fti non metallic cladding system -...

FTI Non Metallic Cladding System

FibaShield and FibaRoll

improvements in Constructability and Integrity of

Corrosion and Insulation Protection Systems

Objective of Presentation

• Background• FTI Services and Products• Benefits of FTI• Projects• Discussion

When completed, you will see how FTI products can:

Improve scheduleReduce project costReduce operating and maintenance costsSimplify pipe support designAllow greater flexibilityReduce health and safety risk

FTI Group

Established in 1995 in UK

Offices and agents Worldwide

Capacity 90,000 sqm per month

ISO 9001 through Bureau Veritas Quality International

Dedicated design, application and inspection support team

Mobile construction team for FibaShield projects

FTI Services Training of contractors in the use of all products

Quality Control and Inspection services to support contractors and client

Design and drawings for clients

Installation procedures and details

Testing and design for piping systems using FibaShield pre-insulated pipe

Application Training and Inspection

Three Main Product Types1) Fibaroll – uncured cladding that is flexible and hardens upon exposure to UV

light. Has excellent chemical resistance and excellent mechanical strength. Excellent for pre-insulated equipment.

2) FibaClad – preformed sections of Fibaroll made to specific pipe sizes. Similar in installation to pre-formed metal jacketing. Excellent for maintenance work and indoor projects

3) Fibashield – machine applied system for large projects with same performance as Fibaroll. Ideal for straight run of pipes and projects.

2 Main Grades FR M1 - Used for areas where good fire

rating is needed VECR – Used for its great chemical

resistance

Thicknesses from 1 – 2 mm Can be installed in ambient

temperatures from -15 C to 55 C Easily cut and fabricated into shapes Meets ASTM E-84 Good adhesion to all insulation types

including Aerogel No additional attachment systems

required Overlap forms a chemical bond

High strength of FibaRoll allows for pre-insulation of pipes and vessels

Sealed seams allows for greater resistance to moisture and mechanical openings

Highly chemical resistant

Reduce life cycle costs compared to metal

Is FibaRoll tough and strong?

•

FibaRoll Insulated Spheres –Russia & Spain

FibaRollButadiene & Intermediate

Storage Tanks -Nanhai

Insulation Protection at Shell Sakhalin LNG

FibaRollExxonMobil, St Fergus

Pre-Insulation of Vessels

ECC Project 2008-09 Singapore

Insulation Protection Shell Sahhalin LNG

Insulation Protection Shell Sakhalin LNG

Difficult termination –Completely sealed

Comes in 1 meter lengths Diameters from 3” to 36” Tees, Long Radius, Short

Radius, and End Caps Available Easily Installed Along with FibaGel or

FibaBond adhesive the joint forms a chemical bond

Ideal for low UV areas or indoors

Excellent resistance to high pressure water

Faster installation

Sealed seams allows for greater resistance to moisture and mechanical openings

Highly chemical resistant

Reduce life cycle costs compared to metal

Tough yet Flexible

FibaClad Installations

Id Ideal for pipe rack, jetty and FPSOs

1-2mm thick glass reinforced coating.

Ideal for pipes after coating to avoid mechanical damage

Saves up to 80% of onsite labour. Reduction in Health & Safety risks.

Highly Chemical resistant

Benefits of FibaShield Minimize damage to coatings

Reduction of 80-90% of onsite labour

Reduce H&S risk from reduction of onsite labour

Operating temperature covering high risk CUI range

Seamless insulation/no joints – improved performance

Seamless waterproof cladding

Simplified pipe support design

Improved QC with shop application

Improved flexibility of construction – removal of cladding/insulation from critical path

Reduced scaffolding costs- Reduced construction time

Chilled water lines

FibaShield and Pipe Supports

Pipe Support Design with FibaShield

No High Density PUR for pipe supports

Better fit even when pipe is out of roundQuick installationImproved insulationStress analysis shows 10x safety marginMajor cost saving


Load testing of pre-insulated pipe at LloydsTesting of pipe sizes 3”, 14” and 24”Finite Element Analysis to build modelEvaluation of Safety Factor


Conditions:

Shoe Length = 750mmClamp = 180 DEGPipe/ PIR/FibaShield = 1400mmWearpad = 1000mm longThickness = 12mm; 360 DEGLoad Applied: 32800Kg


FE Analysis correlates well with Lloyds Test Data. FE Model gives Peak Stress as 28 Mpa compared with 33 MPa UTS. Both with initial Lloyds tests and FE Analysis under Normal Load

the system performance at the support area is controlled by the stiffness of the FRP and the Poisson's ratio of the PIR.

