Fireproofing From Chevron

1700 Fireproofing

AbstractThis 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 fire-proofed and fire resistant systems for critical control systems. API RP 2218 is the industry standard for fireproofing.

Contents Page

1710 Introduction 1700-2

1711 Definition of Terms

1712 Company and Industry Documents

1720 Support Structures 1700-3

1721 Where Fireproofing of Support Structures Is Warranted

1722 Level of Protection Required

1723 Layout and Design Considerations

1724 Materials

1725 Specific Applications

1730 Critical Valves, Instrumentation, and Shutdown Systems 1700-14

1731 Emergency Shutdown or Isolation Valves

1732 Tank Block Valves

1733 Air Supply

1734 Switchgear Housing and Junction Boxes

1735 Instrument and Electrical Cables

1736 Home Runs for Cable Trays and Conduit Banks

1740 Materials Suppliers and Applicators 1700-20

1741 Support Structures

1742 Critical Valves, Instrumentation, and Shutdown Systems

1750 Fireproofing Test Methods 1700-22

1760 References 1700-25

Chevron Corporation 1700-1 June 2000

1700 Fireproofing Fire Protection Manual

for

to

quid

a

ate-

s-

m-.

heir

ow

1710 IntroductionSelecting a fireproofing material involves answering three questions:

• What level of protection is required, if any?• What materials will provide this level of protection?• Of those materials, which is the appropriate choice?

Section 1720 answers these questions for support structures and Section 1730critical valves, instrumentation and shutdown systems.

This section defines terms used in this section and lists relevant Company and industry documents.

1711 Definition of Terms

Fireproofing: Protection that provides resistance to fire and heat transfer long enough to allow critical structures to remain standing or critical control systemsoperate, while the fire is brought under control.

Fire-Exposed Envelope:

• For structural steel, vessel/column skirts, etc., the area within a horizontal radius of 20-40 feet and 20-40 feet vertically of fire-potential equipment. Distances can be expanded or reduced based on drainage, pressure and liholdup.

• For instrumentation, electrical power cables and/or air piping/tubing, the arewithin a 50' horizontal radius or 50' vertically.

Fire Potential Equipment:

• Fired equipment, including heaters and furnaces, that handles flammable mrials.

• Rotating or reciprocating mechanical equipment, such as pumps or compresors, that handles flammable materials.

• Drums, exchangers, columns, and similar operating vessels that handle flamable materials and have a volume of more than 1000 gallons (24 barrels)

• Plot-limit piping manifolds that contain flammable materials and ten or morevalves.

• Tanks, spheres, and spheroids that contain flammable materials including tdrainage and relief path and impounding basis.

Flammable Materials: For the purpose of this section of the manual, flammablematerials include flammable gases, vapors, and liquids having a flash point bel100°F or being handled at temperatures above their flash point.

Emergency Shutdown or Depressuring System: A system that will shut down a plant or other facility under emergency conditions, either automatically or by

June 2000 1700-2 Chevron Corporation

Fire Protection Manual 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 emer-gency 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.

1712 Company and Industry DocumentsSee Section 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 Petro-chemical Processing Plants as a guide to determine the extent of fireproofing required. This section is a supplement to that publication.

1720 Support StructuresThis section presents guidelines for fireproofing support structures to protect them from failure due to fire exposure for specific time periods.

1721 Where Fireproofing of Support Structures Is WarrantedFireproofing of the principal members is warranted if the structure is in the fire-exposed envelope and failure of these members could cause any of the following:

• Threat of injury to personnel• Loss or serious damage to valuable or critical supported equipment• Release of large volumes of flammable material• Release of toxic material• Threat to adjacent property and structures of high value• Serious loss of productive capacity



to

, orts

ether

d -ip-(see y n of

ent n ire &

tec-

rd ithin s

r e-uch

the ed

Conversely, fireproofing is not warranted in these situations:

• The value of the structure and supported equipment is low when comparedthe cost of fireproofing.

• Member failure would not cause failure of the structure or equipment. Thuswind and earthquake bracing and other secondary members, such as suppfor stairs, platforms, and walkways, are not normally fireproofed.

• The structure is far enough removed from the source of a fire to preclude serious damage.

• The fire would cause failure or serious damage to supported equipment whor not the structure was fireproofed.

• The structure supports piping that is not carrying flammable liquids. Piping carrying only gases does not normally justify fireproofing of the supports.

1722 Level of Protection RequiredMajor factors that determine the level of fireproofing needed are the intensity anduration of potential fire and the importance of the structure or equipment. Typically, fireproofing should protect structures supporting high-risk or valuable equment from reaching 1000°F for a period of three hours, as defined by UL 1709 Section 1750). For dense concrete, this is equivalent to four hours as defined bASTM E-119, the test used prior to 1984. (Refer to Section 1750 for a discussiothe differences between ASTM E-119 and UL 1709 fire tests.) Fireproofing in excess of these requirements may be necessary for special high valued equipmsuch as reactors or equipment handling large quantities of flammable material icongested areas. Non-critical structures are not protected. Consult the CRTC FProcess Safety Team if you feel the above criteria do not fit your needs.

