FIREPROOFING MATERIALS AND SYSTEMS - G-SiGN · PDF fileΘ Repsol Química...
Transcript of FIREPROOFING MATERIALS AND SYSTEMS - G-SiGN · PDF fileΘ Repsol Química...
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ALFRAN – THE COMPANY
p2
Business
Turn Key Integral Refractory, Fire Protection, Insulation and Heat Treatment Services
Activities
Design & Engineering, Predictive Maintenance, Demolition, Anchors, Manufacture,
Installation, Supervision, Heat treatment, Dry out
Specialties
Monolithic applications, Shotcreting (Alfranjet), Passive Fireproofing Mortars, Steel Thermal
Treatment, Refractory Dry out
Customers
All industries, All major applications - Steel - Copper
- Cement - Lime
- Petrochemical - Non-Ferrous
- Power Plants - Nuclear Plants
- Incineration - etc
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ALFRAN – HISTORY
p3
41924 Start up. Ceramic water pipes
41934 Refractarios F. Dominguez: Silica Refractories
41950/70 Expansion Period: Alumina Refractories. Key supplier to Steel, Cement and
Glass in Southern Spain
41982 New Plant in Triana
41985 Refractarios Alfran: Only refractory Co. in Southern Spain
41991 Alcala Plant. New facilities. Starts Refractory Services
41994 ISO 9002. 1st refractory company in Spain
41995 Ladle Monolithic Lining
41997 Alfranjet System
41998-2003 Alfranjet Introduction in Steel (1998), Cement (1999), Petrochemical and
Lime (2001), Power Plants (2002), and Celluloise, Lumber and Timber (2003).
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ALFRAN – HISTORY II
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42000 Montajes Termicos. Acquisition of installation company in Asturias.
42003 ISO 14001. 1st refractory company in Spain.
42004 Grupo Aldomer. Holding for all companies in the Group.
42006 Refractarios Alfran Mexico.
42007 Fireproofing Division.
42007 Intec-Heat adquisition. Heat Treatment.
42008 Prodomer. Passive Fireproofing for Construction Building.
42009 OSHAS 18001 Safety & Health Management System
42010 Alget Maghreb
42011 Alfran do Brasil + Alfran Saudi Arabia
42012 Alfran Andino.
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4 BUSINESS UNITS
Θ Fireproofing
Θ Refractaries
Θ Thermal Insulation
Θ Thermal Treatments
Θ Over 90 year history
Θ > 30 mill € Sales
Θ > 250 employees
ALFRAN – THE COMPANY
DIVERSIFICATION
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Θ Refractarios Alfran – Refractaries, Passive
Fireproofing and Thermal Insulation to
industrial plants
Θ Intec-Heat – Thermal Treatment for vessel and
pipe welding & refractory dry out
Θ Alfran Mexico – Since 2004
Θ Alfran do Brasil – Since 2010
Θ Alfran Andino – Since 2011 (Colombia)
Θ Alget – Since 2008 (Morroco)
Θ Alfran Saudi Arabia – Since 2010
Θ South Africa – Since 2005
Θ Egypt – JV since 2008
INTERNACIONALIZATION
ALFRAN – THE COMPANY
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Θ Innovative Integral Solutions. Through combination of experience, technology,
manufacturing and installation resources: Alfranjet, No cement castables, Clean series
Θ Latest technology for physical, chemical and thermal analyses
Θ Collaboration with most advanced research institutes in Europe (Instituto de Ceramica y
Vidrio, ITMA, Warringtonfire, Applus, Underwriters Laboratories, and several prestigious
universities)
Θ Trials and quality certificates for every lot produced and sample analyzed both for raw
materials and final products
Θ Joint Customer-Alfran research projects for improved material and application solutions
INNOVATION
p8
ALFRAN – THE COMPANY
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• Refractory Installation in Petrochemical Industry since 1980 • Procedures approved by Quartis Ltd
• References: Conoco (UK), Lukoil Bourgas (Bulgaria), Amoc (Egipto), Pemex (México), Repsol YPF, Cepsa, BP Oil (Spain), Total Fina Elf (France), etc.
