Fireproofing From Chevron
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1700Fireproofin roofing 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
1711 1711 Defini Definitio tion n of Ter Terms ms 1712 Company Company and and Indust Industry ry Docum Documents ents 1720 Support Structures
1700-3
1721 Where Fireproofi Fireproofing ng of Support Support Structures Structures Is Warrant Warranted ed 1722 Level Level of Protect Protection ion Requi Required red 1723 Layout Layout and Design Design Conside Considerat rations ions 1724 1724 Mate Materrials ials 1725 1725 Speci Specific fic Applica Applicatio tions ns 1730 Critic tical Va Valves, In Instrum rument entation, and Shutdown Sy Systems
1700-14
1731 Emergency Emergency Shutdown or Isolation Valves 1732 Tank Block Block Valve Valvess 1733 1733 Air Air Supp Supply ly 1734 Switchge Switchgear ar Housing Housing and and Junction Junction Boxes Boxes 1735 Instrum Instrument ent and and Electr Electrical ical Cables Cables 1736 Home Runs Runs for Cable Cable Tray Trayss and Conduit Conduit Banks Banks 1740 Materials Suppliers and Applicators
1700-20
1741 1741 Suppor Supportt Struc Structur tures es 1742 Critical Critical Valves, Valves, Instrumenta Instrumentation, tion, and Shutdown Systems Systems
ChevronCorporation
1750 Fireproofing Test Methods
1700-22
1760 References
1700-25
1700-1
J une 2000
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1700 Fireproofing
Fire Protection M anual
1710 Introduction Selecting a fireproofing material involves answering three questions: •
What What leve levell of of prot protec ectio tion n is is requ requir ired, ed, if any? any?
•
What What mate materia rials ls will will provid providee this this leve levell of protec protectio tion? n?
•
Of thos thosee mate materia rials, ls, which which is the the appr approp opria riate te choi choice ce??
Section Section 1720 answers 1720 answers these questions for support structures and S and Secti ection on 1730 for 1730 for critical valves, instrumentation and shutdown systems. This section defines terms used in this section and lists relevant Company and industry documents.
1711 Defini efiniti tion onofTerms Fireproofing: Protection that provides resistance to fire and heat transfer long enough to allow critical structures to remain standing or critical control systems to operate, while the fire is brought under control. Fire-Exposed Envelope: •
For struc structur tural al steel, steel, vess vessel/c el/colum olumn n skirts, skirts, etc. etc.,, the area area within within a horiz horizonta ontall 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 instr instrumen umentat tation, ion, elec electric trical al power power cable cabless and/or and/or air air piping piping/tub /tubing, ing, the area area within a 50' horizontal radius or 50' vertically.
Fire Potential Equipment: •
Fired Fired equipm equipment, ent, includin including g heater heaterss and furna furnaces ces,, that handles handles flamm flammable able matematerials.
•
Rotating Rotating or reci reciproc procatin ating g mecha mechanica nicall equipm equipment, ent, such as pumps pumps or compr compresessors, that handles flammable materials.
•
Drums, Drums, excha exchanger ngers, s, colum columns, ns, and simil similar ar opera operating ting vessels vessels that handle handle flam flam-mable materials and have a volume of more than 1000 gallons (24 barrels).
•
Plot-lim Plot-limit it piping piping manifo manifolds lds that that contai contain n flammab flammable le mater materials ials and ten ten or more valves.
•
Tanks, anks, spheres, spheres, and sphero spheroids ids that that contain contain flam flammabl mablee materi materials als includ including ing their their drainage and relief path and impounding basis.
Flammable Materials: For Materials: For the purpose of this section of the manual, flammable
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Fire Protection M anual
1700 Fireproofing
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.
1712C 2Company andIndustry ry Docu cuments See Section Section 1760, 1760, References, for a complete listing of Company and industry guidelines for fireproofing. The Standard Drawings can be found in the Standard Drawings section. Use API RP 2218, Fireproofing Practices in Petroleum and Petrochemical Processing Plants as a guide to determine the extent of fireproofing required. This section is a supplement to that publication.
