Rubber Lining Procedure

8/2/2019 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


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RUBBER LINING FOR CORROSION AND ABRASION SERVICECode : RL-01/01

Issue : 1

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RUBBER LINING

CONTENTS

No. Description Doc. Nr. Rev. Nr

1. Contents RL-01/01 02. Introduction RL-01/02 03 Reference Standards RL-01/03 04 Design of Pipes and Structures RL-01/04 05 Lining Materials RL-01/05 0

6 Technical Data sheet for rubber material Technical Data sheet for Priming and Bonding

solutionRL-08/01 to 04 0

7 Rubber Lining Flow Chart RL-09/04.01 08 Rubber lining Process Control RL-01/06 0

9 Operation Manual Pre Inspection of LiningComponents RL 9.5 0

10 Operation Manual Lining Material Selection RL 9.6 011 Operation Manual Surface Preparation RL 9.10 0

12 Operation Manual Adhesive Coating RL 9.11 013 Operation Manual Lining RL 9.12 014 Operation Manual Curing RL 9.13 015 Operation Manual Repair of Rubber Linings RL 9.14 0

16 Operation Manual Final Inspection and Testing RL 9.15 0

17 Operation Manual - Handling, Storage, Packagingand Delivery of rubber lined products RL 9.18 0

18 Quality Plan Rubber Lining PL-20-01 019 Quality Control Formats

A. Pre Inspection Report F-20-01 0

B. Inspection Report - Blasting F20-02 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

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RUBBER LINING

CONTENTS

1.0 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 andstructures.

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 outrubber lining works.

2.3 Acceptance of the design of the metal equipment to be lined shall be inaccordance with BS 6374: Part 5: Clause 2.2. Areas found otherwise shall berejected from being lined and proper, corrective actions shall be taken by the clientor if approved at our works.

2.4 Acceptance of the fabrication of the metal equipment to be lined shall be inaccordance with BS 6374: Part 5: Clause 2.3. Areas found otherwise shall berejected 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.

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RUBBER LINING

CONTENTS

2.8 The areas to be lined shall be grit blasted to SA 3.0 degree of cleanliness inaccordance with SIS 005 590. Grit blasting of the surfaces shall be carried out asper Operation Manual RL 9.10.

2.9 The grit blasted areas shall be coated with appropriate primer, elastomer bondingagent and rubber solutions and then rubber lined as detailed in Operation ManualRL 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 inOperation Manual RL 9.18.

3.0 DistributionThis manual RL-01 is confined to the companies and the contractors andmanufacturers/suppliers nominated by them.

This manual RL-01 is intended for use in oil refineries, chemical plants, desalinationplants, industrial plants etc where applicable.

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RUBBER LINING FOR CORROSION AND ABRASION SERVICE

Code : RL-01/03

Issue : 1

Revision : 0

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REFERENCE STANDARDS

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 shallbe obtained and met after review compliance, wherever applicable.

5

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 bymeans of pocket hardness meters

ASTM 09.01 Annual book of ASTM standards - Rubber, Natural

Rubber and Synthetic - General Test Methods; Carbon Black ASTM 09.02 Annual book of ASTM standards - Rubber products, Industrial

Specifications and related test methods ; Gaskets; Tires


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RUBBER LINING

DESIGN OF PIPES AND STRUCTURES

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RUBBER LINING

LINING MATERIALS

1.0 Material Selection

Material selection is determined by:

Service condition - Application, Pressure, Temperature, type of medium, mediumconcentration 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 applicationor in accordance with clients specifications. The client prior to use approvestechnical 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 andprimer to be used.

2.4 Appropriate rubber solutions compatible with the rubber material, primer andbonding solution to be used for holding the rubber sheets in position while lining.

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RUBBER LINING MATERIAL DATA SHEET

POLYMER: NEOPRENE RUBBER CODE: CR65A

SL No Physical properties Test Method Units Specification

1 Specific Gravity - 1.45 1.552 Hardness ISO 7619 SHORE A 60 703 Tensile Strength ISO 37 Kg/ Cm 2 Min. 804 Elongation at Break ISO 37 % Min. 300

5

After ageing propertiesAt 100 C for 72 Hrs.Change in HardnessChange in TensileChange in E.B.

