PPG - PITT-CHAR® Passive Fire Protection

Epoxy Intumescent Passive Fire Protection System

The ultimate solution for extreme hydrocarbon fire scenarios

M. Naser – Technical Support PFP Manager
Date: 22nd April 2020
Definition of Epoxy Intumescent Fireproofing coating

Before fire
A coating which reacts to heat by swelling
exposure in a controlled manner to many times its
original thickness to produce a Upon Fire exposure
carbonaceous char, which acts as an
insulating layer to protect the steel
substrate.”

Epoxy intumescent provide excellent corrosion protection, durability and

resistant to both Pool and Jet Fire exposure.
Epoxy Intumescent PFP coatings
Rigid and Flexible system

API Publication 2218 – Fire Practices

- Provide guidance for selection FP system
- Characteristic of FP material – Physical properties and Fire behaviour

1. Vibration Resistance and Compressive, Tensile, and Flexural Strength

“may be important to the life expectancy of fire-proofing. In some applications, vibration can
fracture fire-proofing material and destroy bonding of rigid coatings to the substrate. Flexible
epoxy intumescent fireproofing materials designed for elasticity and vibration tolerant are
available, and …..perform well in such applications.”

2. Coefficient of Expansion
“can be significant when fire-proofing materials are used on substrates that are subjected to
expansion caused by changes in temperature or in the operating pressure of the equipment.
Too rigid a material can lose its bond to the substrate and spall off the protected member.
Flexible epoxy intumescent fireproofing materials designed for elasticity, thermal insulation
designed for fire protection, ….. are able to effectively contain such assemblies.

3
 Epoxy Intumescent PFP coatings – Rigid system

Rigid System–Vibration/Movement Induced Cracking

Don’t Crack under Pressure

PITT-CHAR Fire Protective Coating 4

 Main Features of Pitt-Char XP

Unique Flexibility
•
Pitt-Char XP, manufactured by PPG
Coatings, is the Only flexible epoxy
intumescent coating in the market that
provides long term Corrosion, Fire
and/or Cryogenic Protection as a Single
Product System.

Pitt-Char XP is based on unique

and patented flexible cross-linked epoxy
resin, that enables the coating to relieve
the internal stress incurred during
thermal cycling/thermal shock, and to
withstand movement and vibration of a Don’t Crack under Pressure
structure, while offering a high impact
resistance properties

PITT-CHAR Fire Protective Coating 5

Flexible Epoxy Intumescent PFP

Tolerant to Flexing, Vibration and Blast Explosion

- Flexibility design for elasticity and vibration tolerant

Benefits – Minimize damage during operation service life; hence reducing repairs
and down time / compromise to fire protection.
6
Flexible Epoxy Intumescent PFP
Blast Explosion

7
Flexible Epoxy intumescent PFP

Impact Resistance
- Misconception that material need to be harder (rigid system) in
order to resist impact damages

Benefits – Minimize damage during fabrication, transportation and in service

operation; hence minimizing repairs and saving in overall project management and
maintenance.
8
Suncor Canada – Oilsands Producer
Fabrication / Transportation / Low Temp Service
PFPs coated in Korea on
Dec. 2013 and shipped to
Canada arrived in Jan 2014

Pitt-Char XP in almost
RIGID PFP EPOXY SYSTEM
perfect condition

9
Flexible Epoxy intumescent PFP

Low Temperature Service / Thermal Cycling Performance

- Flexibility design to achieve good tensile strength and elongation
Flexible and Tough Rigid PFP – Hard and Brittle
PFP

Close to zero

Benefits – Durability in low temp / cold climate service; hence minimizing repairs
and down time / compromise to fire protection.
10
 Flexible Epoxy intumescent PFP

Cryogenic Protection
- Flexibility provides Single product solution for Fire and Cryogenic
Spill Protection (-162°C)

Cryogenic and Fire Protection – Extreme Thermal Stress

Benefit – Process simplification and production efficiency;

No complex QC issue compare to conventional duplex
(rigid) system – Insulation + PFP
11
Flexible Epoxy intumescent PFP

Weathering/Exterior exposure and Durability – Service

Norsok M-501 Ed 6 Coating System 5A
Pitt-Char XP provides good corrosion protection and the product is
tested to Ageing (Cyclic) Procedure in accordance to ISO 20340 as
without a topcoat.
Exova Warringtonfire Report WF 376536:

