BHARAT HEAVY ELECTRICALS LIMITED Flue Gas Desulphurization Group-FGD,

Boiler Auxiliary Plant (BAP), Ranipet

(A GOVT OF INDIA UNDERTAKING)

TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS

SPECIFICATION NO : FGD:GFL-TNKS

BUYER (EPC) : BHEL, BAP Ranipet

APPLICATION : WET LIMESTONE FGD

00 31-03-2020 Fresh Release Jyotish Kumar Patel Shanmuga Sundaram S V.Kesavan

REV Date Description Prepared Checked Approved

This document is meant for the exclusive purpose of bidding against this specification and shall not
be transferred, reproduced or otherwise used for purposes other than that for which it is specifically
issued.
 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS

SNO. CONTENTS
A DOCUMENTS TO BE SUBMITTED ALONG WITH OFFER
B DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT
1 INTENT OF SPECIFICATION
2 CODES AND STANDARDS
3 QUALIFICATION REQUIREMENTS
4 SCOPE OF SUPPLY
5 ATMOSPHERIC CONDITION REQUIREMENTS
6 PRELIMINARY CHECK REQUIREMENTS
7 SURFACE PREPARATION
8 COATING APPLICATION

9 INSPECTION AND TESTING OF GLASS FLAKE LINING

10 REPAIRING PROCEDURE FOR GLASS FLAKE COATING

11 PERFORMANCE GUARANTEE
12 PACKING

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
A) DOCUMENTS TO BE SUBMITTED ALONG WITH OFFER

Sl.
Description Purpose
No.

Performance certificate from end user for meeting Qualification requirement for
1
the qualification requirement considering the offer

Qualification requirement for

2 Reference list / experience list as per Annexure-III
considering the offer

All pages of specification and all filled annexures

3 Technical evaluation
duly signed & sealed

Write-up on technical features of glass flake lining

4 offered for primer and build up coats along with Technical evaluation
Catalogues, Resin composition, drawings,etc.

5 Data sheets of the Glass flake lining material. Technical evaluation

Surface preparation, erection sequence/Procedure

6 of the Glass flake lining. Detailed flow chart from Technical evaluation
start to finish of the lining to be furnished.

Storage methods to be followed at site and the

7 Technical evaluation
shelf life of glass flake

Man days required to complete the Glass flake

8 Technical evaluation
lining for each area is to be spelt from start to finish

Vendor should clearly indicate the price (for both

9 material and application)of Glass Flake lining per Commercial evaluation
square meter

10 Priced offer Commercial evaluation

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
B) DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT

Sl. Delivery
Description Purpose
No. Time
List of datasheets/documents to be
CUSTOMER/BHEL approval
1 submitted for review, approval and 1 week
to start manufacturing
information with submission dates
Catalogue/Datasheets for the Vinyl ester CUSTOMER/BHEL approval
2 2 week
based Glass Flake Lining material to start manufacturing
Detailed dimensional drawing of the lining
surfaces indicating the design data and
CUSTOMER/BHEL approval
3 information about the material, scope of 2 week
to start manufacturing
work and weight of the material supply,
Packing procedure etc
CUSTOMER/BHEL approval
4 Surface preparation and Lining procedures 2 week
to start manufacturing
Manufacturing Quality Assurance Plan for
CUSTOMER/BHEL approval
5 Glass flake material and adhesive to be 2 week
to start manufacturing
submitted for approval.
Field quality plan for surface preparation
CUSTOMER/BHEL approval
6 and lining application procedure along with 2 week
to start manufacturing
testing
Repair and rectification procedure for Glass CUSTOMER/BHEL approval
7 2 week
Flake lining to start manufacturing

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
1. INTENT OF SPECIFICATION

a) This Specification defines the minimum requirements of glass flake lining of Slurry Tanks in the
Flue Gas Desulphurization (FGD) plant for NTPC Projects.

b) Tanks/Sumps to be lined contain Limestone Slurry/Gypsum Slurry/Process water. Slurry Tank

