Project:

NIRMA PPA PROJECT

Project No.: Holds: Page No.:

Document number:
MILPP1101 1 of 29
PP1101-ME-SP-7200-005
Document title: Client document No.:

TECHNICAL SPECIFICATION FOR FRP

MIXER/SETTLERS EQUIPMENT

This Document defines requirements for FRP

Mixer-Settlers Equipment for Reverse Flow
Mixer-Settlers for the NIRMA PPA project

0 28.08.17 FOR CONSTRUCTION RKA NGA MKT

P0 17.08.17 FOR COMMENTS RKA MKT
REV. DATE REASON FOR ISSUE PREP’D BY CHK’D BY APPRV’D BY APPRV’D BY
BAT CLIENT

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REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

P0 ALL FOR COMMENTS
0 ALL CHANGE OF DOCUMENT NUMBER; AMENDMENTS

Hold
Para. Description of Hold
No.

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Table of Contents
1. INTRODUCTION ............................................................................................................................. 4
2. SCOPE OF SUPPLY....................................................................................................................... 4
3. STANDARDS AND CODES ........................................................................................................... 6
4. ABBREVIATIONS ........................................................................................................................... 6
5. GENERAL TECHNICAL REQUIREMENTS ................................................................................... 7
6. MATERIALS .................................................................................................................................... 9
7. MANUFACTURE ........................................................................................................................... 13
8. INSPECTION AND TESTING ....................................................................................................... 19
9. TAGGING AND MARKING ........................................................................................................... 21
10. PACKING, MARKING, PREPARATION FOR SHIPMENT ...................................................... 22
11. DOCUMENTATION ................................................................................................................... 23
12. HEALTH, SAFETY AND ENVIRONMENT ............................................................................... 23
13. DISCREPANCIES ..................................................................................................................... 24
14. TRANSPORTATION ................................................................................................................. 24
APPENDIX A: DEVIATION FORM................................................................................................ 25
APPENDIX B – SUPPLIER DRAWINGS AND DATA REQUIREMENTS ........................................... 26
APPENDIX C – DRAWINGS................................................................................................................. 29

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INTRODUCTION

General Outlines

This Specification defines the scope and minimum technical requirements for supply of FRP
equipment including Mixer Tanks, Settlers, Launders, Settlers Roof and Balancing Legs for the
Nirma PPA Project, located in the Republic of India. Equipment made of glass fiber reinforced
vinyl-ester plastics (FRP) will be complete shop produced, assembled for test (where relevant),
packed and ready for transportation. The settlers are made of FRP with steel frames support
around the walls. Parts of the Settlers will be shop production supplied with additional supports
for transportation, lifting device and lugs for erection and site connection. Services and limits
of supply are written in this specification.

DEFINITIONS

 The word "shall" is to be considered as mandatory.

 Client, Vendor and other are defined in terms and conditions of Purchase Order.
 Tenova Advanced Technologies ("Purchaser") is the party that carries out all part of the
basic engineering, procurement and supervision of the Nirma project.
 Vendor is a synonymous with the term manufacturer SUPPLIER, which is the party that
designs, manufacturers and/or supplies equipment and services to perform the duties.
 FRP EQUIPMENT shall refer to FRP Mixer Tanks, Settlers (including external carbon steel
epoxy painted supporting frame and pillars), Settlers Roofs, Launders and Balancing Legs.

LOCATION

The project is located in the Republic of India.

SCOPE OF SUPPLY

The Scope of Vendor Supply Includes:

1. Mechanical shop design in accordance with Purchaser mechanical drawings.

2. Mechanical guarantee as per General Conditions of Purchase and Special Terms of
Purchase.
3. Vendor's drawings shall be submitted for Purchaser's approval prior to fabrication.

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4. The Mixer Tanks, Launders, Roof and Balancing Legs will be shop made. Discharge
launder will be bonded by Client on the site according to Purchaser design. After
complete shop fabrication the equipment will be packed for inland shipping on trucks.
5. Supply of all required materials such as:
 Resins, fiber-glass and other reinforcements.
 Viscosity control agents, hardeners and accelerators, carbon surfacing mats.
 UV stabilizers, fire retardant additives, carbon black powder, solvents, paint, etc.
 Accessories: FRP and steel parts, interacting with the support structure, gaskets,
washers, bolts, nuts; nozzle covers (blind flanges), lifting lugs, anchor lugs,
grounding lugs.
 All auxiliary materials, molds and tools necessary to perform the shop job.
 Materials and special tools required for site-erected Settlers parts connection and
the equipment erection.