ISO 188 10Max. - 20Max. - 30

6 Compression Set

At 100 C for 24 Hrs.ISO 815 % 30 Max.

7Water AbsorptionAt 70 C for 7 days.Change in Volume

ISO 1817 % 5 Max.

8 Spark resistance Spark Tester - No Spark

9

General Characteristics:

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 - Black

Prepared By: Approved By: Date:

The information provided is believed to be accurate but the company disclaims any responsibility for consequences arising fromusage of material, in that the conditions of usage are beyond the companys control

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RL-08-01RL-08-01


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Issue No: 1 Rev No: 0 Date: 02.04.2003


POLYMER: NITRILE RUBBER CODE: NB70A


1 Specific Gravity - 1.25 1.35

2 Hardness ISO 7619 SHORE A 60 70

3 Tensile Strength ISO 37 Kg/ Cm2

Min. 80

4 Elongation at Break ISO 37 % Min. 300

5


ISO 188 10Max. - 20Max. - 30

6 Compression SetAt 100 C for 24 Hrs. ISO 815 % 30 Max.

7Oil resistanceAt 100 C for 7 days in ASTM3 Oil.Change in Volume

ISO 1817 % 5 Max.


9

General Characteristics :

Excellent resistance to Chemicals.

Excellent resistance to mineral Oils, grease, many refrigerants water and crude oils.

Colour - Black

Prepared By:

Approved By: Date:



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RL-08-02RL-08-02


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POLYMER: NATURAL RUBBER CODE: NR70D


1 Specific Gravity - 1.20 1.302 Hardness ISO 7619 SHORE A 60 703 Tensile Strength ISO 37 Kg/ Cm 2 Min. 804 Elongation at Break ISO 37 % Min. 300

5


ISO 188 Shore A %%

10Max. - 20Max. - 30

6 Compression SetAt 100 C for 24 Hrs. ISO 815 % 30 Max.

7Oil resistanceAt 100 C for 7 days in ASTM3 Oil.

Change in Volume

ISO 1817 % 5 Max.


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Good resistance to Acid.

Good resistance to Water.

Good resistance to Tear.

Colour - Black

Prepared By:

Approved By: Date:



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RL-08-03RL-08-03


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POLYMER: EBONITE - NATURAL RUBBER CODE: EB70A


1 Specific Gravity - 1.50 0.05

2 Hardness ISO 7619 SHORE D Min. 60


4 Service Temperature - - - 20 C to + 100 C

5


Good resistance to Acid (32 % HCl).

Good resistance to Water containing H 2S 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 fromusage of material, in that the conditions of usage are beyond the companys control .


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RL-08-04RL-08-04


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RUBBER LINING

RUBBER LINING PROCESS CONTROL

RECEIVING INSPECTION

1.1 Based on Operation Manual RL 9.5 , Foreman and Stores in Charge to receivecustomer supplied products and verify the products for transit damage andconformance to the specified requirements. J.O. Number shall be marked onaccepted products. Acceptance of the design of the metal equipment to be linedshall be in accordance with BS 6347: Part V: Clause 2.3. Any minor grinding is tobe done on the customer supplied products against the requirement for lining iscarried 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 therange 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 withOperations 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 theweather condition.Responsibility: Operator .

1.4 Apply cover coat (40 microns minimum) by hand brushing. Allow 30 to 40 minutesdrying time.

Responsibility: Operator

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RUBBER LINING


LAYING OF RUBBER SHEETS

1.5 Based on Operation Manual RL 9.12, Lab in Charge & Foreman will select thesuitable rubber compound required in consultation with FM/ QAMResponsibility: Lab in Charge/ Foreman

1.6 Foreman will inform the Mill Operator the required weight for mixing. Lab inCharge will check the physical properties of the compound and give clearancecertificate 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 morefinal batches based on the quantity required to complete on job card. Final lotnumbers 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 asindicated below. The Foreman decides this. The rubber thickness is as per thecustomers specification.Responsibility: Foreman/ Operator

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RUBBER LINING


1.9 Cut the sheets carefully with a knife and place it on a white fabric spread on atable. Roll the compound strapped in textile in such a way that the compound doesnot 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 therubber in position. Allow 5 to 15 minutes per coat as drying time depending onweather conditions.Responsibility: Operator .

