ASTM D5364-93(2002)

Standard Guide for Design, Fabrication, and Erection of Fiberglass Reinforced Plastic Chimney Liners with Coal-Fired Units

SIGNIFICANCE AND USE
This guide provides information and recommendations for design professionals, fabricators, installers and end-users of FRP chimney liners. FRP is a cost-effective and appropriate material of construction for liners operating at moderate temperatures in a corrosive chemical environment.
This guide provides uniformity and consistency to the design, fabrication, and erection of fiberglass-reinforced plastic (FRP) liners for concrete chimneys with coal-fired units. Other fossil fuels will require a thorough review of the operating and service conditions and the impact on material selection.
This guide is limited specifically to FRP liners within a supporting concrete shell and is not applicable to other FRP cylindrical structures.
SCOPE
1.1 This guide offers direction and guidance to the user concerning available techniques and methods for design, material selection, fabrication, erection, quality assurance, and control.
1.2 These minimum guidelines, when properly used and implemented, can help ensure a safe and reliable structure for the industry.
1.3 This guide offers minimum requirements for the proper design of a FRP liner once the service conditions relative to thermal, chemical, and erosive environments are defined. Due to the variability in liner height, diameter, and the environment, each liner must be designed and detailed individually.
1.4 Selection of the necessary resins and reinforcements, composition of the laminate, and proper testing methods are offered.
1.5 Once the material is selected and the liner designed, procedures for proper fabrication of the liner are developed.
1.6 Field erection, sequence of construction, proper field-joint preparation, and alignment are reviewed.
1.7 Quality-assurance and quality-control procedures are developed for the design, fabrication, and erection phases. The quality-assurance program defines the proper authority and responsibility, control of material and fabrication, inspection procedures, tolerances, and conformity to standards. The quality-control procedures provide the steps required to implement the quality-assurance program.
1.8 Appendix X1 includes research and development subjects to further support recommendations of this guide.
1.9 Disclaimer—The reader is cautioned that independent professional judgment must be exercised when data or recommendations set forth in this guide are applied. The publication of the material contained herein is not intended as a representation or warranty on the part of ASTM that this information is suitable for general or particular use, or freedom from infringement of any patent or patents. Anyone making use of this information assumes all liability arising from such use. The design of structures is within the scope of expertise of a licensed architect, structural engineer, or other licensed professional for the application of principles to a particular structure. There is no similar or equivalent ISO standard.
1.10 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

General Information

• Status: Historical
• Publication Date: 09-Nov-2002
• ICS: 83.140.99 - Other rubber and plastics products
• Technical Committee: D20 - Plastics
• Drafting Committee: D20.23 - Reinforced Thermosetting Resin Piping Systems and Chemical Equipment

Relations

• Replaces: ASTM D5364-93e1 - Standard Guide for Design, Fabrication, and Erection of Fiberglass Reinforced Plastic Chimney Liners with Coal-Fired Units
• Effective Date: 10-Nov-2002
• Replaced By: ASTM D5364-08 - Standard Guide for Design, Fabrication, and Erection of Fiberglass Reinforced Plastic Chimney Liners with Coal-Fired Units
• Effective Date: 01-Nov-2008

Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
An American National Standard
Designation: D 5364 – 93 (Reapproved 2002)
Standard Guide for
Design, Fabrication, and Erection of Fiberglass Reinforced
Plastic Chimney Liners with Coal-Fired Units
This standard is issued under the fixed designation D 5364; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
INTRODUCTION
Federal and state environmental regulations have imposed strict requirements to clean the gases
leaving a chimney.These regulations have resulted in taller chimneys (600–1000 ft (183–305 m)) and
lower gas temperatures (120–200°F (49–93°C)) due to the use of scrubbers. These regulations led to
the development of fiber reinforced plastics (FRP) chimney liners in the 1970’s.
Fiberglass-reinforced plastic liners have proven their capability to resist corrosion and carry loads
over long periods of time. Successful service has been demonstrated in the utility and general-process
industries for over 40 years. Appendix X4 is a partial listing of FRP-liner heights and diameters
currently in the generating industry.The taller FRPstructures and larger diameters (10–30 ft (3–9 m))
imposed new design, fabrication, and erection challenges.
Autility-industry survey of FRPliners was conducted in 1983 (4). This survey summarized the 19
FRP liners constructed in the power-utility industry; including Owner/A-E/Contractor, overall
configuration, fuel type, and specific operating experience.
The design, fabrication, and erection of FRP liners involves disciplines which must address the
specific characteristics of the material. Areas that have been shown to be of importance include the
following:
(1) Flue-gascharacteristicssuchaschemicalcomposition,waterandaciddewpoints,operatingand
excursion temperature, velocity, etc.
(2) Plant operation as it relates to variations in the flue-gas characteristics.
(3) Material selection and laminate design.
(4) Quality control throughout the design, fabrication, and erection process to ensure the integrity
of the corrosion barrier and the structural laminate.
(5) Secondary bounding of attachments, appurtenances, and joints.
(6) Installation and handling.
Chimney components include an outer shell, an inner liner, breeching ductwork, and miscellaneous
platforms,elevators,ladders,andmiscellaneouscomponents.Theshellprovidesstructuralintegrityto
environmentalforcessuchaswind,earthquake,ambienttemperatures,andsupportsthelinerorliners.
The liner or liners inside the shell protects the shell from the thermal, chemical, and abrasive
environment of the hot boiler gases (120–560°F (49–293°C)). These liners have been made of FRP,
acid-resistant brick, carbon steel, stainless steel, high-alloy steel, shotcrete-coated steel, and
shotcrete-coated shells. The selection of the material type depends on the chemical composition and
temperature of the flue gas, liner height, diameter, and seismic zone. Also, variations in flue-gas
characteristics and durations of transients affect material selection and design.
1. Scope
1.1 This guide offers direction and guidance to the user
This guide is under the jurisdiction of ASTM Committee D20 on Plastics and
concerning available techniques and methods for design, ma-
is the direct responsibility of Subcommittee D20.23 on Reinforced Plastic Piping
terial selection, fabrication, erection, quality assurance, and
Systems and Chemical Equipment.
Current edition approved Nov. 10, 2002. Published March 2003. Originally control.
approved in 1993. Last previous edition approved in 1993 as D5364–93.
The boldface numbers in parenthesis refer to the list of references at he end of
this guide.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
D 5364 – 93 (2002)
1.2 These minimum guidelines, when properly used and
Static Electricity Build-Up 5.8
Flame Spread 5.9
implemented, can help ensure a safe and reliable structure for
Materials 6
the industry.
Raw Materials 6.1
1.3 This guide offers minimum requirements for the proper
Laminate Composition 6.2
Laminate Properties 6.3
design of a FRP liner once the service conditions relative to
Design 7
thermal, chemical, and erosive environments are defined. Due
Design 7.1
tothevariabilityinlinerheight,diameter,andtheenvironment,
Assumptions 7.2
Dead Loads 7.3
each liner must be designed and detailed individually.
Wind Loads 7.4
1.4 Selection of the necessary resins and reinforcements,
Earthquake Loads 7.5
composition of the laminate, and proper testing methods are Thermal Loads 7.6
Circumferential Pressure Loads 7.7
offered.
Load Factors 7.8
1.5 Once the material is selected and the liner designed,
Resistance Factors 7.9
procedures for proper fabrication of the liner are developed. Loading Combinations 7.10
Allowable Longitudinal Stresses 7.11
