YY Saas _ JOB SPECIFICATION FOR RUBBER LINING FOR INTERNAL PROTECTION OF CS TANKS, PIPING, VALVES, FITTINGS AND CS EQUIPMENT IN DM WATER PLANT r SMMS DEPARTMENT PROJECT : BRAHMAPUTRA PETROCHEMICAL COMPLEX OWNER : BRAHMAPUTRA CRACKER AND POLYMER LTD. PMC : ENGINEERS INDIA LTD. o JOBNO. : 6907J08 SPECIFICATION FoR RUBBER stern LING FOR INTERNAL PROTECTION OF EMERSON WUNGFOR INTERNAL PROTECTION OF oor geez Koo ‘AND CS EQUIPMENT IN DM WATER Revo PLANT, BCPL roeees ‘SMMS DEPARTMENT CONTENTS 1.0 GENERAL 2.0 REFERENCE DOCUMENTS 3.0. TERMINOLOGY 4.0 SURFACE PREPARATION 5.0 MATERIALS 60 METHOD OF LINING 7.0 ‘THICKNESS REQUIREMENT 8.0 INSPECTION 9.0 POST LINING INSPECTION 10.0 REPAIR OF LINING 11.0 SAFTEY REQUIREMENT Format No. 6-00-0001-F1 Rev. 0 ‘All ighis reserved10 20 30 40 50 JOB SPECIFICATION FOR RUBBER SECTION LINING FOR INTERNAL PROTECTION OF (CS TANKS, PIPING, VALVES, FITTINGS _ 6907-0642-RL-K09 AND CS EQUIPMENT IN DM WATER Rev.0 PLANT, BCPL ‘SMS DEPARTMENT. eee GENERAL This specification defines the surface preparation, selection and application of Rubber lining, inspection and testing for the intemal surfaces of carbon stel tanks, piping, fittings and CS equipment filters in DM water plant, Brahmaputra Petrochemical Complex Project, BCPL. The contractor is totally responsible forall the materials application, quality requirements and performance gurantee for rubber lining job being carried out by him as per the scope of work of contract. REFERENCE DOCUMENTS: 1, 18:4682 (Part-1)-1994 Indian standard: Code of practice for lining of vessels and equipment for chemical process. Part-I Rubber lining. 2. 18:3400 (Part I1)-1995: Methods of test for vuleanized rubber: Hardness test 3. Surface preparation standard: SIS-05-5900 Swedish standard/ISO-8501-1988, 4, 18:3400 (Part 1)-1987: Test method for Tensile strength and Elongation of break of vulcanized rubber sheets. 5. ASTM D 2240.97 Durometer Hardness for Rubber & Rubber products TERMINOLOGY 3.1 VULCANIZATION A process in which rubber, through a change in its chemical structure, is converted to ‘ condition in which the elastomeric state exists over a greater range of temperature: in some ceases the process is extended so that the substance becomes rigid, 3.2. EBONITE: The vulcanization process for EBONITE shall be done in an Autoclave of a lining ‘manufacturer in their shop to obtain the shore-D hardness of 70-80D for pipe sections, valves and fittings. ‘SURFACE PREPARATION ‘The surface to be lined should be the roughly cleaned either by sweating with steam or solvent. The cleaned surface is grt-blasted to remove rust and scale and to prepare the surface for lining. After blasting, the surface is inspected and any grit, metallic particles or dust remaining is removed. ‘The surface preparation should conform to Sa2 1/2 of Swedish standard SIS-05-5900/1SO-8501 (latest edition), MATERIALS, 5.1 Natural Rubber sheets for tank lining and Dual media filter ‘The rubber sheets for lining shall be made of excellent quality natural rubber, as. per general guidelines given in IS 5424-(Latest edition) and having the following physical and chemical properties. The natural rubber shall have chemical resistance to immersion £ Hydsochlasic acid, Juding Denineralised Water and most aliphatic Format No. 8-00-0001-F1 Rev. 0 ‘Copyright Ell Al gh reservedseasrecremouronmuesen ——_ascnon undib ee apanae ron nuneER, EMEES ORD WINGFORITERNAL PROTECTION poor g647.-K09 ‘AND CS EQUIPMENT IN DM WATER, Revo PLANT, BCPL a 'SMMS DEPARTMENT. panne carboxylic acids. The natural rubber shall be suitable for use in the continuous immersion ‘temperature of 0 deg.C to 65 deg. C. for an intended service of storage tanks, pipes and fittings. The first layer natural rubber lining shall have a shore-A Durometer hardness of, 30-40A and second and third layers of natural rubber lining shall have a shore-A Durometer hardness of 55-65A minimum after vulcanization and the same shall be verified in the field on vulcanized sample sheet in addition to test given in 6.2 5.2 EBONITE: FOR PIPE SECTIONS, VALVES AND FITTINGS Ebonite shall be made from natural rubber or styrene butadiene rubber or nitrite rubber in incorporating sufficient sulphur to saturate substantially the sites available for cross Hany Hokie sal be allo be as Sra De, bbe 70-80 shore D. Physical properties for natural rubber sheets and Ebonite. The material shall be free from blisters, pin holes, cracks, embedded foreign matters and other defects which may impair its serviceability when visually examined. ‘Tensile strength: Approx.50 kgflsq.cm. min, THoupetorat sak sppron 190% ini fo natural bbe. Approx 10% for ebonite. impression st: shall not exceed 10%, naam AGEING PROPERTIES(for both Natural Rubber sheets and Ebonite) The tensile strength and clongation at break of the test samples, when subjected to ageing for 7 days at 65 deg. C + 1 deg. C shall not exceed the following limits of the corresponding values obtained before ageing. Percentage from the permissible original value Tensile strength +10/-25 Elongation at break +10/-25, * 5.5: WATER ABSORPTION bots Naural Rubber sets an Bone) Shall not absorb water more than Smg/sq. em. 56 CHEMICAL RESISTANCE(for both Natural Rubber sheets and Ebonite) The lining shall be resistant to immersion test of concentrate HCI acid, DM. waterand for the recommended service product. Testing shall be done as per ASTM D 471 5.7 TEST METHODS (for both Natural Rubber sheets and Ebonite) 5.1.1 Tensile strength and as per IS-3400(Part-1)-(latest edition) elongation at break 5.7.2 Ageing at 70 1 deg.C as per IS-3400(Part-IV)-(latest edition) Format No, 6-00-0001-F1 Rev. 0 Capyight BIL — Aight reserved| , JOB SPECIFICATION FOR RUBBER SECTION LINING FOR INTERNAL PROTECTION OF eSB ORM) UNE NTE TESTERS sur. co ‘AND CS EQUIPMENT IN DM WATER Revo PLANT, BCPL f 'SMMS DEPARTMENT eee 5.7.3 Compression set at 27 + 2 deg. C as per IS-3400(Part-X)-latest edition) 5.7.4 Chemical Analysis ‘as per ASTM D297-93 of rubber products 5.15 WATER ABSORPTION TEST (for both Natural Rubber sheets and Ebonite) Weigh a test piece, 2 cm square, with clean cut edges ond immerse in DM, water a temp. of 27 + 2 Deg. C for 168 hrs. Remove and dry quickly with blotting paper and roweigh ina sintered weighing bottle. Express the increase in weight as mg/square em, of the pieve(total surface.) 5.8 The manufacturers shall submit test certificate from competent authority on the characteristics of the materials supplied. In addition manufacture’ test certificate for the batches of materials supplied shall also be submitted alongwith materials, o 60 METHOD OF LINING 6.1 LINING AFTER SURFACE PREPARATION 6.1.1 The adhesives are applied immediately as an even coating, the solvent being allowed to evaporate. 6.1.2 The pre-vuleanized Rubber sheet, preshrink where is hand-tailored to fit and surface to be lined, the side of the sheet which will be in contact with adhesive is wiped with a rubber solvent to clean its surface and to increase its tack. 6.1.3 As soon as the solvent has evaporated and while the Rubber sheet still retains its surface tack, the Rubber sheet is applied to the metal, Care is necessary in positioning the Rubber sheets accurately. (One method of achieving this involves the temporary use of a sheet of canvas or drill cloth between Rubber and base metal, the cloth is removed when the Rubber isin its correct position and the air behind the Rubber is forced out. + 6.14 JOINTS ‘Vulcanized sheets should be joined by strapped joints. Joints between Rubber and pipe linings and the Rubber on the flange faces should not protrude either to restrict the bore of the pipe or to prevent efficient sealing between the flange faces of adjacent lengths. The lining is vulcanized by suitable heat treatment to produce the required physical and chemical properties. 6.1.4.1 STRAPPED JOINTS In strapped joints, the sheets are skived and joined, and a chamfered strap is then centrally aligned over the joint. ‘The path to earth through the joint should not exceed 30mm. The thickness of the strap may be upto 0.8mm less than that of the lining but in no case less than 1.3mm strapped seam in 3mm sheet, 9mm long scarf, 3mm overlap, 30x2.5mm_ strap. Format No. 6-00-0001-F1 Rev. 0 ‘Conyrahv EL — Al rghis reservedJop specincamion ron ruse secron | ui Pon iTERNAl BROTECTION OF PEPEEE ORAM] UNNGLORINTERNAL PROTECTIONS goo. g6a2-RL-K00 omens Rearmnaseen AND CS EQUIPMENT IN DM WATER Rev.0 PLANT, BCPL ‘SMMS DEPARTMENT. ene 62 70 80 81 6.1.42 FLUSH JOINTS Flush joints are used for the staggered joints in the double lining method of application. 6143 OVERLAP BEVEL JOINTS Overlap joints are made only in un-vulcanized material, The total contacting surface between two shects shall be a minimum of four times the sheets thickness, but shall not exceed 30mm at any point. Overlap joints should be made so that the overlap follows the direction of the liquid flow. 61.5 FLANGES The Natural Rubber lining on the outer edges of flanges should be finished flush to prevent the lining being rubbed or peeled off during transit. LINING INSITU When lining insitu the method of applying the Natural Rubber sheet follows the same general patter and the metal surfaces should be prepared by grit blasting or grinding ‘whenever possible. The method of vuleanizing insitu depends on the design and equipment, its overall dimensions and facilities on site. On very exposed sites where vulcanization is carried out by heating, care should be taken to minimize heat losses from equipment. MONITORING: A carbon steel sample piece of size 1ft x 1 f. shall be blast cleaned to Sa 21/2 finish. Then apply the adhesive and 3 layers of Rubber lining as per the same procedure of actual lining in vulcanization-process for monitoring the vulcanization of lining time to time by checking the hardness and adhesion. ‘THICKNESS REQUIREMENT OF LINING The minimum thickness of Rubber lining will be decided on: a) Corrosion conditions b) Abrasion conditions and ©) combination of both the above factors, ‘The recommended thickness forthe CS storage tanks and CS/MS dual media Filter is -For internal surface: Three layers of 1.5mm each=4.5mm minimum -For piping, valves, fing: Minimum 3mm INSPECTION QUALITY OF SHEET The sheet should be examined to ensure that a) it is free from blisters and any other imperfection which would seriously affect the performance of the lining and b) The thickness tolerance on nominal dimensions should be +10%. Test results on the properties as ‘given in column No.4.0 shall be checked. Format No, 00-0001-F1 Rav. 0 Copyright EL — Al rghis resavedeae OND JOB SPECIFICATION FOR RUBBER SECTION LINING FOR INTERNAL PROTECTION OF (CS TANKS, PIPING, VALVES, FITTINGS 6907-0642-RL-KO9 "AND CS EQUIPMENT IN Dl WATER Revo PLANT, BCPL poe [SMM DEPARTMENT 82 LABORATORY ADHESION TEST Check for adhesion of the lining to the metal should be carried out in laboratory on the samples prepared using the same combination of solutions and conditions of vulcanization as specified. A metal surface prepared as above shall be kept inside the vessel being vuleanized and can be used for monitoring the vulcanization operation. The adhesion of the rubber may be determined in accordance with the 1S:3400(Part-V)- (Latest edition) method B or Part 14. For a rate of separation of 25mm per minute, the values of adhesion shall not be less than 3.6 kgfem for pressure vulcanization and 2.7 ‘kgfiom for vulcanization by hot water or steam at atmospheric pressure. 8.3 HARDNESS (As per IS:3400 Part II-1995) Hardness testing should be carried out on a flat smooth surface. If the surface is too rough, alight local scrapping or buffing may be carried out to facilitate testing. Readings obtained should confirm to the specified hardness of the compound with:+5%. The first layer of natural rubber should have shore hardness 30-40A Second and third layer of natural rubber should have 55-65 A shore hardness. A minimum of three hardness readings should be taken for each square meter of lining where a reading is outside the agreed range, further readings shall be taken on the same panel to ensure the general level of hardness where repairs have been carried out or ‘here marking is feasible the areas concerned should be separately tested. 84 TEST FOR CONTINUITY OF LINING VISUAL INSPECTION: The inspection for visual defects should be carried out over the entire surface in a good light. The entire surface shall be free of cracks, traces of bubbles, lack of adhesion, hollow spaces etc, Presence of hollow spaces maybe checked by tapping with a wooden mallet. 85 HIGH FREQUENCY SPARK TEST A high voltage, high-frequency spark discharge be directed at the lining, where a defect occurs in the lining the discharge is earthed producing a strong bluish white continuous spark. The surface of the lining should be clean and dry when the test is carried out. Excessive voltage or long residence time or both may puncture the lining, and care should therefore be taken to select the correct voltage and to ensure that the probe does not remain in one position for too long. The voltage shall be 5 to 6 Kvimm thickness of the lining. 86 THICKNESS MEASUREMENT This thickness of the covering should be checked in the areas specified by the user by using a suitable thickness measuring instrument. 8.7 HYDRAULIC TESTING OF LINED VESSELS. When required by the user, a hydraulic test, at an agreed pressure and for an agreed time should be applied to the lined equipment in the manner specified by the user. Format No -00-0001-F1 Rev, 0 Copyright EI ~All aghis resewed208 SPECIFICATION FoR RUBBER SECTION LINING FOR INTERNAL PROTECTION OF CS TANKS, PIPING, VALVES, FITTINGS _6907-0642-RL-KO9 : — ‘AND CS EQUIPMENT IN DM WATER Rev.0 PLANT, BCPL onsaus ‘SUMS DEBARTMENT 88 VACUUM TESTING OF LINED VESSELS A vacuum test should be carried out wherever necessary by evacuating the lined vessel fitted with the appropriate joint rings to the specified vacuum, The Vacuum should be ‘maintained for a specified period usually one hour and the lining should not show defects on re-inspection. 89 RESISTANCE TO BLEEDING BY LINING When contamination of the liquids by the lining material is detrimental check tests should be carried out previously by the customer on samples of the compound supplied by the rubber contractor. This avoids the lengthy soaking periods for the lined or covered articles to assess the degree of contamination. 9.0 POST-LINING ANNUAL INSPECTION Annual inspections of all lining should be carried out. Areas where adhesion has broken down and which have not developed in to an obvious blister, can generally be detected by light tapping with a wooden mallet and listening for a hollow sound, All the suspected areas of the lining should be checked for continuity by the high frequency spark test and the whole lining should be checked in this manner. 10.0 REPAIRING OF LINING Repair to the lining can generally be done insitu by skilled labour. The defective and adjacent linings are thoroughly neutralized, cleaned and dried. In some cases it may be necessary to treat the whole of the lining. All loose and defective rubber is cut away, the exposed edges of the Lining bevelled and the shell of the equipment buffed clean. The area exposed is cleaned with a suitable solvent and any excess shall be allowed to evaporate. The adhesive solutions are then applied, according to the manufacturer's instructions and allowed to dry. The patch of the new sheet, which has been previously cut to shape and made “tacky' by the application of the solution or adhesive, is then applied, in accordance with the contractor's instructions, to the prepared area and rolled down firmly with an edge- wheel on any other suitable tool to exclude any air. In arcas where tension is likely to develop, the patch is tightly wrapped. The patch is then vulcanized. The repaired area should be checked for hardness and continuity. 11.0 SAFETY REQUIREMENTS FOR APPLICATION OF RUBBER LINING 11.1 While doing Blast cleaning, itis essential to use basting hood wit respirators 11.2 Ventilation and lighting shall be adequate in the working area, 113 All flammable liquid containers shall be clearly identified and property stored with protection. 11.4 Proper type and numbers of extinguishers shall be kept available nearby. Format No. 800-0001-F1 Re. 0 Copyight EL Al ighis reserved