12
Flexible Epoxy intumescent PFP

Weathering/Exterior exposure and Durability – Service

UL Exterior Environment Exposure – evaluate effect on exterior
exposure to the fire resistance performance.
- Aging; circulating air oven at 80°C for 135 days
- High Humidity; controlled humidity at 97-100% (at 95°F) for 180 days
- Industrial Atmosphere (CO₂-SO₂ mixture); (at 95°F) for 30 days
- Salt Spray; ASTM B117-64 for 90 days
- Wet Freeze Dry Cycling; alternate water (-40°F/24hr) dry atm (140°F/72hr) – 12 wks
- Acid Spray; fog spray consisting of 2% vol of Hydrochloric acid in water
- Solvent Spray; solvent/dry 6 hr, solvent/dry 18hr, 5 cycles
- Fire Test to UL 1709

Significance of the UL Exterior exposure ? UL to issue a letter on the expected life (20
year ageing) based on the accelerated laboratory test.
13
 Pitt-Char XP Fire Certification

• Pitt-Char XP is fully certified for both onshore and offshore

application; Pool fire and Jet Fire
– UL1709
– Lloyd’s Register (LR)
– Det Norske Veritas (DNV)
– Bureaus Veritas (BV)
– American Bureau Shipping (ABS)
– Russian Federation (GOST)

• UL1709 certified for application over Galvanized Steel

Same product offering protection to hydrocarbon pool and Jet Fire

14
Heritage - > 30 + years of Experience
Track Records

Petronas
Myanmar 2011
Aristech
1994 - EM 1993
Beryl B Aristech Saga Varg FPSO Petronas Myanmar

PITT-CHAR PITT-CHAR
. Introduced XP launched 2019
1980 1993 Continuous improvement R&D

1988-Piper A

1996 - CP Ekofisk 2/4J Shell Pearl 2010 – MOG Halfdan

>&> offshore
>&> onshore
projects worldwide
Introduction to PPG PITT-CHAR® NX

17
PPG PITT-CHAR® NX
A major advance in epoxy intumescent PFP technology

Developed in-house with the following key objectives…

Outstanding resistant to the most severe hydrocarbon hazards allowing design
SAFER
against all credible fire events

The most durable PFP product; resisting damage during fabrication, transportation,
TOUGHER
construction and withstanding severe environments for the life of your asset

THINNER Significantly thinner film thickness across all fire ratings and structures

LIGHTER Reducing material costs and providing significant weight savings

Ease and speed of application increases productivity, throughput and reduces

FASTER
construction schedules

18
PPG PITT-CHAR® NX SAFER
Next generation flexible passive fire protection
Designed to protect against the full range of
hydrocarbon hazards.
You no longer need to choose between jet fire or pool fire
protection for the optimized PFP solution – this product
does both and is proven to resist severe explosions and
impact without affecting performance.

• UL1709 Rev 5
• BS 476 hydrocarbon fires
• ISO 22899-1 jet fire ( the only industry recognized standard)
• IMO FTP Code
• ISO 20902:1 fire rated divisions such as decks and bulkheads

19
Hydrocarbon fire – Type approval testing
Multi-temperature/ Multi-section assessments
• Hydrocarbon fire curves
• BS 476-20 Annex D / EN 1363-2 / ISO 834-3 standards
• Open sections (I & H shapes, Channels, Angles) and hollow sections
(CHS, SHS, RHS)
• UL1709 Rev 5 (Multi-temperature)
• Largest range of section sizes
• 30/m to 340/m Hp/A
• Fullest range of limiting/critical core temperatures
• 150, 200, 250, 300, 350, 400, 427, 450, 500, 538, 550, 600, 620, 650, 700
and 750°C
• Widest range of fire durations
• 15, 30, 45, 60, 90, 120, 150, 180, 210, 240, 270 and 300 minutes

Whatever your structure and fire rating – we have it covered!

