Fireproofing is a critical safety consideration in process and petrochemical industries, presenting unique complexities in brownfield and revamp onshore oil and gas projects. These challenges are often amplified by significant interfaces with existing facilities and the necessity to balance stringent safety requirements with project schedule and cost constraints. This paper addresses the complexities of fireproofing determination and material selection, particularly distinguishing between protection against pool fires and jet fires. A specific brownfield project experience where the initial client specification mandated only pool fire protection, despite the credible risk of jet fires from high-pressure hydrocarbon systems. Through collaborative engagement between EPC and the client, a pragmatic compromise was reached. Furthermore, the project highlighted the substantial cost of intumescent fireproofing and demonstrated how early collaboration with suppliers and a rationalization of steel profiles into specific DFT bands led to significant cost optimization. The lessons learned underscore the importance of flexible, risk-informed decision-making, robust technical discussions, and collaborative strategies in overcoming complex fireproofing challenges. This approach facilitated the timely determination of fireproofing requirements and material selection, effectively mitigating potential project schedule delays and cost overruns while ensuring adequate safety measures in challenging brownfield and revamp project environments.