6. Painting of carbon steel parts with epoxy according to manufacturer standard approved
by the Purchaser.
7. Packing of all parts for inland and sea shipping.
8. Supply of the complete documentation on soft copy as native files and hard copies.
9. Supporting structure for inland and sea shipping.
10. Inspection of prefabricated parts.
11. Settlers, connecting launder and mixer tanks sets preassembling and hydrostatic test.
12. Site erection supervision, if required.
13. FCA (Vendor premises) supply according to INCOTERM 2010.
14. Preparation and submission of Fabrication and Quality Control Plan (FQCP).
15. Supply of all special tools and all necessary accessories for transportation and work on
site.

EXCLUDED FROM THE SCOPE OF SUPPLY

 Transportation to the site

 Anchor bolts
 Installation

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STANDARDS AND CODES

All materials, workmanship and equipment shall comply with the latest issue of the relevant
codes and standards where applicable, which shall include the following:

 BS EN 13121:3 – 2016 GRP tanks and vessels for use above ground. Design and
workmanship
 EN 1990:2002/A1:2005 Eurocode - Basis of structural design
 ISO 8501-1:2007 Preparation of steel substrates before application of paints and
related products -- Visual assessment of surface cleanliness
 ASME/ANSI 16.5, Flanged nozzle drillings according to 150 lb up to 600 mm(24”)
nominal bore (see also Table 24, BS EN 13121) ;
 ASTM A193 Grade B8M Class 2 for Stud Bolts, and ASTM A194 Grade 8M for Heavy
Hex Nuts;
 ASTM 193, B7 c/w Nuts per ASTM-194, Grade 2H for Hold down bolting;
 ASTM A283 for Carbon Steels materials (guides, supports, etc);
 ASTM A240 for Stainless Steel materials; (earthing eyes, etc)
 ISO 9001:2015; Quality Management System.

ABBREVIATIONS
CM: Complex Mat

COC: Certificate of Conformance

CSM: Chopped Strand Mat glass-fiber reinforcement

FW: Filament Wound

FRP: Fiber Reinforced Plastic

GRP: Glass-Fiber Reinforced Plastic

HLU: Hand Lay-Up

ITP: Inspection Test Plan

MDR: Manufacturer's Data Report

NCR: Non Conformance Report

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TC: Top Coat

CB: Chemical Barrier

SM: Surfacing Mat

CV: Carbon Veil

UD: Unidirectional fabric reinforcement

WR: Woven Roving glass fiber reinforcement

SV: Surfacing Veil reinforcement (may be glass fiber, carbon fiber or

synthetic fiber)

QC: Quality Control

QA: Quality Assurance

SR: Scope of Supply / Equipment Material Requisition

MR: Material Requisition

GENERAL TECHNICAL REQUIREMENTS

GENERAL

This Specification covers shop and site assembling of FRP Mixer tanks, Connecting Launders,
Settlers Roof, Balancing Legs and Settlers.

The equipment and materials supplied under this Specification shall comply in design,
construction and quality control with expected surface resistivity.

Chopped spray up is not permitted for laminate construction to meet the corrosion barrier or
structural laminate requirements of construction.

ORDER OF PRECEDENCE

The order of precedence shall be as follows:

 The Request for Quotation or Purchase Order

 The drawings
 This Specification

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 Project Specifications.
 International and National codes and standards.

Should there be any conflict between the Request for Quotation/ Purchase Order, Drawings,
Specifications, Codes and Standards, or lack of clear definition as to the applicability of any
specification or standard, the Fabricator shall obtain a written clarification from the Purchaser
before proceeding.

Tolerances

Dimensional tolerances shall be as indicated on the drawings or in accordance with above

mentioned standards, whichever is tighter.

Construction Details

The Mixers shall be constructed from FRP, the Settlers from FRP with steel supports. FRP
structures for mixers and connecting launders shall have internal and external electro-
conductive layers with expected surface resistivity from any point to grounding system not
more than 1×106 Ω. FRP structure is detailed below:

CORROSION BARRIER AND CONDUCTIVE LAYER

The resin used in the corrosion barrier shall be Ashland Derakane Momentum-470-300.

The final thickness of the combined corrosion barrier and conductive layer shall not be less
than 3.0 mm.

The corrosion barrier is ignored in the design calculations.

STRUCTURAL LAYERS

5.3.2.1 All structural layers of external layers shall be in accordance with the calculation
and as described in the approved drawings by Purchaser.

5.3.2.2 The allowable way of production is hand lay up or filament winding. Chopped
spray application in not acceptable.

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5.3.2.3 An intermediate layer of CSM 300 g/m2 shall be applied prior to any new filament
winding layer. This intermediate layer shall be applied in the “Wet on wet”
technique.
The requirement for such intermediate layers shall not necessarily appear on the
fabrication drawing as it is fabricating practice and may change with lamination
conditions. However, all bedding layers shall be recorded in fabrication QC
reporting and included in the MDR.

