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DEP SPECIFICATION

PASSIVE FIRE PROTECTION FOR ONSHORE FACILITIES


Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

DEP 34.19.20.11-Gen.

February 2017

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2017 Shell Group of companies

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned
after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 4
1.1 SCOPE ....................................................................................................................... 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 4
1.4 CROSS-REFERENCES ............................................................................................. 5
1.5 SUMMARY OF MAIN CHANGES............................................................................... 5
1.6 COMMENTS ON THIS DEP ....................................................................................... 6
1.7 DUAL UNITS............................................................................................................... 6
1.8 NON NORMATIVE TEXT (COMMENTARY) .............................................................. 6
1.9 PROJECT DOCUMENTATION REQUIREMENTS .................................................... 6
2. GENERAL .................................................................................................................. 7
2.1 OBJECTIVES.............................................................................................................. 7
2.2 GENERAL REQUIREMENTS..................................................................................... 7
2.3 FIRE SEVERITY ......................................................................................................... 7
2.4 FIRE RESISTANCE DURATION ................................................................................ 7
3. PASSIVE FIRE PROTECTION OF EQUIPMENT AND STRUCTURES ................... 8
3.1 STRUCTURES SUPPORTING EQUIPMENT AND PIPING ...................................... 8
3.2 COLUMN AND VESSEL SKIRTS............................................................................... 8
3.3 CABLES AND INSTRUMENTATION ......................................................................... 9
3.4 PROCESS UNIT PIPE RACKS AND PIPE SUPPORT COLUMNS........................... 9
3.5 BUILDINGS ................................................................................................................. 9
4. WARRANTY AND CONTRACTOR RESPONSIBILITIES ......................................... 9
4.1 WARRANTY ............................................................................................................... 9
4.2 CONTRACTOR RESPONSIBILITIES ...................................................................... 10
5. PRE-APPLICATION REQUIREMENTS ................................................................... 11
5.1 MATERIAL SELECTION .......................................................................................... 11
5.2 MATERIAL DELIVERY AND STORAGE .................................................................. 11
6. MATERIAL PROPERTIES AND APPLICATION OF PASSIVE FIRE
PROTECTION .......................................................................................................... 12
6.1 STEEL SUBSTRATE PREPARATION ..................................................................... 12
6.2 CORROSION CONSIDERATIONS .......................................................................... 12
6.3 CONCRETE .............................................................................................................. 13
6.4 SHOTCRETE ............................................................................................................ 14
6.5 MESH REINFORCEMENT ....................................................................................... 15
6.6 BRICK ....................................................................................................................... 15
6.7 ALTERNATIVE PROPRIETARY MATERIALS ......................................................... 16
7. REFERENCES ......................................................................................................... 18

APPENDICES
APPENDIX A DOCUMENTATION REQUIRED IN PROJECT PHASES .............................. 20
APPENDIX B PIPERACK DETAILS ...................................................................................... 22
APPENDIX C TYPICAL DETAILS OF CONCRETE FIREPROOFING OF
STRUCTURAL MEMBERS............................................................................. 23
APPENDIX D STRUCTURAL COLUMN DETAILS ............................................................... 24

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1. INTRODUCTION

1.1 SCOPE
This DEP specifies requirements and gives recommendations for the design and
application/installation of passive fire protection (PFP) of steel in Fire Protection Zones
(FPZs).
This DEP applies to steel supporting structures and piping and equipment in process areas
and processing plants as well as to storage facilities, jetties and pipe bridges (including
those outside the battery limits) in oil/gas/petrochemical installations.
This DEP is intended to ensure that the extent of PFP applied is effective and practical in
terms of maintainability and reduction of risks.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual (DEM) 1 – Application of Technical Standards.
This is a revision of the DEP of the same number dated February 2015; see (1.5) regarding
the changes.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS


Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorisation to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification and distribution. This DEP may also be applied in
other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.

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1.3.2 Abbreviations

Term Definition

FPZ Fireproofing Zone

HCM Hazard Consequence Modelling

ITP Inspection and Test Plan

PFP Passive Fire Protection

TSA Thermally Sprayed Aluminium

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (7).