When fireproofing of structural supports is warranted, the following types of protion are recommended:

Three-hour fireproofing as shown on Standard Drawing GA-N33336 (in StandaDrawings Section) is for main support members of structures and equipment wthe fire-exposed envelope (see Section 1711). A three-hour level of protection iappropriate for a typical hydrocarbon processing unit fire duration.

Less than three-hour protection. Thinner coatings may be used where three-houprotection is not warranted. See Figures 1700-1 and 1700-2 for guidance. Threhour protection may not be justified in areas where the flammable inventory is sthat a three-hour fire is unfeasible.

A three-hour rating for formed and poured concrete fireproofing is usually worthsmall incremental cost of the additional concrete. If gunite concrete is used, it iseconomical to use the thickness corresponding to the particular fire rating needbecause cost is more nearly proportional to thickness.



Comparative Fire RatingThe 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 1700-2

.


1700 FireproofingFire Protection M

anual

June 20001700-6

Chevron Corporation

Fig. 1700-1 Properties of Cementitious Base Fireproofing Materials

STRENGTH

yrocrete 241 Fendolite M II(1)

rietary inorganic ent formulation

Spray-applied vermiculite portland cement mix

55 44

817 548

0.87 1.32

55 40-41

ign No. XR-701 Design No. XR-704

11/16” 1”

15/16” 1-3/16”

1-1/8” 1-7/16”

- 1-5/8”

1-3/8” 1-13/16”

1-9/16” 2-5/16”+

None(4) Epoxy(3)

None(4) Note(4)

otes(10) (7) (9) Notes(7) (9)

HIGH STRENGTHINTERMEDIATE

STRENGTH LOW

Product NameConcrete (poured-in-place

or gunited)Haydite Vermiculite Mix Pyrocrete 240 (High Yield) P

Specifications

Standard mix of portland cement and rock aggregate

Haydite and Vermiculite (light weight aggregate)

plus portland cement

Proprietary inorganic cement formulation

Propcem

Density (lbs./cu ft) 140-150 75-95 47

Compressive Strength (PSI) 2500-3000 1500-2000 836

Thermal Conductivity (BTU in/deg F-hr-sq ft @ 75 deg F mean temperature)

13 3 1.19

Hardness (Shore D) 70-90 70-90 55

UL 1709 Fire Time Rating (thickness in inches at:

Design No. XR-716 Des

1 hour - - -

1.5 hours - - 11/16”

2 hours - - 1-1/8”

2.5 hours - - -

3 hours 2.5” Note(2) 2” Note(2) 1-3/8”

4 hours - - 1-9/16”

Recommended Primer Epoxy(3) Epoxy(3) Note(4)

Recommended Topcoat None(5) None(5) Note(4)

Recommended Use Note(6) Note(7) Notes(8) (7) (9) N

(1) Chevron has not used this system extensively. Before using it, contact the CRTC Materials and Equipment Engineering Specialist.(2) While there is no test data to support this number, it is equivalent to a 4 hr ASTM E-119 rating, for which test data is available.(3) Coating System Data Sheet 4.4 in the Coatings Manual (Quick Ref Guide page 69).(4) Follow manufacturer’s recommendations.(5) For severe weathering and corrosive conditions, consider an epoxy topcoat.(6) Structures such as piers, legs, pipe supports, etc., where weight is not a concern.(7) Vessels, skirts and other applications requiring lighter weight aggregate. Generally not used on structural steel.(8) Better for modular designs where flexing occurs during transport.(9) Oil platforms and other applications requiring lighter weight and low volume.(10) Chevron has good experience with this product.

Fire Protection Manual

1700 Fireproofing

Chevron Corporation1700-7

June 2000

FINSULATING

p (Elec-ays)

Eternit Promat H

cium sili-tion

High density calcium sili-cate insulation

54

1420

1.14

?

1986 HIFT Test Results

-

-

Note(2)

Note(2)

Note(2)

Note(2)

Note(2)

Note(2)

None

Note(3)

ys Note(1)

g Specialist.

s.

ig. 1700-2 Properties of Non-Cementitious Base Fireproofing Materials INTUMESCENT SUBLIMING

Product NameChartek VII Pittchar XP(1) Thermolag 3000 (100%

Solids)Super Fire Tem

tric Cable Tr

Specifications100% solids epoxy intu-

mescent100% solids epoxy intu-

mescentTwo-component epoxy

subliming coatingHigh density cal

cate insula

Density (lbs./cu ft) 62.4 73 78.5 28

Compressive Strength (PSI)

2700 2264 2190 900

Thermal Conductivity (BTU in/deg F-hr-sq ft @ 75 deg F mean tempera-ture)

1.48 1.69 0.076 ?

Hardness (Shore D) 70 60 50 ?

