Advanced insulation & fire protection systems to the oil and gas industry Asaf Hisherik – Upstream Surface Engineering Bill Rivers – General Manager USA
• Introduction • Part 1 - Technical background • Part 2 - Passive Fire Protection systems • Part 3 – Site Application • Q & A Session
Advanced Insulation Systems , formerly known as Alderley Materials Ltd, specialises in the manufacture and supply of unique phenolic resin based syntactic foam insulation and flexible Passive Fire Protection (PFP) systems. AIS is a single source for insulation and fire protection systems to the oil and gas industry and represents one of the most respected and progressive names in topside and subsea insulation worldwide.
AIS offers a wide range of products to meet the growing demand for fire protection systems adaptable for elevated service temperatures and pressures.
AIS provides a complete ‘supply and apply’ service for all passive fire protection and insulation needs:
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Sourcing and supply of materials
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Shipping and site logistics
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Worldwide application and manpower supply using own pool of qualified certified applicators
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Verifiable audited performance records for the entire contract
• Head Office
Leeds (UK)
Gloucester (UK) • Research & Development Gloucester (UK) •Manufacturing
Abu Dhabi & Dubai
Singapore (Asia)
(UAE) Gloucester
(UK)
Gloucester (UK) Leeds (UK) Dubai (UAE) • Sales Gloucester (UK) Abu Dhabi & Dubai (UAE) Singapore Houston (US) Aktau (KZ)
Houston
Aktau
(USA)
(Kazakhstan)
• • •
Quality Management LRQA ISO9001 - 2008 Environmental Management LRQA ISO 14001 Occupational Health and Safety BS OHSAS 18001
The above ISO certification include the manufacture, supply and apply of insulation and fire proofing products and services.
AIS qualified products are now used worldwide by major oil and gas companies and by their contractors.
Market Segments
Offshore Platforms/ Vessels
Onshore
LNG
Subsea
Offshore Applications Hot Riser Insulation/ Protection
Vessel Insulation/ Protection
Valves/ ESDV/ Flange Insulation /Protection
Process Pipe Work Pipe Support
Blast Wall & Blast wall Coating
Deck Insulation/ Protection
Cold Splash/ Thermal Shock Insulation Protection
Onshore Facilities Junction Box Insulation/ Protection
Cable Tray Protection
Valves/ ESDV/ Flange Insulation Protection
Storage Tank Protection
Process Pipe work
LNG Spill Reservoir / Tranches Insulation Protection
Tranches/ spill reservoir PFP
Storage Tank Protection
Process Pipe Work
Jetty
Structural Thermal Shock Insulation Protection
My Aim….. Demonstrate the benefits of utilizing integrated thermal insulation and PFP system on structural, processing and Civil applications
Part 1 – Technical Background
The purpose of applying fireproofing is to provide temporary protection until such time when fire fighting systems and loss control measures may be employed.
Loss control systems measures may include:
• Depressurization of vessels • De-inventory of vessels • Isolating fuel flow/limiting fuel availability shutting down units • Actuating suppression/exposure • Active cooling systems
BS EN ISO 13702: 1999, Petroleum and Natural Gas Industries – Control and mitigation of fires and explosions on offshore production installations – Requirements and guidelines
API RP 14C - Safety Analysis for Production Platforms Specifies the requirements for the analysis, design, installation and testing of surface safety systems for offshore production platforms.
• Valve will be limited to a maximum surface temperature of 200°C for the duration of a 60 minute jet fire. • Actuator will be limited to a maximum surface temperature of
100°C for the duration of a 60 minute jet fire. • The protection will be provided up to and including the conductor hang-off flange and seal arrangements.
Typical Design Requirements – Offshore •
BS EN ISO 13702 indicates that a typical critical temperature for structural steel is 400°C.
•
PFP systems shall resist a blast overpressure of 800mbar and provide the full specified fire performance after the blast.
