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Rubber Lining Proceduredoc PDF Free
Rubber Lining Proceduredoc PDF Free
PROJECT
CLIENT
Code : RL-01/01
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Rubber Issue : 1
Products RUBBER LINING
Division Revision : 0
CONTENTS
Page : 1 / 1
Prepared by Approved by
Date :
3
Code : RL-01/01
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Rubber
Products Issue : 1
Division RUBBER LINING
Revision : 0
CONTENTS
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1.0 Scope
This RL-01 is applicable to vulcanized rubber lined process equipment, piping and
structures.
2.0 Procedure
2.1 Receiving the structure to the rubber lined at our works in Jebel Ali (UAE).
2.2 Inspection of areas to be lined for the suitability and feasibility of carrying out
rubber lining works.
2.6 Upon acceptance of the metal equipment to be lined, all rubber lining procedures,
testing and acceptance, criteria shall be in accordance with related ASTM, BS,
SIS, and etc. reference standard as per Operation Manual RL 9.5.
Code : RL-01/02
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Rubber Issue : 1
Products RUBBER LINING
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CONTENTS
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2.8 The areas to be lined shall be grit blasted to SA 3.0 degree of cleanliness in
accordance with SIS 005 590. Grit blasting of the surfaces shall be carried out as
per Operation Manual RL 9.10.
2.9 The grit blasted areas shall be coated with appropriate primer, elastomer bonding
agent and rubber solutions and then rubber lined as detailed in Operation Manual
RL 9.11 and RL 9.12.
2.10 Rubber lined areas shall be tested and accepted in accordance with BS 903 in our
Operation Manual RL 9.15.
2.11 The rubber-lined equipment shall be collected from our works as detailed in
Operation Manual RL 9.18.
3.0 Distribution
This manual RL-01 is confined to the companies and the contractors and
manufacturers/suppliers nominated by them.
This manual RL-01 is intended for use in oil refineries, chemical plants, desalination
plants, industrial plants etc where applicable.
5
Code : RL-01/03
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Rubber Issue : 1
Products
Division Revision : 0
REFERENCE STANDARDS
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The following Standards, latest editions are normally followed in the execution of the works.
Specific standards related to the rubber compound to be applied are to be followed, wherever
applicable. In addition to the above standards, any other standards specified by the client shall
be obtained and met after review compliance, wherever applicable.
6
Code : RL-01/04
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Rubber Issue : 1
Products RUBBER LINING
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DESIGN OF PIPES AND STRUCTURES
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7
2.1 The rubber material to be used for lining is determined for the specific application
or in accordance with client’s specifications. The client prior to use approves
technical data sheets of the material to be used.
2.2 Appropriate primer material compatible with the rubber material to be used.
2.3 Appropriate elastomer bonding solution compatible with the rubber material and
primer to be used.
2.4 Appropriate rubber solutions compatible with the rubber material, primer and
bonding solution to be used for holding the rubber sheets in position while lining.
8
9
10
11
12
RL-08-01
Water Absorption
7 At 70 ˚C for 7 days. ISO 1817 % 5 Max.
Change in Volume
Good resistance to mineral Oils, grease, many refrigerants water and crude oils.
Colour - Black
The information provided is believed to be accurate but the company disclaims any responsibility for consequences arising from
usage of material, in that the conditions of usage are beyond the company’s control
RL-08-02
2
3 Tensile Strength ISO 37 Kg/ Cm Min. 80
Oil resistance
At 100 ˚C for 7 days in ASTM
7 ISO 1817 % ± 5 Max.
3 Oil.
Change in Volume
General Characteristics :
Colour - Black
The information provided is believed to be accurate but the company disclaims any responsibility for consequences arising from
usage of material, in that the conditions of usage are beyond the company’s control
RL-08-03
14
Oil resistance
At 100 ˚C for 7 days in ASTM
7 ISO 1817 % ± 5 Max.
3 Oil.
Change in Volume
8 Spark resistance Spark Tester - No Spark
General Characteristics:
Colour - Black
The information provided is believed to be accurate but the company disclaims any responsibility for consequences arising from
usage of material, in that the conditions of usage are beyond the company’s control
RL-08-04
RUBBER LINING MATERIAL DATA SHEET
15
The information provided is believed to be accurate but the company disclaims any responsibility for consequences arising from
usage of material, in that the conditions of usage are beyond the company’s control.
