LIST OF CONTENTS
1.
LPG and Flammable Gas Vessel Protection -
The Problem
-
The Solution
2.
Chartek Epoxy Fireproofing – Key Features
3.
Chartek Epoxy Fireproofing – Application Procedure
4.
Reference List
5.
Standards for the protection of LPG Storage Vessels
6.
Chartek Epoxy Fireproofing – Technical Data
7.
Chartek Epoxy Fireproofing – Material Safety Datasheets
8.
Contacts for further information
LPG and Flammable Gas Vessel Protection The Problem Pressurised hazardous gas containing vessels, particularly LPG (Liquid Petroleum Gas), are very susceptible to fire exposure.
The heat from the fire can cause the liquefied gas
contained in the vessel to boil and expand, creating sufficient pressure in the vessel resulting in a BLEVE (Boiling Liquid Expanding Vapour Explosion). The results of a BLEVE can be devastating and damage caused by the resulting fireball and flying debris can be extensive.
In many countries legislation has now been passed requiring that LPG and hazardous gas containing vessels be protected by sound methods including passive fire protection. Over the years it has been shown that cement based fire protection materials are not the answer due to the likelihood of corrosion forming under the cement based material which, in itself, is a hazard which can damage the integrity of the vessel.
The Solution By combining corrosion protection and fire protection in one coating, the Chartek family of epoxy intumescent fire protection materials provides a fully qualified system for protection of LPG and hazardous gas vessels. Key criteria and qualification for Chartek materials include:
•
A fully tested and qualified system – Chartek materials have been extensively tested for LPG protection to various standards including BAM, Germany; GASAFE, France and DOT, USA. In addition, Chartek materials are fully tested for structural applications including fire protection of vessel legs and supports.
•
Corrosion protection and weatherability – Chartek materials are tested to various corrosion protection and weathering standards and by methods including NORSOK M501 with subsequent fire test exposure. In addition, as part of both the BAM and GASAFE programmes, Chartek materials were tested for their corrosion protection capabilities as well as durability.
•
Durability and damage resistance – Chartek has had over 25 years proven weatherability in some of the most hostile environments globally in both onshore and offshore locations.
Chartek materials have excellent resistance to water
uptake, which is a severe restriction to a number of epoxy intumescent materials. In addition, the physical properties of Chartek mean it is highly resistant to mechanical damage, including explosion up to 1.5 bar overpressure.
•
Resistance to spill – Chartek is resistant to low temperature spill of LPG and LNG. It also has excellent resistance to most chemicals, acids and hydrocarbons.
•
Low weight impact – having a spray applied density of only 1.0g/cc as well as minimal installation thicknesses; the weight impact of Chartek to an LPG vessel is minimal. As an example, on a medium-sized LPG sphere having a surface area of 500m2 the installed weight of Chartek would typically be 3000kg versus 13000kg for a lightweight cementitious material.
•
Track record – in recent years in excess of 120 LPG vessels, including spheres of up to 25 metres in diameter, have been protected with Chartek at various installations in Europe and elsewhere.
•
Application Quality – Chartek materials are applied only by qualified application companies fully trained by International Paint Ltd, to ensure high quality application.
Due to the aforementioned capabilities of the Chartek materials, a proven track record and support given to Chartek by International Paint, the product continues to be a qualified material of choice for LPG retrofit and new construction fire protection requirements.
Chartek ® and LPG Protection Chartek fireproofing materials have over 20 years experience in protecting LPG tanks in applications worldwide.
In fact, since 1989 over 100 large LPG tanks
(diameter>12m) have been protected by Chartek in Europe (major clients include Shell, BASF, Atochem, BP, Total, Veba, DEA, ICI, ROW, RVI, AGIP amongst others). Legislation across the European Union, but predominantly in Germany, France and the UK, has required that LPG operators address the fire protection of LPG tanks in refineries,
petrochemical
plants
and
gas
distribution
outlets.
Specification
requirements have varied from 90 minutes to 4 hours protection with varying fire heat load requirements to cover hydrocarbon, jet fire and low heat flux conditions (75kW/m2). International Paint Ltd have used leading fire test agencies in Germany, France and the UK to qualify the use of Chartek for LPG protection ensuring that Chartek has been more extensively tested than any other fireproofing material.
Chartek fireproofing is the ideal material choice for protection of LPG tanks. In comparison to other fireproofing materials, International Paint Ltd can provide proof that Chartek provides 100% maintenance free service with no corrosion or loss of fire protection integrity for the design life of the plant. Chartek’s formulation has been especially developed to make it safe, quick and easy to apply. It also has 0% VOC and no discernable smell. In conjunction with our proprietary HK-1 fibre scrim, it is regarded by Applicators worldwide to be the most user-friendly material on the market. In summary, this means good aesthetics and a clean hassle free application. For further information, a brief application procedure is attached.
