FPM Du 5091 Tco

Design and Installation of Passive Fireproofing for
Hydrocarbon Pool Fires in Onshore Processing Facilities
FPM-DU-5091-TCO
-
() FPM-DU-5091-A,
(), ,
.

.
, ,
(T).
This specification modifies the CES specification FPM-DU-5091-A, for use in
Tengizchevroil (TCO) Tengiz Plant, Republic of Kazakhstan. The modifications to the
original CES are marked in the English language sections of this specification by a bar in the
left hand margin and an entry in the Revision Sheet.
The revision numbers and dates shown in this document pertain to the TES specification.

REVISION SHEET
REVISION
0
0
CLAUSE
ALL
1.0
2.0.1
2.0.2
2.0.3
2.0.4
2.0.5
3.1
3.2
3.2.4
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REVISION DESCRIPTION

Russian language translation added
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[REPLACE WITH] Text modified as per TCO comment
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[ADD] Text modified as per TCO comment
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2012

2012 by Tengizchevroil LLP
COMPANY CONFIDENTIAL
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0
3.2.6
3.2.7.c
3.2.7.d
03.02.2017
03.02.2019
03.02.2026
03.02.2028
4.0
4.1
4.4.9
4.4.9.a
4.4.9.b
4.4.9.c
04.04.2010
5.0.2
5.0.3
6.0.1
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6.0.1.a
6.0.1.a
Table
6.0.2
6.0.3
6.1.2
7.1.5
7.1.5.b
7.1.6
7.2.1
7.2.2.d
Table
7.3.4
7.3.4 Table
7.3.4.c
7.3.4.d
7.4.1
7.4.2
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FPM-DU-5091-TCO
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[ADD] Table modified as per TCO comment
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7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.6
7.6.9
07.06.2010
07.06.2011
07.06.2013
8.1
8.2
8.3.2
/
Appendix A
B /
Appendix B
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FPM-DU-5091-TCO
/CONTENTS
1.0
........................................................................... 9
1.1
1.2
................................................................................................... 9
......... 9
2.0
.................................................................... 10
2.1
2.2
2.3
2.4
.......................................................... 10
.................................................................................. 12
................................................................................. 12
................................................ 13
3.0
...................................................................................... 13
3.1
3.2
................................................................................................. 13
............................................................................................... 13
4.0
19
4.1
4.2
4.3
4.4
........................................................................... 19
................................................... 20
() ................................................... 21
........................................................... 21
5.0
.................................................................... 22
6.0
................................................................. 23
6.1
6.2
6.3
.................................................................................... 26
...................................................................... 27
........................................... 27
7.0
............................................... 27
7.1
7.2
7.3
7.4
7.5
.................................................................................... 27
............................................................. 31
................................................................ 35
...................................................................... 36
/
............................................................................................... 37
,
....................................................................................................... 37
7.6
8.0
............................................................... 38
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
..................................................................................................... 38
...................................................................................... 38
.................................................................. 40
...................................................... 41
..................................................................................... 41
......................................................................... 42
...................................................................................................... 42
, .................................................................. 42
............................................................................... 43
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9.0
...................................... 43
9.1
9.2
9.3
9.4
9.5
9.6
9.7
..................................................... 43
............................................................................. 43
.................................................................... 44
........................................................................ 45
......................................................................................... 45
............................................................................ 45
.............................................................. 46
APPENDIX A. ........ 47
APPENDIX B.
...................................................................... 52
1.0
SCOPE ........................................................................................................ 54
1.1
1.2
Application .................................................................................................... 54
Fireproofing Philosophy ................................................................................ 54
2.0
REFERENCES ............................................................................................ 55
2.1
2.2
2.3
2.4
Industry Codes and Standards ...................................................................... 55

Purchaser Document .................................................................................... 57
Standard Drawings ....................................................................................... 57
Conflict Resolution ........................................................................................ 57
3.0
TERMONOLOGY ........................................................................................ 57
3.1
3.2
Acronyms ...................................................................................................... 57
Definitions ..................................................................................................... 58
4.0
DETERMINING FIREPROOFING NEEDS ................................................... 62
4.1
4.2
4.3
4.4
Evaluate Fire Hazards .................................................................................. 62

Develop Fire Scenarios ................................................................................. 64
Define Fire-Exposed Envelopes (FEE).......................................................... 64
Perform Needs Analysis................................................................................ 64
5.0
FIRE RESISTANCE RATINGS .................................................................... 65
6.0
FIREPROOFING MATERIALS SELECTION ............................................... 66
6.1
6.2
6.3
Structural ...................................................................................................... 69
Critical Systems ............................................................................................ 69
Fire Barrier Penetrations ............................................................................... 70
7.0
SPECIFIC APPLICATIONS ......................................................................... 70
7.1
7.2
7.3
7.4
7.5
7.6
Structural ...................................................................................................... 70
Critical Equipment ......................................................................................... 73
Main Cable Runs .......................................................................................... 76
Actuators ...................................................................................................... 77
Penetrations Through Fire Walls and/or Fire Barriers ................................... 78
Control Rooms, Living Quarters and Other Buildings in Process Areas ........ 78
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8.0
INSTALLATION AND WORKMANSHIP...................................................... 79
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
Introduction ................................................................................................... 79
General ......................................................................................................... 79
PFP for Equipment Items .............................................................................. 81
PFP for Metal Surfaces ................................................................................. 81
PFP for Penetrations..................................................................................... 81
PFP for Flexible Items ................................................................................... 82
Thickness ..................................................................................................... 82
Reinforcing, Laths, and Studs ....................................................................... 82
Workmanship ................................................................................................ 83
9.0
QUALITY ASSURANCE PROVISIONS....................................................... 83
9.1
9.2
9.3
9.4
9.5
9.6
9.7
Installation Contractor Qualification ............................................................... 83

Quality Control Plan ...................................................................................... 83
Quality Control Forms ................................................................................... 84
PFP Thickness Requirements ....................................................................... 84
Sample Area ................................................................................................. 85
Final Inspection ............................................................................................. 85
Preparation for Shipping and Storage ........................................................... 85
APPENDIX A. PROFORMA FIREPROOFING SCHEDULE .................................... 86

APPENDIX B. ......................................................................................................... 90
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1.0
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MII TG, 1, . 4.
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6.2
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2012
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), ,

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3.
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d. U.L. (UL 263, UL 1479).

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a.
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a.
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.
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Appendix A.

A.1.1. X
,
X, .
A.1.2.
.
A.1.3.
.
A.1.4.
.
A.1.5. ,
.
A.1.6.
.
A.1.7.
.
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A.1.8. -
.
A.1.9.
.
A.1.10.
.
A.1.11.
.
A.1.12. Y
,
Y, .
A.1.13.
.
A.1.14.
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A.1.15.
A.1.16. ,
A.1.17.
A.1.18.
A.1.19. -
A.1.20.
A.1.21.
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A.1.22.
.
A.1.23. Z
,
Z, .
A.1.24.
.
A.1.25.
.
A.1.26.
.
A.1.27. ,
.
A.1.28.
.
A.1.29.
.
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A.1.30. -
A.1.31.
A.1.32.
A.1.33.
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Appendix B.
..
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D.

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7 . / .
28 .. / .
..
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1.0
FPM-DU-5091-TCO
SCOPE
1. This specification defines the minimum technical requirements for the design of passive
fireproofing systems at Tengizchevroils facilities at Tengiz in the Republic of
Kazakhstan. Unless specified otherwise, the Systme Internationale (SI) system of metric
units shall be used.
2. This specification defines minimum technical requirements to determin the need for
fireproofing select, fireproofing materials to protect steel substrates from the effects of
hydro carbon pool fire.
3. This specification incorporates the structured approach to determining fireproofing needs
as documented in API Publication 2218, Fire Proofing Practices in Petroleum and
Petrochemical Processing Plants, Second Edition. See Section 4.0
1.1
Application
1. This specification shall apply to the design of onshore processing petroleum and
petrochemical processing facilities.
2. This specification shall be utilized during CPDEP Phases 2 - 4.
1.2
Fireproofing Philosophy
1. Passive Fireproofing (PFP) shall be provided for equipment and structures where fire
exposure or catastrophic failure could result in unacceptable consequences to the facilities
including:
a. Threat of injury to personnel.
b. Loss or serious damage to valuable or critical equipment or structures.
c. Release of large volumes of flammable material.
d. Release of toxic material.
e. Threat to adjacent property and structures of high value.
f.
Serious loss of production capacity.
2. Fireproofing shall not be installed in these situations:

a. The value of the structure and supported equipment is low when compared to the cost
of fireproofing.
b. Member failure would not cause failure of the structure or equipment (e.g., wind and
earthquake bracing and other secondary members, such as supports for stairs,
platforms, and walkways).
c. The structure is far enough removed from the source of a fire or the drainage path
from a fire to preclude serious damage e.g., outside the Fire Exposed Envelope
(FEE).
d. The fire would cause failure or serious damage to supported equipment whether or
not the structure was fireproofed.
e. The structure only supports piping that is not carrying flammable liquids.
f.
Piping that carries only gases because the risk of a hydrocarbon pool fire is low.
g. Determining fireproofing needs shall involve an experienced and risk-based

evaluation including developing fire scenarios from which the needs analysis evolves.
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FPM-DU-5091-TCO
REFERENCES
1. All works and materials shall conform to the requirements of the GOST and SNiP Codes,
Standards and Specifications, National and International Codes and Standards as listed in
this specification.
2. Where a GOST or SNiP specifies a requirement which is at variance with this
specification the most stringent requirement shall apply.
3. Where no acceptable GOSTs or SNiPs Codes and Standards are available equivalent
internationally recognized codes and standards may be proposed by Contractor / Supplier
for Purchaser acceptance.
2.1
Industry Codes and Standards

