OISD - STD-164

FOR RESTRICTED
CIRCULATION ONLY

FIRE PROOFING IN OIL & GAS INDUSTRY

OISD – STD – 164

First Edition, July, 1998

OIL INDUSTRY SAFETY DIRECTORATE

Government of India
Ministry of Petroleum & Natural Gas
 OISD - STD-164
First Edition
July, 1998

FOR RESTRICTED
CIRCULATION ONLY

FIRE PROOFING IN OIL & GAS INDUSTRY

Prepared by:

FUNCTIONAL COMMITTEE ON FIRE PROOFING

OIL INDUSTRY SAFETY DIRECTORATE

2nd FLOOR, “KAILASH”,

26, KASTURBA GANDHI MARG,
NEW DELHI 110 001
 NOTE

OISD (OIL INDUSTRY SAFETY DIRECTORATE) publications

are prepared for use in the oil and gas industry under Ministry of
Petroleum & Natural Gas. These are the property of Ministry of
Petroleum & Natural Gas and shall not be reproduced or copied and
loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy

and reliability of the data contained in these documents OISD
hereby expressly disclaims any liability or responsibility for loss or
damage resulting from their use.

These documents are intended to supplement rather than

replace the prevailing statutory requirements.
 FOREWORD

Oil Industry in India is more than 100 years old. Over the
years a variety of practices have been in vogue because of
collaboration/ association with different foreign companies and
governments. Standardisation in design, operating and maintenance
practices was hardly in existence at a national level. This lack of
uniformity, coupled with feed back from some serious accidents that
occurred in the recent past in India and abroad, emphasised the
need for the industry to review the existing state of art in designing,
operating and maintaining oil and gas installations.

With this in view, the Ministry of Petroleum and Natural Gas in

1986 constituted a Safety Council assisted by the Oil Industry Safety
Directorate (OISD) staffed from within the industry in formulating and
implementing a series of self regulatory measures aimed at removing
obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of
functional committees comprising of experts nominated from the
industry to draw up standards and guidelines on various subjects.

The present document on Fire Proofing in Oil & Gas Industry

was prepared by the Functional Committee on Fire Proofing. This
document was prepared based on the accumulated knowledge,
experience of industry members and various national/international
codes and practices.

This document will be reviewed periodically for improvements

based on the new experiences and better understanding.

Suggestions from industry members may be addressed to :

The Coordinator
Functional Committee on Fire Proofing
Oil Industry Safety Directorate
2nd Floor, “Kailash”,
26, Kasturba Gandhi Marg,
NEW DELHI 110 001.
 FUNCTIONAL COMMITTEE
ON
FIRE PROOFING IN OIL & GAS INDUSTRY

NAME DESIGNATION ORGANISATION

LEADER
Shri B. K. Raut DGM (SMMS) E.I.L.

MEMBERS
Shri R. P. Saxena DGM (M) MRBC, ONGC

Shri S.G. Subrhamoney CH.MGR, (PROJECTS), HPCL

Shri S. Neelakantan SR.MGR(ENGG.SERVICES) MRL

Shri B. K. Singh SR. INSP. MGR IOC

Shri H.C. Mehta SR. MGR. (LPG-OPER) HPCL (MKTG)

Shri U. V. Mannur MGR (LPG - ENGG) IOC (MKTG)

Shri B.S.M. Krishna MGR (ADV ENGG-CIVIL) BPCL

MEMBER COORDINATOR

Shri K. R. Soni ADDL.DIRECTOR (ENGG) OISD

===================================================================
In addition to the above, several other experts from Industry contributed in the
preparation, review and finalisation of this document .
 CONTENTS

SUBJECT

1.0 INTRODUCTION 1

2.0 SCOPE 1

3.0 DEFINITION 1

4.0 FIRE PROOFING MATERIALS AND SYSTEM 2

5.0 FIRE RATING SYSTEMS 4

6.0 AREAWISE APPLICATIONS 6

7.0 METHODS OF APPLICATIONS OF FIRE

PROOFING 10

8.0 QUALITY CONTROL IN APPLICATION OF FIRE

PROOFING 14

9.0 PERIODIC INSPECTION AND MAINTENANCE 14

10.0 REFERENCES 16

ANNEXURE 1 TO III 17

FIGURE 5.1 – 5.4 20

 OISD-STD-164

FIRE PROOFING IN OIL & GAS INDUSTRY

1.0 INTRODUCTION
2.0 SCOPE
This standard provides technical
details, including inspection and This standard covers technical
maintenance requirements, for details of materials used for fire
selection and application of fire proofing , fire rating, selection and
proofing in Oil Industry. This application methods for different
publication applies to on-shore areas, methods of application of fire
installations for exploration & proofing materials, quality control
production, refineries and marketing measure and inspection during
installations; however, it can be application of materials, including
applied to a limited extent to offshore periodic inspection and maintenance
exploration & production of fire proofing. Active fire protection
installations. system and its effects are beyond
the scope of this standard.
Only passive fire proofing systems
have been covered and details of 3.0 DEFINITIONS:
active systems such as automatic
water deluge, which are used to i) Fire Proofing : Fire proofing is
protect pressure vessels, processing an insulation that provides a
structures, equipment etc. are degree of fire resistance to
excluded. Passive fire protection protect substrates like vessels,
shall be used alongwith active fire piping and structures for a
protection systems like water deluge, predetermined time period
sprinkler systems etc. against fire.

