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THERMAL CERAMICS
Fire Protection forProcess Equipment
hydrocarbon and jet fire protection
FM Process Equipment_Jan2020_ENG.indd 1FM Process Equipment_Jan2020_ENG.indd 1 5/5/2020 7:05:32 PM5/5/2020 7:05:32 PM
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
FM Process Equipment_Jan2020_ENG.indd 2FM Process Equipment_Jan2020_ENG.indd 2 5/5/2020 7:05:32 PM5/5/2020 7:05:32 PM
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
FM Process Equipment_Jan2020_ENG.indd 3FM Process Equipment_Jan2020_ENG.indd 3 5/5/2020 7:05:33 PM5/5/2020 7:05:33 PM
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
FM Process Equipment_Jan2020_ENG.indd 4FM Process Equipment_Jan2020_ENG.indd 4 5/5/2020 7:05:33 PM5/5/2020 7:05:33 PM
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.
FM Process Equipment_Jan2020_ENG.indd 5FM Process Equipment_Jan2020_ENG.indd 5 5/5/2020 7:05:34 PM5/5/2020 7:05:34 PM
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
FM Process Equipment_Jan2020_ENG.indd 6FM Process Equipment_Jan2020_ENG.indd 6 5/5/2020 7:05:35 PM5/5/2020 7:05:35 PM
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
FM Process Equipment_Jan2020_ENG.indd 7FM Process Equipment_Jan2020_ENG.indd 7 5/5/2020 7:05:35 PM5/5/2020 7:05:35 PM
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
FM Process Equipment_Jan2020_ENG.indd 8FM Process Equipment_Jan2020_ENG.indd 8 5/5/2020 7:05:35 PM5/5/2020 7:05:35 PM
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
FM Process Equipment_Jan2020_ENG.indd 9FM Process Equipment_Jan2020_ENG.indd 9 5/5/2020 7:05:36 PM5/5/2020 7:05:36 PM
10Fireprotectionforprocessequipment
FM Process Equipment_Jan2020_ENG.indd 10FM Process Equipment_Jan2020_ENG.indd 10 5/5/2020 7:05:39 PM5/5/2020 7:05:39 PM
FireMaster® PipeworkJet and Hydrocarbon
fire protection
FIRE PROTECTION
11
FM Process Equipment_Jan2020_ENG.indd 11FM Process Equipment_Jan2020_ENG.indd 11 5/5/2020 7:05:43 PM5/5/2020 7:05:43 PM
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
FM Process Equipment_Jan2020_ENG.indd 12FM Process Equipment_Jan2020_ENG.indd 12 5/5/2020 7:05:45 PM5/5/2020 7:05:45 PM
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
FM Process Equipment_Jan2020_ENG.indd 13FM Process Equipment_Jan2020_ENG.indd 13 5/5/2020 7:05:47 PM5/5/2020 7:05:47 PM
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
FM Process Equipment_Jan2020_ENG.indd 14FM Process Equipment_Jan2020_ENG.indd 14 5/5/2020 7:05:49 PM5/5/2020 7:05:49 PM
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
FM Process Equipment_Jan2020_ENG.indd 15FM Process Equipment_Jan2020_ENG.indd 15 5/5/2020 7:05:50 PM5/5/2020 7:05:50 PM
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
FM Process Equipment_Jan2020_ENG.indd 16FM Process Equipment_Jan2020_ENG.indd 16 5/5/2020 7:05:52 PM5/5/2020 7:05:52 PM
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.
FM Process Equipment_Jan2020_ENG.indd 17FM Process Equipment_Jan2020_ENG.indd 17 5/5/2020 7:05:55 PM5/5/2020 7:05:55 PM
Fireprotectionforprocessequipment
18
Examples of FireMaster® JetWrap system on bendsPipe bends
FM Process Equipment_Jan2020_ENG.indd 18FM Process Equipment_Jan2020_ENG.indd 18 5/5/2020 7:05:58 PM5/5/2020 7:05:58 PM
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
FM Process Equipment_Jan2020_ENG.indd 19FM Process Equipment_Jan2020_ENG.indd 19 5/5/2020 7:06:00 PM5/5/2020 7:06:00 PM
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
FM Process Equipment_Jan2020_ENG.indd 20FM Process Equipment_Jan2020_ENG.indd 20 5/5/2020 7:06:03 PM5/5/2020 7:06:03 PM
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
FM Process Equipment_Jan2020_ENG.indd 21FM Process Equipment_Jan2020_ENG.indd 21 5/5/2020 7:06:05 PM5/5/2020 7:06:05 PM
Fireprotectionforprocessequipment
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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Fireprotectionforprocessequipment
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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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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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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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.
Fireprotectionforprocessequipment
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.
Fireprotectionforprocessequipment
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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Fireprotectionforprocessequipment
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.
Fireprotectionforprocessequipment
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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52
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.
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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.
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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.
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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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74
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]
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