Details and Slurry conditions are given in Annexure-Tank Details . The glass flake lining shall
offer better resistance to corrosion/erosion and shall be based on Vinyl ester resin. Thickness
of glass flake lining required is 3 mm thk .

c) This specification covers the general design, selection of suitable glass flake material/resin,
manufacture, shop inspection (As per latest applicable statutes, regulation and safety codes in
the locality where the lining are to be carried out) and delivery at site, surface preparation of
lining surface, lining the surface to the satisfaction of the customer, jointly calculation of total
area lined, inspection of the lining at site, handling over to the ultimate customer.

d) Compliance to this specification shall not relieve the vendor of the responsibility of furnishing
glass flake lining materials of proper design, materials and workmanship to meet the specified
requirements.

e) In case of deviation, it shall be listed in the vendor's proposal under separate section titled as
“list of deviations/exceptions” to the enquiry documents. Any deviation not mentioned in this
list , but mentioned elsewhere in the proposal will not be considered.

2.0 CODES AND STANDARDS:

The glass flake lining shall conform to the latest version of
Indian/British/American/International Standards. Nothing in this specification shall construe
to relieve the contractor of the required statutory responsibility. The Glass Flake Lining
material shall be designed for the corrosion protection of the Slurry tank. The lining shall be
glass flake filled vinyl ester based coating system. Only Proven material has to be offered by
the bidder

REFERENCE STANDARDS:

ASTM D 4285 Standard Test Method for Indicating Oil or Water in

Compressed Air

ASTM D 4541 Standard Test Method for Pull-Off Strength of Coating

Using Portable Adhesion Testers

ASTM E 337 Standard test Method for Relative Humidity by Wet and
Dry Bulb Psychrometer

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
ASTM D 4618 Standard Specification for Design and Fabrication of Flue
Gas Desulfurization System Components for Protective
Lining Application

ASTM D 5162 Practice for Discontinuity (Holiday) Testing of Non-

Conductive Protective Coating on Metallic Substrates

NACE Standard RP0178-2003 Fabrication Details, Surface Finish Requirements, and

Proper Design Considerations for Tanks and Vessels to be
lined for Immersion Service

ISO 8501-1, 1988 Preparation of Steel Substrates Before Application of

Paints and Related Products - Visual Assessment of
Surface Cleanliness

SSPC”PA2 Measurement of Dry Paint Thickness with Magnetic

Gauges

3.0 QUALIFYING REQUIREMENTS

(1) Glass Lining material selected should have been used in Wet Limestone based FGD application
for coal fired power plants or similar corrosive environment for minimum 2500 sq.m for atleast
one (1) project.

(2) The lining material should have completed minimum 2 years of operation reckoned as
on/before the date of techno-commercial bid opening of the tender/enquiry.

(3) The manufacturer should have designed, manufactured, supplied and supervised the installation
of Glass lining of the referred plants.

(4) Any Patch work/repair work will not be considered as experience/qualifying requirement unless
it is done for the entire area.

(5) Performance certificate from end user for meeting the above qualifying requirements altogether
shall be provided by the bidder.

Lining material shall be supplied from such manufacturer who has got the proven material and
meets the above Qualification requirements. Performance certificate from end user for meeting
the above qualifying requirements altogether shall be provided by the bidder.

4.0 SCOPE OF SUPPLY

a) Complete selection and procurement/manufacture of all materials required for lining, storage,
preparation of the surfaces for lining near site and installation of lining. All equipments
required for lining shall be arranged by the lining vendor. Testing and supply of glass flake
lining material for the duty condition specified in Table-1.

b) Erection and Commissioning of the glass flake lining as per the requirement. Delivery of
material to site, Storage of the material, surface preparation of the surfaces to be lined, lining

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
the surface to the satisfaction of the customer and testing the lined surface for proper
adhesion, complete coverage and intactness with the base material/surface shall be under
bidder's scope, cost for Erection and Commissioning shall be included in the offer. The lining
shall extend through all internal surfaces and over flange faces. The lining shall cover all the
baffles inside the tank.