UL 1709 Fire Time Rating (thickness in inches at):

Design No. XR-617 Design No. XR-612 Design No. XR-618 -

1/4 hour - - - 1”

1/2 hour - - - 1.5”

1 hour - 0.28” 0.12” -

1.5 hours 0.40” 0.40” 0.21” -

2 hours 0.60” 0.52” 0.31” -

2.5 hours 0.80” 0.63” 0.41” -

3 hours - 0.75” 0.50” -

4 hours - - 0.69” -

Recommended Primer Note(3) Note(3) Note(3) None

Recommended Topcoat Note(3) Note(3) Note(3) Note(4)

Recommended Use Note(5) Note(5) Note(6) Cable Tra

(1) Chevron has not used this system extensively. Before using it, contact the CRTC Fire & Process Safety Team or CRTC Materials and Engineerin(2) See manufacturer’s brochure for calculation instructions (page 18-19).(3) Follow manufacturer’s recommendations.(4) Outdoor installations need weatherjacketing. Silicone waterproofing is recommended by Johns Manville and may be adequate for dry location(5) Oil platforms and other applications requiring light weight and low volume.(6) Thermolag 3000 has both on and off-shore applications. See Manufacturer’s brochures for each market.


d nsid-ion.

d

c-

effec- and

-

se mate-(See

from pera-ass scent e

1723 Layout and Design ConsiderationsThe API Publication 2218, “Guideline for Fireproofing Practices in Petroleum anPetrochemical Processing Plants,” gives a sequence of steps to follow when coering what to fireproof. This section of the manual offers supplemental informat

Consider the following during design:

• General layout of the plant (see Section 1300).

• Drainage (both of the plant area and within structures) should carry hydro-carbon spills away from supports, structural members, and equipment. Thisreduces the amount of potential fire damage due to an accidental spill. Where drainage does not meet these criteria, additional fireproofing may be justifie(see Section 1400).

• Fire risks in plants should be adequately spaced from one another (see Section 1300).

• Sources of ignition—furnaces, shops, etc.—should be located as far as pratical from areas where flammable vapor might be released to the air. Whererisks are not adequately separated, additional fireproofing may be justified.

1724 Materials

Types of Fireproofing MaterialsThe Company usually uses concrete material because it is often the most cost-tive. Many commercial products are also available. They have specialized usesare usually more expensive than concrete. Fireproofing materials come in threecategories:

• Cementitious-based materials such as concrete, Carboline’s Pyrocrete 241, and Hydraulic Press Brick Co.’s Haydite-Vermiculite field mix.

• Ablative materials or non-cementitious coatings such as Thermal Science Inc.’s (TSI) Thermolag 3000 (subliming) and Textron’s Chartek VII (intumescent)

• Insulation-based material such as Johns Manville Super Firetemp

Figures 1700-1 and 1700-2 give the UL 1709 and/or ASTM E-119 rating for thematerials. Use these figures to compare the relative performance of the tested rials. New applications should use materials that have been rated by UL 1709. Section 1750.)

Both cementitious-based and insulation-based materials insulate the structure heat generated during a fire. These materials are not destroyed by the high temtures of a fire. Both intumescent and subliming coatings absorb heat through mreduction. Subliming coatings absorb heat by transforming to a gas and intumecoatings work by quickly swelling to four times their original thickness to insulatthe structure.



ed

red a ics al

used

y of ht n

al ght-gth high-

lso.

and

e ht not

ith rb

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 Section 1750) indicates that gunitconcrete 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 considecost-effective fireproofing method for low-risk, lower-value areas where aesthetis not a high priority. Consult with the Fire Protection Staff about using it in critichigh risk areas.

Properties of Fireproofing MaterialsFigures 1700-1 and 1700-2 compare fireproofing materials. Some of the terms 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 densit150 lb/cu ft. Less dense materials minimize dead weight. However, lighter weigmaterials may not save money because they are generally more expensive thaconcrete.

Compressive Strength. Will the area you are fireproofing be subject to mechanicabuse? Compressive strength is a good indicator of impact resistance. Some liweight fireproofing systems such as Pyrocrete 241 have low compressive strenand are more easily dented or damaged. These materials should not be used intraffic, high-maintenance areas.

Thermal Conductivity. Normally, thermal conductivity is not a major factor in choosing a fireproofing material unless the material is to insulate the structure aFigures 1700-1 and 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/Chemical Composition of Fireproofing MaterialsThe composition of a fireproofing material determines its compressive strengththe need to use primers and/or topcoating with the material.

Concrete and Haydite-Vermiculite Mix. Concrete fireproofing is a standard mixture of Portland cement and rock aggregate conforming to ASTM C-150. ThHaydite-Vermiculite (H-V) mixture also uses Portland cement but with lightweigaggregates. Except in severe freeze-thaw service, concrete and the H-V mix donormally need a topcoat. Haydite is an expanded shale/clay and Vermiculite is expanded Mica.

Lightweight Cementitious Materials. Commercial lightweight cementitious fire-proofing materials must be topcoated. They are mostly lightweight aggregate wjust enough cement to hold them together. The lightweight aggregates will abso



en-

n-been ted ring

a-der-

e shelf e

fire-

by eds a is

ra-in is ther ion re not

ng

d dra-

ial g

water and tend to degrade much faster than normal concrete. Topcoating slows degrading.

Pyrocrete 240 & 241 have lower range compressive strengths, and now being chlo-ride-free, do not cause corrosion problems. Refer to the manufacturer’s recommdations for primers and topcoats.

Noncementitious Materials. The Company has limited experience with noncemetitious coatings like Thermolag 3000 and Chartek VII. Thus far, experience has good on the few existing applications. However, a cautious approach is warranwith their use. Thermolag 3000 is a subliming coating which just chars away dua fire.

Intumescent coatings, like Chartek VII, work by quickly swelling up to four timestheir original thickness during a fire. The swelled material forms a strongly oxidtion-resistant char layer. In this manner, it resists the fire. It also protects the unlying 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 aproblem.