Republic of Kazakhstan Codes and Standards
GOST 20910-90
Heat Resistant Concretes. Specifications
GOST 30247.0-94
Building Structures. Fire Resistance Tests. General Requirements
GOST 30247.1-94
Building Structures. Fire Resistance Tests. Bearing and Enclosing

Structures
GOST 30247.2-94
Building Structures. Fire Resistance Test Methods. Doors, Gates
GOST 30402-96
Building Materials. Flammability Tests
GOST 30403-96
Construction Structures. Methods of Defining Fire Hazard
GOST 12.1.010-76
Explosion Hazard. General Requirements New Edition 1999
ST RK 615-2001
Fireproofing Compounds for Painting and Coating Wood and Metals.

Specification
PUE
Electrical Rules. Electrical Installation in Fire Danger Zones Chapter 7
VUPP-88
USSR Ministry of Oil Refinery and Petroleum Industry Engineering

Design Standard Instruments for Fire Fighting Planning of
Enterprises, Buildings and Structures for the Oil Refinery and
Petrochemical Industry
VNTP-81
Design Standards for Thermal Power Plants
VUP SNE-87
Departmental Guidelines for Design of Loading/Unloading Railway

Racks for Flammable and Combustible Liquids and Liquefied
Hydrocarbon Gases
SNiP RK 2.02-05
-2009
Fire Safety of Buildings and Facilities
SNiP 2.11.03-93
Crude Oil and Petroleum Products Storage Tank Farms
International Codes and Standards

Factory Mutual Research Corporation (FM)
Approved Product Guide
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American Petroleum Institute (API)

API 2218
Fireproofing Practices in Petroleum and Petrochemical Processing

Plants.
API 2510
Design and Construction of LPG Installations.
API 2510/A
Fire Protection Considerations for the Design and Operation of

Liquefied Petroleum Gas (LPG) Storage Facilities.
American Society for Testing Materials (ASTM)

C692-00
Standard Test Method for Evaluating the Influence of Thermal

Insulations on External Stress Corrosion Cracking Tendency of
Austenitic Stainless Steel.
C795-92(1998)e1
Standard Specification for Thermal Insulation for Use in Contact with

Austenitic Stainless Steel.
E-119
Fire Tests of Building Construction Materials.
C150-94
Specification for Portland Cement.
C580-93
Flexural Strength and Modulus of Elasticity of Chemical Resistant

Mortars, Grouts and Monolithic Surfacings.
D962
Specification for Coarse Aggregate for Bituminous Paving Mixtures.
D2240-95
Test Method for Rubber Property Durometer Hardness.
E84-94
Test for Surface Burning Characteristics of Building Materials.
E119-95
Method for Fire Tests of Buildings Construction and Materials.
E605-93
Thickness and Density of Sprayed Fire-Resistive Material Applied to

Structural Steels.
E736-92
Cohesive/Adhesion of Sprayed Fire Resistive Materials Applied to

Structural Steels.
E759
Test Method for Effect of Deflections of Sprayed Fire Resistive

Material Applied to Structural Members.
E761-92
Compressive Strength of Sprayed Fire Resistive Material Applied to

Structural Members.
International Electrical Committee

IEC 60331
Tests on Electric Cables under Fire Conditions.
British Standards
BS6387
Performance Requirements for Cables Required to Maintain Circuit

Integrity under Fire Conditions.
Chevron Standards
Section 200
Chevron Tank Manual Fire Protection Safety in Designs Manual.
RPS-1000
Project Standard. Chevron Fire Protection Guidelines for New Projects.
UK Health and Safety Executive

OTI 95 634
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Jet Fire Resistance Test of Passive Fire Protection Materials.

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National Association of Corrosion Engineers (NACE)

NACE RP 0198
The Control of Corrosion Under Thermal Insulation and Fireproofing

Materials-A Systems Approach.
National Fire Protection Association (NFPA)

NFPA 321
Standard on Basic Classification of Flammable and Combustible

Liquids.
Underwriter Laboratories (UL)

UL 1709
2.2
Standard for Rapid Rise Fire Tests of Protection Materials for

Structural Steel.
Purchaser Document
ICM-SU-4929-TCO Instrumentation for Packaged Equipment.
CIV-SU-850-TCO
2.3
2.4
Plain and Reinforced Concrete
Standard Drawings
M-ST-6009-01
Fire-proofing details sheet 1
M-ST-6009-02
Fire-proofing details sheet 2
C-ST-6006
Insulation and fire-proofing supports
Conflict Resolution
In the event of any inconsistency between the requirements stated in the various technical and
reference documents, the following order of precedence shall apply:
1. Local country statutes, regulations, and directives
2. Local country codes and standards
3. The project requisition
4. Data sheets
5. This specification
6. Client specific standards
7. Other international codes and standards
8. Good International Industry Practice
Notwithstanding the stated hierarchy, any discrepancies between the requirements of the
above documents shall be forwarded in writing to the Purchaser for resolution.
3.0
TERMONOLOGY
3.1
Acronyms
FGP - Future Growth Project
FSGI - Future Sour Gas Injection
HFPE - High Fire Potential Equipment
LFPE - Low Fire Potential Equipment
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MFPE - Medium Fire Potential Equipment

