MMI Engineering
PFEP systems, common anomalies and general inspection procedure for PUK Assets
Dr Simon Thurlbeck
Assessment of Ageing PFP SystemsLECBrandweer BRZO
Networking Meeting, 8th November 2018, Arnhem
Dr Simon ThurlbeckHigh14 Technologies Ltd
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Agenda
• The first session covers Checklist 2: Has the PFP System Under Assessment Been Designed and Specified Correctly?
• This is to make sure that the installed system is being used correctly for the situation.
• The second session covers Checklist 3 – Is the integrity of the PFP system being managed correctly.
• This is to make sure that its condition is being monitored to ensure that its performance is not reduced from that originally specified.
• Also including responses to questions raised during the training sessions and any from these sessions.
Documents To ReviewFind an example of PFP on the site and follow the documents
Integrity Management Documents
PFP register or list of PFP installedInspection plan for PFPInspection proceduresAssessment criteria for actionRepair proceduresInspection recordsMaintenance recordsWork management requests
Checklist 3
Management Documents
Fire protection philosophy and strategy (site or company)Fire Brigade permit showing where PFP is notedSafety report including description of PFP measures used and hazard scenariosRoles and ResponsibilitiesCompetency and training requirements
Checklist 1
Design and Specification Documents
Risk assessmentsPFP design calculationsPFP specification and/or performance standardsPFP drawingsVendor packages with supporting performance evidence
Checklist 2
Part 1Assessing Suitability
The Importance of Assessing Suitability• To assess that the PFP material or
system is fundamentally suitable, regardless of its condition, to mitigate the fire hazards that it will be exposed to.
• This is not always the case, particularly on older establishments.
• Our understanding of fires has developed and old systems may no longer be suitable
• The assessment needs to• Have a clear specification of what
the system needs to do• Compare against evidence of how
the system does perform
• Key Message - Many problems will arise because the PFP system is fundamentally unsuitable for the fire hazards or has failed to recognise other factors that have led to the system becoming damaged.
The required performance will cover:• Fire• environment, • process conditions, • operational requirements, • other hazards such as explosions• etc.
Assessing Whether a PFP System is Inherently Suitable
Understand the hazards that might be present
Establish the required performance rating
Understand what process is being used to demonstrate the
PFP performance
Ensure that an appropriate test is being used
Review evidence: Does the process demonstrate that the PFP systems are suitable for the
situation that they are being used in?
Checklist 2 - Has the PFP System Under Assessment Been Designed and Specified Correctly?
Is there a risk assessment in place that shows why this PFP is needed?Is the system a PFP system or is it process insulation? Or both?Is the type and make of installed PFP system known and documented?Is the PFP system suitable for the item that is being protected?How has the extent of PFP used to protect the item been established – by reference to a code orstandard, by analytical demonstration, or by experience?Is the system detailed correctly or is there evidence of poor practices being used that might cause afailure of the PFP system or its supporting structures?Is there a record of the original design and selection of the PFP?Is there a documented CURRENT fire resistance performance rating for the PFP system that specifieshow the system should perform?Is there evidence/a process to show that the PFP provides the required fire resistance performance?Is there evidence that the PFP system performance will not be affected by non-fire hazards?If active fire protection and firefighting are also present, is there a demonstration that the PFPfunctions correctly during a fire?Have the fire hazards changed since the PFP system was first installed and has PFP been re-assessed?
Fires On Seveso Establishments
• Flammable liquids – unrefined or refined hydrocarbon products, or solvents:
• Flammable gases – typically hydrocarbon, hydrogen, or synthetic gases
• Flammable solids – in the form of fine chemicals, metals, or cellulosic materials.
• The different fire types have different characteristics.• PFP systems can be installed that are not correct for the type of fire.• Fire scenarios can last from a few minutes to many hours.
Fires Types
• Key Point - Ensure that the PFP system can resist the type of fire
Cellulosic FiresCaused by the burning of cellulosic materials
Pool FiresLiquid and diffuse, confined and unconfined
Jet FiresGas jet fires and 2-phase (spray) fires
Understanding the Types of Fires
Chemical & Metal FiresMay be too hot for PFP, or may become cellulosic and pool fires. May need specialist mitigation
Fire Test Time-Temperature ModelsMass Release Rate (Kg/s) Temp (⁰C)
0.1 1 10 >30
Gas jet fire, total heat flux (kW/m2)
180 250 300 350 >1200
Two phase jet fire, total heat flux (kW/m2)
200 300 350 400 >1400
Where (and why) is PFP Used?
Fire protection is required to either:
Permit immediate evacuation of personnel to a place ofsafety, to shelter safely, or permit emergency responseactivities.
or:To prevent escalation of the fire that could that could leadto an unacceptable risk of harm to personnel, theenvironment or the facility.
