Rubber Lining Procedure
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RUBBER LINING FOR ABRASION AND CORROSION SERVICE
PROJECT
CLIENT
RL-O1 / 02.04.2003/ Issue 1/ Rev 0
2
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Revision :
No.
7 8
Description Contents Introduction Reference Standards Design of Pipes and Structures Lining Materials • •
Technical Data sheet for rubber material Technical Data sheet for Priming and Bonding solution
10 11 12 13 14 15
Rubber Lining – Flow Chart Rubber lining Process Control Operation Manual – Pre Inspection of Lining Components Operation Manual – Lining Material Selection Operation Manual – Surface Preparation Operation Manual – Adhesive Coating Operation Manual – Lining Operation Manual – Curing Operation Manual – Repair of Rubber Linings
16
Operation Manual – Final Inspection and Testing
9
17 18 19
:
1
RUBBER LINING CONTENTS
6
: RL-01/01
Issue
Rubber Products Division
1. 2. 3 4 5
Code
Page
0 :
1 / 1
Doc. Nr.
Rev. Nr
RL-01/01 RL-01/02 RL-01/03 RL-01/04 RL-01/05
0 0 0 0 0
RL-08/01 to 04
0
RL-09/04.01 RL-01/06
0 0
RL 9.5
0
RL 9.6 RL 9.10 RL 9.11 RL 9.12 RL 9.13 RL 9.14
0 0 0 0 0 0
RL 9.15
0
Operation Manual - Handling, Storage, Packaging and Delivery of rubber lined products Quality Plan Rubber Lining Quality Control Formats A. Pre Inspection Report
RL 9.18
0
PL-20-01
0
F-20-01
0
B. Inspection Report - Blasting
F–20-02
0
C. Inspection Report – Adhesive Coating
F-20-03
0
D. Material Inspection Report
F-20-04
0
E. Inspection Report - Lining
F-20-04
0
F. Curing Sheet - Lining
F-20-05
0
G. Final Inspection Report
F-20-06
0
H. Material Test Report
F-28-02
0
Prepared by
Approved by
3 Date :
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Rubber Products Division
: RL-01/01
Issue
:
1
RUBBER LINING Revision : CONTENTS
1.0
Code
Page
0 :
1 / 2
Scope This RL-01 specifies requirements, gives recommendations for the application, qualification testing, production testing, inspection and transportation of rubber lined process equipment, piping and flanges. 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.
2.3
Acceptance of the design of the metal equipment to be lined shall be in accordance with BS 6374: Part 5: Clause 2.2. Areas found otherwise shall be rejected from being lined and proper, corrective actions shall be taken by the client or if approved at our works.
2.4
Acceptance of the fabrication of the metal equipment to be lined shall be in accordance with BS 6374: Part 5: Clause 2.3. Areas found otherwise shall be rejected from being lined and proper, corrective actions shall be taken by the client or if approved at our works.
2.5
Control plan for rubber-lined equipment is as per PL-20-01.
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.
2.7
Material specifications shall be as per RL-01/05.
4
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Code 01/02
: RL-
RUBBER LINING
Issue
:
Rubber Products Division
CONTENTS
Revision : Page
3.0
1 0
:
2 / 2
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.
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
RUBBER LINING FOR CORROSION AND ABRASION SERVICE Rubber Products Division
REFERENCE STANDARDS
Code 01/03
: RL-
Issue
:
Revision : Page
1 0
:
1 / 1
The following Standards, latest editions are normally followed in the execution of the works.