1.5 SUMMARY OF MAIN CHANGES


This DEP is a full revision of the DEP of the same number dated February 2015. The
following are the main non-editorial changes to align DEM1 requirements with
DEP 80.47.10.30-Gen:

Section/Clause Change
All Restructured and clarified requirements, enforced use of
shall/should/may for normative statements.
3.3 Added notes from Appendix B.
3.1 Added notes from Appendix C.
6.2 Included notes from Appendix D.

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1.6 COMMENTS ON THIS DEP


Comments on this DEP may be submitted to the Administrator using one of the following
options:

Shell DEPs Online Enter the Shell DEPs Online system at


https://www.shelldeps.com
(Users with access to
Select a DEP and then go to the details screen for
Shell DEPs Online)
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.

DEP Feedback System Enter comments directly in the DEP Feedback


System which is accessible from the Technical
(Users with access to
Standards Portal http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form
and submit.

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record


feedback and email the form to the Administrator at
(other users)
standards@shell.com.

Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.

1.7 DUAL UNITS


This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

1.8 NON NORMATIVE TEXT (COMMENTARY)


Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.

1.9 PROJECT DOCUMENTATION REQUIREMENTS


In order for a project to comply with this DEP, documentation, as specified in (Appendix A),
shall be provided to Principal in the Definition and Execution phases of the project.

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2. GENERAL

2.1 OBJECTIVES
Passive fire protection (PFP) is intended to improve the fire resistance of structures that
support pressure vessels, piping and other equipment located in FPZs. PFP is provided
by the application of concrete or other approved protection materials to structural steel
supports. PFP offers protection against the adverse thermal effects of fire for a defined
period and a defined degree of exposure.
1. PFP should not be considered as a replacement for active firefighting or lead to
relaxation of normal design requirements (spacing and layout considerations) or
precautions in operation and maintenance.

2.2 GENERAL REQUIREMENTS


1. The extent of PFP SHALL [PS] be established on the basis of a fire safety assessment
executed for the particular plant or unit, with reference to DEP 80.47.10.30-Gen.
The zones where PFP is required are called Fire Protection Zones (FPZs). For
designs inside the USA the concept of Potential Fire Source is used.
2. The extent (area of coverage) of PFP applied to equipment and structures shall be
indicated on layout and construction drawings.
3. As there is a wide variation in the design requirements for structures, this DEP shall be
used when specifying PFP for structures not specifically mentioned in (3).

2.3 FIRE SEVERITY


1. The severity of the fire shall be based on hydrocarbon pool fires using the fire
temperature profile per UL 1709.
The hydrocarbon fire test as defined in UL 1709 is applicable to all PFP systems
applied on steel supports and structures.
2. Refer to ISO 22899-1 to determine the performance of PFP material selected for the
protection of structures against credible jet fire scenarios.
The PFP performance test specified in ISO 22899-1 is complementary to other
hydrocarbon fire resistance tests of PFP materials, as specified in UL 1709, BS 476
and ISO TR 834-3.

2.4 FIRE RESISTANCE DURATION


1. Refer to DEP 80.47.10.30-Gen. for the required protection time to be provided by PFP.
For steel structures and equipment requiring passive fire protection, a typical
minimum of 30 minutes protection time against a hydrocarbon fire is provided.
The need for protection times is provided in the FSA, which takes into account fire
size, duration, extent of flame impingement and availability of fixed/mobile
firefighting system. The FSA uses HCM methods, which are mathematical models
to estimate the effect of explosions, fires and dispersion.

