It has recently been demonstrated that 50 mm thick industrial grade thermal insulation may serve as passive fire protection of jet fire exposed thick walled steel distillation columns. The present study investigates the performance of thermal insulation in conjunction to 3 mm, 6 mm, 12 mm and 16 mm steel walls, i.e., where the wall represents less heat sink, when exposed to 350 kW/m2 heat load. Regardless of the tested steel plate thicknesses, about 10 min passed before a nearly linear steel temperature increase versus time was observed. Thereafter, the thinnest plates systematically showed a faster temperature increase than the thickest plates confirming the wall heat sink effect. To study thermal insulation sintering, 50 mm thermal insulation cubes were heat treated (30 min holding time) at temperatures up to 1100 °C. No clear sign of melting was observed, but sintering resulted in 25% shrinkage at 1100 °C. Thermogravimetric analysis to 1300 °C revealed mass loss peaks due to anti-dusting material at 250 °C and Bakelite binder at 460 °C. No significant mass change occurred above 1000 °C. Differential scanning calorimetry to 1300 °C revealed endothermic processes related to the anti-dusting material and Bakelite mass losses, as well as a conspicuous endothermic peak at 1220 °C. This peak is most likely due to melting. The endothermic processes involved when heating the thermal insulation may to a large part explain the 10 min delay in steel plate temperature increase during fire testing. Overall, the tested thermal insulation performed surprisingly well also for protecting the thin steel plates.

Abstract:In the oil and gas industry, hydrocarbon process equipment was previously often thermally insulated by applying insulation directly to the metal surface. Fire protective insulation was applied outside the thermal insulation. In some cases, severe corrosion attacks were observed due to ingress of humidity and condensation at cold surfaces. Introducing a 25 mm air gap to prevent wet thermal insulation and metal wall contact is expected to solve the corrosion issues. This improved insulation methodology does, however, require more space that may not be available when refurbishing older process plants. Relocating structural elements would introduce much hot work, which should be minimized in live plants. It is also costly. The aim of the present study is therefore to develop a test concept for testing fire resistance of equipment protected with only air-gap and thermal insulation, i.e., without the fire-protective insulation. The present work demonstrates a conceptual methodology for small scale fire testing of mockups resembling a section of a distillation column. The mockups were exposed to a small-scale propane flame in a test configuration where the flow rate and the flame zone were optimized to give heat flux levels in the range 250-350 kW/m 2 . Results are presented for a mockup resembling a 16 mm thick distillation column steel wall. It is demonstrated that the modern distance insulation in combination with the heat capacity of the column wall indicates 30+ minutes fire resistance. The results show that this methodology has great potentials for low cost fire testing of other configurations, and it may serve as a set-up for product development.

The present work outlines a method for measuring the cooling efficiency of droplets impinging onto hot metal discs in the temperature range of 85 • C to 400 • C, i.e., covering the boiling regimes experienced when applying water to heated objects in fires. Stainless steel and aluminum test discs (with 50-mm diameter, 10-mm thickness, and a surface roughness of Ra 0.4 or Ra 3) were suspended horizontally by four thermocouples that were used to record disc temperatures. The discs were heated by a laboratory burner prior to the experiments, and left to cool with and without applying 2.4-mm diameter water droplets to the discs while the disc temperatures were recorded. The droplets were generated by the acceleration of gravity from a hypodermic injection needle, and hit the disc center at a speed of 2.2 m/s and a rate of 0.02 g/s, i.e., about three droplets per second. Based on the recorded rate of the temperature change, as well as disc mass and disc heat capacity, the absolute droplet cooling effect and the relative cooling efficiency relative to complete droplet evaporation were obtained. There were significant differences in the cooling efficiency as a function of temperature for the two metals investigated, but there was no statistically significant difference with respect to whether the surface roughness was Ra 0.4 or Ra 3. Aluminum showed a higher cooling efficiency in the temperature range of 110 • C to 140 • C, and a lower cooling efficiency in the temperature range of 180 • C to 300 • C compared to stainless steel. Both metals gave a maximum cooling efficiency in the range of 75% to 85%. A minimum of 5% cooling efficiency was experienced for the aluminum disc at 235 • C, i.e., the observed Leidenfrost point. However, stainless steel did not give a clear minimum in cooling efficiency, which was about 12-14% for disc temperatures above 300 • C. This simple and straightforward technique is well suited for assessing the cooling efficiency of water droplets impinging onto heated metal objects. The test rig also worked well for demonstrating droplet boiling regimes and water droplet cooling efficiency to fire safety engineering students.

In the present work, the cooling efficiency of water droplets falling onto hot aluminum and stainless steel discs from heights of 12.5 cm, 25 cm, 50 cm and 100 cm, corresponding to speeds of 1.5 m/s, 2.2 m/s, 3.1 m/s and 4.4 m/s, respectively, were studied. The discs were aligned at 0° (horizontal), 30° and 60° inclination. The water application rate was 0.022 g/s and the droplet diameters studied were 2.5 mm, 3.2 mm and 3.7 mm. Acetone solutions (300 ppm and 700 ppm) as well as a NaCl (35 g/kg) solution, emulating seawater, were tested to evaluate the influence of an active surfactant on the recorded cooling efficiency. The droplets with higher impact speed resulted in lower cooling efficiency, especially at disc temperatures above the Leidenfrost temperature, likely due to more vigorous droplets bouncing. Larger inclination did, as expected, result in lower cooling efficiency. At temperatures associated with nucleate boiling, the water droplets with NaCl conspicuously displayed higher cooling efficiency at about 110 °C. However, at temperatures between 120 °C and the Leidenfrost temperature, acetone and NaCl additives did not significantly alter the cooling efficiency of the water droplets. Above the Leidenfrost temperature, a minor increase in cooling efficiency was observed for the acetone solutions. Overall, the additives only marginally changed the water droplet cooling efficiency. The standard industrial water application rate (i.e., 10 L/min∙m2) is shown to be insufficient compared to the heat fluxes expected in pool and jet fires (i.e., 250 kW/m2 and 350 kW/m2, respectively).