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THERMAL CERAMICS Fire Protection for Process Equipment hydrocarbon and jet fire protection
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Page 1: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

THERMAL CERAMICS

Fire Protection forProcess Equipment

hydrocarbon and jet fire protection

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Page 2: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

THERMAL CERAMICS

For all enquiries, please contact our specialist sales and manufacturing sites:

Europe Morgan Advanced Materials Morgan Drive Stourport-on-Severn Worcestershire DY13 8DW United Kingdom

T +44 (0) 1299 872210 F +44 (0) 1299 872218 [email protected]

AsiaMorgan Advanced Materials 150 Kampong Ampat 05-06A KA Centre Singapore 368324

T +65 6595 0000 F +65 6595 0005 [email protected]

South AmericaMorgan Advanced Materials Avenida do Taboão 3265- São Bernardo do Campo – SP CEP 09656 000 Brasil

T +55 (21) 3305 0400 F +55 (21) 2418 1999 [email protected]

North AmericaMorgan Advanced Materials 4000 Westchase Boulevard Suite 170, Raleigh, NC 27607-3970 USA

T +1 (855) 809 9571 F +1 (706) 622 4424 [email protected]

Thermal Ceramics is a business of Morgan Advanced Materials Quadrant, 55-57 High Street, Windsor, Berkshire, SL4 1LP United Kingdom

www.morganthermalceramics.comwww.morganadvancedmaterials.com

A B O U T M O R G A N A D VA N C E D M AT E R I A L S

MANUFACTURING IN

>30 COUNTRIES

LISTED ON THE LONDON

STOCK EXCHANGE OVER

9000 EMPLOYEES

SELLING INTO

>100 COUNTRIES

Morgan Advanced Materials is a global engineering company offering world-leading competencies in materials science, specialist manufacturing and applications engineering.

We focus our resources on the delivery of products that help our customers to solve technically challenging Problems, enabling them to address global trends such as

energy demand, advances in healthcare and environmental sustainability.

What differentiates us?Advanced material science and processing capabilities. Extensive applications engineering experience.

A strong history of innovation and reinvention. Consistent and reliable performance. A truly global footprint. We find and invest in the best people.

Copyright 07/14 Designed and Produced by JSA Creative

R6909 Morgan Brochure Template Thermal version2.indd 1 08/07/2014 06:54

Morgan Advanced Materials is a global engineering company offering world-leading competencies in materials science, specialist manufacturing and applications engineering.

We focus our resources on the delivery of products that help our customers to solve technically challenging Problems, enabling them to address global trends such as energy demand, advances in healthcare and environmental sustainability.

What differentiates us?Advanced material science and processing capabilities. Extensive applications engineering experience. A strong history of innovation

and reinvention. Consistent and reliable performance. A truly global footprint. We find and invest in the best people.

ABOUT MORGAN ADVANCED MATERIALS

2

THERMAL CERAMICS

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Page 3: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

Introduction ..........................................................................................................................................................................................................4

Hydrocarbon, Jet Fire and Explosion testing and certification ............................................................6

Classification ..........................................................................................................................................................................................7

FireMaster® Pipework Jet and Hydrocarbon fire protection ..............................................................11

Jetfireprotectionofsteelpiping ...........................................................................................................................14-16

ExamplesofFireMaster®JetWrapsystemonbends .........................................................................18-19

Foamglasspipesystem ....................................................................................................................................................20-21

Aguidetospecificationandcertification .......................................................................................................22-24

AcousticinsulationpropertiesofFireMasterpipefireprotectionsystem ...................25-29

FireMaster® Rigid Enclosure System (RES) ......................................................................................................31-38

Valveandactuatorfireprotection ................................................................................................................................39

FireMaster® Flexible Enclosure System (FES) ...............................................................................................41-47

FiretestperformanceofFireMasterFlexibleEnclosureSystem ...................................................48

FireMaster® Instrument cable tray fire protection .........................................................................................49

30minutehydrocarbonfireprotection ...................................................................................................................52

Weatherproofingsystem ......................................................................................................................................................53

Cabletrayfireprotectionfiretestingandcertification ...................................................................54-55

FireMaster® vessel fire protection system ..................................................................................................................57

Hydrocarbonfireprotectionforprocessvessels .................................................................................58-62

Explosion resistance testing of FireMaster® Process Equipment

fire protection systems ...............................................................................................................................................................63-66

FireMaster® structural steel fire protection .............................................................................................................67

Fireinsulationtosteelbeamsandcolumns ................................................................................................68-71

Structuralsteelfireprotectionsystem-GuidetoSpecificationandCertification .........72-74

SectionWizardsoftware..............................................................................................................................................................75

Fireprotectionforprocessequipment

3

Contents

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Page 4: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

ThismanualpresentsThermalCeramicsfireinsulationsolutionsforprotectionofcriticalprocessequipmentincludingtheprotectionofstructuralsupportsteelwork.

Passivefireprotectionisdesignedtoprotectcriticalprocessingandsafetyequipmentintheeventofafireforlongenoughtoallowasafeandcontrolledplantshutdown.Itslowsthespreadofjetandpoolfiresanddelaysthepossibilityofequipmentmalfunction,allowing personnelmoretimetoescape.

Onoffshorefacilitiesandpetrochemicalprocessingsites,passivefireprotectionistypicallyspecifiedforequipmentrequiredforemergencyshutdownandprocessequipmentthatmustremainintactduringafire.Critically,theprotectionspecificationshouldensurethattheequipmentremainsbelowitsfailuretemperaturethroughouttheperiodspecifiedsothatitcontinuestooperatenormallyandcanplayitspartineffectingacontrolled shutdown.

ThermalCeramicsoffersarangeofproductsandsystemsforfireprotectionofprocessequipmentinchemicalprocessingandoilandgasproductionfacilitiesbothonshoreandoffshore.Thesesystemsprovidefireinsulationtocriticalplantorserviceswhenexposed tohydrocarbonpoolorjetimpingementfires.

Inadditiontoprocessfireprotection,wealsosupplysystemsforfirerateddivisionssuchasbulkheads,decksandfirewallsfromA15uptoH120andJ30.Detailsofthosesystemscanbefoundinour‘MarineandOffshoreFireDivisions’manual.

Thismanualcontainsdetailsofthefollowingsystems:

Application System PagePerformance/Testing

FireMasterBlanketandMicroporousinsulationsystem

Pipework 11 - 29

HydrocarbonFireProtectionEN13381-4upto200minutes

JetFireProtectionISO22899-1forupto180minutes

Explosionresistanceto0.5bar

FireMasterCableTraySystem

Instrumentcabletrays

49 - 55HydrocarbonFireprotectionfor30minutesASTM1725-95

Processvessels 57 - 62

FireMasterMarinePlusblanket

Structuralsteel

67 - 74

HydrocarbonFireProtectionupto120minutesEN13381-4

CelluosicFireProtectionupto180minutesEN13381-4

Fireprotectionforprocessequipment

4

FireMasterVesselSystem

JetfireprotectiontoISO22899-1forupto180minutesExplosionresistanceto0.5bar

FireMasterFESFlexibleEnclosureSystem

JetfireprotectiontoISO22899-1forupto175minutes

Valves,actuatorsandflanges

31 - 48

FireMasterRES-RigidEnclosureSystem

JetfireprotectionISO22899-1upto60minutesExplosionresistanceto0.5bar

FireMasterFES-FlexibleEnclosureSystem

JetfireprotectionISO22899-1upto175minutes

FireMasterFESFlexibleEnclosureSystem

JetfireprotectiontoISO22899-1forupto150minutes

Jetfireprotection60minutestoOTO95-634

Explosionresistanceto0.7bar

Introduction

FireMasterBlanketwithcellularFoamglas

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Page 5: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

5Fireprotectionforprocessequipment

Thermal Ceramics offers a range of products and systems for fire protection of process equipment in chemical processing and oil and gas production facilities both onshore and offshore.

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Page 6: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

Thismanualpresentsanumberofsystemsforfireprotectionagainsthydrocarbonandjetimpingementfires.Thesubjectoffiretestingofsuchsystemsisnotalwayswellunderstoodasthestandardsarelessprescriptivethanthosefoundinindustriessuchasconstructionormarine.Thepurposeofthissectionistohighlightsomesignificantfactorsthatshouldbeborneinmindwhenevaluatingfireinsulationsystemsforprocessequipment.

PerformancerequirementsCommonlyusedstandardsforthespecificationorthefiretestingofpassivefireprotectionsystemsareusuallybasedonensuringthecriticaltemperaturesofstructuralelementssuchassteelworkorfirewallsarenotexceeded.Whereasstructuralsteelsectionsmayhaveacriticaltemperatureoftypically400°C,thecriticaltemperaturelimitsofprocessingequipmentsuchasvalves,flangesoractuatorsisoftenmuchlower;forexamplelessthan150°C.

Itisthereforeadvisabletoensurethatsystemsofferedforthefireprotectionofcriticalcomponentsareindependentlytestedandapprovedtoprovideadequateprotection,i.e.thattheyensurethespecifiedcriticaltemperatureofthecomponentwillnotbeexceeded.Inaddition,allcomponents(fixings,sealantsetc)ofthefireinsulationsystemasfittedonsiteshouldalsohavebeendemonstratedtobesuitablethroughrelevantfiretesting. Afiretestonanyfireinsulationsystemdemonstratesboththeintegrityofthesystemanditsinsulationcapability.

Carefulconsiderationmustbemadeofthelimitationsofsizeormassofthecontentsoftheequipmentprotectedbythesystem,aschangestothefireinsulationusedmayberequiredforequipmentthathavealowercriticaltemperatureorlessheatcapacity.Insuchcases,certificationforthefireinsulationsystemmayplaceamaximumlimitofthesurfaceareatomassrelationship(or‘sectionfactor’)oftheitemprotectedoralternativelyencompassanapprovedmethodforchangingtheinsulationspecificationtosuitcontentswithvaryingmass,sectionfactorsorcriticaltemperatures.

DesignfiresHydrocarbonfireshavevaryingheatfluxdependingonthenatureofthefire.Standardtemperature/timerelationshipsareincorporatedintofireteststandardstosimulatehydrocarbonfiressothatfurnacetestingofprotectionsystemscanbecarriedout.Thisaidsreliabilityoftesting.Insomecasesalternativehydrocarbonfirescenariosotherthanstandardtemperature/timerelationshipmaybeappropriate.

