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Indian Standard
CODE OF PRACTICE FOR LINING OF
VESSELS AND EQUIPMENT FOR
CHEMICAL PROCESSES
PART 1 RUBBER LINING
(First Revision)
Second Reprint DECEMBER 2001
© BIS 1994
B U R E A U OF I N D I A N S T A N D A R D S
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
CONTENTS
SECTION 1 GENERAL
PAGE
1 SCOPE .. ... ... ... 1
2 REFERENCES ... ... ... ... 1
3 TERMINOLOGY .. ... ... ... 1
4 EXCHANGE OF INFORMATION ... ... ... ... 1
5 COMPLIANCE ... ... ... ... 2
SECTION 2 DESIGN, FABRICATION AND SURFACE FINISH OF
EQUIPMENT TO BE LINED
6 GENERAL ... ... ... ... 2
7 DESIGN OF METAL EQUIPMENT TO BE LINED ... ... ... 2
8 FABRICATION OF METAL EQUIPMENT TO BE LINED ... ... ... 3
9 DESIGN OF CONCRETE EQUIPMENT TO BE LINED ... ... ... 6
10 CONSTRUCTION OF CONCRETE EQUIPMENT TO BE LINED ... ... 9
SECTION 3 SELECTION AND QUALITY OF LININGS
11 SELECTION OF LINING ... ... ... ... 9
12 QUALITY OF LINING ... ... ... ... 10
SECTION 4 METHOD OF LINING
13 SURFACE PREPARATION ... ... ... ... 10
14 ADHESION SYSTEM AND APPLICATION ... ... ... 11
15 PRODUCTION OF LINING MATERIAL ... ... ... ... 11
16 APPLICATION OF THE SHEET TO THE SUBSTRATE ... ... ... 11
17 VULCANIZATION ... ... ... ... 13
SECTION 5 INSPECTION AND TESTING
18 RESPONSIBILITY FOR INSPECTION AND TESTING ... ... ... 14
19 INSPECTION ... ... ... ... 14
20 TESTING ... ... ... ... 16
20.1 Hardness Tests .. .. ... ... 16
20.2 Continuity of Lining ( High Frequency Spark Test ) ... ... 16
20.3 Bond Strength Tests ... ... ... ... 16
20.4 Lining Thickness ... ... ... ... 17
20.5 Hydraulic Testing of Lined Equipment ... ... ... 17
20.6 Vacuum Testing of Lined Equipment ... ... ... 17
21 RECTIFICATION OF FAULTS IN FULLY CURED LININGS ... ... 17
SECTION 6 STORAGE, HANDLING, TRANSPORTATION,
INSTALLATION AND MAINTENANCE
22 GENERAL ... ... ... ... 17
23 MAINTENANCE ... ... ... ... 17
ANNEX A LIST OF REFERRED INDIAN STANDARDS ... ... ... 18
ANNEX B LINING OF USED EQUIPMENT ... ... ... ... 18
ANNEX C CHARACTERISTICS OF LINING MATERIALS ... ... ... 19
ANNEX D EFFECT or MATERIALS ON WATER QUALITY ... ... ... 21
ANNEX E VULCANIZATION ... ... ... ... 21
ANNEX F METHOD OF TEST FOR CONTINUITY TESTING ... ... ... 22
FOREWORD
This Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards, after the
draft finalized by the Chemical Engineering Plants and Related Equipment Sectional Committee
had been approved by the Heavy Mechanical Engineering Division Council.
( Continued on third cover )
AMENDMENT NO. 1 AUGUST 1996.
TO
IS 4682 ( Part 1) : 1994 CODE OF PRACTICE FOR
LINING OF VESSELS AND EQUIPMENT FOR
CHEMICAL PROCESSES
PART 1 RUBBER LINING
(First Revision)
( Page 16, clause 20.1.3, second line ) — Substitute '±5°' for '±5 percent'.
( Page 16, clause 20.3.3, second line ) — Substitute 'method A' for
'method B'.
( HMD 17 )
Printed at Simco Printing Press, Delhi, India
IS 4682 ( Part 1 ) : 1994
Indian Standard
CODE OF PRACTICE FOR LINING OF
VESSELS AND EQUIPMENT FOR
CHEMICAL PROCESSES
PARTI RUBBER LINING
( First Revision )
SECTION 1 GENERAL
3.0 For the purpose of this standard the definitions 4 EXCHANGE OF INFORMATION
given in IS 7503 (Parts 1, 2, 3 and 4) : 1988 shall
apply, together with the following. 4.1 Early consultation shall be arranged between all
parties concerned with the application of this standard,
3.1 Purchaser to establish the following information which shall he
The organization or individual who buys the lined fully documented:
equipment for its own use or as an agent for the
owner. i) Design and fabncation details of the equipment
to be lined and provision of drawings (see 7,
3.2 Fabricator 8, 9 and 10).
The organization or individual responsible for the
ii) Details of gasket materials (see 7.9 and
fabrication of the equipment to be lined.
7.10).
3.3 Applicator
iii) Details of the contents of the vessels or
The organization or individual responsible for the equipment, including trace materials [.see 1.1.1.3
application of the lining. (a)].
1
IS 4682 ( Part 1 ) : 1994
iv) The design temperature [see 11.1.3 (b)]. are required for the correct application of the
lining (see 14 and 16).
v) The design pressure [see 11.13 (c)].
xix) The minimum temperature required during
vi) The details of any solids to be handled [see the vulcanization of the lining (see 17).
11.1.3 (e)].
xx) The vulcanization schedule, where applicable.
vii) Any specific mechanical properties required xxi) Inspection techniques/procedures to be
of the lining including suitability for machining employed, acceptance levels and stages of
[see 11.1.3 (g)]. inspection (see 18 and 19).
viii) The methods of heating and/or cooling [see xxii) Handling, transport storage and installation
11.1.3 (b)]. procedure [see 11.1.3 (g) and 22.1 to 22.7].
ix) Cleaning methods, for example, water washing, 4.2 Both the definitive requirements specified in this
solvent washing, boiling out or steaming [see standard and the items documented in 4.1 shall be
11.1.3 (a)]. satisfied before a claim of compliance with the
standard can be made and verified.
x) Where the lining work will be done.