5.3.2.4 The resin used in the structural layers shall be Ashland Derakane Momentum
470-300 or Purchaser approved equivalent.

5.3.2.5 The resin used in the exterior 4 – 5 mm of structural layers shall be, as indicated
on fabrication drawings, Ashland Derakane Momentum 510A-40 with antimony
trioxide added.

EXTERNAL LAYERS (TOP COAT)

5.3.3.1 The external layer shall comply with the Purchaser drawings and other
documents.
The resin should be Ashland Derakane Momentum 510A-40 with antimony
trioxide, UV absorber, carbon veil (if required) and paraffin wax
All additives shall be incorporated and premixed strictly in accordance with the
manufactures recommendations.
End color– white for settler covers and balancing legs; black – for settler and for
mixer tanks and connecting launder, with UV absorber.

MATERIALS
All FRP materials shall be in accordance with the requirements of BS EN 13121 and this
specification. In case of conflict between this specification and other documents, the following
order of precedence shall apply:

1. Data Sheets and Drawings

2. This Specification
3. Purchase Order/Agreement and attachments
4. Other Applicable Standards

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FRP equipment shall be manufactured using commercial grades of reinforcements and vinyl
ester resins as indicated in this specification, and detailed fabrication drawings.

Material properties must be verified by carrying out the tests listed on BS EN 13121.

Substitution of specified materials shall not be made without Purchaser approval in writing.

RESINS

Each fabricated item will be fabricated by the use of the same resin group from the same
supplier.

ADDITIVES

The Resins shall not contain fillers, pigments, dyes or colorants except as required for viscosity
control, ultra violet absorption, conductivity additives and antimony trioxide. Additives shall be
used in accordance with the suppliers and the resin manufacturer’s instructions. Viscosity
control agents shall not be used in resins for corrosion barrier laminate.

CURING SYSTEM

Resin curing system shall be in accordance with the resin manufacturer’s instructions for
ambient temperature air cure. No deviation from resin manufacturer’s instructions shall be
allowed.

GLASS FIBERS

The reinforcing material shall be commercial grade of glass fiber having a coupling agent which
will provide a suitable bond between the glass reinforcement and the resin.

CHOPPED STRAND MAT

For the corrosion barrier layers, the chopped strand mat shall be Owens Corning Advantex
type glass, 300 g/m2 and 450 g/m2 as indicated on the design documents and fabrication
drawings.

For structural layers or top coat layers, the chopped strand mat shall be Owens Corning
Advantex type glass, 300 g/m2 and 450 g/m2 as indicated on the design documents and
fabrication drawings, or Purchaser approved equivalent.

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WOVEN ROVING

For structural layers, woven roving shall be Owens Corning Advantex type glass, nominal 800
g/m2 or 500 g/m2 plain weave Silane sizing as indicated on the design documents and
fabrication drawings.

COMPLEX MAT AND WR

For structural layers, woven roving and chopped strand mat Complex may be used as indicated
on the design document and Purchaser data sheets or fabrication drawings. The Complex
construction shall be 500 g/m2 WR and 300 g/m2 CSM at least. The glass shall be Owens
Corning Advantex type glass with Silane sizing.

FILAMENT WINDING CONTINUOUS ROVING

Structural filament winding layers shall be Owens Corning Advantex type glass as indicated
on the design documents and Purchaser data sheets or fabrication drawings. Glass sizing shall
be Silane.

UNIDIRECTIONAL FABRIC

Unidirectional fabric used for axial reinforcement in combination with machine filament winding
shall be Owens Corning Advantex type glass 500 g/m2 as indicated on the design document
and fabrication drawings. Glass sizing shall be Silane.

SURFACE VEILS

GLASS SURFACING VEIL (NONE WOVEN)

Synthetic veil Viledon T1773 with a coupling agent and minimum unit weight of 22 g/m2 shall
be used as and if indicated on relevant drawings.

CONDUCTIVE CARBON VEIL

Conductive carbon veil shall be Südchemie Donacarbo S259P, 30 - 50g/m2 with surface
resistance of Max 20 Ω m2. The conductive veil shall be compatible with the resin and shall
be used where indicated on the TAT drawings.

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CONDUCTIVE CARBON POWDER

Pure Conductive Carbon Black in Powder form, -Ketjenblack EC-P300J or Purchaser

approved equivalent, shall be used as an additive to the resins used in the internal and external
conductive layers as indicated on the design document and fabrication drawings. The carbon
black powder shall be used at the dosage of 1.5-2% w/w of resin

ADDITIVES

ANTIMONY TRIOXIDE

Antimony Trioxide shall be used as an additive only to Ashland Derakane Momentum 510A-
40 at the dosage of 3% w/w of resin.