TheUKDept.ofEnergy,NorwegianPetroleumDirectorate,EN1363-2:1999,ISO834-3,ASTM1529andUL1709aresomecommonlyusedhydrocarbonfirecurves.

Figure1,seepage7,comparesseveraldesignfirescenarios.

Jetfiresareacknowledgedtohavevaryingintensityandunlikewithhydrocarbonfiresno‘standard’jetfirespecificationexists.Whereashydrocarbonfiresaredefinedastemperature/ timerelationships,jetfireexposuresaremostoftenspecifiedusingheatfluxvalues.

TheheatfluxobtainedinjetfiresisnotaspecifiedvalueoftheISO22899-1jetfireteststandardwhichisdesignedtoprovideauniformfiretestmethod,repeatablewithadegreeofreliabilitybasedonaspecifiedpropaneflowrateof0.3kg/sprovidingfuelforthejetflame.

ItisestimatedthattheheatfluxobtainedintheISO22899-1testisonaverage240kW/m²atthebackwallofthetestbox,comparedtoanassumedheatfluxofapproximately200kW/m²estimatedinahydrocarbonfurnacetest,seepage7.WithinISO22899-2peakheatfluxesof300kW/m²areacknowledgedaspossibleintheISO22899-1standardjetfiretest.

Insomecases,firetestsutilisinghigherheatfluxesthan240kW/m²maybeproposed.ThesefiretestsinevitablyrequirethemodificationofthetestequipmentspecifiedinISO22899-1inordertoobtainhigherheatfluxesresultingina‘non-standard’firetestbeingcarriedout.CautionshouldbeappliedwhenassessingsuchfiretestsastheydepartfromthetestmethodspecifiedintheISO22899-1standard.

Fireprotectionforprocessequipment

6

Hydrocarbon and jet fire testing and certification

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Page 7: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

ClassificationISO22899-1andISO22899-2containfiretestproceduresforfiretestingequipmentinjetfireexposureconditions.Classificationofsystemstestedisspecifictotheintendeduseapplicationandtakesthefollowingform:JF/Application/Critical Temperature/Time to Critical Temperature

Example:Insulationthicknessforstructuralsteel400°Ccriticaltemperatureprotectedfor120minuteswouldbeclassifiedas:JF/Structural Steel/400°C /120 minutes

CombinedJetandHydrocarbonFiresJetfiretestsmaycarriedoutforextendedtimeperiods(60and120minutesarecommon)butoftenonoffshorefacilities,thedesignfirescenarioconsistsofaninitialjetfire(possiblyfollowinganexplosion)ofmuchshorterdurationfollowedbyalonger-period,lower-intensity,hydrocarbonpoolfire.TheISO22899-2standardincludesguidanceonhowtoassessinsulationrequirementsforthesecombinedjetandhydrocarbonfirescenarios.

Section9ofthestandardexplainstheuseof‘sectionfactor’versusinsulationthicknesstablesforspecificcriticaltemperaturesandfiredurationtimes.Thesetablesarederivedfromhydrocarbonfiretests.Forpassiveinsulationmaterials,Jetfireprotectionusually

requirestheuseofmoreinsulationthanisrequiredforhydrocarbonfireprotection.ISO22899-2introducesan‘erosionfactor’concepttoallowforextramaterialrequirementsinjetversushydrocarbonfires.

This‘erosion’factorwhenusedwithpassiveinsulationmaterialsistheextrathicknessrequiredtoobtainthesameinsulationperformancefromaprotectionsysteminajetfiretestasisobtainedinahydrocarbonfurnacetest.Itisthenusedincombinationwiththesectionfactorversusthicknesstablesforhydrocarbonfirestodeterminetherequiredthicknessforthecombinedfire.

Forexample,ifa15minutejetfirefollowedbya30minutepoolfireisspecifiedthentheoverallfiredurationistakenas45minutes.Thethicknessofmaterial(e.g.50mm)requiredtoprotectaspecimenofthedesiredsectionfactorfor45minutesisthendeterminedfromthesectionfactor versusthicknesstableforahydrocarbonfire.The‘erosionfactor’fora15minutejetfiretestisdetermined(e.g.5mm)andthisisaddedtothefurnacetestthicknesstogiveatotalrequiredthickness(50+5=55mm).Adetailedexampleofthiscalculationcanbefoundonpage22.

Anexplanationofsectionfactorsandtheircalculationcanbefoundinthismanualinthepipefireprotectionandstructuralsteelprotectionapplicationsectionsseepages22-24.

Figure1:Variouspossiblefirescenarios

7Fireprotectionforprocessequipment

55 60 65 70 75 80 85 90 95 100 105 110 115 12015 20 25 30 35 40 45 500 5 10

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

0

Elapsedtimeinminutes

Exposuretemperature(°C)

Initialtemperature=20°C

HC-fire:200kW/m2ISO834-3

250kW/m2AverageheatfluxofISO22899-1Jetfiretestis240kW/m²

Jetfire:1243°C300kW/m2

Jetfire:1176°C250kW/m2

HC-fire:200kW/m2ISO834-3

Cellulosefire:ISO834-1

300kW/m2MaximumheatfluxofISO22899-1JetFireTestis300kW/m²

Cellulosefire:ISO834-1

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Page 8: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

CombinedfireandexplosionIntheeventofanaccidentalreleaseofflammablegasorvolatileliquidonaninstallationthereisthepotentialforanexplosion.Itispossiblethatthepassageofflameintheexplosionwilligniteareleaseofflammablegasresultinginafire.Inordertoprotectprocessplantandstructuralmembersfromtheeffectsoftheoverpressureproducedbythegasexplosionandanysubsequentfireitiscommonpracticetousepassivefireprotection.Intheeventthatagasexplosionprecedesafire,thepassivefireprotectionmustremainintactafterthegasexplosion.

Explosiontestingofpassivefireprotectionsystemsiscarriedouttoassesstheirintegrityafterexposuretoexplosionpressures.Intheabsenceofinternationalteststandardsdetailingtheprotocolofsuchtests,thecommonapproachistomakeanevaluationoftheintegrityofasampleofthepassivefireprotectionsystemafterblastexposureinordertoevaluateifitcanbeassumedtoprovidethesamedegreeoffireresistanceasonenotexposedtoblastpressure.

Thevariouspotentialexplosionscenariospossiblerequirecarefulconsiderationasboththedegreeanddurationofover-pressuremustbeincludedintesting.Asthesevaryconsiderablyinpractice,availabletestdatamustbecarefullyassessedagainstdesignconditions.

FordetailsoftheexplosiontestingofFireMasterProcessEquipmentfireprotectionsystemsseepage63-66.

Fireprotectionforprocessequipment

8

Figure2:Exampleofgasexplosiontestpeakpressureanddurationvalues

Time(ms)

-400

-300

-200

-100

0

100

200

300

400

500

600

Pressure(mbar)

53400 53480 53560 53640 53720 53800 53880 53960 54040 54120 54200

P1P2P3P4P5P6P7

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Page 9: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

BlastLoadProfilesThediagrambelowshowstheidealisedprofileofpressureinrelationtotimeforthecaseofafreeairblastwave.Thepressureisinitiallyequaltotheambientpressureand itundergoesaninstantaneousincreasetoapeakpressureatthearrivaltime.

Thetimeneededforthepressuretoreachitspeakvalueisverysmallandfordesignpurposesitisassumedtobeequaltozero.Thepeakpressureisalsoknownaspeakoverpressure.Thevalueofthepeakoverpressureaswellasthevelocityofpropagation oftheshockwavedecreasewithincreasingdistancefromthedetonationcentre.Afteritspeakvalue,thepressuredecreaseswithanexponentialrateuntilitreachestheambientpressure;thisisthepositivephaseduration.

Afterthepositivephase,thepressurebecomessmallerthantheambientvalue(thisisthenegativephase),finallyreturningtoambientpressure.Thenegativephaseislongerthanthepositiveone.Duringthisphase,structuresandpassivefireprotectionsystemsaresubjectedtosuctionforces.

Blasttestinginvestigatestheresponseofpassivefireprotectionsystemstoboththepeakoverpressureandsuctionforcesresultingfromexplosions.Thevaluesofpeakoverpressureandpositivedurationareimportantinspecifyingexplosiontestscenarios.

9Fireprotectionforprocessequipment

Positiveimpulse[is]

Incidentpressure[Pt]

Negativeimpulse[is]

tA+to+to

Time[t]

Pressure

Peakpressure[Pse]

Peakoverpressure[Pso

-Po]

Ambientpressure[Po]

Negativepressure[Pso]

Negativeduration[to]

Positiveduration[to]

Arrivaltime[tA]

tA+totA

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10Fireprotectionforprocessequipment

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Page 11: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

FireMaster® PipeworkJet and Hydrocarbon

fire protection

FIRE PROTECTION

11

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Page 12: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

FireMaster® Marine Plus blanket has been fire tested for the fire protection of pipes for up to 200 minutes in hydrocarbon fires according to the EN13381-4 standard.

The system consists of FireMaster® Marine Plus blanket 128kg/m³ density wrapped around the pipe and held in place with steel wire. Exterior cladding is applied for mechanical and weather protection.

The same system is also fire tested against jet fires of 60 minutes duration to the ISO 22899-1 fire test standard. To provide protection against the impinging jet, a stainless steel cladding is installed over the blanket. Two different grades of steel have been jet-fire tested for maximum flexibility in design.

Fireprotectionforprocessequipment

12

The system has been demonstrated to have blast resistance to 0.5 bar overpressure. See page 65 for details.

Jet fire protection of steel piping

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13Fireprotectionforprocessequipment

Our systems provide a lower-cost alternative to custom-made jacket systems and are:

● Lightweight ● Easy to install ● Easy to engineer and modify on site,

requiring minimal site surveying ● Cost-effective

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ba

c d e f g h

aSteelCladding-forjetfireeither:1. 316grade0.7mm2. 304grade0.6mm

b Stainlesssteelclipsusedtoretainsteelbandstrap(SeeitemD).

c No8typestainlesssteelscrewsat100mmcentres.

d Stainlesssteelbandstrap20mmwidespacedat200mmcentres.

eSteeltiewireforretentionofFireMasterMarinePlusblanketspacedatnominal50mmfromblanketedgeandatcentreofblanketwithmaximumof300mmspacing.

f FireMasterMarinePlusblanket128kg/m³installedinaminimumoftwolayerstorequiredcertifiedtotalthickness.

g FilamentadhesivetapeasrequiredfortemporaryfixingofFireMasterMarinePlusblanket.

h Steelpipe.

