API RP 2218 - Fireproofing Practices in Petroleum and Petrochemical Processing Plants
Draft D13 Pre-Ballot Review Sept 6, 2010
Fireproofing Practices in
Petroleum and Petrochemical
Processing Plants
API Recommended Practice 2218
Third EDITION, XX-XX2010
THIS DRAFT DOCUMENT IS FOR REVIEWER USE ONLY.
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Seventh Revision Review Draft for API 2218 3rd Edition
Revised by API Working Team & Kendall C. Crawford, PE, CSP
for the American Petroleum Institute
Considerations for Update of RP 2218
API received a “recommendation” from CSB suggesting changes in API 2218 largely directed toward jet fires. Annex C discusses Jet Fire Considerations” while RP 2218 remains a pool fire standard.
CSB Recommendation 2007-5-I-TX-2 (with 2218 revision response in italics)
Revise API 2218, Fireproofing Practices in Petroleum and Petrochemical Processing Plants, so that conformance with the standard:
addresses jet fire scenarios, -- This is the subject of Annex C
requires more protective fireproofing radii for pipe rack support steel -- addressed specifically in the Foreword, Sections 4.2.3 and 5.1.2.1 and in Annex C
and other measures (e.g., emergency isolation valves, depressuring systems) for pipe rack support steel near process units containing highly pressurized flammables.
Use of isolation is in Sections 1.3, 3.2, 4.1, 5.1.8.1 and especially Section 5.1.9 “Emergency Valves Within A Fire Scenario Envelope”
.
SPECIAL NOTES
This section will be updated by API to use current terminology
Special Notes
API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.
API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction.
Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety datasheet.
Neither API nor any of API's employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of API's employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.
API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.
API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.
Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.
Copyright ~ 2009 American Petroleum Institute
FOREWORD
This publication is intended to provide guidelines for developing effective methods of fireproofing in petroleum and petrochemical processing plants. It is not a design manual. This is a guideline -- a starting place and not a prescriptive set of limits; each facility should review their needs and act accordingly. Thus the title is fireproofing “practices”. It seeks to share good practice which has evolved over the years. Participants in developing this third edition included representation from both producers and users of fireproofing.
In this third edition the section arrangement and numbering has been revised for consistency with API standard style guidelines. Essentially all section numbers have changed
By its nature fireproofing is passiveproperty protection. Effective protection of equipment in petroleum and petrochemical plants may reasonably be expected to have a benefit in reducing risks for personnel. Where fireproofing helps control structural damage and potential incident escalation it should benefit life safety concerns.
API 2218 is a “pool fire” standard. It uses facility configuration and equipment knowledge as a means of identifying probable liquid fuel release locations and the extent of resulting pool fires. This leads to development of “fire-scenario envelopes”. This is the first step in determining fireproofing needs. The process is shown in simple form in Figure 1.
Planning for (and prevention) of all types of fire is of concern. Although infrequent, jet fires are dramatic and can cause significant damage. While API 2218 is not a “jet fire” standard, this edition includes substantial new information. The body refers to jet fire concerns where they “fit” including the statement “The U.S. Chemical Safety Board recommends more protective fireproofing scenario radii for pipe rack support steel near process units containing highly pressurized flammables”. Annex C provides an overview of “Jet Fire Considerations” including the extensive body of research knowledge.
As used this recommended practice “shall” denotes a minimum requirement in order to conform to the recommended practice and “should” denotes a recommendation or that which is advised but not required in order to conform to the recommended practice.
API publications may be used by anyone desiring to do so. Every effort has been made by the institute to assure the accuracy and reliability of the data contained in them; however, the institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict.
Suggested revisions are invited and should be submitted to the director of the Health & Environmental Affairs Department, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C.20005.