Antimony is a suspected carcinogen and shall be handled with care.

UV ABSORBER

UV absorbers such as ‘Tinuvin 326’ shall be added to the final exterior top-coat at the dosage
of 0.1%-0.3% w/w of resin. It shall be premixed with diluents strictly in accordance with the
manufacturer recommendations and added strictly in the proportions recommended by the
resin manufacturer.

PARAFFIN WAX

Paraffin wax shall be used as an additive only in the final external resin ‘hot coat’. It is provided
premixed in styrene solution at rate of 10%. It shall be added to the resin at the dosage of 3%-
4% w/w.

STEEL COMPONENTS

1. Steel components shall be manufactured strictly in accordance with the requirements

as per Purchaser approved fabrication drawings.
2. Earth grounding lugs shall be fabricated from 316 stainless steel; welds shall be full
penetration. After fabrication all weld splatter shall be removed; welds shall be ground
smooth, corners and all plate edges rounded 3 mm (chamfered edges are
unacceptable). Prior to being incorporated the surfaces to be embedded shall be grit
blasted to ISO 8501-1: Sa 2.5 with a profile height of 50 microns minimum and
immediately primed with Ashland Derakane Momentum 470-300 resin with carbon
powder added.
3. Lifting lugs shall be manufactured from carbon steel A-283 Gr.C or equivalent; welds
shall be full penetration. After fabrication all weld splatter shall be removed, welds

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shall be ground smooth, corners and all plate edges rounded 3 mm minimum
(chamfered edges are unacceptable).
4. Prior to being incorporated all surfaces shall be grit blasted to ISO 8501-1: Sa 2.5
with a profile height of 50 microns minimum.

MANUFACTURE

All the requirements apply for shop and for site manufacturing.

MANUFACTURING METHODS

Manufacture may be done by a combination of filament winding, hand lay-up and contact
molding.

Quantity, type and order of reinforcement and resin layers will be as described in the design
calculation document and Purchaser approved fabrication drawings.

All manufacturing methods shall conform to BS EN 13121.

The instructions in this specification take priority over BS EN 13121 and Purchaser
construction drawings. Prior written approval by Purchaser is required for any deviations from
this specification.

FABRICATION MOLDS

Surfaces of molds shall be clean and free of discontinuities or defects that might cause surface
imperfections on the final product. Mold dimensions shall meet the tolerance requirements
indicated on the construction drawings. A review of all molds shall be a part of the Vendors
ITP with appropriate report forms to be included in the MDR.

LAYERS

CORROSION BARRIER AND INTERNAL CONDUCTIVE LAYER

The internal conductive layer shall be made of carbon veil as clause 6.3.2 above. The corrosion
barrier resin used to saturate the conductive tissue shall be Ashland Derakane Momentum
470-300 and contain 1.5-2% carbon black powder.

This shall be followed by layers of CSM saturated with corrosion barrier resin without additives.

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Carbon Black Powder has tendency to settle in the resin; mixing is required during all working
time.

The corrosion barrier and internal conductive layer shall be allowed to gel and exotherm before
proceeding to the structural layers.

Glass content in the corrosion barrier layers shall be 30%±5% (weight).

CORROSION BARRIER AND INTERNAL NON-CONDUCTIVE LAYER

The internal non-conductive layer shall be made of Synthetic veil Viledon T1773 as clause
6.3.1 above. The corrosion barrier resin used to saturate the veil shall be Ashland Derakane
Momentum 470-300 or Purchaser approved equivalent.

This shall be followed by layers of CSM saturated with corrosion barrier resin without additives.

The corrosion barrier shall be allowed to jell and exotherm before proceeding with the structural
layers.

Glass content in the corrosion barrier layers shall be 30%±5% (weight).

STRUCTURAL LAYER

One grades of resin shall be used for impregnating the glass fibers in the structural layer. The
inner portion shall be laminated with normal Vinyl Ester resin as specified. The outside
structural portion shall be integrated with fire retardant Vinyl Ester resin as specified.

Ashland Derakane Momentum 470-300 without any additives shall be used to saturate the
inner glass laminate.

Resin at the outer 4-5 mm structural layers shall be Ashland Derakane Momentum 510A-40
with addition of antimony trioxide.

With the use of antimony synergists class I Flame Spread may be achieved (according to
ASTM E-84).

Resin mixing is required during working process to prevent settling of the antimony trioxide
powder.

