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TRAINING MANUAL PIPING

RUBBER LINED PIPING SYSTEM


Uhde India Limited

DOC No. : 29040-PI-UFR-0031


Rev.

: R0

Page

: 1

CONTENTS

Page
0.0

Cover Sheet

1.0

Introduction

2.0

Lining Material

3.0

Lining Process

4.0

Rubber Lined Piping System

36

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TRAINING MANUAL PIPING


RUBBER LINED PIPING SYSTEM
Uhde India Limited

1.0

DOC No. : 29040-PI-UFR-0031


Rev.

: R0

Page

: 2

INTRODUCTION:

Corrosion is a menace in operating and maintaining a Chemical Process Plant. Hence given a
choice one would be tempted to dispense away with Steel all together as a material of
construction for piping used in a Chemical Plant. Unfortunately it is not practical to undermine
the usefulness of Steel in sustaining the Pressure and Temperature conditions normally
foreseen in any Process Plant. That brings the concept of composite piping wherein an
attempt is made to make use of the mechanical strength of Steel, at the same time to impart
a high degree of corrosion resistance to the wetted surface of the component made of Steel.
Carbon Steel Piping internally lined with Rubber is a classic example of such composite
piping. Due to the intimate bonding between Rubber and Steel during vulcanizing process, it
provides one of the most practical solutions in dealing with chemically corrosive fluids within
the limitations posed by the endurance of Rubber for the operating temperatures.

2.0

LINING MATERIAL:
Following are the commonly used Rubber varieties in the Chemical Plant in general

3.0

Natural Rubber
Butyle Rubber
Nitrile Rubber
EPDM

LINING PROCESS:
The Rubber Lining is a process of application of liner material (normally in the form of rubber
sheets or extruded tubes) over the internal surface of the steel piping followed by vulcanizing
at the required temperature to attain the desired degree of hardness.
The Lining Process generally consists of following steps

Inspection of Piping Items for verifying its fitness for the purpose. The aspects which need
to be considered with respect to above, are the accessibility of the internal surface for
application of lining and suitability of the internal contours for achieving a defect free
lining.
Note: In order to provide reasonable access to the internal surface of the Piping for
application of liner, necessitates that Piping profile is broken down into flanged spools/
fittings of predetermined dimensions.

Surface preparation in terms of removal of scale/ rust either by wire brushing or sand/
shot blasting.

Application of Rubber Solution/ lining material

Curing of Liner material (i.e. vulcanizing) at the required temperature either by employing
hot water or steam. The vulcanizing of Rubber could also be done at ambient temperature
by adding certain accelerators along with the filler materials used in the Rubber Stock.

Inspection of the lined surface for possible defects such as pin holes/ blisters etc.

Hydro testing of the lined components

TRAINING MANUAL PIPING


RUBBER LINED PIPING SYSTEM
Uhde India Limited

DOC No. : 29040-PI-UFR-0031


Rev.

: R0

Page

: 3

4.0 RUBBER LINED PIPING SYSTEM:


The limited temperature endurance of the Rubber Lining Material prohibits any welding on
steel subsequent to lining. That means that the Rubber Lined Piping System needs to be
necessarily prefabricated. At the same time the total profile is also required to be broken down
into flanged spools of such configuration that the internal surface requiring lining is accessible
from at least one of the open ends for application of lining. It is from the above concern that
the line size of Rubber Lined Piping is recommended to be NS 2 and above.
A Rubber lined Piping System therefore is an assembly of various flanged Spools/ Fittings
prefabricated to a predetermined dimensions. The supporting system employed for Rubber
Lined Piping is normally a clamp and shoe arrangement. Welding of any support component
to steel surface of the lined piping is completely prohibited. The accessories to Rubber lined
Piping include soft Rubber gasket and full threaded Fasteners.