c) To install the linings, full scaffolding access shall be provided to reach the internal walls and
the entire area. Scaffold shall be properly erected with full planking in all work areas.
Scaffolding shall not contact wall surfaces in work areas during lining application and surface
preparation

d) The execution of the surface preparation and lining shall be carefully planned in stages to
obtain optimum lining quality with freedom from contamination and overspray or damage to
lined surfaces from preparation in adjacent areas. Surface preparation will commence from
the top and proceed progressively to the wall base and floor.

e) Lining and preparation works shall be staggered or proceed progressively in order to meet
cleanliness requirements or overcoating times indicated in this specification.

a) The total area to be lined/coated as indicated in this specification may vary +/-10%. Hence,
after the completion of work the total area lined will be jointly calculated by BHEL and the
vendor. Final payment will be made based on the calculated area. Lining price quoted by
vendor per sq.m shall be considered for making the final payment.

b) Air-Compressor, Airless Spray pumps, hopper, blasting hose, lining hose, spray tip, blasting
gun, spray gun and other equipment for blasting and spray application has to be arranged by
lining vendor. Power required for running the compressor, lighting, welding, cold storage, etc
will be provided by BHEL free of cost. In case of Diesel compressor, vendor to arrange the
diesel themselves. Water, if required, shall be provided by BHEL free of cost. Compressed air
and instrument air will not be provided. Any cold storage container, if required, shall be
arranged by vendor. Any scaffolding shall be made of Steel only. Scaffolding material shall be
arranged by vendor. All travel, TA/DA, Stay charges, site visit charges shall be in vendor’s
scope.

c) 10 copies of Operation and Maintenance Manuals containing all details of reference drawings
and technical data shall be furnished by the Bidder.

5.0 ATMOSPHERIC CONDITION REQUIREMENTS

This section deals with the atmospheric condition requirement to be checked while
undertaking the Glass Flake Lining at site.
1. Blasting or Coating shall not be applied if following conditions prevail.

 When temperature of the surface to be coated is less than 3°C above the dew point, or
the relative humidity is higher than 85%.

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
 When the base metal temperature is greater than 60°C.
 When the atmospheric temperature is below 4°C.
 When there is, in the opinion of lining Contractor, the likely hood of an unfavourable
change in the weather condition within 2 hours after coating.
 When there is deposition of moisture in the form of rain or condensation.

2. Humidity shall be calculated by bidder using whirling hygrometer whose thermometers are
calibrated.

3. Surface temperature shall be measured using suitable temperature gauge and calibration
certificate of the same shall be provided by bidder.

4. Record will be maintained throughout the execution period. Readings shall be taken once in
every 4 hours up to the time work is in progress. The frequency of reading should be
increased during adverse weather conditions.

5. While working in unfavourable weather conditions (like monsoons or winters or if provided

for in the contract or in large confined spaces where blasting and priming of the entire
surface cannot be completed in one days operation, use of dehumidifier shall be resorted to.
The dehumidification equipment will have to be maintained in such a way that the humidity
is around 65% -75% inside the sump at all times during the work. No flash rusting of the blast
surface should take place till the time it receives a primer coat.

6. Where dehumidification equipment is to be used the humidity readings are to be taken

inside and outside the equipments to be coated.

7. Dehumidification equipment may not be necessary for contained space working if work is
done at near ideal atmospheric conditions as described above.

8. In cases where dehumidification is not possible, alternate methods of warming up the work
front like use of halogen lights, room heaters are to be adopted.

9. Humidity is to be taken at the location where the blasting coating operations taking place.

5.1 APPLICATION & MEDIUM:

Glass flake lining is done in order to protect the slurry tanks which contain limestone/gypsum
slurry. Coated surfaces are exposed to slurry whose conditions are given in Table-1 . Typical
Drawing of the Tanks is enclosed.

6.0 PRELIMINARY CHECK REQUIREMENTS

This section deals with the preliminary check requirements to be done while doing the lining
work.