As nothing can be made totally safe ii) Fire Rating : Fire rating is
from the effects of fire, the term "Fire expressed in number of hours of
Proofing" is therefore misleading. protection selected to maintain
Nonetheless, the term continues to structural integrity for a
be widely used in Industry. In this predetermined length of time.
standard, “Fire Proofing” refers to
selection and application of the iii) Fire-Exposed Envelope : A fire-
materials that provide a degree of exposed envelope is the three-
fire resistance to protect substrates dimensional space into which fire
like vessels, piping and structures for potential equipment can release
a predetermined time period. flammable or combustible fluids
that are capable of burning long
All commonly used structural enough and with enough
materials lose their strength on intensity to cause substantial
being exposed to fire,. The primary property damage.
role of passive fire protection is to
delay and limit the temperature rise 4.0 FIRE PROOFING MATERIALS
of substrates. This is to enable AND SYSTEMS
structural integrity to be maintained
and to gain valuable time during 4.1 GENERAL
which vessels can be depressurised,
evacuation of personnel can be Passive fire proofing materials &
carried out and the fire can be systems should conform to the
brought under control. Passive fire following parameters :
protection therefore seeks to
minimise the consequences of a fire a) It should fulfill its protection role
and to prevent fire escalation. by limiting the temperature of
 substrate of a vessel or structure
to be within the guaranteed Materials normally used for
maximum temperature over a fireproofing are dense concrete, light
specified time period. weight concrete, mastic and
prefabricated panels. Prior to use,
b) The fire protection should not fail these materials should be checked to
at the end of this specified period, relevant specifications.
but should continue to offer a
reasonable measure of protection 4.2.1 Dense Concrete
beyond this period.
This traditional material has been
c) It should have a system integrity used for decades as fire proofing and
so that the protection remains in is the standard by which other
place during a fire, and can materials are judged. Tough and
withstand both the thermal dense, (approx. density 2200-2400
stresses and impingement of fire Kg/cum) they provide long term
water from hoses/monitors. Test protection in most environments.
checks as necessary should be
carried out. Thermal protection is afforded by
mechanisms of heat absorption
d) The fire protection must be non- through sensible energy rise and
corrosive to the substrate and be breakdown of the chemically attached
compatible to environmental water in the Portland cement. Their
conditions. It must not in itself sheer mass provides enough heat
become a hazard in a fire sink in most fire environments.
condition whether by spalling, Concrete must be poured into forms
spreading flame, or producing and requires steel reinforcements.
toxic fumes. Gunnite is a mixture of sand and
Portland cement which is pumped
e) Selection of the fire proofing and sprayed onto reinforcing mesh
system must take into account the installed around the steel. Adequate
weight limitations imposed on the protection should be taken for
strength of steel supports to be equipment in the vicinity, as a lot of
fireproofed especially for existing dust gets generated in the process of
installations. gunniting.

