Specification For Proprietary Cementitious Fireproofing - Rev 00B

 

Wheatstone Project LNG Plant Specification for Proprietary Cementitious Fireproofing

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© Chevron Australia Pty Ltd

 

Wheatstone Project LNG Plant Specification for Proprietary Cementitious Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

Wheatstone Project LNG Plant

Specification For Proprietary Cementitious Fireproofing

Bechtel Confidential © Bechtel Oil, Gas and Chemicals, Inc. 2010. All rights reserved. This document contains information that is confidential and proprietary to Bechtel Oil, Gas and Chemicals, Inc.

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BECHTEL OG&C

© Chevron Australia Pty Ltd

CHEVRON DOCUMENT NO.

REV.

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BECHTEL DOCUMENT NO.

REV.

25504-100-3PS-NF00-F0002

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Page 2

 

 

Wheatstone Project LNG Plant Specification for Proprietary Cementitious

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

TABLE OF CONTENTS 1.0  SCOPE ........... ....................... ....................... ....................... ........................ ........................ ....................... ....................... ...................... ............ .. 4  2.0  QUAL QUALITY ITY STANDA STANDARDS........... RDS....................... ....................... ...................... ....................... ....................... ...................... ...........4 4  3.0  SUBMI SUBMITTAL TTALS.................. S.............................. ....................... ...................... ...................... ....................... ........................ .................... ........ 5  4.0  MATER MATERIALS.................... IALS................................ ...................... ...................... ....................... ....................... ........................ .................... ........ 6  5.0  MOCKMOCK-UP............. UP........................ ....................... ...................... ...................... ....................... ....................... ........................ .................... ........ 7  6.0  INSTA INSTALLAT LLATION ION OF FIREPR FIREPROOFING OOFING .......... ...................... ...................... ...................... ........................ .............. 8  7.0  EXTER EXTERNAL NAL TOPCOA TOPCOAT T .......... ...................... ........................ ...................... ...................... ....................... ....................... .............. 9  8.0  INSPECTION AND TESTING...... TESTING.................. .......................... .......................... ......................... ......................... .............. .. 9 

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Page 3

 

 

Wheatstone Project LNG Plant Specification for Proprietary Cementitious

1.0

SCOPE

1.1

General

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

This specification provides the requirements for installation of fireproofing materials for structural steel and vessel/equipment supports. Proprietary cementitious fireproofing, Carboline Pyrocrete 241, at a thickness of 32mm (1 ¼ inch) required to be acceptable for an LNG fire incident shall be applied to the surfaces. An LNG fire test shall be a 3 barg over pressure explosion test followed by a J-30 jet fire test. Unless indicated otherwise, caulking of joints and external top coating of the fireproofing shall be included. 1.2

Extent of Fireproofing The materials requisition or contract attachments indicate the extent of fireproofing. Fireproofing heights and construction block-outs are indicated on structural steel drawings. Equipment skirts and saddles requiring fireproofing are indicated on equipment drawings or equipment lists. Controls/instrumentation fireproofing is excluded from the the scope of this specification.

1.3

Safety and Environmental

1.3.1 All surface preparation, materials, and coatings work work shall comply with all applicable environmental and safety provisions, laws, regulations, ordinances, etc., of the city, county, state, province, in NW Australia pertaining to the work being performed and the coating materials being used. 1.3.2 Seller shall comply fully with OSHA Hazard Communication St Standard andard 29 CFR 1910.1200 and 19CFR 1926.59 or the applicable c country ountry code. Material Safety Data Sheets (MSDS’s) shall be available for review at the jobsite. 1.3.3 The volatile org organic anic compoun compound d (VOC) con content tent of all materials shall meet Federal, State, and Local or other Regulatory requirements.

2.0

QUALITY STANDARDS

2.1

General

2.1.1 The Seller shall control the quality of items and services to assure that completed fireproofing work conforms to the requirements o off this speci specification fication and the applicable codes and standards. The quality program sh shall all provide for assuranc assurance e that only ac accepted cepted fireproofing materials are used, that inspection of the surface preparation and the fireproofing application is implemented for all phases of work performed, and that documentation is prepared and maintained to furnish evidence of compliance with this Standard Specification and acce accepted pted procedures. The application subcontractor shall be approved by the material supplier prior to beginning work.

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Bechtel Confidential. Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved. Electronic documents, once printed, are uncontrolled and may become outdated. Refer to electronic documents in the E DMS for current versions. 25504-100-3PS-NF00-F0002-00B

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Wheatstone Project LNG Plant Specification for Proprietary Cementitious

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

2.1.2 The Seller, including any low lower-tier er-tier organizations engaged by him, shall be subject to surveillance inspection and audit by the Buyer's inspector for compliance with the requirements of this specification. This surveillance inspection and audit does not relieve the Seller from the responsibility for conformance to the requirements set forth in the procurement documents. 2.1.3 The Buyer's insp inspector ector shall be prov provided ided with a detailed schedule an and d shall be n notified otified of all required and witness pointstorequiring by the Buyer prior to the scheduled date for hold fireproofing. Failure provideinspection the required notification shall res result ult in the requirement for reinspection or rework. 2.1.4 The Seller's inspector shall iden identify tify and document all uncorrected uncorrected deviations from the specification, codes and standards and shall transmit these deviations to the Buyer for review and disposition. 2.1.5 The noz nozzlemen zlemen shall be qu qualified alified to ACI Guide 506.3. Qualification testing shall be subject to inspection, review and acceptance by the Buyer. 2.2

Codes and Standards The latest revisions of the following specifications are applicable to the extent specified:  ACI 506.3

Guide to Certification of Shotcrete Nozz Nozzlemen lemen

 ASTM C 309

Specification for Liquid Membrane-Forming Compounds Compounds for Curing Concrete

 ASTM D 790

Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

 ASTM E 605

Test Methods for Thickness a and nd Density of Sprayed Fire Resistive Resistive Material Applied to Structural Members

 ASTM E 2240

Durometer Test for Indentation Hardness of of Homogeneous Materials

 AWS D1.1

Structural Welding Code - Steel

WS1-0000-CRR-SPC-BEC-000-00101-00 25504-100-3PS-NX00-F0001 Specification for Protective Coatings

3.0

SUBMITTALS

3.1

The Seller shall submit a listing of all materials to be used in s shop hop and field fireproofing including field repair of blockouts. Seller shall submit detailed sketches sketches showing location of reinforcement and cross section of typical fireproofed steel shapes and equipment supports.

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Wheatstone Project LNG Plant Specification for Proprietary Cementitious

Document No: Revision: Revision Date:

Fireproofing

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

3.2

The Seller's written procedures for s storage, torage, shipping, handling, topcoating, surface preparation, environmental control, application, touch up and repair, curing, and inspection of the fireproofing system shall be submitted for Buyer’s review and permission to proceed prior to use. For shop applied fireproofing, blockouts, handling and and shipping procedures procedures,, as well as the schedu schedule le must be cov covered ered in detail. Conflicts, if any, betw between een Seller's recommendations and this Specification shall be noted; however, this specification shall prevail.

3.3

The Seller's proposed fireproofing verification forms for daily inspection records shall be submitted for Buyer’s review and permission to proceed prior to use.

3.4

A detailed fireproofing verification report, in accepted form, s shall hall be completed each day during the work and shall be submitted for record. The final verification rep report ort shall include the values from testing obtained in accordance with this specification and a statement of conformance verifying that the required materials were used and that the accepted application procedures and specifications were followed. The responsible inspector must approve and sign these reports on a daily basis.

3.5

The seller shall furnish manufacturer's test certificates indicating that the fireproofing material conforms to printed data sheet values for the following laboratory tests: • •

Flexural strength per ASTM D 790. Surface hardness per ASTM E 2240.

3.6

A d detailed etailed welding procedure shall be submitted for Buyer’s review and permission to proceed prior to use if the required reinforcement anchors were not attached by the structural steel or equipment fabricator and must be attached by welding by the Seller.

4.0

MATERIALS

4.1

Proprietary Cementitious Fireproofing The material shall be the following at the specified thickness: Carboline Pyrocrete 241 - 32 mm (1.25 inches) minimum thickness,.  Alternate materials shall not be acceptable. System design shall be warranted against cracking for a period of one year from initiation of plant operation, and design basis is 20 year minimum service life. Fireproofing materials shall be durable, weather resistant, corrosion resistant, and unaffected by chemicals typic typical al of LNG processing plan plantt environments. These materials shall also be UV resistant.

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Wheatstone Project LNG Plant Specification for Proprietary Cementitious

4.2

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

Reinforcement

4.2.1 Reinforcement shall be in accordance with the fireproofing material manufacturer’s instructions for the LNG LNG acceptance testing. Tie wire and hog rings shall be used every 150mm along reinforcement joints to keep overlapping sheets of lath flush together. 4.2.2 For large flat surfaces such as skirts, Nelson studs (of a suitable height for the rating and thickness) shall be written spaced procedure spaced on 300 mmand (12 inch) both direc directions. tions. Alletc., welding to be be done per Seller’s AWS centers D D1.1. 1.1. in Where studs, clips, must welded to coated surfaces, touch-up paint the weld area and attachment. 4.2.3 For steel shapes only, anchors must be pneu pneumatically matically driven pins such as Hilti EDN or ENK types placed by the Seller. 4.2.4 Use 18 gag gage e soft ann annealed ealed tie w wire ire and hog rings to lace reinforcing panels together. 4.2.5 Reinforcing lath s shall hall be 1.85 kg/square mete meterr (3.4 lbs/square yard), galvaniz galvanized ed metal. 4.2.6 Hexagonal mesh s shall hall be 50 mm (2 inches) by 18 gauge, galvaniz galvanized ed and PVC coated. 4.3

Caulking  Any joints between fireproofing and steel where water may enter shall be caulked with Dow Corning 795, Carboline Acrilast 570, or ap approved proved equal. Exposed edges edges shall be s sealed ealed with caulk, mastic, or flashing to prevent seepage of water behind the fireproofing.

4.4

External Coating External coating materials shall be a clear epoxy sealer or other coating as specified in the referenced coating specifications. specifications. Deviations must be approved by the Buyer.

5.0

MOCK-UP  A meter (3 foot) long shall betested fireproofed by each with nozzleman for thesample work. 1The sample shall be column ins inspected pected and in accordance Sectionqualified 8.0. Upon acceptance of all physical properties, the finish shall be subject to inspection by the Buyer and, if accepted, serve serve as a comparator tto o judge the trowel finish on the work. The finish o off the work for all surfaces shall be at least as smooth as the surfaces on one of the accepted mock- ups.

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Bechtel Confidential. Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved. Electronic documents, once printed, are uncontrolled and may become outdated. Refer to electronic documents in the E DMS for current versions. 25504-100-3PS-NF00-F0002-00B

Page 7

 

 

Wheatstone Project LNG Plant Specification for Proprietary Cementitious

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

6.0

INSTALLATION OF FIREPROOFING

6.1

Anchors shall be touched-up as specified in either the engineering coating specifications.  All surfaces must be cleaned free from oil or grease. Glossy surfaces, loose or flaking paint, or similar surface conditions which would affect adhesion, must be corrected before being covered.

6.2

For all structural members with field ins installed talled fireproofing, and a web depth of 305 mm (12") or less, the fireproofing shall be a "box "boxed ed in" configuration. For all structural members with a web web depth greater than 305 mm, and all shop installed fireproofing, the fireproofing shall be a contoured configuration. configuration. The applications shall c conform onform to the LNG design bas based ed on acceptance testing. For horizontal m members embers where the top surface is not fireproofed, the fireproofing shall extend completely over the bottom surface of the t he top flange and extend full thickness outward and around the flange edg edge. e. The top surface of fireproofing shall be sloped to allow for drainage.

6.3

For shop application before erection, blockout of the fireproofing for th the e field connections are required. Shop applied reinforcement m mesh esh shall extend at leas leastt 57.2 mm (2.25 inches) into the area where the fireproofing material is blocked out to facilitate tie-in of site applied mesh and site fireproofing.

6.4

Flat sur surfaces faces s such uch as walls, ceilings, decks, and column web areas over 305 m mm m (12 inches) deep require the use of reinforcing mesh anchored on 305 mm centers.

6.5

Fireproofing shall b be e a applied pplied be between tween 12.7°C (55°F) and 3 37.7°C 7.7°C (100°F) ambient temperature with maximum relative humidity of 95%. Unless s specified pecified oth otherwise erwise in the purchase order, curing shall be accomplished by continuous dampening the fireproofing or use of an ASTM C 309 coating/curing membrane.

6.6

Two application methods are approved: formed or shotcrete applied. All fireproofing not placed in forms shall be finished smo smooth oth using the use of a wood float or trowel. The final appearance shall be smooth, smooth, even, and aesthetically pleasing. The finish shall be as g good ood as or better than the work sample prepared and accepted by the Buyer as outlined in Section 5.0.corner Light for sanding or or troweling uncure uncured d surfaces may by be shotcrete req required uired to obtainwith an acceptable caulking caulking surface of ap appearance. pearance. Application method a trowel finish f inish is acceptable utilizing qualified, experienced nozzlemen.