6.1 CHLORIDE CONTAMINATION TEST:

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
The 2% ferricyanide paper method will generally be used to determine the chloride
contamination as described below:
1. Apply de-mineralized water on approximate 12 cm² area of substrate and wait for 3 to 4
minutes.
2. Remove excess moisture by patting the substrate with clean lint free cloth.
3. Press a ferricyanide paper of approximate 12 cm² area against the substrate for
approximately 5 seconds and remove the paper.
4. Total absence of blue spots on paper indicates the substrate is free from soluble salts
5. Light speckling paper indicates the substrate has still contamination but it is as the
acceptance level. The component should be released for further process.
6. Large blue spots on the paper indicate the substrate is heavily contaminated.
7. In this case the following procedure to be done before coating.
i. Pressures wash the substrate with copious amount of town water.
ii. Dry the substrate completely.
iii. Re-blasts the surface.
iv. Follow the salt contamination checking procedure again till you get the desired
results.
8. The Ferricyanide papers should be stored by vendor in air tight container before and after
use and the shelf life of Ferricyanide paper shall be one month.

6.2 ABRASIVE DRYNESS CHECK:

The abrasive to be used will be checked for dryness by taking a small quantity of abrasive on a filter
/tissue paper and checking of traces of moisture absorbed in the filter/tissue paper. Frequency of test
shall be once in day prior to blasting operation.

6.3 COMPRESSED AIR DRYNESS CHECK:

Compressed air to be used for blasting shall be free from oil & moisture and shall be tested adopting
“Blotter Test” by vendor. A piece of blasting Paper will be held in front of blast hose nozzle to check for
traces of oil/moisture captured by the blotting Paper. Frequency of test shall be once in day prior to
blasting operation.

7.0 SURFACE PREPARATION

This section deals with the methods of surface preparation before coating application
7.1 MASKING:

1. Bidder to ensure that areas not being coated are fully and adequately masked.
2. Bidder to ensure that stud holes, dowel/oil ways etc. are suitably masked or plugged to prevent
ingress of blasting abrasives.

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
7.2 SURFACE PREPARATION METHODS:

The method of surface preparation dry abrasive manual blasting shall be done as follows:
1. Surface to be coated shall be abrasive blasted. Before this operation, removal of existing coating to be
carried out by chipping, grinding or by other suitable means. The walls of the tanks are painted with
min 60µ DFT of Red Oxide Phosphate(rust proof primer), which is to be removed by vendor during
blasting. Clean & dry Copper Slag Abrasive shall be used for ferrous base substrate.

2. Bidder is requested to go through all sections of the Typical GAD drawing of Slurry tank. Vendor my
raise their observations during pre-bid query. Any other new requirements brought forward during
technical evaluation stage shall not be considered by BHEL.

3. The minimum recommended compressed air required for Blasting shall be 7.0 m3/min at 6 kg/cm²
pressure. NACE No.1/SSPC-SP-5 equivalent to SA 2½ of Swedish Standard blast profile (75 to 100
Microns) to be followed for cleaning the surface.

4. The blasted surface shall be cleaned with dry compressed air/vacuum cleaner or with clean brush so
that there is no presence of Dust & other foreign material. The surface will be then checked for
chloride contamination (Refer Clause.5.1 for Chloride contamination check procedure). If
contamination is found then the surface to be washed and reblasted till contamination gets removed.
Vendor to ensure that the blasted surface free from chloride contamination
5. When cleanliness and blast profile are acceptable, the masking tape adjacent to the area to be coated
shall be peeled back to prevent overlap and subsequent edge contamination.

6. If the blasted surface has not been primed within specified time or if there is any previous visible sign
of blast condition change then the surface shall be checked for metallic salt contamination and shall
be reblasted. Where large areas are required to be blasted in a day, blasting shall be carried out from
morning to evening ensuring weather condition. This shall be followed by a light sweep blast of the
entire area, before priming. The blast cleaned surface shall be blown off with dry oil free compressed
air or vacuum cleaned. A cell tape shall be thoroughly pasted to the cleaned surfaces. The tape shall
be removed after a minute to check presence of dust if any. Comparator shall be used by vendor for
checking the blast profile.