CONTENTS
SECTION 1 — PURPOSE, SCOPE & INTRODUCTION
1.1 Purpose
1.2 Scope
1.3 Introduction
1.4 Units Of Measurement
SECTION 2 REFERENCED PUBLICATIONS
SECTION 3 - DEFINITIONS
SECTION 4 - GENERAL
4.1 The Function of Fireproofing
4.2 Determining Fireproofing Needs
4.2.1 Fire Hazard Evaluation
4.2.2 Fire-Scenario Development
4.2.3 Fire-Scenario Envelope Definition
4.2.4 Needs Analysis
4.2.5 FireResistance Rating Selection
4.2.6 Effect of Heat on Structural Steel
SECTION 5 -- FIRE SCENARIO ENVELOPE FIREPROOFING CONSIDERATIONS
5.1 Fireproofing inside Processing Areas
5.1.1 Multi-Level Equipment Structures (Excluding Pipe Racks) Within A Fire—Scenario Envelope
5.1.2 Supports For Pipe Racks Within A Fire-Scenario Envelope
5.1.3 Air Coolers Within A Fire-Scenario Envelope
5.1.4 Tower And Vessel Skirts Within A Fire-Scenario Envelope
5.1.5 Leg Supports For Towers And Vessels Within A Fire-Scenario Envelope
5.1.6 Supports For Horizontal Exchangers, Coolers, Condensers, Drums, Receivers, And Accumulators Within A Fire-Scenario Envelope
5.1.7 Fired Heaters Within A Fire-Scenario Envelope
5.1.8 Power And Control Lines Within A Fire-Scenario Envelope
5.1.9 Emergency Valves Within A Fire Scenario Envelope
5.1.10Special Hazard Fireproofing
5.2 Fireproofing Outside Processing Units
5.2.1 Pipe Racks Within A Fire-Scenario Envelope
5.2.2 LPG Storage Spheres Within A Fire-Scenario Envelope
5.2.3 Horizontal Pressurized Storage Tanks Within A Fire-Scenario Envelope
5.2.4 Flare Lines Within A Fire-Scenario Envelope
SECTION 6—FIREPROOFING MATERIALS
6.1 General
6.2 Characteristics of Fireproofing Materials
6.2.1 General
6.2.2 Physical Properties
6.2.3 Behavior During Exposure To Fire
6.3 Types of Fireproofing Materials
6.3.1 Dense Concretes
6.3.2 Lightweight Concretes
6.3.3SPRAY-APPLIED FIRE RESISTIVE MATERIALS (SFRM)