PFP buys time:• Wont provide immediate protection (unless a barrier)• Will provide longer term protection to permit emergency
response to occur, and to control escalation
What does PFP do?
PFP Use on Seveso Establishments
• Bulk chemistry• Trade and distribution• Transshipment and transport • Energy• Fine chemistry• Waste• Petrochemistry• Rubber and Plastic• Others
Key Message - There is no typical PFP scheme with a typical list of equipment.Seveso establishments have different layouts, design approaches, processes, inventories, protected items, fire protection strategies, owners, etc
PFP is Part of a Fire Protection StrategyOther mitigations include:
• Fixed or mobile Active Firefighting Protection (AFP) uses water to cool plant and equipment and extinguish fires.
• The containment and redirection of released flammable liquid inventories using :
• Bunds• Barriers• Gradients and trenches
• Isolation and depressurisation systems minimise gas volumes and remove pressurised gas inventories.
PFP and Firefighting• Does no fight fires but may permit
firefighting• PFP can influence, and be influenced by,
fire fighting.• Can protect against scenarios that are
larger than the credible scenarios for firefighting.
PFP and Water• Water is ineffective against high pressure
gas -https://www.youtube.com/watch?v=Or1kRh9j8wE
• AFP may make some PFP systems with active ingredients ineffective
• Testing of water systems can damage PFP• Fixed water systems can be damaged by
explosion.
Typically protect Critical Items (often called Safety Critical Elements) that permit emergency response or prevent escalation. These are usually:
• Structural Steelwork • Barriers (eg Firewalls, inc Penetrations) • Buildings used in Emergency Response (usually Barriers)• Process Vessels and Reactors (HP and LP)• Storage Tanks and Vessels• Pipework (process and delivery)• ESD Valves and Actuators• Vessel, Pipe and Tank Supports
Items needing protection against fire are identified by the risk assessment for the facility required by Seveso III Directive.
The items fail in a specific way and the PFP is one way of protecting against specific failures.
What is Typically Protected with PFP
Photograph courtesy of Esterline
Photograph courtesy of AIS plc
Barriers (often making up buildings) fail when they:• Rupture because of the build-up of high
thermal strains, or• Through a loss of integrity when the
connections to their supporting structure fail, or
• When the insulation effect of the PFP is inadequate and the unheated side exceeds the require performance specification.
• Penetrations fail
Structures and supports fail when:• Average section temperatures exceed 400⁰C, and
steel begins to lose its strength, and:• A failure mode develops in the section, and;• There is no alternative loadpath to redistribute
loads and the structure collapses • Just because the temperature reaches 400⁰C does
not mean that failure of the structure has occurred.
Critical Item Failure
Pipework fails because:• The supports collapse, or;• There is a rupture failure similar to a vessel or tank, or;• The flange fails due to bolts loosening or flange seals
being damaged (Long flange bolts are worst)
Critical control systems, cabling and control lines fail because:• They overheat, or;• Are directly damaged by the fire, or;• They catch fire themselves and cause fire spread
Critical Item Failure
High/Low Pressure vessels and tanks fails because:• The supports collapse, or;• A thermal rupture occurs which is caused by an expansion of
the contents and resultant increase in internal pressure, or;• a loss of strength of the containment, or;• more likely a combination of the two.
Valves and actuators fail because:• The seals within the valve heat up and leak, either
through the valve body heating or through conduction through the actuator
• The actuator sticks open and will not close• The control systems of non-failsafe valves are damaged• A “fire-safe” valve is not appropriate for the fire type
Critical Item Failure
• Is the length of time that PFP is resistant to a fire scenario a concern?• The length of time is the critical. If the fire scenario lasts 1 hour and
the PFP only provides protection to ensure the required for performance for 30 minutes then that is not acceptable
• The required performance might be to prevent structural collapse, or to ensure a vessel doesn’t rupture or to ensure electrical systems function
• The fire test undertaken to test the material should represent the conditions of the fire scenario – type of fire and duration of exposure
PFP System Performance Question
PFP System Recap
PFP Systems – Not Just About Coatings
Trade names:
Fendolite M2, Mandolite 550, Pyrocrete 241, Grace
“Site mix” also used – company specific
Lightweight Cementitious (LWC) PFP
Dense Concrete is similar but has reinforcement and aggregate can affect performance in a fire
Pictures reproduced from Promat
Trade names: Chartek, Jotachar, PittChar, Firetex, Pyroclad, Hempacore, Aleschar
Epoxy Intumescent PFP
• Insulation used to reduce the rate at which heat is conducted into a protected item.
• The insulation is combined with another material or product to give integrity.
• Requires a retention system to keep it attached.
