E ItHro{CP.oo EKCP-Rl.-l-REV.

2/

Rubber Lining procedure

DT.7.10.2021

1. SCOPE: This procedure specifies requirements for the lining of equipment for
the roUer; fabricated structural's and steel fabricated equipments
refer annexure A for Horizontal Belt Fitter and annexure B for
Thickener items

2. Storage of tiDing Materials:

• Rubber sheets &: relevant Adhesives shoukt not be exposed to direct

sunUght and the temperature should not exceed 50°F (10°C).

• The materials shall be not be exposed to freezing conditions, heat,

flame, or spark which could damage or catch fire the material.

• The materials should be issued on AFO basis (first in first out,

considering the shelf life).

• Materials shall be transported to and stored at the work area in a

manner to prevent their damage, contamination or access by
unauthorized personnel.

• Rubber linings should never be exposed to direct sunlight or direct

outdoor weathering, for periods longer- than a few days.

• No hot works to be carried out on outside of the rubber lined vessel

which will affect the bonding of the rubber lining.

3. SAFITY PRECAUTIONS

3.1 Fire and explosion hazards. many of the rubber compounding additives
are fire sensitive, pafticutarly:

• Sulphurs and organic peroxides (used as curing agents)

• Azodicarbonamide (used as a btowing agent in some open celled

rubber I lattices )

• The chemical items which are explosive in nature should be stored

separately with sign board and entry to be allowed with permission.

3.2 Mechanical hazanls

Hazard of drawing - in and or crushing between the calendar rolls or

between a calendar roll and material it can be rectified by preventing
access to the trapping zone by means of safeguarding placed at the
entrance of the trapping zone

Page loflO
E IBh'CO- aD Rubber lining procedure
EKCP-Rl.-I-REV.2/ DT.7.10.2021

4. APPLICATION PROCEDURE:

4.1 Welding Requirement: AUsurface area/welded joints prepared for rubber

lining should be free from projections/undercuts/cracks/blow holes. Flush
grinding is required to be done on welded surfaces to be rubber lined.

AU stag, anti-spatter compounds or similar materials shall be removed. All

weld spatters shall be removed by chipping and/or grinding.

Surface defects such as scores, pitting and rolling defects shall be removed
by grinding, or where necessary repaired by welding provided that the
requirements of design and construction are met.

Weld profile details shaU be generaUy in accordance with Fig. 1,2,3 & 4

Fig.1 NOTE - The details shown in (a), (b), (c), (d), (e) and (f) are all permissible,
that shown in (g) is not permissible.

Page 2 of 10
 EKCP-Rl-I-REV.2/ Or.7.10.2021

Rubber Lining procedure

(b) WELD FLAT AND SMOOTH

", , -. "
,,',,-
"

"
.
.'
.
-,
, '
,
-,

FIG. Z WELD PROFILE DETAILS BUTT WELDS

NOTE2 - the details shown in (a), (b), (c), and (d) are all permissible, those shown in (e),
(f), and (g) are not permissible.

Page 3 of 10
 EJOCP-Rl.-I-RfV.2/

Rubber Lining procedure

FIG. 3 WELD PROFILE DETAILS INTERNAL CORNER & EDGES

NOTE- The details shown in (a), (b), (e), and (d) are all permissible, that shown in (e) is
not permissible.

Page 4 of 10
 Rubber Lining procedure

AG. 4 WEill PROAl[ DETAILSCONCAVE HEADS

Page 5 of 10
E 18V((){CP' L1D
EKCP-Rl-I-RfV.2/ DT.7.10.2021

Rubber lining procedure

FIG. 5 TYPiCAl JOINTS IN RUBBER UNINGS

Page 6 of 10
E 1Bt«:Q{CP, DB Rubber Lining procedure
EKCP-RL-l-REV.2/ DT.7.10.2021

4.2 SURFACE PREPARATIONS:

• AUsurface area to be rubber lined will be cleaned with high pressure

fresh water I air.

• AU surface area to be rubber lined will be cleaned from any scale

formation/rust/dust by shot/sand blasting to achieve SA 2 1/2 finish
which plays a vital role in increasing the bond strength of the rubber
sheet to the metat surface.

• The blasted area will be cleaned by high pressure compressed air.

• AU surface area/welded joints prepared for rubber lining will be

checked again for any projections I undercuts I cracksl blow holes.

4.3 MIXING AND CAlENDARING:

• Raw rubber and chemicals wiU be weighed using precision electronic

wejghing scale in appropriate proportions as per our formula.

• The preliminary mixing (compounding) of rubber and chemicals

(excluding the accelerators) will be carried out in an internal
mixture (Kneader Machine) and the compounded rubber will be
stored for a minimum of 12 hours for self settlement.

• The primer mixture will be mixed with accelerator using a mixing

mill and again stored for a minimum of 12 hours for settlement.

• The fully mixed (compounded) rubber sheet will be warmed up in

the open mixing mill and immedIately fed through the three roll
calendar machine and calendered.

• The required thickness of rubber sheet will be calendered and rolled

over a liner (cotton doth/fabric) using a doubling belt of size 1m
width x 10m length.

• Calendered and rolled rubber sheets win be stored in an air

conditioned storage room maintaining a temperature of 10 to 20
degree centigrade.

• Necessary testing of vulcanized rubber sheet as per

drawing/purchase orderr service condTtion of the items will be
carJied out as per is 3400.
! li'CO{CP.l1D Rubber Lining procedure
EKO»-Rl-l-REV.2/ DT.7.10.2021

4.4 LINING OF RUBBER:

Thickness of the lining:

• The rubber lining thickness should selected as per drawing

specifications OR purchase order requirement OR as per the
suitability for service condition.

Climatic Condition for Apptication:

• The rubber lining activity including adhesive appUcation should not

be carried out if the humidity is more than 80%.

2.5.2 Application of Rubber.

• The application of adhesive will be carried out in a dust proof and

controUed temperature area to avoid humidity/high temperature.

• The Excess air humidity will lead to condensation of water particles

on the adhesive surface and excess temperature wilt lead to loose
bonding of rubber sheet on the metal surface.

• The blasted area will be deaned with thinner/Hexane to remove

any fine dirt/dust/oil particles before adhesive application.

• Viscosity of the adhesive wilt be checked using a viscometer

suitable for first, second and third coat application.

• F1rst, second, and third coat of the adhesive will be applied with
proper intervals as per our standards allowing a minimum of 12
hours(during summer) or maximum of 24 hours(during winter)
between each coat depending on the weather condition.

• Calendered and rolled rubbff sheet (Un-cured and with the liner still
fixed to the surface of the sheet) of appropriate thickness will be
spread over a wortdng table.

• The rubber sheet will be checked for surface finish (V or punch

marks)/ sheet air.

• The rubber sheet will be cut forming tapered edges to the required
shape and size using appropriate cutting tool.

• The tapered edges, the surface of the rubber sheet to be fixed onto
the metal surface, and the metal surface will be cleaned using
thinner / Hexane.

• The rut and deaned rubber sheet will be affixed on the surface of
the metal to be rubber lined and then the liner cloth will be
removed.

• The affixed rubber sheet on the metal surface will be rolled and
pressed from the center of the sheet using appropriate pressing
tool to ensure proper removal of air and create perfect bonding
with the metal.
E'DCP.liD
E.KCP-Rl-1-REV.2/ DT.7.10.2021

Rubber Lining procedure

• Points 1 to 6 will be followed to complete aU required surface area

to be rubber lined with proper overlapping joints as per IS 4682 Part
1/B5 6374 Part 5.

• AU flange surfaces wilt be rubber lined at least 1 mm more than the

required thickness as an allowance for machining/sandering after
curing/vulcanizing.

• AU rubber tined area will be checked for airlocks and spark tested
for pin holes.

• The rubber lined items win be left for settlement (at least for 24
hours) and again inspected for any air/gas locks or pinholes before
vulcanizing.

• Rubber lining will be carried out as per IS 4682 Part1

• The details of edge preparation shaLL be as follows: refer: fig 5

a) Overlap scarf jomt - The edges shall be bevelled at 30 to 35°.
0

0
b) Simple scarf joint - The edges shall be bevelled at 40 to 500 .
c) Cover straps - The edges shall be bevelled at ]0 to 35°.
0

3 VULCANIZATION:

• Steam curing/vulcanizing cydes differ from compound to compound

as per our standard.

• Specific graph (Temperature Vs Pressure Vs Time) for

vulcanmng/Curing Cycle of that particular rubber lined items (as
per the service condmon and the rubber compound) will be issued
to the boiler operator.

• Vulcanizing of the rubber lined items wilt be carried out at 0.5 bar -
3 bar pressure and temperature using saturated steam maintaining
a temperature of 8{} to 135 degree centigrade.

• After completion of the cyde, the vessel wiH be brought down to

atmospheric temperature by blowing down steam and pressure.

• The Vessel will be opened only after at least an hour after blow
down.
E IIa) Rubber Uning procedure
EKCP-Rt-l-REV.2/ DT.7.l0.202l

4 INSPECTION:

• The entire rubber lined area for the items will be tested for
hardness, airlock, loose bonding and spark leak,

• For spark testing, the standard high frequency voltage will be

SKV/mm of rubber thickness and for carbon/graphite loaded rubber
compound the spark test voltage wiil be 1.5 to 2 KV/mm of rubber
thickness.

• The entire flange surface will be mad1ioed/sandered (to a

maximum of 1mm thickness) for flatness and aU flange edges witt
be smoothened to avoid sharp edges.

• After compietion of inspection, testing, and finishing, the vessel

will be hydraulic/vacuum tested if required as per
drawing! purchase order I service condition of the items.

• Appropriate exterior blasting and layers of painting (Epoxy primer I

Enamel) will also be carried out if it is spedficaUy required by the
customer as per drawing/purchase order.

• finaUy the vessel will be visuaUy inspected and spark tested before
packing.

• AU the outside exposed/open area like nozzles and manholes will be

covered with soft, rubber I polythene gaskets fitted with
steel/wooden dummies.

• The property pocked rubber lined items of Thickener and HBF

packages will be loaded with due care onto a container/vehicle
without damaging any rubber lined area.

• Inspection, Testing, finishing, handling, and transportation for the

rubber lined items win be carried out as per IS 4682 Part 1 I BS
6374 Part 5.

Prepared by Approved
by

Page 100fl0