MSDS - Material Safety Data Sheet
P&ID - Piping and Instrument Diagrams
PBF - Pressure Boost Facility
PHA - Process Hazard Analysis
PSMR - Process Safety Management Report
TCO - Tengizchevroil
TERP - Tactical Emergency Response Plan
3.2
Definitions
The following standard definitions are used within this document:
1. Ambient Conditions - the normal or average environmental and/or operating conditions
(temperature, humidity, wind, etc.) to which the fireproofing material will be exposed.
2. CPDEP - the Company project development and execution process.
3. Combustible materials - combustible liquids. Based on NFPA 321, combustible liquids
are liquids with flashpoints at or above 38C (100F), and may be subdivided as follows:
a. Class II liquids have flashpoints at or above 38C (100F) and below 60C (140F).
b. Class IIIA liquids have flashpoints at or above 60C (140F) and below 93C
(200F).
c. Class IIIB liquids have flashpoints at or above 93C (200F).
d. Many combustible chemicals that are solids at 38C (100F) or above are classified as
solids.
1) When heated, the solid becomes liquid and gives off flammable vapors
flashpoints can then be determined.
2) In their liquid state, these solids should be treated as liquids with similar
flashpoints.
4. Company-Tengizchevroil (TCO).
5. Contractor - The Company responsible for specifying, supplying and applying the
fireproofing systems required for the project in accordance with this specification.
6. Critical Instrument or Electrical Cables - cables or tubing associated with safety
interlock, emergency shutdown, depressuring, or isolation systems. Includes cabling
which, upon failure, could result in immediate loss of production or major process hazard
in one or more process units.
a. Typically, these systems are designed to be failsafe.
b. If they are not failsafe, they must maintain their operational integrity to facilitate safe
unit shutdown for at least 20 minutes into a fire.
c. This time may be longer if the controls need to operate longer to safely shutdown,
isolate and/or depressure the equipment, e.g., if controlled depressurization is
calculated to take longer than 20 minutes.
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7. Critical Valves - valves that are equipped with remotely operated actuators that must
retain their operational integrity for a minimum of 20 minutes under UL 1709 fire
conditions to facilitate safe shutdown. Fireproofing when provided within fire hazard area
envelopes on critical service instruments (de-pressurisation service), non-fail safe
actuated valves and junction boxes, shall meet the following criteria. It shall protect the
internal elements of the equipment from exceeding a temperature of 93C for a minimum
duration of 20 minutes when exposed to a steady state hydrocarbon fire at a constant
temperature of 1093C (+/- 110C).
8. Emergency Block Valves (EBVs) - remotely actuated valves which meet the following
criteria:
a. The valves are fire safe (have no parts that will yield in a fire, as defined in API 607).
b. The actuators are either fail safe (mechanical spring energy to close) or fire safe
(protected with fireproofing to a 20 minute limit).
c. The valves are critical for shutting down units safely, depressuring equipment or
isolating a fuel source greater than 9,464 L (2,500 gallons) that is feeding a fire and
the valves are located within a FEE. Air supply or hydraulic tubing for control and
motive power for air and hydraulic operated emergency isolation valves shall be
stainless steel. It shall be supported less than every 1.8 m in horizontal runs or every
2.44 m in vertical runs. Type 304 or 316 stainless steel tubing, without fire proofing
can safely be used for instrument air through a fire hazardous area as long as it is well
supported.
d. Where plant compressed air is used for motive power of emergency isolation valves,
the air filters, lubricators, and solenoids shall be located outside the fire hazardous
area. Where hydraulic fluid is used for motive power of double acting, fail in last
position emergency isolation valves, the hydraulic power units and accumulators shall
be located outside the fire hazardous area. If this is not practical, then for non-failsafe
emergency isolation valves, these items shall be fireproofed along with the valve
actuator. Hydraulic service tubing shall also be fireproofed. Darshield Engineered
Fire Protection Enclosures by Darchem or approved equal may be considered.
9. Emergency Isolation System - a system of automatic or remotely-actuated valves to
isolate a piece of equipment or unit involved in a fire or other emergency, thus limiting
the supply of fuel or the release of hazardous materials. This may be an individual pump,
compressor, vessel, LPG sphere, etc., or it may encompass an entire area inside the plot
limits of a plant or battery.
10. Emergency Shutdown or Depressuring System - a system that will shut down a plant
or other facility under emergency conditions, either automatically or by remote actuation
of block valves to stop the flow of flammable liquids or gases; stop heat input to process
furnaces, reboilers, or heaters; stop the rotation of associated machinery (especially
pumps); or depressure the equipment through a vent, if appropriate.
11. Fire-Exposed Envelope (FEE) - the three-dimensional space into which fire-hazardous
equipment can release flammable or combustible materials that are capable of burning
long enough and with enough intensity to cause substantial property damage to structural
steel, vessel/column skirts, critical instrumentation, etc. The boundaries of the FEE are
defined as follows:
a. Horizontally 12 m (40') from the closest edge of all fire-hazardous equipment.
b. Vertically 12 m (40') from the source of liquid or gas fuel.
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c. Within 15 m (50') of an LNG or LPG vessel or within the spill containment area of an
LNG or LPG vessel.
Note: As described in Section 1.2 item 3, the FEE dimensions may be larger that
defined above for some process conditions and a detailed review involving
qualified fire protection engineering resources should be conducted.
12. Fire-Hazardous Equipment:
a. Fired equipment, including heaters and furnaces that handle flammable materials that
will ignite when released.
b. Rotating or reciprocating mechanical equipment, such as pumps or compressors that
handle flammable materials, including their drainage paths.
c. Drums, exchangers, columns, and similar operating vessels that handle flammable
materials and have a volume of more than 3,785 L (1000 gallons), including their
drainage paths.
d. Piping manifolds that contain flammable materials and ten or more valves.
e. Tanks, spheres, and spheroids that contain flammable materials including their
drainage and relief path and impounding basins.
13. Fireproofing/Passive Fireproofing (PFP) - protection that provides resistance to fire
and heat transfer long enough to allow critical structures to remain standing or critical
control systems to operate, while the fire is brought under control.
a. Fireproofing can also be applied to allow sufficient time for personnel to access
escape routes, etc.
b. Fireproofing also refers to materials, application of materials or assemblies which are
intended to provide a degree of fire resistance to the protected structures or
equipment.
14. Fire Resistance Rating - the time period that a specific fireproofing material will protect
structures or equipment upon which it is applied from collapse or failure, when exposed
to a fire of a specified intensity.
15. Fire Resistant Wiring - electrical/instrument wiring/cable that will withstand UL 1709
fire conditions for at least 20 minutes. The cable shall be installed inside a steel conduit
for support.
16. Failsafe - that the valve or controls will move to the safe position if either the electrical or
the pneumatic power supply to the actuator fails.
17. Fire safe - that the component/asset being protected will retain its operational integrity
for a minimum of 20 minutes under UL 1709 fire conditions. For valves, fire safe shall
means the design will meet the API 607 fire test for stem leakage and through leakage.
18. Flame-Spread Rating - A measurement of the speed of flame travel across a given
surface in accordance with ASTM E84 (the 10-minute Steiner Tunnel Test). Generally
identified with evaluation of fire hazards of "interior finishes".
19. Flammable materials - flammable gases, vapors, and liquids having a flash point below
38C (100F), or combustible liquids being handled at temperatures within -7C (20F) of
their flash point, or above their flash point per NFPA 321.
20. Flangeless Valves - valves which are designed to be installed between two flanges, and
which have exposed bolts which do not pass through the body of the valve.
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21. High Fire-Potential Equipment (HFPE) - types of equipment (and special piping items)
that could release appreciable quantities of combustible or flammable liquids. High Fire
Potential Equipment is defined in API 2218.
22. High Rise Fire Conditions - the fire conditions experienced during a typical
hydrocarbon pool fire. High rise test conditions include attaining 1093C (2000F) within
five minutes as described in UL 1709.
23. Home Runs - large groups of multiconductor signal cables that are routed from the
control house to the main junction boxes in the plant.
a. Home runs are expensive to install and time consuming to repair.
b. Their loss may cause significant lost production or damage to plant areas outside the
fire area as a result of loss of control.
24. Hydrocarbon Fire Test - a test in which a fireproofing material specimen, which
resembles as closely as possible the intended construction of the barrier, is subjected to
high rise fire conditions based on UL-1709 (pool fires) or OTI 95 634 (jet fires).
25. Insulated Bag Fireproofing System - a fireproofing system which utilizes thermal
insulation pads laced together with stainless steel wire to form a bag that fully encloses
the motor actuator on a critical valve, including the motor, gearbox and drive nut, or the
entire housing of the protected component.
a. The insulation bag is constructed of semi-flexible pads of ceramic fiber or fiberglass
insulation.
b. The assembly has a weather protected Dacron cover that is designed to keep the
internal temperature of electrical components at or below 93C (200F) for 20
minutes if exposed to a 1093C (2000F) fire, as described by UL 1709.
26. Insulated Box Enclosure - a box-like assembly to fully enclose the motor/air operator of
a critical valve including motor, gearbox, and drive nut or the entire housing of the
protected component.
a. The fireproofing enclosure is made from a refractory ceramic fiber (RCF) block
inside a stainless steel weather jacket.
b. It is designed to keep the internal temperature of electrical components at or below
93C (200F) for 20 minutes during a fire.
27. Intumescents - fireproofing materials that expand to several times their own volume
when exposed to heat, and form a protective insulating ash or char at the barrier that faces
the fire.
28. Medium Fire-Potential Equipment (MFPE) - types of equipment (and special piping
items) that could release moderate quantities of combustible or flammable liquids or
where those liquids have a lower flame height to pool diameter ratio. Medium FirePotential Equipment is defined in API 2218.
29. Needs Analysis - the methodology used to quantify the magnitude of potential fire
scenarios and FEEs for the purpose of understanding the level of fireproofing required to
protect a structure, equipment, or component.
30. Non/Low Fire-Potential Equipment (LFPE) - Includes knockout and blowdown drums
isolated from other high fire potential equipment. Piping is not considered high fire
potential equipment except where numerous flanges exist or the ability to quickly detect
and isolate a spill is lacking. Low/non Fire Potential Equipment is defined in API 2218.
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31. Plot Limit Valves - the boundary valves for a plant area containing a complete operation
or group of operations that may be shut down as a unit. These valves are used for
isolation on turnarounds or emergencies.
32. Purchaser - The party who awards the purchase order or contract. The Purchaser may be
Company or Company's authorised agent.
33. Subliming Materials - fireproofing materials that use massive amounts of thermal
energy in effecting a transformation of a solid material directly into gases without an
intermediate liquid stage.
34. Substrate - the material upon which the fireproofing material is applied.
35. Supplier - Any vendor, seller, provider or supplier of goods to Company.
36. Thixotropic - Pertaining to the ability of a fluid, such as cement or drilling mud, to
develop gel strength over time when not subject to shearing, and then to liquify when
agitated.
4.0
DETERMINING FIREPROOFING NEEDS

1. Fireproofing requirements for industrial process plants are established through a process
whereby the surfaces exposed to fire hazards are identified and proven methods of
fireproofing are implemented for those surfaces exposed to the fire hazard. These
requirements shall be noted on the detail design drawings.
a. The following process shall be used to identify locations where fireproofing is
justified. The Contractor shall provide fireproofing for structural supporting members
of systems in the vicinity of fire hazard area envelopes containing fire potential
equipment which could release significant volumes of flammable liquids and gases.
The structural supporting members include supports for storage tanks, supports for
fired heaters, tower skirts, supports for vessels, pipe rack supports, structure
supporting elevated fire potential equipment, critical pipe supports, fin-fan coolers,
supports of critical service cable trays, structural elements of buildings and shelters.
4.1
Evaluate Fire Hazards