Hydrocarbon rated divisions – Type approval
Decks & Bulkheads
• Hydrocarbon fire cure per BS476 / EN 1363-2 / ISO 834-3
• Tested in accordance with IMO FTP Code 2010 per
Resolution MSC.307(88)
• Tested in accordance with new ISO 20902-1:2018 standard
• Decks up to H-180 Class; Bulkheads up to H-120 Class
• Fully satisfies requirements for resistance, integrity and
insulation (R.E.I.)

IMO Smoke and Toxicity testing for surface

materials and primary deck coverings
(2010 FTP Code, Annex 1 – Part 5)
Fundamentals of our product development
Jet fire erosion resistance
• Jet fires are the most common type of fire both onshore and
offshore – occurring with both liquids and gasses
processed, transported or stored at pressures higher than 2
barg (30 psi).
• Jet fire are controlled by process isolation and
depressurisation.
• API 521 recommends that process segments are blown-
down to half pressure within 15 minutes but that may still be
up to 6.7 barg (100 psi) – at this pressure jet fire are still
occurring.
• API 2218 Rev 3 identifies that PFP should be designed to
address jet fire hazards and also states that deluge is not Photo: Associated Press
effective against jet fires.
PPG PITT-CHAR® NX
Excellent jet fire resistance!
• Many modern PFP system do not have good resistant to jet
fires – they are optimized to pass UL1709 testing
• PITT-CHAR NX is different – not only do you get the best
UL1709 results but the product has excellent jet fire resistance.
• It is fully tested to the ISO 22899-1:2007 standard – this is the
only certifiable standard for jet fires.
• Testing arrangements include for structural I-sections, tubular
hollow sections and division.
• Jet fire tested for over 3-hours
• Best-in-class erosion factors
• No additional thickness for up to 30 minutes
• Erosion factors for full range of CCT’s (200°C to 600°C)
• Erosion factors for jet fires up to 3 hours duration
• 60 and 120 minutes erosion is typically only 2 to 3 mm
PPG PITT-CHAR® NX
Excellent jet fire resistance!
UL 1709 Jet fire
Best-in-class UL witnessed
results testing

An industry first!
PPG PITT-CHAR® NX TOUGHER

Enhanced environmental resistance

• PPG PITT-CHAR NX has been formulated to have
outstanding performance in accelerated weather test
programs.
• Suitable for use in offshore, marine, coastal and industrial
environments
• Tested to the very latest standards:
• NORSOK M501 Revision 6 – System 5a
• UL 2431 Category I–A Outdoor, Heavy Industrial
• ISO 12944-9: 2018 Category CX
• ISO 20340 Category C5-M

All testing carried out without topcoat

Over
25
20 years life – no degradation
PPG PITT-CHAR® NX
NORSOK M501 Rev. 6 Parameter Criteria Result

Corrosion Creep < 3mm Pass

• Tested to latest revision of NORSOK M501 Ri 0
• System 5a tested: Blistering 0 (S0) Pass
• Zinc Rich Epoxy – 60 µm SIGMAZINC 68 SP
• Epoxy Tie-coat – 40 µm AMERCOAT 71TC Cracking 0 (S0) Pass

• PFP Coating – 6mm PPG PITT-CHAR NX Flaking 0 (S0) Pass

• Tested without top-coat
Adhesion >5 Mpa Pass both cohesion
unexposed and adhesive
• Assessment Report Ref: WF 404454 Adhesion >3 MPa Pass both cohesion
exposed >50% and adhesive
Fire test <10% Pass
Deviation
Water Report value <0..2%
absorption Coating only

26
PPG PITT-CHAR® NX
Not rigid, flexible enough!
• PPG PITT-CHAR XP is famous for its incredible, patented,
flexible formulation
• Providing the ultimate resistance to flexing, vibration, impact
and extremely cold temperatures PPG PITT-CHAR XP

• Our latest PITT-CHAR NX has been designed to retain

flexibility while enhancing fire performance and durability
• A patent is pending on this innovation, we continue to be the
market leader in this field

PPG PITT-CHAR NX

27
Cracking resistance
Thermal cycling on T-bar test
• PITT-CHAR NX was designed to withstand the thermo-
mechanical strains resulting for severe temperature
cycling. Competitor Product 1 cracked after 15 cycles

• T-Bar test widely used to test tank linings in cyclic service

• Cold / Hot Temperature Cycle of -20°C to +35°C per cycle
• Patent Pending for resistance to thermal cycling stresses