5 COMPLIANCE
xi) Site conditions which may affect the work,
for example, availability of services. 5.1 Fabricator
xii) Any special requirements for materials used The fabricator shall comply with the following:
in blast cleaning (see 13.1.1 and 13.1.2).
a) Section two [see 4.1 (i)];
xiii) The rubber lining to be used (see 11.1).
b) Requirements given in 18.1 (a) and 18.1; and
xiv) The minimum thickness of the vulcanized
lining and where applicable the maximum c) Section six as agreed in 4.1 (xxii).
thickness (sec 12.2).
5.2 Applicator
xv) The provision of test plates [see 12.1 (c)].
The applicator shall comply with the following:
xvi) When the lining is to be applied outside the
applicator's works and the primers and/or a) Section three (see also 12.1);
adhesives as applied contain solvents, the types
of solvents are to be stated, together with b) Section four;
their Hash points and threshold limit values. c) Requirements given in 18.1 (c), (d), (e)
and (f);
xvii) Specilied adhesion system (see 11.1, 12.3
and 14). d) Requirements given in F-3;
e) Requirements given in 21; and
xviii) The minimum and n)aximum allowable
temperature and allowable humidity which I) Section six as agreed in 4.1 (xxii).
7.8 Discontinuities, crevices and sharp projections Nominal Pipe Maximum Length
shall be avoided. Size Between Flanges
mm mm
7.9 Fittings which have to be installed after the
completion of the lining process shall be designed to 25 2 000
be lined or fabricated from materials that will not be 32 2 500
affected by the process conditions. 40 3 000
50 3 500
7.10 Normally all connections to lined parts of 65 4 000
equipment shall be flanged. If for any reason screwed 80 to 600 6 000
connections are required, then these parts shall be
fabricated in corrosion-resistant materials.
7.13.3 Pipes less than 25 mm diameter shall not be
7.11 Branches and outlets, except for plain ended rubber lined. Pipes less than 250 mm diameter shall
pipes, shall be as short as possible and flanged so that be of seamless construction only. Screwed fittings
the lining may be taken over the flange face to prevent shall not be rubber lined.
the ingress of process fluid between the lining and
the substrate. 7.13.4 Where flat face or raised face flanges are
NOTE — Acceptable flange systems arc shown in Fig. 1. used they shall be welded square to the pipe or fitting
according to normal manufacturing tolerances.
7.11.1 Plain-ended pipes shall be designed so that 7.13.5 Flanges which are attached to a pipe by fillet
the lining may be turned over the end and the outside welding (for example slip-on flanges) shall be suitably
of the pipe. vented to allow any air trapped between fillet welds
to escape to atmosphere during lining and vulcanizing.
7.11.2 Where pads are required they shall be designed
as shown in Fig. 1 (d). Drilled and tapped holes in NOTH — This may be accomplished by using a vent hole in
pads for studs shall not penetrate the shell of the the tlange, providing this meets piping design standard
equipment. requirements.
7.12 Heating coils, immersion heaters and sparger 8 FABRICATION OF METAL EQUIPMENT
pipes shall be installed after the completion of the TO BE LINED
lining process and shall be located so that no part is
closer than 100 mm from a lined surface. In the case 8.1 All welds shall be continuous on surfaces to be
of nozzles through which heating coils, etc, enter lined.
equipment, a smaller clearance is permitted provided
that the temperature of the pipe through the nozzle NOTE — Butt welds art preferred to fillet welds.
does not exceed 80°C. In no case shall this clearance
be less than 25 mm. Fluids introduced through sparger 8.1.1 Stitch welding, spot welding and other non-
pipes or dip pipes shall not impinge directly on to continuous welding proces.ses shall not be used.
the lining. External heating of equipment shall not
be permitted without full consultation with the applicator 8.2 Weld surfaces shall be smooth. Some welding
of the lining. procedures provide surfaces of adequate smoothness
but, in other cases surfaces shall be ground wholly
7.13 The design of pipework shall be such as to or partly to remove weld ripples. The grinding process
allow ready access to welds and bends for weld and shall be done so that the remaining weld does not
surface preparation. have sharp edges.
3
IS 4682 (Part I) : 1994
NOTE — The details shown in (a), (b), (c), (d), (c) and (f) are all permissible, that shown in (g) is not permissible.
4
IS 4682 ( Part 1) :1994
NOTE — The details shown in (a), (b), (c) and (d) are all permissible those shown in (e), (f), (g) and (h) are not permissible
5
IS 4682 ( Part 1) : 1994
8.3 Welding procedures shall be chosen to avoid 8.10 Where there is a requirement that a rotating
porosity on the side of the weld to be lined. part shall be balanced, then this balancing shall be
done both before and after lining.
NOTE — It is preferable that capping runs are applied to the
lining side in order to minimize this effect.
8.11 All slag, anti-spatter compounds or similar
materials shall be removed. All weld spatter shall be
8.3.1 All welds shall be free from the following removed by chipping and/or grinding.
surface defects :
8.12 Surface defects such as scores, pitting and rolling
a) Undercutting, defects shall be removed by grinding, or where
b) Cracks, necessary repaired by welding provided that the
requirements of design and construction are met.
c) Porosity,
d) Any other type of surface cavity, and 8.13 Surfaces shall be presented to the lining applicator
in a clean condition free of all contamination, for
c) Lack of fusion. example oil, grease, temporary protective coating,
such that no pre-treatment is required other than any
8.3.2 Weld defects that are exposed either on initial grit blasting which is to be part of the lining process.
inspection or after blast cleaning shall be repaired.
9 DESIGN OF CONCRETE EQUIPMENT TO
8.3.3 Repairs shall be by grinding or by welding BE LINED
(with or without subsequent grinding) provided that
the requirement for equipment design and fabrication 9.1 Whilst it is not possible to eliminate shrinkage
are met. cracks in conerete, the design shall be such that structural
cracking is eliminated. Particular attention shall be
8.4 Weld profile details shall be generally in paid to avoiding cracking due to thermal stresses.
accordance with Fig. 1 and Fig. 3 to 6. The ability of the lining to accommodate cracking
of the concrete shall determine the selection of the
NOTE — Incorrect details are also illustrated. rubber. Equipment shall be designed to IS 456 : 1978.
8.5 Filler materials, such as resin, putties, fillers and 9.2 If necessary, extra reinforcements shall be used
low melting point solders and brazes, shall not be and construction joints treated so as to promote a
used. bond between adjacent areas of concrete. Expansion
joints create special problems in lining and shall not
8.6 Before the equipment is passed for lining, all be used without consultation between the purchaser
allachments to be made by welding, for example and the applicator of the lining.
lagging cleats and lifting lugs, shall be complete.