1.6 Field erection, sequence of construction, proper field-
Allowable Circumferential Stresses 7.12
joint preparation, and alignment are reviewed.
Design Limits 7.13
1.7 Quality-assurance and quality-control procedures are
Tolerances 7.14
Deflections 7.15
developed for the design, fabrication, and erection phases.The
Critical Deign Considerations and Details 7.16
quality-assurance program defines the proper authority and
Fabrication 8
responsibility, control of material and fabrication, inspection Fabrication 8.1
Reponsibility of Fabricator 8.2
procedures, tolerances, and conformity to standards. The
Fabrication Facility 8.3
quality-control procedures provide the steps required to imple-
General Construction 8.4
ment the quality-assurance program. Fabrication Equipment 8.5
Resin Systems 8.6
1.8 Appendix X1 includes research and development sub-
Reinforcement 8.7
jects to further support recommendations of this guide.
Fabrication Procedures 8.8
Handling and Transportation 8.9
1.9 Disclaimer—The reader is cautioned that independent
Erection Appurtenances 8.10
professional judgment must be exercised when data or recom-
Tolerances 8.11
mendations set forth in this guide are applied. The publication
Erection of FRP Liners 9
of the material contained herein is not intended as a represen- Erection Scheme and Sequence 9.1
Handling and Storage on Site 9.2
tation or warranty on the part ofASTM that this information is
Erection Appurtenances 9.3
suitableforgeneralorparticularuse,orfreedomfrominfringe-
Field Joints 9.4
Quality Assurance and Quality Control 10
ment of any patent or patents. Anyone making use of this
Quality Assurance and Quality Control 10.1
information assumes all liability arising from such use. The
Quality-Assurance Program 10.2
design of structures is within the scope of expertise of a
Quality-Assurance Surveillance 10.3
Inspections 10.4
licensed architect, structural engineer, or other licensed profes-
Submittals 10.5
sional for the application of principles to a particular structure.
Operation Maintenance and Start-Up Procedures 11
Initial Start-Up 11.1
NOTE 1—There is no similar or equivalent ISO standard.
Operation and Maintenance 11.2
Annex A.
1.10 This standard does not purport to address all of the
Typical Inspection Checklist A1.
safety concerns, if any, associated with its use. It is the
Appendixes X.
responsibility of the user of this standard to establish appro- Commentary X1.
Further Research and Development X2.
priate safety and health practices and determine the applica-
Sample Design Calculations X3.
bility of regulatory limitations prior to use.
FRP Chimney Liners in the Power-Generation Industry X4.
Section Steady-State Temperature Distribution in Liner X5.
References
Introduction and Background
Scope and Objective 1
Referenced Documents 2
2. Referenced Documents
ASTM Standards 2.1
ACI Standard 2.2 2.1 ASTM Standards:
NFPA Standard 2.3
C518 Test Method for Steady-State Thermal Transmission
ASME Standards 2.4
Properties by Means of the Heat Flow Meter Apparatus
Terminology 3
ASTM Standard General Definitions 3.1
C581 Practice for Determining Chemical Resistance of
Applicable Definitions 3.2
Thermosetting Resins Used in Glass-Fiber-Reinforced
Descriptions of Terms Specific to This Standard 3.3
Structures, Intended for Liquid Service
Symbols 3.4
Significance and Use 4 C582 Specification for Contact-Molded Reinforced, Ther-
Service and Operating Environments 5
mosettingPlastic(RTP)LaminatesforCorrosionResistant
Service Conditions 5.1
Equipment
Environmental Severity 5.2
Chemical Environment 5.3
Erosion/Abrasion Environment 5.4
Operating Temperature Environment 5.5
Abnormal Environments 5.6 3
Annual Book of ASTM Standards, Vol 04.06.
Other Operating and Service Environments 5.7 4
Annual Book of ASTM Standards, Vol 08.04.
D 5364 – 93 (2002)
D638 Test Method for Tensile Properties of Plastics 3.5 Barcol hardness—measurementofthedegreeofcureby
D648 Test Method for Deflection Temperatures of Plastics means of resin hardness. The Barcol impressor is the instru-
Under Flexural Load in the Edgewise Position ment used (see Test Method D2583).
D695 Test Method for Compressive Properties of Rigid
3.6 binder—chemical treatment applied to the random ar-
Plastics
rangement of glass fibers to give integrity to mats. Specific
D790 TestMethodsforFlexuralPropertiesofUnreinforced
binders are utilized to promote chemical compatibility with
and Reinforced Plastics and Electrical Insulating Materi-
various laminating resins used.
als
3.7 blister—Refer to Terminology D883.
D792 TestMethodsforDensityandSpecificGravity(Rela-
3.8 bonding—joining of two or more parts by adhesive
tive Density) of Plastics by Displacement
forces.
D883 Terminology Relating to Plastics
3.9 bond strength—force per unit area (psi) necessary to
