ECC DB AND FR PROJECT

PROCEDURE FOR FIREPROOFING

Project ECC DB & FR Project

Originating Company Hertel Singapore Private Limited

Document Title Procedure for Fireproofing

Document Number HSPL/ECCBD/QC-009

Document Revision 0.00

Document Status IFA-Issued For Approval

Document type QC-009 Procedure for Fireproofing

Originator / Author Rodelio B. Remo

Security Classification Confidential

Issue Date 05 February 2014

Revision History is shown next

page

COMPANY HERTEL MAIN CON CLIENT

NAME Rodelio B. Remo

POSITION QA/QC Lead

SIGNATURE

DATE 05-Feb-14

Revision 0.00 Page 1 of 13

REVISION HISTORY
Note: Latest changes to narrative shall be identified in Italics.

Rev # Date of Issue Description Originator Reviewer Approver

Procedure for
0.00 05-Feb-14
Fireproofing

ISSUENOTE:

Rev # Date Description

0.00 05-Feb-2014 First Issue for Company Review and Approval

RECORD OF REVISIONS

Note:

Latest changes to narrative will be identified in Italics. All previous revision

identification is removed.

Revision No. Date Description of Revision

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

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1. SCOPE 4

2. PURPOSE 4

3. DEFINITIONS 4

4. REFERENCE DOCUMENTS 4

5. APPLICABLE INSULATION MATERIAL 4

6. MATERIAL STORAGE AND HANDLING 5

7. INSTALLATION PROCEDURE (STELL STRUCTURES) 5

8. INSTALLATION PROCEDURE (EQUIPMENT SKIRTS) 6

9. MIXING PROCEDURE FIREPROOFING MATERIAL 6

10. APPLICATION PROCEDURE 6

11. QUALITY CONTROL REQUIREMENTS 7

12. REPAIR PROCEDURES 8

13. SURFACE FINISH 8

14. SAFETY HOUSEKEEPING & HEALTH PRECAUTION 9

15. ATTACHMENTS 9

1. Scope

This procedure covers the site fireproofing procedure for the application of Fendolite MII
(Fireproofing) to be applied on vessel / equipment skirt and for structural beams and
columns at Shell ECC DBN & FR Project at Pulau Ular Bukom, Singapore.
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2. Purpose

This procedure is designed to ensure that all relevant staff and workers involved are fully
understand the sequence and inspection required for the implementation of each work
process according to the project specification for fireproofing.

This procedure shall be used in conjunction with inspection and test plan for the application
of fireproofing.

3. Definitions

a) Project : Shell Ethylene Cracker Complex – Debottlenecking and

Flare Revamp (ECC-DB-FR) Pulau Bukom, Singapore
b) Company : Shell Eastern Petroleum Ltd.
c) EPCM Contractor : Toyo Engineering Corporation – Singapore Branch.
d) IC : Hertel Singapore Private Limited
e) Site : Land or place where the work to be executed or ‘field’.
f) Project Specification : Technical specification, documents or standards which
form part of the contract documents that serves as guide
for the execution of the project.

4. Reference Documents

The following documents shall form a part of the requirements of this specification.

4.1 Project Specification for Insulation Document no. SE-00000-PN-7880-0001

4.2 Design and Engineering Practice (DEP) – DEP 34.19.20.11 Gen Dec. 1999
(Fireproofing of Steel Structures)
4.3 Project Specification for Fireproofing – E-00000-BN-0011 Rev. 3.00
4.4 Material Data Sheet for Fendolite MII technical data sheet

5. Applicable Fireproofing Material

All applicable materials for the Fireproofing works shall be as follow.

5.1 Materials

5.1.1 Fendolite MII (UL 1709, BS476: Part 20: 1987 Appendix D)

5.2 Fastening Material (For Steel Structure)

5.2.1 Impact Pin (X-EGN 14MX) with galvanized non return washers (S-150).
5.2.2 Material 1.5mm diameter PVC coated galvanize hexagonal mesh (38 x 38).

5.3 Silicone Sealant

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5.3.1 Hardex Silicone Sealant (Clear)

5.4 Topcoat (Mellow Colour)

5.4.1 Acrylic Resin Based Emulsion Paint (DNT Brand)

6. Material Storage and Handling

All Fireproofing materials shall be kept and stored in accordance with manufacturer
requirements and shall be kept elevated at the ground, undercover and away from
wet or dump surfaces. Storage temperature are not critical as long as dry condition
are securely maintain. Material shelf life is up to a maximum 12 months under good
and dry conditions.

All material shall be off loaded to a designated lay down areas required. Only
necessary quantity of material and equipments shall be bring and transported on
actual site area for work.

