Professional Documents
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Fireproofing From Chevron
Fireproofing From Chevron
Abstract
This section describes various types, relative merits, and properties of fireproofing
materials. It gives guidelines for determining structures that require fireproofing and
recommended materials and suppliers. It also discusses the various types of fireproofed and fire resistant systems for critical control systems. API RP 2218 is the
industry standard for fireproofing.
Contents
Page
1710 Introduction
1700-2
1700-3
1700-14
1700-20
Chevron Corporation
1700-22
1760 References
1700-25
1700-1
June 2000
1700 Fireproofing
1710 Introduction
Selecting a fireproofing material involves answering three questions:
Section 1720 answers these questions for support structures and Section 1730 for
critical valves, instrumentation and shutdown systems.
This section defines terms used in this section and lists relevant Company and
industry documents.
For structural steel, vessel/column skirts, etc., the area within a horizontal
radius of 20-40 feet and 20-40 feet vertically of fire-potential equipment.
Distances can be expanded or reduced based on drainage, pressure and liquid
holdup.
For instrumentation, electrical power cables and/or air piping/tubing, the area
within a 50' horizontal radius or 50' vertically.
Fired equipment, including heaters and furnaces, that handles flammable materials.
Rotating or reciprocating mechanical equipment, such as pumps or compressors, that handles flammable materials.
Drums, exchangers, columns, and similar operating vessels that handle flammable materials and have a volume of more than 1000 gallons (24 barrels).
Plot-limit piping manifolds that contain flammable materials and ten or more
valves.
Tanks, spheres, and spheroids that contain flammable materials including their
drainage and relief path and impounding basis.
Flammable Materials: For the purpose of this section of the manual, flammable
materials include flammable gases, vapors, and liquids having a flash point below
100F or being handled at temperatures above their flash point.
Emergency Shutdown or Depressuring System: A system that will shut down a
plant or other facility under emergency conditions, either automatically or by
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remote push button; actuate remote block valves to stop the flow of flammable
liquids or gases; stop heat input to process furnaces, reboilers, or heaters; stop the
rotation of associated machinery (especially pumps); or depressure the equipment
through a vent, if appropriate.
Emergency Isolation System: A system of remote-operated valves to isolate a
piece of equipment or unit involved in a fire or other emergency, thus limiting the
supply of fuel. This may be an individual pump, compressor, vessel, LPG sphere,
etc., or it may encompass an entire area inside the plot limits of a plant or battery.
Critical Instrument or Electrical Cables: Cables or tubing associated with emergency shutdown, depressuring, or isolation systems. Typically, these systems must
maintain their operational integrity to facilitate safe unit shutdown for at least 20
minutes into a fire.
Home Runs: Large groups of multiconductor signal cables from the control house
to the main junction boxes in the plant. Home runs are expensive to install and time
consuming to repair. Their loss may cause damage to plant(s) outside the fire area as
a result of loss of control.
Plot Limit Valves: The boundary valves for a plant area containing a complete
operation or group of operations that may be shut down as a unit. These valves are
used for isolation on turnarounds or fire emergencies. They should have at least a
50-foot separation from other hydrocarbon-handling facilities.
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The value of the structure and supported equipment is low when compared to
the cost of fireproofing.
Member failure would not cause failure of the structure or equipment. Thus,
wind and earthquake bracing and other secondary members, such as supports
for stairs, platforms, and walkways, are not normally fireproofed.
The structure is far enough removed from the source of a fire to preclude
serious damage.
The fire would cause failure or serious damage to supported equipment whether
or not the structure was fireproofed.
The structure supports piping that is not carrying flammable liquids. Piping
carrying only gases does not normally justify fireproofing of the supports.
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Chevron Corporation
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June 2000
INTERMEDIATE
STRENGTH
LOW STRENGTH
Pyrocrete 241
Fendolite M II(1)
HIGH STRENGTH
Product Name
or gunited)
Standard mix of portland
cement and rock aggregate
Proprietary inorganic
cement formulation
Proprietary inorganic
cement formulation
Spray-applied vermiculite
portland cement mix
140-150
75-95
47
55
44
2500-3000
1500-2000
836
817
548
13
1.19
0.87
1.32
70-90
70-90
55
55
40-41
Specifications
Density (lbs./cu ft)
Hardness (Shore D)
UL 1709 Fire Time Rating
(thickness in inches at:
1700-6
1 hour
11/16
1.5 hours
11/16
15/16
1-3/16
2 hours
1-1/8
1-1/8
1-7/16
2.5 hours
1-5/8
2 Note(2)
1-3/8
1-3/8
1-13/16
3 hours
4 hours
2.5 Note
(2)
1-9/16
1-9/16
2-5/16+
Recommended Primer
(3)
Epoxy
Epoxy(3)
Note(4)
None(4)
Epoxy(3)
Recommended Topcoat
None(5)
None(5)
Note(4)
None(4)
Note(4)
Recommended Use
Note(6)
Note(7)
Notes(7) (9)
Chevron has not used this system extensively. Before using it, contact the CRTC Materials and Equipment Engineering Specialist.
