FIREPROOFING OF STEEL STRUCTURES
DEP 34.19.20.11-Gen. January 2010
DESIGN AND ENGINEERING PRACTICE
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DEP 34.19.20.11-Gen. 34.19.20.11- Gen. January 2010 Page 2 PREFACE DEP (Design and Engineering Practice) publications r eflect the views, at the time of publication, of: Shell Global Solutions International B.V. (Shell GSI) and/or Shell International Exploration and Production B.V. (SIEP) and/or other Shell Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Shell Operating Units. Where appropriate they are based on, or reference is made to, international, regional, national and industry standards. The objective is to set the recommended standard for good design and engineering practice applied by Shell companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by Shell GSI, in most cases under Service Agreements primarily with Shell companies and other companies receiving technical advice and servi ces from Shell GSI or another Shell Service Company. Consequently, three categories of users of DEPs can be distinguished: 1)
Operating Units having a Service Agreement with Shell GSI or other Shell Service Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2)
Other parties who are authorized to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).
3)
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Service Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Service Company, or companies affiliated to these companies, that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell GSI. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 34.19.20.11-Gen. January 2010 Page 3 TABLE OF CONTENTS 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7
INTRODUCTION ........................................................................................................4 SCOPE........................................................................................................................4 DISTRIBUTION, APPLICABILITY AND REGULATORY CONSIDERATIONS..........4 DEFINITIONS .............................................................................................................4 CROSS-REFERENCES .............................................................................................5 SUMMARY OF CHANGES SINCE PREVIOUS EDITION .........................................6 COMMENTS ON THIS DEP .......................................................................................8 PROJECT DOCUMENTATION REQURIEMENTS ....................................................8
2. 2.1 2.2 2.3
OBJECTIVES OF FIREPROOFING...........................................................................9 GENERAL...................................................................................................................9 FIRE SEVERITY .........................................................................................................9 FIRE RESISTANCE DURATION................................................................................9
3.
FIREPROOFING OF TYPICAL EQUIPMENT AND STRUCTURES IN AN FIRE PROTECTION ZONES....................................................................................10 STRUCTURES SUPPORTING EQUIPMENT AND PIPING ....................................10 COLUMN AND VESSEL SKIRTS.............................................................................10 CABLES AND INSTRUMENTATION LOCATED WITHIN AN FPZ..........................10 PIPING AND EQUIPMENT.......................................................................................11 PROCESS UNIT PIPE RACKS AND PIPE SUPPORT COLUMNS.........................11 BUILDINGS...............................................................................................................11
3.1 3.2 3.3 3.4 3.5 3.6 4. 4.1 4.2 4.3
MATERIAL REQUIREMENTS / PROPERTIES AND INSTALLATION OF FIREPROOFING SYSTEMS ....................................................................................12 GENERAL.................................................................................................................12 CONCRETE FIREPROOFING .................................................................................13 PROPRIETARY MATERIAL FIREPROOFING.........................................................16
5.
REFERENCES .........................................................................................................19 APPENDICES
APPENDIX 1
PROJECT DOCUMENTATION REQUIREMENTS.........................................21
APPENDIX 2
INSPECTION AND MAINTENANCE AFTER APPLICATION OF FIREPROOFING .............................................................................................23
APPENDIX 3
TYPICAL DETAILS OF CONCRETE FIREPROOFING OF STRUCTURAL MEMBERS .............................................................................24
APPENDIX 4
STRUCTURAL COLUMN DETAILS................................................................25
APPENDIX 5
PIPERACK DETAILS.......................................................................................26
APPENDIX 6
CONCRETE FIREPROOFING OF VESSEL SKIRTS.....................................27
APPENDIX 7
CONCRETE FIREPROOFING OF VESSEL STRUCTURAL SUPPORT LEGS ...............................................................................................................28
DEP 34.19.20.11-Gen. January 2010 Page 4 1.
INTRODUCTION
1.1
SCOPE This DEP specifies requirements and gives recommendations for the design and application/installation of passive fire protection (PFP or fireproofing) of steel. The extent of fireproofing and PFP requirements SHALL [PS] be established on the basis of the requirements of DEP 80.47.10.30-Gen. and a fire safety assessment executed for the particular plant or unit. The zones where PFP are required are called Fire Protection Zones (FPZ). The extent of the fireproofing around equipment and structures SHALL [PS] be indicated on layout and construction drawings. This DEP applies to steel supporting structures (and in some cases piping and equipment) in process areas and processing plants as well as to storage facilities, jetties and pipe bridges (including those outside the battery limits) in oil/gas/petrochemical installations. This DEP is intended to ensure that the degree of fireproofing applied is effective and practical in terms of maintainability and reduction of risks. As there is a wide variation in the design of structures, the intent of this DEP SHALL [PS] be considered at all times when prescribing the fireproofing of structures not specifically mentioned in (3). This DEP is not applicable to jet fires. This is a revision of the DEP of the same number dated December 1999; see (1.5) regarding the changes.