f) The materials should have This material provides adequate

adequate adhesion, strength and service for long periods of time. If
durability. failure occurs, it is usually because
of the intrusion of moisture and/or
g) The fire proofing system should acid & airborne salts through cracks
be adequate for the desired fire or porous areas and may spall
rating hours. during water exposure in a fire. In
SO2 or other corrosive environments,
h) The fire proofing material/coating a top coat of suitable anticorrosive
should be resistant to weather paint may be provided.
effects such as chalking and
erosion. Top coat, wherever Dense concrete is generally used for
provided, must be resistant to fire proofing of Supporting
solar ultra violet radiation. structurals of Pipe racks, vessels,
furnaces, air fin coolers, exchangers
4.2 TYPES OF FIRE PROOFING etc.
MATERIALS
4.2.2 Light Weight Concrete
Following materials are covered
This concrete is made of light weight under mastics:
aggregates such as vermiculite,
mica, perlite and cements. Dry A) Subliming Coating
densities range from 640 to 960
kg/cum. Lightweight materials are Subliming coatings consist of two
usually sprayed on but they may be components applied with
troweled or formed in place using reinforcement. They absorb large
light reinforcing mesh. amount of heat in the event of
fire and they change directly
Lightweight concrete materials are from solid to gaseous state.
fairly durable and have limited
maintenance requirements. They B) Intumescent Mastics
are capable of withstanding direct
flame impingement upto 1093 deg C Intumescent mastics provide
(2000 deg F) and can withstand protection by expanding during
thermal stresses and high pressure heating and forming an insulation
water streams. These materials are layer of char. The quality of char
applied by qualified and trained and resistance to oxidation
applicators. determines the performance of
the material. The material is
These materials can be applied applied along with reinforcement.
over any configuration in varying These materials are durable,
climatic conditions. As these light weight and also provide
materials are susceptible to hairline long term corrosion protection to
cracks, a good paint system for the steel. However, they need
substrate and top coat of fire stringent surface preparation.
proofing is desirable.
C) Ablative Coatings
Light weight concrete is normally
used for fire proofing of Vessels and Ablative mastics absorb heat as
supporting structurals of Pipe racks , they lose mass. These materials
vessels, furnaces, air fin coolers, have good bond strength, high
exchangers etc. coefficient of elongation and are
also resistant to most industrial
4.2.3 Mastics chemicals and solvents.
However, stringent surface
The mastic coating system has good preparation is required for these
durability, corrosion protection and materials.
resistance to environmental
conditions. In addition, such systems 4.2.4 Pre-Fabricated Panels
are very light weight and lend
themselves to application on any Preformed inorganic panels are
shape. All mastics are sprayed on the precast or compressed fire resistant
substrate in one or two coats, panels made of a lightweight
depending on the degree of the fire aggregate and a cement binder or a
resistance/protection required. A compressed inorganic insulating
positive mechanical reinforcements material such as calcium silicate.
such as reinforcing fabric or wire is The panels are attached to the
required to ensure the integrity of the substrate by mechanical fasteners
system during fire situation if that are designed to withstand
thickness of coating is higher.
 exposure to fire without appreciable nearly continuous radiation in the
loss of strength. infrared region making the hot gas
and soot particles behave as a gray
These panels are convenient and body radiator. Petrochemical fire
clean during installation and not temperatures reach as high as 1300
much of surface preparation is deg C (2400 Deg. F) but average
required. However, this material 1000 deg C (1850 deg F) because
cannot be used for small steel of various factors including
members and complicated shapes. radiational cooling of the fire ball,
When panels are used outdoors, an winds and geometry. Free burning
external weather-proofing system is fires normally do not achieve the
usually required to prevent moisture theoretical combustion temperatures
from penetrating. All joints must be for the fuels involved. During fires
caulked or sealed with fire rated with high pressure fuel sources,
mastic. convection plays a larger role and
can even be the primary mode of
Preformed materials are heat transfer. Jet fires are
advantageous because they can be characterized by high convective
applied cleanly, they have no curing inputs. Annexure 1 summarises the
time, and they have low conductivity. parameters for a wide range of fire
Preformed materials are more environments.
susceptible than dense concrete to
damage from impact. Outdoor testing is becoming
increasingly difficult due to
5.0 FIRE RATING SYSTEMS environmental considerations and
hence, furnace testing is heavily
5.1 FIRE TESTS AND STANDARDS relied upon today. However, some
testing organisations have
The criteria for judging a material's successfully carried out tests on
thermal performance in a fire loaded vessel’s in outdoor. Some
exposure should be actual fire tests years ago, it was also recognized
on a sufficiently large enough scale that the ASTM E-119 test standard
to realistically determine the did not produce a severe enough
behaviour of both the material and environment to properly evaluate
the installation design. Test materials destined for use in the
environments should closely match hydrocarbon industry where fire
the fire exposure expected in an reaches maximum temperatures in
end-use situation. In the case of minutes or less and temperature
the hydrocarbon processing industry levels and heat fluxes are higher.
- this could be anything from free Therefore, the "high rise" or "high
burning pools of liquid to high intensity" fire test environment was
pressure jets of hot hydrocarbons. adopted by industry as a more
Therefore, it is imperative to test realistic test and several test
materials in as severe an agencies are now equipped to run
environment as possible. this test. This test, although short on
convective heat transfer, is a
For the most part, liquid and reasonable simulation when
gaseous hydrocarbon fires are compared to an open pool fire.
characterized by highly luminous Nearly all fire protective materials
flames resulting from hot carbon are now evaluated in the "high rise"
particles (soot). Because of limited fire environment for Hydrocarbon
mixing with oxygen, combustion processing industry applications.
gases are fuel-rich and produce The characteristics of various fire
 environments are detailed at
Annexure-I. a) When the average of all
thermocouples at any level
5.2 TEST LABORATORIES reaches 538 deg C (1000 deg F)
or;
There are a number of fire test
laboratories in North America and b) If any individual thermocouple
Europe, of which a partial directory is reaches 649 deg C (1200 deg
given at Annexure - II These F).
laboratories conduct fire tests
according to defined standards and Environmentally exposed materials
depending upon performance, a are tested against control material to
rating is determined for the particular determine the effect on fireproofing
type of test run. A rating is given in performance. A loss in performance
time units with temperature limits of 25% or more in any of these tests
imposed on the protected part of the prevents a material from receiving
test assembly. Annexure - III list an external use rating. Even though
some of the important ratings used these evaluations are helpful in
in the Hydrocarbon processing determining material suitability for
industries for structural and industrial use, the aging tests are
personnel protection of stationary accelerated and small losses in
materials. performance may turn into
significantly larger ones over long
The oldest and most widely used periods of time. However, this test
independent testing organisation is program is an important tool in rating
Underwriters Laboratories, Inc. (ULI) and monitoring potential fire
in USA. ULI provides fire test and protection materials for outdoor use.
manufacturing follow-up services for
many products on a nonprofit basis. After successful completion of the
ULI was the first testing organisation test, a listing or rating is offered,
to standardize the "high rise" fire which in the case of ULI, is printed in
test as UL 1709 and offer it as one an annual Fire Resistance Index
of their services. Other testing under X or XR classifications for
laboratories now conduct similar columns for the hourly period tested.
tests. Listings in the X classification are for
designs tested to the ASTM E-119
In the case of the UL 1709 test, the cellulosic fire environment whereas
furnace temperature is brought up to those in the XR classification have
1093deg C (2000 deg F) within 5 been tested to the UL 1709 high
minutes and held within a tolerance intensity fire environment. XR
of this level for the duration of the ratings (listings) include mandatory
test. Tests are usually run on a light additional testing for environmental
column designated as a W10X49, aging such as freeze thaw cycling,
but they can be run on lighter or salt fog, high humidity, and SO 2 /
heavier sections. Less material is CO2 exposures. For X
required to protect heavier classifications, environmental
members, so the user should be testing is optional.
careful to determine which
member was tested. Steel While, UL -1709 is the minimum
temperatures are measured beneath requirement for a fire proofing
the protective material at 4 levels material, materials being used for
with 3 thermocouples per level. pressurised storage vessels must
Failure criteria for columns are : have preferably undergone
 independent tests successfully on 144 whereas for other areas, it
such type of vessels. should be as per API - 2218.

