Selecting optimal Passive Fire Protection (PFP) for high-risk oil and gas assets in brownfield projects involves complex engineering decisions. The choice hinges on analyzing credible fire scenarios (e.g., pool, jet), required fire-resistance duration, and long-term performance under harsh conditions. Project constraints like shutdown windows, site accessibility, and Total Installed Cost (TIC) significantly impact feasibility. Construction strategy (modular vs. stick-built), client preferences, and subcontractor capabilities further influence material selection. Two-component epoxy intumescent coatings are often preferred for their robust fire resistance, mechanical durability, and low weight, minimizing structural load in revamps. Their smooth finish aids inspection, unlike bulky cementitious alternatives. However, on-site application in brownfield settings is challenging due to sensitivity to temperature and humidity, risking rework and adhesion issues. Multi-day curing delays construction, and achieving proper surface preparation on aged steel is difficult, complicating Quality Assurance/Quality Control (QA/QC). This paper proposes an integrated solution using prefabricated, factory-cured composite PFP systems like ProClad. These systems require minimal surface preparation, are insensitive to environmental conditions, and provide immediate fire protection upon installation. By shifting quality-critical processes to controlled factory settings, they eliminate curing delays, reduce VOC risks, accelerate timelines, and lower costs, making them ideal for retrofit projects prioritizing speed and safety.