1.11 Apply sheeted uncured rubber by hand application. Stitch properly with specialtools (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:

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RL -9.4.1 FLOW CHART RUBBER LINING

DEFECTOK

OK

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CUSTOMER PROPERTY

P R E L I M I N A R Y

I N S P E C T I O N

REMOVAL OFRUBBER

BLASTING

ADHESIVESYSTEM

LINING

INSPECTION

CURING

FINALINSPECTION

MIXING

AGEING ROOM

EXTRUDER /CALENDER

SHEET

RAWMATERIALS

LABTESTINGG

REPAIR

DELIVERY

REPAIR


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RUBBER LINING


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 intowhich a person can crawl and do the lining. Rubber lining of a small diameter pipeis done by making a tube and pulling the tube through the pipes using a protectivecloth. Remove the cloth from another end and adhere the rubber tube of the wallsof 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 theproject) are marked and such areas are repaired by filling with rubber. Deflashexcess rubber wherever to be trimmed and wherever detected, loose bondingshall be stitched properly.Responsibility: QC Inspector/Operator.

CURING

1.12 Complete rubber lining of the whole structure and carry out the curing process at 0kg/cm 2 pressure for open steam curing and up to 5 kg/cm 2 pressure for autoclavecuring as indicated on the job card. Water curing and chemical curing are alsocarried 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 thesize and shape of the product, thickness of lining and recommendations in the JobOrder Card F-08-04 and as per Operation Manual RL 9.13 for determining thecuring time.

1.14 After the minimum stipulated time of curing is completed, stop steam supply andremove 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

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OPERATION MANUAL Code : RL 9.5Issue : 1

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RUBBER LINING

PRE INSPECTION OF LINING COMPONENTS

Purpose:

Scope:

Responsibility:

Definition:

Procedure:

Related Documents:

References:

Distribution:

To ensure that components, materials and products given to the company as a part of the joborders is suitable for Rubber Lining.

All Rubber Lining Components.

Factory Manager (FM) / Production Manager (PRM) / Stores In charge (SI) / ProductionForeman (PF)

Nil.

1. Stores In Charge in co-ordination with PF will check and verify all components anditems on receipt against delivery documents for type, quantity and visuallyexamines 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 Customers 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 toavoid 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 filesas described under Control of Documents. QSP 02

Job Order Card F-08-04Customer Property Register RG-25-01Pre Inspection Report F-25-01Customer Property Identification Tag L-25-01.

Document Control QSP 02

FM/ QAM/ PRM/ SI

Prepared by:

QA/QC Manager Date:

Approved By

Executive Director Date:

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RUBBER LINING

LINING MATERIAL SELECTION

Prepared By

QA/ QC ManagerDate:

Approved By

Executive DirectorDate:

Purpose:

Scope:

Responsibility:

Definitions:

Procedure:

Related Documents:

Distribution:

To ensure that the material selected for the lining is correct and conforms to the specifiedrequirement.

All Lining materials.

FM/ QAM/ SM / LIC

Nil.

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 existingrubber Lining.

3.0 The compound to be used is written in the JOC.

Job Order Card F-08-04

FM/ QAM/ PRM/ SM/ SE / LIC.

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OPERATION MANUAL Code : RL9.10Issue : 1

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RUBBER LINING

SURFACE PREPARATION

Purpose:

Scope:

Responsibility:

Definition:

Procedure:

Related Document:

Distribution:

To establish procedures which will generate a steel substrate suitable for lining.