5.3 FIRE RATING 6.0 AREAWISE APPLICATION

Determination of fire proofing needs
The following factors should be involves a three step procedure that
considered in selecting the rating of establishes:
the material to be applied :
a) The location of fire-hazardous
a) The source volume of leak areas or fire-exposed envelopes,

b) The time required to block flows b) The size of the fire-exposed

and backflows of fuel that may envelope, and
be released.
c) The rating or thickness of fire
c) The time required to apply proofing material that need to be
adequate and reliable cooling applied within each of the fire-
water from fixed monitors, fixed exposed envelope
water spray systems, and hand
hose lines. 6.1 FIRE -EXPOSED ENVELOPE :

d) The time required for the area’s A fire-exposed envelope is the three-
drainage system to remove a dimensional space into which fire
spill. potential equipment can release
flammable or combustible fluids that
e) The layout of the equipment, are capable of burning long enough
particularly if congestion exists. and with enough intensity to cause
substantial property damage.
f) The physical properties of mate
rial that may be spilled. 6.2 FIRE POTENTIAL EQUIPMENT
CLASSIFICATION
g) The fuel’s burning rate.
Fire-potential equipment includes
h) The fuel’s heat of combustion. types of hydrocarbon-handling
equipment that can release
i) The severity of operating appreciable quantities of flammable
conditions, particularly the fluids.
temperature if the material being
handled is above its autoignition 6.2.1 High Fire Potential Equipment :
point.
a) Fired heaters that charge liquid
j) The importance of the unit to or mixed phase hydrocarbons,
continued plant operations and under the following conditions :
earnings.
i) Operation at temperatures
k) Availability & proximity of fire and flow rates that are
fighting resources in and around capable of causing coking
the plant and time required for within the tubes.
evacuation of personnels.
ii). Operation at pressure and
Further, fire rating for LPG storage flow rates that are high
vessels should be as per OISD-STD- enough to cause large
 spills before the heater 6.2.3 Low Fire-Potential Equipment :
can be shut in.
a) Pumps that handle Class IIIB
iii) Charging of potentially liquids below their flash points.
corrosive fluids.
b) Piping that is within battery
iv) Incorporation of a high limits and has a concentration
level of automation and of valves, fittings, and flanges.
complex peripheral
equipment such as c) Heat exchangers that may
combustion air preheater. develop flange leaks.

b) Pumps that handle flammable 6.3 SIZE OF FIRE-EXPOSED

and combustible liquids at or ENVELOPE:
above their flash point or
autoignition temperatures, at A frequently used frame of reference
high pressure, or at high flows. for a fire-exposed envelope is one
In some cases, maintaining that extend 20-30 feet (6.1-9.1
seals without serious leaks meters) horizontally and 30-40 feet
may be difficult because of the (9.1-12.2 meters) vertically from a
liquid being pumped. source of liquid fuel.

c) Reactors that operate at high The following conditions within the

pressure or are apt to produce fire-exposed envelope can either
exothermic or runaway limit or extend the envelope’s
reactions. reference dimensions :

d) Compressors along with a) The source & volume of the leak.

related lube-oil system.
Compressors do not have a b) Pressure and possible leak
high liquid - fire potential; rates.
however, they can generate a
fire-exposed envelope if the c) The surface drainage area and
likelihood exists that there will capacity of the drainage system.
be a prolonged release of gas
and intense fire in the vicinity d) The fuel’s burning rate.
of important structural e) The fuel’s heat of combustion.
supports.
Because of the size and importance
6.2.2 Medium Fire Potential of large vessels such as reactors,
Equipment : regenerators and vacuum towers
that are mounted on high support
a) Accumulators, feed drums, and structures, fireproofing materials
other vessels that may leak as should be considered for the entire
a result of broken exposed support system regardless
instrumentation, ruptured of its height.
gaskets, or other apparatus.
6.4 FIREPROOFING INSIDE
b) Tower that may leak as a result PROCESSING UNITS :
of broken gauge columns or
gasket failure on connected 6.4.1 Multilevel Equipment Structures:
piping and bottom reboilers.
a) When structures support fire-
potential equipment, fireproofing f) Except for the upper surface of
should be used for the vertical the top flange, fireproofing
and horizontal steel support should be considered for beams
members from the grade up to that support equipment in fire-
the highest level at which the exposed areas.
equipment is supported (see
Figure 5.1). g) The earthing lugs should be kept
clear of the fire protection.
b) Elevated floors and platforms
that could retain significant 6.4.2 Support For Pipe Racks :
quantities of liquid hydrocarbons
should be treated as though they a) When a pipe rack is within a fire-
were on the ground floor level. exposed envelope, fireproofing
should be used for all vertical and
c) When structures support non-fire horizontal supports upto and
potential equipment, fireproofing including the first level (see Figure
should be considered for the 5.3.).
vertical and horizontal steel
members from grade up to and If a pipe rack carried piping that has
including the level that is a diameter greater than 6 inches at
nearest to a 30-foot (9.1 meter) levels above the first horizontal
elevation above grade if the beam or large hydrocarbon pumps
collapse of unprotected are installed beneath the rack,
structural supports could result in fireproofing should be considered
substantial damage that would upto and including the level that is
involve nearby fire-potential nearest to a 30-foot (9.1 meter)
equipment (see Figure 5.2). elevation (see Figures 5.3 and 5.4.)
Wind or earthquake bracing and
d) Fireproofing should be used for non-load bearing stringer beams that
knee and diagonal bracing that run parallel to piping need not be
contributes to the support of fireproofed.
vertical loads or to the horizontal
stability of columns if it is located b) If air fin-fan coolers are installed on top
within the fire-exposed envelope. of a pipe rack, fireproofing should be
Knee and diagonal bracing that used for all vertical and horizontal
is used only for wind, support members on all levels of the
earthquake, or surge loading pipe rack including support members
need not be fireproofed (see for the air fin-fan coolers, regardless
Figure 5.1). of their elevation above grade.

