aboard FPSO.pdf - Industrial Fire Journal

FPSO – PASSIVE SAFETY
All aboard FPSO safety
Floating production storage and offloading (FPSO) units
and other offshore assets require critical firewater to be
readily available at a moment’s notice – but how to
ensure fire systems and piping are not adversely
affected by the challenging environments they are
expected to work in? Jose Sanchez de Muniain looks at
the latest in fire water protection solutions as well as
Allan Beeston,
Global Manager
(Fire Protection) for
Morgan Thermal
Ceramics’ range of
FireMaster
products.
FireMaster 607 is
popular because it
can be easily
installed and
removed –
depending on the
jacketing system
used – with no
welding.
more established systems.
Flexible piping for critical firewater
The Elastopipe project began in 1996 as a collaboration between
Swedish company Trelleborg and a number of industry stakeholders
(Conoco-Phillips, Norsk Hydro, BP Amoco, Statoil amongst others)
and Royal Norwegian Navy Material Command.
These stakeholders had noted the launch in 1990 of a jet-fire
resistant rubber compound by Trelleborg. Hans-Leo Hals, Elastopipe
Group Product Manager, explains more: “They wanted to see a
non-corrosive system that could also withstand both high impact
and jet fires. They already knew we had Firestop (technology
providing blast-proof, passive fire protection of structures and
equipment), so the question was, could it be used to coat existing
materials, or could we develop a new type of solution?” The answer
was a resounding yes, and since its commercialisation in 1998 ,
Elastopipe systems have been installed in six offshore locations for
companies that include BP Amoco, Statoil and Conoco-Phillips.
So what makes Elastopipe special? Three layers make up the
non-corrosive, rubber-like Elastopipe – an outer fire shield, middle
pressure liner, and inner layer. The outer layer provides the jet-fire
resistance, and it can resist a heat flux of 390kW/m 2 , as well as
temperatures above 1,350°C and flame speeds above the speed
of sound, for an impressive one hour, with no water in the pipe for
the first five minutes.
It also has a high impact resistance, and when struck it behaves
similarly to a car tyre – first it bends and then it goes back to its
original shape. “That means that even after impact it will transport
the liquid inside it,” explains Hals. In fact, the system can maintain
burst pressure following a collision force of up to 800J. It can also
tolerate an explosive overpressure pulse of 1.5 bar and 200 ms
duration. But perhaps what makes this solution unique in the
market is its corrosion-free properties. Hals points out that in some
areas of the world traditional water deluge systems incorporating
stainless steel pipes can suffer significant degradation in as little as
two years – which can result in expensive refurbishment or even
replacement programmes. “In Australia for example you have high
temperature and humidity, so all the ingredients for corrosion are
there. In other areas marine growth can close up nozzles within
months.” In locations such as these, high levels of maintenance and
repair not only add significant costs, but also – importantly – they
can interrupt production. “Traditional steel piping requires hot-work
on site which naturally has an impact on normal operations.” This
isn’t the case with Elastopipe, which requires no hot-work and – in
the case of a refurbishment – little if any disruption.
The maintenance-free side of the Elastopipe system is important
not only in the context of traditional piping for critical water, but also
in the context of the latest generation of oil and gas exploration. The
expected lifetime of offshore assets used to be in the region of 20
years – no longer, points out Hals. “New technology is allowing
operators to dig deeper and we are finding in the oil industry that
the lifetime of assets is increasing to 30 years – in some regions
there is demand for 40 years. We are now currently working on a
lifetime version of 40 years.”
Elastopipe FOR (fire and oil resistant) is the latest version of the
Elastopipe family. As its name suggests, as well as being jet-fire
resistant, the new version of the synthetic rubber-based flexible
piping system can transport organic materials without degrading.
The latest development incorporates a polymer-based lining
material with high resistance against degradation by hydrocarbons
(lifetime of 30 years). Offering weight advantages over conventional
steel the Elastopipe FOR is suitable for H2S ventilation lines,
produced water (water mixed with oil), open and closed drains, and
waste lines.
Ceramic protection
Family-owned Norwegian company Favuseal AS has been supplying
glass-reinforced epoxy (GRE) piping protection since the invention
of the Favuseal Fire Barrier System (FFBS) in 1988.