1. Identify the location and types of fire-hazard areas.
2. Identify potential fuel sources including quantities, pressures, temperatures and chemical
composition.
3. In terms of the equipment involved in the loss of containment of flammable and/or
combustible liquids, determine if the fire-potential is high, medium, low or if there is nonfire potential.
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Develop Fire Scenarios

1. What might happen to released materials that could fuel a fire?
a. Can a pool fire develop?
b. Where is the drainage path and collection area?
c. Is there potential for Jet impingement fires?
2. How fast might the fuel be released.
3. What the capacity of the drainage system is for removing a hydrocarbon spill.
4. If ignited, what the character and extent of the fire is including:
a. Volatility
b. Burning rate
c. Heat of combustion
d. Physical properties of released materials
e. How much heat would be released if ignited
f.
4.3
How long the fire might burn if unabated.
Define Fire-Exposed Envelopes (FEE)

1. Utilize the data developed in Section 4.1 and 4.2 to determine what equipment and
support structures are present in a horizontal distance of 12 m (40') from the fuel source
12 m (50 ft.) for LNG and LPG sources).
2. Determine the height to which equipment and support structures must be protected.
a. Usually this is 12 m (40') but may be higher if critical equipment or structures are at
higher elevations.
b. When the fire hazardous equipment is located above grade, the total height of the
FEE shall extend 9.1 m (30') above the level of the equipment.
3. Disregard the effects of automatic and manual fire suppression when defining FEEs.
4. Consider the capabilities of the emergency isolation and depressurization system.
4.4
Perform Needs Analysis

1. Consider the inherent fire resistance of structures and equipment within the FEEs.
2. Identify the specific items to be protected.
3. Specify the rating for the protection provided.
4. Identify appropriate PFP material alternatives.
5. Specify appropriate PFP material and performance criteria. The selection of the items to
be protected shall meet the code requirements as stipulated in the design premise and all
relevant project technical specifications (refer to Section 5.0 below).
6. Ensure PFP systems selected for the final design have fire ratings that exceed the fire
durations defined by the Needs Analysis.
7. Identify other areas/items requiring passive fire protection.
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8. Provide documentation justifying the use and type of protection being provided and the
need for the passive fire protection.
a. Contractor shall refer to the following project specific documents, produced for each
area of the project containing fire hazard areas, for the extent of fireproofing to be
applied on a particular project:
b. Fireproofing Schedule.
A project specific fireproofing schedule shall be prepared for each area of the plant,
based on the requirements of this specification, the fire hazard area drawings and the
proforma fireproofing schedule contained within Appendix A of this document.
c. Fire Hazard Area Drawings.
The fire-exposed envelopes for a project shall be detailed in Fire Hazard Area
Drawings. These drawings shall be referenced in the project specific Fireproofing
Schedules.
d. Fire Potential Equipment Schedule.
A schedule detailing whether fire potential equipment is rated none/low, medium or
high fire potential as defined in API 2218. The rating defines the size of the fire
exposed envelope around the fire potential equipment which is used as a design tool
to aid developing the fire hazard area drawings and populate the passive fireproofing
schedules regarding fireproofing requirements for fire potential equipment.
e. A template example of a fireproofing schedule is contained within Appendix A of this
specification.
5.0
FIRE RESISTANCE RATINGS

1. Major factors that determine the level of fireproofing needed are the intensity and
duration of potential fire, structural design load and the importance of the structure or
equipment.
2. Onshore fireproofing shall protect structures supporting high-risk or valuable equipment
from reaching 538C (1000F) for a period of three hours, as defined by UL 1709
(Section 1740).
3.
Fireproofing provided on steel structures, vessel skirts and saddles, critical pipe and
cable tray supports shall protect the steel support structure from exceeding a temperature
of 500C for a minimum duration of 1, 2 or 3 hours, as defined in the following sections
of this specification, when exposed to a steady state hydrocarbon fire at a constant
temperature defined in GOST 30247.0-94 and GOST 30247.1-94.
4. Intumescent Fireproofing Systems

a. Intumescent Fireproofing Systems - Intumescent epoxy fireproofing systems are
tested and certified for use against hydrocarbon pool fires and jet fires. Systems rated
for jet fires require an additional thickness allowance over pool fire thicknesses.
Systems used for structural firewalls and insulating divisions shall have zero VOC.
Activation temperature can be 80 deg. C. upwards. Specific attention should be given
to the possibility of fume or smoke hazard which may be caused by intumescent
coatings in the event of fire.
b. Intumescent epoxy fireproofing systems approved for use in-country shall be applied
strictly in accordance with the manufacturers certification and recommendations,
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including surface preparation, method of application and protective surface finishes.

Prior to application, steel substrate shall be free of dirt, grease and loose scale. Steel
shall be prepared using a caustic solution and by scraping, wire brushing or grit
blasting. Primer materials shall be in accordance with Specification for Painting and
Protective Coatings No. 60-0000-L-SPE-0007.
5. Three-hour fireproofing as shown on Standard Drawing M-ST-6009-01, M-ST-6009-02
shall be installed for main support members of structures and equipment within the Fire
Exposed Envelope (FEE).
6.0
FIREPROOFING MATERIALS SELECTION

1. Each type of the fireproofing materials have unique uses tailored to their combination of
physical and chemical properties. The Contractor shall confirm the material types and
thicknesses noted in this specification for the fire ratings defined, the fire proofing
schedules, structural drawings and equipment data sheets are based upon tests compliant
to Kazakh standards. All fireproofing materials shall be new. Fireproofing materials and
systems shall be certified approved to Kazakh GOST standards. Proprietary Kazakh
GOST certified approved systems stated herein shall be used.
a. Fendolite MII Vermiculite Concrete
1) Topcoating material shall be Cafco T200 topcoat, two coats, to the material
manufacturers recommendations and shall be approved.
2) Fendolite MII - A single package factory controlled premix, based on vermiculite
and Portland cement. The surface may be either spray textured, roller or float
finished. Contractor to confirm thicknesses. The applied premix shall be
reinforced with plastic coated wire mesh with fixings. Reinforcing wire mesh
shall be lapped 50 mm minimum at joints. The reinforcing mesh shall be spaced
out from the substrate surface about one half the fireproofing thickness. Concrete
shall be properly tamped and vibrated after placement. Tops of columns, where
water could penetrate between steel and concrete, shall be weatherproofed with a
caulking bead consisting of a 2 part oil resistant polysulphide sealant.
3) Prior to installation of concrete, steel substrate shall be free of dirt, grease, and
loose scale. Steel should be prepared by using a caustic solution and by scraping,
wire brushing, or grit blasting. Primer materials shall be in accordance with
Specification for Painting and Protective Coatings No. 60-0000-L-SPE-0007,
followed by the application of Cafco PSK101, one coat, as a primer sealant.
4) Topcoating for Fendolite MII applied to structural steel shall be Cafco T200
Topcoat, two coats to be applied. Topcoating for Fendolite MII applied to vessel
supports shall be Cafco T201 primer, one coat, followed by FT201 topcoat, two
coats to be applied.
b. Fendolite MII Fireproofing Tabulation
1) Table of required thickness of fireproof coating Fendolite MII dry layer in
accordance with GOST 30247.0-94 and GOST 30247.1-94 for beam and column
protection with different Hp/A factor (ratio of exposed heated perimeter to cross
sectional area), table of fire rating for different coating thickness for critical steel
temperature of 500C.
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Note: Hp exposed heated perimeter of protected structure in mm.

