COMPANY STANDARD PROCEDURE FOR FIBER REINFORCED

EPOXY/FIBER REINFORCED POLYESTER LINING

1.0 SCOPE

This Procedure covers the minimum requirements for lining material

specifications, application procedures, inspection and testing requirements of
FRE/FRP lining of pipelines/valves/exchangers/vessels etc.

2.0 MATERIALS

Fibre Reinforced Epoxy (FRE) lining consists of epoxy resin mixed with suitable
hardener and a fibre glass mat. Fibre Reinforced Polyester (FRP) lining consists
of unsaturated polyester resin mixed with suitable catalyst, accelerator and a
fibre glass mat.

2.1 EPOXY RESIN AND HARDENER

The epoxy resin and hardener shall conform to the specifications given in
Anexure I.

2.2 UNSATURATED POLYESTER RESIN, CATALYST AND

ACCELERATOR

The polyester resin, catalyst and accelerator shall conform to the specifications
given in Annexure II.

2.3 FIBRE GLASS MAT

The fibre glass reinforcing mat shall conform to the specifications given in
Annexure III.

3.0 LOCATION/TYPE OF LINING-TYPICAL RECOMMENDATIONS

LOCATION THICKNESS TYPE OF

LINING
i External surface of pipeline running 3 mm FRP
underground in sleeves.
ii C.S. Valves in salt water service. 3 mm FRE
iii C.S. Channel box/ cover of coolers in salt 3 mm FRE
water service.
iv Any other contoured surface previously Original thk / FRRE/FRP as
lined or to be lined as per Inspection's as existing / as
recommendation. recommended. recommended

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 v Internal of vessel / storage tank for 3 mm to 5 mm FRE
protection from corrosion where (as recomm-
recommended. ended)
vi External of vessel/ storage tank. 3 mm FRP

4.0 APPLICATION

The job shall be performed in the following order: (For inspection refer 5.0)

i. Surface preparation.

ii. Preparation of resin mixture.

iii. Application of first coat of resin mixture.

iv. Wrapping of chopped strand fibre glass mat.

v. Application of final coat of resin mixture.

vi. Curing.

4.1 SURFACE PREPARATION

The prerequisite for good adhesion of a lining is cleanliness and roughness of the
surface. The surface to be coated shall be shotblasted to remove mill scale and
rust, existing paint and to expose the bare metal surface.

(Recommended Surface cleaning to Swedish Standard SIS-05-5900 with

blasting to Sa 2 finish, equivalent to SSPC-SP6-63.

4.2 PREPARATION OF RESIN MIXTURE

The resin mixture shall be prepared just before application.

EPOXY RESIN

The epoxy resin system shall be prepared by mixing the epoxy resin and
hardener. The proportion of the mixture shall be as recommended by the
manufacturer. Suitable weigh scales/volumetric gauges shall be used for gauging
quantity of resin and hardener. The proportion of resin and hardener used shall
not reduce the properties below that given in Annexure I.

POLYESTER RESIN

The polyester resin system shall be prepared by mixing the polyester resin,
catalyst and accelerator. The proportion of the mixture shall be as recommended

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by the manufacturer. Suitable weigh scales/volumetric gauges shall be used for
gauging exact quantity of resin, catalyst and accelerator. While preparing the
mixture, accelerator shall never be mixed with catalyst. The accelerator shall be
blended with resin first and the catalyst added immediately before use. Though
the proportion of resin, catalyst and accelerator may be changed to reduce gel
time, care shall be taken so as to not to reduce the properties below that given in
Annexure II.

The above resin mixture must be used within its gel time.

4.3 APPLICATION OF FIRST COAT OF RESIN MIXTURE

The first coat of resin mixture shall be applied to the metal surface within hour
of completion of surface preparation. The application shall be done using a brush
so as to completely cover the substrate.

4.4 WRAPPING OF FIBRE GLASS MAT

The chopped strand fibre glass mat cut to appropriate dimensions shall be
wrapped onto the surface as soon as the first coat is tacky. The wrapping shall
be accompanied by first coating the initial coat with the resin mixture and then
wrapping it with fibre glass mat so that it gets impregnated with the resin. The
fibre glass mat shall be levelled with a roller to avoid wrinkles or folds. There
shall be an overlay of ends of at least 50 mm of the fibre glass mat. Except on
asymmetrically contoured surface the fibre glass mat shall be applied in a single
piece upto the maximum manufactured width. In case of asymmetrically
contoured surfaces like valves the maximum no. of pieces of fibre glass mat shall
be that which is required to avoid wrinkles.

In order to build the thickness a second layer of fibre glass mat shall be similarly
wrapped. The wrapping shall be started when the earlier applied resin is still
tacky.

4.5 APPLICATION FINAL COAT OF RESIN MIXTURE

After wrapping the fibre glass mat a final coat of resin mixture shall be applied
over the glass mat before the resin with which it is impregnated sets hard. The
top coat must completely cover all the glass fibres.

On completion the resin to glass ratio shall be 2:1 by weight.