1720 SupportStructures This section presents guidelines for fireproofing support structures to protect them from failure due to fire exposure for specific time periods.
1721WhereFireproofi Fireproofing ngofSup SupportStructu Structures Is Warranted Fireproofing of the principal members is warranted if the structure is in the fireexposed envelope and failure of these members could cause any of the following: •
Thre Threat at of inju injury ry to per personn sonnel el
•
Loss or serious serious damage damage to valua valuable ble or criti critical cal supporte supported d equipm equipment ent
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1700 Fireproofing
Fire Protection M anual
Conversely, fireproofing is not warranted in these situations: •
The valu valuee of the structur structuree and and suppor supported ted equipmen equipmentt is low low when when compa compared red to the cost of fireproofing.
•
Member Member failu failure re would would not cause cause failure failure of the the struc structure ture or equip equipment ment.. Thus, Thus, wind and earthquake bracing and other secondary members, such as supports for stairs, platforms, and walkways, are not normally fireproofed.
•
The struc structure ture is far far enoug enough h remove removed d from from the the source source of a fire to prec preclude lude serious damage.
•
The fire fire would would cause cause failur failuree or serio serious us damage damage to suppor supported ted equip equipmen mentt whether whether or not the structure was fireproofed.
•
The struc structure ture supports supports piping piping that that is not carr carrying ying flammab flammable le liqui liquids. ds. Pipin Piping g carrying only gases does not normally justify fireproofing of the supports.
1722Level of Protecti ection onRequired uired Major factors that determine the level of fireproofing needed are the intensity and duration of potential fire and the importance of the structure or equipment. Typically, fireproofing should protect structures supporting high-risk or valuable equipment from reaching 1000°F for a period of three hours, as defined by UL 1709 (see Section Section 1750). 1750). For dense concrete, this is equivalent to four hours as defined by ASTM E-119, the test used prior to 1984. (Refer to Se to Sectio ction n 1750 for 1750 for a discussion of the differences between ASTM E-119 and UL 1709 fire tests.) Fireproofing in excess of these requirements may be necessary for special high valued equipment such as reactors or equipment handling large quantities of flammable material in congested areas. Non-critical structures are not protected. Consult the CRTC Fire & Process Safety Team if you feel the above criteria do not fit your needs. When fireproofing of structural supports is warranted, the following types of protection are recommended: Three-hour fireproofing as fireproofing as shown on Standard Drawing GA-N33336 (in Standard Drawings Section) is for main support members of structures and equipment within the fire-exposed envelope (see Sec (see Section tion 1711 1711). A three-hour level of protection is appropriate for a typical hydrocarbon processing unit fire duration. Less than three-hour protection. Thinner coatings may be used where three-hour protection is not warranted. See Figures 1700-1 Figures 1700-1 and and 1700-2 1700-2 for for guidance. Threehour protection may not be justified in areas where the flammable inventory is such that a three-hour fire is unfeasible. A three-hour rating for formed and poured concrete fireproofing is usually worth the small incremental cost of the additional concrete. If gunite concrete is used, it is
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Fire Protection M anual
1700 Fireproofing
ComparativeFire FireRating Rating The required weight and thickness of fireproofing material for a given duration of fire exposure varies depending on the type of material chosen. Estimated weights and thicknesses for different types of material and different ratings are given in Figures 1700-1 and 1700-1 and 1700-2
.