e) When reactors, towers, or similar c) Fireproofing should be considered for

vessels are installed on knee and diagonal bracing that
protected steel or reinforced contributes to the support of vertical
concrete structures, fireproofing loads. Knee or diagonal bracing that
materials should be used for is used only for wind or earth-quake
protection of supporting steel loading need not be fireproofed.
brackets, lugs, or skirts ( see
Figure 5.1). The insulating effect d) Frequently, the layout of piping requires
of the fireproofing material must that auxiliary pipe supports be
be considered in the design of placed outside the main pipe rack.
supports for vessels that operate These supports include small
at high temperatures. laterals pipe racks, independent
 stanchions, individual T columns, exchangers to towers or tower
and columns with brackets. skirts.
Whenever these members support
piping with a diameter greater than 6.4.5 Leg Supports For Towers &
6 inches or important piping such as Vessels :
relief lines, blowdown lines, or pump
suction lines from accumulators or If towers or vessels are elevated on
towers, fireproofing should be exposed steel legs. fireproofing the
considered. leg supports to their full load-
bearing height should be used.
e) Consideration should be given for
installing a fireproofed catch beam 6.4.6 Supports for Horizontal
or bracket, beneath larger piping Exchangers, Coolers,
(greater than 6 inches) that is Condensers, Drums, Receivers
supported by exposed steel spring and Accumulators :
hangers or rods. Sufficient
clearance should be provided Fireproofing should be considered
between the bracket or beam and for steel saddles that support
the pipe to permit free movement. horizontal heat exchangers, coolers,
condensers, drums, receivers, and
6.4.3 Grade-Level Air Coolers : accumulators that have a diameter
greater than 30 inches (0.76 meter)
Fire-proofing should be considered if the vertical distance between the
for supports for air fin-fan coolers in concrete pier and the shell of the
hydrocarbon service. vessel exceeds 18 inches (0.46
meter).
6.4.4 Tower & Vessel Skirts :
6.4.7 Fired Heaters :
a) Fire-proofing should be used for
the exterior surfaces of skirts that a) Fireproofing should be used for all
support tower and vertical supports for fired heaters in
vessels. Consideration should hydrocarbon service. Heaters are
also be given for fireproofing often supplied with short, steel legs
interior surfaces of skirts if there that are set on reinforced concrete
are flanges or valves inside the piers. Consideration should be
skirt. Interior surfaces of skirts given to fireproofing these legs from
need not be fireproofed if there is the concrete piers upto the point
only one manway opening where the steel columns are welded
through the skirt and its diameter to the steel floor plate of the firebox.
is not greater than 2 feet (0.6
meter). Openings other than the b) If structural supports is provided by
single manway may be closed horizontal steel beams beneath the
with removable steel plate at firebox of an elevated heater,
least 1/4 inch (6.4 millimeters) fireproofing should be used for the
thick. Consideration should be beams unless at least one flange
given to minimizing the effect of face is in continuos contact with the
draft through vent openings and elevated firebox.
space that surrounds pipe
penetrations in the skirt. c) If common chimneys or stacks handle
flue gas from several heaters,
b) Fireproofing should be used for fireproofing should be considered for
brackets or lugs that are used to the structural support for ducts or
attach vertical reboilers or heat
 breeching between heaters and requirements stipulated in OISD-
stacks. STD-144.

d) When fired heaters in other than Fireproofing shall be provided on the

hydrocarbon service, such as steam aboveground portion of the vessel’s
superheaters or catalytic cracking- supporting structures. The
unit air heaters, are located within a fireproofing shall cover all support
fire-exposed envelope, fireproofing members required to support static
should be considered for their load of the full vessel. Fireproofing
support members if a collapse would shall not encase the points at which
result in damage to adjacent the supports are welded to the
hydrocarbon-processing equipment vessel.
or piping.
6.5.3 Horizontal Pressurised Storage
6.5 FIREPROOFING OUTSIDE Tanks :
PROCESSING UNITS:
Horizontal pressurised storage tanks
6.5.1 Pipe Racks : should preferably be installed on
reinforced concrete saddles.
a) Fireproofing should be Fireproofing should be considered
considered for pipe rack for exposed steel tank supports that
supports outside processing are more than 18 inches (0.46 m)
units if they are located within a high, measured at the lowest point of
fire-exposed envelope. Bracing the tank shell.
for earthquakes, wind or surge
protection and stringer beams 6.5.4 Flare Lines :
that run parallel to piping need
not be fireproofed. Fire proofing should be considered
for supports for flare lines if they are
b) If important pipe racks run within within a fire-exposed envelope or if
20-30 feet of open drainage they are close to open ditches or
ditches or channels that may drainage channels that may receive
contain oil waste or receive large accidental spills of
accidental spills, either hydrocarbons.
fireproofing should be
considered for the pipe rack 7.0 METHODS OF APPLICATION
supports as described in 6.5.1.1 OF FIRE PROOFING
or the ditch should be covered.
7.1 GENERAL
6.5.2 Storage Spheres/ Vessels & its
Supports : The process of fire proofing
application consists of but not limited
Fire proofing protects the LPG to, attaching pins for retention of
vessel by reducing the heat input to metal/fabric mesh reinforcement,
the vessel and also by controlling abrasive blasting where required,
the rate of rise of vessel wall priming with appropriate and
temperature. Fireproofing provides approved primer system, installation
protection in case water supply is of reinforcing mesh, masking where
interrupted. necessary, mixing, spraying,
trowelling and leveling, rolling top
Fire proofing of all LPG vessels, their coating if required, and demasking.
supports and connected/ nearby
pipelines should conform to the
7.2 QUALIFICATIONS OF
APPLICATORS : 7.6 WORK START-UP

