Passive Fire Protection Information
History of Fireproofing Systems
Overview of fireproofing development including insulated metal boxes, blanket-type insulation, ceramic fibre enclosures and K-Mass® coating.
Passive Fire Protection for Emergency Flow Control
A hydrocarbon processing unit carries flammable products in many pipes and vessels. A severe fire in such a unit has the potential of turning into a roaring inferno if fire control efforts are unreliable or ineffective.
The emergency shut-down system that uses remote control valves is an important part of the initial response to the fire. These automated valves are used to divert or stop the flow of flammables to the fire. These valves are also commonly used to activate the deluge systems and other fire control devices. Since these valves will be exposed to the fire, measures must be taken to ensure their functionality.
Most metal-seated valves now in use are designed to be fire-safe, according to the API 607 standard. However, the valve actuators, and soft-seat valves, are most in need of fire protection.
30 minutes or less to avert a disaster
Modern processing units tend to be highly automated. Operated and monitored from remote control centers, fewer personnel are needed on-site. In the event of a major fire, the absence of personnel can compound the problem. The time lag between ignition, discovery, and onset of control efforts can allow a small fire to grow larger quickly.
A large petroleum fire can reach temperatures in excess of 1093°C (2000°F) in less than 5 minutes. A tremendous amount of energy is released, and can produce "fire storms" that generate actual physical force. Valve actuators and controls must be well protected in order to survive this severe environment. If the emergency shut-down equipment fails, unlimited fuel can allow the fire to become uncontrollable, causing massive destruction to the unit and possible toxic gas releases.
In the past, engineers selecting fire protection for these critical valve actuators have had few options from which to choose:
All these options can be effective, but have the same weakness; they require conscientious, ongoing maintenance to be reliable.
As an answer to the problems outlined above, Thermal Designs, Inc. has developed a product that can solve these problems. The system is called K-MASS fireproofing. It is an epoxy based, intumescent coating. This type coating has been in use for many years as a structural steel coating, as well as being used in the space exploration program. Thermal Designs is the first company to adapt this type material to coat critical components of the emergency shut-down system.
Our process is to permanently bond the K-MASS to the surface of the individual components. This allows the plant personnel, using standard tools, to service the equipment without hindrance from the fire protection. We call this making fire protection "people-proof". After servicing, the actuator is reassembled, and the fireproofing is automatically in place as a result. No special fasteners or straps are required to reseal the fireproofing.
The K-MASS coated equipment is sent to the plant and installed with no additional space required. As the coating is integral to the equipment, there is no additional costs for installation of the fireproofing.
The K-MASS coating is durable, weather-resistant, and corrosion-resistant. The coating does not absorb moisture, and is unaffected by most process chemicals. The only recommended maintenance is a repainting of the top coat every 3 to 5 years with a top quality, UV resistant paint.
K-Mass® has successfully passed fire tests conducted by the Alberta Research Council Canada, Lloyds of London, Sintef of Norway, Faverdale England, and Southwest Research Labs San Antonio, Texas. All tests have been based on the UL1709 time/temperature curve.
Fire tests have been performed on various makes and models of equipment since 1988. We have participated in over 20 third-party tests, as well as many in-house, witnessed tests.
K-Mass® Fire Tests
Summary
K-MASS is approved by most major oil companies, and has been specified as the fireproofing of choice on many major projects throughout the world. Our experience in the production and testing of fireproof materials has gained Thermal Designs and K-MASS world-wide acclaim as the best solution for fireproofing of emergency shut-down equipment.