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J u n e 2 0 0 0
Fig. Fig.1700-1 Properties of Cementitious Base Fireproofing Materials INTERMEDIATE STRENGTH
LOWSTRENGTH
Concrete (poured-in-place Haydite Vermiculi Pyrocrete 240(High Yield) culite Mix Mix Pyrocrete
Pyrocrete 241
Fendolit lite M II(1)
HIGH STRENGTH Product ct Name
or gunited) Standard mix of portland cement and rock aggregate
Haydite and Vermicul Vermiculite ite (light weight weight aggregate) plus portland cem c ement ent
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
3
1.19
0.87
1.32
70-90
70-90
55
55
40-41
Design No. XR-716
Design No. XR-701
Design No. XR-704
Specifications Density (lbs./cu ft) Compressive Strength (PSI) Ther Therm mal Condu onducti ctiv vity ity (BTU (BTU in/deg F-hr-sq ft @ 75 deg F mean temperature) Hardness (Shore D) UL 1709 1709 Fire Time Time Rating Rating (thickness (thickness in i n inches at: 1 7 0 0 6
1 hour
-
-
-
11/16”
1”
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”
3 hours
2.5” Note(2)
2” Note(2)
1-3/8”
1-3/8”
1-13/16”
-
-
1-9/16”
1-9/16”
2-5/16”+
Recommended Primer
4 hours
Epoxy(3)
Epoxy(3)
Note(4)
None(4)
Epoxy(3)
Recommended Topcoat
None(5)
None(5)
Note(4)
None(4)
Note(4)
(6)
(7)
Recommended Use
C h e v r o n C o r p o r a t i o n
Note
Note
(8) (7) (9)
Notes
(1) (1) Chevron has has not used this systemextensively. extensively. Before using it, contact the CRTC Materials Material s and Equipment Engineering Engineering Specialist. Speciali st. (2) (2) While there is no test data to support support this num number, ber, it is equivalent to to a 4 hr ASTM E-119 E-119 rating, rating, for which whic h test data data is available. (3) (3) Coating System System Data Sheet 4.4 4.4 in the the Coatings Manual (Quick Ref Guide page page 69). 69). (4) Follow manufacturer’s recommendations. (5) (5) For severe weathering weathering and and corrosive condition conditions, s, consider an epoxy epoxy topcoat. (6) (6) Structures Structures such as piers, legs, legs, pipe supports, supports, etc., etc., where weight weight is not a c oncern. (7) (7) Vessels, skirts and ot other her applications requiring lighter lighter weight aggregate. aggregate. Generally Generally not used on structural structural steel. (8) (8) Better for modula modularr designs where flex flexing ing occurs during transport. transport. (9) (9) Oil platforms platforms and other other applications requiring lighter weight and low volume. volume. (10) (10) Chevron has has good experience with this product.
(10) (7) (9)
Notes
1 7 0 0 F i r e p r o o f i n g
Notes(7) (9)
F i r e P r o t e c t i o n M a n u a l
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C h e v r o n C o r p o r a t i o n
Fig. Fig.1700-2 Properties of Non-Cementitious Base Fireproofing Materials IN INTUMESCENT Pittchar XP
100% solids epoxy intumescent
100% solids epoxy intumescent
Density (lbs./cu ft)
62.4
73
78.5
28
54
Compressive Strength (PSI)
2700
2264
2190
900
1420
Ther Therm mal Cond onductiv uctivit ity y (BTU in/deg F-hr-sq ft @ 75 deg F mean temperature)
1.48
1.69
0.076
?
1.14
Specifications
Therm rmola lag3000(100% Solids)
INSULATING
Chartek VII Product Name
Hardness (Shore D)
SuperFire FireTemp(Elec(Electric CableTrays)
Eternit Eternit Promat H
Two Two-com -compone ponen nt epox epoxy y High density calcium sili- High density calcium silisubliming subliming coating c oating cate insulation cate insulation
70
60
50
?
?