• Integral Service (Engineering, Supply & Apply) • FCC units • Sulphur Recovery units • Process Heaters • Special Repairs: Acid Protection, Demolition with Asbestos
• Refractory Material Supply • Dense and Insulating Bricks and Castables, Ceramic Fiber • Special Pieces (Muffle blocks)
OIL & GAS: REFRACTORIES
p9
ALFRAN – OIL & GAS
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Θ Industrial and Commercial Solutions
Θ +25 year experience team
Θ Integral Service
Θ Assessment of techniques and standards
Θ Solution design and engineering
Θ Materials supply and manufacturing
Θ Application with maximum quality & safety
Θ Products
Θ Cementitious, mineral wool and gypsum mortars
Θ Fibresilicate boards
Θ Epoxy coatings
Θ Encapsulated ceramic fibre
Θ Firestopping materials
Θ Applications: Structural steel, Cable
trays, ventilation ducts, penetration seals,
sectorization
p10
PASSIVE FIREPROOFING
ALFRAN – OIL & GAS
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• Insulation construction services for both hot and cold industrial applications
• Industries
• Refineries, Petrochemical & Gas
• Power plants
• Cement and Paper plants
• Solar and biomass plants
• Applications
• Hot and cold pipe insulation
• Criogenic tanks
• Reactors and boilers
• Control rooms
• Pumps
THERMAL INSULATION
p11
ALFRAN – OIL & GAS
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• Heat Treatment Solutions - Pre-Heating - Heat Treatment of Pipelines - Electrical, Gas or Diesel Heat Treatment - Refractory Dry Out - Heat Treatment of Spheres, Deposits, Reactors, Ethylene Cracking units, Stripper Columns, etc
• Digital Programmer and Registers
• Portable Furnaces
• Nuclear Power Plants, Petrochemical, Cement, Power Plants, Ship building
THERMAL TREATMENTS
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ALFRAN – OIL & GAS
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Latest References: FIREPROOFING
p13
Θ GALP Sines, Portugal: Pîpe Rack Hydrocraker (2012). Tecnicas Reunidas.
Θ REPSOL Campo Margarita, Bolivia: Cable Trays (2012). INITEC
Θ PEMEX Cangrejeras, Mexico (2012). CCC Platforming
Θ PEMEX Minatitlan, Mexico. (2011). Dragados Industrial.
Θ Petronor Muskiz, Spain (2011)
Θ Repsol Química Puertollano, Spain: Cable tray (2010-2011)
Θ Cepsa San Roque, Algeciras, Spain: Fireproofing structural and vessel skirts (2010-2011)
Θ Repsol Cartagena: New Refinery (2010-2011). Tecnicas Reunidas / INITEC
Θ Petronor Muskiz: Proyecto ADI-1000 (2009-2011)
Θ Repsol Química Puertollano, Spain: Cable tray (2010)
Θ Repsol Cartagena, Spain: U-617 Platforming Unit (2008-2009)
Θ Repsol Puertollano, Cable tray, structural steel and activator valves (2008-2009)
Θ Repsol Tarragona, Spain T-59 Project. (2008-2009)
Θ Repsol Cartagena, Spain: C-29 Fuel Unit (2008-2009)
Θ Petronor Muskiz, Spain: (2008-2010)
Θ Repsol Puertollano, Spain (2008)
Θ Ertisa La Rábida, Huelva, Spain: Fenol III (2008)
Θ Cepsa San Roque, Algeciras, Spain: Fuel plant (2008)
ALFRAN – REFERENCES
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MATERIALS AND SYSTEMS FOR
HYDROCARBON FIRES
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p15
SYSTEMS FOR HYDROCARBON FIRES
Structural Steel Protection: Industry Standards
Θ Fire Hazardous Zone: 7-10m horizontally and
vertically from fire-hazardous equipment
Θ Piping supports: Vertical and horizontal
columns to lowest horizontal member above
fire-hazardous zone
Θ Performance Criteria: 2-4 hours protection
(UL 1709 test or equivalent)
Θ Preferred Material: Cementitious mortars and
epoxy mastics
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Θ Cementitious Mortars
Θ ALFRAN FIRE IND
Θ PYROCRETE
Θ MONOKOTE
Θ FENDOLITE
Θ Epoxy Coatings
Θ THERMO-LAG 3000
Θ CHARTEK 1709
Θ PITTCHAR XP
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
MATERIALS
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p17
SYSTEMS FOR HYDROCARBON FIRES
Structural Steel Protection: Industry Standards
APPLICATION TECHNIQUES
Θ Manual or semi-casting
Θ Projection
Θ Application in shop and blockouts on site
Θ Protection Design
Θ Contour
Θ Boxed
Θ Solid