This procedure will cover preparation and inspection of fabricated components, cleaningof the steel and blasting for lining

Production Manager (PRM) / Production Foreman (PF)

Blasting - Removal of rust, scale or any foreign material by use of abrasives propelledthrough a nozzle.

1. The Welding should be continuous and the steel surface shall be ground such thatthere are no sharp corners, to achieve a radius 3 5 mm maximum.

2. Any surface defects particularly surface laminations, scars, which are likely toaffect the linings, shall be removed by dressing. All welds are to be inspectedand 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 insufficientto obtain the required finish.

4. All welding flux and waste must be removed and welds rounded to obtain asmooth 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-bondthe 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 asolvent.

7. Blasting media must be clean, new material or properly separated to removefines to ensure a proper profile and clean surface.

8. The temperature of the substrate shall be minimum 3-5 C above the dew pointduring surface preparation. The relative humidity shall not exceed 85%. Thisshall 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 brushingor by blowing compressed air.

10. Air used for blowing shall be moist free.

Inspection Report - Blasting F 20 02

FM/PRM/PF

Prepared By

QA/ QC Manager Date:

Approved By


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RUBBER LINING

ADHESIVE COATING

Purpose:

Scope:

Reference:

Responsibility:

Procedure:

Reference:

Distribution:

To ensure that the application of adhesive is appropriate for Lining. This procedures covers the timing and application guidelines for the different coats of theadhesive used.

Manufacturer specification and Material Safety Data Sheets.

Production Manager (PRM) / Production Foreman (PF)/ Liner

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 thefinal coat.

7. Care should to be taken that all surface / including corners and bolt holesare 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.

Inspection Report Adhesive Coating F 20 - 03Material Data sheet.

FM/ PRM / PF

Prepared By


Approved By


OPERATION MANUAL Code : RL 9.12

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RUBBER LINING

LINING

Purpose:

Scope:

Responsibility:

Definitions:

Procedure:

Related Documents:

Distribution:

To establish a procedure for the application of the rubber lining to tanks, pipes and other steelfabrications.

The procedure will define the steps involved in the application of the sheet in rubber lining.

PF/ Liner.

Nil.

1.0 According to the JOC check whether the rubber sheet material is as per therequirement (compound code, thickness).

2.0 The Ok sheet is put on the table and care should be taken to avoid anygrinding/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 used5.0 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 thesheet 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 andworked towards the edges.

8.0 It is essential that the rubber lining be rolled tightly against the metal surface toremove 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 aconcern.

11.0 Rubber panels shall be joined together by making skived lip of approximately 1 to 2inches.

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.

Inspection Report Lining F 20 - 04

FM/ QAM/ PRM/LIC/ QCO/ PF.

Prepared By


Approved By


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RUBBER LINING

CURING

Purpose:

Scope:

Responsibility:

Definitions:

Procedure:

Related Documents:

Distribution:

To ensure the correct curing methods to achieve consistent quality Lining.

All Rubber Lining products.

FM / QAM / PRM / PF/ Liner.

Nil.

1. Curing characteristics are decided based on the compounds, type of cure and arewritten on the JOC.

2. Refer the JOC for curing conditions.

Curing Sheet - Lining F - 20 - 05

FM/ QAM/ PRM/LIC/ QCO/ PF.

Prepared By


Approved By


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RUBBER LINING

REPAIR OF RUBBER LININGS

Purpose:

Scope:

Responsibility:

Procedure:

To ensure that defects observed are rectified in pre and post Vulcanization of rubber Linings. For all defects before and after Vulcanization.

Quality Assurance Manager (QAM) / Lab in charge (LIC) / Production Foreman (PF) /Operator

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 un-vulcanized rubber.

2.0 Repair After Cure:

Repairs will be done after curing by any one of the methods

2.1. Hot Repair 2.2. Cold Repair 2.3. Self Curing Compounds

2.1 Hot Repair

2.1.1 The repair areas vary from small blister or cracks to major failure innumerous 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. Thesurface 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 vulcanizedrubber sheet.