Fireprotectionforprocessequipment

14

Jet fire protection of steel pipingSteel pipe system. Explosion resistance to 0.5 bar

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Page 15: hydrocarbon and jet fire protection · Morgan Thermal Ceramics factories worldwide. 55 Fire protection for process equipment Cable tray fire protection fire testing and certification

c

a

d

b

f

e

aSteelCladding-forjetfireeither:1. 316grade0.7mm2. 304grade0.6mm

b Overlaponsteelcladdingof75mmsealedwithDowCorningFireStop700masticorequivalent.

c No8typestainlesssteelscrewsat100mmcentres.

d Stainlesssteelbandstrap20mmwidespacedat200mmcentres.

eSteeltiewireforretentionofFireMasterMarinePlusblanketspacedatnominal50mmfromblanketedgeandatcentreofblanketwithmaximumof300mmspacing.

f FireMasterMarinePlusblanket128kg/m³installedinaminimumoftwolayerstorequiredcertifiedtotalthickness.

15Fireprotectionforprocessequipment

Steel pipe system - detail view

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b c da

e f g h

aSteelCladding-forjetfire:304grade0.6mmFixedwith10mmlongstainlesssteelrivetsat100mmcentres.

b Stainlesssteelclipsusedtoretainsteelbandstrap(SeeitemD).

c 10mmlongstainlesssteelrivetsat100mmcentres.

d Stainlesssteelbandstrap20mmwidespacedat200mmcentres.

eSteeltiewireforretentionofFireMasterMarinePlusblanketspacedatnominal50mmfromblanketedgeandatcentreofblanketwithmaximumof150mmspacing.

f FireMasterMarinePlusblanket128kg/m³appliedinsinglelayertorequiredcertifiedtotalthickness.

gBTUFlexibleInsulationtorequiredcertifiedthickness220kg/m³(stitchedinlongitudinaldirection)appliedin10mmthicklayers.

h Steelpipe.

Fireprotectionforprocessequipment

16

180 minute Jet Fire Protection System for steel pipes

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b c da

e f

g h

17Fireprotectionforprocessequipment

aSteelCladding-forjetfire:304grade0.6mmFixedwith10mmlongstainlesssteelrivetsat100mmcentres.

b Stainlesssteelclipsusedtoretainsteelbandstrap(SeeitemD).

c 10mmlongstainlesssteelrivetsat100mmcentres.

d Stainlesssteelbandstrap20mmwidespacedat200mmcentres.

Temperaturerise after60mins(°C)

155

BTUthickness

20

FireMasterthickness

50

Systemthickness(mm)

70

Pipesectionfactor(m-1)

115

115305080113

207038108206

14570-70254*

40405090120

Temperaturerise after90mins(°C)

265

200

50

230

90

Temperaturerise after120mins(°C)

365

280

90

300

165

Temperaturerise after180mins(°C)

-

405

220

415

305

155403878345 310 - -

*testedasadrainplugdetailseeTypeApprovalCertificatefordetails

Continuous wrap alternative

eSteeltiewireforretentionofFireMasterMarinePlusblanketspacedatnominal50mmfromblanketedgeandatcentreofblanketwithmaximumof150mmspacing.

f 38mmor50mmFireMasterMarinePlusblanket128kg/m³ appliedinsinglelayertorequiredcertifiedtotalthickness.

g

BTUflexibleinsulationappliedin20mm,30mm,40mmor70mmthicknessdependingonpipesectionfactor,fireduration(uptoamaximumof180minutes)andpipecriticaltemperatureriseallowable.ForfulldetailsrefertoMorganThermalCeramics.BTUFlexibleisappliedeitherinmultiplelayersof10mmorasacontinuouswrap.

h Steelpipe.

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Fireprotectionforprocessequipment

18

Examples of FireMaster® JetWrap system on bendsPipe bends

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aSteelCladding-forjetfireeither:1. 316grade0.7mm2. 304grade0.6mm

b Overlaponsteelcladdingof75mmsealedwith DowCorningFireStop700masticorequivalent.

c No8typestainlesssteelscrewsat100mmcentres.

d Stainlesssteelbandstrap20mmwidespacedat200mmcentres.

eSteeltiewireforretentionofFireMasterMarinePlusblanketspacedatnominal50mmfromblanketedgeandatcentreofblanketwithmaximumof300mmspacing.

f FireMasterMarinePlusblanket128kg/m³installedinaminimumoftwolayerstorequiredcertifiedtotalthickness.

b

c

d e f

a

19Fireprotectionforprocessequipment

Pipe bends - detail view

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20

a

b c d e

a 316gradeStainlessSteelCladding0.7mmthick.

b

c FireMasterblanket25mmx128kg/m³.

FilamenttapeforretentionofFireMasterblanket.

d PittsburghCorningFoamglassT439mmthicksuppliedinhalfshellsections.

e Steelpipe.

Fireprotectionforprocessequipment

20

Jet fire protection of steel pipingFoamglass pipe system. Blast resistance : 0.7 bar

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21Fireprotectionforprocessequipment

a 316gradestainlesssteelcladding0.7mmthick.

b

c

Stainlesssteelbandstrap20mmwidespacedat200mmcentres.

No8typestainlesssteelscrewsat100mmcentres.

d

e

c

a

d

b

e

f

f

Overlaponsteelcladdingof75mmsealedwithDowCorningFireStop700masticorequivalent.

FireMasterblanket25mmx128kg/m³.

FilamenttapeforretentionofFireMasterblanket.

Foamglass pipe system - detail view

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22

Thethicknessofinsulationthatisrequiredtobeappliedtopipeworktoprovidefireprotectionwilldependonanumberoffactors.Theseare:

1. Fireloadandduration2. Criticaltemperaturespecifiedforthepipe;i.e.themaximumpermittedtemperature forthepipeduringthefire3. The‘sectionfactor’ofthepipe;arelationshipofexternalpipesurfaceperimeter andpipewallthickness4. Theinitialoperatingtemperatureofthepipe

Thesefactorsareveryimportantindesignofpipefireinsulationsystems.

CriticalpipetemperaturePipeworkisnormallyinsulatedagainstfiretomaintainitstemperaturesbelow400°C,thelimitusuallyappliedforstructuralsteel,inordertopreventruptureorcollapse.Othertemperaturelimitsthanthismayalsobeapplied.Thethicknessoffireinsulationthatmustbeappliedwillvarywiththepipecriticaltemperature;increasingasthecriticaltemperaturedecreasesforthesamesizeofpipe.

SectionfactorThesectionfactorrelatesthesurfaceareaofthepipeexposedtofiretotheamountofsteelinthewallofthepipeavailabletoabsorbheatfromthefire.

Assteeloffersalarge‘heatsink’effect,increasingwallthicknessprovidesanincreasedmassofsteeltobeheated,resultinginaslowerriseintemperature.Therateofheatincreasealsodependsonhowmuchheatisinputintothepipe.Thiswillvarywiththesurfaceareaavailabletoabsorbheat.Aspipediameterincreases,theheatedsurfaceareaincreases.Aswallthicknessincreases,thevolumeofsteelavailabletoabsorbheatincreases.

Thesectionfactorofapipeiscalculatedbydividingtheoutsideexternalpipesurfacepe-rimeterbythecross-sectionalareaofthewall.

Example:

Thetablebelowillustratestheeffectofsectionfactoroninsulationthicknessfortwodifferentsizedpipes:

Firetestingofpipefireinsulationisdesignedtorelatesectionfactortoinsulationthicknessforavarietyoffailuretemperaturesandthisrequiresalargevarietyofpipestobetested.FireMasterMarinePlusblankethasbeenfullytestedon13pipesinordertogeneratetherequiredthicknesstablesinaccordancewithAnnexE4ofEN13381-4firetestprocedureforstructuralsteelwork.

Outsidediameter=200mm

Wallthickness=20mm

4 4-SectionFactor=∏od/(∏od²∏id²)=(∏*0.2)/(∏*0.2²/4–∏*0.16²/4)=56m-1

Sectionfactor(m-1)Pipeserialnumber Insulationthicknessrequiredtomaintainpipe

temperatureto400°Cforonehourinahydrocarbonfire

776inchschedule120 25mm

2053inchschedule40 75mm

FireMaster® pipe fire protection systemA guide to specification and certification

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23Fireprotectionforprocessequipment

FireloadanddurationTheheatfluxortemperaturetowhichthepipeisexposedwillinfluencethethicknessofinsulationrequiredforfireinsulation.Ingeneralajetfireisexpectedtohaveahigherheatfluxthanahydrocarbonpoolfireandthereforemoreinsulationwillberequiredwheninsulatingapipeagainstajetfirethanahydrocarbonpoolfire.

Oneproblemwhendeterminingthicknessrequirementsforjetfireinsulationsystemsisthatitisnotpracticaltotestthelargevarietyofpipesrequiredtoobtainsufficientdatatoconstructthicknessversussectionfactortables.

Thecommonsolutiontothisproblemistofirsttestasufficientvarietyofsizesinafurnacehydrocarbonfiretestandthentoselectatleast2ofthepipes,identicallyinsulatedandsubjectthemtoajetfiretest.Arelationshipoftemperaturerisesobtainedineachfirescenariocanthenbemade.Morethan2pipesmayberequiredtobejetfiretesteddependingonthereliabilityoftherelationship.

FireMasterMarinePlusblankethasbeentestedinaccordancewiththisprocedureandthetestresultsusedtoconstructatableofthicknessrequirementversussectionfactorforjetfireprotectionaswellashydrocarbonfireprotection.

ThicknessrequirementsjetfireandhydrocarbonfireThetablesoppositeonpage24comparethethicknessrequirementsforjetandhydrocarbonfireprotectionofpipesofvaryingsectionfactorforacriticaltemperatureof400°Cassuming60minutesfireduration.ForafullrangeofcriticaltemperaturesandtimeperiodsreferencecanbemadetotheLloydsRegisterTypeApprovalcertificate.