FE Analysis demonstrates a Load Safety Factor of 10 for this support Geometry.

The model can be used for any pipe diameter and insulation thickness

Benefits of FTI products over metal cladding systems

SS Al FibaRoll FibaClad FibaShield

Allows for Pre-Insulation No No Yes Yes Yes

Chemical Bond at Overlap No No Yes Yes Yes

Mechanical Fastening Required

Yes Yes No No No

Can Withstand Foot Traffic No No Yes Yes Yes

Can Minimize moisture ingress

No No Yes Yes Yes

Meets E-84 Yes Yes Yes Yes Yes

Fire Tested in UL -1709 Yes No Yes Yes Yes

Projects• Sakhalin - Shell – FibaRoll• ECC – Shell – FibaRoll, FibaClad• Gate LNG – FibaShield• BLNG – FibaShield, FibaRoll• Pearl GTL – Shell – FibaRoll, FibaClad• Vopak – FibaShield, FibaRoll, FibaClad• Total - Pazflor – FibaRoll, FibaClad• Nexen – Buzzard Platform – FibaRoll, FibaClad• Exxon – Adriatic LNG – FibaRoll• Exxon – Fowley – FibaRoll• Exxon- St. Fergus – FibaRoll, FibaClad• Dow Corning – HSC – FibaRoll• Chevron Phillips – FibaRoll• Nanhei – Shell - FibaRoll

Pearl GTL - Qatar•FTI Product: FibaRoll & FibaClad•Client: Shell

•Date: June 2009 – Present Day

•EPCM / PMC: JGC / KBR

•Main Contractor: Hyundai, Chiyoda,

Linde, CCIC, Veolia, Toyo

•Scope: 150,000 sqm Cold Insulation

Cladding

•Other factors: Due to the use of 6

insulation contractors a high level of

vendor support was required for this

project

Sage Gas Terminal - Scotland•FTI Product: FibaRoll•Client: Exxon Mobil

•Date: 2007 – Present

•Main Contractor: BIS Salamis UK

•Scope: Re-insulating and cladding 4 Fractioning Columns whilst on-line

•Other Factors: 2 Columns insulated with Tarek Kingspan PUR, 3rd

Column insulated using Pyrogel and Cryogel due to differential -22 C - + 120 C operating temperature.

BLNG - Brunei

•FTI Product: FibaRoll

•Client: Shell, Mitsubishi & Brunei State Government•Date: 2006 – Present day

•Contractors: Mashhor, Joffren Omar & SKS

•Scope: A full rejuvenation project of all existing insulation and cladding.

•Other Factors: Some areas are thermal scanned and if sound, the metal cladding is overclad using FibaRoll

ECC Project – Singapore

•FTI Product: FibaRoll & FibaClad

•Client: Shell

•Date: 2008 - 2010

•Main Contractor: CB&I,

Lummus & TOYO

•Scope: Expansion project to existing plant which suffered multiple failures of traditional cladding system•Other Factors: The tanks in the photo are slab mineral wool at high CUI risk 120 C.

Pazflor FPSO – South Korea•FTI Products: FibaRoll, FibaClad Straights & Fixtures

•Client: Total

•Date: 2010 – Present Day

•Main Contractor: Daewoo Shipping & Marine Engineering•Scope: Largest FPSO new build worldwide. 16 process units > 25,000 sqm.•Other Factors: Very tight access & low natural light was a major factor in specifying FibaCladstraights & fixtures

VOPAK - Singapore•FTI Products: FibaRoll, FibaClad & FibaShield

•Client: Vopak

•Date: 2009 – 2010

•Main Contractor: Chiyoda•Scope: 6.5km x 4” pre-insulated 50mm PUR waterlines and 12,000 sqmof FibaRoll and FibaClad for cold insulation including two cold service spheres.•Other Factors: Due to the tropical high humidity on the Island nation of Singapore, GRP coatings are used extensively to prevent CUI.