• The typical insulation materials found in PFP systems are:
• Syntactic Phenolic Thermal Insulation• Cellular Glass Thermal Insulation• Man-Made Mineral Fibre (MMMF) Thermal
Insulation• Microporous and Thin Layer Thermal Insulation
• Selection dependent on the situation, the operating environment, and cost!
Insulation used in Dry Fit and Wet Applied PFP Systems
Key Point: When used as part of a dry-fit or wet applied system, can provide process insulation AS WELL AS cold spill and PFP protection. Check this!
PFP Material Question
• Wet Applied Systems: what are synthetic (correction: should be syntactic) phenolic materials (PFP)? Are they not flammable?
• Wikipedia - Syntactic foams based on phenolic resins are very advantageous because they can act as low-density ablatives. They have been successfully used for the thermal protection of atmospheric re- entry space vehicles and to prevent structures from the extreme heat flux of rocket exhaust plumes.
• Syntactic means “put together”. Hollow spheres of glass or phenolic combined with a phenolic resin provide a good insulator
• Phenol-formaldehyde (phenolic) resin is made by reacting phenol with formaldehyde.
• Different resins have different properties some are difficult to ignite, some are flammable and most ablate. The outer skin protects them.
• Panels of Polyurethane (PUR) and Polyisocynate (PIR) will burn.
PFP Material Question
• Can Rockwool burn? Think of the façade panels in relation to building fires.
• Rockwool is made from a naturally fire resistant stone (volcanic dolomite), along with limestone and other components
• Heated to 1500 °C, and fibres spun from the molten material.
• The fibres don’t burn but they can melt at temperatures above 1000°C.
• The fibres are held together with a binder and an oil is used to provide water resistance. The binder which will evaporate at temperatures in excess of 250°C or more
• Cladding or panels manufactured from pre-cast epoxy intumescent
• Stainless steel external skin, with Man Made Mineral Fibre internally as required for insulation.
• Structural composites with internal insulation
• Jacket systems.• Structural systems
manufactured from steel and LWC material (e.g. Durasteel).
• Provide both direct shielding from fire and insulation 28
Dry-Fit Systems
Wet Applied Duplex Systems
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Applied on site as an insulation layer coated with a protective layer.Outer layer provides integrity, water tightness and fire resistance
• Syntactic phenolic + GRP outer protective layer
• Syntactic epoxy thermal insulation + epoxy intumescent coating outer protective layer
• Mineral wool or AES blanket + retention system + epoxy intumescent coating outer protective layer
• Cellular glass + epoxy intumescent coating outer protective layer
Wet Applied Systems
Photographs courtesy of AIS plc
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BarriersBarriers Uses• Free-standing fire and blast barriers
that provide shielding from direct flame impingement
• The walls and roof of Control Rooms and Occupied Buildings, including temporary buildings
• Enclosures involved in Emergency Response (ER) or Evacuation, Escape and Rescue (EER)
• Barriers used in segregation of bulk hazardous materials to provide containment.
• Localised heat shielding and thermal radiation protection, often to protect escape routes.
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BarriersBarrier Systems• Plain carbon steel or stainless-steel barrier (either stiffened
plate or corrugated plate)• A steel barrier with an insulator on unexposed face to
provide internal insulation.• A steel barrier with an epoxy or LWC coating, wet applied
system or dry fit system on the fire-exposed face to provide integrity and/or insulation.
• A perforated steel sheet with internal LWC material (e.g. Durasteel)
• Composite material panels and mounted on a steel frame.• Thermal radiation shielding• Internal partitions of fire resistant board/facing material
and insulation.• Brickwork or blockwork – unreinforced or reinforced.• Earth embankments.
Penetrations
• Pipe Penetrations• Certified Gaiter Type (e.g.
Bestobell)• Certified Mastic Sealing (e.g. Rise)• Certified Pipe Collars (e.g. Roxtec)• Other certified bespoke designs• Other non-certified Bespoke
Designs• Cable Transits• Doors (Fire rated, Fire and Blast
rated, etc.)• Windows (Fire rated, Fire and
Blast rated, etc.)• Ducts (including short sections
which support dampers)32
Penetrations
• Control rooms• Firepump rooms• Permanent
offices/stores/workshops/ laboratories
• Enclosures containing safety critical equipment – MCC, ESD, F&G, etc
• Enclosures or areas which contain electrical services
• Buildings that combine process and occupied spaces
• Storage and warehouses• Temporary buildings
• External fabric of the enclosure or building (brick, concrete, panel systems, etc).
• Coatings or claddings that are used to protect any internal steelwork
• Panels systems which forms the walls to enclosures and technical rooms
• Barriers which are used for internal segregation of hazardous materials
• Penetrations through barriers for ducts, cables, services and potentially hazardous inventories
• Penetrations through the barriers such as doors and windows.