AdditionallyMorganThermalCeramicsprovidesasoftwarepackage‘SectionWizard’toallowstraightforwardaccesstothefiretestapprovedthicknessdatawithouttheneedtocalculatesectionfactorsorlookuptables.MoredetailsonSectionWizardcanbefoundonpage71.

GuidelinesondeterminationofthethicknessofFireMasterMarinePlusblanket requiredincombinedjetandhydrocarbonfireprotectionofpipesISO22899-2(Section9)providesguidelinesondeterminingthethicknessoffireprotectionrequiredforcombinedhydrocarbonandjetfires.

Thisisexplainedinmoredetailonpage7ofthismanual.ThefollowingexampleillustratesthismethodologyforpipesfireprotectedwithFireMasterMarinePlusblanket.

Example:30minuteinitialjetfirefollowedbya30minutehydrocarbonfire-totalfiredurationof60minutesona6”(DN150)schedule40pipe.UsingthefiretestdataonpipesinsulatedwithFireMasterMarinePlusblanketinhydrocarbonandjetfires,thicknessvsectionfactortablesareavailableforhydrocarbonandjetfiresforawidevarietyofpipesectionfactors.

Thesetablescanbeusedtodeterminethenecessarythicknessesusedintheexamplebelowor(formaximumaccuracy)throughuseofMorganAdvancedMaterials “SectionWizard”Software.

A guide to specification and certification

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ISO22899-2guidanceoncombinedjetandhydrocarbonfires.Forthecombined30minutejetfirefollowedbya30minutehydrocarbonfire, ISO22899-2guidanceisasfollows:

1.Selecttheinsulationthicknessrequiredfor60minuteshydrocarbonfireprotection 2.Selecttheinsulationthicknessrequiredfor30minuteshydrocarbonfireprotection 3.Selecttheinsulationthicknessrequiredfor30minutesjetfireprotection 4.Calculatethe“erosionfactor”ofjetversushydrocarbonfireforthe30minutesfire protectionperiodbydeductingthethicknessin(2)from(3)above 5.Addthis“erosionfactor”tothethicknessrequiredfor60minuteshydrocarbonfire selectedin(1)above.

Fortheexampleabove:6”inchschedule40pipe–sectionfactor147m-1assumedcriticalpipetemperature400°C. 1.Thicknessrequiredfor60minuteHydrocarbonfire=51mm 2.Thicknessrequiredfor30minuteHydrocarbonfire=25mm 3.Thicknessrequiredfor30minuteJetfire=38mm(1)

4.“ErosionFactor”(SeeISO22899-2Section9)for30minuteJetfire=38-25=13mm 5.Thicknessrequiredforcombinedfire=51+13=64mm.Theneareststandard thicknessofFireMasterBlankettothiswouldbe75mm(25+50mm).

1 For400°Ccriticaltemperatureonpipesinjetfiresusethethicknessrequiredfora200°CcriticaltemperatureofthecorrespondingpipeinahydrocarbonfireinaccordancewiththeTypeApprovalofFireMasterMarinePlusBlanketforpipesinjetandhydrocarbonfires.SectionWizardSoftwarecanbeusedtoprovideexactthicknessvaluesifstandardtablesarenotavailableordonotprovidesufficientlyprecisedata.

StandardsuppliedthicknessesofFireMasterMarinePlusblanketrequiredtolimitthe temperatureriseofasteelpipeto400°Cinhydrocarbonandjetfiresof60minutes duration.

HydrocarbonfirePipesectionfactor(m-1)

25mm≤75

38mm76to105

50mm106to145

63mm146to200

75mm201to275

88mm276to400

Jetfire

51mm

Pipesectionfactor(m-1)

≤65

63mm66to85

75mm86to110

88mm110to160

100mm151to205

24

A guide to specification and certification

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Forinsulationintendedtobeusedonpiping,genericsoundtransmissionlossvaluesfortheinsulationmaterialisnotsufficientdata.Soundtransmissionlossvaluesmustbemeasuredonpipesinsulatedwiththeintendedinsulationsystem.

TestingforsoundtransmissionlossusestheISO15665:2003insertionlossmethod.Pipesof3differentdiameters(DN100,DN300andDN600)insulatedwiththeinsulationsystemaretested.InsertionlossesofpipesizesuptoDN1000canthenbeextrapolatedinaccordancewithISO15665inordertoallowclassificationforthe3pipesizesspecifiedin the standard.

Thebasicconceptofinsertionlosstestingisstraightforward.“Pinknoise”in1/3octavebandoverafrequencyrangeof50to10,00Hzisintroducedintothe3pipeswhicharelocatedinananechoicchamber.Thesoundtransmissionfromeachpipeintothechamberisthenmeasured.Thetestisrunfirstlyonasetofuninsulatedpipesandthenonasetofpipesfittedwiththeinsulationsystembeinginvestigated.Soundtransmissionvaluesfortheuninsulatedandinsulatedpipescanthenbecomparedtoobtainthesoundreductionvalueoftheinsulationsystem.Thegeneralarrangementofthetestisshowninthedrawing(right).

Althoughsimpleinconcept,theacousticperformanceofpipeinsulationiscomplicatedduetointeractionofthepipeandinsulationsystem.Vibrationofthepipeatlowfrequenciesisanadditionalsourceofnoiseandtransmissionofvibratedsoundthroughanyexternalcladdingusedontheinsulationwillinfluencetheoverallsoundtransmissionloss.Thesoundtransmissionlosswillvarybypipediameter(increasedsurfaceareacanincreasesoundtransmission)andfrequencyrange(lowfrequencyvibrationand“drumming”ofthesystemcanbesignificanttolowdensityinsulationsystems).Thepropertiesofcladdingmaterialsarealsosignificant.

TestPerformanceofFireMasterPipeFireProtectionSystemAseriesoftestshavebeenrunonthesystem.ThesehaveinvestigatedtheperformanceofvariousthicknessesofFireMasterMarinePlusBlanketwith

variousthicknessesofsteelcladdingandalsotheinfluenceofanti-drummingmaterialsusedtoimprovelowfrequencysoundtransmission.

ThetestedsystemsandtheirperformancearesummarisedinTables1to2(page44-45).Notethatnegativevaluesindicateanincreaseinsoundtransmission(i.e.“worse”soundreduction)comparedtotheun-insulatedpipecase,thisisnotunusual.

Fireprotectionforprocessequipment

Schematicofthetestarrangementusedtomeasureinser-tionlosstoISO15665:2003method.

25

Acoustic insulation properties of FireMaster pipe fire protection system

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InsulationSystem

FireMasterMarinePlusBlanket50mm+0.6mmsteelcladding

DN100

Pipe

DN300

DN600

-8

63

-5

-4

-12

125

-6

-4

-6

250

-7

-5

1

500

3

3

13

1000

13

1

20

2000

25

21

23

4000

29

35

32

8000

41

44

Frequency(Hz)

FireMasterMarinePlusBlanket50mm+1mmsteelcladding

DN100

DN300

DN600

2

-2

-2

-3

-6

-4

1

-5

-5

6

1

2

11

8

10

12

20

19

27

26

33

36

39

42

Table1:ThirdoctaveBandInsertionLoss(dB)measuredforFireMasterMarinePlusBlanket128kg/m³appliedonpipes

FireMasterMarinePlusBlanket75mm+0.8mmsteelcladding

DN100

DN300

DN600

3

-7

-6

0

-16

-9

-6

-4

-2

4

2

5

10

13

20

21

26

30

33

31

42

42

36

37

FireMasterMarinePlusBlanket100mm+0.6mmsteelcladding

DN100

DN300

DN600

-10

-7

-9

-16

-7

-14

-7

-1

0

5

5

13

13

15

27

21

26

33

28

32

46

33

50

47

TypicaltestarrangementofpipestestedinsulatedwiththeFireMasterpipefireprotectionsystem

Acoustic insulation properties of FireMaster pipe fire protection system

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Fireprotectionforprocessequipment

InsulationSystem

FireMasterMarinePlusBlanket50mm+0.6mmsteelcladding

DN100

Pipe

-8

63

-12

125

-6

250

1

500

13

1000

20

2000

23

4000

32

8000

Frequency(Hz)

FireMasterMarinePlusBlanket50mm+0.6mmsteelcladding+3mmanti-drummingcompound

-5 -4 -4 3 12 27 33 35

Table2:ThirdoctaveBandInsertionLoss(dB)measuredforFireMasterMarinePlusBlanket128kg/m³andanti-drummingcompoundappliedonpipes

FireMasterMarinePlusBlanket75mm+0.8mmsteelcladding

DN300

-7 -16 -4 2 13 26 31 36

FireMasterMarinePlusBlanket75mm+0.8mmsteelcladding+3mmanti-drummingcompound

-8 -7 -2 5 16 31 37 32

FireMasterMarinePlusBlanket75mm+0.8mmsteelcladding

DN600

-6 -9 -2 5 20 30 42 37

FireMasterMarinePlusBlanket75mm+0.8mmsteelcladding+3mmanti-drummingcompound

-4 -9 -1 8 25 35 44 39

27

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Fireprotectionforprocessequipment

28

Table3:ThirdoctaveBandInsertionLoss(dB)measuredforFireMasterMarinePlusBlanket128kg/m³withandwithoutcladdingappliedonpipes

InsulationSystem

FireMasterMarinePlusBlanket50mmnocladding

Pipe

-1

63

-5

125

-6

250

3

500

12

1000

23

2000

35

4000

32

8000

Frequency(Hz)

FireMasterMarinePlusBlanket50mm+0.6mmsteelcladding

-4 -4 -5 3 11 21 35 44

FireMasterMarinePlusBlanket50mm+1mmsteelcladding

-2 -4 -5 2 10 19 33 42

DN600

DN600

DN600

ImportantnoteontestingresultvaluesFrequenciesof63dBand125dbarebelowthelowerfrequencyrangeofthetestroomusedaccordingtoISO3741.Themeasuredinsertionlossvaluesinthetableshavebeenincreasedby3dBaccordinglyasspecifiedinthetestreport.