In combination with the market leading Chartek product, International Paint Ltd supply a world beating technical back-up service. From our offices in the US or UK, technical support is available almost 24 hours a day. In combination with this, full field service support is provided where a International Paint Ltd technical representative, fully qualified in the application of Chartek, will visit site at regular intervals to support the application. To back all of this up, International Paint Ltd have an extensive worldwide network of local agents specially trained by International Paint Ltd to provide technical and sales support in the local language.
In summary, the above shows that International Paint Ltd is working 24 hours a day to provide the very best fireproofing solutions to the market. This is why Chartek is the first choice of most LPG and petrochemical companies worldwide. For more information please do not hesitate to contact us at the address detailed above.
Chartek ® - Key Features
•
100% maintenance free fireproofing system with over 20 years experience in protecting LPG tanks worldwide
•
Widely tested at renowned certification authorities worldwide including Lloyd’s in the UK; DNV in Norway; BAM in Germany; GASAFE in France and Underwriters Laboratory in the USA. Chartek has been specifically tested for use with LPG at BAM, GASAFE and the HSE in the UK
•
Able to provide both corrosion protection and fire protection in a single coating. Both real time and accelerated weathering data to prove long term durability of the system
•
NORSOK M-501 testing in Norway by the major oil companies has proven that Chartek, compared to other fireproofing materials is a lot more environmentally resistant, does not require a topcoat to maintain its performance and has no discernible maintenance costs attached to it during the life of the plant
•
Proven jet fire capability in the widely recognised full scale jet fire test facility in Spadeadam, Cumbria, UK
•
Compatible with existing water deluge or remote water monitors. Proven ability to withstand the erosive nature of active protection systems
•
Chartek, applied at typical thickness of between 5mm and 7mm, will not contribute a high factor of insulation in the absence of fire
•
Charcast™, a castable form of Chartek, can be moulded to protect man ways, valves, piping and wind bracing. This system will provide the same properties of abuse resistance as spray applied Chartek. The covers can be removed and replaced without damage
International Paint Ltd, the World’s leading supplier of thick film epoxy intumescent coatings, provide field service to audit the quality of application. All Applicators undergo training prior to being qualified to apply Chartek materials. International Paint’ approach to field service is in accordance with their certification as an ISO9001 supplier of fire protection materials •
Low added weight.
For typical LPG applications the weight contribution for
Chartek will be 6.00kg/m2 compared to 34kg/m2 for conventional cementitious fireproofing products or 7.08kg/m2 typically for alternative epoxy systems.
Chartek ® Recommended Application Procedure 1.
Abrasive blast clean the steel surface to Sa 2½ and apply a International Paint Ltd approved primer system. Check with International Paint Ltd for approved systems and recommended dft’s.
2.
Apply first coat of Chartek fireproofing, typically 2-3mm for LPG protection. See Photograph 1.
3.
Trowel first coat of Chartek fireproofing to ensure surface is fully wetted out. See Photograph 2.
4.
Apply HK-1 (M)TM mesh reinforcement ensuring 50mm overlap between adjacent strips of reinforcement.
Ensure adhesion to the Chartek by lightly
rolling the HK-1 (M) into the Chartek. See Photographs 3 and 4.
5.
Apply a final coat of Chartek fireproofing ensuring full mesh coverage. Lightly roll the surface to obtain a non-dirt fast finish. See Photographs 5 and 6.
Photograph 1
Photograph 2
Photograph 3
Photograph 4
Photograph 5
Photograph 6
REFERENCE LIST CHARTEK USE IN THE EUROPEAN LPG MARKETPLACE
To meet the growing legislative requirements for protection of LPG storage vessels, Chartek fireproofing has been tested to key European standards. Chartek is now the most extensively used passive fire protection material for LPG application in Europe. The following are some of the main installations.