A cross sectional area of protected structure in cm.
Hp/A ratio of exposed heated perimeter of cross sectional area in m .
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Table 1. Required thickness of fireproof coatings dry layer in mm to provide fire ratings
to protected structure in hours
Hp/A, m
0,5 hr
0,75 hr
1,0 hr
1,5 hr
2,0 hr
2,5 hr
3,0 hr
4,0 hr
30
14
15
15
16
20
23
26
33
40
14
15
16
19
23
27
31
39
50
14
15
17
21
25
30
34
42
60
14
16
18
23
27
32
37
45
70
15
17
19
24
28
34
39
48
80
15
18
20
25
30
35
40
50
90
15
18
21
26
31
37
42
52
100
15
18
21
26
32
38
43
53
110
16
19
22
27
32
38
44
54
120
16
19
22
28
33
39
45
55
130
16
19
23
28
34
40
45
56
140
16
20
23
28
34
40
46
57
150
17
20
23
29
34
41
47
58
160
17
20
23
29
35
41
47
59
170
17
20
23
29
35
42
48
60
180
17
20
23
30
36
42
48
190
17
21
24
30
36
43
49
200
17
21
24
30
36
43
49
210
18
21
24
30
36
43
49
220
18
21
24
31
37
44
50
230
18
21
24
31
37
44
50
240
18
22
25
31
37
44
50
250
18
22
25
31
37
44
50
260
18
22
25
31
37
44
51
270
18
22
25
31
38
45
51
280
18
22
25
31
38
45
51
290
18
22
25
32
38
45
51
300
18
22
25
32
38
45
52
310
18
22
25
32
38
45
52
320
18
22
25
32
38
45
52
330
19
23
26
32
38
45
52
All testing for Fendolite MII shall be undertaken in accordance with the Fendolite MII
Applications Manual.
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Fendolite MII and Fendolite TG Application Manual, Issue 1, Rev 4. Issued by Cafco Int.,
UK.
6.1
Structural
1. The contractor shall use either Portland cement concrete or Pyrocrete 241 for structural
PFP and shall comply with the requirements of this section. For items where alternative
fireproofing methods and/or materials are identified but are not Company-approved, the
choice shall be made based on economics and the requirement of this section and shall be
submitted for Company review and approval.
2. Formed Concrete - Air-entrained, normal weight poured concrete consisting of surface
dry aggregate and cement conforming to GOST 20910-90 with the identification
designation of BR-P-B20-N12 and conform to grade K25AE per Specification for Plain
and Reinforced Concrete CIV-SU-850-TCO shall be used, and shall be 65mm/2.5 thick,
which gives 3 hours fireproofing. The mix shall consist of one part cement and 2 parts
each of sand and gravel passing a 9.5 mm sieve. Water cement ratio shall not exceed 0.50.
The concrete shall be reinforced by electrically welded wire fabric, 50 mm x 50 mm x 2.3
mm (12 US Gage.) For outdoor use, the wire mesh shall be galvanised. Tie wire shall be
1.6 mm diameter, annealed black iron. Reinforcing wire fabric shall be lapped 50 mm
minimum at joints. The reinforcing fabric shall be spaced out from the substrate surface
about one half the fireproofing thickness. Concrete shall be properly tamped and vibrated
after placement. Tops of columns, where water could penetrate between steel and
concrete, shall be weatherproofed with a caulking bead consisting of a 2 part oil resistant
polysulphide sealant.
3. The Contractor shall provide copies of the material specs and the Material Safety Data
Sheet (MSDS) for all proprietary fireproofing materials proposed for the project.
Materials containing asbestos shall not be used.
4. Materials used to fireproof austenitic stainless steel surfaces shall be approved for use on
austenitic stainless steel, in accordance with ASTM C795.
5. The material manufacturer shall furnish test reports to demonstrate that the material
which will be furnished for the particular project has passed the pre-production corrosion
test, in accordance with ASTM C692.
a. However, unless otherwise directed by Company, certification of chemical analysis is
not required for each production lot from which material is to be furnished.
b. All materials for use on austenitic stainless steel are subject to approval by Company.
6.2
Critical Systems
For critical systems including valve actuators, instrumentation and shutdown systems that
require PFP, the contractor shall use the following PFP materials:
1. For valve actuators, K-Mass shall be used.
2. For power cable in conduits, high temperature thermal insulation wrapped in stainless
steel jacketing and banding shall be used.
3. For cable trays, high density calcium silicate such as Eternit Promat H or Super Fire
Temperature wrapped in weatherproof jacketing and banding shall be used.
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FPM-DU-5091-TCO
Fire Barrier Penetrations

Fire barrier penetrations shall be sealed with Nelson Firestop products or 3M Fire Dam
Caulking.
7.0
SPECIFIC APPLICATIONS
7.1
Structural
For structures, support and equipment that require fireproofing, the contractor shall follow the
requirements below.
1. Install fireproofing for vertical and horizontal steel supporting elements for containers of
flammable and combustible liquids from grade to highest level of support.
2. Install fireproofing for vertical and horizontal steel supporting elements for noncombustible containers from grade up to and including level that is nearest to a 12 meter
(40 foot) elevation above grade if collapse of unprotected structural supports could result
in substantial damage to nearby equipment and result in increased fire severity.
3. Install fireproofing for knee and diagonal bracing that contribute to the support of vertical
loads or horizontal stability.
4. Elevated floors and platforms that could retain significant quantities of combustible
materials shall be considered as grade.
5. For pipe racks that require fireproofing, the contractor shall:
Figure 1:
No
Multilevel Equipment Support Structure in Fire Hazard Area
Yes
No
Multilevel Equipment Structure
Supporting Fire Potential Equipment
No
Yes
Multilevel Equipment Structure

Collapse Promotes the Spread of Fire
Yes
Yes
Multilevel Equipment Structure with

Solid Floor Level at Elevation other
than Grade Level
No
Fireproof All Vertical and Horizontal Steel

Fireproof All Vertical and Horizontal
Support Structure From the solid floor level
Steel Support Structure From Grade up to
to the next solid floor level or equipment,
the highest level supporting fire potential
or 12m, whichever is the higher
equipment.
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a. Install fireproofing for vertical and horizontal steel supporting from grade to and
including level that is nearest to a 12 meter (40-foot) elevation above grade.
b. Install fireproofing for air fin-fan cooler supports that are installed on top of pipe rack
from grade to point of support for the air cooler including the air cooler support legs.
Figure 2:
6. For towers and vertical vessel skirts, the contractor shall:
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Figure 3:
a. Install exterior fireproofing for the full load bearing height.

b. Install interior fireproofing if the skirt has either:
1) An access opening greater than 600 mm in diameter.
2) More than one access opening.
3) Pipe openings with an annulus clearance around the pipe or pipe insulation in
excess of one inch.
c. Install fireproofing for skirts that contain flanged piping.
d. Install fireproofing for skirts that are not closed off at bottom such that interior could
be exposed to fire from below.
e. Refer to Standard Drawings C-ST-6006 M-ST-6009-01, M-ST-6009-02.
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Anchor bolts for vertical or horizontal vessels shall not be fire proofed or covered
over by fire proofing.
7. For hydroprocessing reactor skirts, the contractor shall:

a. Install fireproofing to the bottom of the hot box.
b. For hydro processing reactor skirts with a proprietary hot box design at the shell-toskirt joint, the hotbox shall be insulated with high temperature calcium silicate with
an installed stainless steel jacket. Contact the ETC Fire & Process Safety Team for
details.
8. For horizontal vessels and exchangers, the Contractor shall install fireproofing if the
saddles are more than 300 mm in height at the lowest point from the bottom of the vessel
to the top of the foundation support.
9. For fired heaters and/or furnaces, the Contractor shall:
a. Install fireproofing on the vertical columns and horizontal beams supports up to the
heater/furnace floor level
b. Not install fireproofing on the main frame and side plates of the fired heater/furnace.
10. For firewalls, bulkheads and decks/floors, the Contractor shall install the fireproofing on
the side of the bulkhead exposed to the fire hazardous equipment to the rating specified
by Company.
7.2
Critical Equipment
1. The contractor shall employ a total system approach to protecting critical
instrumentation. This means protecting all components of the critical system including
power, control, instrument and alarm wiring; and pneumatic tubing, valve actuators,
junction boxes, and home runs.
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Figure 4:
2. For Critical Systems Including Valves, Instrumentation and Shutdown Systems that
require fireproofing, the Contractor shall consider these alternatives:
a. Failsafe design
b. Routing/locating outside of FEE wherever possible
c. Where the above have not been used, one of the following protection systems shall be
employed (in order of preference):
d. Critical instrument and power cables within fire hazard areas shall be fire resistant,
steel wire armoured, designed and certified to IEC 331, enhanced to withstand 950C
for 3 hours.
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Figure 5:
Fire-Resistant Wiring Needing Steel Conduit - uses wiring or cable with electrical
insulation which will withstand exposure up to 1093C for at least 20 minutes. The
cable must be installed inside a steel conduit for support (e.g., Cable USA, Inc.'s
Integraflame Circuit Integrity Cable).
Fire-Resistant Wiring with Rigid Sheathing - can be of two types: 1) wiring
enclosed by mineral insulation inside an Incoloy 825 shield (e.g., Pyrotenax MI
Cable); or 2) nickel conductors enclosed by silicon dioxide insulation in a stainless
steel sheath (e.g., Meggitt Safety Systems' SI 2400 Fire Cable). Neither system
requires conduit.
Nonfire-resistant Tubing or Wiring with Thermal Insulation - protects critical
instrument leads or electrical wiring that is not heat resistant (e.g., plastic tubing and
wiring with PVC insulation). It consists of the tubing or wiring inside a rigid steel
conduit covered by thermal insulation and stainless steel weather jacketing.
Conduit - rigid steel with steel fittings and covers. Supports should be spaced 2 m or
less in horizontal runs and 2.5 m or less in vertical runs to support the weight of the
fireproofing material and to avoid sagging during a fire. In fire hazard areas, conduit
supports should be insulated because they may conduct heat inside the fireproofing
during a fire.
Thermal - insulation that can withstand exposure up to 1093C for at least 20
minutes should cover the conduit. Due to the short exposure, most thermal insulation
for pipe will be adequate if it is at least 38mm thick. Extended protection may be
gained by using ceramic fiber or two-layer calcium silicate insulation. Mineral wool
would also work, but for a shorter length of time. To seal against weather and protect
against mechanical damage, a galvanized or stainless steel weather jacket secured
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with stainless steel bands should cover the insulation. Aluminum weather jacketing
would melt, exposing the insulation to damaging effects of the fire or hose streams.
3. Controls and Power Circuits
a. The Contractor shall consider protecting the electrically energized control circuits by
using fire resistant cable or fireproofing electrical conduit with high temperature
thermal insulation protected by 10 guage stainless steel sheathing held in place by
stainless steel banding.
b. Switchgear housing and junction boxes for power and control of emergency
shutdown and isolation valves and motor starters shall be located outside the FEE.
1) If this equipment must be placed closer, the entire enclosure, as well as the rear of
any exposed mounting support plate, shall be fireproofed.
2) Switchgear and junction boxes can also be protected to a lesser degree by
installing a radiant heat shield between the enclosure and the potential fire source.
c. The Contractor shall consider protecting the normally pressured pneumatic control
circuits by using 304 or 316 stainless steel tubing.
1) The Contractor shall determine if exposing the pneumatic tubing to UL 1709 fire
conditions for 20 minutes will adversely affect the action of the valve actuator.
2) If so, the Contractor shall fireproof the pneumatic tubing within the FEE by installing high temperature thermal insulation protected by 10 gage stainless steel
sheathing held in place by stainless steel banding.
7.3
Main Cable Runs