UL 1709 Fire Time Rating (thickness in inches at):
Design No. XR-617
Design No. XR-612
Design No. XR-618
-
1986 HIFT Test Results
1/4 hour
-
-
-
1”
-
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
(3)
(3)
(3)
1 7 0 0 7
Recommended Primer
J u n e 2 0 0 0
SUBLIMING (1)
Recommended Topcoat
Note
Note
Note
Recommended Use
Note(5)
Note(5)
Note(6)
(1) (1) (2) (3) (3) (4) (4) (5) (5) (6) (6)
(4)
Note
Cable Trays
Chevron has has not used this this systemextensively. extensively. Before using it, contact the CRTC CRTC Fire & Process Proc ess Safety Teamor CRTC Materials Material s and Engineering Engineering Specialist. Specialis t. See manufacturer’s manufacturer’s brochure broc hure for calculation cal culation instructions i nstructions (page 18 18-19) -19).. Follow manufacturer’ anufacturer’s recomm recommendation endations. s. Outdoor Outdoor installations need weatherjacketing. Silicone waterproofing is recom rec omm mended by J ohns Manville and may be adequate adequate for dry locations. Oil platforms platforms and other other applications requiring light weight and low volume. volume. Thermolag Thermolag 3000has both on and and off-shore applications. applic ations. See Manufacturer’ M anufacturer’ss brochures for each eac h market. market.
F i r e P r o t e c t i o n M a n u a l
None Note(3) Note(1)
1 7 0 0 F i r e p r o o f i n g
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1700 Fireproofing
Fire Protection M anual
1723Layout andDesign DesignConsiderati Considerations ons The API Publication 2218, “Guideline for Fireproofing Practices in Petroleum and Petrochemical Processing Plants,” gives a sequence of steps to follow when considering what to fireproof. This section of the manual offers supplemental information. Consider the following during design: •
Gene Generral layo layout ut of the the plan plantt (se (seee Section Section 1300) 1300).
•
Drainage Drainage (both (both of the plant plant area area and and within within structur structures) es) should should carry carry hydrohydrocarbon 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 Section 1400) 1400).
•
Fire risks risks in plants plants should should be adequ adequatel ately y space spaced d from from one one anothe anotherr (see (see Section Section 1300). 1300).
•
Sources Sources of of ignition ignition—fu —furna rnaces, ces, shops, shops, etc.— etc.—shoul should d be loca located ted as as far far as prac prac-tical from areas where flammable vapor might be released to the air. Where risks are not adequately separated, additional fireproofing may be justified.
1724Material erials s Types of Fireproofing reproofingMaterial Materials s 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: •
Cementitious-based materials Cementitious-based materials such as concrete, Carboline’s Pyrocrete 241, and Hydraulic Press Brick Co.’s Haydite-Vermiculite Haydite-Vermiculite field mix. mi x.
•
Ablative materials or non-cementitious coatings such as Thermal Science Inc.’s (TSI) Thermolag 3000 (subliming) and Textron’s Chartek VII (intumes-
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Fire Protection M anual
1700 Fireproofing
If you use concrete, follow Specification CIV-EG-850, Plain and Reinforced Concrete. Concrete should be specified as ASTM C-150, Type II. If you use other materials, follow the manufacturer’s recommended installation procedures. UL 1709 “rapid rise” fire testing (described in Se in Sectio ction n 1750) 1750) indicates that gunited concrete may not provide the same protection as cast-in-place concrete. Even though Company experience with gunited concrete in actual fire conditions is limited, it does not indicate that gunited concrete is inferior to cast-in-place concrete. Until experience indicates otherwise, gunited concrete can be considered a cost-effective fireproofing method for low-risk, lower-value areas where aesthetics is not a high priority. Consult with the Fire Protection Staff about using it in critical high risk areas.
Properties of Fireproofing Material erials s Figures 1700-1 and 1700-1 and 1700-2 compare 1700-2 compare fireproofing materials. Some of the terms used in the figures are discussed below. Applied Weight. Design of structures must include the weight of fireproofing, which can significantly add to the total dead weight load. Concrete has a density of 150 lb/cu ft. Less dense materials minimize dead weight. However, lighter weight materials may not save money because they are generally more expensive than concrete. Compressive Strength. Will the area you are fireproofing be subject to mechanical abuse? Compressive strength is a good indicator of impact resistance. Some lightweight fireproofing systems such as Pyrocrete 241 have low compressive strength and are more easily dented or damaged. These materials should not be used in hightraffic, high-maintenance areas. Thermal Conductivity. Conductivity. Normally, thermal conductivity is not a major factor in choosing a fireproofing material unless the material is to insulate the structure also. Figures 1700-1 and 1700-1 and 1700-2 show 1700-2 show 75°F mean temperature K factors for some common materials. If used as both insulation and fireproofing, these materials should not be exposed to continuous temperatures over 200°F.
