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
Pre-Insulation of Vessels
ECC Project 2008-09 Singapore
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
FibaClad Installations
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
Vopak
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
Pipe Support Design with FibaShield
Load testing of pre-insulated pipe at LloydsTesting of pipe sizes 3”, 14” and 24”Finite Element Analysis to build modelEvaluation of Safety Factor
Pipe Support Design with FibaShield
Pipe Support Design with FibaShield
Conditions:
Shoe Length = 750mmClamp = 180 DEGPipe/ PIR/FibaShield = 1400mmWearpad = 1000mm longThickness = 12mm; 360 DEGLoad Applied: 32800Kg
Pipe Support Design with FibaShield
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