Shelf Life of Fireproofing Materials. Some of these specialty fireproofing mate-rials have a limited shelf life, similar to some brands of coatings. Therefore, it isunwise to purchase excessive amounts that cannot be used in a short time. Thlife of Pyrocrete 241, for example, is two years. In general, suppliers will not taktheir material back and there will be disposal costs for the expired material.

Weathering. Long-term environmental exposure does not have much effect on proofing materials. Dense cementitious materials are usually unaffected. Light-weight cementitious materials and noncementitious materials can be protectedtopcoating. However, the weathering resistance of noncementitious coatings nemore careful evaluation. Figures 1700-1 and 1700-2 indicate where topcoating recommended.

In a 1975 test program by the Smithers Company, (an independent testing labotory), a noncementitious, intumescent coating, Albi Clad 890, was found to retaonly 30% of its fireproofing capabilities after an accelerated weathering test. Thloss in fireproofing was greater than that indicated by physical appearance. Anointumescent coating, Firex RX 2384, showed only a nine-minute time of protectin a high rise fire after accelerated weathering. Consequently, these products arecommended.

The Smithers program did not test Chartek VII and Thermolag 3000. However, product literature states that these two products can pass accelerated weatheritests without significant loss of fireproofing capabilities.

Reuse After a Fire. Cementitious fireproofing materials are not necessarily ruineafter exposure to a fire. Remaining properties depend on how much water of hytion was lost. The amount lost is a function of the intensity and duration of fire exposure. Concrete is a good insulator and it is not unusual to find much of theremaining concrete in good condition after a fire. All loose and damaged matermust be removed. The fireproofing can then be rebuilt to original thickness usin



h fire- the rob-

ucts rod-

r-on orro- a

ons,

the inal tly

es-

d se sh

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. Insu-lation-based systems would normally also need to be replaced after a fire.

Problems with FireproofingThe Company has no reported failures of a fireproofing material during a fire. However, fireproofing has caused the following problems:

• Severe corrosion of the structural steel and reinforcement mesh underneatproofing. The primary cause is water that gets between the fireproofing andsteel. As noted above, some proprietary fireproofing may cause corrosion plems if the steel is not coated. Refer to the Corrosion Prevention Manual, Section 630, for more information on corrosion under fireproofing.

• Excessive cracking of cementitious fireproofing.

Corrosion Prevention. Abrasive blasting and priming the structural steel prior to fireproofing and proper cure of cementitious fireproofing are important in elimi-nating corrosion. Flashing or caulking prevent entry of water between the fire-proofing and the steel. Acceptable sealants should be specified. Two such prodare Dow Corning No. 732 Silicone elastomeric sealer and H. B. Fuller, Foster Pucts Division No. 95-44 butyl caulking.

Commercial fireproofing manufacturers usually specify primers to be epoxy, inoganic zinc, or combinations of the two. However, epoxy provides better protectiagainst corrosion. Epoxy is preferred in plants that have a previous history of csion under fireproofing. Standard Drawings GA-N3336 and GD-N99994 specifypolyamide 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 restrictisuch as low-temperature climates, limit the use of epoxy.

Touchup is required if the primer is damaged during shipment or application of reinforcing anchor studs. The touchup coating must be compatible with the origprimer. Also consider economics— spraying a new primer coat may be less costhan extensive touchup.

Cracking and Proper Cure. Proper cure of cementitious fireproofing materials greatly reduces the amount of cracking. In some geographic locations, it is necsary to take extra measures like spray-applying a curing compound to seal the surface to prevent moisture loss. Another measure is to wrap the freshly poureconcrete work with burlap or polyethylene sheet; however, this method can caustaining. The concrete can also be cured by continuous application of a fine frewater mist to keep the surface moist.



dily instal-

ore d

the lcula-ance fing

st claim

ard ore

r the s ible

g or

A-

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.

• Spalling of concrete, removing more than 20% of depth.• Many long, full-thickness cracks wider than 1/8 inch.• Substantial thinning of the steel substrate.

Selecting the Appropriate SystemConcrete has usually been the most cost-effective fireproofing material. It is reaavailable and the materials are least expensive. It does not require specialized lation techniques like some commercial fireproofing materials.

Some proprietary fireproofing systems, such as Pyrocrete 241, are becoming mcompetitive with concrete from an installed cost standpoint, and have performebetter than concrete in fire tests.

Consider the long-term costs of fireproofing systems. If a topcoat is required in original design, plan to recoat it about every 10 years. Discounted cash flow cations may show this maintenance cost to be low; however, also consider the chthat the required planned maintenance will not be carried out. Concrete fireprooavoids this problem.

The weight savings of lightweight fireproofing does not always translate into cosavings. Some offshore platforms are exceptions. Users should be wary of this and be sure that the benefits are real.

1725 Specific ApplicationsRefer to API RP 2218 for guidance on where to apply fireproofing. This sectionprovides supplemental information.