Either of three modes of laminate reinforcement lay-up may comprise the structural layer
following the corrosion barrier as required by the design document and indicated on the
detailed fabrication drawings approved by Purchaser.

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The Vendor shall not substitute between types of reinforcement lay-up indicated in the design
document or detailed fabrication drawing without formal revision of these documents and
approval of Purchaser. All such revisions shall be reviewed by the independent design and
surveillance bodies.

7.3.3.1 Hand Lay-Up Structural Layers

These consist of CSM or alternate layers of CSM and WR as indicated on drawings. CM may
be used as an alternative to the separate CSM/WR layers where indicated in the design
document and detailed fabrication drawings approved by Purchaser. The Vendor shall not
make random substitution with CM.

Glass content in hand layup layers shall be 40%±10% (weight).

7.3.3.2 Filament Wound Structural Layer

This consists of a sequence of layers of machine controlled hoop filament winding and axial
unidirectional fabric where indicated in the design document and detailed fabrication drawings
approved by Purchaser.

The Vendor shall ensure that the glass winding is distributed evenly on the mandrel surface
without voids between roving strands and forms a dense and compact laminate.
Glass and resin weight control shall be performed, monitored and recorded during the winding
operation.

Glass content in filament wound layers shall be 65%±5% (weight).

EXTERNAL TOP COAT LAYER

The resin used to saturate the external top coat layer shall be Ashland Derakane Momentum
510A-40 or Purchaser approved equivalent with the additions listed on 5.3.3 above.

The reinforcement content in this layer shall be 5-10% (weight).

Conductive layer in Corrosion Barrier of mixer tanks, settlers and connecting launder shall
continue in corresponding Top Coat without interruption.

Resin mixing is required during the working process to prevent settling of the antimony trioxide
and carbon powders.

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SECONDARY BONDING AND JOINTS

Laminated secondary bonding for shop and side connection of parts, attachment,
compensation laminate and joints shall be made by hand lay-up. Secondary laminate
reinforcement type, sequence and width shall be determined in the design calculation
documents and indicated on the fabrication drawings. Resin and additives used for joints shall
be same as the joined parts.

Care shall be taken when adjoining conductive layers if any. Conductive laminate shall overlap
conductive laminate by not less than 25 mm.

The entire bonding area shall be ground within 2 hours of lamination. The ground area width
shall be at least 25 mm wider than the lamination width at each location. Surface grinding shall
achieve a roughness of 50 to 75 microns which will be achieved with a fresh, clean 16 to 24
grit sanding disc on a rubber backing pad. ‘Flapper’ sanding discs shall not be used as these
have a tendency to polish the surface. Hard backed sanding discs shall not be used as these
will not follow the surface contour and will produce a series of flats on the surface.

All cut edges shall be resin coated as soon as practical after cutting and prior to laminating.
Edges that will not be laminated over shall be additionally resin coated with resin with the
corresponding additives at the same time as adjacent components. At vessel shell joints
incorporating the special body flanges the resin used to coat the cut and tapered edge of the
flange which exposes the inner conductive surface shall have carbon powder added.
Where there is a break in continuous lamination of more than 48 hours occurs, or 4 hours if
exposed to direct sunlight, the surfaces shall be re-ground to ‘refresh’ before continuing
lamination.

Surfaces shall be cleaned of dust contamination by vacuum, brushing with a clean brush,
wiped with a clean cloth or a combination of these methods. Surfaces shall not be wiped with
acetone and cloth unless it is assured that the cloth is white, pure cotton otherwise
contamination of the surface may result that will adversely affect laminate adhesion.

Gaps in joints shall not exceed 6 mm and shall be filled with a thixotropic paste or putty based
on Ashland Derakane Momentum 470-300 resin. Radius formers for secondary laminate may
also be formed with a thixotropic paste or putty based on Ashland Derakane Momentum 470-
300 resin. If the tangent line length of such radius former is greater than 12 mm the length of
the laminate overlay design shall be increased accordingly to ensure adequate shear length
of overlay. All thixotropic paste or putty shall be allowed to cure hard before being laminated
over.

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These instructions are for all secondary bonds and jointing that shall be performed during shop
and site fabrication.

The Vendor shall not vary the secondary laminate requirements unless authorized in writing
by Purchaser and all such approved variations shall be supported by revised design and
reflected in the as-built drawings.

VESSELS SECONDARY BONDING JOINTS

Vessels secondary bonding of joints shall satisfy the requirements of BS EN 13121 and shall
be performed as indicated on the approved drawings.