D2393 Test Method for Viscosity of Epoxy Resins and
rupture a bond in interlaminar shear.
Related Components
3.10 buckling—a mode of failure characterized by an un-
D2583 Test Method for Indentation Hardness of Rigid
stable lateral deflection due to compressive action on the
Plastics by Means of a Barcol Impressor
structural element involved.
D2584 Test Method for Ignition Loss of Cured Reinforced
3.11 burned areas—areas of laminate showing evidence of
Resins
decomposition (for example, discoloration and cracking) due
D 3299 Specification for Filament-Wound Glass-Fiber-
to excessive resin exotherm.
Reinforced Thermoset Resin Corrosion-Resistant Tanks
3.12 burn out (burn off)—thermal decomposition of the
D4398 Test Method for Determining the Chemical Resis-
organicmaterials(resinandbinders)fromalaminatespecimen
tance of Fiberglass Reinforced Thermosetting Resins By
in order to determine the weight percent and lamination
One-Side Panel Exposure
sequence of the glass reinforcement.
E84 Test Method for Surface Burning Characteristics of
8 3.13 catalyst—anorganicperoxidematerialusedtoactivate
Building Materials
the polymerization of the resin.
E228 Test Method for Linear Thermal Expansion of Solid
3.14 chopped-strand mat—reinforcement made from ran-
Materials With a Vitreous Silica Dilatometer
domly oriented glass strands that are held together in a mat
2.2 American Concrete Institute (ACI) Standard:
form by means of a binder.
ACI Standard307 Specification for the Design and Con-
3.15 chopper gun—a machine used to cut continuous fiber-
struction of Reinforced Concrete Chimneys
glass roving to predetermined lengths (usually ⁄2 –2 in.)
2.3 NFPA Standard:
(13–51 mm) and propel the cut strands to the mold surface. In
NFPA77 Recommended Practice on Static Electricity
the spray-up process, a catalyzed resin is deposited simulta-
2.4 ASME Boiler and Pressure Vessel Code:
neously on the mold.When interspersed layers are provided in
Fiberglass Reinforced Plastic Pressure Vessels
filament winding, the resin spray is not used.
2.5 ANSI Standard:
ASME/ANSI RTP-Reinforced Plastic Corrosion Resistant 3.16 contact molding—processformoldingreinforcedplas-
Equipment tics in which reinforcement and resin are placed on an open
mold or mandrel. Cure is without application of pressure;
3. Terminology
includes both hand-lay-up and spray-up.
3.1 Definitions: 3.17 corrosion barrier—the integral inner barrier of the
3.1.1 Terms used in this guide are from Terminology D883 laminate which is made from resin, veil, and chopped mat.
unless otherwise indicated in 3.2.
3.18 coverage—see winding cycle.
3.2 The following applicable definitions in this guide are
3.19 crazing—the formation of tiny hairline cracks in vary-
provided for reference:
ing degrees throughout the resin matrix, particularly in resin-
3.3 accelerator—a material added to the resin to increase
rich areas.
the rate of polymerization (curing).
3.20 cut edge—endofalaminateresultingfromcuttingthat
3.4 axial—in the direction of the axis (lengthwise center-
is not protected by a corrosion barrier.
line) of the equipment.
3.21 delamination—physical separation or loss of bond
between laminate plies.
3.22 dry spot—an area where the reinforcement fibers have
Annual Book of ASTM Standards, Vol 08.01.
not been sufficiently wetted with resin.
Discontinued. See 1994 Annual Book of ASTM Standards , Vol 08.02.
3.23 edge sealing—application of reinforcement and resin,
Annual Book of ASTM Standards, Vol 08.02.
Annual Book of ASTM Standards, Vol 04.07.
or resin alone, to seal cut edges and provide a corrosion-
Annual Book of ASTM Standards, Vol 14.02.
resistant barrier. The final layer should be paraffinated.
AnnualACITechnical Committee Manual publication.Available fromAmeri-
3.24 entrapped-air void—see void.
can Concrete Institute, P.O. Box 9094, Farmington Hills, MI 48333.
Available from NFPA, 1 Batterymarch Park, Quincy, MA 02269.
3.25 environment—stateofthesurroundingsincontactwith
Available from American Society of Mechanical Engineers, New York, NY,
the internal and external surfaces, including the temperature,
1989, pp. 187–202.
pressure,chemicalexposure,relativehumidity,andpresenceof
Available from American Society of Mechanical Engineers, New York, NY,
1989, Subpart 3B and pp. 111–135. liquids or gases.
D 5364 – 93 (2002)
3.26 exotherm—evolution of heat by the resin during the 3.48 hoop winding—filament winding where the winding
polymerization reaction. angle is essentially 90°. The winding strands are applied
immediately adjacent to the strands applied on the previous
3.27 exotherm ply—that ply of chopped mat at which the
mandrel revolution.
lamination process is stopped to allow gelation and exotherm
3.49 intersperse—chopped fiberglass used in a filament-
of the existing la
...