Vertical Vessel SkirtsFireproofing for skirts of columns and other vertical vessels is detailed in StandDrawing GD-N99994 (see the Standard Drawings Section). Skirts limited to oneaccess openings of less than 24 inches in diameter, with pipe openings of no mthan 1-inch maximum annulus clearance around the pipe or pipe insulation (peStandard Drawing) need not be fireproofed on the inside. Spilled fuel within theskirt cannot get sufficient oxygen through only one opening. Additional openingwould permit cross-ventilation that could greatly increase the intensity of a possfire and would justify fireproofing the inside of the skirt. Fireproofing should be included at the bottom of the skirt in the bolt area between the bottom reinforcinplate and the base plate ring per Standard Drawing GD-N99994. Fireproofing fthe support legs of vertical vessels should be similar to that shown in Drawing GN33336.



to ith top ult a

n e als b, y

cted an 9

e t ls on, lat-

used that

ncrete y test)

tal-

d y for ered

ance legs s of

Hydroprocessing Reactor SkirtsReactors with a “hot box” design at the shell-to-skirt joint should be fireproofed the bottom of the hot box. Insulation covering the hot box should be protected wa 10-gage stainless steel flame shield. The flame shield should extend from theof the fireproofing to the head-to-shell joint and be mechanically secured. Consfireproofing 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 ahigh pressure hydrogen jet. The flame shield protected the underlying insulatiofrom the erosive effects of the hydrogen jet. Concrete fireproofing and Pyrocret241 were also tested, and neither was affected by the hydrogen jet. See MateriDivision Report, “Fireproofing Tests with Hydrogen Jet Impingement,” M.D. GibJanuary, 1990 File No. 56.35, available from Chevron Research and TechnologCompany, Process & Equipment Technology Group.

Piers or Legs for Horizontal VesselsSupport piers or legs for horizontal vessels near ground level, when not construof reinforced concrete, should be fireproofed. (Exception: Metal saddles less thinches high at the lowest point need not be fireproofed.)

Offshore StructuresCementitious fireproofing materials have performed poorly offshore because threinforcing steel in the concrete corrodes. Consequently, these materials are norecommended for offshore structures. Specialty, lightweight fireproofing materiaare often used offshore instead of concrete, to save space and weight. In additithere are no reinforcing bars in the materials to corrode. Chartek was used on Pform Ninian, Pyrocrete 241 was used on Platform Hidalgo, and Thermolag was on Platforms Gail and Esther. (Refer to Section 1750 for a discussion of ratingsapply to offshore fireproofing of decks and bulkheads.)

Fireproofing for Structures Subject to Physical DamageFor structures subject to physical damage, we recommend Portland cement cowith normal aggregates and a compressive strength of at least 2500 psi (28-daor one of the proprietary fireproofing materials with comparable compressive strength. Fireproofing for vessel skirts is normally made with lightweight aggre-gates per Standard Drawing GD-N99994. Follow CIV-EG-850 for the proper inslation and curing procedures for concrete.

Intumescent coatings do not resist mechanical damage nearly as well as guniteconcrete does. For this reason, intumescent coatings should be considered onlpipeway stanchions and secondary risk applications. They should not be considequivalent to gunited concrete for critical applications such as column skirts or major vessel supports without detailed review.

Filling Hollow Supports with ConcreteFilling pipe stanchions and other hollow supports with concrete increases resistto failure from fire exposure up to an hour or longer. Tests have shown that tankconstructed of structural steel tubing and filled with concrete withstood two hour



-

hat to

trol

dous This alve lec-rade

about r a ting,

rating pplied

y

he

mper-e.

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.

Prefabricated Fireproofed BeamsOften 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 Critical Valves, Instrumentation, and Shutdown SystemsRefer to Figure 1700-3 for an overview of this section.

Critical valves are defined as valves equipped with remote operated actuators tmust retain their operational integrity for a minimum of 20 minutes during a fire facilitate safe unit shutdown (refer to Section 1750).

1731 Emergency Shutdown or Isolation ValvesFail-Safe design is preferred for critical and emergency valves. It uses spring opposed valved actuators and normally pressured or electrically energized concircuits. 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 infor-mation on failure modes.

Fireproofing Systems for ValvesIf a fail-safe design is not feasible and the valve must be located in a fire hazararea, the valve must be fireproofed to withstand a UL 1709 fire for 20 minutes. is done by using a fire-safe valve design (see Section 2000) with a fireproofed vactuator, fire-safe air supplies (refer to Section 1733), fire-safe instrument and etrical cables (refer to Section 1735), and locating a remote actuation station at gin a safe location at least 50 feet from the protected equipment.

Valve actuators can be fireproofed with the following systems:

• Intumescent Coating (preferred); K-Mass Fireproofing System. K-Mass is a Chartek-based intumescent coating system shop-applied to a thickness of 1/2-inch. During a fire, the coating swells and forms an insulating char undeglazed surface. Because of the molding-type process used to apply the coaK-Mass systems can be designed to provide normal maintenance and opeaccess to the actuator. The major disadvantage is that the system can be aonly in the Thermal Designs Shop in Houston, TX.

• Insulated Box Enclosure. This system (Figure 1700-4) is a box-like assemblto fully enclose the motor/air operator of a critical valve including motor, gearbox, and drive nut or the entire housing of the protected component. Tfireproofing enclosure is made from a refractory ceramic fiber (RCF) block inside a stainless steel weather jacket. It is designed to keep the internal teature of electrical components at or below 200°F for 20 minutes during a fir



This fireproofing system is easily applied to the smaller-sized and more rectan-gular-shaped valve operators.