ISO 9002 - 1994
Quality Systems Part 2
ISO 83.060
Methods of testing unvulcanised rubber
ISO 37
Tensile Properties
ISO 48
Rubber Hardness IRHD
ISO 188
Accelerated ageing and heat resistance test
ISO 815
Compression Set
ISO 1431 Part 1
Resistance to Ozone Cracking
ISO 1817
Determination of the effects of liquids
ISO 7619
Rubber – Determination of indentation hardness by means of pocket hardness meters
ASTM 09.01
Annual book of ASTM standards - Rubber, Natural Rubber and Synthetic - General Test Methods; Carbon Black Annual book of ASTM standards - Rubber products, Industrial – Specifications and related test methods ; Gaskets; Tires
ASTM 09.02
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
Rubber Products Division
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Code 01/04
: RL-
RUBBER LINING
Issue
:
DESIGN OF PIPES AND STRUCTURES
Revision : Page
1 0
:
1 / 1
7
Rubber Products Division
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Code 01/05
: RL-
RUBBER LINING
Issue
:
LINING MATERIALS
Revision : Page
1.0
1 0
:
1 / 1
Material Selection Material selection is determined by: • • •
Service condition - Application, Pressure, Temperature, type of medium, medium concentration etc. Manufacturing method. Design.
As per Operation Manual RL 9.6
2.0
Lining Materials 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
RUBBER LINING MATERIAL DATA SHEET POLYMER: NEOPRENE RUBBER SL No
Physical properties
CODE: CR65A Test Method
Units
Specification
-
1.45 – 1.55
1
Specific Gravity
2
Hardness
3
Tensile Strength
ISO 37
Kg/ Cm
4
Elongation at Break
ISO 37
%
5
After ageing properties At 100˚ C for 72 Hrs. Change in Hardness Change in Tensile Change in E.B.
ISO 188
6
Compression Set At 100 ˚C for 24 Hrs.
ISO 815
%
30 Max.
7
Water Absorption At 70 ˚C for 7 days. Change in Volume
ISO 1817
%
5 Max.
8
Spark resistance
Spark Tester
-
No Spark
ISO 7619
SHORE ‘A’
60 – 70
2
Min. 80 Min. 300
± 10 Max. - 20 Max. - 30
General Characteristics:
9
•
Excellent resistance to ageing and weather.
•
Excellent resistance to Ozone.
•
Excellent resistance to Flame.
•
Good resistance to Chemicals.
•
Good resistance to mineral Oils, grease, many refrigerants water and crude oils.
•
Good resistance to erosion at high impingement angles. (Bends, Tees etc.)
Colour
Prepared By:
- Black
Approved By:
Date:
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
13 Issue No: 1
Rev No: 0
Date: 02.04.2003
RL-08-02
RUBBER LINING MATERIAL DATA SHEET POLYMER: NITRILE RUBBER SL No
CODE: NB70A
Physical properties
Test Method
Units
Specification
-
1.25 – 1.35
1
Specific Gravity
2
Hardness
3
Tensile Strength
ISO 37
Kg/ Cm
4
Elongation at Break
ISO 37
%
5
After ageing properties At 100˚ C for 72 Hrs. Change in Hardness Change in Tensile Change in E.B.
ISO 188
6
Compression Set At 100 ˚C for 24 Hrs.
ISO 815
%
30 Max.
7
Oil resistance At 100 ˚C for 7 days in ASTM 3 Oil. Change in Volume
ISO 1817
%
± 5 Max.
8
Spark resistance
Spark Tester
-
No Spark
ISO 7619
SHORE ‘A’
60 – 70
2
Min. 80 Min. 300
± 10 Max. - 20 Max. - 30
General Characteristics :
9
•
Excellent resistance to Chemicals.
•
Excellent resistance to mineral Oils, grease, many refrigerants water and crude oils.
Colour
- Black
Prepared By:
Approved By:
Date:
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 Issue No: 1
Rev No: 0
Date: 02.04.2003
14
RL-08-03
RUBBER LINING MATERIAL DATA SHEET POLYMER: NATURAL RUBBER SL No
Physical properties
CODE: NR70D Test Method
Units
Specification
-
1.20 – 1.30
1
Specific Gravity
2
Hardness
3
Tensile Strength
ISO 37
Kg/ Cm
4
Elongation at Break
ISO 37
%
Min. 300
5
After ageing properties At 100˚ C for 72 Hrs. Change in Hardness Change in Tensile Change in E.B.