While there is no test data to support this number, it is equivalent to a 4 hr ASTM E-119 rating, for which test data is available.
Coating System Data Sheet 4.4 in the Coatings Manual (Quick Ref Guide page 69).
Follow manufacturers recommendations.
For severe weathering and corrosive conditions, consider an epoxy topcoat.
Structures such as piers, legs, pipe supports, etc., where weight is not a concern.
Vessels, skirts and other applications requiring lighter weight aggregate. Generally not used on structural steel.
Better for modular designs where flexing occurs during transport.
Oil platforms and other applications requiring lighter weight and low volume.
Chevron has good experience with this product.
Chevron Corporation
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
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June 2000
INTUMESCENT
Chartek VII
SUBLIMING
(1)
Pittchar XP
Product Name
INSULATING
Super Fire Temp (Electric Cable Trays)
Eternit Promat H
62.4
73
78.5
28
54
Compressive Strength
(PSI)
2700
2264
2190
900
1420
Thermal Conductivity
(BTU in/deg F-hr-sq ft @
75 deg F mean temperature)
1.48
1.69
0.076
1.14
70
60
50
1/4 hour
1/2 hour
1.5
1 hour
0.28
0.12
Note(2)
1.5 hours
0.40
0.40
0.21
Note(2)
2 hours
0.60
0.52
0.31
Note(2)
2.5 hours
0.80
0.63
0.41
Note(2)
3 hours
0.75
0.50
Note(2)
4 hours
0.69
Note(2)
Note(3)
Note(3)
Note(3)
None
None
Recommended Topcoat
Note
(3)
Note(3)
Note(3)
Note(4)
Note(3)
Recommended Use
Note(5)
Note(5)
Note(6)
Cable Trays
Note(1)
Hardness (Shore D)
1700-7
Recommended Primer
June 2000
(1)
(2)
(3)
(4)
(5)
(6)
Two-component epoxy High density calcium sili- High density calcium silisubliming coating
cate insulation
cate insulation
Chevron has not used this system extensively. Before using it, contact the CRTC Fire & Process Safety Team or CRTC Materials and Engineering Specialist.
See manufacturers brochure for calculation instructions (page 18-19).
Follow manufacturers recommendations.
Outdoor installations need weatherjacketing. Silicone waterproofing is recommended by Johns Manville and may be adequate for dry locations.
Oil platforms and other applications requiring light weight and low volume.
Thermolag 3000 has both on and off-shore applications. See Manufacturers brochures for each market.
1700 Fireproofing
Specifications
Chevron Corporation
1700 Fireproofing
Drainage (both of the plant area and within structures) should carry hydrocarbon spills away from supports, structural members, and equipment. This
reduces the amount of potential fire damage due to an accidental spill. Where
drainage does not meet these criteria, additional fireproofing may be justified
(see Section 1400).
Fire risks in plants should be adequately spaced from one another (see
Section 1300).
Sources of ignitionfurnaces, shops, etc.should be located as far as practical from areas where flammable vapor might be released to the air. Where
risks are not adequately separated, additional fireproofing may be justified.
1724 Materials
Types of Fireproofing Materials
The Company usually uses concrete material because it is often the most cost-effective. Many commercial products are also available. They have specialized uses and
are usually more expensive than concrete. Fireproofing materials come in three
categories:
Figures 1700-1 and 1700-2 give the UL 1709 and/or ASTM E-119 rating for these
materials. Use these figures to compare the relative performance of the tested materials. New applications should use materials that have been rated by UL 1709. (See
Section 1750.)
Both cementitious-based and insulation-based materials insulate the structure from
heat generated during a fire. These materials are not destroyed by the high temperatures of a fire. Both intumescent and subliming coatings absorb heat through mass
reduction. Subliming coatings absorb heat by transforming to a gas and intumescent
coatings work by quickly swelling to four times their original thickness to insulate
the structure.
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Chevron Corporation
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water and tend to degrade much faster than normal concrete. Topcoating slows
degrading.