Fig. 1700-3 Determining Fireproofing Needs for Critical Valves, Instrumentation and Shutdown Systems



ther r/air tire emi-her l

a l the

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 insula-tion cover and insulation as required. This is a significant disadvantage because frequently these covers or panels are not reinstalled properly, reducing fire protection capabilities.

• Insulated Bag. This system (Figure 1700-5) uses insulation pads laced togewith galvanize- coated steel wire to form a bag that fully encloses the motooperator of a critical valve, including motor, gearbox, and drive nut or the enhousing of the protected component. The insulation bag is constructed of sflexible pads of ceramic fiber or fiberglass insulation. The assembly is weatprotected by a vinyl-coated Dacron cover. It is designed to keep the internatemperature of electrical components at or below 200°F for 20 minutes if exposed to a 2000°F fire, as described by UL 1709.

This fireproofing system is easily applied to the larger-sized and more complex-shaped valve operators.

The enclosure should be designed and installed so that leakage (e.g., fromvalve stem packing) does not enter the enclosure. If there is evidence of oiaccumulation, the enclosure should be promptly removed and cleaned andleakage problem corrected.

Fig. 1700-4 Insulated Box Enclosure for Valve Actuators

Fig. 1700-5 Insulated Bag for Valve Actuators



to

r-

-ery 6 l t as

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 Block ValvesTank 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, fire-proofing 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 valve. For MOVs with a separate control box, it is normally less costly to locate the box outside the tank impounding basin. This is because a water-tight enclosure (NEMA 3 or 4) can be used instead of an XP enclosure (NEMA 7) and fireproofing is not necessary. This also improves access in case of fire.

Fireproofing of motor operators on tank block valves is justified where all of the following conditions are met:

• Tank fill/suction valves are larger than 12 inches.

• Flash point of tank contents is under 100°F.

• Valve or piping failure during a fire would cause burning liquid to spread fireother tanks, equipment, important facilities, or the property of others.

Other considerations that may justify fireproofing include:

• The tank field is operated from a remote control center.

• The facility is considered a major or critical facility.

• The number of personnel available during the first 20 minutes of a fire emegency is limited, so remote operating capability must be maintained.

• The risk of a tank overfill is increased due to high use or filling rate.

• A spill resulting from a fire could cause serious environmental damage.

1733 Air SupplyAir supply tubing for control and motive power for air-operated emergency isolation valves (AOVs) should be steel or stainless steel. It should be supported evfeet in horizontal runs or every 8 feet in vertical runs; or it should be in rigid steeconduit, supported every 10 feet. Type 304 or 316 stainless steel tubing, withoufireproofing can safely be used for instrument air through a fire hazardous arealong as it is well supported.



alling

g” its t

und rays,

ri- alled

he m

tc., fire-d

crit-e

an by

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.

1734 Switchgear Housing and Junction BoxesSwitchgear housing and junction boxes for power and control of emergency shut-down, 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 insta radiant heat shield between the enclosure and the potential fire source.

1735 Instrument and Electrical Cables“Critical control instrument cables, power cables and instrument air piping/tubinis defined as being part of a critical valve/shutdown system that must maintain operational integrity for a minimum of 20 minutes in a fire to facilitate a safe unishutdown.

Critical control tubing, instrument cables, and power wiring should be located outside fire hazardous areas wherever possible. This includes routing undergroand routing in the upper level of elevated pipeways, separate from main cable tto prevent a single incident from disabling both systems.

Critical instrument tubing or electrical cables located above ground within 50 hozontal feet of fire hazardous equipment should be fire resistant or fireproofed towithstand exposure up to 2000°F for at least 20 minutes. Cables should be instin galvanized steel conduit or cable tray (refer to Section 1711, “Definition of Terms”).

Do not locate fire resistant wiring in or under aluminum conduit or cable trays. Ttray or conduit can fail during a fire, causing the wiring to fail, or melted aluminucan fall on the wiring, damaging the sheathing.

Where main cable runs are buried, individual cable risers to motors, switches, eshould withstand exposure up to 2000°F for at least 20 minutes or be externallyproofed if the motors and switches are part of a critical emergency shutdown anisolation system and the system is not fail-safe.

You can use the following systems, presented in order of preference, to protectical wiring or tubing systems located in fire hazardous areas. These systems ardesigned to maintain circuit integrity for at least 20 minutes in a 2000°F fire, asdescribed by UL 1709.

Fire-Resistant Wiring with Rigid SheathingThis system can be of two types: 1) wiring enclosed by mineral insulation insideIncoloy 825 shield (e.g., Pyrotenax MI Cable); or 2) nickel conductors enclosed



s’

de a

t

ain-

port

heat

utes r be

ool

ket her ose

rdous de the

em 0°F,

e ac-

m l

silicon dioxide insulation in a stainless steel sheath (e.g., Meggitt Safety SystemSI 2400 Fire Cable). Neither system requires conduit.

Fire-Resistant Wiring Needing Steel ConduitThis 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 insisteel conduit for support (e.g., DeKoron Fire Resistant Circuit Integrity Cable).

Nonfire-resistant Tubing or Wiring with Thermal InsulationThis system protects critical instrument leads or electrical wiring that is not hearesistant (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 stless steel weather jacketing.

