How Passive Fire Protection (PFP) Works

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1

2 Objectives How passive fire protection (PFP) works Testing and certification requirements for epoxy PFP Main factors that determine PFP thickness Advantages of Pyroclad X1 Estimating a project Sample specification Application methods and equipment

3 How Passive Fire Protection (PFP) Works

4 Why Protect Steel? To protect assets Maintain points of egress for personnel Prevent structural collapse Save lives

5 Why Does Steel Require PFP? Steel looses load carrying capacity as the core temperature increases Steel begins to deform at 427 C (800 F) PFP extends the time it takes to reach the failure point Limiting temperature is project specific (200 C C / 392 F F) Most projects require 400 C limiting temperature

6 Pyroclad X1 Description 100% solids (solvent free) 2 component epoxy PFP Jet fire and hydrocarbon pool fire protection for structural elements, beams, columns, bulkheads, underdecks and risers. Light weight / Low density: 1.03 g/cm³ High Temp Mesh (carbon fiber)

7 How Pyroclad X1 Works Applied like a paint in multiple passes (5 mm/coat) Durable finish that can be topcoated Passive coating under normal conditions When exposed to fire, Pyroclad X1 intumesces, or swells up to 10 times original thickness producing a heat blocking char Reaction insulates steel for a given amount of time

8 Testing And Certification

9 Fire Environments Jet Fire Sonic velocity, high pressure torching Simulates burning pressurized burning gas Erosive fire environment ISO (onshore / offshore) Hydrocarbon Pool Fire Non-torching hydrocarbon fire Simulates burning pool of hydrocarbon fuel UL 1709 (onshore) ISO 834 / BS-476 (offshore)

10 Fire Testing Curves Temp ( F ) Temp ( C ) Jet Fire (ISO ) Hydrocarbon Fire (UL 1709) Hydrocarbon Pool Fire (BS-476/ISO 834) Time (minutes)

11 Testing Requirements Hydrocarbon fire testing (simulates pool of burning hydrocarbon fuel) -IS0 834 / BS 476 Part Appendix D (offshore) -UL 1709 (onshore) Jet fire testing (simulates pressurized burning gas) - IS Environmental testing (simulates atmospheric exposures) - NORSOK M-501 System 5A (offshore) - UL 1709 Environmental test program (onshore) Performance testing (explosion resistance and hose stream resistance) - Overblast explosion testing - NFPA 58 Annex H hose stream testing Physical property testing - Compressive, flexural, tensile, impact, hardness, thermal conductivity, adhesion/cohesion, flame spread/smoke development, moisture absorption

12 Hydrocarbon Fire Testing (ISO 834/BS-476) Tested For: - I-Sections - Tubular Sections - Divisions(Bulkheads/Decks)

13 Jet Fire Testing (ISO 22899) Tested For: - I-Sections - Tubular Sections - Divisions(Bulkheads/Decks)

14 NORSOK M-501 Rev 6 Testing Exposed to 25 cycles accelerated aging (ISO 20340) Corrosion/bond strength panels / Fire test panels Each 168 h (1 week) cycle includes: 3 Days 3 Days 1 Day U VA 340 Bulb ISO 7253 Salt Fog 5% NaCl at 35 C 4 hrs. UV at 60 C / 4 hrs. Condensing at 50 C Thermal Shock at -20 C 72 h of UV/condensing moisture (ISO 11507) 72 h of salt spray (ISO 7253) 24 h thermal shock at -20 C

15 NORSOK M-501 Rev 6 Testing Pass/Fail Criteria: Corrosion creep < 3mm Adhesion > 3 Mpa Fire performance within 10% of non aged sample

16 NORSOK M-501 Rev 6 Fire Testing Fire tested in both vertical and overhead configurations Aged samples performed within 10% of non-aged samples in side by side test

17 Passes NORSOK M-501 Rev 6 Full pass without a topcoat (only 0.2% moisture uptake) Minimal corrosion creep: < 3 mm Maintains adhesion: > 3 Mpa No significant loss of fire properties in aged samples Without Topcoat

18 Overblast Testing Simulates explosion Successful overblast bulkhead testing 5 (127 mm) deflection over 6 (1.8 m) span No cracking or delamination Ensures material performance

19 Hose Stream Testing Simulates high pressure water stream of fire hose NFPA 58, Annex H Hose Stream Test Retains integrity during fire while exposed to hose stream Maintains fire performance

20 Physical Properties Property Pyroclad X1 Leading Competitor Water Absorption (Total immersion in 5% salt room temperature for 76 days) 0.5% (untopcoated) 3.3% (untopcoated) 1.4% (topcoated) Water Absorption NORSOK M-501 System 5A (4,200 hours) Hardness ASTM D2240 Compressive Strength ASTM D695 Flexural Strength ASTM D638 Adhesion/Cohesion ASTM D4541 Flame Spread ASTM E84 Smoke Development ASTM E84 0.2% (untopcoated) Not published Shore D 70 Shore D 70 3,672 psi (25.3 MPa) 2,700 psi (18.6 MPa) 3,925 psi (27.1 MPa) 3,300 psi (22.7 MPa) 1,840 psi (12.7 MPa) (average) ,450 psi (10.0 MPa) (average)

