materials

JF211

Total Solutions for the Oil and Gas Industries

materials JF211

ContraTherm JF211 is a multi-functional material system based on a unique phenolic syntactic and glass reinforced composite technology, which combines:

DESCRIPTION

The heart of the JF211 system is Alderley Materials ContraTherm C50, a cold curing syntactic (i.e. not blown) foam offering: Low thermal conductivity 0.08Wm K
-1

SYNTACTIC PHENOLIC FOAM

Jetfire passive fire protection to 90 minutes Hydrocarbon pool fire PFP Closed cell structure

Low density 500 kg/m

-1

Thermal Insulation

Excellent fire stability

Wide service temperature range (-196oC to +185oC) Low water absorption Resistance to extreme thermal shock (DT=300oC in 10 mins.) Excellent resistance to marine environments Excellent impact resistance

Tolerance to elevated temperatures (185oC) Robust energy absorbing structure Excellent water resistance Ambient curing Will not propagate flame

Tolerance to very low temperatures (-196oC) Low smoke and fumes in the fire condition

The ContraTherm JF211 Passive Fire Protection (PFP) system is backed by five years of research, testing and field experience. It is a truly passive system not relying on any chemical or physical changes on exposure to fire. Consequently, the material has a much wider tolerance to service temperature than conventional PFP materials.
USES

100m

Hot three phase separators Hot slug catchers Hot risers Hot flare stack knock-out drums

Underdecks

Syntactic phenolic foam

Flare stacks Pipework

Steel structures subject to thermal shock. e.g. LNG plant

C50 has a closed cell structure and is therefore highly resistant to water permeation in the event of any accidental damage and exposure to water.
PHENOLIC LAMINATE TOPCOAT

The entire JF211 system is phenolic resin based. Phenolics were selected by Alderley Materials Ltd as the acknowledged first choice resin system for elevated temperature service. Phenolic materials are widely used in high temperature applications, such as brake lining and heat shields, and have excellent performance on exposure to fire with regard to both durability and smoke or toxic fume emission.

RESIN BASE

The ContraTherm JF211 system includes an all-phenolic two part topcoat developed by Alderley Materials Ltd which comprises 4-5mm of glass reinforced C1001 phenolic resin system. Both ContraTherm C50 and C1001 are cold curing systems. This composite topskin is applied to the surface of the ContraTherm C50 foam forming an extremely robust outer skin with high resistance to jet-fire ablation. The cured ContraTherm JF211 system is normally finished with a decorative paint finish.
CORROSION RESISTANCE

Phenolic resins have been used in high performance corrosion resistant coatings for many years. ContraTherm continues this tradition by displaying exceptional chemical resistance to not only salt water, oils and solvents, but also acids and other aggressive chemicals. ContraTherm may be applied directly to primed steel surfaces to provide a highly effective, high integrity corrosion barrier without the need for full multi-coat paint system.

ContraTherm systems have been extensively tested by Alderley Materials Ltd in various modes in both our in-house facilities and at external fire laboratories in order to demonstrate their reaction to fire in terms of integrity and smoke or fume emission.

FIRE TESTING

The JF211 system has also been exposed to the jet-fire resistance test (OT1 95 634), the most aggressive and demanding of all fire scenarios, at the HSE laboratory facility, Buxton, as detailed below.
JET FIRE PERFORMANCE

The planar jet-fire test was conducted on a test specimen insulated on the back face with 50mm of 110 kg/m3 mineral wool. This represents the most demanding condition by simulating a closed vessel application. The test specimens in both cases also included a repair joint through the full thickness of the JF211 system enabling certification of a system repair as well as the as-new condition. The very low temperature rise associated with the JF211 system (as seen in the graph opposite) makes possible operating temperatures as high as 185oC whilst still assuring safe substrate temperature during the jet fire. The pictures below illustrate the progress of the 90 minute tubular section jet-fire test carried out by Alderley Materials Ltd on the JF211 system. After the test, the system was found to be substantially intact with the remaining char being at least 70% of the original system thickness. The C1001 still remained as a protective skin over ca. 95% of the surface of the test piece.
ADVANTAGES

The JF211 system has been tested for jet-fire resistance for planar and tubular steel substrates. Certification by both Lloyds and DNV are available.

ContraTherm JF211 has been successfully tested for 45 minutes on planar steel and 90 minutes on tubular steel at a total application thickness of 35mm. In each case the steel temperature remained well below the normal critical temperature of 400oC.

The function of jet-fire PFP, such as JF211, in the fire condition is to prevent the tensile strength of substrate material from falling below the design stress as a result of elevated temperature. The permissible protection time provided by PFP is limited by the temperature rise produced during the fire, superimposed on the operating temperature of the substrate at the start of the fire.

The ContraTherm JF211 system provides an extremely robust finish offering a range of advantages including:

280 240 200 180 Tem p er at u r e ( C ) 160 140 120 100 80 60 40 20 0 -20
o

JET FIRE RESISTANCE

Totally passive PFP Thermal insulation for heat conservation and/or personnel protection Joint-less corrosion barrier suitable for hostile environments Extremely robust energy absorbing system No metallic cladding system required Water and vapour resistant No structural supports required Ambient curing Simple method of application

10

20

30 Time ( minut es)

40

50

60

Easily repairable at ambient or elevated process temperatures Easily removed for inspection or repair Low maintenance Heat conservation performance not susceptible to impact damage Fire performance not affected by water Wide service temperature range - 196 to 185oC Tolerance to extreme thermal shocks Low smoke and fumes in the fire condition Acoustic insulation

before

during

after

Effective cost savings can be gained by:

COST SAVINGS

The 30mm of ContraTherm C50 is normally applied as a single layer even on overhead surfaces.

Blow down times Using the extensive protection offered by the JF211 system blowdown allowance times can be extended

C1001 Tie Coat C50

Layout The fire protection available from the JF211 system provides the designer with a greater degree of freedom on layout with potential savings on pipework

Lifetime Cost The JF211 system provides seamless high integrity corrosion protection reducing lifetime costs in hostile environments. The extremely robust nature of the system ensures a low maintenance cost for the system and high resistance to accidental damage from adjacent operations.
EXPERIENCE

Primed Steel

Alderley Materials Ltd provide training and supervision/inspection for each application. Alderley Materials Ltd also offers a complete supply and apply service which provides the advantage of a clear single-point responsibility and improved technical and contractual liaison.
CONTRATHERM JF211 SYSTEM DATA
TIECOAT TIECOAT THICKNESS TOP COAT TOP COAT THICKNESS DENSITY THERMAL CONDUCTIVITY YOUNGS MODULUS C50 C1001 GRP C50 C1001 GRP C50 C1001 GRP ContraTherm Phenolic Tiecoat 150m ContraTherm C1001/ Phenolic GRP 4-5mm 500kg/m3 1650 kg/m3 0.08 Wm-1K-1 0.20 Wm-1K-1 463 MPa 6 x 103 MPa 20.3 x 10-6/ C 0 15 x 10-6/ C 1% 2% 4.2 MPa / 622 MPa J90 & as required (thickness dependent) BS476 Pt. 7 Class 1: IM0 A16 (653) Pass BS6853 Category 1 NES713 Toxicity Index <5 > 80% + 185 C
(Alderley Materials can design bespoke systems for use at much higher service temperatures)
0 0

ContraTherm and phenolic composite GRP have been successfully applied to 400 process packages requiring PFP and heat conservation for offshore oil production in highly exposed situations. Projects include: Shell Pelican BP Foinaven Britannia Alliance Saga Varg Statoil sgard A Conoco Belanak Statoil sgard B Amerada Hess South Arne Elf Elgin Franklin Phillips Bayu Undan Phillips Jade Platform Chevron Texaco Sanha

Each part of the JF211 system is supplied as cold curing, two part packs. The entire system is applied by simple trowel and roller techniques. A full ContraTherm JF211 system therefore consists of: 1 Shot-blast steel primed with a high performance primer (where thermally sprayed aluminum (TSA) is used, a ContraTherm phenolic primer is specified).

APPLICATION

EXPANSION COEFFICIENT C50 C1001 GRP TENSILE STRAIN TO FAILURE C50 C1001 GRP SHEAR STRENGTH / MODULUS JET-FIRE RESISTANCE SPREAD OF FLAME SMOKE GENERATION FUME GENERATION OXYGEN INDEX OF TOPSKIN MAXIMUM SERVICE TEMPERATURE

2 ContraTherm Tie Coat (provides a tacky interlayer to hold the syntactic foam and give good bond integrity)

3 ContraTherm C50 normally at 30mm thickness (see later)

4 ContraTherm C1001 phenolic composite top-skin (normally 4-5mm thick) 5 Decorative finish (e.g. single pack acrylic or epoxy)

MINIMUM THERMAL SERVICE TEMPERATURE IMPACT RESISTANCE WATER ABSORPTION WATER PERMEATION COMPRESSIVE STRENGTH

- 196 C Blast tested to 4.2 bar < 1% wt. Impermeable C50 5Mpa JF211 system 30MPa

Application of ContraThermJF211

ContraTherm coated process vessels on FPSO

Alderley Materials Ltd

Rigestate, Station Road, Berkeley, Gloucestershire, GL13 9RL, UK. Tel: +44 (0) 1453 511 600 Fax: +44 (0) 1453 810 108 Email: materials@alderley.com