ProTek™ Fire and Blast Wall Certification · PDF fileIt is common for North Sea oil and gas project in both ... ProTek™ Fire and Blast Wall Certification Summary Copyright

Solent Composite Systems Limited Commercial-in-Confidence

ProTek™ Fire and Blast Wall Certification Summary Copyright SCS

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ProTek™ Fire and Blast Walls Certification Summary



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CONTENTS

CONTENTS ................................................................................................................. 2 1.0 INTRODUCTION.................................................................................................... 3 2.0 CERTIFICATION DETAILS ................................................................................... 3 2.0 RELEVANT PROJECTS ....................................................................................... 4

2.1 Ekofisk Tank (2/4-T) Control Centre ...................................................... 4 2.2 Tartan Alpha Intermodule Fire and Blast Wall...................................... 4 2.3 Ekofisk B11 Stairtower Cladding ........................................................... 5 2.4 Tartan Alpha Temporary Safe Refuge Cladding.................................... 5 2.5 Eldfisk 2/7-FTP Fire and Blast Wall........................................................ 5 2.6 Britannia Lifeboat Fire Protection.......................................................... 5 2.7 Beryl Alpha Acoustic and Fire Protection Modules ............................. 6 2.8 Offshore Substation Transformer Fire Protection Modules................ 6 2.9 MOPUstor Yme Fire & Blast Wall Penetration Panels.......................... 7 2.10 Nexen Scott Fire & Blast Cladding ...................................................... 7 2.11Apache Shaleshaker Fire & Blast Cladding .......................................... 7 2.12TAPTI Escapeway Fire & Blast Cladding .............................................. 7 2.13 North Rankin Fire & Blast Wall Penetration Panels ............................ 8 2.14 ABKATUN A Fire & Blast Walls............................................................. 8

3.0 CONNECTION DETAILS....................................................................................... 9 4.0 SUMMARY............................................................................................................. 10 APPENDIX A – Generic Certification and Product Testing APPENDIX B - ProTek™ Fire & Blast Wall and General Product Reference Lists APPENDIX C - Ekofisk Tank Control Centre Photographs APPENDIX D - Tartan Alpha Fire / Blast Wall Photographs APPENDIX E - Ekofisk Stairtower Photographs APPENDIX F – Tartan Alpha Temporary Safe Refuge Drawings APPENDIX G – Eldfisk 2/7-FTP Fire and Blast Wall APPENDIX H – Britannia Lifeboat Protection APPENDIX I – Beryl Noise Reduction Modules & Data Sheet APPENDIX J – Offshore Substation Transformer Protection Modules APPENDIX K – MOPUstor Yme Fire / Blast Wall Penetrations APPENDIX L – Nexen Scott Fire & Blast Cladding of Steel Columns APPENDIX M – Apache Shaleshaker Fire & Blast Cladding APPENDIX N – TAPTI Underdeck Fire & Blast Cladding of Escapeway APPENDIX O – Photos of Woodside North Rankin pipe penetration panels APPENDIX P – Drawings of ABKATUN A fire and blast walls APPENDIX Q - Typical connection detail drawings & photos APPENDIX R - ISO Certificates



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1.0 INTRODUCTION This document provides information about the certification, engineering and design of ProTek™ Fire and Blast Protection systems and their track record of projects. The report describes how SCS meets project requirements with the ProTek™ Fire and Blast Wall system and includes:

• Certification documentation for individual projects

• Generic certification and performance testing • Typical design details for the ProTek™ Fire and

Blast Wall and connection to steel structures • Relevant project references

2.0 CERTIFICATION DETAILS

The ProTek™ fire and blast wall panels were originally tested and certified for use in 1992 following a significant research and development programme to develop the product and demonstrate its performance in full scale explosion and hydrocarbon jet fire and furnace fire testing. These tests were witnessed by Lloyd’s Register of Shipping and safety representatives from many of the UK oil and gas operators of the time. A summary of the tests is provided in Appendix A along with generic certification documents for the product provided by Lloyd’s Register of Shipping and Det Norske Veritas. In many cases the products were tested beyond available standards of the time so Type Approval documents were not able to be issued. However the summaries in Appendix A show that these tests were witnessed and accepted by the certification authorities for use in an offshore oil and gas environment. It is common for North Sea oil and gas project in both UK and Norwegian sector for SCS to provide project specific certification rather than Type Approval documents. Examples of these project specific certificates are included where available in the individual project summaries given in the Appendices of this document. A summary of fire and blast wall projects with performance requirements along with a more general reference list for ProTek™ products is included in Appendix B.