ISO 188
Shore ‘A’ % %
± 10 Max. - 20 Max. - 30
6
Compression Set At 100 ˚C for 24 Hrs.
ISO 815
%
30 Max.
7
Oil resistance At 100 ˚C for 7 days in ASTM 3 Oil. Change in Volume
ISO 1817
%
± 5 Max.
8
Spark resistance
Spark Tester
-
No Spark
ISO 7619
SHORE ‘A’
60 – 70
2
Min. 80
General Characteristics:
9
•
Good resistance to Acid.
•
Good resistance to Water.
•
Good resistance to Tear.
Colour
- Black
Prepared By:
Approved By:
Date:
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 Issue No: 1
Rev No: 0
Date: 02.04.2003
15
RL-08-04
RUBBER LINING MATERIAL DATA SHEET POLYMER: EBONITE - NATURAL RUBBER SL No
Physical properties
1
Specific Gravity
2
Hardness
3
Spark resistance
4
Service Temperature
CODE: EB70A
Test Method
ISO 7619
Units
Specification
-
1.50 ± 0.05
SHORE ‘D’
Spark Tester
-
-
-
Min. 60 No Spark - 20 ºC to + 100 ºC
General Characteristics:
5
•
Good resistance to Acid (32 % HCl).
•
Good resistance to Water containing H2S and very high alkalinity.
•
Very good resistance to weather and Ozone.
•
Good resistance to Tear.
Prepared By:
Approved By :
Date :
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. Issue No: 1
Rev No: 0
Date: 02.04.2003
16
Rubber Products Division
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Code 01/06
: RL-
RUBBER LINING
Issue
:
RUBBER LINING PROCESS CONTROL
Revision : Page
1 0
:
1 / 5
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
17
RUBBER LINING FOR CORROSION AND ABRASION SERVICE Rubber Products Division
Code
: RL- 01/06
Issue
:
1
RUBBER LINING Revision : RUBBER LINING PROCESS CONTROL
Page
0 :
2 / 5
LAYING OF RUBBER SHEETS 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
18
Rubber Products Division
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Code 01/06
: RL-
RUBBER LINING
Issue
:
RUBBER LINING PROCESS CONTROL
Revision : Page
1 0
:
3 / 5
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:
19
RL -9.4.1
FLOW CHART – RUBBER LINING RAW MATERIALS
CUSTOMER PROPERTY
PRELIMINARY INSPECTION
MIXING LAB TESTINGG
REMOVAL OF RUBBER
AGEING ROOM
BLASTING
EXTRUDER / CALENDER
ADHESIVE SYSTEM SHEET
LINING
INSPECTION DEFECT OK
REPAIR
CURING
FINAL INSPECTION OK DELIVERY
REPAIR
20
Rubber Products Division
RUBBER LINING FOR CORROSION AND ABRASION SERVICE
Code 01/06
:
RL-
RUBBER LINING
Issue
:
1
RUBBER LINING PROCESS CONTROL
Revision : Page
0 :
4 / 5
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/cm2 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
1.16
Inform QC after finishing for inspection. Responsibility: Operator
1.17
Operators are trained in accordance with the Operation Manual RL 9.12. Responsibility: Foreman
21
Rubber Products Division
OPERATION MANUAL
Code
: RL 9.5
RUBBER LINING
Issue
:
PRE INSPECTION OF LINING COMPONENTS
Revision : Page
1 0
:
1/1
Purpose:
To ensure that components, materials and products given to the company as a part of the job orders is suitable for Rubber Lining.
Scope:
All Rubber Lining Components.
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)
2.
Customer property is identified by marking the customer's name or name code on the product and fixing a tag where marking is not practical. ( L-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.
5.