9.3 Pipes and fittings shall be designed with puddle
8.7 All drilling shall be completed before the flanges and cast into the concrete. Where necessary
equipment is passed for lining. Holes to be lined shall such fittings shall be designed in a concrete resistant
have their edges radiused. material. Pipes and fittings shall normally be rubber
lined before being cast into the concrete.
8.8 External corners and edges shall be furnished to
a radius of minimum 3 mm or equal to the thickness 9.4 The arrangements for the blast of equipment
of the rubber, whichever is higher. For internal comers shall be determined at the design stage.
and edges to a radius of minimum 6 mm or twice
the rubber thickness whichever is higher. 9.5 The design of all equipment shall allow for access
during the preparation of the surface and application
NOTE — For typical edge configurations, see Fig. 4 and 5.
of the lining, and for venting of fumes evolved during
8.9 Castings including cast iron shall be produced the operation. In completely enclosed vessels there
by foundry techniques which give dense smooth surfaces shall be at least one manhole complying, after lining,
with IS 2825 : 1969 or IS 803 : 1976 and one additional
free from slag, sand and inclusions, shrinkage cavities,
branch of not less than 75 mm bore to permit adequate
scabs, cracks, porosity and bums and the entrapment
circulation of air.
of air in surface defects.
NOTE — It is recommended that, where practicable, the
8.9.1 Removal of defects shall be by welding and minimum diameter of a manhole should be 600 mm.
grinding or by grinding alone. Grinding alone shall
be used only for small defects such that the ground 9.6 All corners shall be designed to be formed with
cavity blends smoothly with the casting surface and a 45° fillet with a minimum leg length of 20 mm.
does not reduce the sound wall of the casting below
the requirements of the design standard. For larger 9.7 All equipment to be placed below ground level
defects welding shall be used and the repair weld or subject to external water pressure shall be provided
shall be ground flush such that it does not impair the with a waterproof barrier on the outside of the
requirements of the design standard. equipment.
6
IS 4682 ( Part 1 ) : 1994
( e ) WELD UNDERCUT
( g ) IMPROPER GRINDING
NOTE — The details shown in (a), (b), (c), and (d) are all NOTE — The details shown in (a), (b), (c), and (d) are ail
permissible, those shown in (c), (f), and (g) arc not permissible. permissible, that shown in (e) is not permissible.
7
IS 4682 ( Part 1 ) : 1994
(a) PERMISSIBLE
NOTE — The details shown in (a), (b), (c), and (d) are all
permissible, that shown in (c) is not permissible.
8
IS 4682 (Part 1) : 1994
9.8 All equipment shall be designed with a minimum as the concrete leaves the formwork before the curing
of 20 mm of concrete over reinforcement. membrane is applied.
NOTE — This process will reduce the amount of laitance.
10 CONSTRUCTION OF CONCRETE
EQUIPMENT TO BE LINED 10.4 All surfaces not cast against shutters shall be
finished with a wooden float. Curing membranes shall
10.1 Concrete equipment shall be constructed in be applied and not disturbed for 7 days.
accordance with the requirements of IS 3370 (Parts
1, 2, 3 and 4) or IS 456 : 1978 as appropriate. 10.5 Any steps in the concrete due to misalignment
of shutters or surplus material formed because of
10.2 Proper curing of the concrete shall be ensured gaps at joints in shutters shall be dressed off and
by the use of curing membranes. If shuttering is ground smooth.
removed in under 7 days a curing membrane shall 10.6 All holes left after removal of ties to secure and
be applied. Concrete equipment shall be allowed to align formers shall be filled. Any surface defects such
cure tor 28 days before the work of lining proceeds. that the aggregate is exposed shall be filled. The
Concrete hardening solutions shall not be used. material used for filling shall be a sand/cement grout
with a high cement content or a sand/cement water
10.3 Equipment which is slip formed shall be bagged miscible epoxy resin grout or an epoxy mortar.
When the applicator is responsible for selecting the 12.2.2 Normally the thickness refers to the rubber
grade of lining to be applied, he shall verify that such sheet as applied to the substrate. If the purchaser
a lining shall withstand the chemical and physical requires the nominated thickness to apply to the
conditions specified in 11. When the purchaser selects finished lining this shall be stated during the exchange
the grade of lining to be applied, the applicator shall of information [see 4.1 (xiv)].
be responsible only for the correct application. The
applicator shall in either case : 12.3 Bonding of the Lining
a) State the reference number of the rubber to The rubber lining shall be bonded to the substrate.
be used for the lining. The adhesive system shall be suitable for the type
of rubber and for the service conditions. The
b) State the hardness of the rubber after applicator shall be responsible for the selection of the
vulcanization. adhesive system and shall produce evidence that the
adhesive system will produce the bond required
c) Supply test pieces such as panels to which between rubber and substrate when the rubber is
the rubber has been applied and which will applied under the conditions of vulcanization [see 4.1
serve as reference samples [see 4.1 (xv)]. (xvii)].
10
IS 4682 ( Part 1 ) : 1994
13.2.3 Surfaces to be lined shall be treated to remove a) When linings arc produced by calendering,
laitance and shutter release agents. Of the two possible multiply construction shall be employed.
methods for this operation the one preferred is blast
cleaning. The blast cleaning process shall be controlled NOTE — The minimum number of plies employed in the
so that all laitance is removed and exposure of the manufacture of a finished sheet depends upon the rubber
compound. A guide to the number of plies related to a given
profile of the aggregate kept to a minimum. After thickness is given below :
blast cleaning all dust and debris shall be removed.
Thickness Minimum Number
NOTE — The alternative method of removing laitance is that of Lining, of Plies
of acid etching. The process is more difficult to control on mm
vertical and overhead surfaces and the presence of shutter oils
will reduce its effectiveness. The thickness of the laitance of 3 to 5 3
a concrete surface varies considerably and it is very important
that acid is allowed to dwell on the surface a sufficient length 6 4
of time to remove all laitance. When acid etching is used the
next operation is water washing of the concrete, followed by
a drying process. b) When roller die or extrusion methods are
used for the production of lining materials
13.2.4 Unless the lining material will fill or effectively then single-ply or multi-ply sheets arc
bridge the large number of small holes (of varying permissible.
diameter and depth) that invariably remain in the
concrete surface following the removal of laitance, 15.4 Pre-vulcanized Lining Materials
then these holes shall be filled before the work of
lining commences. The unvulcanized lining sheet shall be prepared in
accordance with 15.3 and shall then be vulcanized
NOTE — One material recommended for this purpose is a
smooth paste made from a water miscible epoxy resin and a by heating (normally under pressure in an autoclave)
fine filler and cement (see 10.6). or by a rotary vulcanization process.