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Products RUBBER LINING
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RUBBER LINING PROCESS CONTROL
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RECEIVING INSPECTION
1.1 Based on Operation Manual RL 9.5, Foreman and Stores in Charge to receive
customer supplied products and verify the products for transit damage and
conformance to the specified requirements. J.O. Number shall be marked on
accepted products. Acceptance of the design of the metal equipment to be lined
shall be in accordance with BS 6347: Part V: Clause 2.3. Any minor grinding is to
be done on the customer supplied products against the requirement for lining is
carried out after getting the consent of the customer.
Responsibility: Foreman/ Stores in charge
SURFACE PREPARATION
1.2 Grit blast areas to be rubber lined to SA 3.0. The surface amplitude shall be in the
range of 75 to 100 microns clean blasted areas to remove all dust and foreign
particles by compressed air. Inspection to be carried out in accordance with
Operations Manual RL 9.10. Remove any visible oil or grease prior to blasting.
Responsibility: Operator
1.3 Apply Primer (25 microns minimum) within 4 hours of grit blasting by spraying or
by brush application. Allow primer to dry for 15 to 30 minutes depending on the
weather condition.
Responsibility: Operator.
1.4 Apply cover coat (40 microns minimum) by hand brushing. Allow 30 to 40 minutes
drying time.
Responsibility: Operator
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RUBBER LINING PROCESS CONTROL
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1.5 Based on Operation Manual RL 9.12, Lab in Charge & Foreman will select the
suitable rubber compound required in consultation with FM/ QAM
Responsibility: Lab in Charge/ Foreman
1.6 Foreman will inform the Mill Operator the required weight for mixing. Lab in
Charge will check the physical properties of the compound and give clearance
certificate for further process.
Responsibility: Lab in Charge/ Operator
1.7 Rubber used for lining may be a portion of any final batch or mix of one or more
final batches based on the quantity required to complete on job card. Final lot
numbers and weight consumed shall be indicated on the job card.
Responsibility: Foreman.
1.8 Use the Calendered or Milled sheet for rubber lining and select the type of joint as
indicated below. The Foreman decides this. The rubber thickness is as per the
customer’s specification.
Responsibility: Foreman/ Operator
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Products RUBBER LINING
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RUBBER LINING PROCESS CONTROL
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1.9 Cut the sheets carefully with a knife and place it on a white fabric spread on a
table. Roll the compound strapped in textile in such a way that the compound does
not stick together. Transfer the roll to the desired table for lining.
Responsibility: Operator
1.10 Apply two coats of Rubber Solution by hand brush to ensure proper holding of the
rubber in position. Allow 5 to 15 minutes per coat as drying time depending on
weather conditions.
Responsibility: Operator.
1.11 Apply sheeted uncured rubber by hand application. Stitch properly with special
tools (wheels) to ensure that no air is trapped between the body and the sheets.
Methods of rubber lining flanges can be any one method described below:
RL -9.4.1
19
RAW
CUSTOMER MATERIALS
PROPERTY
INSPECTION
PRELIMINARY MIXING
LAB
TESTING
G
REMOVAL OF
RUBBER AGEING ROOM
BLASTING
EXTRUDER /
CALENDER
ADHESIVE
SYSTEM
SHEET
LINING
INSPECTION
DEFECT
OK REPAIR
CURING
FINAL
INSPECTION REPAIR
OK
DELIVERY
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RUBBER LINING PROCESS CONTROL
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The Foreman according to the nature of the project requirement decides the type.
Linings of pipes are also done by the same method and larger diameter pipe into
which a person can crawl and do the lining. Rubber lining of a small diameter pipe
is done by making a tube and pulling the tube through the pipes using a protective
cloth. Remove the cloth from another end and adhere the rubber tube of the walls
of the pipe either by using compressed air or by using rubber bowls.
Before curing, the Pinholes are detected by the holiday detection (1.5 KV/mm or
as the voltage agreed in the contract and as per the Control Plan as agreed for the
project) are marked and such areas are repaired by filling with rubber. Deflash
excess rubber wherever to be trimmed and wherever detected, loose bonding
shall be stitched properly.
Responsibility: QC Inspector/Operator.
CURING
1.12 Complete rubber lining of the whole structure and carry out the curing process at 0
kg/cm2 pressure for open steam curing and up to 5 kg/cm 2 pressure for autoclave
curing as indicated on the job card. Water curing and chemical curing are also
carried out. The Production Manager decides curing technique for the particular
job.