4.6 CURING

After the final coat the FRE/FRP lining shall be cured by drying in air for at least
24 hours prior to putting it to use.

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5.0 INSPECTION

Samples of the materials used by the contractor shall be submitted for testing
purpose. Contractor shall submit manufacturer's certificate for all the materials.
Contractor shall procure the materials from BPCL approved manufacturer/s only.
In case of other manufacturers prior approval of BPCL shall be sought.

Inspection stages shall be :

i. Material compliance (test certificates must be available).

ii. Surface preparation (Inspection to certify).

iii. After wrapping of fibre glass mat (random check).

iv. Completion of final coat (Inspection to certify).

After completion of final coat, lining shall be offered for inspection.

The entire surface shall be free from cracks, traces of bubbles, lack of adhesion,
hollow spaces etc. The hollow spaces shall be checked by tapping with a
wooden mallet.

v. Lining Thickness

A sample of size 50 mm x 50 mm shall be cut & removed at every 3 m interval in

staggered direction to determine the thickness and bond of the coating. The
same shall be repatched in standard manner as stated above after inspection.

vi. Spark Testing

The contractor shall furnish and operate an electric powered holiday detector of
10,000 Volts output for certifying that lining is free from holidays. The same shall
be witnessed by Inspection Department.

Spark testing shall be done only after a minimum of 24 hours after the completion
of final coat.

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 ANNEXURE I

SPECIFICATION FOR EPOXY RESIN

The epoxy resin shall be prepared using epichlorohydrin and bisphenol A. The
curing agent shall be an Aromatic amine. The properties of cured resin with
reinforcing mat shall be the following :

TESTING
STANDARDS
Epoxy value 5.2 to 5.4 Eq/Kg
Tensile strength 9000 - 10000 psi. ASTM D638
Flexural strength 16000 - 17000 psi. ASTM D790
Heat distortion temp. 80 deg. C. ASTM D648
Water absorption at 25 deg. C 0.2% (max) BIS 6746
(after 72 hours)
Chemical resistance in sea water Excellent upto 70 deg. BIS 6746
C.
Suitable curing temp. 30 to 40 deg. C.

Recommended manufacturer for supply of Epoxy Resin is :

1. M/s. Hindustan Ciba Giegy.

The products generally meeting the above specification is :

Resin - Araldite GY 257

Hardener - HY 830

NOTE : Materials to be accompanied by manufacturer's test certificate.

ANNEXURE II

SPECIFICATION FOR UNSATURATED POLYESTER RESIN

The unsaturated polyester resin shall be an isopthalic acid based resin. It shall
be prepared using suitable organic acid and a polyols. The monomer used shall
be styrene. The curing agent will consist of cobalt (accelerator) and methyl ethyl

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ketone peroxide (catalyst). The properties of cured resin without reinforcing mat
shall be the following :

TENSILE
STANDARD
Tensile strength 9000 - 10000 psi. ASTM D638
Flexural strength 16000 - 17000 psi. ASTM D790
Heat distortion temp. 100 deg. C. min. ASTM D648
Water absorption at 25 deg. C. 0.65% (max) BIS 6746
(after 28 days)
Styrene content 30 to 40%.
Chemical resistance in sea water Exellent upto 70 deg. C. BIS 6746
Suitable curing temp. 30 to 40 deg. C.

Recommended manufacturer for supply of Polyester Resin is :

1. M/s. Bakelite Hylam.

The product generally meeting the above specification is :

Resin - Hylak Resin HSR 8131.

Catalyst & Accelerator - Q-8013 and S-1021.

NOTE : Materials to be accompanied by manufacturer's test certificate.

ANNEXURE III

SPECIFICATION FOR CHOPPED STRAND FIBRE GLASS MAT

The fibre glass reinforcing mat shall be manufactured as per standard BIS-11551
or BS-3496. It shall have the following properties:

TYPE - 'E' Glass Fibre Chopped Strand mat.

Average strand diameter : 8 to 10 microns

Strand length : 25 to 51 mm.
Width : 100 to 150 cm.
Moisture content by mass : 0.5% (max).
Loss on ignition by mass : +/- 2% (max).

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Average mass per unit area : 450 gm/m sq
Cross breaking strength of laminate : Dry 205 MPa, Wet 155 MPa
Conductivity of water extract : 125micromhos/cm(max).
Coupling agent : Silane.

NOTES :-

1. The mat shall be reasonably uniform in colour. It shall be free from discoloured
patches, wet patches, oil and grease spots and other contaminations.

2. The mat shall comply with the above specifications for a period of not less than
one year when stored.

3. Materials to be accompanied by manufacturer's test certificate.

4. MARKINGS

Each roll or its container shall be clearly marked with the following
information :

a. The name or trade mark of the container.

b. The nominal width of the roll (m).

c. The nominal length of the roll (m).

d. The nominal mass per unit area of the mat (gm/m2)

e. Month and year of the manufacture.

Recommended manufacturers for supply of chopped strand mat are:

1. M/s. FGP

2. M/s. UP TWIGA

3. M/s. Ceat TYRE.

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