Any mechanical damage will be rectified after Customer’s approval.
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
Related Documents:
Job Order Card Customer Property Register Pre Inspection Report Customer Property Identification Tag
F-08-04 RG-25-01 F-25-01 L-25-01.
References:
Document Control
QSP 02
Distribution:
FM/ QAM/ PRM/ SI
Prepared by:
Approved By
QA/QC Manager Date:
Executive Director Date:
22
OPERATION MANUAL Rubber Products Division
RUBBER LINING LINING MATERIAL SELECTION
Code
:
Issue
:
Revision : Page
RL 9.6 1 0
:
Purpose:
To ensure that the material selected for the lining is correct and conforms to the specified requirement.
Scope:
All Lining materials.
Responsibility:
FM/ QAM/ SM / LIC
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
2.0
Suitable material will be recommended by QAM/ LIC by analyzing existing rubber Lining.
3.0
The compound to be used is written in the JOC.
Related Documents:
Job Order Card F-08-04
Distribution:
FM/ QAM/ PRM/ SM/ SE / LIC.
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
1
/ 1
23
OPERATION MANUAL
Code 9.10
: RL
RUBBER LINING
Issue
:
Rubber Products Division
SURFACE PREPARATION
Revision : Page
0 :
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
Responsibility:
Production Manager (PRM) / Production Foreman (PF)
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.
7.
Blasting media must be clean, new material or properly separated to remove fines to ensure a proper profile and clean surface.
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. 10. Air used for blowing shall be moist free. Related Document:
Inspection Report - Blasting F – 20 – 02
Distribution:
FM/PRM/PF
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
1
1
/ 1
24
OPERATION MANUAL Rubber Products Division
RUBBER LINING ADHESIVE COATING
Code
: RL 9.11
Issue
:
Revision : Page
1 0
:
1
Purpose:
To ensure that the application of adhesive is appropriate for Lining.
Scope:
This procedures covers the timing and application guidelines for the different coats of the adhesive used.
Reference:
Manufacturer specification and Material Safety Data Sheets.
Responsibility:
Production Manager (PRM) / Production Foreman (PF)/ Liner
Procedure:
1.
The bonding agent as in the JOC is taken from the Store.
2.
Mix thoroughly the contents in the tin before using.
3.
Avoid exposure to sunlight and keep away from sources of ignition.
4.
Before coating metal surface to be cleaned with Solvent.
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.
9.
Coated surface should not be exposed to direct sun light.
Reference:
Inspection Report – Adhesive Coating F – 20 - 03 Material Data sheet.
Distribution:
FM/ PRM / PF
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
OPERATION MANUAL
Code
:
/ 1
RL 9.12
25
RUBBER LINING Rubber Products Division
LINING
Issue
:
Revision : Page
1 0
:
1
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.
Responsibility:
PF/ Liner.
Definitions:
Nil.
Procedure:
1.0 2.0 3.0
4.0 5.0 6.0 7.0
8.0 9.0 10.0
11.0
12.0 13.0
14.0 15.0 16.0 17.0
According to the JOC check whether the rubber sheet material is as per the requirement (compound code, thickness). The Ok sheet is put on the table and care should be taken to avoid any grinding/dusting operations near it. The un-vulcanized sheet is kept for shrinking. Individual sheets shall be tailored to fit the surface to be lined. The edges are prepared as per the joint to be used 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. The sheets are allowed to dry for 10-15 minutes for the solvent to evaporate. 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. 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. Puncture any air blisters that are found with the help of a needle. 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. Rubber panels shall be joined together by making skived lip of approximately 1 to 2 inches. 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. Where ever possible it is to be seen that the over lap joint made is in the direction of the product flow. 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. 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. In case any spark is observed then the area is repaired by filling and again spark tested. All uneven edges and excess rubber shall be trimmed properly.
Related Documents: Inspection Report Lining F – 20 - 04 Distribution:
/ 1
FM/ QAM/ PRM/LIC/ QCO/ PF.