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3. PASSIVE FIRE PROTECTION OF EQUIPMENT AND STRUCTURES

3.1 STRUCTURES SUPPORTING EQUIPMENT AND PIPING


1. For PFP on pressure equipment legs or lugs, a minimum gap of 25 mm-50 mm
(1 in-2in) shall be maintained between the PFP and pressure retaining parts.
2. Bolted moment connections of shop-applied, fireproofed, main pipe racks blockouts
should be fireproofed in the field subsequent to erection.
Block outs are typically fireproofed subsequent to erection; however, moment
connection block outs in pipe racks can be ignored with consultation with the
Principal.
3. Structural bracing shall only be fireproofed when required for load cases that are
included with the base fire case and for primary stability of the structure.
4. Where concrete fire proofing is applied to primary or secondary structural members,
refer to Appendix C, and the following notes shall apply:
a. structural sections with a depth less than 300mm (12”) shall be box section;
b. structural sections with a depth greater than 300mm (12”) may be contoured in
shape;
c. reinforcing mesh anchors should be spaced on 500mm (19.5”) centers;
d. anchor clips should be attached to the structural anchor using epoxy mastic;
e. when using hollow box sections of less than 300mm (12”), fire stops shall be
installed every 1.5m (5ft);
f. where proprietary materials are used for reinforcing mesh installations,
Manufacturer/Supplier recommendations should be followed;
g. where economically beneficial, cylindrical forms may be used for columns.

3.2 COLUMN AND VESSEL SKIRTS


1. PFP shall be directly applied on skirts and vessel supports as indicated in
S 20.002-001 and S 20.003-001, if they meet the criteria stated in 3.3.2 Item 1 of
DEP 80.47.10.30-Gen.
a. The skirt PFP shall stop well below the vessel insulation tangent line for hot or
cold insulated vessels.
i. The separation distance between the ring angle and the vessel insulation
tangent line shall either conform to S 20.003-001, or be determined using
heat transfer and stress calculations.
1). Heat transfer and thermal stress calculations shall determine the type
and amount of reinforcement required.
b. The inside of the skirt SHALL [PS] be protected with:
i. PFP if there are flanged pipe connections inside the skirt;
ii. fire resistant insulation material if insulation is required inside the skirt and
there are no flanged pipe connections inside the skirt.
2. PFP shall be applied to steel saddles as required by DEP 80.47.10.30-Gen. Section
3.3.3.
For details of column and vessel skirt fire proofing and sphere support leg fire
proofing, refer to Standard Drawings S 20.002 and S 20.003.

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3.3 CABLES AND INSTRUMENTATION


1. For fireproofing of cables and instrumentation, refer to DEP 80.47.10.30-Gen.
a. Where cable trays have an intumescent PFP material, a non-perforated tray
cover shall be used (Appendix B).
b. Cable trays that are to have PFP shall not be galvanised.

3.4 PROCESS UNIT PIPE RACKS AND PIPE SUPPORT COLUMNS


1. Piping supported from spring hangers or rods shall be protected against failure of the
spring hanger or rod by either:
a. a fireproofed bracket, or
b. a beam located beneath the pipe, with clearance between the beam and the pipe
to permit free vertical movement.
Where failure of the hanger rod will not lead to collapse of the pipe, the
bracket/beam beneath the pipe is not required (Appendix D).

3.5 BUILDINGS
The fireproofing standards, methods and materials specified in this DEP are applicable
to enclosed structures/buildings containing process equipment.
1. All enclosed buildings shall conform to the local fire regulations and building code, as
a minimum.
a. Where enclosed buildings containing process equipment are not included in the
local fire regulations or building code, the requirements specified in this DEP shall
supplement the local regulations/code.

4. WARRANTY AND CONTRACTOR RESPONSIBILITIES

4.1 WARRANTY
1. Contractors undertaking PFP work shall guarantee the quality of their work.
2. For all PFP, the Contractor shall agree with the Principal on a warranty period and
associated condition status, with the following conditions:
a. a minimum period of five (5) years;
b. including details of the material used the surface preparation and the application
method.
3. Five years after the acceptance date of the completed intumescent coating, PFP work
shall comply with the following:
a. no degree of general or pinpoint rusting, as defined by ASTM D610;
b. the quality of adhesion between the PFP and the steel substrate, and between
PFP layers, of not less than 70% of the values specified in DEP
30.48.00.31-Gen.
c. no visual cracking, mud cracking, flaking or blistering of the coating systems, as
defined by ISO 4628-2 and ISO 4628-4;
d. no conspicuous discolouration in the topcoats exposed to the atmosphere.
4. For further details on warranty of liquid-coating systems reference is made to
DEP 30.48.00.31-Gen.
5. For details on concrete material requirements reference is made to
DEP 34.19.20.31-Gen.