6.3.4 Preformed Units Or Masonry
6.3.5 Endothermic Wrap Fireproofing
SECTION 7 – TESTING AND RATING FIREPROOFING MATERIALS
7.1 General
7.2 Standard Testing of Fireproofing Systems for Structural Supports
7.2.1 UL 1709
7.2.2 ASTM E 1529
7.2.3 ISO TR 834-3 / Pr EN 13381-8 (EN1363-2)
7.2.4 Comparing Test Results
7.2.5 PFP Environmental Testing
7.2.6 Other Tests Used to Evaluate Fireproofing Systems
SECTION 8 -- INSTALLATION AND QUALITY ASSURANCE
8.1 General
8.2 Ease Of Application
8.3 Fireproofing Installation Considerations
8.4 Quality Control In Application
SECTION 9 – INSPECTION AND MAINTENANCE
9.1 Effects Of LongTerm Exposure
9.2 Inspection
9.3 Maintenance
9.3.1 Hairline Cracking
9.3.2 Substrate Bonding
9.3.3 Bond Failure
9.3.4 Top Coating
9.3.5 Management of Change (M.O.C.)
ANNEX A: Definition of Terms Used in this Standard Which Are in General Use in the Petroleum Industry
ANNEX B – Testing And Rating Fireproofing Materials
B.1 General
B.2 Rapid Rise Hydrocarbon Pool Fire Tests
B.3 Standard Testing for Fireproofing of Structural Supports
B.3.1 UL 1709 Standard for Rapid Rise Fire Tests for Protection Materials for Structural Steel
B.3.2ASTM E 1529 Standard Test Methods for Determining Effects of Large Hydrocarbon Pool Fires on Structural Members and Assemblies
B.3.3ASTM E 1725 Standard Test Methods for Fire Tests of Fire-Resistive Barrier Systems for Electrical System Components
B.3.4UL 2196 Standard for Tests of Fire Resistive Cables
B.3.5ASTM E 119 Method for Fire Tests of Building Construction and Materials
ANNEX C -- JET FIRE CONSIDERATIONS
Ref. 17: ISO 22899-1 “Determination of the resistance to jet fires of passive fire protection materials”ANNEX D – FIREPROOFING QUESTIONS AND ANSWERS
ANNEX D – FIREPROOFING QUESTIONS AND ANSWERS
BIBLIOGRAPHY
E2226-10 Standard Practice for Application of Hose Stream
E119 - 09c Standard Test Methods for Fire Tests of Building Construction and Materials
TR-834-3 Hydrocarbon SO/TR 834-3:1994
HAZARD & RISK
List of Figures (Page numbers will change)
1 Flowchart – Selecting Fireproofing Systemsxx
1AFireproofing Process with M.O.C.xx
2A Effect of Temperature on the Strength of Structural Steelxx
2B Heating of Unwetted Steel Plates Exposed to Gasoline Fire on One Sidexx
3A Structure Supporting FirePotential Equipment in a Fire-scenarioxx
3B Structure Supporting FirePotential and NonFirePotential
Equipment in a Fire-scenario Area...... xx
3C Structure Supporting NonFirePotential Equipment in a
Fire-scenario Area...... xx
4A Pipe Rack Without Pumps in a Fire-scenario Area...... xx
4B Pipe Rack With Large FirePotential Pumps installed Below ...... 'xx
4C Pipe Rack Supporting FinFan Air Coolers in a Fire-scenario
Area...... xx
4D Transfer Line With Hanger Support in a Fire-scenario Area ...... xx
4E Transfer Line Support in a Fire-scenario Area ...... xx
List of Tables
Table 1 -- Dimensions of fire scenario envelope
Table 2 -- Level of Fireproofing Protection in Fire Scenario Envelope
Table B -- Comparison of Standardized Fireproofing Test Procedures
Fireproofing Practices in Petroleum and Petrochemical Processing Plants
SECTION 1 — PURPOSE, SCOPE & INTRODUCTION
1.1 Purpose
This publication is intended to provide guidance for selecting, applying, and maintaining fireproofing systems designed to limit the extent of fire-related property loss from pool firesin the petroleum and petrochemical industries.Where comparable hazards exist, and to the extent appropriate, it may be applied to other facilities that could experience similar severe fire exposure and potential losses
1.2 Scope
This publication uses a risk-based approach to evaluate fireproofing needs for petroleum and petrochemical plants where hydrocarbon fires could rapidly expose structural supports to very high temperatures. API RP 2218 specifically focuses on property loss protection for pool fires scenarios in on-shore processing plants.
Only passive fireproofing systems are within the scope of this publication. The following are outside the scope of RP 2218:
active systems (such as automatic water deluge) used to protect processing equipment including exposed structural steel supports. (API RP 2030)
explosion protection
fireproofing for LPG storage vessels (addressed in API RP 2510 & RP 2510A).
fireproofing for personnel protection
fireproofing for buildings
fire prevention (addressed in API RP 2001, Fire Protection in Refineries)
regulatory compliance
jet firesa,b
Footnote abecause of the uncertainty of jet fires and low likelihood (frequency) explained by the discussion in Annex C
Footnote bAlthough not within the defined Scope of RP 2218, fireproofing for pool fires may provide benefits in reducing potential damage for structures exposed to a jet fire.
1.3 Introduction
Properly implemented fireproofing (passive fire protection) can protect against intense and prolonged heat exposure which otherwisecould cause collapse of unprotected equipment, leading to the spread of burning liquids and substantial loss of property. Fireproofing may also mitigate concerns for life safety and environmental impactby reducing escalation. Fireproofing and other fireresistance measures may be appropriate for fire protection where hazardous chemicals could be released with the potential for exposure of employees or persons outside the facility. Resources listed in the Bibliography may help those addressing these issues.
The term “Fireproofing” is widely used, although strictly speaking the term is misleading since almost nothing can be made totally safe from the effects of fireexposure for an unlimited time. In effect, fireproofing “buys time” for implementation of other protective systems or response plans such as isolation and use of EIV/ROSOV,unit shutdown, deployment of fire brigades or evacuation.
Fireproofing refers to the systematic process (including materials and the application of materials) that provides a degree of fire resistance for protected substrates and assemblies API RP 2218 addresses fireproofing of structural supports in process units and supports for related equipment (such as tanks, utilities and relevant off-site facilities). Fireproofing can also be used to protect instruments, emergency shutoff valves and electrical equipment that may be used to mitigate fire.