Pyrocrete 240 & 241 have lower range compressive strengths, and now being chloride-free, do not cause corrosion problems. Refer to the manufacturers recommendations for primers and topcoats.
Noncementitious Materials. The Company has limited experience with noncementitious coatings like Thermolag 3000 and Chartek VII. Thus far, experience has been
good on the few existing applications. However, a cautious approach is warranted
with their use. Thermolag 3000 is a subliming coating which just chars away during
a fire.
Intumescent coatings, like Chartek VII, work by quickly swelling up to four times
their original thickness during a fire. The swelled material forms a strongly oxidation-resistant char layer. In this manner, it resists the fire. It also protects the underlying steel by being a good insulator. Chartek VII comes in the form of a strong
epoxy. Epoxies are not very permeable, so leaching of chloride should not be a
problem.
Shelf Life of Fireproofing Materials. Some of these specialty fireproofing materials have a limited shelf life, similar to some brands of coatings. Therefore, it is
unwise to purchase excessive amounts that cannot be used in a short time. The shelf
life of Pyrocrete 241, for example, is two years. In general, suppliers will not take
their material back and there will be disposal costs for the expired material.
Weathering. Long-term environmental exposure does not have much effect on fireproofing materials. Dense cementitious materials are usually unaffected. Lightweight cementitious materials and noncementitious materials can be protected by
topcoating. However, the weathering resistance of noncementitious coatings needs a
more careful evaluation. Figures 1700-1 and 1700-2 indicate where topcoating is
recommended.
In a 1975 test program by the Smithers Company, (an independent testing laboratory), a noncementitious, intumescent coating, Albi Clad 890, was found to retain
only 30% of its fireproofing capabilities after an accelerated weathering test. This
loss in fireproofing was greater than that indicated by physical appearance. Another
intumescent coating, Firex RX 2384, showed only a nine-minute time of protection
in a high rise fire after accelerated weathering. Consequently, these products are not
recommended.
The Smithers program did not test Chartek VII and Thermolag 3000. However,
product literature states that these two products can pass accelerated weathering
tests without significant loss of fireproofing capabilities.
Reuse After a Fire. Cementitious fireproofing materials are not necessarily ruined
after exposure to a fire. Remaining properties depend on how much water of hydration was lost. The amount lost is a function of the intensity and duration of fire
exposure. Concrete is a good insulator and it is not unusual to find much of the
remaining concrete in good condition after a fire. All loose and damaged material
must be removed. The fireproofing can then be rebuilt to original thickness using
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standard concrete repair practices found in the Civil and Structural Manual, Section
260.
Proprietary materials (e.g., Pyrocrete 241) may require reapplication of material to
bring the total thickness back to the required fire rating.
Intumescent and subliming fireproofing systems must be replaced after a fire. Insulation-based systems would normally also need to be replaced after a fire.
Severe corrosion of the structural steel and reinforcement mesh underneath fireproofing. The primary cause is water that gets between the fireproofing and the
steel. As noted above, some proprietary fireproofing may cause corrosion problems if the steel is not coated. Refer to the Corrosion Prevention Manual,
Section 630, for more information on corrosion under fireproofing.
Corrosion Prevention. Abrasive blasting and priming the structural steel prior to
fireproofing and proper cure of cementitious fireproofing are important in eliminating corrosion. Flashing or caulking prevent entry of water between the fireproofing and the steel. Acceptable sealants should be specified. Two such products
are Dow Corning No. 732 Silicone elastomeric sealer and H. B. Fuller, Foster Products Division No. 95-44 butyl caulking.
Commercial fireproofing manufacturers usually specify primers to be epoxy, inorganic zinc, or combinations of the two. However, epoxy provides better protection
against corrosion. Epoxy is preferred in plants that have a previous history of corrosion under fireproofing. Standard Drawings GA-N3336 and GD-N99994 specify a
polyamide epoxy (Coating System Data Sheet 4.4 in the Coatings Manual) on a
near white metal finish.
Chlorinated rubber coatings may also be considered where application restrictions,
such as low-temperature climates, limit the use of epoxy.
Touchup is required if the primer is damaged during shipment or application of the
reinforcing anchor studs. The touchup coating must be compatible with the original
primer. Also consider economics spraying a new primer coat may be less costly
than extensive touchup.
Cracking and Proper Cure. Proper cure of cementitious fireproofing materials
greatly reduces the amount of cracking. In some geographic locations, it is necessary to take extra measures like spray-applying a curing compound to seal the
surface to prevent moisture loss. Another measure is to wrap the freshly poured
concrete work with burlap or polyethylene sheet; however, this method can cause
staining. The concrete can also be cured by continuous application of a fine fresh
water mist to keep the surface moist.