Home runs for cable trays and conduit banks shall be routed outside FEEs wherever possible.
This includes routing underground and routing on the upper level(s) of elevated pipeways at
least 15 m (50 feet) above the ground and outside the drainage path of hydrocarbon spills.
1. Home runs located within 15 m (50 feet) of fire hazardous equipment or drainage that
could expose them to a spill fire (e.g., areas within the drainage pattern of pumps
operating over 315C (600 F), or over the auto-ignition temperature, or pumps with a
history of fires) shall be fireproofed if loss from the home run and corresponding facility
down time is unacceptable.
2. It is often preferable to separate the critical instrumentation and alarm wiring from the
home runs.
3. Non-critical home run cables shall be fireproofed based strictly on economics (e.g., cost
of fireproofing is much less than the cost of replacing the home run damaged by fire).
4. Critical cables shall be protected by one of the following methods to prevent internal
temperature from exceeding 93C (200F) for 20 minutes in a 1093C (2000F) fire per
UL 1709:
a. The conduit bank or tray shall be wrapped with flexible blanket insulation designed
for use at 1093C (2000 F) and covered with stainless or galvanized steel weather
jacket and stainless steel bands.
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Figure 6:
b. Boxed-in cable trays shall be fireproofed with high temperature calcium silicate
prefabricated panels and weather jacketing.
c. Derating the reduction of electrical cable current rating (current-carrying capability)
due to the inability of the surrounding medium, usually air, to adequately dissipate the
heat of operation. Thermal insulation and fireproofing covering cables may restrict
normal cooling and cause derating.
d. Nameplate/tags must be fastened external to the Darmatt.
7.4
Actuators
The Contractor shall use an intumescent coating such as K-Mass to fireproof the actuators of
critical valves
7.4.1
K-Mass Fireproofing System
1. K-Mass is a Chartek-based intumescent coating system, shop applied to a thickness of

approximately 13mm
Critical electric motor operated valves requiring fireproofing shall have their motors
fireproofed, together with the connecting cable glands. Flame paths of the motor housings
shall be maintained, with the K Mass chamfered at 45 degrees at the exit of the flame paths to
maintain the certified flame path length. Nameplate/tag fastenings shall be external to the K
Mass. The handwheel and engaging lever shall not be fireproofed and shall be accessible
outside the fireproofing. The thermal overload cut-off device of the motor shall not be
removed, since MOV valves are not normally in continuous powered use. The fireproofing
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design shall, however, be reviewed with COMPANY to ensure that the valve will not
overheat because of the blocking of heat dissipation through the motor housing.
7.4.2
Darshield Engineered Fire Protection Enclosures
1. The Darshield enclosure system utilises high thermal performance material encapsulated
within stainless steel skins. Panels are designed to be removable for in-service inspection
and maintenance.
Where required, air filters, lubricators and solenoids for AOVs shall be fireproofed with this
system. The enclosures can withstand hydrocarbon flame temperatures in excess of 1200C
for up 120 minutes, and can withstand jet fires and blast overpressure.
7.5
Penetrations Through Fire Walls and/or Fire Barriers

1. Penetrations through fire walls and/or fire barriers shall be sealed.
2. Fire rated doors and windows shall be installed to protect the normal access openings,
while fire rated penetration seals/sealing materials are required to seal openings for
utilities and process piping.
3. A firestop shall satisfy these requirements:
a. Meet the same fire rating as the barrier in which it will be used.
b. Accommodate the penetrating items, including any requirements for motion, thermal
expansion or other functions.
c. Function as a smoke barrier.
d. Be easy to remove and re-apply to allow for future modifications.
7.6
Control Rooms, Living Quarters and Other Buildings in Process Areas
7.6.1
All Buildings
All buildings shall have fire safety of buildings and facilities with SNiP RK 2.02-05-2009.
7.6.2
Buildings Within Fire Hazard Area
1. Pump houses shall have fireproofing on the main vertical columns and main horizontal
beams. Where air coolers, water and air cooling condensers (except for shell and coil
condensers), heat exchangers, reflux and condensate vessels and separators, are located
on the top of a pump house or a blower house, the roof shall be constructed from non
combustible or fire resistant material with a fire resistance rating of at least 1 hr.
Compressor and blower houses shall have fireproofing on the vertical and horizontal steel
structure supporting the crane.
If fireproofing is required on pump, compressor and blower house walls, it shall have a
fire-resistance rating of at least 1 hr.
2. When an installation or building is required to meet an A rating, it shall meet the
requirements of ASTM E-119.
3. When an installation or building is required to meet an H rating, it shall meet the
requirements of UL 1709.
4. H60 1 hour fire resistance without blast overpressure.
5. Equipment may also be mounted outside the boundary of the Fire Hazard Area Envelope.
6. Nameplate/tags must be fastened external to the Darshield.
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7. When an installation or building is required to meet a J rating, it shall meet the

requirements of UK HSE Standard OTI 95-634.
8. J60 1 hour fire resistance.
8.0
INSTALLATION AND WORKMANSHIP
8.1
Introduction
This specification only defines technical requirements. The scope of supply, documentation
requirements and all other commercial/contractual requirements for purchase specifications
are defined in the relevant Material Requisition.
8.2
General
1. Fireproofing shall not be installed if the ambient temperature is below 1.7C (35F) or
above 35C (95F), except when provisions for heating and drying the materials and
protecting the work is provided. The heating and drying provisions shall be approved by
the Company before work starts.
2. Characteristics
a. Performance
1) Fireproofing materials and applications shall be suitable for the operating
conditions specified.
2) Fireproofing shall not interfere with the operation, access or maintenance of the
surrounding equipment.
3) Fireproofing materials and applications shall have a minimum service life of 30
years.
4) Reliability
5) CONTRACTOR shall warrant the fireproofing (materials & application) against
cracking for 1 year after start-up.
6) Fireproofing shall not require any maintenance for the life of the materials.
3. All fireproofing located outdoors shall have exposed edges sealed with mastic, caulking,
or flashing to prevent seepage of water behind the fireproofing. The mastic, caulking or
flashing shall have the same fire resistance rating as the fireproofing.
4. All fire proofing shall be applied to a properly prepared substrate (refer to NACE RP
0198).
a. Preparation of the substrate shall consider the fireproofing material to be applied and
the service expected from the fireproofing material.
b. Surface preparation shall be in accordance with the material manufacturer's
application instructions.
c. Any damage to the surface preparation during transportation or installation shall be
repaired in accordance with manufacturers instructions BEFORE fireproofing is
installed.
d. Precautions shall be taken to prevent over shot, dust exposure, introducing potential
sources of ignition, and other associated hazards prior to preparing existing structural
members or equipment supports for surface preparation and priming.
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5. PFP materials shall be applied using installers that have been approved by the PFP
manufacturer.
6. Precautions shall be taken to prevent over spray, splashing, or dripping of fire proofing
materials or marring or damaging of items or equipment that are not to be fireproofed.
a. All exposed items that are not to be fireproofed shall be masked or otherwise
protected to prevent any carryover, splashing, dripping, marring, or damaging.
b. Upon completion, masking and other materials shall be removed and disposed of
properly.
c. The work area shall be completely cleaned of any excess material and left in a
satisfactory and operable condition.
7. All coated surfaces shall be examined to identify potential water entrance areas that must
be sealed with an appropriate sealing material for the application.
a. All termination points of the coating shall be arranged to drain off water on horizontal
shelf areas.
b. Special care shall be taken to caulk around water stop protrusions such as brackets,
flanges, valves, pipe entrances, stanchions, heavy welded seams and similar welded
attachments and at intersects which interrupt the smooth contour of the protected
surface area.
8. Fireproofing shall not cover nameplates, code inspection plates, or inspection openings.
Non-fireproofed areas shall be masked prior to application.
9. Fireproofing shall be sprayed, troweled, or pneumatically applied to the required
thickness in accordance with this specification and the material manufacturer's printed
application instructions. Exception: Wrap systems for cable trays.
10. If fireproofing is to be applied to a painted surface, the paint shall be fully cured prior to
application and shall be compatible with the fireproofing material selected.
11. All exposed corners shall be chamfered or rounded.
12. Top surfaces of fireproofing shall be sloped for drainage.
13. All installed fireproofing shall be smoothed with trowels, damp paint rollers, and/or
brushes prior to full curing.
14. After curing, a compatible sealer and topcoat shall be applied to the fireproofing unless
otherwise specified by the Company. Topcoating material shall be in accordance with the
manufacturer's recommendation and shall be approved by the Company.
15. All waste, droppings, and spillage shall be cleaned up while material is still wet and
before the material has begun to set.
16. All penetrations shall be completely filled to form a uniform fire rating consistent with
the rating of the barrier.
17. PFP applied to structural components in fabrication yards which are then transported off
shore shall be inspected for damage prior to final acceptance.
a. Connecting joints, buttresses, angles, welded plates, etc., shall be prepared using
similar substrate preparations as applied to the structural members prior to the PFP or
caulking being applied to the connecting joints.
b. Lifting lugs and attachments for rigging shall be left un-fire proofed until final
installation is complete
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8.3
FPM-DU-5091-TCO
PFP for Equipment Items

