Vulcoferran 2190 WE

 Working Instruction ® 32.08.251E – 01/08 VULCOFERRAN 2190 Description VULCOFERRAN 2190 is a graphite filled hard rubber lining based on isoprene rubber (IR) that is vulcanised in layer an autoclave. Depending on the requirements, the between 3 and 6 mm. thickness of the rubber sheet may range Materials Article - No. VULCOFERRAN 2190 sheet VULCOFERRAN 2194 sheet 60 71602 200-600 Primer 1 60 71610 20-60 Primer 2 50 40271 800 Vulkodurit adhesive LS3A 50 40274 800 Vulkodurit adhesive LS3A for 50 40253 801 rubber lining of pipes 50 40269 801 VULCOFERRAN seam solution 2104/N1 50 40703 801 KCH diluent 5 50 40021 890 Working tools Various brushes and rubber lining rollers, rubber lining knives, scrapers (approx. 30 mm wide), heated irons, rubber measuring receptacles. plugs as well as soft rubber roller and Material and substrate temperature Material: lining material should be min. +15°Substrate: favourable range between 10 °C dew point distance min. 5 K C and 30 °C relative air humidity ≤ 75% Substrate Steel - The steel components to be rubber lined must meet the requirements of DIN EN 14879-1. Surface pre-treatment Steel - The steel surface must be blasted to a metallic white specified finish. degree 8503 - 1 must be achieved; minimum roughness of in A preparation degree of Sa 2 ½ as \"medium DIN EN (G)\" ISO as 12944-4 specified and in a DIN roughness EN ISO Rz = 50 µm (Segment 2). With a relative air humidity of ≥ 50% it has to be primed after the blasting. Stainless steel - Stainless steel must be blasted using non-ferritic blast medium. Working To labels, ensure safe working the EC safety data sheets shall be followed.in the operating instruction the hints given as well on the as in The individual components shall be mixed completely and receptacles shall be involved in the mixing process.thoroughly. The wall and bottom of the mixing Substrate Steel substrate Consum(g/m²) ption subsequent coat Waiting time for min. max. Tanks and pipes DN > 500 Vulkodurit adhesive LS3A, brushing 250 2 hours 7 days Vulkodurit adhesive LS3A, brushing 250 2 hours 7 days Pipes DN < 500 Vulkodurit adhesive LS3A, flow coating 500 2 hours 7 days with rubber lining of pipes Stainless steel substrate and Consumalready chemical ption subsequent coat Waiting time for stressed chlor-cells (g/m²) min. max. Primer 1, brushing Primer 2, brushing 150 45 min. 7 days Vulkodurit adhesive 200 1 hours 7 days LS3A, brushing 250 2 hours 7 days Vulkodurit adhesive 250 2 hours 7 days LS3A, brushing Rubber sheets Consum> 4 mm thickness (g/m²) ption subsequent coat Waiting time for min. max. Gluing side Vulkodurit adhesive Ls3A, brushing 200 30 min. 24 hours alternative Seam solution 2104/N1 100 15 min. 24 hours Seams Seam solution 100 15 min. 24 hours 2104/N1 01.01.08 Working Instruction VULCOFERRAN 2190 32.08.251E, Page 2 of 3 Gluing of the rubber sheets Gluing on steel After expiration of the specified flash off periods the rubber sheet cut to size is applied without stretching, slightly pressed by hand onto the substrate and rolled or using a heated iron or scraped onto it. In the areas of weld seams, corners, edges and valleys, as well as rubber lining seams the rubber sheet is firmly rolled onto the substrate using a small steel roller. Multi-layer gluing The gluing side of the lower and upper rubber sheet is brushed once with the seam solution 2104/N1 and Tests prior to vulcanisation Visual inspection for defects (blisters, seam defects, etc.). Testing on continuity according to paragraph “Initial test”. Remedy of defects prior to vulcanisation All defective areas having been detected during testing are cut out rectangularly in a bevelled manner and are mended according to the instructions given in paragraph “Working” using VULKOFERRAN 2190-sheets. allowed to flash off for approx. 15 minutes. The with staggered seams. rubber sheets are applied as described above Rubber lining of pipes A nominal width of the pipe. rubber hose is pre-fabricated according to the Rubber lining of pipes DN < 50 The rubber hose is richly brushed with KCH diluent 5 and solvents pulled in wet condition into the pipe. Once all pressed to the pipe walls. have completely flashed off, the hose is Rubber lining of pipes DN 50 - DN 125 At Vulkodurit adhesive LS3A and allowed to flash off for both ends the rubber hose is brushed inside with at closed. Through an opening of approx. 