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ALFRAN FIRE IND
Θ Based on cement, vermiculite + additives
Θ Application in Refineries and Petrochemical
plants
Θ Lightweight, resistant to exterior weather and
frequent climate changes
Θ High resistance to hydrocarbon fires
Θ Non toxic, asbestos-free. Complies with all
safety requirements in refineries
Θ Tests
Θ EU: EN13381 Warrington
Θ USA: UL 1709
p18
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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ALFRAN FIRE IND
Fire Resistance Test
Θ Based on European Standards: EN 13501-
2: 2007
Θ Hydrocarbon fire curve as per UL-1709
Standard
Θ Official identification of tested product to
guarantee materials sold and applied in
each project
Θ Summary of minimum thicknesses for
500ºC critical steel temperature (see table
attached)
Θ “Solid” Design
Masividad R 120 R 180
5
25 mm
25 mm
25
45
65
85
105 30 mm
125 35 mm
145
165
40 mm 185
205
225 42 mm
245
p19
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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ALFRAN FIRE IND
Fire Resistance Test
Θ Based on UL 1709
standard
Θ Environmental Resistance
Test
Θ Periodic production audit
Θ Contour and box design
XR 722
mm
24,5
30,6
36,6
42,6
48,6
0,0
10,0
20,0
30,0
40,0
50,0
60,0
60 90 120 150 180
Fire Rating
Th
ickn
ess
mm
SYSTEMS FOR HYDROCARBON FIRES
Structural Steel Protection
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p20
APPLICACION PROCESS
Anchors and mesh
• Mesh folding: galvanised 50x50x1,6mm
• Anchor installation: Hilti (300-400mm)
• At half thickness
• Secured with tie wire
Structural Steel Protection: ALFRAN FIRE IND
SYSTEMS FOR HYDROCARBON FIRES
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p21
Mortar Application
• Pour in mixer
• Add water at 95-100% proportion
• Mix and pour into remixer
• Pump
• Apply casted without air or projected with air
• Troweled for finishing
APPLICACION PROCESS
Structural Steel Protection: ALFRAN FIRE IND
SYSTEMS FOR HYDROCARBON FIRES
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p22
Structural Steel Protection: ALFRAN FIRE IND
SYSTEMS FOR HYDROCARBON FIRES
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p23
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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MONOKOTE Z-146, Z-156
Θ Contains cement, bauxite and corrosion
inhibitors
Θ Application in refineries, petrochemical plants
and tunnels
Θ Lightweight material, weather resistant
Θ High resistance to hydrocarbon fires
Θ Non toxic, asbestos-free. Complies with all
safety requirements in refineries
Θ Tests
Θ EU Standards: BS 476 Part 20, EN1993-1-2
Θ USA Standards: UL 1709, Jet Fire
p24
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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PYROCRETE 241 / 241HD
Θ Passive fireproofing in Refineries, Petrochemical plants and Offshore platforms
Θ Lightweight, resistant to exterior weather and frequent climate changes
Θ High resistance to compression and adhesion
Θ HD: Perfect for workshop application
Θ ASTM E119, UL1709 and Jetfire
PYROCRETE EN PEMEX, MINATITLAN , MEXICO
p25
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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BASE IGNIFUGADA
INSTALACIÓN DE METAL DESPLEGADO Y ESQUINEROS
p26
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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DETALLE UNIONES, PEMEX MINATITLAN, MEXICO
DETALLE UNIONES Y MALLA, PEMEX MINATITLAN, MEXICO
p27
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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REPSOL TARRAGONA
PETRONOR, BILBAO, 2009 p28
PIPE RACKS
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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C-10, REPSOL CARTAGENA, 2010 p29
STRUCTURAL STEEL
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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p30
STRUCTURAL STEEL
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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REPSOL QUIMICA TARRAGONA
p31
SPHERE LEGS
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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AEROCOOLANTS, PETRONOR, BILBAO p32
AEROS
CARTAGENA, C-10
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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PETRONOR, BILBAO
p33
SKIRTS
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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REPSOL QUIMICA TARRAGONA p34
HORIZONTAL VESSEL SUPPORTS
Structural Steel Protection
SYSTEMS FOR HYDROCARBON FIRES
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THERMO-LAG / CHARTEK
Θ State-of-the-art, 2 component, epoxy-based, subliming coating
Θ Outdoor weather resistant
Θ Up to R-240 fire rating
Θ Allows workshop application and transport to site without damages (high flexural resistance)
Θ Spray application
Θ Official tests: UL1709, Lloyd’s Register, Det Norske Veritas, Jet Fire, Accelerated weathering
Θ 2 hr protection with 7,9mm
p35
Structural Steel Protection: EPOXY
SYSTEMS FOR HYDROCARBON FIRES
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ADI 1000, PETRONOR p36
Structural Steel Protection: EPOXY
SYSTEMS FOR HYDROCARBON FIRES
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• Fireproofing
• Corrosion free
• Resistance to chemical attacks
• Weather resistant
• Long lasting
• Little maintenance
• Lightweight
• Flexible
• Shop application
ADVANTAGES
p37
WOLLYBUTT GAS, AUSTRALIA
Structural Steel Protection: EPOXY
SYSTEMS FOR HYDROCARBON FIRES
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p38
Structural Steel Protection: EPOXY
SYSTEMS FOR HYDROCARBON FIRES
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p39
Structural Steel Protection: EPOXY
SYSTEMS FOR HYDROCARBON FIRES
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p40
Structural Steel Protection: EPOXY
SYSTEMS FOR HYDROCARBON FIRES
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Θ PROBOARD FS 450:
Fibresilicate boards
Θ PROSEAL UL:
Mastic
Θ FYREWRAP:
Ceramic fibre encapsulated
Instrumentation, Control & Power
p41
SYSTEMS FOR HYDROCARBON FIRES
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PROBOARD FS 450
Θ Based on Calcium Silicate
and fire-proven supporting
fibers
Θ 30 minutes fire rating (UL
1709)
Θ Excellent mechanical
performance: easy to cut,
pierce, screw, clamp
Θ Cleaner than mortars or
mastics
p42
Instrumentation, Control & Power
SYSTEMS FOR HYDROCARBON FIRES
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Cable Trays
Θ Duct formed around the tray
Θ Allows continuity of electrical service to units and avoids fire propagation
Θ 30 minute fire rating
p43
Instrumentation, Control & Power
SYSTEMS FOR HYDROCARBON FIRES
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Θ Mechanically resistant
Θ Registers to maintain cables
Θ Might include electrical boxes protection
Θ Avoid overheating of cables with ventilation grills
Θ Easily installable
Θ Indoor and outdoor
Θ Over 50 minutes resistance
PROBOARD FS 450 Ducts
p44
Instrumentation, Control & Power
SYSTEMS FOR HYDROCARBON FIRES
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Θ Single component coating, water-based used for electric cable protection
Θ Hard but flexible coating
Θ Outdoor weather-proof, does not age
Θ Fire rating: EI-30
Θ When exposed to fire, it goes into a ceramic state through an endothermic reaction that prevents the spread of fire
Θ Airless spray or manual application
Θ Test: Lloyd’s Register, Factory Mutual Research, Cidemco 23334-2
Cable Protection and Firestop Coatings
p45
Instrumentation, Control & Power
SYSTEMS FOR HYDROCARBON FIRES
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Cable Tray Enclosure
Θ API 2218 Testing, Standards: UL 1709, ASTM E1529 & E1725, FM Mutual Global
Θ Ceramic fiber blanket encapsulated in aluminium foil, reinforced with glass fibre mesh
Θ 30 minute fire rating – 1,5” System thickness
p46
Instrumentation, Control & Power
SYSTEMS FOR HYDROCARBON FIRES
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p47
Instrumentation, Control & Power: FYREWRAP
SYSTEMS FOR HYDROCARBON FIRES