1. The material considered in this subsection is for the protection of specific equipment
items with a rigid substrate. Applications include shut down valves, valve actuators,
control and power wiring, etc. that have not been designed to be fail safe.
2. For critical equipment which requires PFP, the entire system (equipment, control and
power) shall be analyzed to determine scope of PFP.
3. The fireproofing shall be able to maintain an internal temperature in the protected
equipment below 149C (300F) for a minimum of 30 minutes in a 1093C (2000F)
petroleum fire. The test should be equivalent to UL-1709 in that it should have a
contained heat flux rate of 65,000 Btu/sq. ft./hr. and shall reach 1093C (2000F) within 5
minutes of ignition.
4. The performance under UL-1709 test conditions shall be substantiated by documented
results of actual fire testing.
5. The material shall be Thermal Designs KMASS or Company approved equal. The
application of this type of fire proofing shall be preformed by the application vendor at
his facility.
8.4
PFP for Metal Surfaces

1. All steel members to be fireproofed shall be thoroughly cleaned of mill scale, rust, loose
concrete, soot, grease, oil, loose or flaking paint, and other materials which might impair
the bond between the member and the fireproofing agent. Metal surfaces shall be
sandblasted in accordance with manufacturer's instructions.
2. Steel and metal surfaces and components shall be primed in accordance with the
fireproofing material manufacturer's recommendations.
3. Exposed joints between steel and the PFP material shall be sealed with waterproof mastic
or caulking material after fireproofing is complete.
4. Any intersections between steel to fireproofing or where water may enter shall be
caulked. The fireproofing shall be sloped to facilitate drainage.
8.5
PFP for Penetrations

1. The protection provided for the penetration shall form a complete system.
a. Where there are penetrations in the barriers, the penetrations shall be protected with
systems and materials that are compatible with the systems, materials, and equipment
provided to form the barrier as well as be consistent with the fire resistant ratings of
the barrier.
b. The following shall be considered penetrations: (including but not limited to) doors,
windows, support brackets, pipe, conduit, cable penetrations, etc.
2. The material for the penetration seal in the barrier shall be:
a. A one part intumescent latex elastomer.
b. Capable of expanding 3 at 538C (1,000F).
c. Thixotropic.
d. Listed by U.L. (UL 263, UL 1479).
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e. 3M Fire Dam 150 Caulk, 3M Fire Barrier CP25EB+Caulk, or Company approved

equal.
8.6
PFP for Flexible Items

1. The materials and application for joining and penetration protection for the selected
material shall be commensurate with the fire proofing system selected.
2. The material considered in this subsection shall be considered for generally flexible
substrate applications such as certain piping, cable trays, cable, etc.
3. The material shall:
a. Be endothermic blankets of felt like material made up of a combination of ceramic
fibers and an inorganic endothermic material.
b. Be flexible and not support flame.
c. Provide low smoke evolution.
d. Be durable, weather, and corrosion resistant.
e. Not absorb moisture.
f.
Be unaffected by chemicals typical of hydrocarbon processing environments.
g. Be covered with stainless steel with stainless steel retaining devices. Exception: Fire
rated blankets for valves and flanges need not be provided a stainless steel weather
jacket.
h. Be 3M Interam E-5 series Mats or Company-approved equal.
8.7
Thickness
1. The thickness of fireproofing shall be noted for each structure, equipment, or component
to be fireproofed.
2. The manufacturer's application recommendations, thickness tables, and curing times shall
be strictly adhered to, unless otherwise specified by the Company.
3. The fireproofing materials approved for use in Section 6.1 of this specification shall be
applied to the following thicknesses for a three hour level of protection:
Pyrocrete 241: 3.5 cm (1-3/8)
Portland Cement concrete: 6.35 cm (2.5).
8.8
Reinforcing, Laths, and Studs

1. All fireproofing shall be reinforced as recommended by the fireproofing manufacturer.
2. Reinforcing materials shall be anchored to surfaces by welding, bolting, wiring, or beam
furring clips. The materials shall be anchored so that no displacement will occur during
the application of fireproofing material.
3. A metal lath overall shall be provided for flat surfaces, such as tower skirts, walls,
ceilings, and decks. The metal lath overall shall be secured with approved anchoring
methods.
4. If laths and studs are required, studs shall be attached by electric welding, ram set,
pneumatic power or epoxy-backed studs, and speed clips.
a. Epoxy-backed studs shall not be used unless approved by the material manufacturer.
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b. Steel studs and weld areas shall be prepared and coated prior to fireproofing.
5. Tie wire or hog rings shall be used every 152 mm (6 inches) to keep overlapping sheets of
lathing flush together. No bows or gaps shall be allowed.
8.9
Workmanship
1. Workmanship shall be in accordance with Company specifications, with the additional
requirement that the primer used on specific painting systems shall be in accordance with
fireproofing manufacturer's recommendations.
2. If the primer required conflicts with Company paint specifications, the alternate shall be
approved in writing by the Company prior to application of the fireproofing.
3. Other trades shall be restricted from working on or adjacent to freshly applied
fireproofing for at least 24 hours after application has been completed if such work will
interfere with or damage the fireproofing.
9.0
QUALITY ASSURANCE PROVISIONS
9.1
Installation Contractor Qualification

The installation Contractor shall demonstrate that both the company and personnel who will
be directly involved on the project are qualified by the manufacturer of the proposed PFP
system. This shall include all relevant specialized equipment.
9.2
Quality Control Plan

1. Quality assurance provisions shall be in accordance with Company specifications, with
the following additional requirements.
2. Contractor shall have a QA/QC program to ensure that the manufacturer's installation
requirements have been fulfilled.
3. A detailed QCP shall be submitted for approval before commencement of the work.
4. The QCP shall include all activities inherent to the PFP works that directly influence the
final quality of the application.
5. The QCP shall include, but not be limited to, the following inspection and control
activities:
a. Material inspection on delivery.
b. Storage of PFP materials.
c. PFP application equipment (type and efficiency).
d. Surface preparation (ambient conditions, substrate cleanliness and roughness).
e. Primer application (approved type of primer, ambient conditions, film integrity, film
thickness).
f.
PFP application (ambient conditions, surface cleanliness and primer cure, masking,
mesh reinforcement installation, ratio checks when using plural component spray
machines, PFP film integrity and thickness).
g. Topcoat application (ambient conditions, surface cleanliness and PFP cure, type and
thickness).
h. Repairs (surface preparation, primer, PFP application as listed above).
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i.
Final inspection.
j.
Final documentation review and submittals.
FPM-DU-5091-TCO
6. The Contractor shall assist the Company representative in making any tests or inspections
required.
7. The materials, methods of application, and quality of work performed shall at all times be
subject to the inspection and approval of the Company.
8. The Contractor shall generate and submit to the Company a fireproofing inspection
report, detailing work scope, dates of application, surface preparation, weather conditions,
material batch, application methods, repairs, comments and thickness measurements
records.
9. The Contractor shall provide the Company with written confirmation that any newly
developed alternate materials have been tested by an approved agency and will provide
the specified endurance rating, using the test(s) methods listed in Section 5.0 of this
specification.
9.3
Quality Control Forms