Buildings (only for emergency response)
Others – Brick and reinforced concrete
Typical Uses of PFP Systems
Good if detailed correctly
Can be/has been used but not preferable
Not recommended
Not applicable or unlikley to be used
See SpreadsheetQuestion: How did the matrix for PFP uses come about? What status do we give this matrix?
And if it’s correct, cabling can also be protected with concrete?
PFP Design
Fire Protection Strategy – What influences the Use of PFP?
Fire protection strategies depend on:
• National and International Regulations that apply
• Onshore or offshore applications • Insurance company requirements• Owner/operator company standards
• It is commonly used now for life safety and environmental protection, but can be used for asset protection.
PFP as part of a Fire Protection Strategy
• Establishments use company or project specific fire protection strategies and philosophies that define the overall fire protection requirements.
• PFP is just one option for mitigating the effects of fires
• PFP can work alongside other measures such as Active Fire Protection, process separation, blowdown, etc
• This is why there is no common set of items that are protected with PFP, or a single PFP protection “standard”.
Code-compliance (prescriptive)
• Follow the rules on what fires exist.
• Apply the PFP to items as defined by the code.
• e.g. API2218 using products tested to UL1709 standard
Consequence-based
• Identify potential fire scenarios (can be worst case),
• Determine their characteristics (analytical or data)
• Assess response of critical items and protect if necessary using a suitable PFP system
• e.g – BP, Shell
Risk-based (probabilistic)
• Undertake a Fire Risk Assessment and identify the likelihood of fires occurring
• Identify fire scenarios with risk levels that are acceptable and determine their characteristics
• Assess response of critical items and protect if necessary using a suitable PFP system
• e.g. FABIG TN13
PFP Strategies (Can be a combination)
Less PFP
Standards QuestionWhich standards are the most important and most commonly known to Brzo companies? Inspectors need standards to be able to translate into finding / enforcement. (this was the absolute nr. 1 question!)Is it possible to add standards and regulations to Appendix C ‘PFP damage assessment tables’?• Yes, although there isn’t much other a
general statement that it should not be damaged.
• General point about falling back on standards for compliance. They are usually related to structural components but get used for non-structural components – which is incorrect.
API 2281 - 10.3 MAINTENANCETimely and consistent maintenance provides assurance that the system is physically in the condition intended.10.3.1 Hairline CrackingWhen more than hairline cracking appears, the openings should be cleaned out and filled with new material according to the manufacturer’s instructions.10.3.2 Substrate BondingLoss of bonding to the substrate may be determined by surface bulges or an abnormal sound when the surface is tapped with a light hammer.10.3.3 Bond FailureIn evident areas of bond failure, fireproofing should be removed and the substrate should be thoroughly cleaned and properly primed before new material is applied.
Typical Standards and GuidanceDocument Source
API Recommended Practice 2218: Third Edition, July 2013: Fireproofing Practices in Petroleum and Petrochemical Processing Plants
API
API RP 2001 - Fire Protection in Refineries, Ninth Edition APIAPI 2510A – Fire Protection Considerations for the Design and Operation of Liquefied Petroleum Gas (LPG) Storage Facilities, Second Edition
API
Guidelines for Fire Protection in Chemical, Petrochemical and Hydrocarbon processing Facilities, August 2003
CCPS
Fire Protection Handbook, 20th Edition, 2008 NFPAStandard for the Fire protection of Storage, NFPA 230. 2003 NFPAFire Protection on Chemical Manufacturing Sites. European Guideline CFPA-E No 18:2008
CFPA Europe
Guidance on Passive Fire Protection for Process and Storage Plant and Equipment. 1st Edition, March 2017
Energy Institute
Experience: Very varied• Fire protection
usually follows a company standard which can contain elements of some of these standards;
• Or its API 2218• These standards
can specify test standards.
• Question: What standards should we purchase so that we can handle them?
• Detailing and implementation of PFP coatings can have a significant influence on whether the systems perform in a fire or cause an integrity issue
• Poor details appear during the actual design and installation of PFP because they are “easy to implement”, or they “have always been done this way”.
Key Message: Poor details to look out for are:• Boxed details• Termination details• Interfaces• Lack of loadpath protection• 3-sided protection• Coatbacks• Standing water• Cut-outs to fit supports
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Detailing of PFP Coating Systems
Boxed Coating Details
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Detailing PFP Coating SystemsTermination Details
Interfaces Between Systems
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Detailing PFP Coating SystemsLack of Loadpath Protection
Protected
Unprotected
3-sided Protection
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Detailing PFP Coating SystemsCoatbacks
(Reproduced from FABIG TN13)
Standing Water
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Detailing PFP Coating SystemsCut Outs
• Over-dimensioning steel constructions as a form of PFP: does it occur and what do we have to pay attention to?