4.1 DESIGN CONSIDERATIONS:

A minimum of NS 2 line size is recommended for Rubber Lined Piping

The maximum length of straight Flanged Spools shall be as per Uhde Standard GENL
PI- UZ-0003. These dimensions are decided to allow a reasonable accessibility for lining
application and to avoid any pipe to pipe welding joint within the spool length based on
Single Random Length of Steel pipe. It is logical to use straight Pipe Spools of Standard
Dimensions (i.e. the maximum recommended spool length as per Uhde Standard) as far
as possible, to minimize the number of flange joints and at the same time to facilitate
interchangeability of the spools. However the last spools at the corners or branch
locations of the profile (or at any location specific situation) shall be adjusted to suit the
dimension of the profile.
The straight Flanged Spools (Refer GENL-PI-UZ-0003, Gr. No. 6.203) employ fixed
flange at 1 end and loose flange (i.e. lap flange with stub end) at the other end to
accommodate the bolt hole rotational mismatch of the flanged fittings bolted to the
straight spools.

In order to facilitate interchangeability, all flanged fittings (including Tee) shall be of a


Standard Dimension as per Uhde Standard GENL-PI-UZ-0003. Use of flanged fittings of
non-standard dimensions is however permitted (under exceptional situations) provided
they are procured as non-standard Special Parts.

For tapping of small size (i.e. Instrument / Drain-Vent Connections etc) a sandwich type
Carrier Flange with nozzle of the required size will be employed and procured as a
standard Special Part.

It is likely that due to erection deviations, the prefabricated/lined chain of flanged spools
may either leave some gap or may have excess length while connecting the end terminals
at site. A design solution (i.e. by employing spacers) for such deviations is impractical
and hence the spools requiring adjustment as per site condition shall be fabricated as per
actual site condition and sent for lining on a rush basis. During order finalization a
commitment on crash delivery of such spools (including material supply) will be obtained
from the Vendor. The complete activity shall be coordinated from site in consultation with
Project Group.

As a contingency measure some Solid Spacers (made of Hard Rubber/ Ebonite) of


predetermined dimension (refer Annexure-2 of GENL-PI-UZ-0041) are procured as
standard Special Parts. These spacers can be cut into small rings at site to suit the Gap
(encountered during assembly of Rubber Lined Piping) and sandwiched between the
flange joint to fill the gap. It may however be noted that the above solid spacer can be

TRAINING MANUAL PIPING


RUBBER LINED PIPING SYSTEM
Uhde India Limited

DOC No. : 29040-PI-UFR-0031


Rev.

: R0

Page

: 4

used to fill small gaps (of the order of 25 mm) only due to the limited strength of the
Rubber. Any gap in excess of 25 mm shall be handled as described in the earlier
paragraphs.

During the design stage it may be necessary to incorporate some spacers to bridge the
corner to corner dimensions of the profile. Lined Spacer fabricated from Carbon Steel and
subsequently Rubber lined (refer Annexure-1 of GENL-PI-UZ-0041) are employed for the
above purpose. As far as possible the Lined Spacer of discrete thickness of 50mm,
75mm and 100 mm shall be used.

The Rubber Lining may obstruct the opening of flap of Sandwich type Butterfly/ Wafer
Check Valve into the pipe. In order to address the above issue the Lined Spacer (Type-1)
shall be used across the Valve. The thickness of the above spacer shall be decided as
per the requirement of the valve under question.

All the straight flanged spools (including non-standard special parts) shall be assigned
part no., in the Isometric Drawings.

The supporting of Rubber Lined lines is done similar to Carbon Steel Piping with the
following exceptions.
1. The lines are recommended to be supported, by employing Shoe and Clamp type
supports.
2. No welding (e.g. Dummy/ Trunnion) is permitted on the Rubber Lined Piping
components subsequent to lining.

4.2 BILL OF MATERIAL CONSIDERATIONS:


Enquiry Bill of Material:

The Enquiry BOM shall be prepared on completion of about 90% of the Isometrics for
Rubber Lined Piping.

The Pipe quantity shall be indicated in terms of the total requirement for each size based
on the Isometrics

The quantity of Flanged Fittings shall be counted from the Isometrics and indicated in
numbers.

The Flange quantity shall represent the requirement of Flanges on straight Pipe Spools.
The quantity of each of fixed and loose type Flanges of a particular size will be equal to
the number of straight spools of that size.