ConduitConduit should be rigid steel with steel fittings and covers. Supports should be spaced 6 feet or less in horizontal runs and 8 feet or less in vertical runs to supthe weight of the fireproofing material and to avoid sagging during a fire. In fire hazard areas, conduit supports should be insulated because they may conductinside the fireproofing during a fire.

Thermal insulation that can withstand exposure up to 2000°F for at least 20 minshould cover the conduit. Due to the short exposure, most thermal insulation fopipe will be adequate if it is at least 1-1/2 inches thick. Extended protection maygained by using ceramic fiber or two-layer calcium silicate insulation. Mineral wwould also work, but for a shorter length of time. To seal against weather and protect against mechanical damage, a galvanized or stainless steel weather jacsecured with stainless steel bands should cover the insulation. Aluminum weatjacketing would melt, exposing the insulation to damaging effects of the fire or hstreams.

1736 Home Runs for Cable Trays and Conduit Banks

LocationHome runs of cable trays and conduit banks should be routed outside fire hazaareas wherever possible. This includes routing underground and routing on theupper level(s) of elevated pipeways at least 30 feet above the ground and outsidrainage path of hydrocarbon spills.

Home runs located within 50 feet of equipment or drainage that could expose thto a spill fire (e.g., areas within the drainage pattern of pumps operating over 60or over the auto-ignition temperature, or pumps with a history of fires) should bfireproofed if loss from the home run and corresponding facility down time is unceptable.

It is often preferable to separate the critical instrumentation and alarm wiring frothe home runs. Non-critical home run cables do not require fireproofing. Criticacables should be protected as described in Section 1735.



se tain-

. es)

er,

r .

DesignGenerally, 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 addi-tions should be taken into account during initial construction. Fireproofed cable tray networks should contain about 20% spare cables or tubing for future additions and replacements because the tray is totally enclosed by the fireproofing system.

Where home run conduit and cable trays enter control buildings, wall penetrations should be sealed to prevent entry of vapors, smoke, and fire.

Methods of FireproofingThe following methods of fireproofing prevent internal temperature from exceeding 200°F for 20 minutes in a 2000°F fire per UL 1709.

• Wrap the conduit bank or tray with flexible blanket insulation designed for uat 2000°F and cover with stainless or galvanized steel weather jacket and sless steel bands.

3M’s Interam system uses ceramic fiber blanket with an aluminum coveringThis material is thinner than conventional insulation (0.6 inches vs. 1.5 inchand can be used economically on odd shaped sections where fitup of thickmore rigid systems is difficult.

• Box-in cable trays with prefabricated panels (usually calcium silicate) and weather jacketing. This type of system is economical for simple rectangulashapes. Promat-H and Johns Manville Super Firetemp can be used for this

1740 Materials Suppliers and ApplicatorsThe recommended sources listed below are current as of 1999.

1741 Support Structures

Fireproofing MaterialsHaydite-Vermiculite MixHydraulic Press Brick Company8900 Hemlock Rd.P.O. Box 31330Cleveland, OH 44130Phone: (216) 524-2950



Chartek201 Lowell St.Wilmington, MA 01887Phone: (978) 657-2904

Fendolite M IIMandoval Industrial Fireproofing Products7025 W. Tidwell, Suite 111Houston, TX 77092Phone: (800) 847-5768

PittcharPPG Industries151 Colfax St.Springsdale, PA 15144Phone: (724) 274-3473

Super FiretempJohns Manville1559 9th AvenueSan Francisco, CA 94122Phone: (415) 665-0767

PyrocreteCarboline1401 South Hanley Rd.St. Louis, MO 63144Phone: (925) 838-7571

ThermolagThermal Sciences Inc. 2200 Cassens Dr.St. Louis, MO 63026Phone: (314) 349-1233 or (281) 482-7000

1742 Critical Valves, Instrumentation, and Shutdown SystemsFor sources of acceptable wire other than those listed below, we strongly recom-mended that you consult with CRTC, Machinery & Electrical Systems Team.

Valve Actuator FireproofingK-Mass Fireproofing System and Box EnclosuresThermal Designs, Inc.5352 Prudence StreetHouston, TX 77045Phone: (713) 433-8110



High Temperature WireDeKoron Fire Resistant Circuit Integrity CablesUSA Cables1199 So. Chillicothe RoadAurora, OH 44202Phone: (800) 562-5151

MI (Mineral Insulated) CablePyrotenaxBICC General750 E. Green St. Suite 301Pasadena, CA 91101Phone: (626) 796-1040

SI 2400 Fire CableMeggitt Safety Systems1955 Surveyor Ave.Simi Valley, CA 93063Phone: (805) 584-4100

Cable Tray Fireproofing3M Interam3M Ceramic Materials DepartmentBuilding 225-4N, 3M CenterSt. Paul, MN 55144Phone: (800) 328-1687

Promat HEternitVillage Center DriveReading, PA 19607Phone: (800) 255-3975

Super FiretempJohns Manville1559 9th AvenueSan Francisco, CA 94122Phone: (415) 665-0767

1750 Fireproofing Test MethodsVarious tests measure the level of protection offered by a fireproofing material or system. If the material fails the test after 2 hours, it gets a 2-hour rating on that test; if it fails after 4 hours, it gets a 4-hour rating.