21 Certification Authorities Choice of certification organization is dependant on project requirements Lloyd s Register (LR) Det Norske Veritas (DNV) American Bureau of Shipping (ABS) Underwriter s Laboratories, Inc. (UL) NORSOK (Environmental)

22 Pyroclad X1 Certification Types Structural steel (LR, DNV, ABS) - I-sections (beams and columns) Tubular hollow sections (LR, DNV, ABS) - Rectangular hollow sections - Round hollow sections Divisions (LR, DNV, ABS) - Bulkheads - Decks - Firewalls, blast walls, accommodation modules - H Class (H-0, H-60, H-120) - J Class (J15, J-30, J-60, J-120) *Ratings will vary with member type.

23 Service Environments Offshore - Offshore platforms - Oil and gas installations - FPSOs Onshore - Refineries - Petrochemical plants - LNG terminals - LPG storage facilities

24 Structural Steel I-Sections

25 Tubular Hollow Sections

26 Structural Steel I-Sections/Tubes

27 Tank Supports

28 Vessel Skirts

29 Fire Rated Divisions (Underdeck)

30 Fire Rated Divisions (Bulkhead)

31 Fire Rated Divisions (Accommodation Modules)

32 Fire rated Divisions Hydrocarbon Fire - H Class - H-0, H-60, H-120 Jet Fire - J Class - J15, J-30, J-60, J-120 Prevent heat transfer and passage of flame and smoke from the fire exposed side to the non-exposed side during a 2 hour hydrocarbon fire test

33 H Class Divisions Non-exposed side must stay below 140 C (average) / 180 C (single point) above ambient for designated time No flame or smoke penetration for 2 hours H-0 only must only stay below 400 C for 2 hours (no flame and smoke requirement) Fire Class Time (minutes) H-0 0 H H

34 J Class Divisions Non-exposed side must stay below 140 C (average) / 180 C (single point) above ambient for designated time No flame or smoke penetration for 2 hours To calculate the thickness required, the jet fire erosion factor is added to the required hydrocarbon thickness (from appropriate certification) Fire Class Time (minutes) J J J J

35 How To Determine Thickness Requirement What type of structural member (I-section, hollow section, division)? What is the Hp/A section factor (30-300)? What is the critical limiting temperature for the project specification? What is the fire duration? What is the fire type (hydrocarbon, jet or combination)? What classification has to be used (LR, DNV, ABS, UL)? If plate or division, what is the thickness of the steel? If division, what fire class and duration is specified (H or J / 0, 15, 30, 60, 120 minutes)?

36 Factors That Affect PFP Hp/A: Heated perimeter/area Steel with smaller Hp/A has greater mass The more mass a steel section has, the less PFP thickness it requires The higher the critical limiting temperature, the less thickness is required The longer the fire durations require more thickness Jet fire ratings require jet fire erosion factor to be added to hydrocarbon thickness Thickness

37 Critical Limiting Temperature Temperature at which strength of steel will fall below limit required for the project. Specified by project, may vary for structural supports, equipment, piping, etc. 200 o C-600 o C (392 o F-1,112 o F) for jet fire and hydrocarbon protection 400 o C (752 o F) typical Specification may vary according to project and operational requirements

38 Hydrocarbon Ratings Example

39 Jet Fire Erosion Factor Additional material added to hydrocarbon thickness to withstand the effects of the jet fire. Thickness differential between hydrocarbon and jet fire is jet fire erosion factor. Compares thickness requirements for specific steel size (Hp/A: 100) at same limiting temperature (hydrocarbon fire vs jet fire) The jet fire erosion factor is added to the hydrocarbon thickness required.

40 Pyroclad X1 Coating Systems Primers Carboguard 888 Carboguard 890 Carboguard 893 SG Carboguard 60 Carboguard 635 Carbomastic 94 Carbomastic 615 Carbozinc 858 Global Carbozinc 11 HS / Carboguard 893 Topcoats Carbomastic 94 (6 mils/150 microns) Carbothane 134 HG (2-3 mils/50-75 microns) All other primers and topcoats must be approved Primer or primer system thickness shall be between 3-5 mils ( microns) Primers and topcoats in bold are part of NORSOK tested system

41 Mesh Reinforcement High Temp Mesh used for all applications Approximately 1,000 ft² (93 m²) roll Installed at nominal midpoint to 2/3 point. Mesh placement and overlap requirements will depend on the configuration of the steel and the fire exposure type.