Recommended Practice 2218 is not a design manual. It doesnot specify fireproofing requirements directly applicable to specific units or plants. Discussion of fire scenario envelopes in Section 4.2 are generic guides. RP 2218 should help site management understand fireproofing issues. This understanding can help them define protection needs and facilitate effective relationships with fireproofing designers, material suppliers and installers. This Recommended Practice assists in the evaluation of options available, including where, and to what extent, fireproofing might be applied to mitigate the effects of a severe fire.
For protection against high rise hydrocarbon pool fires suitable fire test standards for assessing the performance of materials exposed to a hydrocarbon fire curve are UL 1709, ASTM E1529, ISO TR 834-3 and EN1363-2. As explained in Annex C, ISO 22899-1 is the most widely accepted fireproofing test for jet fires.
1.4 Units Of Measurement
Values for measurements used in this document are generally provided in both English and SI (metric) units. To avoid implying a greater level of precision than intended, the second cited value may be rounded off to a more appropriate number. Where specific test criteria are involved an exact mathematical conversion is used.
SECTION 2 REFERENCED PUBLICATIONS
There are no Normative References for this standard. Fire protection resources of potential relevance are listed in the Bibliography by subject.
NOTE TO REVIEWERS -- ALL THE REFERENCES FROM SECTION 2 WERE MOVED TO THE BIBLIOGRAPHY -- ANY REFERENCES DETERMINED TO BE “NORMATIVE” SHOULD BE MOVED BACK to this section
SECTION 3 - DEFINITIONS
Terms specific to fireproofing or in less common use are defined in 3.1 through 3.35. Definition of Terms Used in this Standard Which Are in General Use in the Petroleum Industry are found in Appendix A.
3.1 ablative - dissipation of heat by oxidative erosion of a heat protection layer.
3.2 active protection - requires automatic or manual intervention to activate protection such as water spraysystems,emergency isolation valves, process depressuring or fire water monitors.
3.3 char (n) - a carbonaceous residue formed during pyrolysis which can provide heat protection
3.4 cementitious mixtures - cementitious mixtures are binders, aggregates and fibers mixed with water and may be applied by spray or trowel.
3.x emergency isolation valves (EIV) -- an EIV is intended to provide a means of shutting off flow of a fuel(see ROSOV) with either manual or remote power operation
3.5 endothermic fire protection - heat activated chemical and/or physical phase change reaction resulting in heat absorption by anon-insulating heat barrier.
3.6 fire performance - response of a material, product or assembly in a “real world” fire as contrasted to laboratory fire test results under controlled conditions.
3.7fireproofing - a systematic process, including design, materialselection, and the application of materials, that provides a degree of fire resistance for protected substrates and assemblies.
3.8 fire resistance rating - the number of hours in a standardized test without reaching a failure criterion. (In this publication UL 1709 or functionally equivalent test conditions are presumed for pool fires unless otherwise stated.)
3.9 fire scenario areas - areas where there may be potential for a fire
3.10 fire-scenario envelope - is a threedimensional space into which firepotential equipment might release flammable or combustible fluids capable of forming a pool fire which could burn long enough and with enough intensity to cause substantial property damage.
3.11fire-test-response characteristic - a response characteristic of a material, product, or assembly to a prescribed source of heat or flame as in a standard test.
3.12 functionally equivalent performance - ability to perform a given function under specific conditions in a manner equivalent to alternatives at the same conditions for a designated time duration.
3.13 hazard– a situation or inherent chemical or physical property with the potential to do harm (flammability, oxygen deficiency, toxicity, corrosivity, stored electrical, chemical or mechanical energy).
3.15intumescent fire protection - a chemical reaction occurring in passive materials when exposed to high heat or direct flame impingement that protects primarily by expanding into an insulating layer of carbonaceous char or glasseous material.
3.16 jet fire -a turbulent diffusion flame resulting from the combustion of a pressurized fuel continuously released with some significant momentum in a particular direction or directions. Jet fires (sometimes called torch fires) can arise from pressurized releases of gaseous, flashing liquid (two phase) and pure liquid inventories.