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K-MASS 
Intumescent Epoxy

        K-MASS  HAS BEEN SPECIFICALLY FORMULATED FOR PROTECTION OF CRITICAL PROCESS CONTROL EQUIPMENT (CPCE) IN HYDROCARBON FIRES 
K-MASS is a proprietary moldable epoxy intumescent epoxy that becomes reactive in the presence of heat, expanding to several times its original thickness as it develops the insulating char that inhibits CPCE temperature rise. This pyrolytic reaction shields wire insulation, solder connections, circuit boards, terminal blocks, relays and metallurgy allowing the CPCE to remain operational during the fire.
How K-MASS Intumesces
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As the fire starts

K-MASS starts to react at 85.6°C. A chemical process causes the coating to expand (intumesce). Evaporation
on the surface then takes place which also has a cooling effect. The outside surface then starts to char.
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During the fire

The surface char deepens reflecting 80-90% of the heat back into the fire. Intumescing continues and forms a barrier, both insulating and cooling.
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Long term exposure

The heat will penetrate the first layer, then the K-MASS below will start to react. The layers react until the fire is extinguished or the material is consumed.
Our intumescent epoxy provides superior insulation characteristics in high heat flux, rapid temperature rise hydrocarbon fires by maintaining cooler surface temperatures, lower heat transfer rates, and cooling the components in sudden ambient temperature increases to 1093°C/ 2000°F. 
Hydrocarbon vs Cellulosic Fire
Hydrocarbon vs cellulose heat rise.tif
Of all the fire tests available UL 1709 is the most demanding, with the fastest temperature rise coupled with one of the highest heat fluxes.  This is why UL 1709 has been adopted by the petrochemical industry.
Thermal Designs in-house ANSI/UL 1709 as per API 2218 compliant burn test (1093°C/ 2000°F for minimum of 30 Minutes)
K-MASS has been tested in accordance with UL 1709 Rapid Rise Fire Test of Protection Materials for Structural Steel as per API 2218. Structural steel fire test temperature criteria are less stringent than the pass/fail criteria of CPCE. Structural steel can loose up to 50% of its strength at temperatures below 440°C/824°F, temperatures well above the failure point of electrical and electronic equipment, and metallurgy used in the manufacture of components for CPCE.
 
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Before the fire 

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  • A new actuator coated with     K-MASS  DB

  • The coated actuator appears and operates the same as the uncoated actuator

K-Mass after fire.jpg

Externals after the fire 

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  • The 3/4 inch (19mm)  K-MASS 

         coating has intumesced resulting               in much thicker char

  • The expanded char completely encapsulates the actuator

K-Mass K-Electronics after fire.jpg

Internals after the fire

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  • Electronics remain undamaged

  • The “O” ring is still intact

  • May be possible to replace the         K-MASS and return the actuator   into service

         Benefits of K-MASS 

  • Cannot be removed and left off during servicing activities, so the fireproofing is never compromised.

  • Because it is an epoxy product directly bonded to the equipment, it adds an extra layer of corrosion        protection.

  • Does not permit Corrosion Under Insulation (CUI)

  • Full access to equipment with no special tools required

  • Doesn’t affect the flame paths on explosion proof actuators and the equipment initial ATEX approval is maintained

  • Will last the life of the actuator if the paint integrity is maintained

  • Actuators can be fire tested to industry standards such as UL 1709 to prove functionality for a specified time, typically 30 min

  • Weather and chemical resistant

  • Allows complete access to equipment to operate and maintain

  • Molded on, not hand applied or sprayed

  • The process precisely controls the thickness and shape of the coating bonded to the outer surface of each component part

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