1.2
DISTRIBUTION, APPLICABILITY AND REGULATORY CONSIDERATIONS Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. This DEP is intended for use in oil refineries, chemical plants, gas plants, supply/distribution installations and onshore exploration and production facilities. When DEPs are applied, a Management of Change (MOC) process should be implemented; this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regard to the safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible. NOTE:
1.3
National and/or local regulations for fire protection are generally intended for structures erected in populated areas and may therefore be inappropriate for oil, gas and chemical plants, where the fire loadings and risks are different.
DEFINITIONS The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant to act for, and on behalf of, the Principal. The lower-case word shall indicates a requirement.
DEP 34.19.20.11-Gen. January 2010 Page 5 The capitalised term SHALL [PS] indicates a process safety requirement. The word should indicates a recommendation. 1.4
CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (5).
DEP 34.19.20.11-Gen. January 2010 Page 6
1.5
SUMMARY OF CHANGES SINCE PREVIOUS EDITION The previous edition of this DEP was dated December 1999. Listed below are the main changes. Old section
New section
Change Process safety requirements have been indicated by the use of the capitalised term "SHALL [PS]".
General
2.2
---------
Removed old section – Fire Proofing Zone (FPZ). Added a new section – Fire Severity.
2.3
---------
Removed old section - Resistance Against Fire. Added new section – Fire Resistance Duration.
2.4
---------
Removed: Section regarding design considerations
3.1
----------
Reworded section.
3.1.1
----------
Deleted subheading.
3.2
----------
Reworded section
3.2.1
----------
Deleted subheading
3.3
----------
Reworded section.
---------
3.4
---------
3.5
---------
3.6
Added new section - Buildings
4.1
-------------
Deleted text in general section
---------
4.1.1
Added new section – Basic Materials.
---------
4.1.2
Added new section - Corrosion Under Fireproofing
4.2
4.2
4.2.1
4.2.1
-----------
4.2.1.1
Added new section - Piping and Equipment Added new section - Process Unit Pipe Racks and Pipe Support Columns
Changed: Title changed to Concrete Fireproofing Removed: General fireproofing performance requirements Added: Design of concrete fireproofing Added new section – Environmental Controls Moved: content moved to 4.2.1
4.2.2
4.2.2
4.2.3
4.3
---------
4.2.3
---------
4.2.4
Added new section – Concrete Fireproofing Inspection and Testing During Application.
4.2.4
4.2.5
Moved: Brickwork Fireproofing section moved to 4.2.5
continued…
Changed: Title changed to Normal Weight Concrete Fireproofing Standards and Specification Moved: Section on proprietary fireproofing systems moved to 4.3 Changed: Title changed to Proprietary Material Fireproofing Added: Concrete Fireproofing Installation
DEP 34.19.20.11-Gen. January 2010 Page 7
Old section
New section
Change
4.3
---------
---------
4.3.1
Added: General section on proprietary material fireproofing
---------
4.3.2
Added: Proprietary lightweight fireproofing systems
---------
4.3.3
Added: Proprietary intumescent and subliming fireproofing systems
---------
4.3.4
Added: Installation coordinator
---------
4.3.5
Added: Inspection
4.4
---------
Deleted Section
4.5
---------
Deleted Section
5
---------
Deleted Section
Removed: Fireproofing Equipment Inside Buildings
Moved: References moved to Section 5 Added to Shell Standards: DEP 30.46.00.31 DEP 33.64.10.10 S 20.002 Report GS 06.50615 to Shell Standards Added to American Standards and Industry Practices:
6
5
ACI 216.1/TMS-0216 ACI 318 ACI 506.2 ACI 506.3 ASTM A185 ASTM C33 ASTM C150 ASTM E119 UL 1709 API Publ 2218 Added to European Standards and Industry Practices: FIB Bulletin No. 34 EN 197-1 EN 197-4 EN 1992 Removed: DEP 00.00.05.05-Gen.from Shell Standards DEP 00.00.06.06-Gen. from Shell Standards BS 8110 from British Standards
Appendix 1
Appendix 3
Appendix 2
Appendix 4
Moved: Typical details of concrete fireproofing - solid encasement to Appendix 3 Moved: Typical details - cover plates for weather protection to Appendix 4 Changed: Title changed to Structural Column Details
---------
Appendix 1
Added: Project Documentation Requirements
---------
Appendix 2
Added: Inspection and maintenance after application of fireproofing
---------
Appendix 5
Added: Pipe Rack Details
---------
Appendix 6
Added: Concrete Fireproofing of Vessel Skirts
---------
Appendix 7
Added: Fireproofing of Vessel Structural Support Legs
DEP 34.19.20.11-Gen. January 2010 Page 8
1.6
COMMENTS ON THIS DEP Comments on this DEP may be sent to the DEP Administrator at
[email protected]. Shell staff may also post comments on this DEP on the Surface Global Network (SGN).
1.7
PROJECT DOCUMENTATION REQURIEMENTS For Projects to ensure compliance with this DEP proper documentation is required in the Definition and Execution Phases of the Project. The requirements for this documentation are set out in (Appendix 1).
DEP 34.19.20.11-Gen. January 2010 Page 9 2.
OBJECTIVES OF FIREPROOFING
2.1
GENERAL Fireproofing is a measure intended to improve the fire resistance of structures that support pressure vessels, piping and other equipment located in fire hazardous areas. Protection is provided by the application of concrete or other approved insulating materials to structural steel supports. Fireproofing offers protection against the adverse thermal effects of fire for a defined period and defined degree of exposure. It should not be considered as a replacement for active fire fighting or lead to relaxation of normal design requirements (spacing and layout considerations) and precautions in operation and maintenance.