Thefrequencyof250dBisclosetothefrequencylimitforthetestroomandthemeasuredinsertionlossvaluesinthetableshavebeenincreasedby1dBfromthemeasuredresults,againasspecifiedinthetestreport.

Acoustic insulation properties of FireMaster pipe fire protection system

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Fireprotectionforprocessequipment

SoundTransmissionClassesISO15665:2003Theminimuminsertionlossrequiredtomeeteachclassisgivenbelowforreferenceonly.Inreferencingtheseclasses,thefollowinginformationshouldbeconsidered.

1. TheprimarypurposeofFireMasterMarinePlusblanketistoprovidefireinsulationand nottomeetaspecificsoundtransmissionclassification.

2. Inordertoachievejetfireresistance,thechoiceofcladdingmaterialrequiredtomeet fireprotectionrequirementsmaynotbeoptimalforacousticpurposes.

3. Whendesigningfireprotectionsolutions,thicknessofinsulationvariesaccordingto criticalpipetemperatureriselimits(withvaryingoperatingtemperatures)andpipe sectionfactor.Itmaynotbepossibletocomplywithsoundinsulationclasslimitsin alloctavebands.Astheouterdiameteroftheinsulationsystemincreasesduetohigher thicknessoffireinsulation,insertionlossmaybecomeworseinverylowfrequency octavebandsforexample.

4. ThespectralclasslimitsdefinedinISO15665:2003arespecifiedforgeneralpipe assembliesnottakingintoaccountthespecificcompositionoftheactualsound emissionsforoperatingprocess.Forexample,forhighfrequencynoisefromgas pipestheinsertionlossvaluesatlowfrequencieswouldbeofnegligibleimportance.

<300

<650

<1000

-4

125

-4

-4

-4

250

-4

-5

2

500

2

3

9

1000

9

1

16

2000

16

21

22

4000

22

35

29

8000

29

44

Frequency(Hz)

PipeMaxDiameter(mm)

≥300

≥650

PipeMinDiameter(mm)

A1

A2

A3

Class

<300

<650

<1000

-9

-9

-7

-3

-3

2

3

6

11

11

15

20

19

24

29

37

33

36

35

42

42

≥300

≥650

B1

B2

B3

<300

<650

<1000

-5

-7

-1

-1

4

9

11

14

17

23

24

26

34

34

34

38

38

38

42

42

42

≥300

≥650

C1

C2

C3

29

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30Fireprotectionforprocessequipment

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FireMaster®

Rigid Enclosure System(RES)

FIRE PROTECTION

31

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The FireMaster® Rigid Enclosure System consists of a stainless steel enclosure incorporating our high performance FireMaster® insulation products.

It is fire tested for jet fire protection of valves, actuators and pipe flanges to ISO 22899-1 standard for up to 60 minutes. Very low critical temperature items can be insulated due to the high performance insulation used in the enclosure.

The FireMaster® RES is custom-manufactured in sections designed to fit around the item requiring protection and can incorporate water drain and inspection hatch features if required.

Fireprotectionforprocessequipment

32

FireMaster® Rigid Enclosure SystemFireMaster® RES - Rigid Enclosure System

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● Easy fitting and removal is ensured through a simple clip fixing system with fire sealing materials incorporated into the shells.

● The robust stainless steel casing is especially suitable for use in weather-exposed areas.

33Fireprotectionforprocessequipment

● The system has been demonstrated to have blast resistance to 0.5 bar overpressure. See page 65 for details.

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34

FireMaster® Rigid Enclosure SystemFireMaster® RES - Rigid Enclosure System

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Fireprotectionforprocessequipment

Forlargeunitsrequiringfireprotection,theRESSystemisinstalledaspanelsontoasupportingframework.Exampleshowninthese

photographsisaskidunitforactuatorsfor50minutejetfire protection.Exteriorunitdimensionswere4mlongx2.2mdeepx2.8mhigh.Accessdoorscanbeincorporatedintothepanelsystem.

35

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ba c d e

RigidEnclosedSystem-system1,showingstainlesssteeloutercasing

a Pipe.TheRESsystemisinstalledovertheappliedpipefireinsulationsystemwherefireinsulationisfitted.

b

c Valve.

Integralcollarincorporatinginsulation.

d Internallightweightstainlesssteelcasing.

e 316stainlesssteeloutercasing.

Fireprotectionforprocessequipment

36

FireMaster® Rigid Enclosure SystemFireMaster® RES - Rigid Enclosure System. Explosion resistance to 0.5 bar

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edcba

RigidEnclosedSystem-system2,showingstainlesssteeloutercasing

Fireprotectionforprocessequipment

a Pipe.TheRESsystemisinstalledovertheappliedpipefireinsulationsystemwherefireinsulationisfitted.

b

c Flangeunit.

Internallightweightstainlesssteelcasing.

d RetentionclipsforREScasing.

e Collarattachmentforpipeincorporatinginsulation.

37

FireMaster® RES - Rigid Enclosure System

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ba

c d

RigidEnclosedSystem-flangefireprotection a 316stainlesssteeloutercasing.

b

c Integralcollarincorporatinginsulation.

RetentionclipsforREScasing.

d Pipe.TheRESsystemisinstalledovertheappliedpipefireinsulationsystemwherefireinsulationisfitted.

Fireprotectionforprocessequipment

38

FireMaster® Rigid Enclosure SystemFireMaster® RES - Rigid Enclosure System - flange fire protection

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Commonlyusedstandardsforthespecificationorthefiretestingofpassivefireprotectionsystemsareusuallybasedonensuringthecriticaltemperaturesofstructuralelementssuchassteelworkorfirewallsarenotexceeded.Whereasstructuralsteelsectionsmayhaveacriticaltemperatureoftypically400°C,thecriticaltemperaturelimitsofprocessingequipmentsuchasvalvesoractuatorsorflangesisoftenmuchlower;forexamplelessthan150°C.

Itisthereforeadvisabletoensurethatsystemsofferedforthefireprotectionofsuchcriticalcomponentsareindependentlytestedandapprovedtoprovideadequateprotection,i.e.thattheyensurethespecifiedcriticaltemperatureofthecomponentwillnotbeexceeded.Inaddition,allcomponents(fixings,sealantsetc)oftheassemblyasfittedonsiteshouldalsohavebeendemonstratedtobesuitablethroughrelevantfiretesting.Whereenclosuresareusedthataredifferentinsizetothosethathavebeenfiretested,theirdesign(e.g.jointtypeandlocations)shouldbeauthorizedwithinaTypeApproval.

Afiretestonanenclosuresystemdemonstratesboththeintegrityoftheenclosureanditsinsulationcapability.Carefulconsiderationmustbemadeofthelimitationsofsizeormassofthecontentsoftheenclosureastested,aschangestothefireinsulationfittedintoeachenclosuremayberequiredforcontentsthathavealowercriticaltemperatureorlessheatcapacity.Insuchcases,certificationfortheenclosuresystemmayplaceamaximumlimitofthesurfaceareatomassrelationship(or‘sectionfactor’)ofthecontentsoralternativelyencompassanapprovedmethodforchangingtheinsulationspecificationtosuitcontentswithvaryingmass,sectionfactorsorcriticaltemperatures.

FireMaster®RESindependentfiretestresultsandTypeApprovalTwoalternativedesignsoftheFireMaster®RESpassivefireprotectionsystemhavebeenfiretestedincorporatinginspectionhatches,drainplugandalternativeinsulationdesigns.

ThetestsutilisetheRESsystemasprotectionforatubularsteelspecimenwithacentralsteelsectionconstructedtorepresentthebodyofavalveoractuatorofmaximumsectionfactor80m-1protectedbytheenclosure.

60-minutedurationTheRESenclosurehasbeenfiretestedin2impingingjetfirestestswitnessedbyLloydsRegisterandcarriedoutatDNV-GL,Spadeadam,UKinaccordancewiththeISO22899-1testmethodfortubularspecimens.

FireMaster®REShasLloydsRegisterTypeApprovalasfollowsMaximumSectionFactorofitemtobeprotected:80m-1

InsulationSystem1JF/PipeSystemComponents/125/60JF/PipeSystemComponents/75/45JF/PipeSystemComponents/35/30

InsulationSystem2JF/PipeSystemComponents/220/60JF/PipeSystemComponents/130/45JF/PipeSystemComponents/50/30

ExplosionResistanceTheRESsystemhasbeentestedatDNV-GLSpadeadamlaboratoryforresistancetogasexplosionoverpressureto0.5bar.Seepage65fordetails.

39Fireprotectionforprocessequipment

Valve and actuator fire protection

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40Fireprotectionforprocessequipment

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FireMaster®

Flexible Enclosure System (FES)

FIRE PROTECTION

41

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The FireMaster® Enclosure system is specifically designed to provide high performance jet fire protection, especially for vulnerable equipment with low critical temperature limits.

Flexible systems are lighter in weight than rigid enclosures and typically used where regulations do not require metallic enclosures to be fitted but an easily removable system is still desired.

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42

FireMaster® Flexible Enclosure System (FES)Jet fire protection - for vulnerable equipment with low critical temperature limits

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43

FireMaster® FES contains low thermal conductivity FireMaster XLS blanket and flexible microporous insulation in an outer layer of weather and jet-fire resistant fabric. The use of a special fabric avoids the need for rigid metal meshes or foils in the jacket, improving ease of installation.

The system is Lloyds Register Certified for protection of pipes for jet fires of up to 150 minutes duration and for fire barriers, vessels and enclosures incorporating edge details for jet fires up to 175 minutes duration.

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a b c d e

FireMaster®FlexibleEnclosureSystem(FES)-Pipes

Jacketthicknessis70mm(2x25mmofFireMasterXLSand2x10mmofmicroporousinsulation).Outerclothfacingthejetfireisdifferentfromtheinnercloth.Theouterisjetfireresistantandtheinnerisonlyweatherresistant.

Thejacketisheldinplacewithbandingstrapsandlacingandthereisanoverlapatthejoint.Seeadditionaldata.

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44

a Outerclothjetfireresistant,innerclothweatherresistantsiliconefabric.

b

c Jacketheldinplacewithbandingstraps.

2x25mmofFireMasterXLSand2x10mmofmicroporousinsulation.

d Fabricstrapstoholdjacketinpositionduringinstallation.

e Wirelacingtoholdjacketinplace.

