure 22. Hammer testing has revealed that the fireproofing material is sound and shows no signs of delamination where arms-length inspection is possible. To prevent water ingress the advised repair procedure consists of caulking all visible cracks.

EquipmentThe Depentanizer Tower is in very good condition only requiring caulking between the retaining ring and fireproofing material to prevent water ingress as shown in Figure 24.

Pipe SupportsFigure 26 shows a pipe support west of the reactor pipe rack which is severely cracked and delaminated. Heavy corrosion and pack rust is also noticeable throughout the exposed steel. Given the severity of distress, the existing fireproofing should be removed and replaced.

JT Thorpe & Son, Inc.Fireproofing Division

17 Ferry Street, Pittsburgh, PA 15056Ph: 412-787-1705 Fax: 412-787-2295



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Figure 1. Structure of Combined Feed & Platformer Effluent Exchangers

Figure 2. Delamination of Fireproofing material

Figure 3. Reactor Structure Figure 4. Cracking sealed previously

Figure 5. Cracking on columns Figure 6. Cracking on lower beams





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Figure 7. Depentanizer Structure Figure 8. Condition of Depentanizer Structure as observed

Figure 9. N/S Rack East of Depentanizer O.H. Pumps Figure 10. Deterioration, Disintegration and corrosion of fireproofing

Figure 11. Delaminated fireproofing exposing column substrate

Figure 12. Corroded corner tab





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Figure 13. E/W Rack North of Platformer/UDEX shelter Figure 14. Severe cracking

Figure 15. E/W Rack North of Platformer/UDEX shelter Figure 16. E/W Rack North of Platformer/UDEX shelter

Figure 17. E/W Rack North of Platformer/UDEX shelter Figure 18. E/W Rack North of Platformer/UDEX shelter





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Figure 19. E/W Rack South of Reactors Figure 20. Severe Cracking

Figure 21. N/S Rack West of Depentanizer Exchangers Figure 22. N/S Rack West of Depentanizer Exchangers

Figure 23. Depentanizer Tower Figure 24. Depentanizer Tower





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Figure 25. Pipe support West of Reactors Figure 26. Pipe support West of Reactors



marathon field assessment daily log - terra millennium...

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