Responsibility: Operator
1.13 Steam temperature, pressure and curing duration is determined depending on the
size and shape of the product, thickness of lining and recommendations in the Job
Order Card F-08-04 and as per Operation Manual RL 9.13 for determining the
curing time.
1.14 After the minimum stipulated time of curing is completed, stop steam supply and
remove the products.
Responsibility: Operator
1.15 Remove excess rubber, overflows, etc. and repair the areas, if any.
Responsibility: Operator
1.17 Operators are trained in accordance with the Operation Manual RL 9.12.
Responsibility: Foreman
Code : RL 9.5
OPERATION MANUAL
21
Issue : 1
RUBBER LINING
Rubber Revision : 0
Products PRE INSPECTION OF LINING COMPONENTS
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Purpose: To ensure that components, materials and products given to the company as a part of the job
orders is suitable for Rubber Lining.
Responsibility: Factory Manager (FM) / Production Manager (PRM) / Stores In charge (SI) / Production
Foreman (PF)
Definition: Nil.
Procedure: 1. Stores In Charge in co-ordination with PF will check and verify all components and
items on receipt against delivery documents for type, quantity and visually
examines for any damages etc. and enter in the Customer Property Register.
(RG-25-01)
3. Foreman in co ordination with QCO will verify the suitability of the components for
lining
(Pre Inspection Report F-20-01)
4. Any discrepancies are reported to the PRM who will inform the FM / SM for
notifying the customer.
6. The type and quantity of the items received is informed to the SPCO.
7. The components, items and materials are handled using appropriate methods to
avoid damage or lost throughout the production process.
8. Any damage or loss is reported immediately to the FM for notifying the customer
and a note is made on the job order of such damage or loss.
9. Customer drawings and specification sheets are filed in the respective customer files
as described under Control of Documents. QSP 02
OPERATION MANUAL
Code : RL 9.6
22
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Products RUBBER LINING
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LINING MATERIAL SELECTION
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Purpose: To ensure that the material selected for the lining is correct and conforms to the specified
requirement.
Definitions: Nil.
Procedure: 1.0 The material suitable for lining the particular item is identified by the FM/
QAM / SM taking into consideration the,
1.1 Service condition, type of medium and its concentration, temperature of
use etc.
1.2 Lining method.
1.3 Design
Prepared By Approved By
OPERATION MANUAL
Code : RL 9.10
23
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SURFACE PREPARATION
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Purpose: To establish procedures which will generate a steel substrate suitable for lining.
Scope: This procedure will cover preparation and inspection of fabricated components, cleaning
of the steel and blasting for lining
Definition: Blasting - Removal of rust, scale or any foreign material by use of abrasives propelled
through a nozzle.
Procedure: 1. The Welding should be continuous and the steel surface shall be ground such that
there are no sharp corners, to achieve a radius 3 – 5 mm maximum.
2. Any surface defects particularly surface laminations, scars, which are likely to
affect the linings, shall be removed by dressing. All welds are to be inspected
and repaired prior to the blasting.
3. Cuttings / Heat application produces hard zones on the edges of plates, flanges,
grinding is to be done in these areas. i.e. Where normal blasting is insufficient to
obtain the required finish.
4. All welding flux and waste must be removed and welds rounded to obtain a
smooth radius.
5. In case the item has damaged rubber linings the lining is removed first by either
chipping / de-bonding application of heat on the external surface as to de-bond
the rubber inside.
6. All metal surfaces to be blasted shall be free from oil, grease or any other
foreign matters. Cleaning of the surface should be done by washing with a
solvent.
8. The temperature of the substrate shall be minimum 3-5 ˚ C above the dew point
during surface preparation. The relative humidity shall not exceed 85%. This
shall be monitored at the beginning and every four hours during continuous
blasting.
9. After the blasting, the grit particles shall be removed from the steel by brushing
or by blowing compressed air.
Distribution: FM/PRM/PF
Prepared By Approved By
OPERATION MANUAL
Code : RL 9.11
24
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ADHESIVE COATING
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Scope: This procedures covers the timing and application guidelines for the different coats of the
adhesive used.
Procedure: 1. The bonding agent as in the JOC is taken from the Store.
5. Apply primer with out any dilution by brush/ spray / roller to get thin,
uniform coating.
6. The primer coat should be allowed to dry for 30 – 40 minutes before the
final coat.
7. Care should to be taken that all surface / including corners and bolt holes
are fully covered.