2.2
FIRE SEVERITY Unless otherwise specified the severity of the fire shall be based on hydrocarbon pool fires. For hydrocarbon pool fire exposures, the fire temperature profile will be based on UL 1709. The hydrocarbon fire test as defined in UL 1709 is applicable to all fireproofing systems applied on steel supports and structures. This fire is more severe than the cellulose type of fire which is usually referred to in building regulations. During the test a protected steel column is exposed to a particular heat flux that produces a temperature of 1093 °C (2000 °F). The test is terminated (failure point) when the average temperature of the steel substrate reaches 538 °C (1000 °F).
2.3
FIRE RESISTANCE DURATION The required protection time resulting from this and/or other local conditions shall be established based on the requirements of DEP 80.47.10.30-Gen.
DEP 34.19.20.11-Gen. January 2010 Page 10 3.
FIREPROOFING OF TYPICAL EQUIPMENT AND STRUCTURES IN AN FIRE PROTECTION ZONES
3.1
STRUCTURES SUPPORTING EQUIPMENT AND PIPING The Principal SHALL [PS] determine which structural members within the FPZ are to be fireproofed. The extent of fireproofing around equipment and structures SHALL [PS] be indicated on layout and construction drawings. In addition to main support steel the Principal shall consider the fireproofing of critical supports. Fireproofing on pressure equipment legs or lugs SHALL [PS] not contact pressure retaining parts. There shall be a 25 mm to 50 mm (1 in to 2 in) gap between the fireproofing and the pressure retaining part. Bolted moment connections of fireproofed main pipe rack bents may remain un-fireproofed (exposed) when shop applied concrete fireproofing is specified and the unit has moderate or lower fire risk. Size of fireproofing block outs around moment connections shall be minimized if the block outs will remain exposed. The Contractor shall provide weatherproofing details for all block outs that will remain open for approval by the Principal. Members having only a bracing function should not be fireproofed since the load case maximum wind/ earthquake is assumed not to coincide with the fire case. Bracing required for load cases that are considered to be included with the base fire case as well as for primary stability of the structure shall be fireproofed. Therefore diagonal bracing required for lateral loads due solely to design wind or seismic activity, platform live loads, trolley beams, etc. should not require fireproofing.
3.2
COLUMN AND VESSEL SKIRTS Skirts of columns and vessels SHALL [PS] be fireproofed if they are located within the FPZ (as identified in DEP 80.47.10.30-Gen. and the fire safety assessment). Fireproofing SHALL [PS] be directly applied on skirts and vessel supports as indicated in (Appendix 6). Concrete fireproofing shall be reinforced to prevent shrinkage cracks. Fireproofing systems are susceptible to cracking due to fire or due to thermal stresses caused by operating temperature differences between the skirt and the face of the fireproofing. To avoid cracking of normal weight concrete fireproofing due to operating temperatures the skirt fireproofing shall stop well below the tangent line for hot or cold insulated vessels. See (Appendix 7) for separation distances between the ring angle (drip angle) and the vessel tangent line. Alternatively, heat transfer and thermal stress calculations shall be made to where smaller separation distances are to be specified. The un-fireproofed portion of the skirt SHALL [PS] be covered with fire-resistant insulation. To avoid cracking of light-weight concrete and other proprietary fireproofing due to operating temperatures the skirt fireproofing separation distance SHALL [PS] calculated. Heat transfer and thermal stress calculations SHALL [PS] also determine the type and amount of reinforcement required.
3.3
CABLES AND INSTRUMENTATION LOCATED WITHIN AN FPZ For fireproofing of cables reference is made to DEP 80.47.10.30-Gen. Cables and instrumentation located within an FPZ are normally not protected by fireproofing because typically safety instrumentation is designed to fail in the safe position upon loss of power or signal. See DEP 33.64.10.10.Gen However, whenever fireproofing is required (e.g. for some emergency shutdown and emergency depressuring valves), the cables (or cable enclosure) and associated instrumentation (e.g., valves) shall be of a fireproof construction in accordance with IEC 60331-21 (e.g. cables shall remain operable during a fire exposure environment of at least 750 °C (1382 °F) for a period of 90 minutes). Note that t he Principal shall provide the required performance standard in jurisdictions where the referenced IEC code is not applicable,
DEP 34.19.20.11-Gen. January 2010 Page 11 3.4
PIPING AND EQUIPMENT Fire protection may also be required on piping, or equipment, to reduce the fire relief load or reduce the likelihood of excessive pipe/equipment temperature and possible failure. For further guidance reference is made to DEP 80.47.10.30-Gen One method to provide this protection is to use fire-resistant insulation with a steel or stainless steel metal jacket. Relief design may take into account fireproofing of equipment (DEP 80.45.10.10.Gen.). Reference is also made in this respect to DEP 30.46.00.31-Gen. Proprietary systems (4.3) such as intumescent coatings may be used with approval of the Principal for uninsulated piping and equipment requiring this level of fire protection.