COUNTRY
LOCATION
YEAR
INSTALLATION ON
Belgium
Tessenderlo Chemie
2003
2 spheres
France
ESSO Gravenchon
2003
1 sphere
Germany
Veba Refinery, Gelsenkirchen
2003
2 spheres
Italy
Sarpom Trecate
2003
2 spheres
Italy
EniChem Brindisi
2003
2 spheres
Italy
EniChem Brindisi
2002
3 spheres
Switzerland
Petroplus (Shell) Niederhasli
2002
Sphere legs
Belgium
BRC
2001
4 spheres
Italy
EniChem, Sarroch
2001
Italy
EniChem Brindisi
2001
3 spheres and 2 bullets 4 spheres
Italy
EniChem, Marghera
2000-2001
2 spheres
Germany
Bayernoil
2000
2 spheres
Germany
Elenac
2000
2 spheres
Italy
Montell Terni
1999-2000
2 spheres
France
Elf Atochem, Notre Dame de Gravenchon
1999
2 large bullet tanks
COUNTRY
LOCATION
YEAR
INSTALLATION ON
Germany
OMV, Burghausen
1997-1999
6 spheres
France
Elf Atochem, Balan
1997-2000
3 spheres
France
Elf Atochem, St
1997-2000
5 spheres
1997
3 spheres
Germany
Condea, Gelsenkirchen Shell, Godorf
1996-1997
3 spheres
Germany
EC Dormagen
1996-1997
20 spheres
Germany
ERN, Neustadt
1995-2000
8 spheres
Germany
ROW, Wesseling
1995-2000
22 large spheres
Germany
ERE, Wintershall
1994-1996
8 spheres
Germany
Hoechst, Ruhrchemie
1994-1996
Germany
RVI, Ingolstadt
1993-2000
France
ICI, Chocques
1992
3 spheres and 6 bullets 14 spheres and 4 bullets 1 large ethylene oxide sphere
UK
BP Grangemouth
1992
2 large spheres
Belgium
BASF, Antwerp
1991-1993
4 spheres
UK
Associated Octel, Ellesmere Port Ludwigshafen
1991-1994
6 reactor vessels
1989-1994
5 spheres and 1 large bullet tank
Auban Germany
Germany
Synopsis Chartek has been applied to over 140 spheres and structures in Europe in the last 10 years. Predominant in the success of Chartek has been the demonstrable long term track record, both in the aggressive climate of the North Sea, Middle East, Far East and United States.
Standards for the Protection of LPG Storage Vessels
Since the mid 1970’s there has been concern about fire protection pressurised storage or transportation of Liquefied Petroleum Gases (LPG). In the United States the National Fire Protection Association Standard, NFPA-58-84, “Storage and Handling of Liquefied Petroleum Gases” recommends several methods for protection LPG storage when the aggregate of 4000 liquid gallons (15.1m 3) are subject to exposure from a single fire. Among the several methods recommended for the protection of LPG storage vessels is the use of thermal insulation systems (passive fireproofing). NFPA-58 Standards require that the LPG storage vessel be protected to a maximum shell temperature of 8000 oF (4270oC) for 50 minutes. The 1985 edition of NFPA-58-84 establishes a test procedure in Appendix H, “Procedure for Torch Fire and Hose Stream Testing of Thermal Insulation Systems for LP-Gas Containers”. This test procedure is a modified version of the Department of Transportation’s Railroad Tank Car Program, discussed below.
In the 1970’s, following a number of serious incidents involving railroad tank cars while being used to transport LPG, the United States Department of Transportation (DoT) established a requirement that a certain class of railroad tank car used in the transportation of LPG be insulated. The requirement was to limit the steel shell temperature of the tank car to 8000oF (4270oC) when exposed to a hydrocarbon pool fire for 100 minutes and an impinging LPG ‘torch fire’ for 30 minutes. The DoT sponsored a test programme and qualified several ‘fireproofing’ materials for this type of protection. International Paint’s Chartek 59 was one of the products qualified under that program. For a number of reasons, the actual LPG tanks of railcars used fibre insulation and an outer (second) steel shell. However, a significant amount of fireproofing was used on the manway (safety valve and fill connections) housing and the sub-sills (tank saddles). Chartek 59 was (and continues to be) used extensively on railroad tank cars used in the transport of LPG.
In the early 1980’s The National LP Gas Association (an industry association in the United States) tried to use the DoT railroad tank requirements to apply to stationary LP Gas storage vessels. As part of this effort, Chartek 59 was tested at the DoT test facility and that test was witnessed by Underwriters Laboratories, Inc (UL). UL issued a witness report (which was used because there was no ‘standard’ to issue a test report). This procedure was never accepted by the LP Gas industry nor was it ever extensively used.
The American Petroleum Institute (a hydrocarbon process industry association), in one of its ‘Operating Practices’, recommended that when LP Gas storage vessels required fireproofing the ANSI/UL 1709 2-hour rating be used. In that the ANSI/UL 1709 is a structural rating (with a failure temperature of 1000 oF (538oC), there is no correlation between that rating and an LP Gas storage vessel (with a failure temperature of 800 oF (427oC)). The API recommended operating practice was never widely used and has since been abandoned.