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
26
OPERATION MANUAL Rubber Products Division
RUBBER LINING CURING
Code
:
RL 9.13
Issue
:
1
Revision : Page
Purpose:
To ensure the correct curing methods to achieve consistent quality Lining.
Scope:
All Rubber Lining products.
Responsibility:
FM / QAM / PRM / PF/ Liner.
Definitions:
Nil.
Procedure:
0 :
1
1.
Curing characteristics are decided based on the compounds, type of cure and are written on the JOC.
2.
Refer the JOC for curing conditions.
Related Documents:
Curing Sheet - Lining
F - 20 - 05
Distribution:
FM/ QAM/ PRM/LIC/ QCO/ PF.
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
/ 1
27
OPERATION MANUAL Rubber Products Division
RUBBER LINING REPAIR OF RUBBER LININGS
Code
: RL 9.14
Issue
:
Revision : Page
1 0
:
Purpose:
To ensure that defects observed are rectified in pre and post Vulcanization of rubber Linings.
Scope:
For all defects before and after Vulcanization.
Responsibility:
Quality Assurance Manager (QAM) / Lab in charge (LIC) / Production Foreman (PF) / Operator
Procedure:
1.0 Repair Before Cure: 1.1 Remove the rubber by knife carefully in the defective area. 1.2 Grind defective area if required. 1.3 Clean the surface with Solvent. (Toluene or MEK) 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 unvulcanized rubber. 2.0
Repair After Cure:
Repairs will be done after curing by any one of the methods 2.1. 2.2. 2.3. 2.1
Hot Repair Cold Repair Self Curing Compounds Hot Repair 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, • • •
The Type of Lining Defects Extent of repair
2.1.2
Pinhole repair must be prepared by buffing and grinding. The surface of the rubber adjacent to the repair area to be buffed back for a minimum 2 – 3 inches around the periphery to ensure good bond between the parent and repair material.
2.1.3
Clean the buffing and grinding dust with brush or blow air.
2.1.4
Clean the buffed surface with solvent. (Toluene or MEK)
2.1.5
Apply the bonding agent and rubber solution.
2.1.6
After drying, the to-be-repaired area is lined with un vulcanized rubber sheet.
2.1.7
2.2 Cold Repair:
The repaired area is then vulcanized.
1
/ 1
28
2.3
Reference: Distribution:
3.1.
Remove the lined rubber completely until the visible.
metal surface is
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.
3.4.
Clean the surface using solvent. (Toluene or MEK)
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.
3.10.
The stabilization period for the repair is minimum 12 hours.
Repair with self curing compound: 2.3.1
Remove the lined rubber completely until the visible.
2.3.2
Grind / Buff the metal surface of the rubber Lined product.
2.3.3
Clean the ground surface using Toluene or MEK.
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.
2.3.6
Two stage compounds should be mixed thoroughly in equal quantities before applying.
2.3.7
Allow the repaired area for self-curing for 48 Hrs.
2.3.8
After curing is over, the area to be grinded smoothly and level the repaired area.
Rema Tip Top Manual. FM/SM/PRM/QAM/PF/ Liner
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
metal surface is
29
OPERATION MANUAL RUBBER LINING
Rubber Products Division
FINAL INSPECTION AND TESTING
Code
: RL 9.15
Issue
:
Revision : Page
1 0
:
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.
Responsibility:
QAM / QCO/ LIC / PRM / PF
Definitions:
Nil.