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2.0 RELEVANT PROJECTS

SCS has provided ProTek™ fire and blast walls and other protection systems for a number of demanding offshore oil and gas projects, which are summarised along with their performance requirements in Appendix B. Details of some of these projects are described below:

2.1 Ekofisk Tank (2/4-T) Control Centre

This project was part of a platform refurbishment by Phillips Petroleum and was designed to improve the fire resistance of the control centre by attaching thin and lightweight fire and blast resistant panels to the existing support structure. Photographs are attached in Appendix C that show the existing control centre both before and after the ProTek™ “Thin Wall H60” fire and blast wall panels were installed. In this case the fixing methods were based upon the use of “Hilti” fixings that were attached to the main steel supports. Panels were made to span 3.5m between vertical supports and were built up over the entire 1,000 m² surface of the control centre. The project requirements also included an installed system that did not reduce the positive pressure integrity of the control centre. In addition there were a number of environmental performance requirements for wind, rain, snow and ice loadings. The project performance requirements are 0.1 barg overpressure blast loading and H60 fire performance. A copy of the DNV Type Approval certificate awarded for the “Thin Wall H60” product is given in Appendix C.

2.2 Tartan Alpha Intermodule Fire and Blast Wall This project was part of a platform upgrade to divide an existing module and to separate the divided module with a lightweight fire and blast wall. Photographs are attached in Appendix D to show the installed ProTek™ fire and blast wall. This was provided as a gas tight barrier to resist the effects of an explosion load of 1 barg followed by fire loading for 1 hour jet fire (J60) and 2 hour hydrocarbon pool fire (H120). The connection method is a bolted arrangement to steel plates that are welded to the main tubular structure similar to that shown in the drawing in Appendix O. Lloyd’s Register certification is given in Appendix D.



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2.3 Ekofisk B11 Stairtower Cladding This project was part of a platform upgrade to protect a new stairtower that was constructed to provide safe egress from a hazardous area of the platform. Photographs are attached in Appendix E to show the panels attached to the stairtower structure. The ProTek™ panels were provided as a gas tight barrier to resist the effects of an explosion load of 0.2 barg followed by fire loading for 1 hour (A60). A copy of the DNV certificate issued for the ProTek™ product is included in Appendix E.

2.4 Tartan Alpha Temporary Safe Refuge Cladding This project was part of a platform upgrade to improve the fire protection of a Temporary Safe Refuge on the Tartan Alpha platform. SCS were requested to design an A60 fire barrier to be entirely sealed to prevent water ingress and maintain a positive pressure within the refuge itself. Drawings of the proposed ProTek™ solution are included in Appendix F.

2.5 Eldfisk 2/7-FTP Fire and Blast Wall This project was part of a platform upgrade to install a new barrier to an existing platform offering protection against an explosion load of 0.3 barg followed by hydrocarbon fire loading for 2 hour to H0 standard. A document showing a drawing of the fire and blast wall along with details of doorways, pipe and cable penetrations is given in Appendix G. A copy of the DNV certificate issued for the ProTek™ product is included in Appendix G.

2.6 Britannia Lifeboat Fire Protection

This project was part of a platform upgrade to install new accommodation on the Britannia platform, which required an additional lifeboat to meet the regulations for the additional personnel on board. SCS provided a ProTek™ Fire and Blast protection cladding system to prevent damage to the underside of the new lifeboat from the effects of a pool fire in the sea. The protection requirements are H0 for 1 hour’s hydrocarbon fire at 200kW/m² heat flux and resist explosion loads of 0.1 barg Photographs are included in Appendix H.



