SPECIFICATION PAGE 1 OF 8

FAUJI FERTILIZER BIN QASIM LTD. TITLE SPECIFICATION NO.:

DAP PLANT REVAMP Fabricated Glass Fiber 198-D-A9-120
Reinforced Equipment for
Fluoride Service
KARACHI, PAKISTAN Date: 20-Sep-06
Rev: A
PROJECT NUMBER: 28-DC73-00
REV DATE BY CK APPROVALS PAGES REMARKS
DEPT PROJ CLIENT-DATE
. .

A 20-Sep-06 HHS NRG HHS KJP 8 Approval

SPECIFICATION ISSUED FOR:

ENTIRE SPECIFICATION
ISSUED THIS REVISION REVIEW PURCHASE
CLIENT APPROVAL CONSTRUCTION
REVISED PAGES ONLY
ISSUED THIS REVISION INQUIRY/BID INFORMATION

ISSUED
 SPECIFICATION PAGE 2 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06

1.0 SCOPE

This specification covers the design, materials, construction workmanship, and the methods of
inspection of fabricated glass fiber reinforced process equipment and fume exhaust handling
components that are to be exposed to fluoride bearing streams.

Data sheets issued for specific projects will refer to this specification. Where there are
differences between data sheets and this specification, the data sheets shall govern.

2.0 GENERAL REQUIREMENTS

Equipment shall be constructed in accordance with the applicable provisions of the codes and
regulations from the following organizations:

ASTM – American Society for Testing & Materials

NBS - National Bureau of Standards

OSHA - Occupational Safety and Health Administration

3.0 DESIGN

3.1 Equipment and components may be designed based on the following technologies:

3.1.1 Hand lay-up, contact molding fabrication or combination thereof shall be in accordance with the
guidelines of ASTM D-4097 “Standard Specification for Contact Molded Glass-Fiber-Reinforced
Thermoset Resin Chemical Resistant Tanks” or D-3982 for ducts.

3.1.2 Filament wound glass fiber reinforced construction in accordance with the guidelines of ASTM D-
3299, “Standard Specification for Filament Wound Glass-Fiber-Reinforced Thermoset Resin
Chemical Resistant Tanks”.

3.1.3 Provisions of these basic specifications are applicable except as they may be supplemented or
superseded elsewhere within this specification.

3.2 The minimum physical properties of the laminate shall comply with the values established in
D4097 or D-3982, regardless of the type of resin used.

ISSUED
 SPECIFICATION PAGE 3 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06
3.3 Filament wound tank design stress shall be based on an allowable strain value of 0.001 mm/mm
maximum.

3.4 The design stress for contact molded equipment shall be 10 percent of the minimum ultimate
tensile stress of the selected laminate thickness providing a factor of safety of 10:1.

3.5 Wall thickness shall be calculated for the conditions shown on the drawings. Minimum wall
thickness of duct work shall be as follows:
750 mm (30” )diameter and larger – 9mm (3/8” ) thick
Less than 750 (30” )mm diameter – 6 mm (1/4” ) thick

4.0 MATERIALS

4.1 RESINS

4.1.1 Resins used shall be of a commercial grade acceptable for the service and environment.
Recommended resins will be specified on the data sheets. Alternate resins shall have a letter
from the resin supplier attesting to the suitability of the resin for the service.

4.1.2 Fillers up to two (2) percent by weight of thixotropic agent Cab-O-Sil or equivalent may be used
for viscosity control provided it does not interfere with visual inspections.

4.1.3 The cure system used for the resin shall be inn accordance with the manufacturer’s
recommendation. Surface hardness shall be per D4097 paragraphs 10.2 and 11.7.

4.1.4 A separate cured, unreinforced gel coat shall not be used.

4.1.5 No chemical resistant surface, interior or exterior, shall be acetone sensitive. Where application
of polyester film to prevent air inhibition of these surfaces is impractical, a wax containing resin
coating, formulated according to the resin manufacturer’s most recent recommendations, must
be used.

4.1.6 Equipment shall be designated for outdoor service. Ultraviolet inhibitors shall be applied at the
rate recommended by resin manufacturer. Under no circumstances shall the UV additive be used
in the inner liner.

4.2 REINFORCEMENT

4.2.1 Surfacing mat for interior shall be 2 layers (veil) of nexus veil with a silane finish and a binder
compatible with the lay-up resin.