3.5
PROCESS UNIT PIPE RACKS AND PIPE SUPPORT COLUMNS Piping supported from spring hangers or rods shall be protected against failure of the spring hanger or rod by a fireproofed bracket or beam located beneath the pipe. Sufficient clearance shall be provided between the beam and the pipe to permit free vertical movement. Where, however, failure of the hanger rod will not lead to collapse of the piping, these stops are not required (Appendix 5).
3.6
BUILDINGS All enclosed buildings shall as a minimum follow the requirements of the local fire regulations and building code. The fireproofing standards, methods and materials specified in this DEP are applicable to buildings or enclosed structures containing process equipment. Where industrial structures containing process equipments are not completely covered in the local building code requirements and local fire regulations, this DEP SHALL [PS] supplement the local requirements.
DEP 34.19.20.11-Gen. January 2010 Page 12 4.
MATERIAL REQUIREMENTS / PROPERTIES AND INSTALLATION OF FIREPROOFING SYSTEMS
4.1
GENERAL
4.1.1
Basic Materials The following should be considered when selecting fireproofing materials and an applicator: •
For new structures, reinforced concrete support columns and beams are preferable to fireproofed steel because it is economical, robust, and it has been proven to be effective.
•
When there are significant economic incentives or physical limitations, then proprietary materials may be used instead of concrete. The experience of the applicator shall be assessed. The importance of surface preparation and correct application of proprietary materials cannot be overstressed.
•
If surface preparation requires blasting this may rule out the application of the material in an operating plant.
•
Flammable solvents used in the mixing of some proprietary materials shall be rigidly controlled.
•
The capacity of the structure to handle the weight of the fireproofing SHALL [PS] be assessed.
•
Climatic conditions during installation may rule against the selection of certain materials.
The standard fireproofing material is normal weight concrete because of: Durability
•
Availability
• •
Good pool fire protection
•
Inherent torch fire protection
•
No or minimum ongoing maintenance when applied correctly.
Proprietary fireproofing systems (4.3) may be used if approved by the Principal. Mixed systems of approved proprietary fireproofing and normal weight concrete fireproofing are acceptable. The type of fireproofing material and its construction method shall be specified by the Contractor and approved by the Principal. Where proprietary materials are proposed Contractor SHALL [PS] provide the Principal with calculations or other documentation demonstrating that the design will provide the specified fire protection for approval. The Principal shall specifically authorize the use of hollow box fireproofing designs where it is envisioned that maintenance activities or personnel access requirements will not damage the fireproofed member. Otherwise this design shall not be used. 4.1.2
Corrosion Under Fireproofing 1.
Steel surfaces to be fireproofed shall be coated in accordance with approved coating system (galvanized or paint) to prevent environmental corrosion.
2.
Top side fireproofing/steel joint on vertical galvanized steel columns and horizontal galvanized steel beams exposed to the weather SHALL [PS] be protected from moisture ingress. For beams where the facility does not experience freeze/thaw cycles, and where there is no prospect of standing water, galvanised steel shield requirement maybe relaxed (refer sections in Appendix 3).
DEP 34.19.20.11-Gen. January 2010 Page 13 3.
Joint shall be protected with a continuously welded galvanized steel shield (recommended in design Class III plants subject to severe freeze/thaw cycles). Shield shall be a minimum of 3 mm (1/8 in) thick and shall have a drip lip.
4.
For moisture ingress protection for fireproofing for structural steel, see (Appendix 4). The corrosion protection shall be compatible with the fireproofing to be applied and shall be in accordance with DEP 30.48.00.31-Gen.
5.
Moisture ingress protection for fireproofing for non-galvanized steel equipment supports (e.g., vessel skirts, and vessel support legs) shall be steel drip angles regardless of plant class or freeze/thaw potential (3.2).
6.
Penetrations through fireproofing, such as clips, attachments, etc., shall be sealed with a polysulfide or other approved material, typically these need replacement every 5 to 10 years and need to be maintained.
7.
Fireproofing should be applied monolithically where practical. The designer shall consider appropriate fireproofing block-outs for assembly and for expected attachments. Where welding of fixtures to the surfaces after the application of the fireproofing is required, the materials and procedures used shall be approved by the Principal.
4.2
CONCRETE FIREPROOFING
4.2.1
Design of Concrete Fireproofing Concrete is the most commonly used fireproofing material for protection of general structural steel in process plants. Prefabricated or reinforced concrete structures or supports may be considered as a cheaper alternative to fireproofed structural steel. This may sometimes be the case for prefabricated pipe racks, depending on material and labour costs, availability of fabrication yards and means of transport. The application of reinforced concrete elements or structures supporting equipment or pipe racks located in the FPZ shall be considered as an alternative to fireproofed steel, if economically attractive. Any assessments in this respect shall take into account lifecycle costs. However, the use of pre-stressed or post tensioned concrete elements for this purpose is not permitted within hydrocarbon processing plants. A normal weight concrete with a minimum thickness of 50 mm (2 in) (se Appendix 3) applied on structural and supporting steel in accordance with this DEP can provide a protection to the underlying steel during a hydrocarbon fire lasting 90 minutes according to UL 1709.
4.2.1.1
Environmental Controls A topcoat is normally not required for concrete fireproofing surfaces, but it can be beneficial depending on the environment. 1.
