Spec. No.

SPECIFICATION FOR REPLACEMENT

A200-0643-SP- FP-01
OF FIREPROOF COATING OVER Rev. No. 0
PENTANE BULLETS, GAIL-GANDHAR Page 1 of 12

SPECIFICATION FOR REPLACEMENT OF

FIREPROOF COATING OVER
PENTANE BULLETS, GAIL- GANDHAR

ENGINEERS INDIA LTD.

(SPECIALIST MATERIALS & MAINTENANCE SERVICES DEPARTMENT)

0 12/10/11 ISSUED TO CLIENT PP PS PPL

Rev. No Date Purpose Prepared by Reviewed by Approved by

Template No. 5-0000-0001-T1 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 2 of 12

1.0 INTRODUCTION

The fireproof coating over pentane bullets at GAIL- Gandhar are in service over 10
years. Out of the three fireproofing system recommended in the EIL specification
no.6-79-09, cementitious type was selected and installed at GAIL-Gandhar. The
fireproofing system is deteriorated over a period of time and needs to be replaced.
This specification outlines the technical requirements, quality aspects and Vendor
data requirement concerning replacement of the fireproofing system.

2.0 FIRERATING AND THICKNESS THE OF FIREPROOF COATING

2.1 The fireproof coating material / system should be certified by Underwriters’

Laboratory as per their UL 1709 test method (Hydrocarbon fire test) for minimum 1.5
hours fire rating.

2.2 The thickness of fireproof coating material selected by the Contractor shall be as
required by applicable UL design number to meet the desired fire rating..

3.0 DISMANTLING OF EXISTING FIREPROOFING AND SURFACE PREPARATION

3.1 Dismantling

The existing fireproof coating shall be dismantled properly without damaging the
vessel surface, and dispose the debris from the site to a assigned place. Surface
shall be cleared of all loose dirt. Unnecessary stud/ cleats welded to the structure
shall be removed or reduce the height if, required so that it will embedded in the
newly applied fireproof coating.

3.2 Surface Preparation

Prior to the commencement of blast cleaning all steel surfaces should be clean and
dry. Blast cleaning may not remove all contaminants and general surface
contaminants may need to be removed by other appropriate mechanical means. Oil
and grease contaminants should be removed by the use of suitable emulsifying
degreasers, suitable clean organic solvents or steam cleaning before the
commencement of blasting.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 3 of 12

Steel surfaces should be prepared by removing scale and rust using abrasive
blasting to a minimum standard of Sa2½ as defined in BS EN ISO 8501-1: 2007 or
SSPC SP 10. A surface profile will usually be specified within the range of 35 – 75
microns and, in general, will not exceed 100 microns. Guidance regarding profile
should be obtained from the primer supplier. All dust and spent abrasive must be
removed from the prepared steelwork. This can be achieved by blowing down with
clean dry compressed air.

If blast cleaning is not possible, surface may be prepared with power tool cleaning in
accordance with SSPC-SP11.

After readiness of the surface where fireproof coating is to be applied, the primer
specified by the fireproof coating manufacturer shall be directly applied instead of any
other primer.

4.0 FIREPROOFING MATERIALS.

4.1 Fireproofing material shall be factory-blended, cementitious direct spray-applied, non-

flaking and non-dusting, with mold and fungi inhibitor added by the manufacturer.
Fireproofing material shall be labeled by Underwriters Laboratories, Inc., for fire
hazard classification, and evidence of the UL classification marking shall appear on
the packages of all fireproofing material.

4.2 The fireproof coating should be able to withstand expansion of the vessel when
hydro-tested up to the required pressure.

4.3 Material containing asbestos & mineral wool will not be acceptable.

4.4 Following materials from the below mentioned supplier are known to have an UL-
1709 certification

Pyrocrete 241 of CDC Carboline

FENDOLITE M-II of CAFCO/ Newkem

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 4 of 12

Materials other than the above having UL-1709 certification shall also be acceptable,
Contractor to submit the valid UL-approved certification for the proposed material,
including the above.

