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DEP 34.19.20.11-Gen.
January 2010
This document is restricted. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell Global
Solutions International B.V., The Netherlands. The copyright of this document is vested in this company. All rights reserved. Neither the whole nor any part of this
document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise)
without the prior written consent of the copyright owner.
DEP 34.19.20.11-Gen.
January 2010
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell Global Solutions International B.V. (Shell GSI)
and/or
Shell International Exploration and Production B.V. (SIEP)
and/or
other Shell Service Companies.
They are based on the experience acquired during their involvement with the design, construction, operation and
maintenance of processing units and facilities, and they are supplemented with the experience of Shell Operating Units.
Where appropriate they are based on, or reference is made to, international, regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice applied by Shell companies
operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such
facility, and thereby to achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at
each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the
attainment of the required design and engineering standards. In particular, for those requirements not specifically
covered, the Principal will expect them to follow those design and engineering practices which will achieve the same
level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting
from his own responsibility, consult the Principal or its technical advisor.
The right to use DEPs is granted by Shell GSI, in most cases under Service Agreements primarily with Shell companies
and other companies receiving technical advice and services from Shell GSI or another Shell Service Company.
Consequently, three categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or other Shell Service Company. The use of DEPs
by these Operating Units is subject in all respects to the terms and conditions of the relevant Service
Agreement.
2) Other parties who are authorized to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI
disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or
person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination
of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell
Service Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Service
Company, or companies affiliated to these companies, that may issue DEPs or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and
the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be
returned after use, including any copies which shall only be made by users with the express prior written consent of
Shell GSI. The copyright of DEPs vests in Shell GSI. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this
requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 34.19.20.11-Gen.
January 2010
Page 3
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................4
1.1 SCOPE........................................................................................................................4
1.2 DISTRIBUTION, APPLICABILITY AND REGULATORY CONSIDERATIONS ..........4
1.3 DEFINITIONS .............................................................................................................4
1.4 CROSS-REFERENCES .............................................................................................5
1.5 SUMMARY OF CHANGES SINCE PREVIOUS EDITION .........................................6
1.6 COMMENTS ON THIS DEP .......................................................................................8
1.7 PROJECT DOCUMENTATION REQURIEMENTS ....................................................8
2. OBJECTIVES OF FIREPROOFING...........................................................................9
2.1 GENERAL ...................................................................................................................9
2.2 FIRE SEVERITY .........................................................................................................9
2.3 FIRE RESISTANCE DURATION ................................................................................9
3. FIREPROOFING OF TYPICAL EQUIPMENT AND STRUCTURES IN AN
FIRE PROTECTION ZONES....................................................................................10
3.1 STRUCTURES SUPPORTING EQUIPMENT AND PIPING ....................................10
3.2 COLUMN AND VESSEL SKIRTS.............................................................................10
3.3 CABLES AND INSTRUMENTATION LOCATED WITHIN AN FPZ..........................10
3.4 PIPING AND EQUIPMENT.......................................................................................11
3.5 PROCESS UNIT PIPE RACKS AND PIPE SUPPORT COLUMNS.........................11
3.6 BUILDINGS...............................................................................................................11
4. MATERIAL REQUIREMENTS / PROPERTIES AND INSTALLATION OF
FIREPROOFING SYSTEMS ....................................................................................12
4.1 GENERAL .................................................................................................................12
4.2 CONCRETE FIREPROOFING .................................................................................13
4.3 PROPRIETARY MATERIAL FIREPROOFING.........................................................16
5. REFERENCES .........................................................................................................19
APPENDICES
APPENDIX 1 PROJECT DOCUMENTATION REQUIREMENTS.........................................21
APPENDIX 2 INSPECTION AND MAINTENANCE AFTER APPLICATION OF
FIREPROOFING .............................................................................................23
APPENDIX 3 TYPICAL DETAILS OF CONCRETE FIREPROOFING OF
STRUCTURAL MEMBERS .............................................................................24
APPENDIX 4 STRUCTURAL COLUMN DETAILS................................................................25
APPENDIX 5 PIPERACK DETAILS.......................................................................................26
APPENDIX 6 CONCRETE FIREPROOFING OF VESSEL SKIRTS.....................................27
APPENDIX 7 CONCRETE FIREPROOFING OF VESSEL STRUCTURAL SUPPORT
LEGS ...............................................................................................................28
DEP 34.19.20.11-Gen.