2.1.7 The repaired area is then vulcanized.

2.2 Cold Repair:

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Reference:

Distribution:

3.1. Remove the lined rubber completely until the metal surface isvisible.

3.2. Prepare the vulcanized sheet. The vulcanized rubber quality should besame 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 bondingagent (SC 2000) and stir well until a homogeneous mixture isobtained.

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 secondcoat dry until it is slightly tacky. (Check with the back of finger). Incase 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.

2.3 Repair with self curing compound:

2.3.1 Remove the lined rubber completely until the metal surface isvisible.

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 therepaired area.

Rema Tip Top Manual.

FM/SM/PRM/Q AM/PF/ Liner

Prepared By


Approved By


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RUBBER LINING

FINAL INSPECTION AND TESTING

Purpose:

Scope:

Responsibility:

Definitions:

Procedure:

Related Documents:

Distribution:

To ensure thorough inspection of Rubber Lining to avoid even a minor defect in the lining.

The inspection practices of visual examination, spark testing for both before and after vulcanization and hardness check.

QAM / QCO/ LIC / PRM / PF

Nil.

1.0 Visual Inspection :

On completion of the rubber lining operation, it is visually inspected with specialattention 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 beobserved. The lining should be checked for wrinkles, blisters, depressionsand 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 highspots. All trapped air should be removed before cure and repair to bemade.

2.0 Spark Testing:

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. andare to be repaired.

2.2 All surfaces must be free of moisture, dirt, grit or foreign matter at thetime of testing.

2.3 No curing is done until the complete lining is inspected and repairs madeare re-inspected and found O.K.

3.0 Hardness:

3.1 Hardness of the rubber after cure is an indication of proper cure.3.2 The readings are measured by the Durometer after the item is cooled to

the ambient temperature.3.3 In case the hardness values are less than the required the item is re-cured

to achieve the maximum hardness.3.4 The readings of the Durometer are taken by making a firm contact between the Durometer and the rubber surface making sure to record theinitial highest reading.

3.5 Record approximately five readings per 100 square ft. to ensurerepresentative readings.

Final Inspection Report Lining F-20-06

FM/ QAM/QCO/ LIC / PF

Reviewed By


Approved By


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Rubber

ProductsDivision


Revision : 0

Page : 1 / 1

RUBBER LINING

HANDLING, STORAGE, PACKING AND DELIVERY

Purpose:

Scope:

Responsibility:

Procedure:

Reference:

Distribution:

To ensure proper handling, shipment and storage of rubber lined items to avoid damage. To protect all the Lined items against damage.

Production Manger (PRM) /Quality Assurance Manger (QAM) /Stores In charge (SI) / Production Foreman (PF)

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 asWelding machines and electric generators.

4. All branches, manholes, Pipe ends and other shall be protected frommechanical 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 beingtransported.

9. Ladders, scaffolding poles are avoided inside the Lined equipment.

Handling and Preservation of Materials QSP 27Storage, Dispatch and Delivery QSP 28

FM/ SM / QAM / PRM / PF / SI

Prepared By


Approved By


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.4.2 QUALITY PLAN RUBBER LINING PL-20-01SLNo. Activity Responsibility

