Steel Integrity in the Heat of the Moment: Managing Fire and Corrosion Risks
In the high-stakes environments of oil, gas, petrochemical, and energy industries, safety is paramount. The risk of fire and explosion presents an ever-present threat to both human lives and valuable infrastructure. One of the major hazards that often leads to these disasters is the corrosion of critical steel structures and equipment. Corrosion can compromise the structural integrity of equipment, valves, and pipes, resulting in dangerous hydrocarbon releases that may ignite and escalate into fires.
A recently published Jotun report, “Maintenance and Corrosion Management in the Global Oil and Gas Industry,” sheds light on these risks and explores how companies can better safeguard their assets. The report, based on the insights of over 1,000 senior professionals in the oil and gas sector, underlines the urgency of addressing fire risks linked to corrosion. According to Ekaterina Mezhentseva, Global Solutions Manager at Jotun, the costs of operational downtime and environmental damage are significant, but the potential human cost and destruction of assets make prevention and protection measures even more critical.
The Role of Corrosion in Fire Incidents
Fire-related incidents in the oil and gas sector often stem from corrosion-induced failures. The Jotun report reveals that 76% of professionals agree that reducing fire risks should be a central focus of maintenance strategies, while 74% emphasize the role of protective coatings in mitigating these risks. Furthermore, 56% of respondents acknowledge corrosion as a major fire hazard, a finding that highlights the need for increased awareness and action. Corrosion has been identified as the root cause in roughly 20% of major refinery accidents since 1984, according to European Commission data.
Without proper corrosion management, equipment is vulnerable to failure, leading to potentially catastrophic consequences, such as the release of hydrocarbons, which could ignite and trigger deadly fires and explosions. This underscores the importance of focusing on both preventive measures and structural protection against fire in oil and gas operations.
Passive Fire Protection Solutions
When considering fire safety in the oil and gas industry, two main strategies come into play: preventing fires from starting and protecting assets in case a fire does occur. Operators must ensure that the integrity of their assets is intact to minimize the risk of corrosion and hydrocarbon release. However, should a fire break out, passive fire protection systems are vital to limit structural failure and minimize damage.
Passive fire protection systems are designed to shield critical steel structures and equipment from the rapid rise in temperature during a fire. These systems provide crucial time for personnel to evacuate and allow emergency services to extinguish fires before they lead to catastrophic structural collapse. Such systems may include lightweight cementitious materials (LWC), concrete applied to steel, fireboarding, or removable insulative jackets. Selecting the right PFP material is essential to ensure that these systems perform as intended in the event of a fire.
Selecting the Right PFP Material: Key Considerations
Choosing the right passive fire protection material is not a one-size-fits-all decision. It requires careful consideration of factors such as climatic conditions, corrosive environments, operating temperatures, and the risk of mechanical damage. For example, lightweight cementitious materials are an economical solution for onshore facilities but must be maintained regularly to prevent water ingress and subsequent corrosion of the steel substrate. If not properly maintained, these materials can deteriorate, leaving steel structures vulnerable to damage in case of a fire.
High-performance epoxy intumescent coatings, often used in offshore operations, offer an effective dual-purpose solution for both fire protection and corrosion management. These coatings expand when exposed to heat, providing a protective barrier that delays the temperature rise and prevents structural collapse. Furthermore, they offer long-term corrosion protection, making them an ideal solution for aging facilities that need repair without undergoing costly and complex system replacements.
The Dual Challenge: Fire Protection and Corrosion Management
The oil and gas industry faces a unique challenge: ensuring that fire protection systems are not undermined by the very corrosion they are designed to prevent. Steel structures that are coated with passive fire protection materials, such as concrete or cementitious systems, can sometimes experience corrosion underneath the coating. This can go unnoticed during inspections, leading to false assumptions about the integrity of the structure.
Epoxy PFP materials offer a solution to this problem by providing both fire and corrosion protection. These coatings can be applied to existing structures, helping to restore the fire protection standards of aged or deteriorating systems. By replacing damaged PFP materials with epoxy coatings, operators can extend the lifespan of their assets and reduce the risks associated with corrosion-related hydrocarbon releases.
Maintenance: The Key to Fire Protection Longevity
The Jotun report stresses the importance of regular maintenance in preventing catastrophic incidents. Facilities that neglect to survey the condition of their installed PFP materials risk facing financial loss, reputational damage, and the safety of their personnel. Maintaining fire protection systems is a relatively modest cost compared to the potential consequences of system failure.
As Ekaterina Mezhentseva pointed out, investing in maintenance and ensuring the ongoing effectiveness of PFP systems should be a priority for operators. Industry guidance and organizations, such as the Energy Institute and the UK Health & Safety Executive, are helping operators understand the importance of proper corrosion and fire protection management.
The Path Forward: Education and Awareness
While solutions are available, there remains a need for greater industry-wide education and awareness regarding the risks of corrosion and fire in the oil and gas sector. As operators become more knowledgeable about the potential causes of fire and explosions, they can take the necessary steps to mitigate these risks effectively.
By adopting comprehensive fire protection strategies, maintaining existing systems, and prioritizing corrosion management, operators can significantly reduce the likelihood of catastrophic incidents. The goal is not just to prevent fires but to safeguard the lives of workers and protect valuable assets, ensuring that operations can continue safely and efficiently.
The oil and gas industry is increasingly recognizing the need for improved fire and corrosion management practices. By taking proactive measures now, companies can ensure safer operations and reduce the risks associated with corrosion-induced hydrocarbon releases.