7. Installation Procedure (For Steel Structures)

7.1 Substrate Preparation

7.1.1 Prior for the application of Fendlite MII (Fireproofing), steel structures
surfaces must be free from rust, oil, grease, loose mill scale and other
contaminants.
7.1.2 Fendolite MII is compatible with galvanized surfaces and no additional key
coat to be applied.

7.2 Mesh Reinforcement Installation

7.2.1 A 1.5mm diameter (38 x 38) PVC coated hexagonal wire mesh shall be
installed on beams and column when fireproofing material are applied
either on profile or solid fill methods of application to achieves the required
thickness.
7.2.2 Hexagonal Wire mesh must overlap at least 50mm at all joints. No more
than 3 layers should overlap at any point

7.3 Fixing of Pins

7.3.1 Using Hilti Impact Pins (X-EGN 14MX) with galvanized non-returnable
washers (S-150) are used to attached wire mesh to substrate with a
maximum of 400mm on staggered pitch.
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8. Installation Procedure (For Equipment Skirts)

8.1 Substrate Preparation

8.1.1 Prior for the application of Fendolite MII (Fireproofing), equipment surfaces
must be free from rust, oil, grease, loose mill scale and other contaminants.
8.1.2 The primer used for equipment skirts is compatible with Fendolite MII,
therefore no key coat are to be applied.

8.2 Mesh Reinforcement Installation

8.2.1 A 1.5mm diameter (38 x 38) PVC coated hexagonal wire mesh shall be
installed on beams and column when fireproofing material are applied
either on profile or solid fill methods of application to achieves the required
thickness.
8.2.2 Hexagonal Wire mesh must overlap at least 50mm at all joints. No more
than 3 layers should overlap at any point

9. Mixing Procedure of Fireproofing Material

9.1 Prior to mixing of Fendolite MII, the operator of the mixing machine shall check if it is
clean and free of old materials and foreign matter and if it is in good running conditions.
9.2 The fireproofing (Fendolite MII) shall be mix as per manufacturer’s recommendation.
The mixture shall require the addition of 15 to 19litres potable water per 20kg per bag
of the material to produce a mixture of suitable consistency.
9.3 Mixing shall be in accordance with manufacturer’s instruction. Mixing time shall be at
minimum of 3 minutes while the outlet gate of the mixing bucket shall be opened before
3 minutes to allow the time required to empty the mixer.

10. Application Procedure

10.1 Fireproofing material (Fendolite MII) shall be applied by means of spray equipment
machine “attachment drawing C”. The material shall be applied to a minimum of 8mm
in a single coat.

10.2 The fireproofing material shall be applied with the correct amount of air introduced at
the nozzle to ensure the consistency of texture and correct density of material. If the
surface has become very dry, it should be well dampened with clean water before
applying.
10.3 The fireproofing material (Fendolite MII) shall not be applied unless the substrate air
and temperatures are greater than 4 OC and less than 45 OC. Surface temperatures
shall be at least 2 OC above dew point.

10.4 Where there is a risk of water accumulation on fireproofing material (Fendolite MII)
the protected surface shall be slope to allow the water to run away. This is
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particularly important on beams where the top flange is protected and on the top
surface of the bottom flange when following the profile of a beam.

10.5 All termination of fireproofing (Fendolite MII) shall be cut to a “V” shape groove and
slope to shed water and sealed by means of Polysulfide sealant or approved
equivalent

11. Quality Control Requirements

Wet Density and Slump Test Measurement

During normal spraying operation, one sample shall be taken from both the mixer and
spray nozzle. The sample shall be taken and place into plastic slump tube (1 litre capacity)
without the use of agitation to increase packing rate. Using the edge of a trowel or
tensioned wire level on the top of the sample shall be cut back immediately after spraying
of sample from the mixer. The sample shall not be compress.

11.1 Wet Density Measurement

11.1.1 Weight the sample within ten minutes and record the bag number(s), the time
of extracting, its weight and volume and the calculation of the wet density.
Wet density = weight (kg) / volume (m3), and is in the range of 690 to 840
kg/m3 for fireproofing (Fendolite MII) from the mixer and 1070 to 1310 kg/m3
wet bulk density at nozzle discharge.

11.2 Slump Test Measurement

11.2.1 Slump shall be within the range of 40mm to 55 mm. The standard slump test
on fireproofing (Fendolite MII) plastic slump test apparatus should be carried out daily
when spraying occurs, and to keep record for each test.

11.3 Thickness Measurement

11.3.1 The thickness of fireproofing 38mm (Fendolite MII) shall be measured by

means of needle type thickness gauge “attached drawing D”
11.3.2 The thickness of fireproofing should be checked continuously during
application to ensure that correct thickness is applied.

11.4 Apparatus Used

11.4.1 A flat clean plate, 150mm ruler, Plastic Slump Tube (I litre volume),
Weighing Scale – 2kg in gram and Temperature and HR gauge.