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4.2 CONTRACTOR RESPONSIBILITIES


4.2.1 General
1. A pre-job meeting to discuss requirements shall be convened, and include a
representative of the Principal, the Contractor, the applicator and the
Manufacturer/Supplier.
2. For all PFP, work plans, method statements, and quality plans for implementing the
requirements shall be prepared by the Contractor and submitted to the Principal for
review and comments.
3. For detailed Contactor responsibilities for the application of proprietary intumescent
and sublimating liquid-coating systems, reference is made to DEP 30.48.00.31-Gen.
4.2.2 Quality assurance and quality control
The Contractor is fully responsible for all quality assurance and quality control activities.
1. To achieve the required service life of the PFP system, the steel substrate shall be
prepared according to the Manufacturer/Supplier requirements.
Quality assurance, quality control and the professional skill of the application
personnel are essential to this process.
2. The following documents shall be submittedprior to the start of any application of the
PFP:
a. concrete mix design report for the proposed mix including test report of all
ingredients to show conformance to the required specifications and codes;
b. inspection and Test Plan (ITP);
c. quality control procedures, including quality control records (QCRs);
d. erection plan, including method statements covering application methods,
temporary facilities to be installed for application and health, safety, and
environment (HSE) aspects;
e. material and workmanship specifications.
3. In areas where PFP materials have been applied which require curing and are
vulnerable to mechanical damages, construction activities should be restricted.
4. For quality assurance and control including inspection of liquid coating systems, refer
to DEP 30.48.00.31-Gen.

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5. PRE-APPLICATION REQUIREMENTS

5.1 MATERIAL SELECTION


Concrete is typically the preferred material for PFP of structural steel in PFZs.
1. If concrete is chosen as the PFP material, reinforced concrete shall have a minimum
thickness of 50 mm (2 in).
API RP 2218 cites the following on concrete thicknesses as being satisfactory for
steel supports:

Dense concrete thickness UK 1709 rating

50 mm (2 in) 2 hr

65 mm (2½ in) 3 hr

75 mm (3 in) 4 hr

2. Use of reinforced concrete structures in lieu of steel structures with PFP to support
equipment or pipe racks in PFZs may be considered.
3. The use of pre-stressed or post tensioned concrete elements in an FPZ shall be
subject to the approval of the Principal
This is not normal within hydrocarbon processing plants.
4. Weather protection shall be provided during installation as per Manufacturer/Supplier
recommendations and project specifications.
5. If there are physical limitations for installation of concrete PFP, or if the weight of
concrete is a significant issue, the following alternative, proprietary cementitious
systems may be considered.
a. Alternatives to concrete that may be considered are as follows:
i. brick work proprietary systems;
ii. intumescent epoxy coatings;
iii. sublimating materials.
6. Contractor shall provide an economic evaluation based on life cycle costs in the
selection of alternatives.
7. The capacity of the structure to support the weight of the PFP shall be assessed.
8. Applied material thickness shall be supported by independent test results as per
section (2.3).

5.2 MATERIAL DELIVERY AND STORAGE


1. Fireproofing materials shall be delivered to the jobsite in the original factory-sealed
containers and be ready for use.
2. The fireproofing materials original, factory-sealed containers shall bear the name of
the Manufacturer/Supplier, brand and product designation and expiration date.
3. Material containers shall be stored off the ground, under cover and within the
temperature limitations recommended by the Manufacturer/Supplier.