• Yes, its OK if done correctly.• More steel slows the rate of heating• Analysis should be used to show adequacy, load
redistribution and whether increasing steel produces a bigger hazard (eg fatigue, vessel BLEVE)
• Is PFP on the inside of a skirt necessary due to open manhole (depending on the fire scenario)?
• In theory, yes, but….:• Difficult and therefore often not done• Dependent on the fire scenario (API2218 again...)• Can demonstrate that it is not needed by analysis.• PFPNet is writing a design guide on detailing for
coatings which will include this.
PFP Detailing Questions
• To what level do you apply PBB to columns for a pool fire?
• Prescriptive guidance is provided in standards.
• Check whether it applies to the circumstance under investigation.
• Check if that code or standard being applied to the establishment
CCPS • 9-12m above grade• Within 4-8m of a potential fireAPI2218• “For liquid hydrocarbon fuels, a
frequently used frame of reference for the fire-scenario envelope is one that extends 20 ft to 40 ft (6 m to 12 m) horizontally, and 20 ft to 40 ft (6 m to 12 m) vertically, from the source of liquid fuel.”
PFP Detailing Questions
Specifying Fire Resistance Performance
Specifying How PFP should perform in a fire
Essential data for specifying fires is:• The type of fire• The items or areas which must
be protected• The failure condition that must
be prevented• The duration that the PFP
system should prevent this failure
• Key Message - It is a common misunderstanding that PFP is described by the terms A60, or H120, or J15, etc. This is for bulkheads and decks on ships…
• Key Message – We use Fire Ratings to describe this data. How this is communicated depends on the type of item being protected.
• Key Message – Barriers and partitions are described by R/E/I• Key Message - Penetrations should have the same rating as the barrier
Fire Rating Fire TypeR
Stability (minutes)
EIntegrity
(minutes)
I Insulation Characteristics
Duration(minutes)
Cold Face Average
Temp. (oC)
Cold Face Max Temp on
a spot (oC)
B0 CF(1) 0 30 0 None None
B15 CF(1) 0 30 15 140 225
B30 CF(1) 0 30 30 140 225
A0 CF(1) 60 60 0 None None
A30 CF(1) 60 60 30 140 180
A60 CF(1) 60 60 60 140 180
H0 HF(2) 120 120 0 None None
H60 HF(2) 120 120 60 140 180
H120 HF(2) 120 120 120 140 180
J0 (4) JF(3) 120 120 0 None None
J15 (4) JF(3) 120 120 15 140 180
J60 (4) JF(3) 120 120 60 140 180
Fire Ratings – Barriers, Walls and PartitionsR - Stability: the structure shallretain its load-bearing capacitythroughout the fire exposureperiod
E - Integrity: partitions shallprevent spread of flames and hotfumes throughout the fire exposureperiodI - Insulation: the unexposed side of partitions shall not reach surface temperatures more than a certain level throughout the fire exposure period.
• Explanation method R / E / I (fire resistance). What standards are these?• R = Stability or load bearing capacity. The ability of a building element to resist a fire when
exposed on one or several sides and when supporting an external load during a time period without losing its stability.
• E = Integrity. The ability of a test specimen of a separating element of building construction, when exposed to fire on one side, to prevent the passage of flames and hot gases and to prevent the occurrence of flames on the unexposed side. Requirements are:
• Cracks or gaps of certain dimensions• ignition of a cotton wool pad • sustained flaming on the unexposed side
• I = Insulation. The ability of a test specimen of a barrier in a building construction when exposed to fire on one side, to restrict the temperature rise of the unexposed face to below specified levels.
• Usually less than 140⁰C average or 180 ⁰C single peak
• Also W, M, C, S and K• The R/E/I method is used in ISO 20902 (new), ISO 13702 (offshore), and EN 1991-1-2 (eurocde for
structures
Question: PFP Material Performance
• Fire rating of PFP applied to structures, equipment and plant items is defined by the critical temperature, the worst type of fire that item is required to withstand, and the period during which the item shall not exceed its critical temperature (sometimes called the Critical Core Temperature – CCT)
• At this temperature structures, plant and equipment can lose integrity, lose stability, or lose functionality.
• The fire rating can be written as T/XF/t, with “T”: Critical Temperature, “XF” type of fire and “t” as specified period of time (i.e. 400/JF/60, 200/CF/60 etc.).
Fire Ratings – structures, equipment and plant
Demonstrating PFP Performance
Certification and Type ApprovalTesting
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Who is Involved in Performance DemonstrationOrganisation Who? Role
Certification Bodies
UL, ABS, DNV, Lloyds Register, Bureau Veritas, BAM, WarringtonFire, etc.
Provide evidence of the performance of PFPEvaluating the results of tests and assessments carried out on the PFP systemsApprove the scope for which the PFP systems are suitable.