FireMaster® Flexible Enclosure System (FES)Jet fire protection - for vulnerable equipment with low critical temperature limits

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a Retentionclips.

b

c TextilebandusedtofacilitatefittingtheFEStopipes.

Stainlesssteelwire.

d Stainlesssteelbandingstrap.

e FESjacket.

c

a

d

b

e

45Fireprotectionforprocessequipment

FireMaster Flexible Enclosure System (FES) - detail view

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46

FireMaster®FlexibleEnclosureSystem(FES)-FirebarriersandVessels

ThesystemmakeupisthesameasdetailedinthePipesectiononpages44and45exceptthereisnooverlapofthejacketattheedgejoint.Insteadtheouterclothlayerisextendedoutfromthejacketedgeandjustfitsoverthejoint(i.e.noinsulationoverlap-onlythetextile).

a-b

TheFESjacketsystemisinstalledwithbuttedjoints.TheedgeofeachsectionoftheFEShasa70mmextensionoftheoutertextilewhichisusedtocoverthebuttedjointbetweenjackets.Thejointsarethenlacedintoplacewithstainlesssteelwireandclips.

c

a

b

c FESJacket.

FireMaster® Flexible Enclosure System (FES)Jet fire protection - for vulnerable equipment with low critical temperature limits

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a b c d

a Stainlesssteelfixingclips.

b

cOverlapofjoints.TheFESjacketsismanufacturedwitha70mmextensionoftheoutertextileattheedge.Theedgeofeachjacketisbuttedtogethertofitandthe70mmtextileextensioncoversthejoint.Thejointsareheldinplacewithstainlesssteeltiewire.

Stainlesssteelwire.

d FESjacket.

47Fireprotectionforprocessequipment

FireMaster®FlexibleEnclosureSystem(FES)-Enclosures

Theuseofthesetypeofsystemsforenclosures(i.e.wheretheRESwouldalsobeusedandanythingwithan“edge”)requiresfiretestevidencetoprovetheedgecanwithstandtheimpactofthejetflame.Thestandardwayofdoingthisistoincorporatearaisedsectioninawalltestsimulatingtheedgesofabox.Youcanseethedetailsofthisinthewalltestsample,page48.

FireMaster Flexible Enclosure System (FES)

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ThecertificationissuedbyLloydsRegisterfortheFireMasterFESallowsitsuseforjetfireprotectionapplicationson“pipework,pressurevessels,valveswithflatpanelswithorwithoutcornersandedges”.

Thefiretestingofthesystemwasspeciallydesignedtoensurethesuitabilityofthesystemforuseasanenclosuresystemcouldbeadequatelydemonstrated.Whenflexiblejacketsareinstalledonanyitemwithanedgedetail,thereisariskthattheouteredgemaynotresisttheerosiveeffectfromthejetflame.InordertoprovetheFireMasterFEScouldwithstandsuchconditions,atestspecimenincorporatingaraisedsectionwasexposedtoajetfiretestof175minuteduration.Additionalthermocoupleswereinstalledonthecornersectionsandtherearpanelareabehindtheraisedsectiontodemonstratethethermalinsulationperformanceofthesystem.

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48

Raisedcornerdetailusedinjetfiretestspecimen

FireBarriersandPressureVesselsTubularSections(max.sectionfactor128m-1)

JF/FireBarrierorPressureVessels/25/15JF/TubularSection/23/15

JF/FireBarrierorPressureVessels/53/30JF/TubularSection/64/30

JF/FireBarrierorPressureVessels/111/60JF/TubularSection/146/60

JF/FireBarrierorPressureVessels/165/90JF/TubularSection/224/90

JF/FireBarrierorPressureVessels/224/120JF/TubularSection/309/120

JF/FireBarrierorPressureVessels/262/150JF/TubularSection/400/150

FireMasterFESsystemClassificationaccordingtoISO22899-1/ISO22899-2

JF/FireBarrierorPressureVessels/272/165

JF/FireBarrierorPressureVessels/277/175

Fire test performance of FireMaster Flexible Enclosure System

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FireMaster®

Instrument cable trayfire protection

FIRE PROTECTION

49

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FireMaster® products insulate cable trays carrying instrument control cables to ensure that the cables can operate long enough to allow process shut down during fires.

The FireMaster® cable tray wrap system provides 30 minutes hydrocarbon fire protection to cable trays carrying control cable wiring.

The FireMaster® cable tray wrap consists of FireMaster® Marine Plus blanket fully encapsulated in aluminium foil supplied and in a roll form. It is wrapped around the exterior of the cable tray and held in place with steel banding straps. Additional weather protection can be installed if required using corrugated aluminium sheeting.

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50

Instrument cable tray fire protection30 minute hydrocarbon fire protection

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● The FireMaster® cable tray wrap system has been installed in many chemical process plants worldwide and is fire tested to the stringent ASTM E1725 method.

● It can be installed in one single layer which means installation time is quick and the wrap can be easily removed from the cable tray if retrofitting of cables is required.

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a b c d e f

a Cabletraycontaininginstrumentcontrolcables.

b

c Meshliningusedtopreventcabletraywrapfromslumpingontopoftray.

Bandingstrapat150mmcentresusedtosupportmeshliningontopofopentrays.

d

Stainlesssteelbandingstrapsminimum12mmwideinstalledat40mmfromtheedgeofeachcabletraywrappiecewithonestrapplacedinthecentre.If1220mmwidecabletraywrapisbeinginstalled,useamaximumspacingof250mmbetweenthebandstraps.Thebandsmustbetightenedsoastosecurelyholdthecabletraywraptothetray,butnotsotightastocutit.

eFireMastercabletraywrap50mmthicksuppliedinwidthsof610mmor1220mm.Installedinonelayerwithoverlappedjointsof75mm.Additionalbandsmaybeplacedasneededsuchasatelbowsand90degreebendstoassuretightjoints.

f Overlapof75mmbetweenadjacentcabletraywrappieces.

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Instrument cable tray fire protection30 minute hydrocarbon fire protection

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a b c d e f

a Cabletraycontaininginstrumentcontrolcables.

b

c Meshliningusedtopreventcabletraywrapfromslumpingontopoftray.

Bandingstrapat150mmcentresusedtosupportmeshliningontopofopentrays.

d

Stainlesssteelbandingstrapsminimum12mmwideinstalledat40mmfromtheedgeofeachcabletraywrappiecewithonestrapplacedinthecentre.If1220mmwidecabletraywrapisbeinginstalled,useamaximumspacingof250mmbetweenthebandstraps.Thebandsmustbetightenedsoastosecurelyholdthecabletraywraptothetray,butnotsotightastocutit.

e FireMastercabletraywrap50mmthicksuppliedinwidthsof610mmor1220mm.Installedinonelayerwithoverlappedjointsof75mm.

f Corrugatedaluminiumsheeting0.6mmthickforweatherprotection.

53Fireprotectionforprocessequipment

Instrument cable tray fire protection with optional weather proofing system

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Instrumentcabletrayfireprotectionhasseveralpurposes.Theseare:

• Maintaincablefunctioninafire• Preventcorrosive/toxicgasemissionwhencableburns• Protectfirefighters• Aidevacuation• Minimiselong-termdamagetocablefacilities

ASTME1725-95‘StandardTestMethodsforFireTestsofFireResistiveBarrierSystemsforElectricalSystemComponents’isdesignedtomeasureanddescribetheresponseofelectricalsystemmaterials,productsorassembliestoheatorflameundercontrolledconditions.Thistestcanbecarriedoutusingeithercellulosicorhydrocarbonfirecurves(ASTME119andE1529respectively).

API2218‘FireProofingPracticesinPetroleumandPetrochemicalProcessingPlants’referencesASTME1725-95testmethodandstatesthatforapplicabilitytopetroleumandpetrochemicalprocessingplants,thefiretestshouldbecarriedoutusingahydrocarbonfiretemperature/timecurve.

API2218considerstheASTME1529andUL1709hydrocarbonfirecurvestobefunctionallyequivalent.Thesefirecurvesaresimilar.TheASTME1529curveisslightlyhigherintemperaturethanUL1709andspecifiesaheatfluxtakenfrommeasurements ofhydrocarbonpoolfires(seeAppendix1ofASTME1529forfurtherinformation).

Thetwofirecurvesareshownonthegraphopposite.

TheASTME1725-95testmethodhasstringentrequirementsforperformanceofcabletrayfireinsulationsystems.Thekeyfeaturesofthetestare:

• Thetestisrunatpositivepressureoveratleast½thetestassembly• Thermocouplesarearrangedinsets,fixedintothetrayevery150mmonbothrailsof thecabletray,andevery150mmonabarecopperwirecenteredinthetray• Thecabletrayisintendedtoberunemptyofcables,providingapprovalfor0%to 100%cableloading• Failureisdeterminedwhenonethermocouple‘set’reachesanaveragetemperature riseof250°F,(121°C)oranysinglethermocouplereaches325°F(163°C)

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Time in minutes

ASTME1529andUL1709FireCurves

Temperature(°C)

60 7020 30 40 500 10

1200

1100

1000

900

800

700

600

500

400

300

200

100

0

UL1709Curve

ASTME1529Curve

SpecifiedHeatFluxes

ASTME1529:158kW/m²heatflux(±8kw/m²)

UL1709:204kW/m²heatflux(±16lw/m²)

Cable tray fire protection fire testing and certification

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AssessingtheperformanceofcabletrayfireinsulationsystemsusingcabletemperatureversuscircuitintegrityASTME1725usescabletraytemperatureasthefailurecriterionbecausecircuitintegrityhasbeenshowntobeunreliableasanindicatoroffailureofacable.

Thisistheresultofresearchthatindicatedcablesbelievedtobeofidenticalcompositionandratinghaddifferentfunctionalfailuretemperatures.

Thismeansthatcircuitintegrityfailurecannotbeassumedtoreliablyoccuratthesametimepointinafire.Therefore,itismorereliabletoestablishamaximumtemperaturebeyondwhichanycablecanbeconsideredtobeatriskoffailure.

Usingcabletemperatureasthefailurecriterionensuresthatthemaximumtemperatureatwhichfunctionalityofanycablecanbeassumedtobemaintainedisnotexceeded,evenifcircuitintegritycanbemaintainedbythesamplecableusedinthefiretest.Furthermore,themeasurementoftrayratherthancabletemperature,withanemptytray,allowsanycableloadingtobeusedinpractice.