1. The quality controls detailed in the QCP shall be recorded on project specific QC forms,
and shall clearly identify the protected item or area, preferably with the use of attached
PFP drawings.
2. The QC forms shall include, but not limited to, the following information:
a. Details of the item or area to be protected.
b. Details of contractor and key personnel.
c. Details of surface preparation and primer application.
d. Ambient conditions during PFP application.
e. Batch numbers of PFP material applied.
f.
Quantity of PFP material and mesh reinforcement installed.
g. Thickness of PFP material applied.

h. Surface area in square meters protected.
i.
Details of equipment used.
3. All QC forms shall be completed within two days (maximum) of referenced PFP
application and shall be signed for acceptance of the work carried out by the owner or his
authorized representative.
9.4
PFP Thickness Requirements

1. The average measured PFP thickness shall be within the following tolerance range of the
specified design thickness: -0 mm/+2 mm (-0"/+0.08").
2. The following criteria shall be used for determining the minimum required PFP thickness.
a. The minimum acceptable thickness at any point shall not be less than 85% of the
design thickness up to a maximum of 1.5 mm (0.06") less than the design thickness.
b. In other words, for thicknesses up to and including 10 mm (0.39") the minimum
allowable thickness is 85% of the design thickness.
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c. For thicknesses above 10 mm (0.39") the minimum allowable thickness is the design
thickness less 1.5 mm (0.06").
9.5
Sample Area
1. Before commencing PFP application, a sample area on the installation itself shall be
identified and protected in accordance with the project PFP requirements.
2. The surface finish shall be agreed on by all parties and used as a reference standard for all
PFP application.
3. Acceptance of the sample area shall be recorded on a specific QC form.
4. The sample area shall have dimensions of at least 2 m x 2 m x 2 m (6.6 ft. x 6.6 ft. x 6.6
ft.) and shall be representative of the surfaces to be protected.
9.6
Final Inspection
1. Final inspection of the PFP work shall be carried out by representatives of the installation
contractor, owner, fabricator and manufacturer. The final inspection shall include, but not
be limited to, the following points:
a. Visual inspection to verify surface finish in accordance with sample area.
b. Visual inspection to verify no reinforcement mesh exposed.
c. Visual inspection to verify no debonding at terminations.
d. Visual inspection to verify no blisters in PFP layer.
e. Final applied PFP thickness.
f.
Physical inspection to check for possible hollow areas or delamination between layers
of PFP material.
g. Physical inspection to verify no cracks > 2 mm (1/8") wide exist in the PFP or
between PFP and sealants and the protected devices.
h. Physical inspection of joints and end surfaces to verify proper application of sealants,
caulking or flashing to prevent water ingress beneath the PFP.
2. Any repairs or rework shall be noted and carried out in accordance with the
manufacturer's approved procedures.
3. Acceptable items or areas shall be signed off by all parties on specific release certificates.
9.7
Preparation for Shipping and Storage

Preparation for shipping and storage shall be in accordance with Company Specifications,
with the additional requirement that the materials shall be furnished in factory sealed
containers. Each container shall have either the UL or FM label indicating independent
production quality control inspection by one or both agencies.
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Appendix A.
PROFORMA FIREPROOFING SCHEDULE
A.1.1. UNIT X
The following tables identify equipment supports, structures and facilities in Unit X that
require fireproofing.
A.1.2. Multilevel Equipment Support Structure
Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts
A.1.3. Piperacks
Tag No.
Description
A.1.4. Air Coolers

Tag No.
Description
A.1.5. Vertical Vessels, Columns and Similar Vessels

Tag No.
Description
Contents
Volume m
Orient
A.1.6. Horizontal Vessels and Heat Exchangers

Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
A.1.7. Fired Heaters

Tag No.
Description
A.1.8. Critical Emergency Shutdown Valves

Tag No.
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Service
F/Proof
Required
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Commemts
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A.1.9. Critical Instrument and Power Cables

Tag No.
Description
Service
F/Proof
Required
Application/
Commemts
Service
F/Proof
Required
Application/
Commemts
A.1.10. Critical Cable Trays

Tag No.
Description
A.1.11. Buildings
Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
A.1.12. UNIT Y
The following tables identify equipment supports, structures and facilities in Unit Y that
Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts
A.1.14. Piperacks
Tag No.
Description
A.1.15. Air Coolers

Tag No.
Description

Tag No.
Description
Contents
Volume m
Orient

Tag No.
Description
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Volume m
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Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts

Cable No.
Description
Service
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts

Cable No.
Description
Service

Identity
No.
Description
Service
Orient
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts
A.1.22. Buildings
Tag No.
Description
Contents
Volume m
Orient
A.1.23. UNIT Z
The following tables identify equipment supports, structures and facilities in Unit Z that
Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
A.1.25. Piperacks
Tag No.
Description
A.1.26. Air Coolers

Tag No.
Description
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Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts

Tag No.
Description
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts
Contents
Volume m
Orient
F/Proof
Required
Application/
Commemts

Tag No.
Description

Cable No.
Description
Service
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts

Cable No.
Description
Service

Identity
No.
Description
Service
Orient
F/Proof
Required
Application/
Commemts
F/Proof
Required
Application/
Commemts
A.1.33. Buildings
Tag No.
Description
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Appendix B.
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Design and Installation of Passive Fireproofing for

Hydrocarbon Pool Fires in Onshore Processing Facilities

Industry Codes and Standards ...................................................................... 55

DETERMINING FIREPROOFING NEEDS ................................................... 62

Evaluate Fire Hazards .................................................................................. 62

FIRE RESISTANCE RATINGS .................................................................... 65

FIREPROOFING MATERIALS SELECTION ............................................... 66

SPECIFIC APPLICATIONS ......................................................................... 70

INSTALLATION AND WORKMANSHIP...................................................... 79

QUALITY ASSURANCE PROVISIONS....................................................... 83

Installation Contractor Qualification ............................................................... 83

APPENDIX A. PROFORMA FIREPROOFING SCHEDULE .................................... 86

d. U.L. (UL 263, UL 1479).

Serious loss of production capacity.

2. Fireproofing shall not be installed in these situations:

g. Determining fireproofing needs shall involve an experienced and risk-based

Industry Codes and Standards

Heat Resistant Concretes. Specifications

Building Structures. Fire Resistance Tests. General Requirements

Building Structures. Fire Resistance Tests. Bearing and Enclosing

Building Structures. Fire Resistance Test Methods. Doors, Gates

Building Materials. Flammability Tests

Construction Structures. Methods of Defining Fire Hazard

Explosion Hazard. General Requirements New Edition 1999

Fireproofing Compounds for Painting and Coating Wood and Metals.

Electrical Rules. Electrical Installation in Fire Danger Zones Chapter 7

USSR Ministry of Oil Refinery and Petroleum Industry Engineering

Design Standards for Thermal Power Plants

Departmental Guidelines for Design of Loading/Unloading Railway

Fire Safety of Buildings and Facilities

Crude Oil and Petroleum Products Storage Tank Farms

International Codes and Standards

American Petroleum Institute (API)

Fireproofing Practices in Petroleum and Petrochemical Processing

Design and Construction of LPG Installations.

Fire Protection Considerations for the Design and Operation of

American Society for Testing Materials (ASTM)

Standard Test Method for Evaluating the Influence of Thermal

Standard Specification for Thermal Insulation for Use in Contact with

Fire Tests of Building Construction Materials.

Specification for Portland Cement.

Flexural Strength and Modulus of Elasticity of Chemical Resistant

Specification for Coarse Aggregate for Bituminous Paving Mixtures.

Test Method for Rubber Property Durometer Hardness.

Test for Surface Burning Characteristics of Building Materials.

Method for Fire Tests of Buildings Construction and Materials.

Thickness and Density of Sprayed Fire-Resistive Material Applied to

Cohesive/Adhesion of Sprayed Fire Resistive Materials Applied to

Test Method for Effect of Deflections of Sprayed Fire Resistive

Compressive Strength of Sprayed Fire Resistive Material Applied to

International Electrical Committee

Tests on Electric Cables under Fire Conditions.

Performance Requirements for Cables Required to Maintain Circuit

Chevron Tank Manual Fire Protection Safety in Designs Manual.

Project Standard. Chevron Fire Protection Guidelines for New Projects.

UK Health and Safety Executive

Jet Fire Resistance Test of Passive Fire Protection Materials.

National Association of Corrosion Engineers (NACE)

The Control of Corrosion Under Thermal Insulation and Fireproofing

National Fire Protection Association (NFPA)

Standard on Basic Classification of Flammable and Combustible

Underwriter Laboratories (UL)

Standard for Rapid Rise Fire Tests of Protection Materials for