42 Mesh Reinforcement

43 Mesh Reinforcement

44 Performance Advantages of Pyroclad X1

45 Advantages of Pyroclad X1 Pyroclad X1 Competitor A Competitor B Competitor C Mix Ratio Best 1:1 2.45:1 2.33:1 2.36:1 Overall Thickness Requirements Lowest Low Highest Higher Installed Weight Lowest Low Highest Higher Water Absorption Best (0.2%) Un-topcoated 3.3% Un-topcoated Worst >4% Not published Shore D Hardness Best (70) Best (70) Lowest (25) Lower (60) Weathering (NORSOK Test) Best Passed without topcoat Best Passed without topcoat Topcoat required Topcoat required Compressive Strength Highest High Lowest Lower Flexural Strength Highest High Lowest Lower

46 Performance Advantages of Pyroclad X1 1. Pyroclad X1 has lower overall thickness requirements for structural steel. - Industry leading hydrocarbon ratings / competitive jet fire erosion factors - Tremendous weight savings to overall structure - Requires less material and labor to install / lower installed cost 2. Pyroclad X1 has the lowest moisture absorption of any PFP material on the market. - Successfully passed NORSOK M-501 System 5A without a topcoat - High resistance to moisture uptake during and after application (0.2%) - Provides assurance that material will stand up to harsh offshore environments - Lower maintenance and repair costs 3. Pyroclad X1 has highest durability. - Highest Bond Strength, compressive strength and flexural strength - Provides better resistance to damage during construction and while in service - Better adhesion, longer service life - Lower maintenance and repair costs

47 Application Advantages of Pyroclad X1 1. Pyroclad X1 has lower overall thickness requirements for structural steel. - Less coats to apply - Faster application - Less material and labor required to achieve rating 2. Pyroclad X1 has a simplified 1:1 mix ratio. - Minimizes off ratio application - Easy visual verification - Simple straight forward application 3. Pyroclad X1 is easiest to apply. - Best spraying material on the market - No special procedures needed to obtain correct spray applied density - Excellent fan pattern and thickness control - Fast recoat intervals

48 Thickness Comparison

49

50

51 Estimating A Project

52 Density And Coverage Pyroclad X1 is sold in 40 kg and 20 kg kits Wet density in can is 1.30 g/cm³ Actual coverage better than theoretical due to entrained air (20-27% better coverage) Typical spray film density ranges between g/cm³ depending on application parameters A spray applied density of 1.03 g/cm³ is achievable by following Carboline guidelines

53 Steps: Project Estimation 1. Find thickness required for specified rating using Hp/A charts 2. Multiply thickness (mm) x density (g/cm³) = weight per unit area in specified thickness 3. Multiply weight per unit area x total m² of project = total material needed for project in kg 4. Divide by kit weight (40 kg or 20 kg kit) = number of kits for project 5. Multiply weight per unit area x price per kg = material cost per m²

54 Packaging Supplied in 40 kg (full) and 20 kg (half) kits Full kits for plural application Half kits used for single component and trowel applications

55 Typical Pyroclad X1 Specification Prepare steel to Sa 2-1/2 (SSPC-SP10) with micron profile Apply approved microns (3-5 mils) DFT Apply Pyroclad X1 to point of mesh placement Apply High Temp Mesh in proper orientation Apply Pyroclad X1 to specified thickness Apply approved topcoat to specified thickness

56 Typical Fire Ratings 1. Hydrocarbon Pool Fire (Offshore) - IS0 834 / BS 476 Part Appendix D - 30 minute 180 minute 2. Hydrocarbon Jet Fire (Onshore/Offshore) - ISO minute 120 minute 3. Hydrocarbon Jet Fire and Hydrocarbon Pool Fire Combination - Any combo of time intervals 4. Hydrocarbon Fire (Onshore) - UL hour 4 hour

57 Example Fire Rating Specification: J30 / H90 for structural steel 30 minute jet fire +90 minute hydrocarbon 120 minute total 400 C limiting temperature Structural I-section (Hp/A: 60)

58 Jet / Hydrocarbon Fire Example STEP 1: Generate required thickness: 1. Add = 120 minutes total 2. Go to the 400 C chart for Hp/A: 120 minutes to get hydrocarbon rating = 6.9 mm 3. Look up jet fire erosion factor for 30 minute for member type = 1.8 mm jet fire erosion factor 4. Add 6.9 mm mm = 8.7 mm (required thickness)

59 Project Estimation STEP 2: Calculate Pyroclad X1 quantity Project size: 10,000 m² Pyroclad X1 thickness: 8.7 mm Pyroclad X1 density 1.03 g/cm³ 8.7 mm (thickness) x 1.03 g/cm³ (density) = mm 10,000 m² x 8.96 kg/m² = 89,600 kg of Pyroclad X1 Estimated loss and overspray: 20% 89,600 kg /.80 = 112,000 kg 112,000 kg / 40 kg (full kit) = 2,800 kits required

60 Coatbacks Extension of PFP beyond primary member onto the secondary nonfireproofed member Prevents heat transfer to primary member Secondary members protection is at the discretion of project The coatback requirement is project specific, a typical coatback requirement is 18 (450 mm) from the primary member. Ensure this is included in project planning

61 Application

62 Application Methods Plural component Batch mix Trowel

63 Approved Equipment Suppliers Spray Quip WIWA

64 Plural Component Spray Equipment

65 Single Component Spray Equipment

66 Trowel Application tools

67 Acceptable Finish

68 Questions?