8.0 COATING APPLICATION

This section deals with the methods & requirements of coating application.

8.1 MIXING:

1. All coating material tins shall be individually stirred thoroughly to obtain a homogenous consistency.
2. While doing spray application, the tins which come in pre measured kits will be fully mixed individually
using a pneumatic stirrer. While doing hand application only small batches of 1 Kg. capacity shall be
taken. Here the mixing will be done by using a metal spatula.
3. The mixing ratios as specified in the respective data sheet will be strictly adhered to. The base will be
weighed out in kgs using mechanical weighing machines calibrated at site using any standard factory
packed commercial product available freely in the market. The catalyst will be measured out in ML using
marked syringes or measuring cylinders.

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS

8.2 APPLICATION PROCESS:

1. The preparation and application of coating is done as per relevant product data sheet. Reference will
be made to product datasheet or where appropriate, contract specifications for carrying out coating.
2. Coating in confined spaces should be done when the ambient temperature is low to avoid excess build
up of styrene fumes.
3. The entire thickness will be built in multiple coating.
4. Each coat will consist of minimum two passes of wet on wet in perpendicular directions.
5. The Dry film thickness will built of each coat will be checked and recorded.
6. All the other people working with the paint will be provided with eye splash goggles and masks.
7. Glass flake lining material shall be chosen considering the slurry conditions given in Annexure-III
8. Minimum and maximum intercoat intervals are as follows.
a. For primer coat -At 20ºC minimum 2 hours, maximum 14 hours.
b. For build-up coats-minimum tack free of previous coat, maximum 3 days.
9. Primer coat shall be of 75-100 μm thickness
10. Built up Coat shall be of 3000-3100 μm in multiple coats.
11. Total System DFT: 3000 microns approx
12. All weld joints phase transition joints will receive a stripe coat by brush in the same sequence of
coating on the shell.

8.3 CURING & FINISH:

1. Curing:
The completed linings shall be allowed to cure for a minimum of 48 hrs at 30°C prior to being placed
in service. However, curing time shall be as per the datasheet provided by vendor for a proven
material.

2. Finish:
It is to be noted that the coating will follow the profile of substrate. Any unevenness or other defects
in the substrate may be reflected in the finish coating also. The finished coating shall have a
matt/semi-glossy finish. A few local paint sag marks will not affect performance of coating and cannot
be completely avoided. Hence this is permitted.

9.0 INSPECTION AND TESTING OF GLASS FLAKE LINING

After the completion of lining, the following tests shall be conducted by the vendor to assess
the quality of glass flake lined surfaces.

1. Lining shall be visually inspected to ensure that it shall be free from poor weed out fibers, entrapped
air and exposed fires. The Glass flake lining shall also be subjected to testing at site as per relevant
standards.
2. Testing of coatings is normally carried out as soon as they are sufficiently cured to give true thickness
& to withstand damage by the test equipment. If defects are found, repair will be carried out as per
clause 10.0
3. Spark test shall be carried out at appropriate areas in the presence of Purchaser. Vendor should
conduct holiday test as per relevant standards. If the performance is found not to meet the
requirements as specified, the Glass flake lining shall be rectified or replaced by the Vendor without
any additional cost to the Purchaser. The repair shall be carried out as per clause 10.0

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
4. Proper documentation with details of tests conducted by the vendor for evaluation of glass flake lining
shall be submitted to the purchaser.