January 2010
Page 4
1. INTRODUCTION
1.1 SCOPE
This DEP specifies requirements and gives recommendations for the design and
application/installation of passive fire protection (PFP or fireproofing) of steel. The extent of
fireproofing and PFP requirements SHALL [PS] be established on the basis of the
requirements of DEP 80.47.10.30-Gen. and a fire safety assessment executed for the
particular plant or unit.
The zones where PFP are required are called Fire Protection Zones (FPZ). The extent of
the fireproofing around equipment and structures SHALL [PS] be indicated on layout and
construction drawings.
This DEP applies to steel supporting structures (and in some cases piping and equipment)
in process areas and processing plants as well as to storage facilities, jetties and pipe
bridges (including those outside the battery limits) in oil/gas/petrochemical installations.
This DEP is intended to ensure that the degree of fireproofing applied is effective and
practical in terms of maintainability and reduction of risks. As there is a wide variation in the
design of structures, the intent of this DEP SHALL [PS] be considered at all times when
prescribing the fireproofing of structures not specifically mentioned in (3).
This DEP is not applicable to jet fires.
This is a revision of the DEP of the same number dated December 1999; see (1.5)
regarding the changes.
1.3 DEFINITIONS
The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the contractor.
The Manufacturer/Supplier is the party which manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party which initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant to act for, and on behalf of, the Principal.
The lower-case word shall indicates a requirement.
DEP 34.19.20.11-Gen.
January 2010
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1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in (5).
DEP 34.19.20.11-Gen.
January 2010
Page 6
Removed old section – Fire Proofing Zone (FPZ). Added a new section –
2.2 ---------
Fire Severity.
Added new section - Process Unit Pipe Racks and Pipe Support
--------- 3.5
Columns
continued…
DEP 34.19.20.11-Gen.
January 2010
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2. OBJECTIVES OF FIREPROOFING
2.1 GENERAL
Fireproofing is a measure intended to improve the fire resistance of structures that support
pressure vessels, piping and other equipment located in fire hazardous areas. Protection is
provided by the application of concrete or other approved insulating materials to structural
steel supports.
Fireproofing offers protection against the adverse thermal effects of fire for a defined period
and defined degree of exposure. It should not be considered as a replacement for active
fire fighting or lead to relaxation of normal design requirements (spacing and layout
considerations) and precautions in operation and maintenance.
3.6 BUILDINGS
All enclosed buildings shall as a minimum follow the requirements of the local fire
regulations and building code. The fireproofing standards, methods and materials specified
in this DEP are applicable to buildings or enclosed structures containing process
equipment. Where industrial structures containing process equipments are not completely
covered in the local building code requirements and local fire regulations, this DEP
SHALL [PS] supplement the local requirements.
DEP 34.19.20.11-Gen.
January 2010
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4.1 GENERAL
4.1.1 Basic Materials
The following should be considered when selecting fireproofing materials and an applicator:
• For new structures, reinforced concrete support columns and beams are preferable to
fireproofed steel because it is economical, robust, and it has been proven to be
effective.
• When there are significant economic incentives or physical limitations, then proprietary
materials may be used instead of concrete. The experience of the applicator shall be
assessed. The importance of surface preparation and correct application of proprietary
materials cannot be overstressed.
• If surface preparation requires blasting this may rule out the application of the material in
an operating plant.
• Flammable solvents used in the mixing of some proprietary materials shall be rigidly
controlled.
• The capacity of the structure to handle the weight of the fireproofing SHALL [PS] be
assessed.
• Climatic conditions during installation may rule against the selection of certain materials.
The standard fireproofing material is normal weight concrete because of:
• Durability
• Availability
• Good pool fire protection
• Inherent torch fire protection
• No or minimum ongoing maintenance when applied correctly.
Proprietary fireproofing systems (4.3) may be used if approved by the Principal.
Mixed systems of approved proprietary fireproofing and normal weight concrete fireproofing
are acceptable.
The type of fireproofing material and its construction method shall be specified by the
Contractor and approved by the Principal.
