Firemaster System Enhances Fire Protection for Refinery Control Circuits

In high-risk industries like oil refineries, fire incidents are not improbable events but persistent operational hazards. Understanding the importance of cable tray fire protection requires quantitative risk analysis.

Historical data reveals relatively high fire occurrence rates in refineries. According to the National Fire Protection Association (NFPA), chemical plants and refineries experience fire incidents at higher rates than other industrial sectors. Each fire event can result in direct economic losses—including equipment damage, production downtime, and compensation costs—potentially reaching hundreds of millions of dollars. Indirect consequences like reputational damage, market share decline, and legal liabilities may create long-term impacts.

As critical components of refinery electrical systems, cable trays' vulnerability directly affects overall plant safety. During fires, cables within trays become susceptible to damage from high temperatures, flames, smoke, and corrosive gases, leading to insulation failure, short circuits, or broken circuits. These failures may cause control system malfunctions and safety equipment failures, potentially escalating into catastrophic events.

Cable tray fire protection systems reduce both the probability of fire incidents and their potential damage. For example, if a refinery has a 5% annual fire probability with average losses of $1 million per incident, installing protection could reduce the probability to 1% and average losses to $200,000. The system's annual value would then be ($1M × 5%) - ($200K × 1%) = $480,000, demonstrating significant economic benefits.

The FireMaster® system provides specialized protection for cable trays and their contents through innovative engineering solutions.

The system utilizes FireMaster® Marine Plus fire blankets with multi-layered composite structures that isolate high-temperature flames while protecting internal cables. Additional aluminum foil layers provide moisture resistance, corrosion protection, and heat radiation reflection. Steel bands and corrugated aluminum plates enhance structural stability.

• Fire Resistance: 30 minutes of hydrocarbon fire protection
• Thermal Insulation: Effective heat transfer prevention
• Certification: Complies with ASTM E1725 standards
• Durability: Long-term performance stability in harsh conditions

• Superior fire resistance duration
• Simplified single-layer installation
• Global implementation experience
• Rigorous quality control processes

Precision installation ensures optimal performance through empirically validated methods:

150mm-spaced steel bands support mesh lining for open trays—a spacing determined through mechanical analysis to balance support strength with material efficiency.

Minimum 12mm-wide bands secure wrapping edges at 40mm intervals with maximum 250mm spacing—dimensions validated through strength testing to withstand fire conditions without material damage.

75mm overlaps between adjacent 50mm-thick wrapping sections ensure flame penetration prevention, with additional banding at bends for enhanced sealing.

0.6mm corrugated aluminum sheets provide optimal balance between protection and cost efficiency.

Cable tray protection serves multiple safety purposes:

• Maintaining cable functionality for emergency shutdowns
• Reducing toxic/corrosive gas emissions
• Enhancing firefighter safety
• Facilitating evacuation procedures
• Minimizing long-term infrastructure damage

The standard establishes rigorous evaluation protocols for electrical system components under controlled fire conditions, using either cellulose (ASTM E119) or hydrocarbon (ASTM E1529) fire curves. API 2218 specifically recommends hydrocarbon curve testing for petrochemical facilities.

• Positive pressure testing conditions
• Thermocouple placement at 150mm intervals
• Empty tray configuration for universal applicability
• Failure criteria: 250°F (121°C) average or 325°F (163°C) single-point temperature rise

Research demonstrates inconsistent functional failure temperatures among seemingly identical cables, making circuit integrity an unreliable indicator. Measuring tray temperature instead provides a more consistent failure threshold applicable to any cable load.

Factory Mutual (FM) certification confirms FireMaster®'s compliance with ASTM E1725-95 standards for 30-minute hydrocarbon fire protection, with global manufacturing approval.

In refinery environments, cable tray fire protection represents a critical safety investment. The FireMaster® system's performance credentials, installation efficiency, and certification pedigree provide reliable protection for critical control systems. Future developments may incorporate smart monitoring technologies and sustainable materials to enhance protection capabilities.