Standards Organisations
ISO, UL, ASTM, NFPA, API, BS, etc. Can be national or international
Identify the characteristics of the hazards and environments that a PFP system may be subjected toDevelop appropriate test methods and standards for PFP systems based on these hazards and environments
Testing Organisations
Warrington Fire, Exova, TNO, Efectis, DNVGL, BAM, UL
Accredited to undertake tests of the PFP systems against the standards and test methods, and report the results.
Manufacturers/Suppliers
Multiple Develop and submit materials and systems to be tested against the standards to gain approval and accreditation by the Certification Bodies on the conditions for which their systems have been assessed as appropriate.
Owners Seveso establishment owners
Select an appropriate PFP system that meets the performance requirements using an appropriate demonstration route
Approvals can be for fire, environmental testing, toxicity testing, fire spread testing, etc
Ways of Demonstrating PerformanceProcess Description
Type Approval Products are type approved against the requirements of an agreed standard or set of standards.Data assessed using standard methodsManufacturer auditedCertificate issued describing scope. Entry in catalogue
Certification As Type Approval but approval applies to only one test.Tests are witnessed.Each Certification Body has their own methods of assessing data.Certificate describes the scope for which it is applicable
Certification by Design Verification / Assessment
Used when there is a deviation from a standard test.The test is witnessed, and the Certificate covers ONLY the particular specimen configuration that was tested
Approval of an ad hoc test
Performance can be demonstrated using a non-standard test of a non-standard test specimen. Owner should accept the test as a performance demonstration. Outside the certification process
The integrity of certification, and any demonstration, assumes that the test conditions used match or exceed the real conditions on the facility. For all approaches used:
1. Make sure that the hazards and conditions present on the establishment are represented by the test or assessment method used for the certification or approval.
2. Make sure that the details used on the actual installed PFP are those which were tested/assessed and then certified or approved.
3. If variation in conditions is permitted, makes sure that the variations are within limits of the certification.
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Key Message for Approval/Certification/Demonstration
Key Points:• The system for demonstration can be mis-interpreted if not understood.• Changes to the establishment may mean that the demonstration no longer
valid.
• What can and can we (not) expect from PFP certification bodies? And how should we critically look at certificates?
• The CB should provide confidence that what is installed will meet the fire threats by reference to approved tests (either standard or adhoc) that they have evaluated and deemed to be OK for a particular application.
• The CB should understand the test and approve any variations from the test that suppliers have proposed.
• Certificates are critical. They vary between CBs and differ in terms of level of detail that is provided on each.
• Certificates:• Provide proof that what was tested is the same as what is installed, • Provide proof of a measured level of fire resistance performance against a test that has been designed
to produce the conditions that might be found on the establishment, • Documents, assesses and approve the conditions of use for PFP if there are any differences between
the test and any standard tests used. • Look for these factors
Certification
Jet Fire Testing for Jet Fires
For example ISO 22899-1:2007
Standard Fire Resistance Test Configurations
Furnace Testing for Cellulosic and Pool Fire Resistance
For example ISO 834-1 or UL1709
Non-Standard Fire Resistance Test Configurations
Firesafe Valve Testing to API 607
Other fire performance Spread of flame, smoke development and toxic gas production.
Major hazard resistance Explosion, Impact and Cold Spill
Accidental condition loadingRapid cooling effects (or heating) during emergency depressurisationHose streamVessel cleaning using steam out.
Process conditions Operating temperature range of protected item.
Mechanical loading Thermal expansion, vibration, flexure of substrate, impact, etc. From operations, method for construction and installation.
Environmental conditions Ambient temperature range (low/high), humidity, salinity, etc Airborne pollutants such as acidic gases, etcExposure to spilled chemicals such as acids, bases, salts, solvents
Materials compatibilityCombination of primers, coatings and protected items.Anti-corrosion requirements.
Inspection and maintenance Access requirements that require removal for inspection and maintenance.
LocationVehicle movements, Crane lifting operations, personnel access routes, items requiring regular maintenance
Other Specification Requirements
Factor Examples
Fire Resistance Tests
UL 263, Fire Tests of Building Construction and Materials.ISO 834-10:2014 Fire resistance tests -- Elements of building construction -- Part 10: Specific requirements to determine the contribution of applied fire protection materials to structural steel elements.BS 476-20 Fire tests on building materials and structures. Method for determination of the fire resistance of elements of construction (general principles). BS 476-21 Fire resistance for loadbearing elementsISO 834-1:1999 Fire-resistance tests - Elements of building construction - Part 1: General requirements.ASTM E 1529UL 1709 Standard for Rapid Rise Fire Tests of Protection Materials for Structural Steel. 5th Edition. February 2017BAM TRB 801 - Technical Regulations for Pressure Vessels. Pressure Vessels for non-corrosive gases and gas mixtures.ISO 22899-1 Determination of the resistance to jet fires of passive fire protection materials - Part 1: General requirements. ISO 22899-2 Determination of the resistance to jet fires of passive fire protection - Part 2: Guidance on classification and implementation methods.Fire test procedures for divisional elements that are typically used in oil, gas and petrochemical industries -- Part 1: Generalrequirements - ISO 20902-1:2018.NFPA 250 Standard for Testing of Passive Protection Materials for use on LP-Gas ContainersNFPA 290
Spread of flame, smoke, toxic gas production. ISO 834-1:1999 Fire-resistance tests - Elements of building construction - Part 1: General requirements.