Terminations shall be tapered not be steeper than 1:6. Joints shall have an internal CB seal
satisfying the requirements of BS EN 13121 and include a conductive internal surface meeting
the requirements of this specification. All cut edges shall be covered by Viledon T1773 and
resin coated as soon as practical after finishing and prior to lamination.

FLANGED NOZZLES

Nozzles smaller or equal to DN80 shall be braced.

Flanged nozzles shall be gusseted with four flat ribs.

All process connections nozzle flanges are in accordance with ASME 16.5, 150# (outside
diameter and drilling details).

All flanged nozzles shall be constructed with a corrosion barrier and internal conductive liner.
The internal conductive liner shall extend across the flange face, the flange outer edge and
across the flange back face without interruption.

Bolt holes in FRP flanges shall be normally obtained by hand lay-up laminations. The internal
surface of the drilled holes has to be coated using resin with hardener.

The bolt holes of the nozzle and manhole flanges shall be always straddle the main center
lines of the equipment or their parallel lines.

Nozzle attachment requirements and compensation laminate requirements shall be designed

following the requirements of BS EN 13121.

All vessel cut outs for all nozzles shall be retained and marked with its respective number and
equipment identification and stored for tests and inspection.

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Cylindrical flange neck tolerances shall be as indicated on Purchaser data sheet or approved
fabrication drawings.

Flange mold design shall consider the laminate shrinkage (umbrella effect).

For flanged nozzles with blind flanges, gaskets and bolts should be consistent with the piping
class and/or the indication on the data sheet.

BODY AND RECTANGULAR FLANGE MANUFACTURE

Body and Rectangular flanges are important and critical vessel parts. All instructions shown in
this specification shall be followed carefully and be with accordance to BS EN 13121.

Quality assurance shall follow in all steps of fabrication of these flanges.

Any deviations shall be recorded and submitted to Purchaser for approval.

Grinding shall be performed on for all secondary bonding in each fabrication step.

Prepared surfaces for secondary bonding shall be inspected and reported of the appropriate
special flange fabrication inspection form and included in the MDR.

7.3.8.1 Flange Corrosion Barrier, Conductive Inner Surface and Conductive Back face by
HLU

7.3.8.2 Spot Facing for Flange Bolt Washer

The back face of vessel body flanges shall be spot faced for washer at each bolt hole. Spot
face diameter shall be 3 times bolt hole diameter or as shown on drawings, parallel to the flat
flange face. The remaining flange thickness shall be as indicated on drawing. Particular care
shall be taken that the conductive layer on the flange back face is not removed by the spot
facing.

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7.3.8.3 Flange Surface Repair

In case the flange is out of tolerance, flange face and may be machined subject to Purchaser
approval. Care shall be taken to rebuild the conductive surfaces to satisfy this specifications
requirement.

7.3.8.4 Flange Face Tolerances

Flanges tolerance shall conform to BS EN 13121.

7.3.8.5 Flange Assembly on Vessel Mold

The produced finished and inspection approved flange shall be "pulled-on" the vessel mold.
The assembly shall be perpendicular to cylinder axis and the bolt holes shall be aligned with
opposing flanges. For assuring perpendicularity, the distance between the flange face and a
fix point shall be measured during rotation of the mold. The maximum permitted deviation shall
be as stated on the Purchaser data sheet or approved fabrication drawings.

INSPECTION AND TESTING

GENERAL

Vendor shall establish and maintain the quality assurance program in accordance with ISO
9001:2008 or an equivalent applicable standard, which shall be enforced by the qualified
personnel.

Vendor shall submit test procedures at least 6 weeks prior to the commencement of testing
and covering the full extent of testing on the completed assembly. The test procedure shall be
approved by Purchaser prior to the commencement of testing and shall be complete with all
equipment tests and checklists.

Inspection and testing of the complete package shall be carried out in accordance with the
approved Vendor project quality plan and shall comply with the requirements of the applicable
design codes, this specification and the specifications attached to the Material Requisition.

Vendor shall provide all necessary assistance, equipment and utility services necessary to
undertake the tests and shall be responsible for ensuring that all calibration and test equipment
have valid certifications.

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Vendor shall prepare an inspection book that includes all the documentation pertaining to the
supply (as construction drawings, mechanical calculations, material certificates,
nondestructive examination certificates and radiographs, welding procedure specifications,
procedure qualification reports, welder qualifications, calibration test certificates, ex-proof
certificates, Hydraulic/pneumatic test certificates, etc.) and shall be always at disposal of the
inspector who will check and stamp the documents as soon as available after each inspection
and test.