Competitor Product 2 cracked after only 1 cycle

28 PPG PITT-CHAR NX
Test stopped after 40 cycles – No cracks Competitor Product 3 cracked after only 1 cycle
PPG PITT-CHAR® NX
Physical Properties*
Property Standard Value (SI units)
Density IMO 1.1 g/cm³
Hardness ASTM D2240 Shore D >70
Impact ASTM D256 Method C 9.8 J/m
Shelf Life PPG Method >18 months
Tensile Strength ASTM D638 12.8 MPa
Compressive Strength ASTM D695 17.6 MPa
Compressive Modulus ASTM D695 122 MPa
Lap Shear ASTM D1002 9.33 MPa
Adhesion ISO 4624 6.29 MPa
(100% Cohesion – no adhesion failure)
*All results are based on testing under laboratory conditions. PPG has undertaken extensive additional testing
for a wide range of conditions to assist with design under severe site conditions.
29
PPG PITT-CHAR® NX
Explosion resistance
• PFP systems must be able to withstand explosions without suffering
damage that may reduce its fire performance
• Currently no standard exists for explosion testing; a standard is
under development with ISO TC 92 SC2 committee
PPG is actively involved with the development of this standard
• PFP systems must be capable of withstanding over-pressure and
drag-loads generated by explosions
• Most importantly the system must be able to withstand any
deflections stress and strains of the item being protected as well as

Overpressure (mBar)
750

withstand potential impact from debris

• PPG commissioned 3rd party testing at DNV-GL Spadeadam 500

• Testing on full range of substrates: 250

• Structural I section for beams and columns 0.00

• Tubular section for pipes, vessels and hollow structural sections

• 5mm and 10mm plate for bulkheads and decks
200.0 300.0 400.0 500.0 600.0 700.0 800.0
Time (ms)

• Achieved > 4.5 Bar overpressure at ~100 ms duration

30
PPG PITT-CHAR® NX
Explosion resistance

31
PPG PITT-CHAR® NX
Explosion resistance

Resistance to deflection effects of 4.8 Barg

32
PPG PITT-CHAR® NX THINNER

Next generation flexible passive fire protection

LIGHTER

• Noticeably thinner and lighter than all alternative PFP

systems.
• Based on our XR658 UL 1709 two-hour fire rating, PPG
PITT-CHAR NX
• 7.98mm (314 mils) thin.
• The coating system is at least 15% lighter than ANY
alternative epoxy PFP system.
• So-called “lightweight” cementitious systems are actually
three times heavier.

33
PPG PITT-CHAR® NX – Competitive Analysis
UL1709 competitor products - Thickness
Fire rating PITT-CHAR Chartek Jotachar Firetex Firetex Hempafire Kansai KCC
(minutes) NX 2218 1709 M93/02 M90/02 Pool 200 AlesChar firemask
U 3500
XR658 XR645 XR647 XR630 XR632 XR654 XR 653 XR648
Thickness mm
30 3.43 5.05 5.39 3.00 4.83 4.20 5.48 4.90
45 3.43 5.05 5.39 5.35 5.61 6.53 5.48 4.90
60 4.19 5.05 5.39 5.35 7.45 6.53 5.48 4.90
90 6.08 6.85 8.08 9.03 10.79 9.32 8.78 7.90
120 7.98 8.67 10.76 11.83 13.66 12.12 12.04 10.80
150 9.88 10.51 13.43 16.07 14.92 14.84 13.80
180 11.77 12.33 16.10 18.02 17.72 18.56
210 13.66 14.16 18.23 19.51 21.82
240 15.56 15.98 21.45 20.54 25.08
270 17.62
300 19.89
Source: http://productspec.ul.com/search.php?type=listing&listing=BYBU

PPG PITT-CHAR® NX is thinner across the range!