ISSUED
 SPECIFICATION PAGE 4 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06
4.2.2 This nexus veil shall be Type 1012 open, Dacron polyester fiber, 0.3 – 0.4 mm (12-16 mil) thick,
as manufactured by Burlington Industries or equal

4.2.3 Chopped strand mat shall be type E glass, 470g per square meter (1 ½ oz. per square foot) with
silane finish and a binder compatible with the resin.

4.2.4 Woven roving shall be Type E glass, nominal 800g/sq. meter (24 oz/sq. yard), 4 X 5 weave, with
a silane-type finish.

4.2.5 Continuous roving used for filament winding shall be Type E glass with a silane-type finish.

5.0 LAMINATE CONSTRUCTION

5.1 HAND LAY-UP

5.1.1 In general, the laminate will follow the configuration established in paragraph 7 of D4097.

5.1.2 To ensure corrosion protection to the inside and the exterior layers, the laminate construction
should be composed as follows:

V / M / M / WR / M / M where:
V = Veil per paragraph 4.2.1 & 4.2.2
M = Mat per paragraph 4.2.3
WR = Woven Roving per paragraph 4.2.4

This composition should be provide minimum thickness and ensure protection to the exterior of
the woven roving layer.

5.2 FILAMENT- WOUND CONSTRUCTION

5.2.1 The inner surface exposed to the environment shall be a reinforced resin-rich layer, 20mils
(0.5mm) thick. Reinforcement shall be two layers of Nexus surfacing veil.

5.2.2 The interior layer shall be in accordance with ASTM D3299-81 using 0.2g (1 ½ oz.) “E” glass
randomly oriented chopped fiber mat, except that the combined thickness of inner/exterior layer
shall not be less than 0.12 mm (5 mil) thick.

5.2.3 The exterior or structural layer shall include a continuous helical filament winding.

ISSUED
 SPECIFICATION PAGE 5 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06
5.3 GENERAL

5.3.1 Reinforcement material shall be lapped; 25 mm (1 inch) for mat and 50 mm (2 inches) for woven
roving. Lapped edges of adjacent layers shall be staggered.

5.3.2 On laminates, cut edges shall be coated with resin and surfacing mat; machined flange faces
shall be faced with “C” glass, or equal. Veil and other cut edges may be resin coated only.

5.3.3 All joints to be butt and strap joints and not socket and solvent weld.

5.4 DUCT CONNECTION

5.4.1 Unless otherwise specified, connections shall be flanged.

5.4.2 The flanges shall be made by hand lay-up. Flanges shall be flat and true to a tolerance of plus or
minus 0.8 mm (1/32” ). If matching is required, the machined surface shall be faced with “C”
glass veil or equal.

5.4.3 The machine facing of the back of hand lay-up flanges is not permitted. All bolt holes shall be
spot faced for SAE size washers, if required.

5.4.4 Flange thickness and drilling on duct connections shall be in accordance with ASTM D3299,
Table4.

5.4.5 The nozzles shall be reinforced with plate gussets. Conical gussets having comparable strength
may be substituted for the plate gussets.

5.4.6 Flanged connections on duct for piping and instrument connection shall be in accordance with
2
ANSI B-16.5 for 15 kg/cm (150 psi) pressure class.

5.4.7 Bolt holes in flanged nozzles are to straddle the vertical centerline. Tolerance in bolt holes
location and in diameter of bolt circle shall be plus or minus 0.8mm (1/32”).

5.4.8 On flanged joints, use 3 mm (1/8” ) thick full faced elastomeric gaskets.

5.4.9 Reinforcement of nozzle openings in duct walls shall consist of alternate plies of mat and woven
roving. The edges of reinforcing overlays shall be tapered to avoid abrupt change in overall
thickness of duct laminates.

ISSUED
 SPECIFICATION PAGE 6 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06
5.4.10 Bolts, nuts and washers shall be type 316 stainless steel. Lubricate threads with “Never-Seez” or
equal.

6.0 INSPECTION

6.1 Access shall be permitted to the plant area at all times during fabrication. One week notice shall
be provided prior to the estimated date of tests and/or inspections. Final inspection and approval
shall be obtained prior to shipment unless written waiver is obtained.