Procedure:
1.0
Visual Inspection:
2.0
On completion of the rubber lining operation, it is visually inspected with special attention to: 1.1 The linings shall be checked against the JOC to see that all areas conform to the requirements. The general appearance of the rubber surface is to be observed. The lining should be checked for wrinkles, blisters, depressions and de-laminations. 1.2 All joints shall be checked for looseness and uniformity. 1.3 Trapped air is detected by holding a light near the surface of the rubber and looking for shadow areas caused by the trapped air forming high spots. All trapped air should be removed before cure and repair to be made. Spark Testing: 2.1
3.0
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. Hardness: 3.1 3.2 3.3 3.4 3.5
Related Documents: Distribution:
Hardness of the rubber after cure is an indication of proper cure. The readings are measured by the Durometer after the item is cooled to the ambient temperature. In case the hardness values are less than the required the item is re-cured to achieve the maximum hardness. The readings of the Durometer are taken by making a firm contact between the Durometer and the rubber surface making sure to record the initial highest reading. Record approximately five readings per 100 square ft. to ensure representative readings.
Final Inspection Report – Lining F-20-06 FM/ QAM/QCO/ LIC / PF
Reviewed By
Approved By
QA/ QC Manager Date:
Executive Director Date:
/ 1
30
OPERATION MANUAL Rubber Products Division
RUBBER LINING HANDLING, STORAGE, PACKING AND DELIVERY
Code
: RL 9.18
Issue
:
Revision : Page
1 0
:
1
Purpose:
To ensure proper handling, shipment and storage of rubber lined items to avoid damage.
Scope:
To protect all the Lined items against damage.
Responsibility:
Production Manger (PRM) /Quality Assurance Manger (QAM) / Stores In charge (SI) / Production Foreman (PF)
Procedure:
/ 1
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.
6.
High local loads on the lined surfaces shall be avoided.
7.
Product delivery is conducted as per delivery procedure.
8.
Loose fittings shall not be placed inside Lined equipment while it is being transported.
9.
Ladders, scaffolding poles are avoided inside the Lined equipment.
Reference: Handling and Preservation of Materials QSP 27 Storage, Dispatch and Delivery QSP 28 Distribution: FM/ SM / QAM / PRM / PF / SI
Prepared By
Approved By
QA/ QC Manager Date:
Executive Director Date:
31
QUALITY PLAN – RUBBER LINING
.4.2
PL-20-01
SL No.
Activity
Responsibility
Machine / Equipment
Ref. Document
Frequency
Quality Records
Location
1
Receiving compounds & Raw materials
Stores in Charge
Fork Lift Hand operated Trolley
QSP 26
-
-
Stores
2
Initial Verification
Stores in Charge
Visual
Delivery Documents
Every Delivery
F-26-01 F-26-02 F-26-05
Stores
3
Initial Inspection and Testing
Lab in Charge
Lab Equipments
Quality Plan
Every Delivery
F-33-01 F-33-02
Lab
4
Storage & Identification
Stores in Charge
Visual
QSP 24
Every Item
-
Stores
5
Issue to production
Stores in Charge/ Product. Foreman
Fork Lift Hand operated Trolley
QSP 26, F-26-05 F-08-03, F-12-02
Every Item
F-12-01
Stores / Production
6
Mixing of Rubber Compounds
Mixing mill Operator
CFC , WI – 20 - 01
100 %
RG–13-01
Mill area
7
Testing of Rubber Compounds
Lab in charge
Lab Equipments
100 %
L–34- 01
LAB
Stores in charge
Fork Lift Hand operated Truck
Delivery Documents
100 %
-
Factory or Site