PPG PITT-CHAR® NX THINNER

PPG PITT-CHAR NX

35
PPG PITT-CHAR® NX – Competitive Analysis LIGHTER
UL1709 competitor products - Weight
Fire rating PITT-CHAR Chartek Jotacha Firetex Firetex Hempafire Kansai KCC
(minutes) NX 2218 r 1709 M93/02 M90/02 Pool 200 AlesChar firemask
U 3500
XR658 XR645 XR647 XR630 XR632 XR654 XR 653 XR648
Mass Kg/m²
30 3.77 5.75 5.39 3.00 4.83 5.46 7.23 5.64
45 3.77 5.75 5.39 5.35 5.61 8.49 7.23 5.64
60 4.61 5.75 5.39 5.35 7.45 8.49 7.23 5.64
90 6.69 7.80 8.08 9.03 10.79 12.12 11.59 9.09
120 8.78 9.87 10.76 11.83 13.66 15.76 15.89 12.42
150 10.87 11.96 13.43 16.07 19.40 19.59 15.87
180 12.95 14.03 16.10 18.02 23.04 24.50
210 15.03 16.11 18.23 19.51 28.80
240 17.12 18.19 21.45 20.54 33.11
270 19.38
300 21.88

PPG PITT-CHAR® NX is lighter than

all other epoxy PFP products – more than 15%!
PPG PITT-CHAR® NX THINNER
Next generation flexible passive fire protection

H120/J30/Structural/400 (Hp/A 100)

PITT-CHAR® NX CHARTEK Jotachar
< 11 mm 14.63 mm 16.20 mm

H120/J120/Structural/538 (Hp/A 160)

PITT-CHAR® NX CHARTEK Jotachar
< 10 mm 15.81 mm 16.60 mm

Competition is at least 50% thicker

PPG PITT-CHAR® NX FASTER

Next generation flexible passive fire protection

Thanks to the thinness advantages, excellent sagging
resistance and fast cure characteristics of
PPG PITT CHAR NX, the complete coating system can
typically be applied in just one day, offering up to 60%
savings in application time.
This greatly enhances productivity, increasing throughput
and reducing construction schedules and application costs
– whether applied on-site or off-site.

Topcoat is only required for aesthetic purposes

38
PPG PITT-CHAR® NX FASTER

The carbon fiber advantage

SAFER
• Extensively tested on reinforcement options during product
development
TOUGHER
• Use of mesh reinforcement allowed for substantial reduction in
PFP thickness
• Faster and lighter
• Safer and Tougher - Enhances durability
• Mesh incorporation turns a coating into a composite
• Improves crack resistance
• Proven to work even if PFP is damaged
• PPG PITT-CHAR CF carbon fiber mesh
• Fast simple installation
• More open area – improved wetting out
• Low material cost – offset by displacement of epoxy

Safer, Tougher, Faster – even with mesh!

39
PPG PITT-CHAR® NX FASTER
Next generation jet fire resistant epoxy intumescent
Faster application – Lower consumption – Typical competitive analysis
• Two hour fire protection can be done in single application in one day
• Below is a comparison of shop application before being able to move the steel

2 hour JF comparisons
Day PPG PITT-CHAR NX Competitor A Competitor B
J120 scenario (mesh-free) (carbon glass hybrid mesh)
DFT 10 mm DFT 17 mm DFT 16 mm
1 10 mm application 8.5 mm first application 8 mm first application

2 8.5 mm second application 8 mm second application

3 Topcoat Topcoat

4 Ready to move/handle Ready to move/handle

Weight 11kg/m² 17kg/m² 16kg/m²

PPG PITT-CHAR® NX THINNER

Next generation flexible passive fire protection

LIGHTER

So-called “lightweight” cementitious systems are actually

three times heavier and considered cost effective.

However PPG PITT-CHAR NX has such low installed

thickness and weight that it can compete against
cementitious and does not require maintenance.

41
PPG PITT-CHAR® NX
Next generation flexible passive fire protection
Life Cycle Cost Comparison Pitt Char NX
PPG PITT-CHAR NX
is a real viable
$6,000,000
solution rather than
Cementitious PFP $5,000,000
materials. $4,000,000

$3,000,000
Similar installation $2,000,000
cost however
$1,000,000
cementitious
maintenance liability $0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
can cost 3 times the
original cost. PITT-CHAR NX Cementitious

Cementitious solutions are 3x heavier!