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Cracking can occur even when concrete is properly cured. The main causes are
thermal cycling, shrinkage, and corrosion of reinforcing steel. If the cracking is bad
enough, it can accelerate corrosion of the underlying steel by allowing in water.
While cracking is undesirable, it is not cause for rejection unless severe.
There are no well-established criteria for judging severity of cracking. However, the
following checks can help you decide if a job needs more thorough review or repair.
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Offshore Structures
Cementitious fireproofing materials have performed poorly offshore because the
reinforcing steel in the concrete corrodes. Consequently, these materials are not
recommended for offshore structures. Specialty, lightweight fireproofing materials
are often used offshore instead of concrete, to save space and weight. In addition,
there are no reinforcing bars in the materials to corrode. Chartek was used on Platform Ninian, Pyrocrete 241 was used on Platform Hidalgo, and Thermolag was used
on Platforms Gail and Esther. (Refer to Section 1750 for a discussion of ratings that
apply to offshore fireproofing of decks and bulkheads.)
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fire exposure without collapse or failure. Under some conditions, this type of
construction provides adequate fireproofing for pipe stanchions because the piping
being supported generally fail in less time.
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Fig. 1700-3 Determining Fireproofing Needs for Critical Valves, Instrumentation and Shutdown Systems
This fireproofing system is easily applied to the smaller-sized and more rectangular-shaped valve operators.
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The enclosure should be designed and installed so that leakage (e.g., from a
valve stem packing) does not enter the enclosure. If there is evidence of oil
accumulation, the enclosure should be promptly removed and cleaned and the
leakage problem corrected.
Normal local operation of an MOV/AOV (e.g., push buttons, lights, declutch,
or handwheel) may be retained by minor modification to the valve operator.
Components that require servicing are made accessible by removing the insulation cover and insulation as required. This is a significant disadvantage because
frequently these covers or panels are not reinstalled properly, reducing fire
protection capabilities.
Insulated Bag. This system (Figure 1700-5) uses insulation pads laced together
with galvanize- coated steel wire to form a bag that fully encloses the motor/air
operator of a critical valve, including motor, gearbox, and drive nut or the entire
housing of the protected component. The insulation bag is constructed of semiflexible pads of ceramic fiber or fiberglass insulation. The assembly is weather
protected by a vinyl-coated Dacron cover. It is designed to keep the internal
temperature of electrical components at or below 200F for 20 minutes if
exposed to a 2000F fire, as described by UL 1709.
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Normal local operation of any MOV/AOV (e.g., push buttons, lights, declutch
or handwheel,) may be retained by minor modification to the valve operator.
Components that require servicing are made accessible by unlacing and
opening or removing the bag, which takes only a few minutes. As with the
insulated box enclosure, this is a major disadvantage of this system.
Valve or piping failure during a fire would cause burning liquid to spread fire to
other tanks, equipment, important facilities, or the property of others.
The number of personnel available during the first 20 minutes of a fire emergency is limited, so remote operating capability must be maintained.
The risk of a tank overfill is increased due to high use or filling rate.
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For air used for motive power of AOVs, consider locating air filters, lubricators, and
solenoids outside the fire hazardous area. If this is not practical, then these items
must be fireproofed along with the valve activator.
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silicon dioxide insulation in a stainless steel sheath (e.g., Meggitt Safety Systems
SI 2400 Fire Cable). Neither system requires conduit.
Conduit
Conduit should be rigid steel with steel fittings and covers. Supports should be
spaced 6 feet or less in horizontal runs and 8 feet or less in vertical runs to support
the weight of the fireproofing material and to avoid sagging during a fire. In fire
hazard areas, conduit supports should be insulated because they may conduct heat
inside the fireproofing during a fire.
Thermal insulation that can withstand exposure up to 2000F for at least 20 minutes
should cover the conduit. Due to the short exposure, most thermal insulation for
pipe will be adequate if it is at least 1-1/2 inches thick. Extended protection may be
gained by using ceramic fiber or two-layer calcium silicate insulation. Mineral wool
would also work, but for a shorter length of time. To seal against weather and
protect against mechanical damage, a galvanized or stainless steel weather jacket
secured with stainless steel bands should cover the insulation. Aluminum weather
jacketing would melt, exposing the insulation to damaging effects of the fire or hose
streams.
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Design
Generally, cable trays are recommended over conduit banks because of their ease of
installation and fireproofing.