6.2 The shop inspection of the equipment shall include the following:

6.2.1 Check for compliance with drawing dimensions and adherence to construction standards.

6.2.2 An acetone wipe test to check surface cure. No surface tackiness is permitted.

6.2.3 A Barcol hardness test meeting at least 90 percent of the manufacturer’s specified hardness.

6.3 Nozzle cutouts from duct wall shall be identified and shall be used for test specimens. Cutouts
shall be retained and shipped with the duct.

6.4 Random cutouts will be selected from a maximum of four items for the determination of tensile
strength, tensile modulus, flexural modulus and glass content.

6.5 Laminate defects and their permissive limits shall be as follows:

6.5.1 Process Surface:

Blisters None
Burned Areas None
Chips None
Cracks None
Dry Spots None
Entrapped Air None at surface. If in laminate, 1.5 mm (1/16” dia.), max.
Exposed Glass None
Exposed Cut Edges None
Foreign Matter None
Pits Maximum 3 mm dia. (1/8” ) X 0.8mm (1/32” ) deep, max. 0.5m²
(5/sq. ft.)
Scratches None (coated)
Surface Porosity None
Wrinkles Maximum deviation 10% of wall thickness
Sharp Discontinuity None

ISSUED
 SPECIFICATION PAGE 7 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06

Non-Process Surface
Blisters Maximum 6 mm (½” ) dia., 1.5 mm (1/16” ) high
Burned Areas None
Chips Maximum 6 mm (½” ) with maximum thickness 10% of wall
Cracks None
Crazing Slight
Dry Spots Maximum 70 cm²/ m² (1 sq. in./sq. ft.)
Entrapped Air 3 mm dia. (1/8”) maximum; no more than 3% of area
Exposed Glass None
Exposed Cut Edges None
Foreign Matter None, if it affects the properties of the laminate
Pits Maximum 3 mm dia. (1/8” ) X 1.5 mm (1/16” ) deep
Scratches None (coated)
Surface Porosity None
Wrinkles Maximum deviation 20% of wall thickness but not exceeding 3
mm (1/8” )
Sharp Discontinuity None

6.6 If the area, which fails to meet the requirements of entrapped air or voids, is less that 40% of the
total surface, those areas may be repaired and reinspected. If the defective areas exceed 40% of
the total surface, the entire duct shall be rejected.

7.0 TESTS

7.1 Mechanical property tests shall be conducted only on specimens cured to required hardness.

7.2 Tensile and flexural properties, hardness and glass content shall be determined by a qualified
and experienced testing laboratory using ASTM Test Methods.

7.3 Hardness tests shall be made on the “liner” surface using the Barcol impressor, Model GYZJ
934-1, calibrated at two points in accordance with ASTM D-2583. Where low readings are
encountered, recheck shall be made by taking ten or more readings, and calculating the average
value after discarding the two lowest and the two highest readings.

7.4 Tensile properties shall be determined on specimens in triplicate per ASTM D-638, speed B. A
load-extension plot shall be made and chart speed recorded.

7.5 Flexural properties shall be determined in triplicate specimens per ASTM D-790, Method 1,
Procedure A, and Table 1. A load-deflection plot shall be made and chart speed recorded.

ISSUED
 SPECIFICATION PAGE 8 OF 8
FAUJI FERTILIZER BIN QASIM TITLE SPEC. NO.:198-D-A9-120
LTD.
DAP PLANT REVAMP Fabricated Glass Fiber DATE (ORIGINAL)20-Sep-
KARACHI, PAKISTAN 06
Reinforced Equipment for
Fluoride Service
REVISION: A
PROJECT NUMBER: 28-DC73-00 DATE: 20-SEP-06
7.6 Flexural tests shall be made with the “liner” face of the laminate in compression (under the
loading nose).

7.7 Glass content shall be determined per ASTM D-2584.

8.0 SHIPPING

8.1 Ducts, which are shipped in horizontal position, shall be mounted on padded cradles.

8.2 Ducts shall be secured to the cradles or skids to prevent rotation or other movement. In turn, the
cradles or skids shall be fastened securely to the transport.

8.3 All tie-in straps shall have provision for thermal expansion and shall be padded where in contact
with the ductwork.

8.4 Flange faces shall be protected from damage by covering with suitable plywood or hardboard
securely fastened.

ISSUED