The application shall be performed Applicator will obtain a release from

by qualified applicator having the Client for a given area to start
training, equipment and experience. on.
Supervisory or lead personnel
involved with the application shall be 7.7 ENVIRONMENTAL CONDITIONS
or have been trained by the
manufacturer of fire proof coating Environmental conditions are
material. Applicator shall submit important for every aspect of the
written verification of such training in Application System.
case of proprietary products.
Environmental specifications for
7.3 SAFETY PRECAUTIONS : blasting where required and priming
are as per manufacturer or relevant
The applicator shall follow standard standard which include but are not
industrial hygiene practices for the limited to ambient temperature,
handling of chemical coatings and substrate temperature, relative
shall confirm to applicable codes of humidity and dew point.
practice and regulations. Necessary Environmental specifications for the
Personal Protective Equipment as system provided by the
detailed in OISD-STD-155 should be manufacturer of fire proof coating,
used. these conditions shall be recorded
for each system since conditions can
7.4 STORAGE OF MATERIAL: vary considerably depending on
location. Record daily environmental
The coating material shall be stored conditions. Where water is required
off the ground in a covered area and to be added, it should be clean,
shall be protected from severe potable and of a quality suitable
temperatures. for use in blending with fireproofing
coatings and should have chloride
content less than 50 PPM.

7.8 APPLICATION DETAILS FOR

7.5 SAMPLE PREPARATION SPECIFIC FIRE PROOFING
MATERIALS
Prior to actual production work, an
approved sample or a sample area 7.8.1 Dense Concrete
will be coated with fire proof coating
following all pertinent procedures A typical composition of dense
and specifications. This sample concrete is one part cement, two
should be typical of the work to be and half part sand and two and half
done. part gravel passing through 9.5 mm
sieve. Water should not exceed 802
This sample or sample area will then liters / cubic meter of cement. In the
be approved by the Client's case of pneumatically applied
Representative, Applicator's concrete the ratio shall be one part
Representative, Consultant's of cement and four parts sand.
representative and any other party Water cement ratio shall remain
as defined and required by the same as above.
contract, for quality of surface finish
and adherence to procedures.
 Dense concrete can be formed in
place or pneumatically sprayed to Mesh shall be overlapped at all
the required thickness using steel joints and no more than three mesh
reinforcement. thicknesses are permitted at any one
joint. Cut ends may be twisted
7.8.2 Lightweight Concrete together to make a more secure
joint. Alternatively, galvanised wire
A) Substrate Preparation ties at 150 mm centers may be
used.
It is recommended that in a
Refinery/Petrochemical environment, For pressure vessels where pins are
the steel should be suitably primed, not permitted, reinforcing mesh is
painted or galvanised prior to the attached to a system of floating rings
application of fireproof coating. and tensioning wires to construct a
monolithic reinforcement.
Paint surfaces must be chemically
resistant and stable at a pH of 12 to D) Fireproof Coating
12.5 when exposed to Portland
Cement. Paints based on two-pack The light weight concrete shall be
epoxy resins, chlorinated rubber or mixed in accordance with the
solvent based vinyl are normally Manufacturer's Instructions for
satisfactory when applied in Application and spray applied in the
accordance with the manufacturer's minimum number of coats or by
instructions. using trowel to the required
thickness as per Manufacturer's
All paints must be fully cured under recommendation. The coating is
the conditions specified in the generally float finish to close down
Manufacturer's Data Sheet. the texture.

B) Mesh Retaining Pins E) Water Shedding

Pins should be fixed to the structural Where water shedding cowls are not
substrate at maximum 400 mm provided, top surfaces and all
centers on a staggered pitch. Stud terminations of fire proof coating
fixing may necessitate the local against steel must be sloped and
removal of the priming system floated to shed water.
which should be reinstated to the
original paint specification after the A `U' shape shall be cut at the
fixing of pins. Welding need not be concrete steel junction to receive
done for fixing pins on pressure mastic sealant.
vessels as the same can be fixed
using other techniques.
F) Top Coating - Weather Barrier
C) Mesh Reinforcement
After the concrete coating has been
Attach reinforcing mesh (made of allowed to cure and dry for at least
GI/SS) to previously installed pins five days, suitable top coat as
using suitable arrangements. recommended by manufacturer may
be applied, if required.
The mesh should be pulled away
from the substrate so as to lie G) Sealing Of Concrete Coating/Steel
substantially within the center of the Junctions:
final fireproof thickness.
 Apply a suitable flexible sealant in E) Masking
the groove which may be
Polysulphide based or Silicone Any surfaces or equipment in the
rubber based. spraying areas which do not receive
mastic must be masked off, using
All sealants must be suitable for use polyethylene or equivalent.
with a concrete mixture and be Regardless of the structural
weather resistant and remain configuration being worked on,
flexible. overspray is always a concern.

