In refineries and chemical parks, you may not see the smoke of war, but danger is always far away. A cable running through a wall, a pipe running through a floor—a seemingly insignificant hole—can be a “highway” for fire, explosion, and toxic gases to spread. According to statistics from the Ministry of Emergency Management, 35% of petrochemical fires are caused by failed cable and pipe seals.

Why? Because the petrochemical environment is incredibly harsh: high temperatures, high pressures, severe corrosion, flammability, and explosiveness… Traditional methods of sealing holes with fireproofing mud and cement have long outdated. Once seals age and crack, flames and toxic smoke can spread throughout the entire facility building in just three minutes. So, how do modern petrochemical plants protect this “lifeline”? The answer: TST SEAL’s professional-grade safety sealing solutions.

Head-to-Head: The “Three Major Challenges” of Petrochemical Sealing

Fire Spreads Fast: Cable trays act like chimneys, allowing flames to spread rapidly upwards through cable bundles during a fire. The corrosive environment: Hydrogen sulfide, salt spray, and acidic and alkaline media can cause ordinary sealing materials to crack and powder within three months.

Maintenance is difficult: The equipment area operates 24/7. Traditional sealing systems are cumbersome to repair and can also lead to secondary risks.

Old methods are no longer effective; new solutions are necessary!

Core weapon: TST SEAL fireproof sealing module – a self-healing firewall

This is no ordinary “fireproof brick,” but an intelligent sealing system, the core of which is the fireproof sealing module.

What does it look like? It resembles a “Lego brick,” constructed from a composite of expanded graphite, ceramic fiber, and a metal frame. During installation, it slots directly into the pre-buried wall bushing for a seamless fit.

Most impressively, its “superpower” is expansion in the presence of fire!

When the temperature reaches 200°C, the module instantly unleashes its power, expanding 8-10 times its volume. Like a rising dough bun, it completely seals all gaps, forming a hard carbonized layer. Even after a three-hour fire (A-180 grade), the temperature of the back-of-fire surface remains below 180°C, fully meeting the requirements of the “Petrochemical Enterprise Design Fire Protection Standard” (GB50160).

Even more impressively, it can withstand a 1.8MPa explosion shock wave, ensuring that in extreme accidents, the fire will not “chain-detonate” through the penetration point.

Real-World Examples: These Factories “Save Danger” with It

Zhenhai Refining and Chemical: TST SEAL Modular Sealing Increases Efficiency Fivefold

In its 10 million-ton refining and chemical integration project, tens of thousands of cables are routed through the walls between the control room and cabinets. Using traditional fireproofing mortar would have taken at least two months. Instead, they adopted TST SEAL’s prefabricated fireproof sealing modular system, which workers installed like “building blocks” within three weeks. Results: Not only did the project pass fire safety inspections, but it also saved valuable time for early commissioning. The client exclaimed, “We saved not only money, but also safety.”

Offshore Platform: Salt Spray Resistant + Explosion-Proof, 5-Year Maintenance-Free

A CEPI platform in the South China Sea operates in a harsh environment characterized by high salt, humidity, and strong winds. Traditional seals corroded and failed within six months. Instead, they adopted a TST SEAL stainless steel frame + EPDM seal + expansion module composite system, achieving IP68 waterproofing, Ex explosion-proof, and salt spray resistance.

Result: No electrical failures due to sealing issues have occurred in five years, and the platform’s safety rating has risen to Class A.

Chlor-Alkali Plant: Corrosion and Fire Protection: Double Protection for Peace of Minor Security

A chlor-alkali plant transports highly corrosive chlorine gas and experienced minor leaks due to aging seals. They upgraded to TST SEAL perfluoroelastomer (FFKM) seals, which are resistant to strong acids and alkalis. Combined with a fireproof layer, they provide a dual protection of “corrosion and fire protection,” completely eliminating potential hazards.

Industry Trends: From “Plugging Holes” to “Smart Protection”

Modularization and Prefabrication Become the Mainstream

TST SEAL sealing modules are prefabricated in the factory as “through-the-wall components” for on-site “plug-and-play” deployment. They offer controlled quality and doubled efficiency, perfectly meeting the rapid construction needs of modern factories.

Multifunctional Integration: One “module” offers multiple functions

Fireproof + Waterproof: For use in underground pump rooms and pipe corridors.

Fireproof + Explosion-Proof: For use in control rooms in explosion-proof areas.

Fireproof + Electromagnetic Shielding: For use in DCS systems to prevent interference.

Fireproof + Small Animal Repellent: Built-in metal mesh protects against rats and snakes.

Green and Intelligent Upgrades

Halogen-Free, Low-Smoke Materials: No toxic gases released during fires, protecting personnel.

Intelligent Monitoring Module: Embedded sensors monitor seal status in real time, enabling “predictive maintenance.”

How to Choose? Recognize the “Three Certificates and One Report”

In the petrochemical industry, sealing can’t be compromised:

Three certificates: Fire protection certification (CCCF), explosion-proof certification (Ex), and classification society certification (BS/BV/CCS/DNV)

One report: A fire resistance test report from the National Fire Testing Center, clearly showing fire resistance time and temperature rise data.

In the petrochemical industry, safety isn’t just a slogan; it’s embedded in every detail. Sealing cables and pipes, while seemingly insignificant, is the first line of defense against escalating accidents. The transition from manual plugging to intelligent modules represents not only a technological upgrade but also an evolution in safety concepts.

In the future, with the development of smart factories and intrinsically safe industrial parks, these “invisible bodyguards” will become even more intelligent and reliable. TST SEAL sealing modules, with the power of technology, silently protect every piece of equipment and every worker, keeping the global petrochemical industry on a safe and steady path.