Where proprietary materials are proposed Contractor SHALL [PS] provide the Principal with
calculations or other documentation demonstrating that the design will provide the specified
fire protection for approval.
The Principal shall specifically authorize the use of hollow box fireproofing designs where it
is envisioned that maintenance activities or personnel access requirements will not damage
the fireproofed member. Otherwise this design shall not be used.
4.1.2 Corrosion Under Fireproofing
1. Steel surfaces to be fireproofed shall be coated in accordance with approved coating
system (galvanized or paint) to prevent environmental corrosion.
2. Top side fireproofing/steel joint on vertical galvanized steel columns and horizontal
galvanized steel beams exposed to the weather SHALL [PS] be protected from
moisture ingress. For beams where the facility does not experience freeze/thaw
cycles, and where there is no prospect of standing water, galvanised steel shield
requirement maybe relaxed (refer sections in Appendix 3).
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January 2010
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The following documents shall be approved by Principal prior to the start of any application
of fireproofing:
1. Inspection and Test plan (ITP)
2. Quality control procedures, including Quality Control Records (QCRs)
3. Erection plan, including method statements covering application methods, temporary
facilities to be installed for application and Health Safety Environment (HSE) aspects
4. Materials and workmanship specifications.
DEP 34.19.20.11-Gen.
January 2010
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The applicator shall establish an inspection system to perform inspections and tests
required to assure compliance with the requirements. Completed QCRs shall be handed
over to the Principal before acceptance of the work
4.2.3.2 Surface Preparation
1. Loose dirt, oil and grease present on the surface shall be removed to ensure
good adhesion of the fireproofing to the primed or galvanized steel.
2. The primer shall be compatible with the fireproofing to be applied.
4.2.3.3 Mesh Reinforcement
1. Mesh reinforcement shall be wrapped around the steel section and retained firmly
by clips. Welded clips shall be pre-fabricated, attached to steel and galvanized
per steel supplier. Field stud welding requires approval of the principal. Overlaps
shall be at least 50 mm (2 in) and shall be wired at approximately 150 mm (6 in)
intervals.
2. The minimum cover applied on any wire mesh installed SHALL [PS] be 25 mm
(1 in)
3. The longitudinal overlap shall be in the web face, and all overlaps shall be
staggered so that no more than three layers of mesh are present at any one point.
4. If spacers are required between the mesh and the steel surface (to keep the
mesh in position during application of the fireproofing material) concrete spacer
blocks may be considered as a cheaper alternative for studs welded to the
steelwork.
5. Reinforcement material used in normal weight concrete fireproofing shall be
galvanized steel. In less severe conditions(e.g. dry arid climates outside the
influence of cooling towers) or where specific site experience prove otherwise the
Principal may consider the use of non-galvanized steel wire mesh and ties.
6. Reinforcing mesh shall be 50 mm x 50 mm x 2.5 mm (min) [2 in x 2 in x 12 BWG
(British Wire Gage)] welded galvanized steel fabric ASTM A 185. In mild or non-
corrosive conditions non galvanized steel mesh may be used in lieu of galvanized
mesh with the approval of the Principal.
4.2.3.4 Proportioning
1. Cast-in-place concrete proportioning shall conform to ACI 318 or local design
code and standard.
2. Shotcrete proportioning shall conform to ACI 506.2 or applicable local design
code and standard.
3. Concrete SHALL [PS] be proportioned so that it develops a compressive strength
of between 21 MPa (3000 psi) and 30 MPa ( 4500 psi) at 28 days with a
maximum aggregate size of 10 mm (3/8 inches). Higher grades are not
recommended due to spalling.
4. Concrete mix SHALL [PS] include an air-entraining admixture if concrete is
expected to be exposed to freezing conditions.
4.2.3.5 Shotcrete
1. Installation of shotcrete shall conform to ACI 506.2, this DEP and applicable local
design code and standard.
2. Surface shall be troweled smooth after installation where required by Principal.
3. Shotcrete nozzlemen shall be certified in accordance with ACI 506.3 or an
equivalent local standard.
DEP 34.19.20.11-Gen.
January 2010
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• Intumescent coatings, which expand and form an insulating, layer when the
temperature increases.
