PITT-CHAR® XPThe single-product solution for fire and cryogenic spill protection

Global experience and reliability

PPG Protective & Marine Coatings (PPG) is a world leader in protective and marine coatings. We develop products that protect customers’ assets in some of the world’s most demanding markets and environments including:

• Civil Infrastructure• Marine New-Build• Marine Dry Dock• Marine Sea Stock• Rail• Offshore• Petrochemical• Power

Our coatings provide unrivaled performance for asset owners, contractors, fabricators and applicators across the globe,helping our customers meet the challenges they face todayand tomorrow.

Experience, innovation and integrity –that is what makes PPG the ideal coatings partner.

PPG Protective & Marine CoatingsUnrivaled performance and protection

PITT-CHAR® XP

Traditional duplex solution

Traditional coating systems for fire and cryogenic spill protection rely on a duplex system (figure 1) combining the properties of thick-film epoxy syntactic foam, for thermal insulation against cryogenic spillage, followed by a rigid epoxy intumescent coating for hydrocarbon and jet fire protection.

Although these traditional duplex systems have reportedly performed relatively well in the past they can be prone to cracking back to the steel substrate during atmospheric aging or in a cryogenic spill situation (figure 2). These cracks expose the steel substrate to the environment, allowing the ingress of water and soluble salts leading to corrosion and undercutting of the system. The premature corrosion may be manageable to some degree; however, the actual situation is that the substrate is exposed to the cryogenic liquid and the direct effects of a hydrocarbon or jet fire.

Exposure of steel to a cryogenic liquid leads to steel embrittlement and changes in tensile strength and elasticity – greatly affecting its structural load-bearing capacity.

The primary reason for cracking under cryogenic spill conditions is the temperature difference between the upper layer directly exposed and the inner layers of the protection system. The cracking under cryogenic spill conditions is related to thermal shock and the rapid cooling and contraction of the system. Cracking in normal non-cryogenic service is related more to thermal cycling with a gradual reduction in flexibility as both the foam and fire protection continue to cure.

The solution to this differential flexibility and subsequent cracking is to use one flexible product that provides both cryogenic protection and fire protection.

Figure 1Traditional duplex solution

Rigid epoxy PFP

Epoxy syntactic foam

Epoxy Primer

Steel substrate

Figure 2Traditional duplex solution – Cryogenic liquid spill

Cryogenic shock causes the system to crack backto the substrate, due to the different flexibility ofsyntactic foam and rigid PFP, allowing cryogenicliquid to come into contact with the steel.

A crack in the system allows cryogenic liquidto come into contact with the steel - leading to potential cracking.

PITT-CHAR® XPOptimal steel protection for hydrocarbon fire

Superior adhesion, tensile strength and elongation under cryogenic conditions

For over 20 years, it has been recognized that the PITT-CHAR XP coating’s unique flexibility provides increased impact and vibration resistance, as well as superior crack resistance in service, resulting in long-term performance in some of the world’s toughest environments.

PITT-CHAR XP – unique flexibility

PITT-CHAR XP – The single-product solution forfire and cryogenic spill protection

• Unique flexibility• Enhanced crack resistance during construction and in service• Superior low-temperature adhesion• Mechanically tough – reducing damage and repair• Increases fabrication speed and efficiency• Helps improve application quality• More cost-effective through service life• Extensively tested and approved by customers and third-party institutes• Protecting lives and assets for decades

PITT-CHAR® XPThe unique single-product solution

PITT-CHAR® XP

Advantage of the PITT-CHAR XP coating over rigid hydrocarbon PFP

The following graphs show the difference in strength, adhesionand flexibility between the PITT-CHAR XP product and rigid epoxy PFP.

This superior single product clearly outperforms a rigid epoxy, which is a critical advantage when protecting lives and assets in the onshore and offshore industry.

Adhesion is an item addressed in international standards where minimum values are specified. These minimum values are often based on values used in the industry for normal rigid epoxy anticorrosive systems, having little relevance for passive fire protection, especially under low-temperature and cryogenic conditions, as shown in Figure 3.