8. Apply the final coat with out any dilution, taking care not to over brush.
Prepared By Approved By
OPERATION MANUAL
Code : RL 9.12
Issue : 1
RUBBER LINING
25
Rubber Revision : 0
Products LINING
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Purpose: To establish a procedure for the application of the rubber lining to tanks, pipes and other steel
fabrications.
Scope: The procedure will define the steps involved in the application of the sheet in rubber lining.
Definitions: Nil.
Procedure: 1.0 According to the JOC check whether the rubber sheet material is as per the
requirement (compound code, thickness).
2.0 The Ok sheet is put on the table and care should be taken to avoid any
grinding/dusting operations near it.
3.0 The un-vulcanized sheet is kept for shrinking.
4.0 Individual sheets shall be tailored to fit the surface to be lined. The edges are
prepared as per the joint to be used
5.0 The contacting surface of the lining sheet shall be made tacky by either wiping with
a solvent or the application of a coat of adhesive, the other surface is on the cloth or
plastic film.
6.0 The sheets are allowed to dry for 10-15 minutes for the solvent to evaporate.
7.0 The tailored sheet is then taken carefully and positioned on the cemented metal and
rolled with a stitcher and the cloth or the plastic film is removed gently. After the
sheet is partially tacked in the place it should be rolled with a steady, firm over
lapping stroke. The rolling or stitching should start at the center of the sheet and
worked towards the edges.
8.0 It is essential that the rubber lining be rolled tightly against the metal surface to
remove any trapped air and assure a complete contact between rubber and the metal.
9.0 Puncture any air blisters that are found with the help of a needle.
10.0 Stretching or applying tension to rubber sheets is to be avoided. Special care is to be
given to avoid stretching in corners of right angled junctions. Use a proper shape
piece as a stock that can be filled in sharp inside corners where stretching is a
concern.
11.0 Rubber panels shall be joined together by making skived lip of approximately 1 to 2
inches.
12.0 The edge of the underlying panel is up skived at a slope of 45 ˚ and the over lapping
panel is down skived at the same slope.
13.0 Where ever possible it is to be seen that the over lap joint made is in the direction of
the product flow.
14.0 For lining nozzles and pipes a tube of the rubber is made and inserted through the
pipe or nozzle and is stitched to remove trapped air.
15.0 At the end of the application of the rubber sheets a spark test is carried out at all
places to ensure that the un vulcanized lining has no blisters or loose bonding.
16.0 In case any spark is observed then the area is repaired by filling and again spark
tested.
17.0 All uneven edges and excess rubber shall be trimmed properly.
Related Documents: Inspection Report Lining F – 20 - 04
Prepared By Approved By
OPERATION MANUAL
Code : RL 9.13
26
Rubber Issue : 1
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CURING
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Purpose: To ensure the correct curing methods to achieve consistent quality Lining.
Definitions: Nil.
Procedure: 1. Curing characteristics are decided based on the compounds, type of cure and are
written on the JOC.
Prepared By Approved By
OPERATION MANUAL
Code : RL 9.14
27
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Products RUBBER LINING
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REPAIR OF RUBBER LININGS
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Purpose: To ensure that defects observed are rectified in pre and post Vulcanization of rubber
Linings.
1.4 Apply adhesive and rubber solution on the area to be repaired and allow it to dry.
1.5 After drying, the to-be-repaired area is lined using the same quality of un-
vulcanized rubber.
2.1.1 The repair areas vary from small blister or cracks to major failure in
numerous rubber sheets. The methods of repair are dictated by,
2.1.3 Clean the buffing and grinding dust with brush or blow air.
3.1. Remove the lined rubber completely until the metal surface is
visible.
28
3.2. Prepare the vulcanized sheet. The vulcanized rubber quality should be
same as the parent rubber.
3.3. Grind / Buff the metal surface of the rubber Lined product and
vulcanized sheet to the size of repair area.
3.5. Apply one coat of metal primer on the metal surface and allow it for
drying.
3.6. Mix 40 grams (4%) of hardener (UTR 20) with 1 Kg. of cold bonding
agent (SC 2000) and stir well until a homogeneous mixture is
obtained.
3.7. Apply two even and thin coats of hardener mixed bonding agent on the
metal surface and vulcanized rubber sheet.
3.8. Allow the first coat to dry completely (at least 30 min.). Let the second
coat dry until it is slightly tacky. (Check with the back of finger). In
case of over drying, apply another coat.
3.9. Put the bonding surfaces on one another, avoiding air entrapment.
Stitch vigorously or press firmly.