SI/ PF
Visual
PIR
100 %
F–20- 01
Factory or Site
Operator
Blasting machine
WI – 20 –01, lRB
Random
F–20- 02
Production Area
8 9 10
Receiving of Lining Components Preliminary Inspection of Components Surface preparation and Inspection
16” x12 “ mixing Mill Avery Balance Electronic Balance
11
Adhesive coating
Operator
Brush / Roller
WI-20-02, IRA
-
F–20- 03
Production Area
12
Rubber Lining
Operator
Tools
WI-20-03, IRL
100 %
F–20- 04
Production Area
13
Curing
Moulding operator/ Prod. Foreman
Auto clave
WI-20-04, IRC
Every Item
F -20-05
Production Area
14
Final Inspection
QAM, QAO, LIC, QCI
Hardness meter , Spark tester , Tape, Venier,
QSP 35, IRF
100 %
L -20-06
Inspection Area
16
Delivery
SCPO, PRM
Fork Lift, Manual
F – 08 - 03
All Lined item
F–08 – 05 F– 08 – 06 DN,
Customer
MATERIAL TEST REPORT Customer:
Date:
F-28-02
32 Invoice No:
Job Order No:
LPO No:
Product:
Quantity:
Polymer:
Code:
Lot No:
Reference Standard: SL No 1
Physical properties
Test Method
Condition
Specific Gravity
2
Hardness
3
Tensile Strength
4
Elongation at Break
Units
Specification
Observed Value
Remarks
-
Kg/ Cm2 %
After ageing properties at 5
Change in Hardness Change in T.S. Change in E.B. Compression Set at
6
% Oil resistance at
7
8
Change in Volume Spark resistance
% Spark Tester
Prepared By:
-
Approved By: Date: Lab in Charge
Issue No: 1
QA/ QC Manager
Rev No: 0
Date: 02.04.2003
F-20-01 PRE INSPECTION REPORT (PIR) CUSTOMER NAME : DESCRIPTION OF ITEMS:
DATE: NO. :
33 DO NO. SL NO
INSPECTION AREA
VERIFICATION STATUS
REMARKS
COMMENTS:
INSPECTED BY Issue No: 1
QA/ QC MANAGER Rev No: 0
Date: 02.04.2003
F – 20 - 02 INSPECTION REPORT – BLASTING (IRB) Customer Name :
Date :
Job order No
No. :
:
Job description :
34 Environment SL No.
Atmosphere Temperature ˚C
Time
Work Area Temperature ˚C
Relative Humidity %
Remarks
Surface Blasting SL No.
Time
Total area blasted
Observation
Remarks
Tested By Issue No: 1
Rev No: 0
Date: 02.04.2003
F – 20 - 03 INSPECTION REPORT – ADHESIVE COATING (IRA) Customer Name :
Date :
Job order No
No. :
:
Job description :
Environment
35 SL No.
Atmosphere Temperature ˚C
Time
Work Area Temperature ˚C
Relative Humidity %
Remarks
Adhesive Coating Details SL No.
Time
Type of coat
Total area coated
Observation
Remarks
Tested By Issue No: 1
Rev No: 0
Date: 02.04.2003
F – 20 - 04 INSPECTION REPORT – LINING (IRL) Customer Name :
Date :
Job order No
No. :
:
Job description :
Rubber Sheet Inspection SL
Sheet Thickness
Spark Test
Remarks
36 No.
Required
Observed
Visual Inspection
Kv
Result
Inspection after Lining SL No.
Lining Area
Spark Test
Visual Inspection
kV
Remarks
Result
Tested By Issue No: 1
Rev No: 0
Date: 02.04.2003
F – 20 - 05 CURING SHEET – LINING (CSL) Customer Name :
Date :
Job Order No
No. :
:
Job Description :
Curing Method : Step – 1 Steam Pressure : Step – 2 Steam Pressure :
Time : Time :
37 Steam Opening Time and Date : T Time
SL No.
Steam pressure Set Observed pressure
Temperature
Atmosphere temperature
Tested by
Tested By Issue No: 1
Rev No: 0
Date: 02.04.2003
F – 20 - 06 FINAL INSPECTION REPORT – LINING (FIR) Customer Name
:
Date :
Job order Card No :
No. :
Job description
Hardness SL No.
:
1
2
3
4
5
Remarks
38 Required Observed
SL No.
Description
Specification
1
Visual Inspection
Free from defects
2
Thickness
3
Spark Tester
Observation
Remarks
No spark at ……. Kv
Tested By Issue No: 1
Rev No: 0
Date: 02.04.2003
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