The quantity of Solid Spacers of each size is estimated based on the following equation
Q

30 * No of Lines per size


500

(rounded to next number)

The above equation is based on an estimated requirement of 1 spacer (25 mm long) per
line per size.

The total quantity Q of Lined Spacers for each size is estimated to be equal to the number
of lines in that size. The above total quantity is split into 3 parts as below
Spacer of 50 mm width
Spacers of 75mm width
Spacers of 100mm width

50% of Q
25% of Q
25% of Q

TRAINING MANUAL PIPING


RUBBER LINED PIPING SYSTEM
Uhde India Limited

DOC No. : 29040-PI-UFR-0031


Rev.

: R0

Page

: 5

The requirement of non-standard Special Parts will be picked up from the Isometrics.

Unlike other Piping Systems, no spares are included in the Bill of Material of Rubber
Lined Piping unless required as per the Contract Agreement.

Order Bill of Material:

At the ordering stage an updated Bill of Material is issued along with the Construction
Isometrics for execution purpose.

The above Bill of Material will account for only as much material as required for the
Isometrics being released for fabrication

It is expected that nearly 80% of the Isometrics would be included in the above lot.

Final Bill of Material:


The Final Bill of Material will account for the remaining 15% (i.e. 100% requirement of the
Project) of the Isometrics which will be issued along with the above BOM.

4.3 TECHNICAL SPECIFICATION CONSIDERATIONS:

The Vendors scope includes supply, fabrication, rubber lining, testing and delivery of
rubber lined flanged spools (including non standard special parts) as per Isometrics.

Items such as Gaskets, Fasteners, On-line Valves, Instruments, Special Parts (with the
exception of non-standard Special Parts) are excluded from the Vendors scope.

The Rubber Lining shall be carried out as per BS 6374.

Prior to Rubber-Lining the internal surface to be lined shall be appropriately prepared by


way of grinding excess weld deposits/sharp corners. Besides the surface shall be made
free of rust/ scale by sand blasting.

The Vendor shall confirm the suitability of Rubber Material against the Fluids indicated in
the Enquiry document

In absence of specific requirement Natural Rubber shall be used

The Finished lining shall have 80 Shore D Hardness and shall be suitable for the
O
O
temperature range of 45 C to 95 C.

A minimum of 3 mm Thick Rubber Lining shall be achieved on all surfaces.

The Rubber Lining shall be done by Vulcanizing Process under controlled temperature.

The Rubber Lined Piping items shall be tested in Accordance with BS 6374 and shall
include, but not limited to, following tests.
Visual Inspection
Peal Test
Spark Test
Hardness Test
Flatness Test of Lined Sealing Surfaces

TRAINING MANUAL PIPING


RUBBER LINED PIPING SYSTEM
Uhde India Limited

DOC No. : 29040-PI-UFR-0031


Rev.

: R0

Page

: 6

Out side surface of all Rubber Lined items shall be painted with 2 coats of Primer (e.g.
Epoxy/ Zinc Phosphate)

The straight Flanged Spools (including non-standard Special Parts) shall be suitably
marked (Whether Proof Marking on the Body and Punching on the Flange rim) the Part
Number and the Isometric Number.

Since the Vendor is required to Quote on a Lump Sum basis it may be pertinent to get the
units rates at the time of enquiry to process the order amendment at a later date based on
the final status of engineering. Normally unit rates of following items shall be obtained for
each size
Lined Pipe without Flanges
Lined Loose Flange including welding
Lined Fixed Flange including welding
Lined Branch Connection including welding
Only Lining

4.4 INSTALLATION CONSIDERATIONS:

The Final Grouting of the Equipment connected with Rubber Lined Piping is done only
after the erection of the connected Rubber-lined Piping.

The Rubber Lined Pieces are handled carefully to avoid damage to the lined surface.

The Flange Joints shall be tightened to the specified Torque Value by employing Torque
Wrench.

The Solid Rubber Spacer (for site adjustment) shall be machine cut as per the required
thickness (a maximum of 25mm gap). The above Solid Spacers shall not be provided
near the equipment connection.

In case the gap is more than 25 mm the corrective action shall be taken by re-fabricating
the pipe spool as per the required dimension and sending it for lining.