10 mm at the least 30 minutes. One end of the hose is tightly opposite The blown-up hose is tightly closed and quickly pulled end compressed air is blown into the hose. into the pipe using a rope. To ensure that the rubber lining fitting is the pipe. plug pressed greased to the with pipe soft walls soap without is pulled blisters, through a Rubber lining of pipes DN 125 - DN 500 The according rubber into the pipe after expiration of the specified flash off to the hose nominal having width been of the pre-fabricated pipe is pulled periods of using an anti-adhesive fabrics. After removal greased the silicon press with cloth a fitting rubber plug (rubber pear) blisters. the rubber soft soap lining is to pulled the through pipe walls the pipe without to Formation of seams The sketch (DIN 28055-1). seams are formed according to the following Vulcanisation Autoclave vulcanisation with hot air Vulcanisation pressure: > 3,5 bar The pressure must be built up prior to heating up and may only be lowered after cooling down is finished. Vulcanisation temperatures Heating up: in 3.0 hours to 138°C Plateau: for > 6.0 hours at 138°C Cooling down: cool down to 90 °C With different loading of the autoclave the program for the heating up period must be modified. Autoclave heating up to 18 mm rubber thickness vulcanisation with steam – air mixture The pressure must be built up prior to heating up and may only be lowered after cooling down is finished. Heating up: in 1.0 hour to 115°C Holding: for 2.0 hours at 115°C Further heating up: in 1.0 hour to 125°C Holding: for 1.0 hour at 125°C Further heating up: in 2.0 hours to 138°C Plateau: for 6.0 hours at 138°C Cooling down: cool down to 90°C With different loading of the autoclave the program for the heating up period must be modified. Tests following vulcanisation The tests are carried out according to DIN 28055-2. Visual inspection Here the lining is inspected for visible defects such as blisters, mechanical damage. entrapments, irregularities, cracks or Hardness test The Shore D hardness is measured. Hardness: (80 ± 5) Shore D 01.01.08 Working Instruction VULCOFERRAN 2190 32.08.251E, Page 3 of 3 Layer thickness measuring With steel substrates measuring is carried out with a magnetic inductive layer thickness tester, e.g. of the company Elektro-Physik. Layer thickness: > (set value - 10%) Observe special order-related regulations. Adhesive strength If required in the order the adhesive strength is tested on sample plates having been produced simultaneously to the work. Tapping test with hammer and chisel: Conchoidal chipping in pieces. Test according to DIN EN ISO 24624 (front peeling off method): Adhesive strength: > 6 N/mm² The test according to DIN EN ISO 24624 is carried out upon special request only. Testing on continuity and cracks Initial test: Test appliance: Elmed-Isotest-II-RT appliance earthed Rubber sheet 2 mm 3 mm 4 mm 5 mm 6 mm thickness Adjustment 0.56 1.35 2.36 3.38 4.35 Reading 1 1 1 2 2 sensitivity Test voltage 6 9 12 15 18 (kV) Test appliance: Wegener Spark Tester \"Weg 20\" Rubber sheet 2 mm 3 mm 4 mm 5 mm thickness Test voltage 15 25 30 30 max. (kV) Other test appliances are not admissible. Repairs Cut out all defective areas rectangularly. Grind the steel metallically white and roughen it. Roughen the adjacent rubber lining areas. Wash off the complete area to be repaired with KCH diluent 5 and brush the steel substrate with primer 2 after expiration of the flash off period. Then apply two coats of Vulkodurit adhesive LS3A. For the further procedure of applying the VULCOFERRAN 2194 sheet refer to paragraph “Gluing of the rubber sheets” etc. After the repair the components are vulcanised again (autoclave or heating plate). Other repair methods are subject to approval by the KCH GROUP, department AT. Cleaning of working tools The working tools are cleaned using KCH diluent 5. Cleaning must be carried out prior to hardening of the material. Waste Waste is to be disposed properly. Storage of materials Shelf life of the products (unopened original containers) - see label ! Higher temperatures shorten the shelf life. The containers are to be kept well locked and be locked again after each material withdrawal. All products are to be stored in a dry and cool place (liquid and pasty products frost-proof). The regulations for the fire and explosion prevention are to be respected. The technical data contained herein represents the current state of our product knowledge and is intended to furnish general information regarding our products and their application spectrum. In view of the diversity and multitude of application possibilities, this data should be regarded solely as general information, which does not guarantee any specific properties and/or suitability of these products for each concrete case of application. Consequently, when ordering a product, please contact us for detailed information relative to the properties required for a specific application. Our technical service will, upon request, furnish a profile of characteristics for the concrete application without delay. KCH Technologies GmbH P.O. Box 11 63, D-56425 Siershahn Phone: +49 2623 600-0 / Fax: +49 2623 600-433 / eMail: technologies@kch-group.com