Machine /Equipment

Ref.Document Frequency

QualityRecords Location

1Receiving

compounds& Raw materials

Stores in ChargeFork Lift

Hand operated Trolley

QSP 26 - - Stores

2 Initial Verification Stores in Charge Visual DeliveryDocuments Every DeliveryF-26-01F-26-02F-26-05

Stores

3 Initial Inspectionand Testing Lab in Charge Lab Equipments Quality Plan Every DeliveryF-33-01F-33-02 Lab

4 Storage &Identification Stores in Charge Visual QSP 24 Every Item - Stores

5 Issue toproductionStores in Charge/Product. Foreman

Fork LiftHand operated

Trolley

QSP 26, F-26-05F-08-03, F-12-02 Every Item F-12-01

Stores /Production

6 Mixing of RubberCompounds Mixing mill Operator

16 x12 mixingMill

Avery BalanceElectronic Balance

CFC , WI 20 - 01 100 % RG13-01 Mill area

7 Testing of RubberCompounds Lab in charge Lab Equipments 100 % L34- 01 LAB

8Receiving of

LiningComponents

Stores in chargeFork Lift

Hand operated Truck

DeliveryDocuments 100 % -

Factory orSite

9Preliminary

Inspection of Components

SI/ PF Visual PIR 100 % F20- 01 Factory orSite

10Surface

preparation andInspection

Operator Blasting machine WI 20 01, lRB Random F20- 02 ProductionArea

11 Adhesive coating Operator Brush / Roller WI-20-02, IRA - F20- 03 ProductionArea

12 Rubber Lining Operator Tools WI-20-03, IRL 100 % F20- 04 ProductionArea

13 Curing Moulding operator/Prod. Foreman Auto clave WI-20-04, IRC Every Item F -20-05Production

Area

14 Final Inspection QAM, QAO, LIC, QCIHardness meter ,

Spark tester , Tape,Venier,

QSP 35, IRF 100 % L -20-06 InspectionArea

16 Delivery SCPO, PRM Fork Lift, Manual F 08 - 03 All Lined itemF08 05F 08 06

DN,Customer

MATERIAL TEST REPORT

Customer: Date:

31

F-28-02


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Invoice No: Job Order No: LPO No:

Product: Quantity:

Polymer: Code: Lot No:

Reference Standard:

F-20-01

PRE INSPECTION REPORT (PIR) DATE:NO. :

CUSTOMER NAME :

DESCRIPTION OF ITEMS:

SL No Physical properties

TestMethod Condition Units Specification

ObservedValue

Remarks

1 Specific Gravity -

2 Hardness

3 Tensile Strength Kg/ Cm 2

4 Elongation at Break %

5

After ageing properties at

Change in HardnessChange in T.S.Change in E.B.

6Compression Set at

%

7Oil resistance at

Change in Volume %

8 Spark resistance Spark Tester -

Prepared By:

Lab in Charge

Approved By:



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DO NO.

SLNO INSPECTION AREA

VERIFICATIONSTATUS REMARKS

COMMENTS:

INSPECTED BY QA/ QC MANAGER


F 20 - 02

INSPECTION REPORT BLASTING (IRB)

Customer Name : Date :

Job order No : No. :Job description :

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Environment

SLNo. Time

AtmosphereTemperature

C

Work AreaTemperature

C

RelativeHumidity

%Remarks

Surface Blasting

SLNo. Time Total area blasted Observation Remarks

Tested By


F 20 - 03

INSPECTION REPORT ADHESIVE COATING (IRA)


Job order No : No. :

Job description :

Environment

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SLNo. Time

AtmosphereTemperature

C

Work AreaTemperature

C

RelativeHumidity

%Remarks

Adhesive Coating DetailsSLNo. Time Type of coat

Total areacoated Observation Remarks

Tested By


F 20 - 04

INSPECTION REPORT LINING (IRL)


Job order No : No. :

Job description :

Rubber Sheet Inspection

SL Sheet Thickness Spark Test Remarks

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No. VisualInspectionRequired Observed Kv Result

Inspection after Lining

SLNo. Lining Area Visual Inspection

Spark TestRemarks

kV Result

Tested By


F 20 - 05

CURING SHEET LINING (CSL)


Job Order No : No. :

Job Description :

Curing Method :Step 1 Steam Pressure : Time :Step 2 Steam Pressure : Time :

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Steam Opening Time and Date :

SL No. T TimeSteam pressure

Temperature Atmospheretemperature Tested bySetpressure Observed

Tested By


F 20 - 06FINAL INSPECTION REPORT LINING (FIR)


Job order Card No : No. :

Job description :

HardnessSLNo. 1 2 3 4 5 Remarks

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Required

Observed

SLNo. Description Specification Observation Remarks

1 Visual Inspection Free fromdefects

2 Thickness

3 Spark Tester No spark at . Kv

Tested By


38