Industrial Pipelines

Flexible Insulation Jackets in Industrial Pipe Systems and Equipment: Application Within Passive Fire Protection Systems In industrial facilities where flammable and combustible hazardous materials are used or stored in standard processes, "pool fires, jet fires, explosions and BLEVE" incidents remain among the possible risks, and following such events, toxic debris threatening the environment and human health may occur. These incidents generally stem from operational errors in operation, maintenance or inspection processes. However, even if operational processes are conducted with near-perfect performance, major industrial accidents triggered by natural disasters such as "earthquakes, floods, landslides, etc." can cause such incidents to arise. In any case, the longer the facility's service life, the greater the tendency for possible risk to increase, and ultimately; it is essential that such high-risk facilities become 100% safe places in terms of human and environmental considerations. In order to minimize the fire risks mentioned above, serious efforts and precautions are being undertaken in industrial facilities. Together with "active fire protection" systems that activate with fire and ensure the fire is controlled as quickly as possible, "passive fire protection" systems intended to prevent fire spread, keep it at the location where it occurs, and prevent more severe cases (jet spray, explosions, etc.) from developing are important components of these measures. These applications are part of much larger activities within strategic plans aimed at preventing accidents in industrial facilities and reducing their effects, in accordance with current regulations and programs. Combined with the facility's own knowledge base, such regulations and similar content provide the necessary infrastructure for optimum solutions compatible with all surroundings. For example, the SEVESO III Directive, which is a serious guide and regulatory document on process safety, aims to prevent major accidents involving hazardous materials. However, since accidents can still occur, such measures aim to limit the consequences of these types of accidents not only for human health but also for the environment. Passive Fire Protection "Passive fire protection" (PFP) systems generally consist of components that prevent fire passage within a particular architectural structure (building, warehouse, etc.) and prevent rapid fire spread by dividing the building plan into certain small zones. In industrial facilities, equipment such as tanks or heat exchangers, pipe systems, connecting elements on the line (valves, flanges, etc.), instruments and supporting steel structures (piperacks, etc.) are equipped with PFP systems. In facilities equipped with PFP systems, suitable conditions for evacuation and fire response are created, and most importantly, time is gained. For this reason; in refineries, oil platforms, petrochemical facilities, chemical process facilities, and all industrial facilities where flammable and/or combustible fluids are used or stored in standard processes, the most effective solution to be implemented to minimize risk or to minimize damage should risk occur is a PFP system. Pump and Actuator Applications PFP systems applied to control equipment (actuators) on any valve allow the relevant equipment to withstand for a certain period in a possible fire, thereby gaining time for actions that could reduce the impact of the fire. For example, in the event of a pool fire or jet fire occurring around an actuator, time is first gained sufficient to shut off the flow in the line associated with the actuator. The same example can be simulated for a PFP application on a pump. In a similar fire scenario, the ability of the relevant pump to continue operating or be shut down could be of vital importance. On the other hand, depending on the capability of the PFP system, these equipment can be protected from fire through extinguishing and other similar active fire response measures and can resume operations after the fire. Of course, depending on the power source type of the relevant equipment, electrical, hydraulic or pneumatic connection lines must be evaluated within the scope of the PFP system and the design must be carried out accordingly. Since flexible insulation jackets are manufactured as custom-made solutions for such equipment, they stand out among passive fire protection applications. Since, in the end, PFP jackets that are extremely easy to install compared to other alternatives, can be easily disassembled and reassembled for routine maintenance work, are extremely useful components for maintenance teams. [caption id="attachment_130008" align="aligncenter"] Figure 1: Actuator PFP Jacket[/caption] [caption id="attachment_130009" align="aligncenter"] Figure 2: Pump PFP Jacket[/caption]