2.3.1 Remove the lined rubber completely until the metal surface is visible.
2.3.2 Grind / Buff the metal surface of the rubber Lined product.
2.3.4 Apply one coat of repair solution over the ground area.
2.3.5 Fill the self curing compound by using the hand extruder or manually.
2.3.8 After curing is over, the area to be grinded smoothly and level the
repaired area.
Prepared By Approved By
OPERATION MANUAL
Code : RL 9.15
29
Issue : 1
RUBBER LINING
Rubber Revision : 0
Products FINAL INSPECTION AND TESTING
Division Page : 1 / 1
Purpose: To ensure thorough inspection of Rubber Lining to avoid even a minor defect in the lining.
Scope: The inspection practices of visual examination, spark testing for both before and after
vulcanization and hardness check.
Definitions: Nil.
2.1 Before and after the rubber lining is cured, it must be tested with a spark
tester to determine the presence of pin hole leaks, punctures, cuts etc. and
are to be repaired.
2.2 All surfaces must be free of moisture, dirt, grit or foreign matter at the
time of testing.
2.3 No curing is done until the complete lining is inspected and repairs made
are re-inspected and found O.K.
3.0 Hardness:
Reviewed By Approved By
OPERATION MANUAL
Code : RL 9.18
30
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Division Revision : 0
HANDLING, STORAGE, PACKING AND DELIVERY
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Purpose: To ensure proper handling, shipment and storage of rubber lined items to avoid damage.
Procedure: 1. All vessels / items are to be lifted by Lifting equipment like Fork Lift, over
head crane etc to prevent damage to the exterior of the items.
2. Lined equipment shall not be stored directly under sunlight. Tarpaulin/ thick
fabric can be used to cover the rubber lined products.
3. Lined product should not be stored near sources of Ozone generation such as
Welding machines and electric generators.
4. All branches, manholes, Pipe ends and other shall be protected from
mechanical damage by using wooden blanks, plastics, plain rubber Sheets or
other suitable materials.
5. Care should be taken to avoid lifting of vessels/ items so that chains and other
lifting aids do not come in to contact with lined surfaces.
8. Loose fittings shall not be placed inside Lined equipment while it is being
transported.
Prepared By Approved By
Hardness meter ,
Inspection
14 Final Inspection QAM, QAO, LIC, QCI Spark tester , Tape, QSP 35, IRF 100 % L -20-06
Area
Venier,
F–08 – 05
16 Delivery SCPO, PRM Fork Lift, Manual F – 08 - 03 All Lined item F– 08 – 06 Customer
DN,
32
Product: Quantity:
Reference Standard:
SL Test Observed
Physical properties Condition Units Specification Remarks
No Method Value
1 Specific Gravity -
2 Hardness
4 Elongation at Break %
After ageing properties at
5 Change in Hardness
Change in T.S.
Change in E.B.
Compression Set at
6 %
Oil resistance at
7
Change in Volume %
Spark
8 Spark resistance -
Tester
The information provided is believed to be accurate but the company disclaims any responsibility for consequences arising
from usage of material, in that the conditions of usage are beyond the company’s control
F-20-01
CUSTOMER NAME :
DESCRIPTION OF ITEMS:
DO NO.
SL VERIFICATION
INSPECTION AREA REMARKS
NO STATUS
COMMENTS:
F – 20 - 02
INSPECTION REPORT – BLASTING (IRB)
Environment
Atmosphere Work Area Relative
SL
Time Temperature Temperature Humidity Remarks
No.
˚C ˚C %
Surface Blasting
SL
Time Total area blasted Observation
No. Remarks
Tested By
F – 20 - 03
INSPECTION REPORT – ADHESIVE COATING (IRA)
Environment
Atmosphere Work Area Relative
SL
Time Temperature Temperature Humidity Remarks
No.
˚C ˚C %
Tested By
F – 20 - 04
INSPECTION REPORT – LINING (IRL)
37
Tested By
F – 20 - 05
CURING SHEET – LINING (CSL)
38
Curing Method :
Step – 1 Steam Pressure : Time :
Step – 2 Steam Pressure : Time :
Tested By
F – 20 - 06
FINAL INSPECTION REPORT – LINING (FIR)
Hardness
SL
1 2 3 4 5 Remarks
No.
Required
Observed
SL
Description Specification Observation Remarks
No.
Free from
1 Visual Inspection
defects
2 Thickness
No spark
3 Spark Tester
at ……. Kv
Tested By