PPG PITT-CHAR® NX can be 3x more efficient
over
42
the life cycle of your asset
 PPG PITT-CHAR® NX

Next generation flexible passive fire protection

43
 Use PFP to Protect Lives
Allow/Buy Time
– Emergency response
– Escape
– Fight the fire

Safeguard & Preserve

– Escape routes
– Preserve shelter area

44
 PFP Uses in Onshore Facilities

45 Refinery, Petrochemical, Chemical Processing, Power Plant, LNG Facilities

 Areas of PFP (Onshore) - Safety Critical Element
• Structural Steelwork
- to prevent structural collapse

• Pipework / Pipe and Supports

- to prevent structural collapse
- To prevent fracture & escalation

• ESD Valves/Actuators
- to ensure containment/prevent escalation

• Vessels
- to prevent inventory temp & press rising
- To prevent BLEVE (boiling liquid expanding vapour explosion)
(fire→ vessel internal pressure↑ →steel weaken →explode)

46
 FPSO - Typical PFP Areas

2
6
2

1. Process Areas - Primary Steel Structures

4 2. Turret / Gantry Structure / Riser Bay Fire Protection

3. Flare Tower Steel Structure / Support

6

4. Fire & Blast Walls For Separation and Control

5. H-rated Bulkheads On Accommodation

6. Process Areas Critical Vessels and Pipework

47
 Fixed Production Platform - Typical PFP Areas

3 1. Structural Steelwork

4 2. Flare Tower Steel Structure / Support

3. Fire wall or Decks

4. Piping and ESDV and Process Vessels

48
 Drilling – Jack-up, Semi, Drillship - Typical PFP Areas

1
1

1. Accommodation or LQ Wall

1 1

49
 • Decks & Bulkheads/Firewalls (Division)
- to prevent the passage of heat & smoke
- to provide insulation and personnel protection

• Main Structural Steelwork

- to prevent structural collapse

• Pipework / Pipe and Vessel Supports

- to prevent structural collapse
- To prevent fracture & escalation due to jet fires

• ESD Valves and Actuators

- to ensure containment & prevent escalation

• Vessels
- to prevent inventory temp & press rising
- To prevent BLEVE
(boiling liquid expanding vapour explosion – fire → internal pressure↑→steel weaken →explode)

Similar to Onshore - except including Division Bulkhead / Decks protection

50
 • Not to worry – Support by AP PFP Team (or separate coaching/training on MTO)
• Refer to Relevant Fire Certifications for PFP thickness – MTO / Thickness
• Generally thicker steel (heavier mass) absorb more heat than thinner steel.
• Hence, the PFP thickness would require less protection (less PFP thickness).
• Need to know Fire Load; Duration; CCT & Steel Size – PFP Spec / Drawing

Heated Perimeter

X Sectional Area

Fire Load – HF, JF or both HF/JF; Duration – Steel Protection Time in mins or hrs; CCT – Critical Core Temp (Layman – Failure Temp)
51
 Fire Rating – Structural

Heated Perimeter ↑ HpA = PFP Thk ↑

X Sectional Area ↓ HpA = PFP Thk ↓

52 CCT – layman term “failure temp”; other terms such as “steel limiting temp” or “restrictive or allowable steel temperature”
 Hence for Onshore UL1709 certification / requirement, we only need to know the resistance time or duration of protection.

53
 Current no clear definition on CSP rating. ISO Technical Committee
formed.
ISO 20088-1. Determination of the resistance to cryogenic spillage of
insulation materials -- Part 1: Liquid phase, is published.
Future parts will cover vapour and jet conditions.

CSP Rating (would be similar to fire rating)

• Need to know criteria
1) Nature of CSP: Liquid / Vapour / Jet – Immersed (Submerged), Splash/Jet
2) Duration of CSP : 15 / 30 / 60 / 120 mins
3) Cold Critical Core Temp (CCT) : -40 / -29 / -60°C depending on structural/design
4) Initial Steel Temperature prior to CSP exposure (θT drops)
5) Steel Sizes – to cal Hp/A (thicker steel will take longer to cool relatively to thinner steel)

Pitt-Char is tested to ISO20088-1 and has conducted a lot of CSP testing with different exposure conditions.
54 For CSP splash or jet condition - the nozzle orifice, distance to steel substrate and LNG flow rate are factors to consider.
 Hp/A (A/V) Calculation: Definitions

55 Footer text
 • PCNX Density – 1100 kg/m³ (1.1 g/cm³) Area = 100m²
• 1100 kg/m³ = 1100 kg/(m².m) = 1100 kg/(m².1000mm) = 1.10 kg/m².mm