Weatherproofing is not required for concrete surfaces. For proprietary systems, a flexible membrane coating or sealant may be required depending on local circumstances and manufacturer’s recommendations.
2.
The top of fireproofing shall be protected by cover plates continuously welded to the steel structure in order to prevent ingress of rainwater between the members and the fireproofing as shown in (Appendix 3) and (Appendix 4). In mild or non-corrosive conditions mastic sealants may be used in lieu of cover plates with the approval of the Principal. Steel Columns shall be protected by a 2 mill (minimum) thick Glass Reinforced Epoxy (GRE) (also known as Fiber Reinforced Plastic (FRP) fabric adhered to concrete and steel surfaces as shown in (Appendix 4). The GRE material selection shall be in accordance with DEP 30.10.02.13-Gen. and it shall be approved by the Principal.
DEP 34.19.20.11-Gen. January 2010 Page 14 4.2.2
Normal Weight Concrete Fireproofing Standards and Specifications Concrete standards other than those listed below SHALL [PS] be approved by the Principal: 1. ACI 318 2. ACI 216.1/ TMS-0216 3. API 2218 4. EN 206-1 5. EN 1992 6. EN 197-4 7. EN 197-1 Concrete fireproofing materials/ methods other than those in accordance with the specifications listed below SHALL [PS] be approved by the Principal: 1. Cement ASTM C150, Type I or per EN 197-4. 2. Aggregate ASTM C33 with a maximum size of 10 mm (3/8 in). 3. Shotcrete materials, proportioning, and application ACI 506.2. 4. Shotcrete nozzlemen ACI 506.3 5. Shotcrete evaluation ACI 506.4
4.2.3
Concrete Fireproofing Installation Adequate ventilation shall be provided during and after application until the materials are dry.
4.2.3.1
Quality Control The preparation for, and the placing of, fireproofing material shall be supervised and inspected during application by trained and experienced personnel. Particular attention shall be paid to the following: 1. The condition of the steel surfaces to be fireproofed; 2. The quality and placing of mesh reinforcement; 3. The quality and application of the fireproofing material; 4. The joints between steel work and fireproofing where exposed to the weather; 5. Weatherproofing, where required. NOTE :
1. Protection against heavy rain, frost and other extreme weather conditions shall be provided during the application of fireproofing. 2.
In extremely dry and hot conditions, appropriated measures shall be taken to keep fire proofing moist until set. Measures such as screening the work area from radian sunlight and wrapping the finished work may be required, depending on the severity of the ambient conditions.
The following documents shall be approved by Principal prior to the start of any application of fireproofing: 1. Inspection and Test plan (ITP) 2. Quality control procedures, including Quality Control Records (QCRs) 3. Erection plan, including method statements covering application methods, temporary facilities to be installed for application and Health Safety Environment (HSE) aspects 4. Materials and workmanship specifications.
DEP 34.19.20.11-Gen. January 2010 Page 15 The applicator shall establish an inspection system to perform inspections and tests required to assure compliance with the requirements. Completed QCRs shall be handed over to the Principal before acceptance of the work 4.2.3.2
4.2.3.3
4.2.3.4
4.2.3.5
Surface Preparation 1.
Loose dirt, oil and grease present on the surface shall be removed to ensure good adhesion of the fireproofing to the primed or galvanized steel.
2.
The primer shall be compatible with the fireproofing to be applied.
Mesh Reinforcement 1.
Mesh reinforcement shall be wrapped around the steel section and retained firmly by clips. Welded clips shall be pre-fabricated, attached to steel and galvanized per steel supplier. Field stud welding requires approval of the principal. Overlaps shall be at least 50 mm (2 in) and shall be wired at approximately 150 mm (6 in) intervals.
2.
The minimum cover applied on any wire mesh installed SHALL [PS] be 25 mm (1 in)
3.
The longitudinal overlap shall be in the web face, and all overlaps shall be staggered so that no more than three layers of mesh are present at any one point.
4.
If spacers are required between the mesh and the steel surface (to keep the mesh in position during application of the fireproofing material) concrete spacer blocks may be considered as a cheaper alternative for studs welded to the steelwork.
5.
Reinforcement material used in normal weight concrete fireproofing shall be galvanized steel. In less severe conditions(e.g. dry arid climates outside the influence of cooling towers) or where specific site experience prove otherwise the Principal may consider the use of non-galvanized steel wire mesh and ties.
6.
Reinforcing mesh shall be 50 mm x 50 mm x 2.5 mm (min) [2 in x 2 in x 12 BWG (British Wire Gage)] welded galvanized steel fabric ASTM A 185. In mild or noncorrosive conditions non galvanized steel mesh may be used in lieu of galvanized mesh with the approval of the Principal.
Proportioning 1.
Cast-in-place concrete proportioning shall conform to ACI 318 or local design code and standard.
2.
Shotcrete proportioning shall conform to ACI 506.2 or applicable local design code and standard.
3.
Concrete SHALL [PS] be proportioned so that it develops a compressive strength of between 21 MPa (3000 psi) and 30 MPa ( 4500 psi) at 28 days with a maximum aggregate size of 10 mm (3/8 inches). Higher grades are not recommended due to spalling.