Mineral/ Mineral/Che Che i al Com sition sition ofFi
ofi
Material rial
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1700 Fireproofing
Fire Protection M anual
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 manufacturer’s 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 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 Figures 1700-1 and and 1700-2 indicate 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
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Fire Protection M anual
1700 Fireproofing
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.
Problems with withFireproofing ofing The Company has no reported failures of a fireproofing material during a fire. However, fireproofing has caused the following problems: •
Severe Severe corros corrosion ion of the struct structura urall steel steel and reinf reinforc orcemen ementt mesh mesh underne underneath ath firefireproofing. 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.
•
Exces Excessiv sivee cra cracki cking ng of of ceme cementi ntitio tious us fire firepr proof oofing ing..
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.
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1700 Fireproofing
Fire Protection M anual
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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Selec Selecti ting ngthe Appropriate riate System Concrete has usually been the most cost-effective fireproofing material. It is readily available and the materials are least expensive. It does not require specialized installation techniques like some commercial fireproofing materials. Some proprietary fireproofing systems, such as Pyrocrete 241, are becoming more competitive with concrete from an installed cost standpoint, and have performed better than concrete in fire tests. Consider the long-term costs of fireproofing systems. If a topcoat is required in the original design, plan to recoat it about every 10 years. Discounted cash flow calculations may show this maintenance cost to be low; however, also consider the chance that the required planned maintenance will not be carried out. Concrete fireproofing
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Fire Protection M anual
1700 Fireproofing
Hydroprocessi rocessing ngReactor Skirts Skirts Reactors with a “hot box” design at the shell-to-skirt joint should be fireproofed to the bottom of the hot box. Insulation covering the hot box should be protected with a 10-gage stainless steel flame shield. The flame shield should extend from the top of the fireproofing to the head-to-shell joint and be mechanically secured. Consult a fireproofing or reactor design specialist for details of the flame shield. The flame shield design was tested in 1989 with a UL 1709 test modified with a high pressure hydrogen jet. The flame shield protected the underlying insulation from the erosive effects of the hydrogen jet. Concrete fireproofing and Pyrocrete 241 were also tested, and neither was affected by the hydrogen jet. See Materials Division Report, “Fireproofing Tests with Hydrogen Jet Impingement,” M.D. Gibb, January, 1990 File No. 56.35, available from Chevron Research and Technology Company, Process & Equipment Technology Group.
Piers Piers or Legs for Horizon rizontal Vessels Vessels Support piers or legs for horizontal vessels near ground level, when not constructed of reinforced concrete, should be fireproofed. (Exception: Metal saddles less than 9 inches high at the lowest point need not be fireproofed.)
OffshoreStructures 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
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1700 Fireproofing
Fire Protection M anual
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.
Prefabric Prefabricated Fireproofed Beams Often it is economical to fireproof structural members off-site. Material such as Pyrocrete 241 can be used to “butter up” the ends of prefabricated concrete fireproofed beams after they are installed.
1730 Criti Critic cal Valves, alves, Instrum Instrumentation, ation,andShutdown Systems Refer to Figure Figure 1700-3 1700-3 for for an overview of this section. Critical valves are defined as valves equipped with remote operated actuators that must retain their operational integrity for a minimum of 20 minutes during a fire to facilitate safe unit shutdown (refer to S to Sect ection ion 1750). 1750).
1731Emergency ergencyShutdownor Isol Isolati ation onValves alves Fail-Safe design is preferred for critical and emergency valves. It uses spring opposed valved actuators and normally pressured or electrically energized control circuits. Failure of the control circuit will cause the valve to move to its fail-safe position. See the Instrumentation and Control Manual, Section 1300 for more information on failure modes.