13.2.5 After removal of laitance all surfaces to be 16 APPLICATION OF THE SHEET TO THE
lined shall be maintained at a temperature at least SUBSTRATE
3°C above the dew point throughout the preparation
and lining processes. If there is a risk that this condition 16.1 General
will not be maintained owing to ambient conditions
or a change in ambient conditions, dehumidifying Detailed methods of working are not specified in this
and/or heating equipment shall be used. standard but the requirements specified in 16.2 to
16.5 shall be met according to whether unvulcanized
14 ADHESION SYSTEM AND APPLICATION sheet, prc-vulcanized sheet or a combination of the
two is being used.
14.1 The adhesive system shall be such that the
required level of adhesion between the lining and the 16.2 Preparation of Lining Sheet
substrate is achieved upon completion of the lining
process. 16.2.1 In the case of unvulcanized sheet any
NOTE — The adhesive system may consist of one or more
preshrinking necessary shall be carried out as a first
individual layers. The primer already applied to the substrate step.
may also be considered as part of the adhesive system.
16.2.2 Individual sheets shall be tailored to fit the
14.2 The adhesives shall be applied to the primed surface to be lined. Edges shall be prepared according
substrate surface by brush, roller or spray, any solvents to the type of joint to be used. Types of joints are
in the adhesive being allowed to evaporate between illustrated in Fig. 7.
the application of successive coats or subsequent
application of the lining. 16.2.2.1 The details of edge preparation shall be as
15 PRODUCTION OF LINING MATERIAL follows :
12
IS 4682 ( Part I ) : 1994
a) Overlap scarf joint — This type of joints is 17 VULCANIZATION
illustrated in Fig. 7(a). The total length of the
contacting surface between adjacent sheets 17.1 General
shall be a minimum of four times the sheet
thickness but shall not exceed 32 mm at any 17.1.1 Vulcanization of the lining shall be carried
point. Overlap scarf joints will tend to affect out by one of the following methods :
the flow in pipes and that effect may be
significant in the case of small bore pipes, a) Autoclave vulcanization,
a fact which shall be considered when the
equipment is designed. Overlap scarf joints b) Using equipment as its own autoclave,
on mating surfaces shall be dressed as necessary c) Steam or hot air vulcanization at ambient
to allow efficient sealing when assembled. pressure,
NOTE — It is preferable that overlap scarf joints should be d) Hot water vulcanization, and
made to that the overlap follows the direction of flow.
e) Self vulcanization at ambient temperature.
b) Straight scarf joints shall be made as illustrated NOTES
in Fig. 7(b).
1 The method employed depends upon the design and size
c) Strapped joints shall be made as. illustrated of the equipment It may be necessary to shield the equipment
to reduce heat losses which would otherwise lengthen the
in Fig. 7(c). The scarf joint in the parent duration of vulcanization when using methods (b), (c) or (d)
sheet shall pass a spark test before the cover above.
strap is fitted. The cover strap with edges
bevelled shall be aligned centrally over the 2 The duration of vulcanization will depend upon the method
joint. The maximum path from an edge of used and the composition of the lining material. More
information on vulcanization is provided in Annex E.
the strap to the substrate shall not exceed 32
mm.
17.1.2 With the agreement of the applicator [see
NOTE — The thickness of the strap may be less than the 4.1 (xx) and (xxi)] interruption of vulcanization shall
thickness of the lining. be permitted to detect and repair any faults present.
The equipment shall then undergo further beat treatment
d) Joints in multiple layer linings shall be scarfed to complete the vulcanization. An inspection for faults
as illustrated in Fig. 7 (b). Joints within one shall be carried out in accordance with section five.
layer shall be offset relative to joints on adjacent
layers. The distance between joints on adjacent 17.2 Methods of Vulcanization
layers shall be a maximum consistent with
the geometry of the equipment. 17.2.1 Autoclave Vulcanization
164 Pretreatment of Lining Sheets The equipment shall be placed in an autoclave which
is then heated to the required temperature and pressure.
The contacting fate of the lining sheet shall be made
tacky so as to adhere to the adhesive layer already 17.2.2 Using Equipment as Its Own Autoclave
on the substrate. Tackiness shall be produced by either
wiping with a suitable solvent or the application of With all outlets sealed and a steam trap condensate
a coat of adhesive. In either case solvents shall be drain attached to a convenient outlet to ensure
allowed to evaporate before the sheet is applied to continuous removal of condensate, saturated stream
the surface to be lined. shall be injected until the equipment is pressurized
to a predetermined pres.sure. The pressure shall be
16.5 Fitting of Lining Sheet to the Substrate within the design pressure limits of the equipment.
Precautions shall be taken against failure of the steam
16.5.1 Exclusion of Air supply since, in such cases, condensation can cause
a vadium and collapse the vessel.
In the application of lining air shall be excluded
between the substrate and lining and between adjacent 17.2.3 Steam or Hot Air Vulcanization at Ambient
layers in multilayer linings. Pressure
NOTE — Exclusion of air is achieved by pressing the lining With outlets covered to reduce steam losses and
against the substrate with a roller or by other means in a
systematic manner. Suitable tools should be used to ensure provision made to drain condensate from the equipment,
complete contact of rubber to substrate at changes of direction the steam shall be injected until the vulcanization
and rubber to rubber at joints. temperature is attained. This temperature shall be
maintained for the required time period. Attention is
16.5.2 Continuity of Lining drawn to 17.2.2 regarding failure of steam supply.
When fitting of the sheet is complete all sheets and NOTE — Hot air may be used as an alternative to steam in
joints whether overlap, scarf, straight scarf or strapped some cases provided that the temperature and beat input can
joints shall be free from pinholes and other defects. be achieved.
