Sometimes size does matter

MFC-G Large Diameter GRE/GRP/FRP Firestop Collars massive size update!

Early this year, we were asked to find a solution for large ships such as Cruise ships, Ferries, Tankers and merchant ships that need to install EGCS (Exhaust Gas Cleaning System) using huge composite pipes to handle the treatment of sea water.

The size of the composite pipes, used on this project, is up to DN1000, meaning a impressive 1050 mm outer diameter and the Engineering team was wondering how they could find a new and innovative solution to achieve the fire stopping on fire divisions required by class where pipes are passing through fire rated divisions.

Our product, named MFC-G – Large Diameter FRP/GRE/GRP Firestop Collars,  is the perfect solution for this, but, until recently, there was still a considerable limitation on the maximum approved size. The MFC-G Collars had already been tested and certified for steel deck and bulkhead installation, for pipes with an outer diameter up to 746mm, already the biggest collars in the market. We were approached by a major cruise line’s Engineering Team that required a much larger collar. We were asked to solve the size limitation and get the product tested and approved by an Agency within 3 months. This is very short amount of time as normally these Engineering projects take 6 to 10 months to complete. So now suddenly a larger size mattered.

Testing in a world that suddenly came to a halt:

As STI Marine Firestop’s core business is to find solutions to help our customers, we started to investigate the possibility to expand the range of our MFC-G Collars up to the DN1000 size. Our Engineering teams started to develop the technical drawings and bill of materials in order to organize the bulkhead and deck fire tests, as soon as possible.

As a leading company in the development of new fire stopping solutions, we are constantly conducting testing at our own fire testing facility and at fire labs all over the world. Because of this, we were able to work closely with one of the third-party fire labs and quickly arrange the construction of two specimens so that we could work within the time frame that we were given.

One of the most critical parts of the project was to produce the two massive collars, as our production was already filled up with ongoing orders. Our Production and Engineering teams were committed to make this critical project work, and they were able to have it manufactured in less than two weeks and ready to be shipped to the fire lab.

The very large  DN1000 pipes, that would be fitted inside the collars, were supplied by our customer that is well immersed in the scrubber market as a composite pipe supplier. STI Marine Firestop selected to test at RINA’s Fire Testing Facility in Genoa, Italy, since their first available test dates would allow the tight schedule to be kept. The workshop at RINA moved quickly  to construct the deck and bulkhead samples and provided assistance for the installation of the pipes and collars.

Composite pipe tested

We were on schedule throughout the project but, at the end of the week before the fire tests, the outbreak of COVID-19 became a reality in Italy and soon after in all the European countries, but despite this terrible event, we were able to manage the completion of the specimen’s construction and the two fire tests.

Bulkhead and deck installation

Bulkhead and deck installation

So, what do these ultra large MFC-G pipe collars replace?

The conventional method is to apply a very high-grade steel pipe section with flanges and often valves. This is typically in SMO steel, which is expensive, has long lead times and is fabricated specifically for these projects. The logistics can be a nightmare as these very heavy pipe sections need to be lowered into the ship using cranes.

By installing the MFC-G Collars, there are several advantages:

  • Composite Pipes are run Continuously – Reduces the number of composite pipe sections and coupling flanges.
  • Reduced Maintenance – Continuous composite pipes eliminates periodic maintenance of the steel pipe sections
  • Simplified Logistics – Collar installations may be done independent of the pipe installation, eliminating staging conflicts.
  • Reduced Weight – Our largest collar is only 14 kg, offering a lightweight alternative to sections of steel pipe weighing several hundred kilograms
  • Easy to Install – Lightweight, split design allows for easy installation and adjustment
  • Reduced Welding – Collars secured to division from one side via stitch welds or screws, as opposed to continuously welding steel pipe on both sides

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 Literature

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 Product Attributes

Applications

Cables

Cable Protection

Blank Opening

Plastic Pipes

Composite Pipes

Multi. Pen.

Metallic Pipes

Duct

Busbar

Properties

Finished Product

Autobonding

All Weather

Watertight

Water Resistant

Smoke Barrier

Re-Enterable

Permanent

Paintable

Noise Reduction

No Expiration

Low VOC

Lightweight

Intumescent

Flexible

 Project References

 Partial list of projects involving STI Marine

Bulk Carrier

– BULK CARRIED 64000DWT

– BULK CARRIED 110000DWT

– BULK CARRIED 50000DWT

– BULK CARRIED 110000DWT

NISHHIN
– BULK CARRIED 82000DWT

TMS Bulk
– 40 vessels – scrubber collars

UK
– BULK CARRIED 64000DWT

Chemical Tanker

– 7950DWT CHEMICAL TANKER

– 7999DWT CHEMICAL TANKER

– 37000DWT

Container Ship

Horizon
– Horizon Kodiak

CPP Platform

Idemitsu Kosan
– Sao Vang and Dai Nguyet (SVDN)