• PCNX Density – 1.10 kg/m².mm PCNX (T) = 100x11.0 = 1100 kg

PCNX (P) = 100x14.30 = 1430 kg
• Assuming PCNX = 10mm (calculated thickness)
• Theoretical Qty = 10 x 1.10 = 11.0 kg/m² Mesh (T) = 100m² (assuming 100% cover)
• Assumption 30% wastage (NOT loss factor) Mesh (P) = 100x50%x1.3 = 65m²
• Estimated Qty = 11.0 x 1.3 = 14.30 kg/m²

• Weight/m² = thickness x density x wastage

• Total weight = thickness x density x wastage x area

PCNX Density as referred to Cured Density (Specific Weight)

56
 PITT-CHAR® – Typical Equipment for Spraying
Heated Plural Component Spray Pump – Covercat 452 PFP

57
 PITT-CHAR® – Functionality of the Pump
Heated Plural Component Spray Pump – Covercat 452 PFP Typical Schematic Diagram
Material Feed System
Water Circulation System
Flushing (hot water) System

Mixer Block

Flush with Hot water during Stoppages

58 Feed / Follower Plate

 PITT-CHAR® NX – Spray Application
Ratio Check – Drain out material from the mixer block – physical weighing
 PCNX material (Component A and B) stored above 30 – 35℃ at least 24 hours prior to use.

 Plural Equipment Setting:

 Typical temperature settings (varies with ambient temperature)
 Base : 55 - 60℃, Hardener : 50 - 55℃, Line heaters : 60 - 70 ℃
 Spraying Tips and Operating Pressure
 Operating Pressure : 240-310bar (3500-4500psi)
 Nozzle Size : 0.84-1.09mm (33-43 thou), Fan angle : 40-60deg
 (This above given as a guide only and maybe adjusted to provide optimum application characteristics)

 Weight Ratio Check Part A : Part B – 3.24 : 1

 Weight ratio should not deviate more than 10%.
 Acceptable range between 2.93 (min) – 3.57 (max) : 1

 Flushing the Equipment (Mixing unit / Spray whip hose line and Gun) with Hot water during stoppages.

59
 PITT-CHAR® NX – Spray Application Video

60
 Approved Primers and Topcoats

Why We Must Have Approval

• Limitation of risk for lives and assets

• Limitation of liability for PPG

• What happens if you are using a wrong primer or topcoat?

- If a protective coating fails rust
- If a tank lining fails contamination
Approved Primers Approved Topcoats

61
 Primer Compatibility of 3rd Parties

• Fabricators of structural steel or Client tend to use their own preferred

coating supplier
• It is therefore very important that the applied primer coat is identified
and checked for compatibility before application of any Pitt-Char
intumescent coating
• In case a primer or topcoat has not been checked up to now, please
provide details as below
- Product Data Sheet
- Material Safety Data Sheet
- The coating system specification, such as dft
- One litre wet sample in each component (optional)
Approved 3rd Parties’ Primers

62
 Intumescent Fireproofing
Pitt-Char XP is suitable for service applications on approved substrates from -40°C to
+80°C

Pitt-Char NX is suitable for service applications on approved substrates from -40°C to

+80°C
• Chemical reaction commenced above 80°C (this is maximum operations service
temperature for PCXP and PCNX)
• Material starts to intumesce/swell at around 200°C
• Reinforcement Mesh is incorporated into the system to reinforce the insulating
char.
• If the substrate is having operating service temperature of above 80°C, thermal
insulation or cellular glass (brand: Foamglas) is to be installed prior to PFP.
• PPG will be having its own thermal insulation product and will be named Insulon
FX, which is now being tested.
• Soon, we can provide one source for thermal insulation and PFP materials.
63
 Flexible Epoxy intumescent PFP
Summary

The Industries require a flexible and resilient hydrocarbon PFP that can
withstand movement, vibration and stress (after application), ability to
tolerate cold temperatures without embrittlement or cracking, and stay
in place after high-pressure blast that cause significant substrate
deflections.

PITT-CHAR®
Epoxy Intumescent Passive Fire Protection System

Flexible Epoxy Intumescent Passive Fire Protection

64