6 Common Installation Errors with Removable PFP
Removable Passive Fire Protection (PFP) systems, especially in the form of jet fire-rated blankets and jackets, are engineered to safeguard critical equipment from intense heat exposure and flame impingement. While the flexibility and reusability of removable PFP make it a preferred solution for refineries, petrochemical facilities, and offshore assets, its fire performance heavily depends on correct installation. Thermal protection can be severely compromised by even a little fitting mistake, making the system unsafe or non-compliant.
Discover common installation errors that compromise the effectiveness of a removable jet fire PFP and learn how to avoid them.
Poor Fit and Coverage Gaps
One of the most frequent issues in removable PFP installation is inadequate coverage caused by poor measurements or incorrect blanket sizing. Gaps between panels or at interface points allow heat to penetrate during fire exposure, which defeats the entire purpose of the system. Jet fire PFP systems are tested under extreme directional flame and heat loads; any exposed surface becomes a critical failure point.
This mistake often occurs when installers trim materials on-site without resealing, or when they force-fit standard-sized jackets onto non-standard geometries. Manufacturers provide measurement and fitting guides precisely to avoid this. Any misalignment, particularly around flanges, valves, or nozzles, increases the risk of localised failure during an incident.
Improper Fastening and Loose Seals
Removable jet fire PFP relies on tightly sealed enclosures to maintain insulation integrity under extreme temperatures.
Fasteners such as Velcro, straps, hooks, or wire locks are engineered to keep the blankets intact during high-pressure jet fire scenarios. Loose fastening, incorrectly routed strapping, or omitted anchor points can cause the PFP to open or flap under fire exposure, allowing flames and heat to bypass insulation layers. Poor sealing in offshore and high-wind conditions can also lead to premature wear or detachment.
All fastening points must be secured exactly as per the manufacturer’s design. Technicians should inspect for tension and integrity immediately after fitting and during periodic maintenance.
Moisture or Contamination Trapped Inside
Water ingress and trapped contaminants during installation significantly degrade thermal performance. Removable PFP blankets often include multiple layers: insulation, fire barrier, and weatherproof outer skin. Once moisture or oil becomes trapped between these layers, it not only increases the thermal conductivity but also introduces risks of steam explosions or corrosion.
Installers working during rain, high humidity, or while equipment is still warm and wet from operation may unknowingly seal moisture inside. Best practices require installations to be done in dry conditions, with surface preparation and pre-installation inspection to confirm that no contaminants are present.
Incorrect Orientation or Layering
Some removable jet fire PFP systems have directional layering or designated inner and outer surfaces. Installing these systems inside-out, or in reverse orientation, severely impacts their flame deflection properties and thermal resistance.
This error is more common when installers lack product-specific training or visual references. Installation drawings, nameplates, and manufacturer labelling should always be referenced.
For complex geometries such as pipe bends, elbows, or junction boxes, the orientation of the seam and overlap direction matters. Incorrect overlap can allow flames to enter seams directly under pressure, accelerating failure.
Inadequate Support Around Protrusions
Penetrations such as brackets, instrument tubing, and cable trays that pass through PFP systems require specialised sealing collars or moulded cut-outs to maintain protection continuity.
Improvised cuts around protrusions that are not resealed or reinforced create weak points for flame ingress. This mistake is particularly dangerous in jet fire scenarios where directional flame force exploits any vulnerability.
Installers sometimes neglect these details when under time pressure or when documentation for protrusion sealing is unclear. Each protrusion must be assessed individually, and the corresponding fire-rated sealing method applied.
Lack of Final Inspection or QA Sign-Off
Finally, bypassing quality assurance checks after installation is a critical mistake.
Every removable PFP installation should be verified against installation drawings and fire protection specifications. Missing tags, undone straps, uneven coverage, or unsealed cuts may seem minor but are enough to compromise the system in an actual emergency.
Third-party inspection or in-house QA procedures must be standard, especially for safety-critical components like valves, actuators, and ESD systems.
Conclusion
Removable PFP systems provide operational flexibility and fire resistance only when installed properly. Mistakes like poor fit, loose sealing, moisture entrapment, or orientation errors may appear small but directly impact system performance during a jet fire. Asset operators and EPC contractors must invest in proper training, follow detailed specifications, and enforce rigorous QA protocols to ensure fire protection integrity is never compromised.
Visit Ancloz Engineering and let us help you get the most out of your removable PFP systems.