4.
Concrete mix SHALL [PS] include an air-entraining admixture if concrete is expected to be exposed to freezing conditions.
Shotcrete 1.
Installation of shotcrete shall conform to ACI 506.2, this DEP and applicable local design code and standard.
2.
Surface shall be troweled smooth after installation where required by Principal.
3.
Shotcrete nozzlemen shall be certified in accordance with ACI 506.3 or an equivalent local standard.
DEP 34.19.20.11-Gen. January 2010 Page 16 4.2.4
Concrete Fireproofing Inspection and Testing During Application
4.2.4.1
Cast-in-Place Concrete
4.2.4.2
4.2.5
1.
Testing shall conform to ACI 318 or applicable local design code and standard.
2.
One set of test cylinders / cubes shall be made for every 40 m (50 cu. yds.) of concrete (i.e. daily testing is not required). The Principal shall select the mixes to be tested.
3.
Slump shall be measured for every batch on every mix.
3
Shotcrete 1.
Evaluation shall conform to ACI 506.4 or applicable local design code and standard
2.
Test panels shall be 450 mm (18 in) long sections taken from shotcrete installed on the smallest structural member.
3.
If shotcrete is to be installed on vessel skirts only, test panels shall be 450 mm x 450 mm (18 in x 18 in) squares.
4.
One panel shall be tested (in addition to the qualification work) for each nozzleman, 3 for each 40 m (50 cu. yds.) of shotcrete placed (i.e. daily testing is not required).
Brickwork Fireproofing Common types of brickwork are sometimes used for fireproofing column and vessel skirts (See Standard Drawing S 20.002). However, for large and/or high skirts, proprietary systems or concrete (site applied by means of the guniting method) may offer a less expensive alternative if labour rates are high, provided a qualified Contractor is available.
4.3
PROPRIETARY MATERIAL FIREPROOFING
4.3.1
General Proprietary fireproofing systems offer weight saving compared with normal weight concrete fireproofing. This aspect is important in the case of modular construction and/or installation of fully dressed assemblies with fireproofed skirts. Proprietary systems may also be more economical for the fireproofing of large/high column and vessel skirts if labour costs for the alternative concrete or brickwork are high. However, the material cost for proprietary fireproofing systems is typically substantially higher than with concrete. Proprietary fireproofing systems may be recommended by the Contractor if they meet the following requirements: 1.
The proprietary fireproofing design SHALL [PS] be UL 1709 listed for structural steel fireproofing applications or equivalent local code.
2.
The Contractor shall review the recommendations in this DEP regarding proprietary materials and provide documentation confirming conformance.
3.
For equipment / pipe fireproofing, the proprietary fireproofing design SHALL [PS] have fire test certification (e.g., Lloyd's Register, NORSOK, etc.). The Contractor shall specify and ascertain that for this specific application the following additional requirements apply: a.
Define the end point metal temperature for the fire exposed piping/equipment. The maximum metal temperature corresponding to end of the specified fire duration shall be specified. This temperature shall be is less than the 538 °C (1000 °F) end point temperature used for structural steel.
b.
Assess how external inspections of the pipe/equipment will be conducted (i.e. will the material interfere with non-destructive metal thickness measurements or will inspection ports be required?)
c.
Confirm that the maximum expected piping/equipment operating temperature is within the design operating range of the proprietary fireproofing material.
DEP 34.19.20.11-Gen. January 2010 Page 17 NOTE:
Some proprietary fireproofing materials have a maximum operating temperature of 82 °C (180 °F). In these cases steam-out of such equipment would not be permitted.
d.
Confirm that the ambient environment (e.g., temperature, humidity, and weather protection) can be controlled within the manufacturer's specifications during the application and cure. This can be a challenge for field application on large equipment.
e.
Determine if torch (jet) fire criteria will be specified by the Principal.
f.
If thermal insulation is required for process reasons, this shall be installed over the proprietary fireproofing (Installing insulation under fireproofing introduces the risk of corrosion).
4.
The system has a proven track record, demonstrating durability under normal climatic conditions of at least 15 years without major problems or excessive maintenance. When applied in special climates such as sub-tropical, tropical, subarctic, arctic etc., the system concerned shall have demonstrated suitability for at least 10 years without problems or excessive maintenance.
5.
A weatherproof topcoat is normally required for most proprietary systems, and may only be omitted with approval of Principal. This weatherproof topcoat must typically be maintained if the performance is to be guaranteed. Any expected maintenance costs shall be included in the life cycle costs when comparing alternatives.
6.
The system is asbestos-free.
7.
The system shall not cause corrosion of the steel work when exposed to the expected ambient conditions (e.g. freeze/thaw or moisture).
8.
The toxicity of off-gasses and excessive production of smoke from the fire exposed proprietary fireproofing shall be assessed for applications where fireproofed equipment or structures are located indoors.
9.
A quality assurance program is established to verify the application complies with specifications. This is particularly important for epoxy based fireproofing materials.