PRE-ASSEMBLING REQUIREMENTS

Mixer Tank, Connecting Launder and Settler shall be pre-assembled at the Manufacturer
workshop. Mixer Tanks, Connecting Launder and Settler (or settler front part with inlet launder)
to be leveled and assembled, supported and fixed in their final position on the flat, hard and
leveled flour or structure according to the assembling drawings provided by Purchaser. The
connecting launders and discharge launders (separated from the Mixer Tanks) to be
connected together and to the settler and, only after this, the discharge launders of Mixer
Tanks will be bonded to Mixer Tanks.

MATERIAL SPECIFICATION

The raw materials shall conform to the requirements of BS EN 13121. All materials should be
supported by its MSDS.

WORKS REQUIREMENTS

Raw materials storage, manufacturing area and condition of laminating shall be according to
BS EN 13121. Curing system has to be checked in accordance with ISO 2535.

Documentation to be prepaid by the Manufacturer – according to BS EN 13121.

Visual and Dimensional Inspection of Parts and the Complete Articles – according to
BS EN 13121-3: 2016 clause 17-4.4 and 17.5-1.

Permissible imperfections in laminates – according BS EN 13121.

Special attention has to be paid to the parts connection.

LIST OF TESTS

 Glass content and Reinforcing Sequence according to EN 13121-3, Annex D.2

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 Unit tensile modulus (based on load carried at 0,25 % strain) according to the test
method given in EN13121-3, Clause D.6
 Ultimate tensile unit strength, according to the test method given in EN13121-3, Clause
D.5
 Inter-laminar shear test (based on max. shear load over a specified shear length),
according to the test method given in EN13121-3, Clause D.7
 Barcol hardness test, according to the test method given in EN13121-3, Clause D.11
 Short term creep test, according to the test method given in EN13121-3, Clause D.10;
 Flexural strength of laminate, according to the test method given in EN13121-3, Clause
D.19

On thick or excessively curved samples flexural test may be an alternative to tensile testing
with the formal approval of the design engineer.

Laminate construction confirmation (sequence, type and number of layers) will be performed
by the test laboratory subsequent to the ignition loss test.

Where the test methods indicated above are not acceptable in the country of vessel installation
or are not practical for other technical reasons then the design engineer shall be responsible
to approve other proposed alternate test methods.

The mechanical test reports shall be reviewed by the design engineer who shall ascertain the
acceptability of the results.

TAGGING AND MARKING

Each item shall have a nameplate complying with BS EN 13121.

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PACKING, MARKING, PREPARATION FOR SHIPMENT

GENERAL

Vendor shall ensure internal protection from moisture and vibration during transportation.
Vendor shall ensure that the package and equipment are adequately protected against
corrosion and mechanical damage during shipment to site and outdoor storage for period up
to 6 months.

PRESERVATION AND PREPARATION FOR TRANSPORTATION

On completion of inspection and tests, equipment shall be thoroughly cleaned and dried
internally and externally. Vendor shall take into consideration the transit route to site and pack
accordingly.

All flanges shall be covered with metal covers and soft rubber gaskets and held by at least four
(4) bolts. Other openings shall be taped closed. Threaded connections shall be capped or
plugged for thread protection. Any external components, which may be subject to damage
during transit and are not easily protected, shall be removed and packed separately to the
package for shipment with all openings capped.

Auxiliary piping connections shall be tabbed or marked for identification in the field.

PACKING

Packing list shall be provided for each container and/or crate indicating package, component,
item identification reference with corresponding identification attached to each component
within the container

Each equipment unit will be provided with BAT sticker

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DOCUMENTATION

The quantities of documents and the schedule for documents delivery shall conform to
the SDDR.

All documentation shall be in the English language with Russian translation where required.

HEALTH, SAFETY AND ENVIRONMENT

SAFETY AND PERSONNEL PROTECTION REQUIREMENT

Consideration of safety and personnel protection shall be given in all aspects of design and
engineering of the equipment.

The Vendor will study and supply all equipment with a risk analysis to ensure conformity to the
Essential Safety Requirements of the applicable European Directives.

Personnel shall be shielded from high temperature surfaces, refer to the relevant insulation
section in this document for further requirements. Personnel protection guards shall be
provided around all exposed, moving components and high-pressure components where
leakage is possible under operating conditions.

Openings (such as inspection doors, cleaning doors or manholes) giving access to the material
flow or equipment internals shall be closed with a positive latching system. Openings which
may expose the operator to risk if opened during operation shall be closed with a system that
requires a tool to open, e.g. bolted.

Where applicable the Vendor shall supply protection from chemical hazard.

ENVIRONMENTAL DATA

Specific attention is brought to the harsh conditions of the environment where the project is
located.

Consideration shall be given to:

 For the storage purposes - Extreme low (-43°C) and high temperatures (41°C)
 Dirty service conditions and the varying maintenance levels.