Cold Spill ResistanceISO 20088-1:2016 (en) Determination of the resistance to cryogenic spillage of insulation materials -- Part 1: Liquid phaseISO/CD 20088-2 Determination of the resistance to cryogenic spillage of insulation materials -- Part 2: Vapor phaseISO/FDIS 20088-3 Determination of the resistance to cryogenic spillage of insulation materials -- Part 3: Jet release
Hose Stream NFPA 58 Liquefied Petroleum Gas Code Annex H
Environmental conditions
UL 1709 Standard for Rapid Rise Fire Tests of Protection Materials for Structural Steel. 5th Edition February 2017NORSOK STANDARD M-501 Edition 6 (2012) Surface preparation and protective coating
Resistance Standards (Not complete!)
Blast Resistance Testing
No recognized standardSome claims are incorrectAsk questions about the test
Non-Fire Resistance Testing
LNG Cold Spill Testing -IS0 20088 – 1,2,3
Hose Stream Testing - NFPA 58
Environmental Testing
Commonly NORSOK M501UL1709 or UL 2431 (new)
• An explanation of the difference in test methods:• Standard fire curve vs. hydrocarbon curve• Direct flame contact vs. heat radiation• This in relation to API 2218 (application and maintenance) and UL1709 (suitability) and FABIG TN13
• Direct flame engulfment: heat transfer by convection and radiation• Convection is the energy transferred by the a convective component from the boundary layer of hot gases
and combustion products flowing over the object (direct contact), and a radiative component from the hot gases and combustion products distributed throughout the fire (non-direct contact).
• Non-flame engulfment: heat transfer by radiation• Radiation is the energy transmitted to air by the fire and onwards to a target. Level based on the SEP of the
fire, the view factor – how much the target sees of the fire - and the distance to from the fire to the target.• Tests reflect these parameters• A standards such as API2218 or ISO13702 (offshore) defines duration and the resistance tests to
be undertaken.• Less prescriptive approaches (TN13) allow the owner to determine duration. Certification then
often defines the tests.
PFP Material Testing Questions
Questions on Part 1?
Part 2Integrity Management
Checklist 3 - Is the Integrity of the PFP System Being Managed Correctly?
Is the PFP system inspected and maintained as part of an integrity management process withinthe Safety Management System?
Does the PFP system show any signs of damage that might affect its performance?
If the PFP system is damaged, how severe is the damage?
If the PFP system has been repaired, has the repair been implemented correctly so that there isno reduction in fire resistance performance?Is the condition of the system good, reasonable, mediocre or bad and is this assessment thesame as the opinion of the establishment?Has the Safety Management System, and its supporting procedures and processes, ensuredthat the PFP is fit-for-purpose?
The primary elements of an Integrity management process for PFP are:
• Clear Roles and Responsibilities• Documented Processes and
Procedures covering • Change Management• Inspection• Assessment• Repair• Documentation and Record keeping
Inspection Management should cover• How all documents for PFP are
managed.• Inspection procedures
• what is inspected, • what methods are used, • how frequently it is inspected,• recording of the inspections, • actions on finding damage or defects,
• Competency of Inspectors and Assessors
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Integrity Management of PFP Systems
Key Point: PFP may lie between disciplines and there may be no “owner”
Key Point: There is no guidance on how to do this but codes, standards and Regulations say you must!
• PFP system inspection is predominantly visual and non-destructive. • Access can sometimes be difficult as much PFP is high up. Binoculars help!• Eyes, ears and touch are the usual tools
• tap test – is it hollow? Is the material soft and crumbling?)• A thermal camera is non-invasive and can help find hidden defects.• Thicknesses, bond strength and hardness can be measured using destructive tests
• Removals of PFP may take place if the item below is being inspected• This may include removals of PFP as part of a CUI inspection programme
Comment on Inspection of PFP Systems
Key Message: It isn’t rocket science and doesn’t need a lot of equipment –you just need to know what to look for.
Question on Testing• How can you test (pfp on) a gas ball?• Usual fire test standards apply• But they are difficult to protect due to surface
area• Visual inspection works - damage is obvious• Legs are important• Tapping finds areas of disbondment
• The repair should not be implemented for the benefit of improving the visual appearance of the damage.