• The liquefied petroleum gases exist as gases at normal temperatures and pressures but can be liquefied under moderate pressure. • If the pressure is subsequently released, the LPG again becomes gaseous. If an LPG vessel is involved in a fire, it may overheat and rupture violently giving an intensely hot fireball and may project pieces of the vessel over considerable distances. • Such a rupture is commonly termed a Boiling Liquid Expanding Vapour Explosion (BLEVE)
Fire tests are performed on fireproofing materials to measure the level of Protection provided by a particular fireproofing system (including material, thickness, application method, etc.). Underwriters Laboratories has developed a test protocol to simulate hydrocarbon fire exposures. This test protocol is UL 1709 and is intended to approximate fire exposures that may be expected in a process plant. The fireproofing material aimed at protecting steel structures and supports from reaching 538 C for a period of 3 hours based on a fire exposure as defined by UL 1709.
Industry Design Fire Curves 1200
1000
Temperature C°
800
Cellulosic Curve
“A” Category – ISO834 1000 C° at 90-100 min
600
400
200
* Max Temp. ** Erosive Force
0 0
15
30
45
60
75
90
105
120
135
Elapsed Time (min.)
150
165
180
195
210
225
240
Industry Design Fire Curves 1200
1000
Temperature C°
800 H - Curve 600
“H” Category – UL1709 1000 C° at 7 min
Cellulosic Curve
400
200
* Max Temp. ** Erosive Force
0 0
15
30
45
60
75
90
105
120
135
Elapsed Time (min.)
150
165
180
195
210
225
240
Pool Fire
Image from Sandia National Laborites
Industry Design Fire Curves 1600
1400
“J” Category – 1350 C° at 2-5 min
Temperature C°
1200
1000 H - Curve 800
J - Curve
Cellulosic Curve
600
400
* Max Temp. ** Erosive Force
200
0 0
15
30
45
60
75
90
105
120
135
Elapsed Time (min.)
150
165
180
195
210
225
240
Jet Fire Testing - ContraFlex®
Part 2 – Passive Fire Protection Systems
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An intumescent is a substance which undergoes a chemical reactions as a result of heat exposure, thus increasing in volume, and decreasing in density
Stage 1
Stage 2
Stage 3
• HEAT Source > React to heat > chemical reaction will start at around 65-80°C.
• Reaction > Material turns soft > emits gases and intumesce & expand into carbonaceous char
• Protection /Insulation > The char provide insulation that restrict the rate of temp rise of the steel. Char has to resist jet fire erosion when exposed to JF.
ContraFlame® is a multifunctional composite system based on unique phenolic syntactic foam and phenolic glass reinforced laminate. Truly passive fire protection
• No chemical reaction • No change in physical dimension • No change in density • No change in material micro-structure
non porous excellent water and vapour resistance chemically stable
can be surface modified
Diameter = 40 - 177µm Glass or ceramic microspheres Actual microspheres at 200x magnification
Property
Value
Compressive Strength @ 20oC
18.3 MPa
Expansion Co-efficient
20.7 x 10-6
Temperature resistance
From -196°C to 185°C
Blast overpressure resistance
4.2 bar
Standard thickness
34mm
Thermal Conductivity @ 20oC
0.054 Wm-1K-1
Flammability
Zero (No spread of flame)
Smoke Generation
Negligible
Features
Epoxy Intumescent
ContraFlame
Jet Fire Protection
Certified
Certified
Thermal Insulation
Low
High
Thermal Conductivity
0.213 W/mK
0.05 W/mK
Service Temp Range
-30°C to +80°C
-196°C to +185°C
ContraFlame® Lloyds certification JF120 1. LR Certificate of Fire Approval JF120 SAS F100180 M1.pdf 2. ContraFlame report v2 pdf.pdf
ContraFlame Blast Testing 4.2 bar
JF120 Lightweight Fire Protection & Insulation
Key Features • Lloyds certify Jet Fire (J120) Rated phenolic syntactic foam • Lloyds certify Blast Protection (4.2 bar) • Superior Thermal insulation/protection (0.05WmK) • Wide service temp. (-196°C to +185°C) • Close Cell structure (i.e no water absorption) • Durable and impact resistance • Proven to eliminate CUI Uses: • • • • • • •
Hot risers Hot three phase separators Hot slug catchers Under decks insulation/protection Top deck spill /blast protection Flare stacks Steel structures that are subject to thermal shock, e.g. LNG plants, jetty • Process pipework and equipment