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2.7 Beryl Alpha Acoustic and Fire Protection Modules

In response to a growing problem of equipment generating high noise levels placing restrictions on the amount of time that can be spent in an affected area on the Beryl Alpha platform SCS developed a concept of cladding and enclosures to restrict the noise levels and deliver fire protection. The ProTek™ protection system is designed to restrict the noise levels, which has been demonstrated by testing to offer up to 38dB reduction. It also offers fire protection to A60 standard and has to maintain a positive pressure within modules housing the equipment. This is achieved by a series of sealed modules built using ProTek™ panels around gas turbines and other noise generating equipment. This also includes moulded protection systems fitted around piping and ducting to prevent noise being emitted elsewhere around the platform. Design drawings showing the arrangements are given in Appendix I along with a data sheet outlining the noise reduction characteristics to the Norwegian NORSOK standard R-004 for piping and related systems.

2.8 Offshore Substation Transformer Fire Protection Modules The development of offshore wind farms has led to a requirement to site high voltage transformer platforms offshore in order to distribute the electricity generated back to shore. SCS have led the development of modules that are designed to offer fire and blast protection in the event of a transformer explosion or fire to protect personnel and other transformers on the platform. This modular system is designed to be weather tight in order to protect the equipment from the offshore environment. It will also allow a controlled atmosphere to be generated around the equipment with an expectation that the module will maintain a positive pressure. This is achieved with proprietary sealing details between panel joints and around any penetrations, doorways etc. A data sheet explaining the protection system concept is attached in Appendix J.



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2.9 MOPUstor Yme Fire & Blast Wall Penetration Panels This project is part of the Yme redevelopment and required protection panels to be supplied to fit around penetrating pipework and structural beams. The double-sided protection panels are designed to meet an explosion load of 0.7 barg, 15 minutes hydrocarbon jet fire with an H60 requirement on one face and H0 on the opposite face. Photographs showing typical pipe and cable penetrations are given in Appendix K. A copy of the DNV certificate issued for the ProTek™ product is included in Appendix K.

2.10 Nexen Scott Fire & Blast Cladding This project is part of refurbishment of the Scott platform and required jet fire and blast protection cladding panels to be supplied to fit around structural beams. The product was selected because of the advantages of using lightweight removable panels that are bolted around the beams compared with the health and safety challenges of applying intumescent paint materials onto the steel. The product was installed in a rapid timescale with less manhours than planned. Photographs of the installed cladding are included in Appendix L

2.11 Apache Shaleshaker Fire & Blast Cladding This project is part of a platform refurbishment that required jet fire and blast protection cladding panels to be supplied to fit around a renovated shale shaker. The product was selected because of the ability to rapidly install the lightweight panels on a live platform with the minimum of manhours. Photographs of the installed cladding are included in Appendix M

2.12 TAPTI Escapeway Fire & Blast Cladding This project is part of a platform upgrade and required cladding protection panels to be supplied to fit beneath the walkway leading to the lifeboat evacuation points on the platform. Panels are designed for explosion and jet fire protection from a possible fire in the process area beneath the accommodation area. Lightweight panels allowed rapid installation from above the deck level with simple bolting arrangements to minimise the installation time offshore. Photographs of the escapeway are given in Appendix N.



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2.13 North Rankin Fire & Blast Wall Penetration Panels This project is part of a platform upgrade and required pipe penetration protection panels to be supplied to fit around existing pipes. The performance requirements could not be met with traditional steel fire and blast walls. Panels are designed for explosion and jet fire from both sides of the wall arising from incidents within the modules. Lightweight moulded panels allowed rapid installation from above the deck level with simple bolting arrangements to minimise the installation time offshore. Photographs of the panels are given in Appendix O.

2.14 ABKATUN A Fire & Blast Walls

This project is part of a platform upgrade to install 3 new fire and blast walls to an existing platform offering protection against an explosion load of 0.7 barg followed by hydrocarbon jet and furnace fire loading for 2 hour (H120 and J120 standard). Drawings of the fire and blast walls are given in Appendix P.



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3.0 CONNECTION DETAILS

The ProTek™ fire and blast wall panels are designed to be bolted to secondary steel structure to form a sealed fire / blast wall that resists fire and blast loading and is gas and water tight. There are many bolted arrangements for the ProTek™ panel and typical examples are given in the drawings and photographs attached in Appendix Q. The design details rely upon a bolted connection because the ProTek™ is manufactured from high strength composite materials that cannot be welded. It is therefore common for steel supports to be welded in place for fixing the panels, which are bolted to the steel supports to transfer the blast loads to the main platform structure. The ProTek™ panels are designed to deflect elastically under the blast load so that they are not deformed and are able to resist a hydrocarbon jet or pool fire if it occurs after the blast. The blast load is absorbed by the panels and transferred to the bolted ends where the panel fixings resist the bending and shear loading and transfer the load into the main platform structure. The fixings are also designed to restrain the panels immediately after the blast overpressure. Following the explosion the resultant air movement generates a smaller negative suction load that pulls the panels away from the wall putting the bolts into tension. The connection details are calculated for every application and form part of any engineering or certification report that is produced for a ProTek™ fire and blast wall. Fixings are either galvanised high strength steel or 316 stainless steel.



