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Guide For Design & Fabrication Substrate For Rubber Lining
Guide For Design & Fabrication Substrate For Rubber Lining
(4) In case where insert pipe is equipped with vessel stand, the pipe shall have rubber lining overlapped as
below figure. Please take care of the finish dimension after rubber lining.
(Example) Case of Rubber lining with thickness of 4mm
4mm
8mm
Rubber Lining 4mm
4
8
Insert Pipe
[Figure-1]
(5) Dimension of inner wall should be calculated by subtracting the thickness of rubber and gasket from the
size of pipe. Flange bolt holes on substrate should be enlarged according to the thickness of rubber liner.
In assembly test before rubber lining, attach a liner sheet having equivalent thickness of rubber liner and
gasket.
(6) Make air vent holes (before welding) where it will be the doubled layer plates, such as nozzles,
reinforcement plate of manholes, and so on.
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(7) The surface that to be lined should be kept as simple as possible. Those reinforcements should be
applied on the surface that will be no lining applied.
(8) Rubber lined vessel should not be heated from outside in order to prevent separation and floating of
rubber sheet. Heating from inside is recommended using heating pipes. When heating from inside,
heating pipes should have distance at least 100mm from rubber lining surface. When you blow steam,
make sure that rubber lining surface is not subjected to steam directly.
Flange Part
or
G
3R 3R
G
3R
[Figure-2]
2
3. Dimension of pipes
3-1. Standard size of pipes
A4
A2
R2
R1
A3
A1
A4
A2
A1 A3
90D Long elbow 45D Long elbow 90D Smooth bend 45D Smooth bend
B
B B L1 L
L1
3
3-2. Maximum possible size of pipes
A2
B
R1
A
1
B
E2
E L3
1
90D Long elbow 45D Long elbow T-pipe
B B
L1 L2
(1) L4
(2)
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3-3. Notes
(1) The table above indicates the dimension of pipes.
(2) Diameter of pipe should be larger than 1B (25A).
(3) Use a reducer of standard size.
(4) The dimension in the table above is based on socket weld flanges of JIS-10K. If you need to use other
flanges, consult us in advance.
Do not use a flange with a gasket groove on the flange face.
(5) As for complicated shape of pipe, another consideration is required to determine the dimension.
(6) As for pipes of dilute sulfuric acid or hydrochloric acid, elbows should be divided to be the standard
dimension as described above.
(7) Maximum possible size of 9000 is determined by assuming transported by 10-ton truck. If the size
exceeds 9000, consult us in advance.
B
C
A
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4. Other cautions
(1) Pipes of lining work should be using seamless steel tubes as much as possible.
(2) Use of long elbow is recommended for L-shape pipe.
(3) Substrate to be lined should not be coated with rust-proof grease or zinc plating.
(4) In case of using rivet, use flush rivet on rubber lined surface and smoothen the surface by full penetration
welding.
(5) Leave parting lines and guide lines for final inspection.
(6) The nozzle shape of a vessel is desirable to be like the one in figure 3. Nozzle diameter should be larger
than 25A. When use of nozzle 20A is necessary, designing the nozzle better be based on pipe diameter /
flange 25A.
[Figure-3]
View on Allow A
[Figure-4]
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II. Standards for design and fabrication of Substrate
Followings are our standards for substrate fabrication. However, this may not be applied to your equipment in
some cases such as stated by regulations, specified in drawing and specifically by client. Inspection of substrate
shall be performed in accordance with our own standards unless otherwise specified.
1. General equipment
Item Guideline
Material should be specified in drawings.
Material Mill sheet (inspection certificate) is required only when specified.
Surface of material should be inspected by human eye.
Edge preparation Edge preparation should be specified in drawings.
1. Diameter tolerance should be within a range of 0.5% in plus or minus of
diameter.
If diameter tolerance exceeds plus or minus 10mm, it should be within plus or
minus 10mm.
2. Tolerance of overall length should be within;
3mm (Length is less than 1m)
5mm (Length is more than 1m)
3. Thickness of shell plate, head plate, nozzle and flanges should be within
specified tolerance.
4. Height of nozzle and manholes should be within mm.
5. Fall angle of nozzle should be within plus or minus 1 degree from the reference
plate.
Dimension
6. Inclination angle of nozzle flange should be plus or minus 1/2 degree.
7. Tolerance of mounting position of nozzle should be within plus or minus 3mm.
Level gauge should be installed.
8. Tolerance of pitch of bolt holes on a foundation should be within plus or minus
3mm.
9. Strain tolerance of the bottom plate is as follows.
Main dimension (mm) Tolerance (mm)
Less than 1000 5
1000 to 3000 10
3000 to 5000 15
Larger than 5000 Maximum 20
10. Machine finishing should be performed in accordance with JIS standard.
When jointing steel plates with different thickness, be sure each of inner diameters fit
perfectly. Thickness difference at joint part should be less than 25% of the thickness
Welding
of the plate. The face of shell flange should be machine finished to make the surface
smooth enough to withstand test pressure.
1. Any defects (such as cavities, pinholes, etc.) are detected on weld lines.
2. No undercut.
Appearance
3. No remarkable damage or faults on the surface.
4. Leave parting lines and guide lines.
Water pressure test, airtight test and vacuum test shall be carried out as specified in
drawings. (Airtight test shall be done by compressed air.)
Pressure test
Airtight test should be executed if it is difficult to perform water pressure test. In this
case, test pressure shall be 1.25 times of the maximum working pressure.
* When assembling the substrate at site, refer to separate standard.
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2. Pipes
Item Figure Tolerance (a) Remarks
Weld
reinforcement
t 10mm
(Weld bead more than 50
edge) Reinforcement
a a = D 0.01mm
Roundness
*D: Diameter
Longitudinal direction
a 1mm.
(The surface should be
finished with a grinder
after welding.)
a
In case inner surface
Discrepancy Circumferential direction grinding is available
a 1mm In case thickness is different
(The surface should be
finished with a grinder
a after welding.)
t1 t2
In case inner surface
grinding is not
available
a 0.5mm (t1 t2) 10
(Root opening is zero
and there is no
welding dripping)
Height of bead
More than 600A
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Item Figure Tolerance (a) Remarks
L < 1m L
a = +0mm
-3mm L
Length
L L 1m
a = +0mm L L
-5mm
Parting b1 or b2
dimension a = +0mm
of T-pipe -3mm
b1 b2
100A
a a
a 1.5mm
125A200A
Inclination angle a 2.0mm
of flange 250A500A
a a 3.0mm
550A
a 5.0mm
Position of bolt
a = 1.5mm
hole
Discrepancy of
bolt holes of end a = 1.5mm
flanges a