13
IS 4682 ( Part I) : 1994
17.2.4 Hot Water Vulcanization 17 2.5 Self Vulcanization at Ambient Temperature
With all outlets below the top flange sealed off and Such robber linings shall be specially designed so
the equipment partially filled with water steam shall that they are capable of vulcanizing under ambient
then be injected into the water, raising the water level conditions.
and temperature. If the water reaches boiling point
before the equipment is full, further water shall be NOTE — The time to vulcanize is temperature-dependent and
added to attain the required level. The temperature at temperatures below 15°C it may be necessary to use
shall then be maintained for the required time period supplementary heating in order lo reduce vulcanization times
while maintaining the water level. to an acceptable period.
18 RESPONSIBILITY FOR INSPECTION AND are free from laitance and that surface defects are
TESTING properly filled.
18.1 The fabricator of the equipment and the applicator 19.3 Quality of the Lining and Bonding Materials
of the lining when requested shall provide a certificate
of inspection and testing. The stages of inspection Before proceeding the applicator shall ensure that all
shall be as follows: materials to be used in the lining process are visually
examined and, where appropriate, physically and
a) The equipment as fabricated. practically tested to connrm that they are in an
acceptable condition. For the unvulcanized rubber
b) The equipment after preparation of welds and sheeting this shall include:
edges in the case of metals; surfaces and
edges in the case of concrete. a) Visual examination to ensure that it has no
imperfection which could significantly affect
c) The equipment after blast cleaning. the performance of the fmished vulcanized
lining.
d) The materials to be used in the lining process.
b) Visual and physical examination to ensure
e) After the lining has been applied and before that it has been prepared in accordance with
vulcanization. section four and that the actual thickness is
within ± 10 percent of the specified thickness.
f) When the arrangements are made to interrupt c) A test to ensure that the sample taken from
vulcanization. each roll achieves the correct hardness when
vulcanized in accordance with the customary
g) After vulcanization is complete. practice of the applicator.
h) Whenever remedial work is carried out.
194 Visual Appearances of the Lining
18.2 In cases where the purchaser requires 19.4.1 Inspection for visible defects shall be carried
independent inspection of the work (i.e. by the out over the entire surface of the lining in a good
inspection authority) at various stages, those stages light, attention being paid to any areas of mechanical
shall be defined [see 4.1 (xxi)]. damage, cuts, blisters, lack of adhesion and poor
jointing.
19 INSPECTION
19.4.2 If the applicator finds a defect prior to
19.1 Surface Cleanliness and Profile of Metal vulcanization it shall be removed and the area overlaid
Surfaces with unvulcanized rubber of the same type as the
19.1.1 Blast-cleaned surfaces shall be inspected to original unvulcanized rubber on to which it is bonded.
ensure that they comply with 13.1. After subsequent vulcanization the area concerned
shall be considered identical to a lap joint or seam
19.1.2 Reference photographs or plates shall be used and thus fully acceptable.
to establish the level of surface cleanliness (see 13.1.3).
19.1.3 If inspection of equipment after blast cleaning 19.4.3 All scarf joints shall be closely inspected. Any
reveals defects in material or welds, the applicator separation of the joint shall be investigated (see Fig.
shall inform the fabricator and/or the purchaser and 8). If the extent of the separation is small then the
any remedial action shall be determined after rubber shall be ground bock. If the separation of the
consultation between the parties concerned [see 4.1 rubber is extensive then the joint and rubber adjacent
(xxi)]. to the joint shall be removed and replaced.
14
IS 4682 ( Part 1 ) : 1994
15
IS 4682 ( Part 1 ) : 1994
unvulcanized rubber both of the same type as used If further evidence is required to show that the bond
for the lining shall then be applied. The size of this between the substrate ind the rubber is satisfactory
patch shall not be greater than 25 mm in any direction the provision of test samples shall be specified during
beyond the defect. The patch shall then be vulcanized. the relevant discussions at an early stage [see 4.1
After rectification, the repaired area shall be tested (xvii)).
for pinholes. Minor wrinkles and surface markings
NOTE — Because there is DO quantitative non-destructive test
which have no significant effect on the performance for assessing the bond strength between a rubber lining and
of the lining shall be acceptable. the substrate no routine bond strength tests are specified for
the actual lining as part of the inspection procedure. The bond
NOTE — After vulcanization defects such as blisters, Wow strength for a particular combination of substrate, rubber and
holes, small cracks or scuffed areas in the lining may be found. adhesive system may be established by laboratory testing.
When such faults are discovered after vulcanization the defect
may be patched. 20.3.2 Test samples shall consist of pieces of substrate,
similar to that used in the manufacture of the equipment,
20 TESTING to which has been applied rubber of the same mix
and thickness used for the main lining. The adhesive
20.1 Hardness Tests system shall be the same as that used for lining. The
conditions of application shall be the same.
20.1.1 Hardness testing shall be carried out on Vulcanization shall be carried out at the same time
completion of vulcanization in accordance with IS as the lining, in the same autoclave or inside the
3400 (Part 2): 1980. If after initial testing any further equipment when vulcanization takes place outside of
vulcanization is required, the lining shall be re-tested an autoclave.
and shall meet the agreed hardness (agreed by contractor
and user) at all points. 20.3.3 The bond strength between rubber and a
substrate shall be measured by method B described
20.1.2 Hardness testing shall be carried out on a flat in IS 3400 (Part 14) : 1984. Minimum load figures
smooth surface. In vessels where readings cannot be for bond strengths obtainable with various types of
taken on the surface of the lining, buttons shall be rubbers, vulcanized by different methods, shall be as
provided in positioas to be agreed between the purchaser given in Table 2.
and the lining contractor. If the surface is too rough,
a light local scraping or buffing may be carried out NOTE — There is no quantitative test for measuring the bond
strength of hard rubber or ebonite to substrates. A qualitative
to facilitate testing. assessment of the bond can be made by chipping the lining
on a test plate with a chisel 25 mm wide when it should be
20.1.3 Readings obtained shall conform to the possible to loosen only small pieces of hard rubber or ebonite
specified hardness of the compound within ±5 percent. at each blow.
A minimum of three hardness readings shall be taken
for each square metre of lining. Where a reading is Table 2 Test Loads for Adhesion of Vulcanized
outside the agreed range, further readings shall be Soft Rubber to Carbon Steel and
taken on the same panel to ensure the general level Concrete Substrates
of hardness. Where repairs have been carried out or (Clause 20.3.3)
where marking is feasible, the areas concerned shall
Type of Rubber Carbon Steel Concrete
be separately tested.