• Subliming mastic materials
4.3.4 Installation and Preparation
The installation contractor and the application equipment to be used shall be certified by the
manufacturer of the fireproofing material and shall have prior experience with the material
to be installed.
For proprietary systems, the following apply:
1. Fireproofing material SHALL [PS] be installed in accordance with the
manufacturer's instructions/specifications and this DEP.
2. Surfaces on which material will be installed shall be clean, dry and free of oil and
other contaminants immediately prior to material installation.
3. Surfaces shall be prepared by abrasive blast cleanings and priming systems,
applied per specifications and manufacturer recommendations.
4. Overcoat shall be installed if required by the material manufacturer.
5. Suitable precautions shall be taken to terminate the fireproofing surface evenly and
without overspray above the termination line.
6. Material overspray on adjacent piping, equipment, etc. shall be avoided.
7. The entire thickness of the material shall be installed in one continuous operation
unless prohibited by manufacturer's instructions.
8. Construction activities shall be restricted for a minimum of 24 hours in areas where
materials that require curing have been installed and are vulnerable to mechanical
damage prior to curing.
9. Damage to the material shall be repaired after construction activities in the area
are finished.
4.3.5 Inspection
A non-destructive testing device or method shall be used to determine the required
thickness gauge.
1. Frequent random thickness measurements of the material shall be taken during
application to ensure correct thickness.
2. Final thickness shall be measured with an approved thickness gage after a
minimum of 48 hours has elapsed.
3. Epoxy-based proprietary systems may be very sensitive to ambient conditions
and product ratios. Testing prior to and during application is required. A detailed
inspection and testing plan shall be developed.
Application work shall be subject to inspection and approval by the Principal and material
manufacturer.
DEP 34.19.20.11-Gen.
January 2010
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5. REFERENCES
SHELL STANDARDS
Non-metallic materials – Selection and application DEP 30.10.02.13-Gen.
Thermal insulation (amendments/supplements to the CINI DEP 30.46.00.31-Gen.
handbook)
Protective coatings for onshore facilities DEP 30.48.00.31-Gen.
Electrical engineering design DEP 33.64.10.10-Gen.
Assessment of fire safety of onshore installations DEP 80.47.10.30-Gen.
Standard Drawing: Skirts with fire-proof protection S 20.002
Shell Inspection And Maintenance (SIAM) Civil Report GS 06.50615
Infobase document ‘Passive Fire Protection’
Inspection and Maintenance
AMERICAN STANDARDS
Code Requirements for Determining Fire Resistance of ACI 216.1/TMS-0216
Concrete and Masonry Construction Assemblies
Building Code Requirements for Structural Concrete ACI 318
Specification for Materials, Proportioning, and Application of ACI 506.2
Shotcrete
Guide to Certification of Shotcrete Nozzlemen ACI 506.3
Guide to the Evaluation of Shotcrete ACI 506.4
Issued by:
American Concrete Institute (ACI)
P.O. Box 9094
Farmington Hills, MI 48333
USA
Standard Specification for Steel Welded Wire Fabric, Plain, ASTM A 185
for Concrete Reinforcement
Standard Specification for Concrete Aggregates ASTM C 33
Specification for Portland Cement ASTM C 150
Fire Tests of Building Construction and Materials ASTM E 119
Issued by:
American Society for Testing and Materials (ASTM)
ASTM International;
100 Barr Harbor Drive
P.O. Box C700
West Conshohocken, PA 19428
USA
Cement –
Part 1: Composition, specifications and conformity EN 197-1
criteria for common cements
Part 4: Compostion, specifications and conformity EN 197-4
criteria for low early strength blast furnace cements
Concrete –
Part 1: Specification, performance, production and EN 206-1
conformity
Eurocode 2: Design of Concrete Structures EN 1992
Issued by:
CEN Secrétariat Central
Rue de Stassart 36
B-1050 Brussels
Belgium
INTERNATIONAL STANDARDS
Tests for electric cables under fire conditions - Circuit IEC 60331-21
integrity - Part 21: Procedures and requirements - Cables of
rated voltage up to and including 0.6/1.0 kV
Issued by:
Central Office of the IEC
3, Rue de Varembé
CH 1211 Geneva 20
Switzerland
Copies can also be obtained from national standards organizations.
DEP 34.19.20.11-Gen.
January 2010
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