Conduit or tray supports should be spaced 6 feet or less in horizontal runs and 8 feet
or less in vertical runs to bear the weight of the fireproofing material and to avoid
sagging during a fire. Supports should be insulated to protect the conduit or tray
within a fire hazard area because they will conduct heat inside the fireproofing.
Conduit should be rigid steel with all steel fittings and covers.
Due to the cost of re-entry into a fireproofed conduit raceway or tray, future additions should be taken into account during initial construction. Fireproofed cable tray
networks should contain about 20% spare cables or tubing for future additions and
replacements because the tray is totally enclosed by the fireproofing system.
Where home run conduit and cable trays enter control buildings, wall penetrations
should be sealed to prevent entry of vapors, smoke, and fire.
Methods of Fireproofing
The following methods of fireproofing prevent internal temperature from exceeding
200F for 20 minutes in a 2000F fire per UL 1709.
Wrap the conduit bank or tray with flexible blanket insulation designed for use
at 2000F and cover with stainless or galvanized steel weather jacket and stainless steel bands.
3Ms Interam system uses ceramic fiber blanket with an aluminum covering.
This material is thinner than conventional insulation (0.6 inches vs. 1.5 inches)
and can be used economically on odd shaped sections where fitup of thicker,
more rigid systems is difficult.
Box-in cable trays with prefabricated panels (usually calcium silicate) and
weather jacketing. This type of system is economical for simple rectangular
shapes. Promat-H and Johns Manville Super Firetemp can be used for this.
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Chartek
201 Lowell St.
Wilmington, MA 01887
Phone: (978) 657-2904
Fendolite M II
Mandoval Industrial Fireproofing Products
7025 W. Tidwell, Suite 111
Houston, TX 77092
Phone: (800) 847-5768
Pittchar
PPG Industries
151 Colfax St.
Springsdale, PA 15144
Phone: (724) 274-3473
Super Firetemp
Johns Manville
1559 9th Avenue
San Francisco, CA 94122
Phone: (415) 665-0767
Pyrocrete
Carboline
1401 South Hanley Rd.
St. Louis, MO 63144
Phone: (925) 838-7571
Thermolag
Thermal Sciences Inc.
2200 Cassens Dr.
St. Louis, MO 63026
Phone: (314) 349-1233 or (281) 482-7000
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UL 1709 Standard for Rapid Rise Fire Tests of Protection Materials for
Structural Steel
Underwriters Laboratories, in cooperation with the industry, has developed tests to
more closely simulate fire conditions expected in a process plant. These tests are
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ASTM E-119 ratings are often longer than the UL 1709 counterpart. For example,
depending on the material, the ASTM E-119 4-hour test is equivalent to only 2-3
hours in the UL 1709 test (concrete). Consequently, the UL 1709 test usually shows
that thicker protection is needed than that predicted by ASTM E-119. It also shows
that the behavior of some materials may be significantly poorer in hydrocarbon fires
than in conventional fires. This is why UL 1709 is now used for both structural
supports and for critical control systems.
ASTM E-1529 closely follows UL 1709 and is also considered a rapid rise fire
test, however, ASTM E-1529 utilizes a lower heat flux factor, and therefore is not
the equivalent of UL1709.
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Off-shore Ratings
For bulkheads and deck sections of offshore installations, fireproofing can be
applied to any of the following ratings, depending upon application: A-60, A-120,
H-60, and H-120. Manufacturers must certify product ratings with test results.
Fig. 1700-7 Examples of Product Rating Tests(1)
Rating
A-60
(2)
(60 min)
H-60
(3)
(60 min)
Normal Configuration
Test Environmental
Temperature
Bulkhead, deck
section 9 sq. m
usually 4.8 mm or
greater steel thickness
Bulkhead, deck
section 9 sq. m
usually 4.8 mm or
greater steel thickness
Criteria to be Met
Test Type
Protected steel
temp not to exceed
a rise of 250F
(139C) for 30
minutes
Follow UL 1709
temp. curve (or
equivalent)
Protected steel
temp not to exceed
a rise of 250F
(139C) for 30
minutes.
No passage of
smoke or flames
and maintain structural integrity for
120 minutes.
(1) A-120 and H-120 are 120-minute tests.
(2) This is an ASTM E-119 test for use in protecting living quarters for 60 minutes under typical combustible materials fire conditions.
(3) This is a UL 1709 test for use in protecting process areas for 60 minutes under high rise fire conditions typical of hydrocarbon fires
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1760 References
American Petroleum Institute (API)
API 2218
PIPSTS03001
Chevron References
Specifications and Engineering Forms:
CIV-EG-850
GD-N99994
Chevron Corporation
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June 2000