Material shall contain the following properties & characteristics as min.

INDICATIVE IMPOSED
CHARACTERISTICS UNITS STANDARDS
DATA VALUES
Applied dry density lbs/ft3 - AS required by ASTM E605
Min. applicable UL
design number
Compressive Strength psi - 550 ASTM E761
Min.
Bond Strength Min. kPa - 750 ASTM E736
Bond Impact Pass ASTM E760
Flame spread - 0 - ASTM E84
Smoke development - 0 - ASTM E84
2
Air erosion gm/ft 0.0 - ASTM E859
2
Corrosion gm/mm - 0.0 ASTM E937

Fire proofing material shall have been tested, classified and listed by Underwriters
Laboratories. Inc. in accordance with the provision of ASTM 1709.

4.5 Auxiliary materials: Sealer shall be transparent-drying, water dispersible, tinted

protective coating as recommended by fire-proofing manufacturer for the selected
fire-resistance design.

4.6 Top coat/ intermediate coat shall be suitable for application over applied fire proofing,
of type recommended by manufacturer for the selected fire resistance design.

4.7 REINFORCEMENT

4.7.1 Reinforcement shall be either metal lath or wire mesh as required by the coating
manufacturer. Metal lath/wire mesh shall be SS-304 and as per the manufacturer.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 5 of 12

5.0 PREPARATION FOR FIRE PROOFING

5.1 The entire steel surface to be fireproofed should be cleared of all loose dirt, oil and
grease etc for better adhesion of the fireproofing to the steel.

5.2 All the steel members, which need to be fireproofed, should be suitably primed for
corrosion protection.

5.3 The primer should be compatible with the fireproofing to be applied.

5.4 Mesh reinforcement should be wrapped around the steel section and retained firmly
by clips/studs. All the studs shall be welded to the structural members. However, if
stud welding is not allowed, studs may be glued to substrate.

5.5 Overlaps shall be 50 mm or more and should be wired at approximately 150mm

centre to centre.

5.6 The longitudinal overlap should be in the web face, and all overlaps should be
staggered so that no more than three layers of mesh are present at any one point.

5.7 Cover all work subject to oversprays during application. Provide temporary enclosure
when necessary to temporarily confine fire proofing and protect the environment.

5.8 Ensure adequate precaution and /or necessary arrangement for keeping substrate
temperature within allowed limits specified by manufacturer.

6.0 INSTALLATION OF FIRE PROOFING.

6.1 Construct fireproofing assemblies that are identical to ULC/UL fire-resistance design
requirement and product as specified, tested, and substantiated by test reports.

6.2 Application of fireproof coating which include surface preparation (where applicable),
primer, reinforcement, intermediate and top coat applications shall be carried out in
line with the standard application instructions of the manufacturer based on which the
installation procedure shall be developed.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 6 of 12

6.3 Spray apply fireproofing to maximum extent possible. Following the sparying
operation in each area, complete the coverage by trowel application or other
placement method recommended by manufacturer.

6.4 Extend fireproofing in full thickness over entire area of each substrate to be
protected.

6.5 Install fireproofing in a single course unless otherwise specified by manufacturer.

6.6 Special attention shall be paid at the supporting legs, mechanical attachment; fire
proofing shall be terminated by 50mm at the location of fire hydrant support pads
coming in contact with vessels.

6.7 Joints between exposed steel work and fireproofing shall be caulked/ sealed to
prevent water from entering the system at this point.

6.8 Provision shall be made for adequate ventilation during and after application, until the
materials are dry. In extremely dry and hot conditions, however, appropriate
measures shall be taken to keep vermiculite-containing systems moist until set.
Measures such as screening the work area from radiant sunlight and wrapping the
finished work may be required, depending on the severity of the ambient conditions.

6.9 Installed fireproofing shall be checked for minimum thickness asper required fire
rating.

6.10 Thickness of sprayed fire-resistive material applied to structural elements shall not be
less than thickness required by fire- resistance design indicated.