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Fire Protection M anual
1700 Fireproofing
Fig. Fig.1700-3 Determining Fireproofing Fireproofi ng Needs for Critical Valves, Valves, Instrum I nstrumentation entation and Shutdown Systems
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1700 Fireproofing
Fire Protection M anual
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. •
(Figure re 1700-5 1700-5)) uses insulation pads laced together Insulated Bag. Bag. This system (Figu 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 200°F for 20 minutes if exposed to a 2000°F fire, as described by UL 1709.
Fig. Fig.1700-4 Insulated Box Enclosure for Valve Actuators
Fig. Fig.1700-5 Insulated Bag for Valve Actuators
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Fire Protection M anual
1700 Fireproofing
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.
1732 Tank Bloc Block k Valves alves Tank valves 12 inches or smaller are easily hand-operated and are not normally power-operated; therefore, fireproofing is not required. For larger size tank valves where air or motor operators have been installed, fireproofing may be justified for the operator, conduit, and controls within the fire hazardous areas. The switchgear should be located outside the tank impounding areas or drainage paths and the conduit should be buried as close as possible to the
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1700 Fireproofing
Fire Protection M anual
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.
1734Switchg Switchgear Housing singand J unction nctionBoxes Switchgear housing and junction boxes for power and control of emergency shutdown, and isolation valves (MOVs), and motor starters should be located outside a fire hazardous area. If this equipment must be placed closer, the entire enclosure, as well as the rear of any exposed mounting support plate, should be fireproofed. Johns Manville—Super FireTemp X Board fireproofing can be used in this application. Switchgear and junction boxes can also be protected to a lesser degree by installing a radiant heat shield between the enclosure and the potential fire source.
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Fire Protection M anual
1700 Fireproofing
silicon dioxide insulation in a stainless steel sheath (e.g., Meggitt Safety Systems’ SI 2400 Fire Cable). Neither system requires conduit.
Fire-Re re-Resistan sistant Wiring ringNeedingSteel Conduit This system uses wiring or cable with electrical insulation which will withstand exposure up to 2000°F for at least 20 minutes. The cable must be installed inside a steel conduit for support (e.g., DeKoron Fire Resistant Circuit Integrity Cable).
Nonfirefire-resi resistan stant Tubingor Wiri Wiringwith withThermal Insulation This system protects critical instrument leads or electrical wiring that is not heat resistant (e.g., plastic tubing and wiring with PVC insulation). It consists of the tubing or wiring inside a rigid steel conduit covered by thermal insulation and stainless steel weather jacketing.
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1700 Fireproofing
Fire Protection M anual
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.
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Fire Protection M anual
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
1700 Fireproofing
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1700 Fireproofing
Fire Protection M anual
High HighTemperatureWire Wire DeKoron Fire Resistant Circuit Integrity Cables USA Cables 1199 So. Chillicothe Road
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Fire Protection M anual
1700 Fireproofing
now used by many companies, including Chevron. Fireproofing manufacturers use the tests instead of ASTM E-119, because the UL 1709 tests more closely approximate hydrocarbon fires. These “high rise” fire tests include a faster temperature rise and higher energy input than ASTM E-119 as shown in Figure Figure 1700-6 1700-6. The ASTM E-119 test is primarily for buildings or combustible structures. Hydrocarbon fires
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1700 Fireproofing
Fire Protection M anual
placed to measure significant temperatures of the component elements of the beam. Thermocouple design is also specified in the test standard. The transmission of heat through the protection material during the period of fire exposure for which Classification is desired shall not raise the average temperature
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Fire Protection M anual
1700 Fireproofing
1760 References Americ erican PetroleumInst troleumInstitute (API) API API 221 2218 8
Guid Guidel elin inee for for Fire Firepr proo ooffing ing Pra Pract ctic ices es in Petr Petrol oleu eum m an and
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