10. The installation is carried out by qualified applicators (approved by the manufacturer) using equipment (approved by the Manufacturer) and is applied per the Manufacturer's procedures or project specific specifications, whichever is more stringent. 11. The surface preparation and any priming of the steel shall be per the Manufacturer's requirements. 4.3.2
Proprietary Light Weight Fireproofing Systems Light-weight cement/vermiculite based fireproofing materials may be considered where weight of fireproofing is a significant issue. These materials offer good fire protection performance. However because of the addition of vermiculate, these materials are not as impact resistant as concrete. Light-weight cement/vermiculate fireproofing may be used for structural steel fireproofing applications. This fireproofing material shall not be used for vessel skirts, or piping or equipment fireproofing unless approved by the Principal. Weather protection (e.g. a top coating) may be required.
4.3.3
Proprietary Intumescent and Sublimating Fireproofing Systems Proprietary fireproofing systems are often selected to reduce weight (e.g. for prefabricated equipment, assemblies or modular units) or to reduce costs due to faster application. Proprietary systems SHALL [PS] be subject to Principal’s approval. Typical proprietary systems include:
DEP 34.19.20.11-Gen. January 2010 Page 18
4.3.4
•
Intumescent coatings, which expand and form an insulating, layer when the temperature increases.
•
Subliming mastic materials
Installation and Preparation The installation contractor and the application equipment to be used shall be certified by the manufacturer of the fireproofing material and shall have prior experience with the material to be installed. For proprietary systems, the following apply:
4.3.5
1.
Fireproofing material SHALL [PS] be installed in manufacturer's instructions/specifications and this DEP.
accordance
with the
2.
Surfaces on which material will be installed shall be clean, dry and free of oil and other contaminants immediately prior to material installation.
3.
Surfaces shall be prepared by abrasive blast cleanings and priming systems, applied per specifications and manufacturer r ecommendations.
4.
Overcoat shall be installed if required by the material manufacturer.
5.
Suitable precautions shall be taken to terminate the fireproofing surface evenly and without overspray above the termination line.
6.
Material overspray on adjacent piping, equipment, etc. shall be avoided.
7.
The entire thickness of the material shall be installed in one continuous operation unless prohibited by manufacturer's instructions.
8.
Construction activities shall be restricted for a minimum of 24 hours in areas where materials that require curing have been installed and are vulnerable to mechanical damage prior to curing.
9.
Damage to the material shall be repaired after construction activities in the area are finished.
Inspection A non-destructive testing device or method shall be used to determine the required thickness gauge. 1.
Frequent random thickness measurements of the material shall be taken during application to ensure correct thickness.
2.
Final thickness shall be measured with an approved thickness gage after a minimum of 48 hours has elapsed.
3.
Epoxy-based proprietary systems may be very sensitive to ambient conditions and product ratios. Testing prior to and during application is required. A detailed inspection and testing plan shall be developed.
Application work shall be subject to inspection and approval by the Principal and material manufacturer.
DEP 34.19.20.11-Gen. January 2010 Page 19 5.
REFERENCES In this DEP, reference is made to the following publications: NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto. 2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS Non-metallic materials – Selection and application
DEP 30.10.02.13-Gen.
Thermal insulation (amendments/supplements to the CINI handbook)
DEP 30.46.00.31-Gen.
Protective coatings for onshore facilities
DEP 30.48.00.31-Gen.
Electrical engineering design
DEP 33.64.10.10-Gen.
Assessment of fire safety of onshore installations
DEP 80.47.10.30-Gen.
Standard Drawing: Skirts with fire-proof protection
S 20.002
Shell Inspection And Maintenance (SIAM) Civil Infobase document ‘Passive Fire Protection’ Inspection and Maintenance
Report GS 06.50615
AMERICAN STANDARDS Code Requirements for Determining Fire Resistance of ACI 216.1/TMS-0216 Concrete and Masonry Construction Assemblies Building Code Requirements for Structural Concrete
ACI 318
Specification for Materials, Proportioning, and Application of ACI 506.2 Shotcrete Guide to Certification of Shotcrete Nozzlemen
ACI 506.3
Guide to the Evaluation of Shotcrete
ACI 506.4
Issued by: American Concrete Institute (ACI) P.O. Box 9094 Farmington Hills, MI 48333 USA
Standard Specification for Steel Welded Wire Fabric, Plain, ASTM A 185 for Concrete Reinforcement Standard Specification for Concrete Aggregates
ASTM C 33
Specification for Portland Cement
ASTM C 150
Fire Tests of Building Construction and Materials
ASTM E 119
Issued by: American Society for Testing and Materials (ASTM) ASTM International; 100 Barr Harbor Drive P.O. Box C700 West Conshohocken, PA 19428 USA
UL Fire Resistance Directory: Fire Resistance Ratings Issued by: Underwriters Laboratories Inc. 333, Pfingsten Rd., Northbrook IL60062 USA
UL 1709
DEP 34.19.20.11-Gen. January 2010 Page 20
Fireproofing Practices in Petroleum & Petrochemical Processing Plants
API PUBL 2218
Issued by: API Publishing Services 1220 L Street, N.W. Washington, D.C. 20005 USA
EUROPEAN STANDARDS AND INDUSTRY PRACTICES Model Code for Service Life Design
FIB Bulletin No. 34
Issued by: Fédération Internationale du Béton (FIB) Case Postale 88 CH 1015 Lausanne Switzerland
Cement – Part 1: Composition, specifications and conformity criteria for common cements
EN 197-1
Part 4: Compostion, specifications and conformity criteria for low early strength blast furnace cements
EN 197-4
Concrete – Part 1: Specification, performance, production and conformity
EN 206-1
Eurocode 2: Design of Concrete Structures
EN 1992
Issued by: CEN Secrétariat Central Rue de Stassart 36 B-1050 Brussels Belgium
INTERNATIONAL STANDARDS Tests for electric cables under fire conditions - Circuit integrity - Part 21: Procedures and requirements - Cables of rated voltage up to and including 0.6/1.0 kV Issued by: Central Office of the IEC 3, Rue de Varembé CH 1211 Geneva 20 Switzerland Copies can also be obtained from national standards organizations.