7.8.3 Mastics F) Intumescent/Subliming Coating

A) Mesh Retaining Pins Solvent based or Solventless

application of Intumescent/
Pin Installation wherever required Subliming Materials shall be done in
shall be done in accordance with the accordance with the procedure
procedure outlined in the outlined by the Intumescent/
Manufacturer's Application Manual. Subliming Materials Manufacturers
Embedded mesh reinforcement shall Application Manual upto the required
be used based on manufacturers’ thickness.
recommendation.
Mixing of material components is
B) Substrate Preparation automatically achieved at the correct
ratio by the equipment volumetric
Substrate preparation shall be done ratioing pumps. Although the
in accordance with product equipment has off ratio detection
requirements. The blast finish/profile devices built into the system, actual
shall be accepted prior to priming. ratio checks must be taken. The
ratio check should be performed at
In the event that the applicator does start-up and at shut down daily.
not perform the actual blasting and
priming, the applicator is responsible G) Surface Finish And Inspection
for obtaining documentation
certifying the steel meets acceptable Surface finish is a visual standard for
blast finish criteria and priming sprayed Intumescent/Subliming
criteria as per the Manufacturer's Material which includes various
Application Manual. structural configurations. Visual
inspection should be performed to
C) Priming Procedure ensure that there is no exposed
mesh, debonding at terminations or
Priming of substrate shall be done in bubbles below the finish surface
accordance with paint manufacturers layer.
application guideline. Only primers Physical inspection would consist of
approved by Material Manufacturers drilling holes in the Intumescent/
can be used. Subliming Material to determine
actual thickness, tapping with a
D) Mesh Reinforcement hammer to detect possible hollow
areas or delamination between
Meshing of substrate shall be done sprayed layers of coating not
in accordance with the procedures visible.
outlined by Mastic Material
Manufacturers Application Manual.
8.0 QUALITY CONTROL IN
APPLICATION OF FIRE 8.5 SURFACE PREPARATION :
PROOFING
Substrate surfaces must be cleaned
8.1 INTRODUCTION : so that they are free from oil, grease,
liquid contaminants, rust, scale and
Quality control during application is dust. If a primer is required, it must
of prime importance. Satisfactory be compatible with the fire proofing
performance of the fireproofing material.
material over its expected life time
depends on the user’s and the 8.6 APPLICATION :
applier’s knowledge of materials and
application techniques and on It is to be ensured that the materials
continuous inspection by qualified must be applied in accordance with
plant personnel. the manufacturer’s
recommendations for dry thickness
Attention to the following points will and use of reinforcing materials.
ensure a quality job : Thickness of material must be
ensured as some of the mastic
8.2 QUALIFIED PERSONNEL : coating shrink as much as 30 per
cent when cured.
Both the user and the applicator
should have a detailed knowledge of 8.7 CURING :
the characteristics of the fireproofing
material and the application Some materials require a controlled
techniques that are necessary to curing period to develop full strength
achieve the desired degree of fire and prevent serious cracking in the
resistance. The applicator should be future. Hence, proper curing is to be
qualified as per Para 7.2. ensured.

8.3 STORAGE OF MATERIAL: 8.8 RANDOM CORE SAMPLE

CHECK :
Materials should be stored at site in
accordance with the manufacturer’s Random core samples should be
recommendations, since some taken after application to verify coat
materials are temperature sensitive thickness, proper bonding, and lack
and others must remain upright in of voids. Defects, if any, should be
their containers for the proper rectified properly.
sealing. Material should not be used
if its shelf life has exceeded. 9.0 PERIODIC INSPECTION AND
MAINTENANCE
8.4 MOCK-UP APPLICATION :
9.1 DETERIORATION DURING
The contractor/applier is required to SERVICE LIFE:
provide a sample of the finished
work so that there is no As fireproofing materials age,
misunderstanding about the desired problems can develop that affect the
texture, smoothness and soundness usefulness of the coating and
of the finished coating. Before start weaken the protected structural
of the application job, mock-up supports.
application should be carried out
over 1Mx1M surface area to Any fireproofing material is subject to
ascertain the skill of the applicator. a certain amount of degradation over
 time, however, some applications should periodically be inspected and
have been known to fail completely tested as per schedule prepared by
at a rapid rate. The failure may be the owner based on local
caused by materials that are environmental conditions and
improperly selected; in most cases, criticality of the equipment. An
however, the failure results from inspection and testing program
poor applications. should include the following steps :

Cracking or bulging of the surface of a) Survey the coating for surface

the material is the first sign of a cracking.
problem. If the problem is not
corrected, moisture, chemicals, b) Selectively remove small
corrosive vapour, and marine sections of fireproofing to
condensation can enter and lead to examine conditions at the face of
corrosion of both the substrate and the substrate and the surface of
the reinforcement materials. reinforcing wire.

Weathering or the use of the wrong c) Visually check for the loss of
top coat can cause the fireproofing fireproofing materials as a result
to become permeable to moisture of mechanical abuse.
and vapour. This permeability can
lead to serious corrosion and d) When the fireproofing material is
deterioration. applied, coat and set aside
several pieces of structural steel
Loss of bonding to the substrate for periodic fire testing over the
seriously affects the material’s expected life of the coating.
performance and may be caused by
moisture, penetration, corrosion, the In the event of a fire, the affected
use of an improper primer on the area of coating should be
substrate, or poor preparation of the thoroughly examined including
substrate before the fireproofing is substrate if required and
applied. necessary jobs carried out.