Figure 3Break Strain (% Elongation) versus temperature

Maximum protection and performanceFully tested and approved

PITT-CHAR XP

Rigid epoxy PFP

Temperature

0˚C(32˚F)

-40˚C(-40˚F)

-20˚C(-4˚F)

0

5

10

15

20

It is the flexibility that makes the PITT-CHAR XP product ideally suited for fire and cryogenic spill protection. Even at temperatures down to -40°C (-40°F) this product is still five times more flexible than rigid epoxy systems and also boasts significantly higher tensile strength and a vastly superior substrate adhesion, as shown in Figure 4.

Figure 4Tensile Strength

The elongation-, tensile- and adhesive strength of the coating contributes to the outstanding performance under cryogenic conditions (figure 5). Even under conditions of rapid cooling, the single product maintains its internal cohesion, providing a continuous film, which insulates at extremely low- and high temperatures at the same time.

Figure 5Adhesive Strength

MPa MPa

Maximum protection and performanceFully tested and approved

PITT-CHAR® XP

PITT-CHAR XP

Rigid epoxy PFP

Temperature

0˚C(32˚F)

-40˚C(-40˚F)

-30˚C(-22˚F)

-10˚C(14˚F)

-20˚C(-5˚F)

0

5

10

15

20

25

PITT-CHAR XP

Rigid epoxy PFP

Temperature

0˚C(32˚F)

-80˚C(-112˚F)

-60˚C(-76˚F)

-20˚C(-5˚F)

-40˚C(-40˚F)

0

5

10

15

20

Traditional duplex solutions often quote ‘real world’ examples with case histories stretching back over 10 years but, on closerexamination, the actual exposure of these ‘real world’ examples has been nothing more than atmospheric exposure.

The applied system has never actually been exposed to a cryogenic spill followed by a hydrocarbon fire. So, although these applications are indeed in the ‘real world’, they are not the actual conditions for which the system was promoted.

Real testing involves cryogenic spill and a fire,not just application and atmospheric exposure

As actual ‘real world’ conditions for a CSP (Cryogenic Spill Protection) system could be catastrophic, extensive laboratory testing is the only viable method to determine system suitability. To prove its suitability, the PITT-CHAR XP product has undergone extensive internal- and external representative testing, often in co-operation with oil companies and global engineering and designing houses specializing in cryogenic spill protection.

Laboratory testing often exceeds practical service

In this test, designed to exceed a practical cryogenic spill and hydrocarbon fire, the coated tube is lowered into an insulated container filled with liquid nitrogen at -196°C (-321°F) and submerged for 75 minutes. After removal from the liquid nitrogen, the tube was subjected to a 3-hour hydrocarbon fire according to UL 1709. Thermocouples were placed at the interface on the tube and temperature measurements recorded.

PITT-CHAR® XP‘Real World’ versus laboratory

Tube coated with the PITT-CHAR XP product loweredinto a liquid nitrogen filled container

The PITT-CHAR XP product passes cryogenicand hydrocarbon fire tests

• Average steel temperature at 75-minute immersion = -29ºC (84ºF)• Average steel temperature at 1-hour fire test = 0ºC (32ºF)• Average steel temperature at 2-hour fire test = 67ºC (152.6ºF)• Average steel temperature at 3-hour fire test = 140ºC (284ºF)

Figure 6Cryogenic Immersion followed by UL 1709 Fire Test (3-hour)

The PITT-CHAR XP product exposed to liquid nitrogen pooling on a boxed steel panel

In these tests, the spill of a cryogenic liquid to a steel deckhas been simulated. A steel panel, with walls to allow the liquid nitrogen used for the spill to pool, has been coated with the PITT-CHAR XP product. The average temperature measured on the backside of the panel after 120 minutes exposure was -18°C (-0.4°F).