Cruise

Aida Cruises
– Aida Nova

American Cruise Line
– American Song
– American Harmony
– American Constellation

American Queen Steamboat Co.
– American Countess
– American Duchess

Carnival
– Liberty
– Legend
– Freedom
– Carnival Victory

Carnival Cruises
– Carnival Sensation
– Carnival Freedom
– Carnival Dream

Celebrity Cruise
– Equinox – Scrubber system
– Celebrity Millennium
– Celebrity Expedition

Costa Cruises
– Costa Smeralda

Genting Cruises
– Superstar Virgo/Explorer Dream

Hapag Lloyd TUI
– Hanseatic Nature
– Hanseatic Inspiration

Holland America Line
– Volendam
– Zaandam
– Westerdam
– Rotterdam
– Zuiderdam
– Oosterdam

Hurtigruten
– Midnatsol
– Trollfjord
– several ships

Lindblad Expeditions
– NatGeo Lindblad Endurance
– National Geographic Venture
– National Geographic Quest

Louis Armstrong Riverboat
– Louis Armstrong

Marella Cruises Tui
– Marella Dream

MSC
– MSC Splendida

Mystic Cruises
– World Explorer
– Douro Azul
– World Explorer

Norwegian Cruise Lines
– NCL Joy
– Norwegian Sky

Princess Cruises
– Star Princess
– Ruby Princess
– Coral Princess
– Diamond Princess
– Coral Princess

RCCL
– Mariner of the Seas
– Majesty of the Seas
– Oasis of the Seas
– Navigator

Royal Caribbean Cruises
– Mariner of the Seas – Scrubber
– Navigator of the Seas
– Oasis of the Seas

SeaDream Yacht Club
– SeaDream II

Silversea
– Silver Spirit

Thomson TUI Cruises
– Onboard refurbishment

Tui Thomson
– Thomson Discovery

Dredge

DSC Dredge
– Oil Sands Dredge

Great Lakes Dredging
– Hull 257

Jan De Nul Group

Drill Ship

Diamond Offshore
– Ocean Pioneer
– Ocean Confidence

Ferry

color Line
– Color Hybrid (Ship of the Year 2019)

Croatian Coastal
– Alu Catamaran Ferry

Estonian Ferry Authority
– Baltic 4500 Ferry

Tallink Ferries
– Tallink Megastar

Viking Lines AB
– Viking m/s Gabriella
– Viking Grace Ferry Cruise

Ferry Ropax

Hurtigruten
– Hull W0269
– Hull W0265
– Hull W0264
– Hull W0266
– Hull W0267
– Hull W0263

Flotel

Hornbeck
– HOS Riverbend
– HOS Achiever

FPSO

Brazilian Petro
– FPSO H415

MODEC
– MV30

Liftboat

Montco

MPSV

Harvey Gulf
– Harvey Sub Sea Hull #249

Navy

Belgium Ministry of Defence

Chinese Coast Guard

Offshore

Hess
– Stampede

Shell
– Appomattox

Offshore Aux LQ

Noble Energy
– Leviathon

Offshore LQ

BP
– South Pass 89

British Gas
– Poinsettia and Hibiscus

Chevron
– Big Foot

HHI
– HHI Sonam

Loadmaster

Noble Energy
– Leviathon

South Atlantic Holding
– Peregrino

Oil & Gas

CNOOC
– CAO FEI-DIAN

ORE Carrier

SK Shipping Co., Ltd.

OSV

Fugro
– Fugro Enterprise Refit

Harvey
– Harvey Gulf Sub Sea

Hornbeck Offshore Supply

Oceaneering
– MSV Ocean Evolution
-Hulls 671, 672, 673

PSV

Beemore
– Hulls 6037

GulfMark
– Hulls 111, 112, 113

Halliburton
– Halliburton STIM Hulls 147 & 148

Harvey Gulf
– Harvey Rain
– Harvey Freedom

Hornbeck
– HOS Bayou

Seacor
– Seacor MPSV

ThomaSea
– Hulls 147-226, 148-131, 148-279

Pushboat

Eymard
-Ted Kaysar
– Hulls 112, 113, 114, 115, 118, 119

Research

University of Hawaii
– Kaimikau O Kanaloa

Semi-submersible

Diamond Offshore
– Ocean Guardian
– Ocean Valiant

OOS
– Semi-submersible

Super Yacht

Voyager
– S/Y Voyager

Survey Vessel / Yacht

– Pressure Drop

T-AKR

USN
– USNS Shughart

Tanker

GRACE
– Oil Tanker

TMS Tankers

T-AO

USN
– Guadalupe

Yacht

– Project Blue

– Cheetah Moon

– Quantum Blue

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