IEC 60331-21
DEP 34.19.20.11-Gen. January 2010 Page 21 APPENDIX 1
1.0
PROJECT DOCUMENTATION REQUIREMENTS
DOCUMENTATION REQUIRED THROUGH THE PROJECT PHASES The following key Technical, Quality and HSSE documents are required during the course of the project to ensure correct realization of the works covered by this DEP. They are therefore required for Projects as a part of compliance with this DEP. Figure 1 illustrates the process of the development of the key documentation.
1.1
DEFINITION PHASE The Project Specification shall be developed by the Contractor and include: • • • •
Amendments to DEP (signed off by the appropriate Principal Technical Authority); Definition Technical Specification - Design; Reference to Standard Drawings on the Shell Standards Forms Website; Definition Technical Specification - Materials and Workmanship.
The above documentation shall be based on the DEP's and Model Technical Specifications contained in the Shell Standards Website to be provided by the Principal. Reference shall also be made in the Project Specification to Standard Inspection and Test Plans (ITP) and Quality Control Records (QCR) contained in the Shell Standard Website for use in the Execution Phase of the Project. 1.2
EXECUTION PHASE The following SHALL [PS] be produced based on the Project Specification: • • • • • • • • •
1.3
Execution Technical Specification - Design Execution Drawings (Approved for Construction) Execution Technical Specification - Materials and Workmanship Method Statement HSE : TS (Task Statement), JSA (Job Safety Analysis) and RA (Risk Analysis) Execution Quality Plan Execution Quality Control Procedure Execution Inspection and Test Plans Execution Quality Control Records
OPERATIONAL PHASE During the Operational Phase the f ollowing shall be used • • • • • • • • •
RBI (Risk Based Inspection) Procedure RCM (Reliability Centered Maintenance) Procedure Maintenance Technical Specification Maintenance Quality Plan Maintenance Quality Control Procedure Maintenance Inspection and Test Plans Maintenance Quality Control Records Maintenance Method Statement HSE : TS (Task Statement), JSA (Job Safety Analysis) and RA (Risk Analysis)
DEP 34.19.20.11-Gen. January 2010 Page 22
Figure 1:
Development Process of the key documentation
DEP 34.19.20.11-Gen. January 2010 Page 23 APPENDIX 2
INSPECTION AND MAINTENANCE AFTER APPLICATION OF FIREPROOFING
Inspections on fireproofing may be carried out every 3 to 10 years, depending on exposure conditions, the age of the plant and type of fireproofing applied. In addition to the details covered in this Appendix, the Principal has access to other resources (e.g. Civil InfoBase) to assist in the evaluation and maintenance of Fireproofing. Corrosion Under Fireproofing (CUF) can occur, especially if rainwater gets between the fireproofing and underlying steel. Regular inspection is required to prevent serious corrosion, especially on critical column and vessel skirts. For concrete fireproofing to adequately perform its function the fireproofing concrete shall be without cracks, honeycombs, delamination, or spalling. Attention shall be paid to the following: •
Surface cracking/distortion/deterioration
•
Blockage of ventilation holes of weep holes by debris
•
Absence of and/or deterioration of rain shields
•
Exposure to contamination such as salt water of chemical spill
•
Heat and/or fire damage.
•
Growth of fungus especially on cold column or vessel skirts.
Depending on the outcome of the inspections it maybe decided to remove the fireproofing locally to assess the condition of equipment supports, skirts or structural steel. In this case, it is recommended to include the toe section of fireproofed skirts, the annular ring of the base plate and the anchor bolts in the inspections. Non-destructive testing of column and vessel skirts underneath fireproofing may be performed by means of the Pulsed Eddy Current (PEC) method.
DEP 34.19.20.11-Gen. January 2010 Page 24 APPENDIX 3
TYPICAL DETAILS OF CONCRETE FIREPROOFING OF STRUCTURAL MEMBERS
DEP 34.19.20.11-Gen. January 2010 Page 25 APPENDIX 4
STRUCTURAL COLUMN DETAILS
DEP 34.19.20.11-Gen. January 2010 Page 26 APPENDIX 5
PIPERACK DETAILS
DEP 34.19.20.11-Gen. January 2010 Page 27 APPENDIX 6
CONCRETE FIREPROOFING OF VESSEL SKIRTS
DEP 34.19.20.11-Gen. January 2010 Page 28 APPENDIX 7
CONCRETE FIREPROOFING OF VESSEL STRUCTURAL SUPPORT LEGS
Last page of this DEP