Favuseal is a thermoplastic compound with extraordinary
properties when subjected to high temperatures. It consists of
mineral fillers inside a thermoplastic “matrix” which is wrapped
around the relevant piping. When subjected to high temperatures
FFBS goes through two phases. Firstly, in the temperature range
200-250 °C, it generates crystal water during an endothermic (heat
absorbing) reaction which prevents the temperature rising further
until the complete release of H 2 O. During the second phase –
which occurs between 700-800°C – the minerals in the fillers
oxidise and form a cellular ceramic material that is glass-like and has
very low thermal conductivity (0.07 W/m°K). The ceramic material
is physically stable in temperatures of up to 1,500 °C, and will
provide 15 minutes of protection with a 5mm layer of Favuseal,
and 30 minutes with 10mm during a violent jetfire – and this is
with dry pipes as opposed to water-filled pipes.
46 ❘ INDUSTRIAL FIRE JOURNAL ❘ FIRST QUARTER 2011 Read our magazine at www.hemmingfire.com

Erik Schlytter-Henrichsen of Favuseal explains that FFBS is often
used to protect the steel and GRE piping in water deluge systems:
“You cannot have a fire protection system containing water due to
the risk of corrosion/contamination and subsequent risk of nonfunctioning
nozzles due to corrosion and foreign contamination. So
the challenge is to keep the pipes' temperature low enough until
the water arrives. So Favuseal buys the system time enough to do
its job.” One of the main benefits of Favuseal is that no hazardous
emissions are created when the system is active: “This makes it
possible for responders to tackle the fire with no risk of inhaling
toxic gases,” explains Erik.
Today the company has installations in South Korea (offshore
and onshore), Middle East, the Netherlands (oil and gas GRE pipes
onshore), Denmark, Norway (cooling systems and firefighting
waterpipes), and a major cable manufacturer is using Favuseal to
protect cables in the North Sea and all over the world.
Traditional solutions
Allan Beeston is Global Manager (Fire Protection) for Morgan
Thermal Ceramics’ (previously Thermal Ceramics) range of
FireMaster products. Thermal Ceramics, headquartered near
Liverpool in the UK, is part of the Morgan Crucible group.
The FireMaster fire insulation solution was especially formulated
in the 80s as a lightweight solution against hydrocarbon and jet
fires, and today it is used in various process and fire protection
solutions both onshore and offshore. Key offshore references for
fire pipe protection include Conoco Sanah, Sevan Marine No4,
Sevan Marine 300 No5, Ningaloo Vision, and Marathon Alvheim.
FireMaster is a non-combustible flexible matt manufactured from
low biopersistence alkaline earth silicate fibres exonerated from
classification as a carcinogenic material under EU health regulations
Elastopipe projects –
new-builds and refurbishments
In August 2008, FPSO Sevan Hummingbird
became the first cylindrical FPSO to be
installed in the North Sea. FPSO owner
Sevan Marine decided to install Elastopipe
for a number of reasons – not least of which
was the material’s corrosion-free properties.
While the original specification for steel
piping calls for system tests every three
months, Elastopipe’s properties mean that
testing is only required every 24 months –
and this only due to the limiting factor of
peripheral materials.
The fact that no welding or metal cutting is
required for Elastopipe installation meant that no disruptions due to hot work were necessary for
the rest of the FPSO Sevan Hummingbird’s installers.
Elastopipe is also experiencing increased take up for major refurbishments of existing stainless
steel fire deluge systems. One such replacement occurred between 2003-2006 on Statoil Hydro’s
Oseberg, which was experiencing corroding welds and pressure leaks. A specifically designed
system was completed by Trelleborg with Aibel Engineering, comprising of 13,000 metres of
Elastopipe, which was installed in a straight one-to-one replacement. Again, no welding or metal
cutting was required.
Hans-Leo Hals of Trelleborg says that with the exception of the Gulf of Mexico, Elastopipe now has
a worldwide presence – not yet the standard of choice on offshore locations but, says Hals,
certainly a material of choice. “It has been time-consuming to certify this type of product because
it is not a standard material, such as steel. However, we have received approval for Elastopipe
installations on a case-by-case basis and hope that it will become a standard material.”