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4.0 SUMMARY

SCS has provided independently certified ProTek™ fire and blast protection solutions over a period of 20 years to meet a wide variety of demanding protection requirements. This document includes generic product certificates and where available project specific certificates issued by independent third party certification authorities such as Lloyd’s Register of Shipping and Det Norske Veritas (DNV). A selection of relevant projects are detailed within this document to demonstrate the company track record in meeting customer’s demands for innovative, long lasting solutions that have low weight and require no maintenance during their 30 year lifetime.



APPENDIX A – Generic Certification and Product Testing



APPENDIX B - ProTek™ Fire & Blast Wall and General Product Reference Lists



APPENDIX C - Ekofisk Tank Control Centre Photographs



Photos showing Ekofisk Control Centre before and after ProTek™ Thin Wall H60 panels fitted

Photo showing general view of Ekofisk Control Centre with ProTek™ Thin Wall H60 panels fitted



APPENDIX D - Tartan Alpha Fire / Blast Wall Photographs



Photos showing ProTek™ Fire & Blast Wall fitted within tubular structure



APPENDIX E - Ekofisk Stairtower Photographs



Photo from hazard side showing ProTek™ A60 Stairtower panels during installation

Photo from inside showing ProTek™ A60 Stairtower panel fixing and gasket seal details



APPENDIX F – Tartan Alpha Temporary Safe Refuge Drawings



APPENDIX G – Eldfisk 2/7-FTP Fire and Blast Wall



APPENDIX H – Britannia Lifeboat Protection



ProTek™ Lifeboat Protection Images



APPENDIX I – Beryl Noise Reduction Modules & Data Sheet



Equipment module and piping protection system for noise reduction and fire protection



APPENDIX J – Offshore Substation Transformer Protection Modules



APPENDIX K – MOPUstor Yme Fire / Blast Wall Penetrations



Fire / Blast Wall Panels fitted around penetrating pipework



APPENDIX L – Nexen Scott Fire & Blast Cladding of Steel Columns



Photographs of installed column cladding on Scott platform





APPENDIX M – Apache Shaleshaker Fire & Blast Cladding



Photographs of Shaleshaker PFP Cladding panels



APPENDIX N – TAPTI Underdeck Fire & Blast Cladding of Escapeway



Fire / Blast Cladding Panels beneath the escapeway to the lifeboat station



APPENDIX O – Photos of Woodside North Rankin pipe penetration panels



Trial Fit - Pipe Penetrations



APPENDIX P – Drawings of ABKATUN A fire and blast walls



APPENDIX Q - Typical connection detail drawings & photos



Typical view of ProTek™ Fire and Blast Wall section (from hazard side)

Typical view of ProTek™ Fire and Blast Wall section (from non-hazard side)



View from hazard side of panel connection details at tubular showing bolts and gasket seal

View from hazard side of panel connection at structural member showing bolts and gasket seal



View from non-hazard side of panel connection at structural member and tubular

Photo from non-hazard side showing panel connection for Ekofisk Fire and Blast Wal

www.solentcomposites.comSolent Composite Systems Ltd., Victoria Barracks, Albany Road,East Cowes, IOW, PO32 6AA, United Kingdom. Tel. +44 (1983) 292602

ProTek™ Fire & Blast Walls and Cladding

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Pipe Flange Cladding

Phillips Ekofisk 2/4-T Cladding

Phillips Ekofisk B11 Fire/Blast Wall Beam Node Protection

Shell Brunei Riser Cladding



APPENDIX R ISO Certificates

Documents

ProTek™ Fire and Blast Wall Certification · PDF fileIt is common for North Sea oil and gas project in both ... ProTek™ Fire and Blast Wall Certification Summary Copyright