Pressure Vulcanization Self
20.2 Continuity of Lining (High Frequency Spark Vulcani- by Hot Water Vulcaniza-
Test) zation or Steam at tion at
Atmosphcric Ambient
Pressure Temp
20.2.1 Testing for pinholes and other discontinuities
(1) (2) (3) (4) (5)
shall be carried out : kN/m kN/m kN/m kN/m
a) When the rubber has been applied and before Natural of synthetic 3.5 2.7 2.7 1.0
vulcanization. polyisoprene
Styrene-butadiene 3.5 2.7 2.7 1.0
b) After interrupted vulcanization. Polychloroprenc 3.5 2.7 2.7 1.0
c) After complete vulcanization. Butyl 3.5 2.7 2.7 1.0
Ethylene-propylene 3.5 2.7 — 1.0
d) After any remedial work. Nitrilc 3.5 2.7 2.7 1.0
20.2.2 When tested in accordance with the method Butadiene and/or 3.5 2.7 — —
blends
described in Annex F, the linings shall be continuous
i.e free from pin holes, crack and lack of adhesion. Chlorosulphonated 2.7 2.7 — 1.0
polyethylene
20.3 Bond Strength Tests
20.3.4 The manner of stripping is of great significance.
20.3.1 All open edges, for example flanges, shall be If the metal is clean or if failure has occurred at the
examined by hand for evidence of poor bond strength. rubber/adhesive interface this should be taken as an
16
IS 4682 ( Part 1 ) : 1994
indication of an unsatisfactory bond. A properly bonded period (normally one hour). The lining shall be
sample should leave traces of rubber sheet adhering subsequently reinspected for defects.
to metal indicating failure within the rubber.
21 RECTIFICATION OF FAULTS IN FULLY
20.4 Lining Thickness Check CURED LININGS
The thickness of the lining shall be checked. Where 21.1 When rectification of faults is to be made in
direct measurement is not possible a suitable thickness linings which are fully vulcanized special attention
metal shall be used. shall be paid to the problems of achieving adhesion
between the new rubber and the vulcanized lining.
20.5 Hydraulic Testing of Lined Equipment
21.2 With all linings a patch which extends 25 mm
Normally pressure testing of equipment is completed beyond the area to be repaired shall be abraded to
before the commencement of the lining operation. promote adhesion.
When specified, pressure tests shall be carried out
[see 4.1 (xxi)]. The joint rings used for this test shall 21.3 When priming of the substrate is an essential
be of the same material and the same dimeasioas as part of the system the first step after preparation shall
those specified for the final service conditions. During be to establish whether the primer is intact. If the
a pressure test no leakage shall occur. The lining primer is damaged when it shall be repaired before
shall be subsequently reinspected for defects. the rest of the work proceeds.
20.6 Vacuum Testing of Lined Equipment 21.4 Rectification of faults using other than the original
material used for the lining shall only be permitted
When specified, a vacuum test within the design with the written permission of the purchaser.
limits of the equipment shall be carried out by
evacuating the lined equipment with the appropriate 21.5 After all rectification work the lining shall be
joint rings in position, to a specified vacuum [see 4.1 subject to inspection as appropriate and in particular
(xxi)]. The vacuum shall be maintained for a specified to continuity testing.
22.1 Lined equipment shall be stored under cover or 23.1 Maintenance of Rubber Lined Equipment
in a protected compound. When necessary, linings
shall be shielded from direct sunlight. 23.1.1 It is recommended that all rubber lined plant
and equipment should be thoroughly inspected at the
22.2 All branches, manholes and other openings shall end of the first year of service. If its condition is
be protected from mechanical damage by using satisfactory and it is not subject to statutory inspection
wooden blanks or other suitable material. after a lesser period some major users do not then
inspect again for a further 5 years. Others refer to
22.3 Lifting shall be arranged so that chains and inspect at more frequent intervals.
other lifting aids do not come into contact with lined
surfaces. 23.1.2 When carrying out inspections it is normally
sufficient if there are visual, supplemented by hardness
22.4 High local loads on lined surfaces shall be tests using a hand meter. If blisters or other evidence
avoided. of failure are discovered then an electrical continuity
test is essential.
22.5 Loose fittings shall not be placed inside lined
equipment whilst it is being transported. 23.1.3 It is essential that personnel be instructed in
the proper procedures to be adopted when entering
22.6 Responsibility for arranging transport of lined rubber-lined vessels. A clearance certificate should
equipment will vary and whoever is responsible always be obtained from the appropriate authority
(purchaser, fabricator or applicator) shall instruct the before doing so. The following points should be
carrier about the precautions in handling [see 4.1 observed :
(xxii)]. a) Personnel should not wear studded boots or
other footwear likely to cause damage. Rubber-
22.7 It is essential that the purchaser issues instructions soled shoes are to be preferred.
to those responsible for installation on the handling
procedures and special reference is made to the need b) In cases where solid deposits have to be
to wear soft clean footwear when entering lined removed the use of metal spades or other
equipment and this need to protect lined surfaces from tools is to be avoided. Wooden or lined
ladders and scaffold poles. implements should be used.
17
IS 4682 ( Part 1 ) : 1994
c) The ends of ladders or scaffolding likely to d) In Urge ebonite-lined vessels precautins to
come in contact with the rubber lining should avoid successive flexing should be taken and
be covered in such a way that damage is walkways laid if necessary.
avoided. Swinging air lines or hoses can
also puncture rubber linings. Metallic ends 23.1.4 Inspection should always be carried out by
should therefore be covered to prevent this two people unless the use of ladders or electrical
occurring. equipment can be avoided.