Flanged Connection Applications

Connecting two separate pipe sections or other fittings on a line using flanges, which are connecting elements designed to be removable, is nearly a routine application. Within a pipe system, a flange is therefore a mechanical component intended to provide a non-permanent connection between two elements. By its nature, it represents weak points in the pipe system, since effects occurring within the line such as pressure, vibration and heat can cause failure in the flange. Flanged connection points on pipe lines carrying flammable/combustible fluids, chemically aggressive products or potentially harmful products of any kind are a source of risk for personnel safety and the overall reliability of the system. In case of possible failure, the fluid in the line can spray from the flange connection with a wide impact area and high kinetic energy and can initiate the incident defined as a Jet Fire. [caption id="attachment_130011" align="aligncenter"] Figure 3: Flange Jacket[/caption] Flanged connection points on lines with similar characteristics in terms of contained fluid and pressure conditions must be covered with suitable components for passive fire protection purposes. The most appropriate covering option for flanged connections is generally flexible insulation jackets. Since they are manufactured as custom-made solutions with optimum technical textile components according to PFP design and installation is also very easy. In this way, it becomes the most suitable PFP application applicable at difficult-to-access points and at the same time provides thermal insulation. Depending on the line and fluid characteristics and the sensitivity of the system, if needed, they are equipped with drainage leak indicators, thus creating an opportunity to observe possible leaks at an early stage. [caption id="attachment_130012" align="aligncenter"] Figure 4: Drainage Cap and Indicator[/caption]

Storage Tank Applications

Even if the fluid contained is not flammable/combustible, a BLEVE (Boiling Liquid Expanding Vapor Explosion) incident can occur due to a fire surrounding a pressurized storage unit. If we are talking about a tank storing flammable/combustible material, a fire that can occur around it can turn into a pool fire along with this storage unit. To prevent similar incidents and to enable timely fire response, such equipment must be equipped with PFP systems. In this way, the relevant equipment is protected for a certain period against external fire both from direct fire contact and from the danger of increased pressure of the fluid inside due to heat transfer. Flexible and modular jacket systems with insulation capability have been frequently preferred in recent years for such preventive applications. These systems, designed and manufactured specific to the equipment, provide high fire resistance along with installation and, if necessary, disassembly convenience as mentioned in the examples above. [caption id="attachment_130013" align="aligncenter"] Figure 5: Reactor PFP System[/caption] Other Applications While not as common and standardized as in the examples above, flexible insulation jackets are also used in some structural steel elements. Special areas within warehouse buildings where hazardous materials are stored or special warehouse areas are the most suitable examples for such applications. Superior PFP performance is achieved through modular and flexible insulation jackets specially designed for structural elements surrounding materials kept in a separate area within a large warehouse space. Thus, should the hazard occur, fire spread from the outside to the area or from the area to the outside can be halted for a certain period, gaining vital time for response and evacuation. Another example of PFP applications in structural steels is "piperacks." PFP applications on the structural steel elements of piperacks located in areas with fire risk can be performed with modular and flexible insulation jackets. In this way, should the hazard occur, events that would further increase danger, such as fire affecting the strength of steel elements, deformation of the piperack structure, partial or complete collapse, can be prevented. The ability to produce irregular parts when manufacturing these systems, designed and produced specific to structural elements, completes the integrity of the PFP system and achieves superior performance in this way. At the same time, these modular systems can be reused with a revised design and, if necessary, production of a small amount of special parts should it be decided in the future to perform PFP application over wider or narrower areas. In order to observe possible corrosion or similar mechanical effects, the system can be partially or completely disassembled regionally, and after inspections and maintenance, can be reassembled and reused. [caption id="attachment_130014" align="aligncenter"] Figure 6: PFP System on Steel Structure[/caption] In industrial facilities where flammable and combustible hazardous materials are used or stored in standard processes, fire risk will always exist, and these risks may depend on many different causes depending on the facility's characteristics. First and foremost, it is necessary to take the necessary precautions to prevent fire from starting and to be prepared should it occur. Generally, in terms of human and environmental safety, and specifically in terms of process safety, it is necessary that risky situations in the facility be well identified, appropriate measures for these risks be determined by specialists in this field, certified products without quality concerns be used, and precautions be taken as required. INSPRO, with its expert and experienced engineering team, necessary equipment and raw material infrastructure for manufacturing suited to any scenario, is capable of conducting PFP jacket design and applications in industrial facilities. INSPRO products have been tested and certified under the ISO 22899-1 standard for jet fire scenarios. Osman Çiçekli Industrial Engineer Application of Flexible Insulation Jackets in Industrial Pipe Systems and Equipment Within Passive Fire Protection Systems Class A Occupational Safety Specialist INSPRO