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6. MATERIAL PROPERTIES AND APPLICATION OF PASSIVE FIRE PROTECTION

6.1 STEEL SUBSTRATE PREPARATION


1. For steel substrate preparation, refer to DEP 30.48.00.31-Gen.

6.2 CORROSION CONSIDERATIONS


1. For corrosion protection requirements, refer to DEP 30.48.40.31-Gen.
2. The steel substrate on which the PFP will be applied shall be protected against
corrosion using an approved system (e.g., galvanised, organic coating), that is
compatible with the PFP.
a. PFP shall not cause corrosion of the steel substrate when exposed to the
expected ambient conditions.
3. Where thermal spray aluminium (TSA) coating is used under PFP that could be
exposed to water, the PFP materials shall be selected such that the environment to
which the TSA coating is exposed remains within a pH range of 4 to 8.
4. Each interface between un-fireproofed and fireproofed galvanized steel column and
beam members exposed to the weather shall be protected by cover plates
continuously welded to the steel column/beam in order to prevent ingress of rainwater
between the fireproofing and the steel:
a. In mild or non-corrosive conditions mastic sealants may be used in lieu of cover
plates, subject to approval of the Principal.
b. On steel columns, the fireproofing/steel joint may be protected by a 2 mm
(3/32 in) thick glass reinforced epoxy (GRE) fabric adhered to the concrete and
steel surfaces:
i. For GRE material selection, refer to DEP 30.10.02.13-Gen.
c. Rainwater ingress protection for fireproofing on non-galvanized steel equipment
supports (e.g., vessel skirts, vessel support legs) shall be steel drip angles
regardless of plant design class or freeze/thaw potential.
5. Penetrations through fireproofing, such as clips, attachments, etc., shall be sealed with
a fire resistant polysulfide sealant or other approved material.
6. All construction related cold joints in PFP shall be prepared and installed according to
the Manufacturer/Supplier requirements and project specifications.
7. Block-outs of the PFP shall be incorporated for assembly and for expected
attachments.
8. If welding of fixtures to the surfaces after the application of the PFP is required, the
materials and procedures to be used shall be subject to approval of the Principal.
9. In Design Class III facilities with severe atmospheric corrosion, column cover plates
may be reinforced using a curable 2mm (80MILS) GRP fabric adhered to the structural
column and cover plate (Appendix D).
10. Where fitted, column rain cap gusset plates should be oriented with a 1% slope
(Appendix D).

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6.3 CONCRETE
6.3.1 Material properties
1. For the design and application of concrete fire protection, refer to
DEP 34.19.20.31-Gen. and the following standards:

ACI 318 Building code requirements for structural concrete

ACI 216.1 Code Requirements for Determining Fire Resistance of Concrete and
Masonry Construction Assemblies

API RP 2218 Fireproofing Practices in Petroleum and Petrochemical Processing Plants –


Second Edition

EN 206-1 Concrete – Part 1: Specification, performance, production and conformity

EN 1992 Eurocode 2: Design of concrete structures

EN 197-1 Cement – Part 1: Composition, specifications and conformity criteria for


common cements

EN 197-4 Cement – Part 4: Composition, specifications and conformity criteria for low
early strength blast furnace cement

2. Cement shall be in accordance with ASTM C150 Type 1 or EN 197.


3. Aggregates shall be in accordance with ASTM C33 or EN 13055, and have a
maximum size of 10 mm (3/8 in).
4. Concrete shall be proportioned so that it develops a compressive strength of between
21 MPa (3045 psi) and 30 MPa (4350 psi) at 28 days.
5. Concrete mix shall include an air-entraining admixture if concrete is expected to be
exposed to freezing conditions.
6. Concrete PFP shall be reinforced to prevent shrinkage cracks.

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6.3.2 Application
1. Preparation and application of concrete PFP shall be supervised and inspected
according to the ITP.
2. During preparation and application of concrete PFP, particular attention shall be paid
to the following:
a. condition of the steel substrate;
b. quality and placing of mesh reinforcement;
c. quality and application of the concrete;
d. joints between concrete and steel where exposed to the weather;
e. weather protection where required.
Manufacture/Supplier requirements and project specifications typically specify
protection against heavy rain, frost and other extreme weather conditions during the
application of concrete.
3. In extreme dry and hot conditions, appropriate measures shall be taken to keep the
concrete moist until it sets.
a. Measures such as screening the work area from radiant sunlight and wrapping
the finished work may be required, depending on the severity of the ambient
conditions.
4. For testing of concrete, refer to ACI 318 or the applicable local code and standard.
a. One set of test cylinders/cubes shall be made for every 40 m3 (1500 ft3) of
concrete (i.e., daily testing is not required).
b. Slump shall be measured for every batch on every mix.
5. Galvanised steel which is to be fireproofed with concrete shall not require priming,
except where damage to the galvanised substrate needs to be repaired before
application of the PFP.
6. The application of a topcoat shall be subject to approval of the Principal.
A topcoat is normally not required on concrete PFP surfaces, but it can be
beneficial depending on environmental conditions.

6.4 SHOTCRETE
6.4.1 Material properties
1. For requirements for Shotcrete, refer to the following standards:

ACI 506 Specifications for shotcrete

ACI 506 part 2 Shotcrete – Materials, proportioning and application

ACI 506 part 3 Shotcrete – Execution

EN 14487 part 1 Sprayed concrete – Definitions, Specifications and


Conformity

EN 14487 part 2 Sprayed concrete – Execution

EN 14488 Sprayed concrete – Testing methods

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6.4.2 Application
1. Shotcrete nozzlemen shall be certified in accordance with ACI 506.3 or an equivalent
local standard.
2. Shotcrete shall be troweled smooth after application.
3. Inspection and testing of shotcrete shall be in accordance with ACI 506 or applicable
local code and standard.
a. Test panels shall be 450 mm (18 in) long sections taken from shotcrete installed
on the smallest structural member.
4. If shotcrete is installed on vessel skirts, test panels shall be 450 x 450 mm (18 x 18 in)
squares.
5. One panel shall be tested for each nozzleman, for each 40 m3 (1500 ft3) of shotcrete
installed.

6.5 MESH REINFORCEMENT


1. Mesh reinforcement shall be a minimum of 50 mm x 50 mm x 2.5 mm
(2 in x 2 in x 0.1 in) welded steel fabric, refer to ASTM A185.
2. Mesh reinforcement used in normal weight concrete PFP shall be galvanized steel.
3. The use of non-galvanised steel mesh and ties shall be subject to the approval of the
Principal.
In less severe conditions (e.g., dry arid climates outside the influence of cooling
towers) or where specific site experiences allow it, the use of non-galvanized steel
mesh and ties can be considered.
4. Mesh reinforcement shall be wrapped around the steel section and retained firmly by
clips.
5. If spacers are required between the mesh and the steel surface (to keep the mesh in
position during application of the PFP) concrete spacer blocks may be considered as a
cheaper alternative for studs welded to the steelwork.
6. Welded clips shall be pre-fabricated, attached to steel and galvanized.
7. Field stud welding procedure shall be submitted and will be subject to approval of the
Principal.
8. Mesh reinforcement overlaps shall be at least 50 mm (2 in), and wired at
approximately 150 mm (6 in) intervals.
9. Mesh reinforcement shall be placed so that there is a 25 mm (1 in) clearance from the
face of the steel, and be carefully bent to fit around corners.
10. The longitudinal overlap of mesh reinforcement shall be in the web face, and all
overlaps staggered so that no more than three layers of mesh are present at any one
point.
11. The minimum concrete cover applied on any mesh reinforcement shall be 25 mm
(1 in).

6.6 BRICK
1. Normal brick may be used for PFP of column and vessel skirts, refer to standard
drawing S 20.002.

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6.7 ALTERNATIVE PROPRIETARY MATERIALS


6.7.1 General
1. Alternative proprietary PFP materials may be as follows:
a. light-weight cement/vermiculite based materials;
b. intumescent and sublimating fire protection systems.
Typical proprietary systems include intumescent coatings, which expand and
form an insulation layer when the temperature increases and subliming mastic
materials.
2. Light weight cement/vermiculite based materials shall not be used for piping or
equipment PFP.
3. Cement based vermiculite PFP may be applied to vessel skirts.
a. The poor mechanical resistance should be allowed for in the design.
4. For proprietary PFP systems an approved primer or substrate shall be applied in
accordance with a certified and proven system from the fireproofing coating
Manufacturer/supplier.
5. A topcoat shall be applied according to the Manufacturer/Supplier’s recommendation.
6.7.2 Material properties
1. The material shall have a UL 1709 certified design for structural steel members.
a. If the material does not have a UL 1709 certified design for the specific structural
members, an engineering analysis that demonstrates equivalent protection shall
be submitted and will be subject to approval of the Principal.
2. Where PFP is being used to protect a pipe or vessel itself (not its support), the
proprietary PFP design SHALL [PS] have a fire test certificate from an approved,
independent testing authority.
a. The nomination of the independent testing authority shall be subject to the
approval of the Principal.
3. The Contractor shall provide documentation demonstrating that the following
additional requirements to UL 1709 have been met:
a. the end point metal temperature for the fire exposed piping/equipment has been
defined;
b. the maximum metal temperature corresponding to end of the specified fire
duration has been defined;
c. how the external equipment/piping inspections will be conducted;
d. the maximum expected piping/equipment operating temperature is within the
design operating range of the proprietary PFP material;
e. if thermal insulation is required for process reasons, the design has the insulation
installed over the proprietary PFP material.
4. Any proprietary PFP material shall be asbestos free.
5. The amount of smoke and toxicity of gasses produced by the PFP when exposed to
fire shall be assessed.
6. For jet fire protection material test certification, refer to ISO 22899-1 and
DEP 80.47.10.30-Gen.
7. Materials shall be resistant to hose stream impingement, refer to NFPA 58 Annex H.
8. Materials shall be resistant to environmental influences, refer to NORSOK M-501.

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6.7.3 Application
1. The application Contractor shall be approved and certified by the
Manufacturer/Supplier of the fire protection material.
2. The application Contractor shall have prior experience with the material to be installed.
For surface protection performance and acceptance criteria of fire protection
coating systems reference is made to DEP 30.48.00.31-Gen.
3. Thickness of the proprietary PFP material shall be in accordance with the
Manufacturer/Supplier’s recommended dry thickness.
Thicknesses that are out of tolerance, either too thick or too thin, have been found
to be inadequate for design life.
4. The entire thickness shall be applied in one continuous operation, unless prohibited by
the Manufacturer/Supplier’s instructions.
5. Surfaces on which the material will be applied shall be clean, dry and free of oil and
other contaminants immediately prior to application.
6. Preparation of the steel substrate shall be by abrasive blast cleaning and priming, in
accordance with the Project Specification and the Manufacturer/Supplier
recommendations.
For abrasive blast cleaning reference is made to DEP 30.48.00.31-Gen.
7. Enabling construction works shall provide overspray protection on adjacent piping and
equipment.

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7. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS

DEP feedback form DEP 00.00.05.80-Gen.


Non-metallic materials – Selection and application DEP 30.10.02.13-Gen.
Protective coatings for onshore and offshore facilities DEP 30.48.00.31-Gen.
Thermal spray coatings of aluminium DEP 30.48.40.31-Gen.
Reinforced concrete structures DEP 34.19.20.31-Gen.
Assessment of the fire safety of onshore installations DEP 80.47.10.30-Gen.
Shell HSSE & SP Control Framework, Design Engineering Manual DEM1
(DEM) 1 – Application of Technical Standards
https://eu001-sp.shell.com/sites/AAAAA8432/CF/default.aspx

STANDARD DRAWINGS

Fireproof protection of skirts S 20.002


Support rings for insulation on vessels and heat exchangers S 20.003

AMERICAN STANDARDS

Code requirements for determining fire resistance of concrete and ACI 216.1/TMS-0216
masonry construction assemblies
Building Code Requirements for Structural Concrete ACI 318
Specification for Shotcrete ACI 506.2
Guide to Certification of Shotcrete Nozzlemen ACI 506.3
Guide for the Evaluation of Shotcrete ACI 506.4R
Fireproofing Practices in Petroleum and Petrochemical Processing API RP 2218
Plants
Standard Specification for Steel Welded Wire Reinforcement, Plain, ASTM A185/A185M
for Concrete
Standard Specification for Concrete Aggregates ASTM C33/C33M
Standard specification for Portland Cement ASTM C150/C150M
Standard Test Method for Evaluating Degree of Rusting on Painted ASTM D610
Steel Surfaces
UL Standard for Safety Rapid Rise Fire Tests of Protection Materials UL 1709
for Structural Steel
Liquefied Petroleum Gas CodeAnnex H Procedure for torch fire and NFPA 58
hose stream testing of thermal insulating systems

BRITISH STANDARDS

Fire Tests on Building Materials and Structures (withdrawn) BS 476-1

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EUROPEAN STANDARDS

Cement – Part 1: Composition, specifications and conformity criteria EN 197-1


for common cements
Cement – Part 4: Composition, specifications and conformity criteria EN 197-4
for low early strength blast furnace cements
Concrete – Part 1: Specification, performance, production and EN 206-1
conformity
Eurocode 2: Design of concrete structures EN 1992
Lightweight aggregates EN 13055
Sprayed concrete – Part 1: Definitions, specifications and conformity EN 14487-1
Sprayed concrete – Part 2: Execution EN 14487-2
Testing sprayed concrete EN 14488
Surface preparation and protective coating NORSOK M501

INTERNATIONAL STANDARDS

Fire resistance tests – Elements of building construction ISO TR 834-3


Part 3: Commentary on test method and guide to the application of the
outputs from the fire-resistance test
Paints and varnishes evaluation of degradation of coatings ISO 4628-2
Designation of quantity and size of defects, and of intensity of uniform
changes in appearance – Part 2: Assessment of degree of blistering
Paints and varnishes evaluation of degradation of coatings ISO 4628-4
Designation of quantity and size of defects, and of intensity of uniform
changes in appearance – Part 4: Assessment of degree of cracking
Determination of the resistance to jet fires of passive fire protection ISO 22899-1
materials - Part 1: General requirements

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APPENDIX A DOCUMENTATION REQUIRED IN PROJECT PHASES

A.1 GENERAL
1. Key documents as specified in this appendix shall be provided during the course of a
project.
The documents are required as part of compliance with this DEP.
Figure 1 illustrates the process of the development of the key documentation.
Figure 1 Development process of the key documentation

A.2 DEFINITION PHASE


1. The Project Specification shall be developed by the Contractor during the Definition
Phase and include the following:
a. Amendments to this DEP (signed off by the appropriate Principal Technical
Authority);
b. Definition Technical Specification - Design;
c. Reference to Standard Drawings;
d. Definition Technical Specification – Materials and Workmanship.
2. The Project Specification shall be based on the DEPs and Model Technical
Specifications to be provided by the Principal.
3. The Project Specification shall make reference to standard Inspection and Test Plans
(ITPs) and Quality Control Records (QCRs) for use in the Execution Phase of a
project.

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A.3 EXECUTION PHASE


1. The following documentation shall be produced during the Execution Phase and be
based on the Project Specification:
a. Execution Technical Specification - Design;
b. Execution Drawings (Approved for Construction);
c. Execution Technical Specification - Materials and Workmanship;
d. Method Statement;
e. HSE: TS (Task Statement), JSA (Job Safety Analysis) and RA (Risk Analysis);
f. Execution Quality Plan;
g. Execution Quality Control Procedure;
h. Execution Inspection and Test Plans;
i. Execution Quality Control Records.

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APPENDIX B PIPERACK DETAILS

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APPENDIX C TYPICAL DETAILS OF CONCRETE FIREPROOFING OF STRUCTURAL


MEMBERS

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APPENDIX D STRUCTURAL COLUMN DETAILS

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