ANNEX A
( Clause 2 )
LIST OF REFERRED INDIAN STANDARDS
456 : 1978 Code of practice for plain and 3400 (Part 2) : Methods of test for vulcanized
reinforced concrete (third revision) 1980 rubbers: Part 2 Hardness (first
revision)
803 : 1976 Code of practice for design,
fabrication and erection of vertical
3400 (Part 14) : Method of test for vulcanized
mild steel cylindrical welded oil
1984 rubbers : Part 14 Adhesion of rubber
storage tanks (first revision)
to metal (first revision)
1876 : 1961 Method for voltage measurement by
means of sphere gaps (one sphere 7503 (Part 1) : Glossary of tenns used in rubber
earthed) 1988 industry : Part 1 Definitions of basic
2825 : 1969 Code for unfired pressure vessels terms (first revision)
3370 (Part 1) : Code of practice for cohcretc
structures for the storage of liquids : 7503 (Part 2) : Glossary of terms used in rubber
1965 industry : Part 2 Definitions of
Part 1 General requirements 1988
additives (first revision)
3370 (Part 2) : Code of practice for concrete
1965 structures for the storage of liquids : 7503 (Part 3) : Glossary of terms used in rubber
Part 2 Reinforced concrete 1988 industry : Part 3 Definitions relating
structures to properties and testing (first
revision)
3370 (Part 3) : Code of practice for concrete
1967 structures for the storage of liquids :
Part 3 Prestressed concrete structures 7503 (Part 4) : Glossary of terms used in rubber
1988 industry : Part 4 Definitions relating
3370 (Part 4) : Code of practice for concrete to processing (first revision)
1967 structures for the storage of liquids :
Part 4 Design tables 10500 : 1991 Drinking water (first revision)
ANNEX B
( Clause 6.2)
LINING OF USED EQUIPMENT
B-1 Provided that previously used plant and equipment B-2 When it is necessary to replace a rubber lining
is structurally sound and that it has not been subjected in existing equipment the old lining shall be removed
to extensive corrosion, relining is normally possible. by one of the following methods:
It is, however, particularly important that the lining
contractor should inspect such items and agree that a) Burning — Most rubbers may be removed by
they are in a suitable condition for him to undertake this procedure but it is subject to certain
the work. disadvantages.
18
IS 4682 ( Part 1 ) : 1994
1) Metal structures may warp as a result aplication of a mechanical chisel to the rubber/
of the heat generated. metal interface.
2) Noxious or toxic fumes will be generated B-3 After removal of the old lining the metal should
and in the case of ebonites and the be prepared in the normal way. Inspection to check
essentially non-combustible poly- the vessel's mechanical suitability for the duty should,
cbloroprene these will be particularly if necessary, be also carried out at this stage.
objectionable and may constitute a
health hazard. B-4 When the old lining has been removed and
inspection has confirmed that the item is mechanically
It is essential therefore that care be taken to sound and in a suitable condition for relining, the
ensure that anti-pollution laws are not infringed standard procedures outlined in this specification should
by this procedure. be followed.
b) Heating — This is a more acceptable alternative B-4.1 However, if there is any reason to suppose
to burning and involves raising the that there has been any impregnation of the metal by
temperature by externally beating the chemicals, it is sound practice to sweat the metal in
equipment so that the bond to the metal is live steam before shot-blasting.
weakened. The heat process is followed by
mechanical removal of the rubber. B-4.2 Where noticeable corrosion has occurred
relining should be avoided. However, linings can be
c) Mechanical Removal — The most effective applied when the surface to be protected is additionally
method in instances where adhesion to the pretreated, for example by grinding, neutralizing, flame
metal is still good is to cut through the rubber descaling or annealing, but the user should be warned
so that it is divided into narrow strips. These of the likely risks entailed in obtaining a satisfactory
can then be most readily removed by lining.
ANNEX C
(Clause 11.1.2)
CHARACTERISTICS OF LINING MATERIALS
19
IS 4682 ( Part I) : 1994
C-3 SOFT RUBBER LININGS rubber NBR) and its variant, carboxylated nitrile robber
(XNBR), have excellent resistance to swelling by
C-3.1 Natural (NR) or Synthetic Polyisoprene (IR) mineral oils and fuels. Polymers of high acrylonitrile
Rubber to butadiene ratios have the best resistance and also
have lower gas permeability. Higher butadiene ratios
Lining compounds based on polyisoprene rubber are have better low temperature proerties. The polymers
resistant to the majority of inorganic chemicals with should not be used with phenols, ketones, strong
the exception of strong oxidizing agents. Resistance carboxylated acids, aromatic hydrocarbons and nitrogen
to organic chemicals is limited with the rubber being derivatives.
unsuitable for use with hydrocarbons, halogenated
hydrocarbons, mineral oils, many vegetable oils and C-3.6.2 Carboxylated nitrile rubber is normally used
esters. When suitably compounded polyisoprene can for its outstanding abrasion resistance especially in
be used over the temperature range of –30°C to +100°C. combination with butadiene rubbers.
20
IS 4682 ( Part I ) : 1994
C-4.2 Hard rubbers and ebonites generally have a elongation at break of 2 percent to 10 percent. Hence
higher resistance to chemicals than soft rubbers based they are brittle compared to soft rubber lining materials
on the same polymer types. This resistance again at ambient temperatures. This brittleness can be reduced
generally increases with decrease in unsaturation of by using flexibilizing additives. Ebonites are
the vulcanized polymer. Resistance to chlorine gas thermoplastic materials.
and most aliphatic carboxylic acids is particularly
improved. C-4.3.1 Ebonites are normally used within the
temperature range 0°C to 100°C. For lower operating
C-4.3 Due to the increase in saturation when high temperatures, ebonites modified with flexibilizcrs or
levels of sulphur are used ebonites usually have a low non-ebonite hard rubbers arc often used.
ANNEX D
(Clause 11.1.4)
EFFECT OF MATERIALS ON WATER QUALITY
D-1 When used under the conditions for which they D-2 Concentrations of substances, chemicals and
are designed, materials in contact with or likely to biological agents leached from materials in contact
come into contact with potable water shall not constitute with potable water, and measurements of the
a toxic hazard, shall not support microbial growth relevant organoleptic/physical parameters shall not
and shall not give rise to unpleasant taste or odour, exceed the maximum values as given in IS 10500 :
cloudiness or discoloration of the water. 1991.