10.0 REPAIRING PROCEDURE FOR GLASS FLAKE COATING

1. If the exposed or damaged surface less than 10cm² then such repair can be carried out without grit
blasting. Any area in excess of this amount should be grit blasted using a vacuum blaster where
possible.
2. In case of damage area less than 10cm² then it can be repaired as following.
a. De-contaminate surrounding area by using a suitable solvent such as methylated spirit,
acetone, xylene etc. After washing clean and allow solvent to evaporate.
b. Roughen up exposed metal & clean using rotary wire brush or a coarse emery paper with at
least 60 grade grit. Brush away residues then further roughen surface of the existing
coating up to 100 mm away from the damaged area. Brush away residues & ensure the
whole area is clean.
c. Apply a thin coat of material to the surface of the exposed metal only taking care not to
cover more than a few millimetre of the existing coating. Allow this freshly applied material
to become tack-free.
d. Brush styrene monomer over the whole surface to be repaired (i.e. the whole area
roughened by emery) & allow to evaporate from the surface.
e. Apply at least 2 main coats material over the treated area taking care not to brush on to
any roughened or contaminated areas. The Glass flake should be allowed to harden
sufficiently to bear the weight of next coat before application of further coats. However it
does not need to be tack-free between coats.

11.0 PERFORMANCE GUARANTEE

The lining shall be guaranteed for uninterrupted minimum life of 25,000 hrs. Performance
parameters to be guaranteed by the vendor and tolerances permitted shall be as indicated in the
data sheet. Glass Flake lining or any portion thereof is liable for rejection, if it fails to give any of the
guaranteed performance parameters. During Guarantee period any defects noticed due to faulty
material and workmanship, shall be rectified by vendor free of cost.

12.0 PACKING

The part items of the Glass flake lining should be identified by Tag numbers and should be
packed as to minimize the possibility of damage during storage or transit. The packing should be suitable
for tropical conditions. BHEL site will arrange for the space for storage. Vendor shall make arrangements
for storing the Glass flake lining materials in AC containers at site. The list of items identified as
despatchable units shall be furnished along with unit weight and the quantity for preparation of packing
slip at BHEL end for dispatch to site and for easy identification, storage and erection at site.

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
Table -1 Process Parameters

The tanks will be handling slurry whose details are given below:

Sl. No. Parameter Slurry

1 Slurry to be handled Limestone/Gypsum Slurry

2 Maximum solid particle size From 75 micron to 7 mm

325 mesh
3 Normal solid particle size,d50
(43 micron)
6 Chloride concentration 30,000 ppm (max)

7 Hardness of particle 5-7 (Mho scale)

8 Slurry concentration 30 wt%

10 Sp. Gravity of Slurry 1.22

11 Sp. Gravity of Limestone or Gypsum 2.32

12 Viscosity 3 cP to 30 cP

13 Temperature(de 70 deg C

Note: Lining material chosen shall withstand a maximum service temperature of 85 deg C.

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
ANNEXURE - I

TECHNICAL DEVIATION (IF ANY)

Enquiry No:

Statement of Reason for Cause of

Sl. No Sec / Clause no. Specification
deviations/variations deviation withdrawal

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Note: All deviations/exceptions, if any must only be given in the Deviation Schedule. Any deviation/
exception mentioned elsewhere would not be considered for evaluation.

SIGNATURE OF BIDDER --------------------

NAME -------------------

DESIGNATION ---------------------

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
ANNEXURE – II- SCHEDULE OF GUARANTEES

We , ,
guarantee that the Glass Flake Lining Lining proposed for this project will have an uninterrupted minimum
life of 25,000 hrs.

The lining is guaranteed for faultless material and workmanship and also for a period as mentioned above
from the date of handing over. During the Guarantee period any defects noticed due to faulty material
and workmanship, the same shall be rectified by us free of cost.

SIGNATURE OF BIDDER (Glass Flake resin Manufacturer) --------------------

NAME -------------------

DESIGNATION ---------------------

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 TECHNICAL SPECIFICATION FOR GLASS FLAKE LINING OF SLURRY TANKS
ANNEXURE – III

REFERENCE LIST as per format shown below.

Coal fired Wet Limestone Based

Project Name , Glass
Yes/No FGD (Yes/No)
S. No. Customer & Plant Year of Commg Lining
capacity Area

SIGNATURE OF BIDDER --------------------

NAME -------------------

DESIGNATION ---------------------

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