6.11 Top coating shall be carried out in accordance with manufacturer’s specification.

6.12 The surface finish shall conform to the reference sample prepared during MOCK-UP
test and manufacturers application guide.

6.13 After completion of each day’s work, the applicator shall clean the area fireproofed.
Remove all excess material and over spray from walls and other adjacent surfaces
that may have received over spray. All exposed wall shall be left in clean condition.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 7 of 12

6.14 Installation of fireproof coating shall be carried out by qualified contractors

representing the manufacturers under their supervision or by the manufacturer
themselves.

7.0 QUALITY CONTROL

7.1 Verification of Material at site.

7.1.1 Inspection certificate of all Fire proofing materials to be verified.

7.1.2 Verify Shelf life of the fireproofing material

7.1.3 Verify test certificate of anchor and ancillary materials.

7.2 Surface inspection & accessories

7.2.1 Prior to the application of the fireproofing material, inspection shall be carried out to
ensure that all surfaces and the work environment are acceptable for work to
commence.

7.2.2 Ensure that all other attachments, such as clips/ studs, hangers, reinforcing mesh,
angles etc. have been installed as required prior to the application of the fireproofing
materials.

7.2.3 Verify that voids and cracks in substrate are filled, and projections are removed where
fireproofing is exposed to view as a finish material.

7.3 Applicator qualification & MOCK-UP Application

7.3.1 The Fireproofing installation shall be carried out by a fireproofing application

contractor having previous experience of similar material application. Credentials of
the fireproofing application contractor shall be submitted along with reference of past
experience (in similar work) for review by Client.

7.3.2 Installer shall be certified, licensed, or otherwise qualified by sprayed fire-resistive

material manufacturer as having necessary experience, staff, and training to install
specified products in compliance with specified requirements.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 8 of 12

7.3.3 Prior to actual application, a MOCK UP application shall be carried out resembling the
actual application conditions over 1 meter by 1 meter area to ascertain skill of the
applicator.

7.3.4 Inspect the installation surface within one hour of application for any shrinkage/ gaps/
cracks.

7.3.5 Incase of shrinkage, cracking mixture and method of application may be adjusted as
necessary.

7.3.6 Parameters maintained in successful mock-up i.e. mixing time, application methods
etc. shall be maintained during actual application.

7.3.7 Test samples shall be taken during mock up, which shall be tested for Bulk density,
Compressive-strength as per applicable standards.

7.3.8 All mock up application and sample testing shall be witnessed and approved by
Client/ or their authorized representative.

8.0 Fireproofing Application

8.1 Check all fireproofing progressively for compliance with thickness requirement.

8.2 Fireproofing materials having limited shelf life must be used within the shelf life
period. For this, procurement shall be suitably planned to minimize storage time.

8.3 Water used for mixing shall be of drinking quality, free from organic and mineral
impurities and pH recommended between 6.9 to 7.1.

8.4 Material shall be mixed in a mechanical mixer with paddle or ribbon- type blades. The
mixer shall be clean and free from previously used and set materials. Mixing shall be
in accordance with Manufacturer’s instructions.

8.5 Partially set, frozen, or lumpy material shall not be used. In all cases, over mixing of
the material shall be avoided. Re-tempering is not permitted.

8.6 Mixing and equipments required for fireproofing application shall be specified in the
procedure.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 9 of 12

8.7 Mix shall be applied within specified time limit.

8.8 Stoppage and termination of coating shall be as per established procedure.

8.9 Application shall be in accordance with the finished representative sample provided
by the supplier so that there is no misunderstanding of the desired texture,
smoothness and soundness of the applied coating (This is some times done on a
piece of representative onsite equipment or structure.).

8.10 Daily log sheet shall be maintained for details of Fireproofing work executed and
quality control records. These shall be approved by the client/or their authorized
representative. All inspection reports, test results, shall be maintained in a systematic
manner with proper traceability.

9.0 Field Quality control

9.1 The Contractor shall take thickness measurement, as witnessed by Client/ or their
authorized representative, of applied material to verify compliance with thickness
requirements.