UL 1709 Standard for Rapid Rise Fire Tests of Protection Materials for Structural SteelUnderwriters Laboratories, in cooperation with the industry, has developed tests to more closely simulate fire conditions expected in a process plant. These tests are



rise M

ed

le, 3 ows ws

fires

ot

ce s n put rmo-er

are

now used by many companies, including Chevron. Fireproofing manufacturers use the tests instead of ASTM E-119, because the UL 1709 tests more closely approxi-mate hydrocarbon fires. These “high rise” fire tests include a faster temperatureand higher energy input than ASTM E-119 as shown in Figure 1700-6. The ASTE-119 test is primarily for buildings or combustible structures. Hydrocarbon firesreach higher temperatures more quickly than building fires. The first standardizoil industry test for high rise fires, UL 1709, came out in late 1984.

ASTM E-119 ratings are often longer than the UL 1709 counterpart. For exampdepending on the material, the ASTM E-119 4-hour test is equivalent to only 2-hours in the UL 1709 test (concrete). Consequently, the UL 1709 test usually shthat thicker protection is needed than that predicted by ASTM E-119. It also shothat the behavior of some materials may be significantly poorer in hydrocarbon than in conventional fires. This is why UL 1709 is now used for both structural supports and for critical control systems.

ASTM E-1529 closely follows UL 1709 and is also considered a “rapid rise” firetest, however, ASTM E-1529 utilizes a lower heat flux factor, and therefore is nthe equivalent of UL1709.

UL 1709 Fire Test ConditionsIn this test, a uniform thickness of a fireproofing material is applied in accordanwith accepted field practice on a steel I-beam at least 8' in length. The I-beam isupported vertically during the application and during the test. The beam is thein a furnace. Temperature of the I-beam is measured by not less than three thecouples located at each of four levels (minimum of 12 thermocouples). The uppand lower levels are 2' from the beam ends and the remaining two intermediatelevels are equally spaced between the upper and lower levels. Thermocouples

Fig. 1700-6 Comparison of Standard and High Rise Time-Temperature Curves



o-

ses ped c-e at

,

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 at any of the four levels of the steel column above 1000°F (538°C) and no thermcouple shall indicate a temperature greater than 1200°F (649°C).

The UL Fire Resistance Directory gives the specific rating for different thicknesand configurations of beams. Some theoretical relationships have been develobetween I-beam size, fireproofing thickness, and fire. UL is paid by the manufaturer to test their fireproofing materials. Therefore, non-proprietary materials likconcrete have no UL rating. However, favorable Company experience shows thconcrete and Haydite-Vermiculite Mix provide the degree of protection recom-mended.

Off-shore RatingsFor bulkheads and deck sections of offshore installations, fireproofing can be applied to any of the following ratings, depending upon application: A-60, A-120H-60, and H-120. Manufacturers must certify product ratings with test results.

.

Fig. 1700-7 Examples of Product Rating Tests(1)

RatingNormal Configura-

tionTest Environmental

Temperature Criteria to be Met Test Type

A-60

(60 min)(2)Bulkhead, deck section 9 sq. m usually 4.8 mm or greater steel thick-ness

Follow ASTM E-119 temp. curve (or equivalent)

Protected steel temp not to exceed a rise of 250°F (139°C) for 30 minutes

Cellulosic fire simu-lation - designed for commercial building. Gas fired furnace.

H-60

(60 min)(3)Bulkhead, deck section 9 sq. m usually 4.8 mm or greater steel thick-ness

Follow UL 1709 temp. curve (or equivalent)

Protected steel temp not to exceed a rise of 250°F (139°C) for 30 minutes.

No passage of smoke or flames and maintain struc-tural integrity for 120 minutes.

Norwegian Petro-leum Directorate high intensity of high rise fire curve. Gas fired furnace.

(1) A-120 and H-120 are 120-minute tests.(2) This is an ASTM E-119 test for use in protecting living quarters for 60 minutes under typical combustible materials fire conditions.(3) This is a UL 1709 test for use in protecting process areas for 60 minutes under high rise fire conditions typical of hydrocarbon fires



1760 References

American Petroleum Institute (API)

American Society for Testing Materials (ASTM)

Chevron ReferencesSpecifications and Engineering Forms:

Coatings Quick Reference Guide

Standard Drawings:

CRTC, Materials Division: “Fireproofing Tests with Hydrogen Jet Impingement,”M.D. Gibb, January 1990, File No. 56.35

Civil and Structural Manual

Coatings Manual

Corrosion Prevention and Metallurgy Manual

Instrumentation and Control Manual

Underwriters’ Laboratories (UL)

Fire Resistance Directory

API 2218 Guideline for Fireproofing Practices in Petroleum and Petrochemical Processing Plants

ASTM E-119 Fire Tests of Building Construction and Materials

PIPSTS03001 Plain and Reinforced Concrete

CIV-EG-850 Plain and Reinforced Concrete

GA-N33336 Standard Details—Concrete Fireproofing for Structural Members

GD-N99994 Standard Fireproofing Specification for Vessel Skirts

UL 1709 Standard for Rapid Rise Fire Tests of Protection Materials for Structural Steel


Date post:	31-Jan-2016
Category:	Documents
Upload:	satheeshkanna
View:	139 times
Download:	17 times