ANNEX E
(Clasue 11.1.1)
VULCANIZATION
E-1 Rubbers are made up of long chain molecules. maintained depends upon the thickness of the lining,
Within these molecules chemically active sites exist its fonnulation and the mass of the substrate.
by means of which the chains can be interlinked. This
process is known as vulcanization and the most E-6 Containers and equipment which because of
common vulcanizing agent is sulphur. transport difficulties or because of their dimensions
cannot be vulcanized in and autoclave, are lined and
E-2 Vulcanization is effected either by means of vulcanized on site. Under such circumstances self-
heat and pressure or by the application of heat alone vulcanizing rubber formulations or prevulcanized rubber
(i.e. without pressure) or in the case of self-vulcanizing sheets may be used, but where these are not considered
rubber compounds by allowing a sufficient period of to be suitable the following methods of effecting
time to elapse at ambient temperature. vulcanization are available:
E-3 Depending on the type of elastomer and a) Pressure vessles or others capable of
formulation used elastic compositions of varying withstanding pressure are normally vulcanized
hardness may be obtained. If sufficient sulphur to by the injection of saturated steam under
substantially saturate the sites available for cross linking pressure.
is added then ebonites are formed. These are very
hard thermoplastic materials. b) Non-pressure vessels may be vulcanized with
hot water, hot air or low pressure steam. When
E-4 When heat is necessary to promote vulcanization vulcanizing with low pressure steam, sudden
and the size of the metal equipment permits, the use changes or pressure should be avoided.
of an autoclave is to be preferred. Saturated steam
or hot air normally within the temperature rangq 125°C E-7 When vulcanizing on site, insulation or covering
to 160°C are usually employed as heat-transfer agents of the vessel is recommended, particularly in the
and the pressure can be up to 4.2 bar. event of low ambient temperatures. It should be noted
that vulcanization times of one or more days will be
E-5 After loading the equipment to be vulcanized required when the application of steam pressure is
the autoclave is heated under pressure to the vulcanizing not possible. For self-vulcanizing compounds,
temperature. The rate of heating to the vulcanizjng vulcanization time may extend to several weeks at
temperature and the time for which the latter is ambient temperature.
21
IS 4682 ( Part I) : 1994
E-8 It should be noted that the shelf life of the refrigerated transport and storage of the sheet may
unvulcanized sheet will be shorter in the case of be necessary. In the case of prevulcanized rubber
rapidly vulcanizing rubbers, self-vulcanizing sheet refrigerated transport and storage are not
compounds having the shortest storage lives. When necessary, but it should be protected from direct
high ambient temperatures are expected, sunlight.
ANNEX F
(Clause 20.2.2)
METHOD OF TEST FOR CONTINUITY TESTING
22
IS 4682 ( Part 1 ) : 1994
150 mm. In the case of linings to pipes, the end of frequency spark tester and the voltage shall be adjusted
the electrode should be shaped to fit loosely the inside to that agreed under 4.1 (xxi).
circumference of the pipe. The rods leaditig down the
probe have to be insulated. NOTE — Normally the spark length should not be less than
32 mm when applied across the surface of the rubber. Very
thin linings or linings where the rubber has a high conductivity
F-2.2.5 When the electrode is held on, or close to may require the test to be modified.
an insulating material there is a corona discharge.
When an insulating material containing a fault is
covering a substrate which is conducting then the F-3.2 The testing of linings shall be done in a
discharge concentrates at that point and the fault is systematic way. The surface of all but small equipment
located. Some rubbers arc compounded so that they shall be divided up by chalk line or other suitable
have a much lower resistivity than those in common marks into smaller areas of about 1 m2
use. These rubbers are sometimes referred to as
conducting rubber. When a high frequency spark test NOTE — By these means it is possible to check that the whole
of the lining has been examined.
is applied to such rubbers the nature of the discharge
is different and will concentrate in such a way that
it may be thought that the rubber contains faults. A F-3.3 Before testing begins the surface shall be made
very experienced operator can detect the difference, dry and free from dirt.
but nevertheless the use of such rubbers for lining
equipment intended for corrosive duties is not F-3.4 The probe shall be moved continuously over
recommended because of the difficulty in testing. the surface of the lining at a speed not exceeding 100
mm/s. Applying the spark to one spot for any
F-2.2.6 Tests have shown that the risk of damage to appreciable length of time shall be avoided.
most rubber linings by high frequency spark testing
is remote if the time the probe is allowed to dwell F-3.5 When a defect in the lining is discovered it
on any place is short. shall be clearly marked.
F-2.2.7 Breakdown of most linings by spark testing F-3.6 If it is necessary to carry out any machining
is by erosion until a critical thickness is reached. of hard rubber or ebonite linings, the spark test shall
During the time that the surfaces exposed to a spark be applied again to the lining to ensure that it has
in test conditions the material lost by spark erosion not been damaged in any way.
is negligible. However there arc some rubbers which,
because of the way they are compounded can be F-3.7 It is essential that inspectors have an
damaged by the spark concentrating through to the understanding of how the instruments work and the
carbon black, causing local burning of the rubber. need to survey the linings in controlled fashion.
Adequate testing of such linings is not possible and
they should not be used for equipment intended for F-3.8 Because of the need to ensure that continuity
a corrosive duty. testing is carried out to the required standard it is
preferable that the test work is done by a person other
F-2.3 Direct Current Spark Testers than the operator(s) who applied the lining.
F-2.3.1 This type of instrument may be powered by F-3.9 The rectification of laults discovered helore
mains or a rechargeable battery. The output voltage vulcanization shall be a normal part of the lining
varies with the make but a common range is 1 000 procedure.
V to 20 000 V. Most instruments do have a voltage
control and a built-in voltmeter and this is the model
recommended for use. F-4 WET SPONGE TESTING
F-2.3.2 With DC instruments it is necessary to have
an earth return. Unlike the high frequency instrument In the case of rubber linings which are normally at
there is only a discharge when the electrode is close least 3 mm thick and may contain scarf joints to 32
enough to a defect for the DC spark to bridge the mm in length wet sponge testing is not recommended.
gap to earth. The length of that gap is limited and This is because the time that may be required for the
is generally less than the length of the scarfed joints electrolyte to penetrate the hole in the rubber, or a
used in lining and therefore this type of instrument leak in a joint may be rather long. By the time the
is unsuitable for testing rubber linings. electrolyte reaches the substrate the probe may no
longer be in a position to complete the circuit.
F.3 TESTING Furthermore, in some cases when the mbber contains
a cut it is passible the electrolyte will not penetrate
F-3.1 The equipment used shall be an a.c. high that cut under the conditions of lest.
23
( Continued from second cover )
This Indian Standard was first published in 1968. This revision of the standard has been brought
out to incorporate the latest developments that have taken place in the country in the lining of
process vessels and other equipments used in the field of chemical processes. Important
modifications done in this standard being: