Favuseal - Fire Barrier System for GRE Piping and Offshore Oil Installations

The Favuseal fire barrier system (FFBS) was introduced in 1988 for the protection of glass-fibre reinforced epoxy (GRE) piping in the offshore industry. Numerous oil installations all over the world are fire protected by FFBS. The system is also used in a vast amount of electrical installations, protecting power cables and signal cables.

FFBS is mainly based on the Favuseal technology developed in the early 1980s. A series of tests on FFBS-protected GRE pipes have demonstrated the system’s excellent properties as a fire barrier. Tests have also been made in ovens and under jet-fire conditions.

Ceramic-forming thermoplastic compound for offshore firefighting

The Favuseal material is a ceramic-forming thermoplastic compound with extraordinary properties when subjected to high temperatures. The material consists of mineral fillers in a thermoplastic matrix. Favuseal is delivered in tape rolls in various widths and also delivered as granulate.

NKX-6174, a thermoplastic compound, contains inorganic fillers in a binder composed of an ethylene copolymer. Supplied in pellet form, the compounds may be processed by extrusion, compression-moulding or injection-moulding. This composition is transformed in a fire from a thermoplastic to cellular ceramic. Other characteristics include:

• Good thermal conductivity in the virgin state
• Good thermal insulation above 200°C
• Swells to approximately twice its original volume in a fire
• Good mechanical stability in its cellular ceramic form
• Acts as a flame barrier
• Halogen-free
• Low smoke emission during transition
• No corrosive gases produced when transforming
• No toxic gases produced when transforming

Environmentally friendly offshore fire barrier system

Favuseal technology is halogen-free and does not generate corrosive gases, or toxic gases in a fire, thus protecting firefighting personnel and the surrounding environment. Favuseal generates a very low smoke emission.

Favuseal is the sole marketing and material supplier of the FFBS system. We also provide technical support such as dimensioning of the barrier and an installation manual. For these calculations, a well-proven mathematical model is developed and used.

Offshore fire barrier system for oil installations

When FFBS is subjected to high temperatures (ex fire), two-phase transitions take place. The first phase takes place between 200°C and 250°C, and the second between 700°C and 800°C. At the first-phase transition, crystal water is generated from the (O-H) groups in the fillers.

The water evaporates and the reaction is a strongly endothermic (heat-absorbing) process because of the energy required to release the H2O. The temperature behind the barrier of Favuseal cannot exceed 250°C - 300°C as long as this reaction takes place, since all energy is consumed releasing the H2O.

The second-phase transition is the oxidation of the filler minerals resulting in the formation of the cellular ceramic material. This reaction is also endothermic, although to a lesser extent than the first phase. The thermal conductivity of the cellular ceramic material is extremely low – as low as 0.07W/m°K.

The ceramic is physically stable in temperatures up to 1,500°C, creating a massive temperature barrier / heat insulator for your installation. Tests have shown that the total reaction time is dependent upon the temperature exposed to the system and the thickness of the Favuseal test specimen.

High-temperature insulating offshore fire barrier system

FFBS will have the following reaction times in case of a H-C fire, with a temperature of 1,150°C:

• Good thermal protection in the virgin state 5mm of Favuseal: 15min
• Good thermal protection in the virgin state 10mm of Favuseal: 30min

Fire barrier system tests for GRE pipes

A range of different testing (including explosion, jet fire and oven testing) has been performed on FFBS-protected pipes from major producers of GRE pipes. All tests were extremely successful and resulted in good results. Some of the tests were witnessed by independent parties, such as Lloyds and DNV.

The two-phase transitions give Favuseal FFBS its unique properties, which can be utilised for fire protection and high-temperature insulation, and give extra, valuable time when fighting a fire. The material can be used as a standalone system or in combination with conventional material, providing extra protection if needed.

Fire protection system technical support and installation

Favuseal provides technical support for FFBS such as dimensioning of the barrier, as well as an installation manual. For these calculations a well-proven mathematical model is developed and used to calculate the amount of materials to any given installation / scenario.

Favuseal can deliver FFBS and other Favuseal products in any quantity all over the world on at relatively short lead times. Favuseal is owned by the Schlytter-Henrichsen family.