12. Repair Procedure

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The repair procedure for any damaged area, if any, should be carried out as follows:

12.1 Cut away any loose fireproofing material (Fendolite MII) and chamfer any sharp
edges. Where mesh reinforcement is exposed, clear the fireproofing (Fendolite MII)
away from the mesh and ensure that it will remain in the mid third of the repair. If
damaged has resulted in mesh failure, totally remove the affected mesh reinstate
with mesh ensuring that a minimum 50mm overlap onto the original mesh is achieved
and that it is secured by the use of wire ties or by twisting cut ends together and
ensure correct mesh position.
12.2 If existing fireproofing material (Fendolite MII) are become dry, dampen the surface
adjacent to the repair site with potable water. Mix the fireproofing (Fendolite MII) in
accordance with the mixing procedure. Apply fireproofing (Fendolite MII) and finish
level with existing material.

13. Surface Finish

13.1 For Steel Structure

13.1.1 Upon the curing of fireproofing on the 7 days a coat of acrylic paint shall be
applied by using roller for surface finishing.
13.1.2 All termination of Fendolite MII steel junction will be sloped to shed water
and be sealed by the used of silicone sealer. A “U” shaped groove
approximately 8mm deep and wide should be cut into the Fendolite MII
immediately adjacent to the junction. The silicone sealant will be installed
after curing of Fendolite MII.

13.2 For Internal Skirt Fireproofing

13.2.1 No coating or silicone sealant is required for internal skirt fireproofing.

13.3 For External Skirt Fireproofing

13.3.1 Same as required for steel structures.

13.3.2 The thickness of Fendolite MII will be calculated in accordance with UL
Directory Formula (Reference Document XR 719).
13.3.3 The recommended thickness tolerance that should be achieved on site is –
0 to + 3mm.

14. Safety Housekeeping and Health Precaution

All Installation and Construction work will be undertaken in accordance with site safety
procedures and main contractors Health and Safety Policy. Work permit will be obtained
and work will commence in accordance with specific itemized on the work permit. All PPE
required will be provided and worn in accordance with site safety procedures. The site
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location of work activities will be kept clean and tidy condition by carry out daily
housekeeping every end of the working day.

Fireproofing material (FendoliteMll) is a mixture of mainly cement and vermiculite and has a
very low toxicity. Precautions shall be taken to avoid skin contact and breathing dust at the
dry stage and to avoid skin contact at wet stage. The workers shall wear proper PPE such
as coveralls, gloves, goggles and approved respirator.

There is a very little hazard to other workers working in the area, but there is always some
slight over spray which gives rise to a layer of dust in the surrounding of the work place.

Prior to commencing of spraying, the site QC / Supervisor shall check all the protections
around the work place area, to ensure that no dust or spray particles can escape into the
surrounding environment.

15. Attachments

Typical Drawings – see attached (A, B, C and D)

Material Data Sheet – see attached

TYPICAL DRAWING:

ATTACHED “A” (Beam and Column)

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8mm GROOVE WITH

SILICON SEALANT
FENDOLITE M II

CD PIN
12mm FORM WORK
25 X 25 X G19 GALV
HEX. WIRE MESH

ATTACHED “B” (Beam and Column Details)

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MAX. 50 mm OVERLAPPING
OF NO MORE THAN 3 LAYERS

8 mm GROOVE WITH
SILICON RUBBER

STUD WELD PINS OR HILTI

IMPACT PINS WITH WASHER
(MAX. SPACING OF 400 mm)

50 X 50 X G19 GALV
HEX. WIRE MESH

FENDOLITE M II
FIRE PROOFING DETAILS FOR COLUMNS FIRE PROOFING DETAILS FOR 3 SIDED BEAMS

ATTACHED “C” (Diagram of Mixer Pump)

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EXTRACTED FROM BS 8202 : Part 1 : 1987.

Annular water / air jets

Central material orifice
Dry material hopper
and feed mechanism
End view of nozzle

Hand held nozzle

Dry material hose
Carding unit
Central air Water
Air

Blower

Note : With certain types of equipment, an air feed to the gun is unnecessary.
(a) Equipment for sprays wetted at the gun.

Wet mixer

Spray nozzle

Hopper

Spray head Compressed air

Pump

Flexible feed hose

(b) Equipment for slurry sprays

Figure 4. Typical equipment for application of sprays.

ATTACHED “D” (Thickness and Measuring Gauge)

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EXTRACTED FROM BS 8202 : Part 1 : 1987.

Disc

70 80 90 100 110 120 130 140 150 Pin

2 3 4 5 6

Figure 5 : Typical needle gauge for direct measurement of coating thickness.

Specified thickness

Figure 5 : measurement of coating thickness to the face of laths.