CertificationapprovalTheFireMasterinstrumentcontrolcabletraysystemisFactoryMutualApprovedfor30minutehydrocarbonfireprotectionofinstrumentcontrolcabletraysinaccordancewithASTME1725-95methodusingtheASTME1529hydrocarbonfirecurve.

TheFMApprovalisvalidformanufactureofFireMastercabletraywrapatanumberofMorganThermalCeramicsfactoriesworldwide.

55Fireprotectionforprocessequipment

Cable tray fire protection fire testing and certification

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56Fireprotectionforprocessequipment

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FireMaster®

vessel fire protection system

FIRE PROTECTION

57

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FireMaster® Marine Plus blanket is applied to process vessels (flare drums, separator vessels etc) to ensure they retain structural integrity in hydrocarbon pool or impinging jet.

The system uses a substrate of wire mesh fixed to the vessel, with strands of the mesh cut to form anchor pins over which the FireMaster® blanket is impaled. The mesh is fixed to the vessel by twisting adjacent sheets together, an important feature as welded fixings are not allowed.

Fireprotectionforprocessequipment

The system has been demonstrated to have blast resistance to 0.5 bar overpressure. See page 65 for details.

58

FireMaster® vessel fire protection systemHydrocarbon and Jet Fire protection for process vessels

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● Weather-protective cladding is applied over the system using ring supports.

● Fire tested in hydrocarbon pool fires for 3 hours. Fire tested for 190 minutes Jet Fire Protection to ISO 22899-1 standard. JF/Process Vessel/195/180. Blanket also provides thermal insulation for the vessel as well as fire insulation.

● Ideally suited for vessels operating at above-ambient temperatures where heat-reactive fire protection materials cannot be used without secondary insulation being first applied around the vessel.

59Fireprotectionforprocessequipment

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a b c d e

a SupportRingforexteriorcladding.

b

c FireMasterMarinePlusblanketwithaluminiumfoilfacing.

FixingsupportforFireMasterMarinePlusfireinsulationblanket.

d RetainingwashersforFireMasterMarinePlusblanket.

e Exteriorcladding.

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FireMaster® vessel fire protection systemHydrocarbon and Jet Fire protection for process vessels

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c

a

d

b

fe

a

SupportRingforexteriorcladdingusedonmainbodyofvessel.Stainlesssteel3mmthick40mmwidestripwithheightadjustedtomeetinsulationthicknessusing3mmup-standsteelsectionsatnolessthan200mmcentres.Thesupportringsareplacedovertheblanketretainingmeshandclampedintoplaceattheiredge.Ifrequired,thecladdingringscanbeappliedoverafibreglasstapetoavoiddirectcontactwiththevesselsteelalthoughthisisnotrequiredforfireprotectionperformance.Claddingsupportringsarenormallyspacednomorethan125mmfromthecladdingsheetedgeandat600mmcentresnominally.AstheFireMasterblanketwidthis610mm,a600claddingsupportringspacingismostconvenient.FireMasterblanketshouldbetightlyfittedintothesupportringeitherbypackingaseparatestriporinsertingtheblanketedgeintotheringvoid.

b

FixingsupportforFireMasterMarinePlusBlanket.Weldedmesh,stainlessorgalvanisedsteel50mmx50mmx2mm.Themeshiscutandbentoutwardstoformafixingpinfortheblanketat200mmcentres.Individualsheetsofmeshareattachedtogetherbytwistingtheedgestrandsofthemeshtogether.Ifnecessarythemeshcanbeattachedusingsteelbandingstrapsforadditionalsupport.

dRetainingwasherforFireMasterMarinePlusBlanketusually38mmdiameterfriction-fittype.Galvanisedorstainlesssteel.Thecutmeshstrandisbentoverthewashertosecurethewasher.

e

ExteriorCladdingappropriatetothefirescenario.ForJetfireprotection,0.6mm304Gradestainlesssteelis used.

c

FireMasterMarinePlusblanket128kg/m³densitywith(optional)aluminiumfoilfacingappliedinaminimumof2layers.Thicknesstobeusedistobeverifiedforeachapplicationinaccordancewithdesignfire,firedurationandspecifiedcriticaltemperaturerequirements.Thesystemhasbeenfiretestedfor190minutesinaJetFiretoISO22899-1standardusing88mmofFireMasterMarinePlusBlanketinsulationachievingJF/ProcessVessels/200/180classification.ContactMorganThermalCeramicsforadviceonthicknessrequirementsforindividualapplications.

61Fireprotectionforprocessequipment

f

Optionallayerofwiremesh.

Hydrocarbon and Jet fire protection for process vessels - detail view

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a

b

aExteriorcladdingondomeendsofvessel.Segmentshaveswagededgeseams.Gradeofsteelandfixingofthesegmentsectionstoeachotherisasoutlinedin(b)below.Claddingsupportringsarenotnormallyrequiredfordomeendsegments.

b

Exteriorcladdingformainvesselbody,0.6mm304gradestainlesssteelmaybeusedforJetFiresupto190minutesduration.Claddingedgestooverlapby75mm.Thetopoverlappingcladdingpanelhasswagededges.(Seedetaildrawingbelowright).

Fixingsusedtojointhecladdingsectionstogetherareinsertedcentrallyintotheswage.Whereswagededgesmeet(e.g.verticalandhorizontaledges),theswageisterminatedat75mmfromthesheetedgetoallowforatightoverlap.

Fixingofcladdingsegmentstobemadewithno.8stainlesssteelscrewsor10mmdiameterstainlesssteelrivetsat100mmspacing.

Stainlesssteelbandingstraps20mmwideat200mmcentrescanbeusedforsecondarysupportofthecladdingifrequired,butdonotformpartofthefireprotectionsystemrequirement.Amasticsealantmaybeusedbetweencladdingjointsifrequiredforweatherprotectionpurposesbutisnotarequirementforfireprotectionperformance.

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Swagedcladdingjointwithscrewfix-ingmadedirectlyinthejoint.

FireMaster® vessel fire protection systemHydrocarbon and Jet fire protection for process vessels - detail view

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Explosion resistance testing of FireMaster® Process Equipment

fire protection systems

FIRE PROTECTION

63

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64

Explosion resistance testing of FireMaster® Process Equipment fire protection systems

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ThefollowingsystemsweretestedforexplosionresistanceattheDNV-GLSpadeadamtestsitein2015:• FireMasterVesselFireProtectionSystem• FireMasterRESSysteminstalledontoa3inchschedulexxspipe• FireMasterPipeFireProtectionSystem o 3inchschedule40pipeinsulatedwithtwoalternativeinsulationspecifications: • 76mmFireMasterMarinePlusBlanket+40mmofMicroporousflexible(totaloutsidediameterofpipe322mm) • 38mmFireMasterMarinePlusBlanket+76mmMicroporousflexible(totaloutsidediameterofpipe306mm)

65Fireprotectionforprocessequipment

PipesandRESsysteminstalledinexplosionchamberpriortoexplosiontesting.

FireMastervesselsysteminstalledonbackwallofexplosioncham-berpriortoexplosiontesting.

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66

ThespecimensweresubjectedtotwoconsecutiveexplosionswiththefollowingoverpressuresTest AverageOverpressure(mbar) AverageDuration(ms)1 430 170 2 500 170 Aftereachtestthespecimenswereexaminedandassessedforintegrityofthefireprotectionsystem.

TestSampleAssessmentofDamage

SomedeformationoftheendcapsFireMasterPipe1

Test 1 Test 2

Somedeformationoftheendcaps

SomedeformationoftheendcapsFireMasterPipe2 Somedeformationoftheendcaps

SomedeformationoftheendcapsRESboxrotated90°FireMasterRES

Somedeformationoftheendcaps.Lossofsomerivetsnear

centreofpipe

NodamageordeformationofFireMasterblanket

FireMasterVesselSystem

NodamageordeformationofFireMasterblanket

FireMasterVesselsystemafter2ndexplosiontest.Nodamageoccurredtothecladding.Aninspectionoftheinsulationwasmadeafterremovalofthecladdingandnodamageorcompressionoftheinsulationthicknesswasnoted.

RESsystemaftersecondexplosiontest.

Pipesystemaftersecondexplosiontest.

Explosion resistance testing of FireMaster® Process Equipment fire protection systems

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67

FIRE PROTECTION

FireMaster®

structural steel fire protection

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FireMaster® blanket and FireBarrier™ products provide fire insulation to steel beams and columns to ensure they maintain load-bearing capacity in a fire, thus preventing collapse of the structure they are supporting.

Traditionally, fire insulation is required to ensure the steel temperature does not exceed 550°C, the point at which steel retains 60% of its room temperature structural strength. However, different maximum temperatures are often specified, taking into account temperature profile and load on the sections. Critical temperatures ranging be-tween 400°C and 620°C are common, with 400°C widely used in the offshore industry.

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FireMaster® structural steel fire protection Fire insulation to steel beams and columns

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● Tested to hydrocarbon fire standards for structural steel protection.

● Fast and simple to install using welded pins. No complicated fixing or preparation work required.

● Ideal for complex shapes, the blanket is flexible, wrapping around the steel profile. Low waste due to minimal cutting required to fit around complex structures as well as low weight contribution.

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a b c d

a Steelbeamorcolumn.

b

FireMasterMarinePlusblanket128kg/m³density.Theblanketisappliedfollowingtheprofileofthesteelsectionasillustrated.Twolayersareinstalledwithjointsbetweeneachlayeroffsetbyapproximately300mm.Jointsbetweenadjacentblanketsaretightlybuttedtogether.Forthicknessrequirementssee‘FireMasterStructuralSteelProtection:GuidetoSpecificationandCertification’section.

c Steelfixinganchorscoppercoatedmildsteel3mmdiameter.Anchorsarespacedat150mmcentreswithjointsbetweenblanketsspacedatthemid-pointoftheanchors,i.e.75mm.

d Exteriorcladdingwhererequired.Forexteriorweatherexposedareas,theuseof3MVentureClad1579GCW-WMissuggested.