Elgin Franklin – North Sea •FTI Products: FibaRoll &

FibaClad

•Client: Total

•Date: 2005 - onwards

•Main Contractor: RBG

•Scope: To clad all

pipeline insulation from

deck level to 3m high and

several columns.

Adriatic LNG – Spain & Italy•FTI Products: FibaRoll•Client: Exxon Mobil, Qatar Petroleum & Edison

•Date: 2008 – 2009•Insulation Contractor:Kaefer•Scope: 70 000 sqmFibaRoll for cold insulation over foamglass & PUR•Other Factors: The worlds first gravity based structure (GBS) was built in Spain and towed to location offshore Venice, Italy. A tough, sealed cladding system was required to withstand this high salt corrosion environment.

Sakhalin LNG - Russia•FibaRoll Products: FibaRoll

•Client: Shell

•Date: 2006 - 2008•Main Contractor: Chiyoda & Toyo•Scope: 270,000 sqm full hot & cold insulation cladding specification•Other Factors: For the harsh Russian climate FTI bespoke manufactured a 1.8mm grade of FibaRoll. A highly successful FibaRoll project achieved by working in close partnership with the insulation contractor Cape East.

GrangeMouth - Scotland•FibaRoll Products: FibaRoll

•Client: BP

•Main Contractor: PFP

•Scope: Two 22mtr diameter spheres coatedusing Foamglass / FibaRoll / Fendelite.•Other Factors: FibaRoll was specified after a major failure of the existing Mastic & Scrim system caused freezing and damaged approximately 50% of the FoamGlass.

Nanhai - China

•FTI Products: FibaRoll

•Client: Shell

•Date: 2006 – 2007

•Main Contractor:Bechtel & Technip•Scope: 250 000 sqm hot & cold insulation•Other Factors: A brand new build petrochemical plant in sub-tropical China requiring a sealed cladding system to resist the extreme humidity.

Buzzard – North Sea

•FTI Product: FibaRoll, FibaClad Straights & Fixtures•Client: Nexen•Date: 2005 – Present Day•Scope: All insulation 14” and below was clad using FibaClad. All larger that 14” was clad using FibaRoll.•Other factors: FibaCladstraights & fixtures were extensively used due to low light levels inside the structure and for ease of application off-shore.

Fawley – Southampton UK•FTI Products: FibaShield, FibaRoll & FibaWearPad•Client: Exxon Mobil•Contractor: FTI UK direct•Date: 2006•Scope: 400m x 12” machine applied GRP direct to Steel on a bunker fuel feed line underneath a jetty.•Other Factors: A highly critical application due to the intense environmental monitoring of the surrounding waterways

BLNG Jetty - Brunei•FTI Products: FibaShield & FibaRoll•Client: Shell, Mitsubishi & Brunei State Government•Insulation Contractor: Sahid•Date: 2007•Scope: 216mtr x 18” single layer 50mm pre-insulated Marine Flare line & 540m x 20” cryogenic 3 layer 150mm pre-insulated Vapour Return Line at the end of BLNG 5 km loading jetty in extremely humid and tropical conditions.

GATE LNG Terminal – Holland•FTI Products: FibaShield, FibaRoll & FibaWearPad•Client: Gasunie & Vopak

•Date: 2010•Main Contractor: Techint & Sener•Scope: 2.3 km of pre-insulated 24”, 30” & 36” cryogenic LNG loading lines. Average 150mm 3 layer poured in place PUR with multiple machine applied zero perm vapour barriers and GRP cladding.

Triton F.P.S.O – North Sea

•FTI Products: FibaClad Straights & Endcaps•Client: Amerada Hess & Shell

•Date: 2009

•Main Contractor: RBG

•Scope: 400 linear meters•Other Factors: FibaClad was used for ease of application in difficult off-shore conditions.

Sabic LDPE – Wilton UK•FTI Products: FibaRoll, FibaClad straights & Fixtures

•Client: Sabic

•Date: 2008 – Onwards

•Main Contractor: CAPE

•Scope: 30,000 sqm

•Other Factors: This was the first project that FibaClad was used extensively and played a key role in helping develop the pre-moulded fixtures and fittings.

Thank you

fti non metallic cladding system -...

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