1.4 advanced pfp seminar 11 2011.pdf

Advanced insulation & fire protection systems to the oil and gas industry

Asaf Hisherik – Upstream Surface Engineering Bill Rivers – General Manager USA

• Introduction

• Part 1 - Technical background

• Part 2 - Passive Fire Protection systems

• Part 3 – Site Application

• Q & A Session

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.

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

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)

• 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.

AIS qualified products are now used worldwide by major oil and gas companies and by their contractors.

Offshore

Platforms/ Vessels

Subsea

LNG

Onshore

Market Segments

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

Cable Tray Protection

Storage Tank Protection

Process Pipe work

Onshore Facilities

Junction Box Insulation/ Protection

Valves/ ESDV/ Flange Insulation Protection

Structural Thermal Shock Insulation Protection

Jetty

Storage Tank Protection

Process Pipe Work

LNG

Spill Reservoir / Tranches Insulation Protection

Tranches/ spill reservoir PFP

Demonstrate the benefits of utilizing integrated thermal

insulation and PFP system on structural, processing and

Civil applications

My Aim…..

Part 1 – Technical Background

The purpose of applying fireproofing is to provide temporary

protection until such time when fire fighting systems and loss control measures may be employed.

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

BS EN ISO 13702: 1999, Petroleum and Natural Gas

Industries – Control and mitigation of fires and

explosions on offshore production installations –

Requirements and guidelines

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.

• 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.

• 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

• 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)

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.

0

200

400

600

800

1000

1200

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240

Tem

pera

ture

C°

Elapsed Time (min.)

Industry Design Fire Curves

Cellulosic Curve

* Max Temp. ** Erosive Force

“A” Category – ISO834 1000 C° at 90-100 min

0

200

400

600

800

1000

1200

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240

Tem

pera

ture

C°

Elapsed Time (min.)

Industry Design Fire Curves

H - Curve

Cellulosic Curve

“H” Category – UL1709 1000 C° at 7 min

* Max Temp. ** Erosive Force

Pool Fire

Image from Sandia National Laborites

0

200

400

600

800

1000

1200

1400

1600

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240

Tem

pera

ture

C°

Elapsed Time (min.)

Industry Design Fire Curves

H - Curve

J - Curve

Cellulosic Curve

“J” Category – 1350 C° at 2-5 min

* Max Temp. ** Erosive Force

Jet Fire Testing - ContraFlex®

Part 2 – Passive Fire Protection Systems

• An intumescent is a substance which undergoes a chemical reactions as a result of heat exposure, thus increasing in volume, and decreasing in density

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.

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

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

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

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

ContraFlame® Lloyds certification JF120

1. LR Certificate of Fire Approval JF120 SAS F100180 M1.pdf 2. ContraFlame report v2 pdf.pdf

ContraFlame Blast Testing 4.2 bar

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

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

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

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

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

• 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

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

• 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)

• 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

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

• 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

ContraFlex® - Key Features

• Valves and Actuators

• Flanges

• Cable trays, conduits and instrument lines

• Electrical junction boxes and circuitry

• Air receivers

• Process vessels

• Hot Pipework

ContraFlex® – Typical Applications

Jebel Ali, Dubai

Mussafah, Abu Dhabi

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

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.

Part 3 – Site Application

Set up – Tools

Contraflame ® - Wet Application

Set up – Steel Preparation

Contraflame ® - Wet Application

Set up – Surface Preparation

Contraflame ® - Wet Application

Stage 1 – Tie Coat

Contraflame ® - Wet Application

Stage 1 – Tie Coat – 150 micron

Contraflame ® - Wet Application

Stage 2 – C50

ContraFlame ® - Wet Application

C50 mixing process

Stage 2 – Material Mixing

Contraflame ® - Wet Application

Stage 2 – Material Applying

Contraflame ® - Wet Application

Stage 2 – Material Applying

Contraflame ® - Wet Application

Stage 2 – Material tampering

Contraflame ® - Wet Application

Stage 2 – Material tampering

Contraflame ® - Wet Application

Stage 2 – Material Curing

Contraflame ® - Wet Application

Stage 3 – Multi Layer Outer Coat D2004

Contraflame ® - Wet Application

Stage 3 – Multi Layer Outer Coat D2004 Contraflame ® - Wet Application

Stage 3 – Multi Layer Outer Coat D2004

Contraflame ® - Wet Application

The Finished System - Vessel

ContraFlame ® - Wet Application

The Finished System - Risers

ContraFlame ® - Wet Application

Leave surfaces rough

Old laminate ground back

Old C50

Contraflame ® - Wet Application Sanha Processing Columns

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.

Half Shells

Contraflame ® - Pre Cast Shells & Enclosures

Half Shells Bands and Tees

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

Contraflame ® - Pre Cast Shells & Enclosures

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: Asaf.Hisherik@aisplc.com

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: sales@aisplc.com