9.2 The contractor shall take field samples of fireproofing material, randomly selected, for
laboratory test to verify compliance with specified density and compressive- strength
as per applicable ASTM standard.

9.3 Proper traceability of the installed coating shall be maintained to ensure correlation of
the test results with installation area. .

10.0 INSPECTION & REPAIRS

10.1 The fireproof coating system application shall be inspected by Client/ or their
authorized representative at various stages of the work to ensure that the same is
being carried out as per the procedure and quality plan.

10.2 Applied coating shall be inspected for

• Coating thickness.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 10 of 12

• Proper bonding to the substrate.

• Soundness.

• Surface cracking/ bulging.

10.3 Defective material or workmanship shall be rejected. All rejected work or materials
shall be repaired or replaced by the contractor without any time and cost implication.

10.4 The thickness of the spray- applied material shall be corrected by additional material
at any location where.

10.4.1 The calculated average thickness of the material is less than that required by the
design.

10.4.2 An individual measured thickness is more than 6mm less than design (for thickness
over 25mm) or design minus 25% for design thickness less than 25mm.

11.0 DELIVERY& STORAGE AND HANDLING.

11.1 Materials shall be delivered to the site in sealed packages properly marked, labeled to
show manufacturer’s name, brand, other identifying data and bearing the proper
Underwriters Laboratories.Inc labels for certification of compliance for fire hazard and
fire resistance classifications.

11.2 Damaged packages found unsuitable for use in the work will be rejected.

11.3 Store materials under cover in a dry location.

11.4 Bages that have been exposed to water before use shall be discarded.

12.0 CERTIFICATION

12.1 After completion of the job, the contractor shall give a certificate for the material and
installation quality for the defined guarantee period.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 11 of 12

13.0 VENDOR DATA REQUIREMENT.

13.1 Following information and documents shall be provided by the contractor at

pre-order stage for review / acceptance of GAIL/or their representative.

13.1.1 Information on selected fireproof coating material & system, fire rating with the
corresponding thickness for minimum 1.5 hours fire rating for the service. The
information shall be submitted in the form of brand names, primer, reinforcement, tie
coat, top coat, caulking compound etc. along with technical datasheet and / or
literature of the materials comprising the system.

13.1.2 Reference list of jobs executed for un-insulated bullets with the proposed fireproof
coating system.

13.1.3 Latest Certificate of Underwriters’ Laboratory for the selected fireproof coating
material as per UL 1709 test method tested on 10W49 column.

13.2 Following information shall be provided by the contractor at post order stage :

13.2.1 Details on fireproof coating system elaborating primer type, reinforcement type &
material quality, tie coat, fireproof coating material, intermediate coat, top coat etc. for
review.

13.2.2 Test certificates for the fireproof coating material and other ancillary materials forming
part of the coating system.

13.2.3 Fireproof coating installation procedure with sequence of installation such as primer,
reinforcement, tie coat, coating, number of coats to achieve the required thickness,
intermediate coat, top coat etc.

13.2.4 Periodic maintenance requirement recommendation by supplier.

13.2.5 Credentials of sub-contractor, past experiences & names of supervisors to be

deployed by the contractor for the fireproof coating job. In this regard, it is to be noted
that the sub contractor shall be either the fireproof coating supplier or their approved
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved
 SPECIFICATION FOR REPLACEMENT Spec. No.
OF FIREPROOF COATING OVER A200-0643-SP- FP-01
PENTANE BULLETS, GAIL-GANDHAR Rev. No. 0
Page 12 of 12

agency. In the latter case, communication to this effect shall be obtained by the
contractor and submitted to GAIL before finalization.

13.2.6 List of tools & tackles required for execution of fireproof coating application.

13.2.7 Inspection & Test Plan, Quality Assurance Plan pertaining to installation of fireproof
coating system. Mock up application shall be carried out over 1 metre by 1 metre
surface to assess the skill of the installation agency prior to actual job.

13.2.8 Certificate against any defects in material and application for the period defined as
part of Performance Guarantee after completion of the job

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved