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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:

Sourcing and supply of materials


Shipping and site logistics Worldwide application and manpower supply using own pool of qualified certified applicators Verifiable audited performance records for the entire contract

Head Office Gloucester (UK) Research & Development Gloucester (UK) Manufacturing Gloucester (UK) Leeds (UK) Dubai (UAE) Sales Gloucester (UK) Abu Dhabi & Dubai (UAE) Singapore Houston (US) Aktau (KZ)
Houston (USA) Singapore (Asia)

Leeds (UK)

Abu Dhabi & Dubai

(UAE)
Gloucester

(UK)

Aktau (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 200C for the duration of a 60 minute jet fire. Actuator will be limited to a maximum surface temperature of

100C 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 400C. 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

800 Temperature C

Cellulosic Curve

600

A Category ISO834 1000 C at 90-100 min

400

200

* Max Temp. ** Erosive Force


0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240

0 Elapsed Time (min.)

Industry Design Fire Curves


1200

1000

800 Temperature C H - Curve 600

H Category UL1709 1000 C at 7 min

Cellulosic Curve

400

200

* Max Temp. ** Erosive Force


0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240

0 Elapsed Time (min.)

Pool Fire

Image from Sandia National Laborites

Industry Design Fire Curves


1600

1400

J Category 1350 C at 2-5 min

1200

Temperature C

1000 H - Curve 800 J - Curve

600

Cellulosic Curve

400

200

* Max Temp. ** Erosive Force


0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240

0 Elapsed Time (min.)

Jet Fire Testing - ContraFlex

Part 2 Passive Fire Protection Systems

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

HEAT Source > React to heat > chemical reaction will start at around 65-80C.

Stage 2

Reaction > Material turns soft > emits gases and intumesce & expand into carbonaceous char

Stage 3

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 - 177m Glass or ceramic microspheres Actual microspheres at 200x magnification

Property

Value

Compressive Strength @ 20oC


Expansion Co-efficient Temperature resistance Blast overpressure resistance Standard thickness Thermal Conductivity @ 20oC Flammability Smoke Generation

18.3 MPa
20.7 x 10-6 From -196C to 185C 4.2 bar 34mm 0.054 Wm-1K-1 Zero (No spread of flame) Negligible

Features
Jet Fire Protection Thermal Insulation Thermal Conductivity

Epoxy Intumescent
Certified Low 0.213 W/mK

ContraFlame
Certified High 0.05 W/mK

Service Temp Range

-30C to +80C

-196C to +185C

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. (-196C to +185C) 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, (+185C to -196C) 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 (+185C to 196C) 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 (+185C to -196C) 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 = 64C 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 (+185C to 196C)

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 1350C (jet fire) = 122.9C

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 122.9C
Blast overpressure resistance 2.57bar

Thermal conductivity 0.032W/m.K


Temperature resistance from -60C to 1,350C

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/m at 50mm

Standard (-36 to +260 C)

High (-36 to +550 C)

Tested to ISO 22899-1 standard and certified by Lloyds Register (certificate number: SAS F090134) Thinner construction two thirds thickness of conventional systems Weight reduction Tailor-made manufactured anywhere in the world Simplified installation technique Full technical support

ContraFlex Construction
cover:
Designed to withstand environmental exposure temperature, weather, marine conditions 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:

Easy to remove yet resistant to environmental exposure and tampering


Inner jacket wired and riveted

Outer jacket uses high temperature Velcro and stainless steel clips

ContraFlex - Key Features

ContraFlex Typical Applications


Valves and Actuators Flanges Cable trays, conduits and instrument lines

Electrical junction boxes and circuitry


Air receivers Process vessels

Hot Pipework

Jebel Ali, Dubai

Mussafah, Abu Dhabi

Property Jet fire resistance (ISO 22899-1) Back face temperature rise Temperature resistance Blast overpressure resistance Standard thickness Thermal Conductivity

Value J120 (standard thickness) 122.9C From -60C to 1,350C 2.57bar 61mm 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 1,100C hydrocarbon fire for one hour with the internal junction box temperature not exceeding 120C.

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: Office: email: Web :

+ 44 (0) 7824 845 910 + 44 (0) 1453 512 144 Asaf.Hisherik@aisplc.com 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: sales@aisplc.com