Figure 7Liquid Nitrogen exposure of a boxed steel plate

PITT-CHAR® XP‘Real world’ versus laboratory

PITT-CHAR® XP

Time in minutes

Tem

per

atur

e

Cryogenic Test Fire Test

180

170

160

150

140

130

120

110

1009080706050403020100706050403020100

150ºC302ºF

130ºC266ºF110ºC230ºF90ºC

194ºF70ºC

158ºF50ºC

122ºF30ºC86ºF10ºC50ºF

-10ºC14ºF

-30ºC-22ºF

-50ºC-58ºF

Time in minutes

Tem

per

atur

e

135

120

1059075604530150

40ºC104ºF

-20ºC-4ºF

-10ºC14ºF

0ºC32ºF

10ºC50ºF

20ºC68ºF

30ºC86ºF

-30ºC-22ºF

Extensive track record

As a result of its unique flexibility, the PITT-CHAR XP product has has been one of the leading hydrocarbon passive fire protection products globally for over 20 years. This exceptional single product has an extensive record of outstanding performance on both offshore and onshore projects for a wide range of customers, including many national and international oil and gas majors.

The PITT-CHAR XP coating intact with excellent adhesion after 13 years’ in service offshore

Uniquely flexible

In fact, the PITT-CHAR XP product often exceeds global standards as its unique flexibility enables it to provide protection during a 4-bar over pressure explosion test when the standard requires only 1 bar. This means that, under explosion conditions, this extremely robust product will protect the steel – even when there issignificant steel deflection – whereas rigid epoxy systems will be prone to crack, exposing the steel substrate to the effects of any subsequent fire.

The PITT-CHAR XP coating intact after 4-bar overpressure blast test

PITT-CHAR® XPConfidence in performance

One-product application – the advantages

Apart from the performance benefits, rationalizing the fireand cryogenic spill protection system by using one product – thePITT-CHAR XP coating – provides simplification and efficiency benefits during fabrication. The standardization to one product, with one mixing ratio, reduces the complication of handling two different products with no need to adjust the application equipment and thus preventing unnecessary equipment cleaning, which would be necessary when using a duplex system.

Rationalize the coating process

Application of just one coating significantly increases application speed, as well as reducing mistakes, thereby increasing application quality and reducing time for subsequent inspection, quality control and remedial repairs. In addition, if there are design changes during construction, or a new CSP area is identified, the single-product solution makes subsequent changes easier with a simple adjustment of the applied film thickness.

PITT-CHAR® XP

Process simplification and production efficiencyReducing complexity

Excellent aesthetic finish achieved with PITT-CHAR XP

Simplification and convenience for the builder – long-term performance in service

The unique flexibility of the PITT-CHAR XP product gives the fabricator the option to apply the CSP system either in-shop or onsite – without the cracking issues during transportation and erection of coated steelwork associated with rigid epoxy systems that have often forced fabricators to change to more expensive and time-consuming application locations and procedures. This flexibility also reduces impact and abrasion damage during construction, reducing subsequent remedial repairs and, once in service, any subsequent repair work due to mechanical damage and other defects is simpler to rectify as only one product is required.

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PPG Protective & Marine Coatings brings unrivaled levels of innovation, experience and expertise in coatings technology, supported through our expanding global supply and distributors’ network in over 60 countries.

We have in-depth knowledge of the industry, our customers’ day-to-day challenges and the environmental, health and safety standards in the marketplace. By working in close partnershipwith customers, our technical service representatives are ableto offer an unsurpassed level of market knowledge. This enables us to respond quickly with efficient, economic solutions in all environments and industries.

The result – performance-enhancing coating systems that canbe applied more easily, resist the elements more effectively,and deliver maximum performance with minimum downtime.

PPG Protective & Marine CoatingsP.O. Box 580341040 HA AmsterdamThe NetherlandsTel +31 (0)20 407 5050Fax +31 (0)20 407 5059Email PMC@ppg.comWebsite www.ppgpmc.com/fireprotection

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our website www.ppgpmc.com. All rights reserved. Bringing innovation to the surface is a trademark of PPG Industries Ohio, Inc. PITT-CHAR is a registered trademark of PPG Architectural Finishes, Inc.