6.7

For field application, surrounding finished surfaces, such as painted walls, floors, exposed ceilings, tile, windows, and in place equipment shall be protected from damage, drips, spatter and overspray. Metal sw switch itch boxes boxes,, junction boxes, co conduits, nduits, sprinkler heads, aluminum window, and similar units shall be masked to protect from overspray of wet material.

6.8

Any overspray or waste shall be removed while still wet and before setting. Clean-up may be done with with scrapers, s soapy oapy water, rags, etc. If fireproofing material is allowed to cure before clean-up, it must be chipped or abraded aw away. ay. Surrounding surfaces shall be restored to the original condition at Seller's expense. © Chevron Australia Pty Ltd

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Wheatstone Project LNG Plant Specification for Proprietary Cementitious

7.0

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

EXTERNAL TOPCOAT The external topcoat, if required by the purchase order, shall be applied to the completed and cured fireproofing in accordance with the Seller's written procedure and the coating specifications. For shop applied fireproo fireproofing, fing, the to topcoat pcoat shall be applied, cured, and inspected prior to shipment.

8.0

INSPECTION AND TESTING

8.1

Any defects disclosed by inspection shall be re-inspected after correction. Necessary corrective actions for areas which do not meet the requirements of this Specification shall be corrected at Seller's expense.

8.2

The s surfaces urfaces to be fireproofed sh shall all be divided into areas or u units nits of prod production uction as a b basis asis for inspection. The inspection points shall be establish established ed as follows: • • • • •

8.3

Prior to the start of work Following installation of reinforcement materials Immediately prior to application of the fireproofing Following the application and curing of the fireproofing After application of the topcoat

The Seller shall provide on-site inspection. The following examinations shall be performed by the Seller's inspector. •

Prior to using compressed air, the quality of the air downstream of the separator shall be tested by blowing the air into a clean, white blotter or cloth for two minutes to check for any contamination, oil, or moisture. This test shall be performed at the beginning and end of each shift and at not less than four-hour intervals. The test also shall be made after any interruption of the air compressor operation or as required by the Buyer. The air shall be used only if the test indicates no visible contamination, oil, or moisture. If contaminants are evident, the equipment deficiencies shall be corrected corrected and the air stream shall be retested. Separators shall be bled continuously. continuously. All lines shall be teste tested d individually prior to use.

•

The nozzlemen shall be qualified to ACI Guide 506.3. Qualification testing shall be subject to inspection, review and acceptance by the Buyer.

•

Substrate must be clean and free of loose particulate matter. All coating must be intact. Any discrepanc discrepancies ies must be rectified b before efore application of the fireproofing.

•

Anchors shall be randomly tested to ensure sound welds by means of a hammer test.

•

All reinforcement shall be inspected to assure conformance to approved design sketches. © Chevron Australia Pty Ltd

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Page 9

 

 

Wheatstone Project LNG Plant Specification for Proprietary Cementitious

Fireproofing

Document No: Revision: Revision Date:

WS1-0000-FGS-SPC-BEC-000-00102-00 WS1-0000-FGS-SPC-BEC-000-00102-000 0 0 13-Jan-2010

•

Wet thickness shall be measured in accordance with ASTM E 605, before material sets hard. On beams and columns, four sets of random measurements s shall hall be taken for each unit or for each 15 lineal meters m eters (50 lineal feet).

•

Visual inspection of fireproofing shall be performed to ensure no honey combing, hollow voids, or other defects exist. Observations shall be made to ins insure ure that the curing membrane, if utilized, was applied properly.

•

The applied fire protection shall be free of defects such as excessive cracks, voids, spalls, or any exposure of the substrate. The appearance appearance and w workmanship orkmanship shall conform to the mock-up.

8.4

The Seller shall furnish the necessary testing and inspection instruments, properly calibrated and maintained. Such equip equipment ment shall b be e available for use by the Buyer in conducting surveillance of the work.

8.5

Defects or d damaged amaged areas detected during assembly or h handling andling shall be repaired in accordance with procedures as permitted by the Buyer.

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Bechtel Confidential. Confidential. © 2010 Bechtel Oil, Gas and Chemicals, Inc. All rights reserved. Electronic documents, once printed, are uncontrolled and may become outdated. Refer to electronic documents in the E DMS for current versions. 25504-100-3PS-NF00-F0002-00B

Page 10