Jet Fire Rated Precast Shells Key Features • Closed cell structure, Pre-cast Insulation/Passive Fire Protection (PFP) for pipe work (size 1" - 36“) including bends, tees, reducers • Rapid, dry installation • Demountable and reusable • J120 Jet fire approved, blast resistance • Superior insulation properties (0.05 Wm-1 K-1) • Wide tolerance to elevated and low service temperatures, (+185°C to -196°C) • Designed to accommodate heat tracing on pipe work Typical Application • Flare Stacks • Risers • Insulated Pipe works size 1” - 36” • Pipe work which requires regular inspection • Pipe work requiring heat conservation /personal protection
Jet Fire Rated Precast Enclosures
Key Features • Integrated Insulation and Passive Fire Protection to J60 or H Rating • Provision of bespoke Construction / configuration to suit protected element • Durable Construction to withstand service and environmental conditions • Complete onsite construction, world wide service • Wide tolerance to elevated and low service temperatures (+185°C to – 196°C) • Truly passive fire protection, material does not undergo any chemical change in the course of the fire • Tested at Spadeadam and verified by 3rd party technical consultancy • Self supported and do not require framing (no steel components) • Cable and pipe penetration can be installed post construction Typical Application • Valves bodies • Actuators • ESDV • Flanges (short base / long base) • Riser Clamps • Pipe supports • Fire Pumps
JF120-200 Riser Protection Key Features Integrated Insulation and Passive Fire Protection to J120 High integrity corrosion protection with joint less corrosion barrier suitable for splash and tidal zone Long term resistance to wave action and debris impact Durable Construction to withstand service and environmental conditions Field joint application can be done on site or offshore Ambient Cure, no specialised curing procedures or equipment Low Heat Transfer Coefficient (U-Value) = 0.91 Wm-2K-1 at 96mm Wide tolerance to elevated & low service temperatures (+185°C to -196°C) • ContraFlame JF120-200 meets Total Specification GS SAF 337 • ContraFlame® JF120-200 system carries jet fire certification for • Use on process equipment, risers and pipework • Maximum temperature rise after 2 hour tubular jet fire = 64°C • Lloyds certification SAS F060240 • Tested on riser system with Hp/A up to 161m-1
Deck Insulation / Protection Key Features • Integrated Insulation and Passive Fire Protection to J120 or H rating • Provision of bespoke thermal insulation (e.g. control U value) for cellar decks, cantilever decks and associated structural components • Durable Construction to withstand service and environmental conditions • Complete onsite construction, world wide service including offshore • Ambient cure, no specialised curing procedures or equipment • Wide tolerance to elevated and low service temperatures (+185°C to – 196°C)
• Truly passive fire protection, material does not undergo any chemical change in the course of the fire • Lloyds certification SAS F100180/M1 structural steel jet fire protection • Suitable for close proximity to accommodation blocks due to zero release of smoke and low spread of flame
Jet Fire (J120) Rated Flexible Protection Jackets
• Jet Fire (J120) Rated Flexible Protection Jackets • Blast Protection (2.57 bar overpressure) • Superior Thermal insulation/protection (back face temperature rise, following 120 min of 1350°C (jet fire) = 122.9°C
Designed for jet fire, hydrocarbon pool fire and simple insulation / personnel protection duties Able to deal with gas cloud / flammable vapour issues
Jet fire resistance for two hours; back face temperature rise only 122.9°C Blast overpressure resistance 2.57bar
Thermal conductivity 0.032W/m.K Temperature resistance from -60°C to 1,350°C
ContraFlex® Light PP Insulation Jackets
• • • •
Personal Protection Jackets (PP) Typical Thickness of 50mm & 75mm Superior Thermal insulation/protection Weight range 9.0 -9.5 kg/m² at 50mm
Standard (-36° to +260° C)
High (-36° to +550° C)
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Tested to ISO 22899-1 standard and certified by Lloyds Register (certificate number: SAS F090134)
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Thinner construction – two thirds thickness of conventional systems
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Weight reduction
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Tailor-made
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manufactured anywhere in the world