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Package shall be designed for the operating conditions within the site environment typical of:

 Copper mineral processing, with liquids and slurries chemical having acid nature.

Unless otherwise specified in more equipment specific documents, equipment shall be

designed for indoor installation.

DISCREPANCIES

In the event that there are discrepancies between this specification and the relevant drawings,
the information in the drawings will take precedence.

TRANSPORTATION

Due to limit of transportation by Road, some equipment listed in the requisition

shall be delivered in several parts (pre-fabricated parts).

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APPENDIX A: DEVIATION FORM

The offer will not be taken into consideration if this form is not completed by the SUPPLIER.

“Does the SUPPLIER offer deviate from requisition” YES  NO 

(Check pertinent answer)

List of deviations (exception and addition requested by the SUPPLIER) from Specifications
Standards and/or Drawings

No. Spec. No. Specification SUPPLIER Proposed

and Para. No. Requirement Clarification, Exception & Reason
Deviation

SUPPLIER NAME:

SUPPLIER SIGNATURE:

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APPENDIX B – SUPPLIER DRAWINGS AND DATA REQUIREMENTS

A. This schedule of Drawings and Data Requirements constitutes a part of the Technical
Specification and Purchase Order – the order will not be regarded as complete unless these
requirements are fully met.

B. Drawings and data are to be forwarded to address indicated in special terms and conditions of
purchase

C. Vendors drawings will be reviewed and approved only as to arrangement, conformity to the
specifications and related drawings – approval shall not be construed to relieve or mitigate the
Vendor’s responsibility for accuracy and suitability of materials and/or equipment represented
thereon.

1) Proposal Drawings shall be manufacturer’s standard drawings in sufficient detail to layout

equipment, drives, access for maintenance and operation.

2) Approval Documents shall be complete with equipment number(s) and purchase order
number – approval drawings shall be stamped certified for construction and signed by an
authorised person and must show all information necessary for the design of foundation
and any connections to other equipment.

3) Certified Documents shall be complete with plant item numbers and purchase order
number, stamped certified for construction and signed by an authorized person.

4) Certification warrants delivered equipment shall conform to the final drawings – should
delivered equipment fail to conform, Vendor shall furnish all materials, labour and
equipment required to correct such failures to the satisfaction of the Owner and
Purchaser.

D. Drawing Quality and Type indicated below:

P = Print
E = Electronic
e.g. 3P = Three Prints

E. Drawing Schedule indicated below:

O = Date of Order
A = Date of Approval
T = Date of Test
D = Date of Despatch
e.g. O + 30 = 30 Days after Date of Order

F. Document Language:
All the documents shall be submitted in English
Where Russian translation is required, this refers only for documents submitted as "Certified"
and "Final (As-Built)".
E = English
R = Russian

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After Receipt of Final Order

Final (As
Item With Approval Certified
Description Built)
No. Tender
Qty Qty Qty Lang
& Sched & Sched & Sched
Type Type Type
0 General
2430V Vendor Name Plate E O+30 3P+E D E/R
Drawings
2440V Commissioning 3P+E D-30 E
Instruction and
Procedures
2450V Pricelist of E O+30 3P+E D E
Recommended
Commissioning
Spares
2460V Pricelist of 3P+E D E
Recommended
Spares For 2 Years
2480V Instructions for 3P+E D-30 E
Storage
Hydrostatic Pressure E T-30 3P+E D E
Test Procedure
2750V Material Test 3P+E D-15 E
Certificates
Pressure Test 3P+E T+7 E
Report & Certificate
2890V Vendor E O+15 3P+E D E
Documentation
Register
5810V Manufacturing
and/or Delivery Bar
E O+15 E
Charts/Contract
Schedule
Packing and 3P+E D-30
Shipping List
Manufacturing MONTHLY E
Progress Report
Quality Assurance
6030V Quality System 3P+E D E
Evidence (ISO 9001)
Certificate of 3P+E D E
Compliance
6220V NDE Procedure E O+45 3P+E D E
6310V Project Quality Plan E O+30 3P+E D E
6340V Data Book / QC 3P+E D
Dossier

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After Receipt of Final Order

Final (As
Item With Approval Certified
Description Built)
No. Tender
Qty Qty Qty Lang
& Sched & Sched & Sched
Type Type Type
6780V NDE Reports 3P+E T+7 E
M Mechanical
M530V Equipment Masses E O+30 3P+E D E
M620V Vendor Mechanical E O+30 3P+E D E
Data Sheet

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APPENDIX C – DRAWINGS

 PRIMARY MIXER TANKS

 CONNECTING LAUNDERS
 SETTLERS
 BALANCING LEGS

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