• The repair must be implemented to restore the required fire rating.
• Badly implemented repairs WILL cause further damage.
• The site should have a written strategy for repairs.
Repairs of PFP Systems
Key Message: A repair with a poor visual appearance is often a sign of a badly made repair
• Complete replacement: • Can use the same PFP system, or a new, equivalent, system.. • Detailing of the interface with any existing systems that are
adjacent is critical.• Partial repair/replacement repair using the same PFP systems:
• It is preferable to carry out the repair on a like-for-like system/material basis using guidance on the repair provided by the PFP system manufacturer.
• Partial repair/replacement using a different PFP system, or non-standard repair:
• Where the repair cannot be implemented using a like-for-like replacement, then a non-standard repair will require a demonstration of its adequacy to meet the required fire.
Repairs of PFP Systems
Key Message: Don’t mix PFP systemsAvoid uncontrolled, ad hoc, repairs made on siteUse Manufacturer or Industry approved repairs
Cracks filled with mastic
Overlapped mesh (good)
Dissimilar materials (good repair)
PFP Systems DamageCoatings - Concrete, Lightweight Cementitious (LWC), Epoxy intumescentInsulationDry-fit systemsWet applied systems
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BarriersPenetrationsBuildingsOthers
Assessment tables
• Assessment tables provided for all the major defects seen in all the different PFP systems. Covering:
• Coatings• Dry-fit systems• Wet applied systems• Barriers• Penetrations
• Established approximate levels of the severity of damage that may be observed.
Assessment Tables
A small crack in pfp can absorb water during extinguishing and cause the pfp to burst when heated by expansion. Simon considers a small crack acceptable. Where do we now set the limit?• Coatings crack during a fire.• There are hose stream tests that looks at the effect of
extinguishing water on PFP (ESTM E2226, NFPA 58, ul10B, ul1479, etc)
• Concrete and LWC have a water content already• Small cracks are not acceptable. Small cracks may not
reduce the immediate fire resistance performance, but may reduce the long term integrity.
• Cracking becomes a real problem when coatings are disbonded AND cracked.
• The importance of cracking also depends on what structure it is on, and whereabouts on the structure it is.
Question on Cracking Damage
Dense Concrete - Damage• Cracked or spalling
materials • Missing materials (dents,
gouges, chips, etc.) • Corrosion staining (from
reinforcement or substrate)
• Loose and spalling materials
• Exposed reinforcement with no concrete cover
• Failed reinforcement
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Lightweight Cementitious - Damage• Loss of topcoat (does not affect fire
performance but will lead to long term degradation)
• Corrosion staining (from retention mesh or substrate)
• Cracks• Loose and spalling materials• Missing materials (dents, gouges, chips)• Hollow/disbonded material• Erosion• Exposed retention system• Failed retention system• Retention mesh in wrong place for fire
threat• Waterlogged and soft material
Cracking – what lies beneath?
• Topcoat damage (No effect on fire performance - leads to long term degradation)
• UV chalking• Cracking • Liquid filled blisters • Disbondment• Chips, gouges and physical damage• Activated material• Low material hardness• Leaching of salts• Corrosion staining (from metal
reinforcing mesh or substrate)• Low material thickness, particularly at
edge features• Reinforcement not fully encapsulated.• Reinforcement damaged at edge
feature.
Epoxy Intumescent- Damage
Dry Fit Systems - Damage• Damage to the outer shell
material.• Damage to insulation
materials where these are deployed.
• Damage to the fixing or retention system.
• Damage at joints or seals within the system.
• Damage at the interface between the dry-fit system and another system, such as a coating or wet applied system.
• A failure to replace any of the components following removal.
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Wet Applied Systems - Damage• Surface anomalies in the
protective outer coating • See coatings section for more
detail• Delamination within material
thickness• Disbondment at substrate• Reinforcement and retention
system damage• Waterlogging of MMMF
insulation material• Open joints in insulation
system beneath outer protective coating
80Pictures courtesy of MMI Engineering
Barriers - Damage• Loss of integrity that results in internal
insulation being exposed to direct fire impingement or moisture or allows smoke/gas ingress.
• Damage to the connections between the barrier and the structure to which it is attached, or connections making up enclosures.
• Damage to any externally applied coating or cladding systems for integrity or insulation (see coating damage)
• Damage to the integrity of any insulation materials through waterlogging
• Damage to any retention systems that retain insulation systems in contact with the barrier substrate
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Penetrations - Damage• Anything that causes fire, smoke
or gas to pass through a penetration or sealed opening in a barrier or enclosure.
• Fire performance of a penetration which is less than that of a barrier. Could be by incorrect specification or poor design
• Anything that could lead to corrosion beneath the penetration
• Any missing or incorrectly installed components
• Any rips, tears, contamination or corrosion.
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Thank You