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Simplified installation technique
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Full technical support
ContraFlex® – Construction cover: •
Designed to withstand environmental exposure – temperature, weather, marine conditions
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Coated or impregnated silica and fibreglass fabrics finished according to operating temperature conditions
Insulation material: •
Different materials selected at thickness appropriate to thermal need, e.g. microporous silica (220-280kg/m3), needle mat
ContraFlex® – Construction •
Critical selection, vital to withstand temperature exposure, e.g. knitted stainless steel wire mesh, high temperature glass cloth
Fastenings:
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Easy to remove yet resistant to environmental exposure and tampering
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Inner jacket wired and riveted
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Outer jacket uses high temperature Velcro and stainless steel clips
ContraFlex® - Key Features
ContraFlex® – Typical Applications •
Valves and Actuators
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Flanges
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Cable trays, conduits and instrument lines
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Electrical junction boxes and circuitry
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Air receivers
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Process vessels
•
Hot Pipework
Jebel Ali, Dubai
Mussafah, Abu Dhabi
Property
Value
Jet fire resistance (ISO 22899-1)
J120 (standard thickness)
Back face temperature rise
122.9°C
Temperature resistance
From -60°C to 1,350°C
Blast overpressure resistance
2.57bar
Standard thickness
61mm
Thermal Conductivity
0.032W/m.K
Client: Eastern Bechtel Co Ltd Location: Abu Dhabi, UAE Scope of supply: Flexible fireproofing solution to instrument junction boxes. Minimum requirements: Fire proofing had to be designed and tested to be suitable for 1,100°C hydrocarbon fire for one hour with the internal junction box temperature not exceeding 120°C.
Part 3 – Site Application
Contraflame ® - Wet Application Set up – Tools
Contraflame ® - Wet Application Set up – Steel Preparation
Contraflame ® - Wet Application Set up – Surface Preparation
Contraflame ® - Wet Application Stage 1 – Tie Coat
Contraflame ® - Wet Application Stage 1 – Tie Coat – 150 micron
ContraFlame ® - Wet Application Stage 2 – C50
C50 mixing process
Contraflame ® - Wet Application Stage 2 – Material Mixing
Contraflame ® - Wet Application Stage 2 – Material Applying
Contraflame ® - Wet Application Stage 2 – Material Applying
Contraflame ® - Wet Application Stage 2 – Material tampering
Contraflame ® - Wet Application Stage 2 – Material tampering
Contraflame ® - Wet Application Stage 2 – Material Curing
Contraflame ® - Wet Application Stage 3 – Multi Layer Outer Coat D2004
Contraflame ® - Wet Application Stage 3 – Multi Layer Outer Coat D2004
Contraflame ® - Wet Application Stage 3 – Multi Layer Outer Coat D2004
ContraFlame ® - Wet Application The Finished System - Vessel
ContraFlame ® - Wet Application The Finished System - Risers
Old laminate ground back Old C50
Leave surfaces rough
Contraflame ® - Wet Application Sanha Processing Columns
Client: PT McDermott Operator: ConocoPhillips Location: South Natuna Sea, Indonesia Storage capacity: 1m barrels Throughput: 500m ft2 gas and 100k barrels of oil and condensate, up to 24,140 barrels of LPG per day Scope of supply: Passive fire protection for 25 process vessels; total area approx. 4,500m2 plus 1.2km of pipework. The tallest column is 175ft.
Contraflame ® - Pre Cast Shells & Enclosures Half Shells
Contraflame ® - Pre Cast Shells & Enclosures Half Shells Bands and Tees
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
Contraflame ® - Pre Cast Shells & Enclosures
For further details and support, please contact
Asaf Hisherik Advanced Insulation Systems Ltd.
Mobile:
+ 44 (0) 7824 845 910
Office:
+ 44 (0) 1453 512 144
email:
[email protected]
Web :
www.aisplc.com
Advanced Insulation Systems Ltd Registered office: Station Road, Berkeley, Gloucestershire GL13 9RL, UK Registered in England: 02405903 Tel: ++44 (0)1453 511600 Fax: ++44 (0)1453 810108 Website: www.aisplc.com Sales:
[email protected]