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FPSO – PASSIVE SAFETY
The Favuseal Fire
Barrier System has
been used to
protect fibre
reinforced epoxy
(as above) and
steel piping
since 1988.
for man-made fibres. Its fire protection properties are impressive
and fire tests, explains Allan, have proven performance of the
FireMaster 607 for up to four hours in hydrocarbon fires and one
hour in jet fires. “It is a common solution for FPSO units where
basically process equipment is fire proofed using some kind of
jacketing system – usually a flexible jacket. Commonly there are
many suppliers with different jacketing designs but with a
FireMaster core.” What makes it popular is that as a dry, passive
material it can be easily installed and removed, depending on the
jacketing system used, with no welding required.
With the FireMaster providing the thermal protection, the main
consideration revolves around weather protection and how well the
system is maintained. “In Norway for example there is a standard
approach which consists of a combination of materials that is
slightly different to the norm. NORSOK standards (formed by the
Norwegian petroleum industry with support from the Norwegian Oil
Industry Association) stipulates foamglass on the pipes, with a layer
of FireMaster, and then on top stainless steel cladding. This makes
the system weather-proof, while the foamglass as a closed cell
material doesn't allow water to get through to the pipe.”
There is currently no clear winner as regards jacketing
technologies vs steel cladding, even with the NORSOK (Norwegian
petroleum industry association) preference for steel cladding.
“Flexible jackets were all the rage 10 years ago, but even with the
Norwegian approach in the last few projects I've seen our clients
have used flexible jackets, so it isn't easy to say.” As for the future,
Allan is unsure that there will be any revolutionary developments in
passive fire protection in this field. Thinner solutions with better
jacketing, perhaps, but jet fires require a robust approach: “There is
nanotechnology floating around out there, and we've seen it for
thermal insulation, but it struggles to meet the temperature
requirements of jet fires of 1,100-1,300°C.”
Aerial Firefighting
Conference &
Exhibition
23rd - 24th March 2011
Washington DC
USA
Draeger’s new products
Draeger has launched new product ranges ideally suited to a wide range
of industrial applications requiring extended duration of breathing air and
highly sophisticated body protection, in combination with light and
functional breathing protection.
Applications range from shut-down management in power stations,
petrochemical plants and oil refineries, and confined space entry in all
industries; to land based systems for the armed forces and
decontamination for fire brigades.
The Draeger PAS MAC series of medium pressure breathing air
compressors is setting new standards in mobile long duration life support
systems.
The new range of fully standards-compliant compressors are designed for
use in the most severe of environments, and are available in four size
outputs varying from 185 l/min to 1710 l/min, supplied with either electric
or diesel drive (electric versions also available ATEX zone 1-compliant).
New too is a limited-use chemical protective suit – the Draeger CPS 5800
– which provides protection from gaseous, liquid or solid hazardous
substances in a large range of industrial applications and operations on
board.
The suit meets the highest international requirements of industry, fire
departments and shipping, such as EN 943-1+2:2002 and SOLAS II-2, Reg.
19 (pending).
The Draeger CPS 5800 is made from high quality material (Zytron 500)
resulting in a service life of up to 10 years and with the proven design of
the Draeger WorkMaster pro ET, this suit is very comfortable to wear and
is equipped with the flexible Draeger face cuff.
For breathing protection there is a brand new SCBA that has been tailormade
for industrial and shipping applications.
The Draeger PAS Lite's main benefits revolve around low maintenance,
robustness, and low weight.
It is also approved to the latest requirements of EN137:2006 type II, which
includes the extended flame retardancy requirements for the materials as
required for firefighting use.
Moreover, all versions of the PAS Lite carry the MED ships' wheel mark
which means the equipment is suitable for use on board ships, whilst
passing the mechanical requirements of ATEX, making the equipment
suitable for use in explosive (Zone 0) atmospheres.
Applications for the PAS Lite range from emergency use "wall hanger" on
ships, to day-long airline use on petrochemical plants or utilities process
working.
According to Draeger, the PAS Lite is ideally suited to all industrial and
shipping applications where a simple-to-use, robust and easy-to-clean
SCBA is required.
The PAS Lite is available with ChargeAir connections – especially useful in
petrochemical industries and mining where the facility to rapid charge the
breathing air cylinder is important in emergency situations.
In addition, the system is certified to the latest airline standard EN14593-1
when fitted with the Draeger PAS ASV, allowing seamless integration into
the airline system portfolio.
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48 ❘ INDUSTRIAL FIRE JOURNAL ❘ FIRST QUARTER 2011 Read our magazine at www.hemmingfire.com