Fire proofing is sometimes scrapped

or knocked off equipment during
construction or maintenance.
9.3 MAINTENANCE
The weathering effects of sunlight
and chemical atmospheres have a) When cracks are wider than
been known to affect some mastic hairline , the opening should be
materials to the extent that they lose cleaned out and filled with new
a significant amount of their material according to the
insulating ability due to development manufacturer’s instructions.
of cracks, disbonding, peeling off top
coat. b) If top coat is required to prevent
moisture from penetrating, it
9.2 INSPECTION : must be renewed at intervals
recommended by the
To reduce the risk of structural manufacturer.
failure from hidden corrosion or the
risk from fire because of fireproofing c) Loss of bonding to the substrate
loosened or damaged by underlying may be noticed when the surface
corrosion, all fireproofed surfaces bulges or if an abnormal sound
 is given off when the surface is
tapped with a light hammer. iv) ASTM –E1529 : Standard test
methods for determining
In areas that have evidence of effects of large Hydrocarbon
bond failure, fireproofing should pool fires on Structural
be removed, and the substrate members and assemblies.
should be thoroughly cleaned
and properly primed before new v) API 2218 : Fireproofing
material is applied. Practices in Petroleum and
Petrochemical Processing
d) Whenever rust stains are plants
observed on the external surface
of fire proof coating, the integrity vi) API- 2510 : Design and
of coating as well as the construction of LPG
condition of substrate should be installations
established by chipping the
affected area. vii) API-2510A : Fire-Protection
consideration for the design
10.0 REFERENCES and operation of LPG storage
facilities
i) UL- 263 : Fire tests of Building
Construction and materials viii) OISD-STD-144 Vol. IV : Safety
and Fire protection in LPG
ii) UL-Subject 1709 : Structural Bottling Plant operations
steel Protected for Resistance
to Rapid Temperature rise fires ix) OISD-STD-155 Part I & II :
Personnnel Protective
iii) ASTM E119 : Method for fire Equipment.
test of building construction
and Material
 ANNEXURE – I

CHARACTERISTICS OF VARIOUS FIRE ENVIRONMENTS :

FIRE AVG. TEMP RADIANT CONVECTIVE TOTAL

SOURCE AFTER 5 MIN HEAT FLUX HEAT FLUX HEAT
deg C (deg F) FLUX
CM2SEC/CAL (BTU/FT 2HR)
Full scale
floor, wall &
column
furnaces

e) High Rise
Test 1093 (2000) 3.77(50000) .38(5000) 4.15(55000)
(UL1709)

f) ASTM
E-119 538 (1000) 1.125(14900) .11(1400) 1.23(16300)
Test
(UL 263)
(ISO 834)
c) ASTM E- - Atleast 8150 C
1529 after first 3
minutes -- -- 3.77(50000)

- Between 10100
C & 11800 C
after 5 min. at
all times

Pressurised
Propane 1216 (2200) 2.2(29100) 3.2(42400) 5.4(71500)
Burners
contained by
4’ x 8’ x 3’ pit
Jet fire test
Open Pool ** 926 (1700) to 3.40(45000) 0.38(5000) 3.77(50000) to
Fire Test 1260(2300) to to 4.6(61000)
3.85(51000) 0.76(10000)

* - As the walls in the furnace heat up, these values rise to a

maximum total heat flux of approximately 4.9 Cal/cm 2Sec (65000
BTU/Ft2 Hr) in approximately 15 minutes.

** - Peak values are largely dependent upon fire size and geometry
 ANNEXURE - II

PARTIAL DIRECTORY OF FIRE TEST LABORATORIES:

Federal Institute for Material Research and Testing Berlin, Germany

(BAM)
Factory Mutual Research Corpn,(FM) Norwood, MA, USA
Loss Prevention Council (LPC) Borehamwood, Herts, England.
Southwest Research Institute (SWRI) San Antonio,TX, USA
TNO Delft, Netherlands
Underwriters Laboratories Inc.(ULI) Northbrook, IL, USA
Warrington Fire Research Center Warrington, Cheshire,
England.
Health & Safety Executive Buxton
U. S. Department of Transportation (DOT) USA
 ANNEXURE - III

TEST RATINGS - STRUCTURAL STEEL FOR OIL INDUSTRY

(STATIONERY MATERIALS)

RATING NORMAL TEST ENVIRON- CRITERIA TO BE TEST TYPE

CONFIG- MENTAL TEMP. MET
RATION

UL 1709 W 10 X49 1093 deg C (2000 Protected steel must High intensity
Column 9” deg F) not exceed or high rise
high 538 deg C (1000 deg fire curve. Gas
F) fired furnace
BAM 90 min. for Horizontal 485 600-900 deg C 250 deg C (482 deg Pressurised
pressurised LPG M3 Tank with (1112 - 1652 deg F) F) maximum wall Propane jets in
tanks (Germany) 6.4 mm wall temperature a series
thickness and measured in the surrounding
50% filled ullage space not the tank.
with Propane adjacent to the
liquid. maximum
internal pressure of
approximately 20
bars.
GESIP (France) Loaded vessel 1000 deg C Protected steel must Simulated
+ + Flame not exceed 427 deg Pool fine
impingement 1100 deg C C (800 deg F) furnace test
and + Hose H/C
Stream
H.S.E. Loaded vessel Pool fire (H/S) 427 deg C Pool fire
(U.K.) 1100 deg C
 Non-Fire
Potential
Equipment

FIRE HAZARDOUS
AREA

Fig. No. 5.2 : Structure supporting Non-Fire-Potential Equipements in a fire Exposed

area
Note : shows Fire Proofed Structures
PIPES

Figure 5.3 : Pipe rack without pumps in a Fire Exposed area

Note : shows Fire proofed Structures

Fire Hazardous
Area

Large Pumps

Figure No. 5.4 : Pipe racks with large Fire-Potential Pumps installed below

Note : shows Fire Proofed Structures