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FireMaster® structural steel fire protection Fire insulation to steel beams and columns

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c

a

d

b

a Steelbeamorcolumn.

b Steelfixinganchorscoppercoatedmildsteel3mmdiameter.Anchorsarespacedat150mmcentreswithjointsbetweenblanketsspacedatthemid-pointoftheanchors,i.e.75mm.

cFireMasterMarinePlusBlanket128kg/m³density.Theblanketisappliedfollowingtheprofileofthesteelsectionasillustrated.Two layersareinstalledwithjointsbetweeneachlayeroffsetbyapproximately300mm.Jointsbetweenadjacentblanketsaretightlybuttedtogether.Forthicknessrequirementssee‘FireMasterStructuralSteelProtection:GuidetoSpecificationAndCertification’section.

d Exteriorcladdingwhererequired.Forexteriorweatherexposedareas,theuseof3MVentureClad1579GCW-WMissuggested.

Forlargesteelbeamsadditionalfixinganchorsareusedwithintheweb.Themaximumspacingforanchorsis300mm.

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Fire insulation to steel beams and columns - alternative fixings

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19.2mm

31.4mm

305x305x198SectionFactor:76m-1

314.1mm

333.9mm

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FireMaster®structuralsteelfireprotectionsystemThethicknessofinsulationthatisrequiredtobeappliedtosteelworktoprovidefireprotectionwilldependonanumberoffactors.Theseare:1. Fireloadandduration2. Criticaltemperaturespecifiedforthesteel;i.e.themaximumpermitted temperatureforthesteelsectionduringthefire3. The“sectionfactor”ofthesteelwork;arelationshipofexternalsurface exposedtofiretothesteelsectionalarea

CriticalsteeltemperatureSteelworkisinsulatedagainstfiretomaintainitstemperaturesbelowaspecifiedcriticaltemperaturelimittoensureitsloadbearingfunctionismaintained.Thelimitusuallycommonlyappliedtosupportingstructuralsteeloffshoreonforexample,livingquartersis400°Cfora60minuteperiod.

Thislimitisalsooftenappliedtoprocessplantequipment.Othertemperaturelimitsmaybeapplieddependingonthefunctionofthestructure.Forexamplesupportsteelworkforemergencyshutdownvalvesisusuallylimitedtoamaximumtemperatureof200°Cfor60minutes.Secondarysteelworkinprocessareasmayhaveamaximumsteeltemperatureof550°Cspecifiedfor60minutes.

SectionfactorThesectionfactorrelatesthesurfaceareaofthesteelsectionexposedtofiretotheamountofsteelinthesectioncross-sectionalareaavailabletoabsorbheatfromthefire.Thesurfaceareaofthefire-exposedsectiondividedbythecross-sectionalareaisdefinedasthe‘sectionfactor’;‘Hp/A’or‘F/A’.Steelsectionswithlargesectionfactorswillexhibitfastertemperatureriseinafirethanthosewithsmallersectionfactorsastheratioofareareceivingheattothemassofsteelavailabletoabsorbthatheatincreases.SectionFactorsarecalculatedbydividingtheexternalfire-exposedperimeterofthesteelsectionbyitscrosssectionalarea.

Theexample,below,comparesthesectionfactorsoftwodifferentsizedsteelcolumns.

Thetableabove,illustratestheeffectofsectionfactoroninsulationthicknessfortwodifferentsizedsteelsections.

Sectionfactor(m-1)Insulationthicknessrequiredtomaintainsteeltemperatureto400°Cfortwohoursinahydrocarbonfire

50mm76

81mm148

305x305x97SectionFactor:148m-1

9.9mm

15.4mm

304.8mm

307.8mm

Structural steel fire protection systemA guide to specification and certification

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Firetestingofstructuralsteelworkfireinsulationisdesignedtorelatesectionfactortoinsulationthicknessforavarietyoffailuretemperaturesandthisrequiresalargevarietyofsectionstobefiretested.FireMasterMarinePlusblankethasbeenfullytestedinordertogeneratetherequiredthicknesstablesinaccordancewithAnnexE4ofEN13381-4firetestprocedureforstructuralsteelworkinhydrocarbonfires.

Thisteststandardalsorequiresloadedbeamstobefiretestedinordertoassessthe‘stickability’oftheinsulationsystemasthebeamdeflectsunderloadwithincreasingtemperature.Thisistoensuretheinsulationsystemhasadequateintegrityforuse.

Inordertoassessanyimpactofthebeamdeflectionontheinsulationsystem,identicallyinsulatedreferencenon-loadedcolumnsofthesamesectionfactorarealsotestedtoallowtemperaturerisedatatobecomparedinloadedandunloadedconditions.

FireloadanddurationTheheatfluxortemperaturetowhichthesteelisexposedwillinfluencethethicknessofinsulationrequiredforfireinsulation.Fromthefiretests,tablesareconstructedusingmultiplelinearregressionanalysisofthefiretestdatatorelatefireexposuretime,sectionfactorandcriticaltemperaturetoinsulationthickness.

FireMaster®structuralsteelsystemfiretestingandcertificationTheFireMasterstructuralsteelsystemistestinginaccordancewithEN13381-4methodusingthehydrocarbonfiretemperature/timecurvespecifiedinEN1363-2forprotectionperiodsupto240minutesandisTypeApprovedbyLloydsRegister.TestingforcellulosicfireprotectionofstructuralsteelworkhasalsobeencarriedoutinaccordancewithEN13381-8methodwithLloydsRegisterTypeApprovalforupto180minutes.

InsulationthicknessrequirementsforhydrocarbonfireprotectionofsteelworkThetableonpage64showsthevariationofthicknesswithsectionfactorforhydrocarbonfireprotectionofstructuralsteelwithacriticaltemperatureof400°Cforvarioustimeperiods.

ForothercriticaltemperaturesandtimeperiodsreferencecanbemadetotheLloydsRegisterTypeApprovalcertificate.

AdditionallyMorganThermalCeramicsprovidesasoftwarepackage‘SectionWizard’toallowstraightforwardaccesstothefiretestapprovedthicknessdatawithouttheneedtocalculatesectionfactorsorlookuptables,seepage65forfurtherdetails.

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A guide to specification and certification

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ExampleofthicknessrequirementsforstructuralsteelfireprotectioninhydrocarbonfiresThetablebelowillustratestherequiredthicknessofFireMasterMarinePlusblankettoensureacriticalsteeltemperatureof400°Cisnotexceededfortimeperiodsintherangeof1to4hours.ForothercriticaltemperaturespleaserefertotheLLoydsRegisterTypeApprovalcertificationoruseourSectionWizardsoftware.

Minimumthickness(mm)ofFireMasterMarinePlusblankettoensureacriticalsteeltemperatureof400°Cisnotexceeded

60 minutes

Sectionfactorm-1

707580859095100105110115120125130135140145150155160165170175180

50

185190195200205210215

90 minutes 120 minutes 180 minutes 240 minutes

50 50 69 9150 50 50 73 9650 50 52 77 10150 50 55 80 10650 50 57 84 11050 50 60 87 11450 50 62 90 119

50 50 65 94 12350 52 67 97 12750 53 69 100 13050 55 71 102 13450 57 73 105 13750 58 75 108 14150 60 77 110 14450 61 78 113 14750 63 80 115 15050 64 82 11850 65 83 12050 67 85 12250 68 87 12450 69 88 12651 70 90 12852 71 91 13052 72 92 13253 73 94 13454 74 95 13655 76 96 13856 76 97 13956 77 99 14157 78 100 143

Minimumthickness(mm)ofFireMasterMarinePlusblankettoensureacriticalsteeltemperatureof400°Cisnotexceeded

60 minutes

Sectionfactorm-1

220225230235240245250255260265270275280285290295300305310315320325330

58

335340345350355260

90 minutes 120 minutes 180 minutes

79 101 14458 80 102 14659 81 103 14760 82 104 14960 83 105 15061 84 10661 84 107

62 85 10863 86 10963 87 11064 87 11164 88 11265 89 11365 89 11466 90 11466 91 11567 91 11667 92 11768 93 11868 93 11869 94 11969 94 12069 95 12070 96 12170 96 12271 97 12271 97 12371 98 12472 98 124

A guide to specification and certification

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Fireprotectionforprocessequipment

SectionWizardSoftwareMorganThermalCeramicsofferstechnicalsupportservicestoassistspecificationofourproducts.Weuseapprovedfinite elementpackagestocalculatefireinsulationrequirementsfor applicationsthatcannotbedirectlyaddressedwithfiretestingalone.Thesecalculationtoolsareusedtosupplementourexistingfiretestingandcertification.

Availabletoallofourcustomersisthesoftwarepackage ‘SectionWizard’(forPConly*).

Thisallowseasyandfastspecificationoffireinsulation requirementstosteelworkorpipesections.Thesoftwarepackageisdirectlylinkedtoourfiretestingforsteelsectionsandpipesandallowsrapidspecificationofthicknessrequirementsbasedonfirescenario,duration,criticaltemperatureandsteelsectionsize.

Standardsteelsectionorpipedimensionsareincludedinadatabasethuseliminatingtheneedforcalculatingsectionfactorsandthenreferencingstandardtablesofthickness.SpecificationoffireinsulationrequirementscanbecarriedoutinashorttimeperiodandalwaysinaccordancewiththerelevantTypeApprovalcertificate.

ToobtainacopyofSectionWizard,contactyourlocalMorganThermalCeramicsoffice.

*CompatiblewithWindows7(32or64bit)OperatingSystemsandhigher

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Forallenquiries,pleasecontactourspecialistsalesandmarketingoffices:

EuropeMorgan Advanced MaterialsThermalCeramicsUKLtdTebay Road, BromboroughWirral, MerseysideCH62 3PHUnited KingdomT +44 (0) 151 334 [email protected]

AmericasMorgan Advanced MaterialsThermalCeramicsInc2102 Old Savannah RoadAugustaGeorgia 30906USAT +1 (706) 796 [email protected]

AsiaMorgan Advanced MaterialsMorganCeramicsAsiaPteLtd150 Kampong Ampat05-06A, KA Centre368324SingaporeT +65 6595 [email protected]

www.morganadvancedmaterials.comwww.morganthermalceramics.comCopyright©02/2020.v4-DesignedandProducedbyJSACreative

THERMAL CERAMICS

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