Wear protection slurry lining
Rexline Rex Premium Test Certificate
| ITEM DESCR: NATURAL RUBBER 38-098-ts-255-RE- INDUSTRIAL RUBBER SHEETS-SOLID ONE SIDE SMOOTH OTHERSIDE BUFF FINISH-12.00MM-1.50MTR-X10.00MTR | |||
| NO. | TEST PARAMETERS | SPECIFICATION | OBSERVATION |
| 1 | POLYMER | NATURAL RUBBER | |
| 2 | SURFACE | RED INDUSTRIAL RUBBER SHEETS SOLID ONE SIDE SMOOTH OTHER SIDE BUFF FINISH | |
| 3 | THICKNESS in (mm) | 2.00+0.2 | 2.10 |
| 4 | WIDTH in (mtr) | 10.00+2% | 1.51 |
| 5 | LENGTH in (Mtr) | 10.00+5% | 10.20 |
| 6 | SPECIFIC GRAVITY | 0.98+0.05 | 0.99 |
| 7 | HARDNESS (ShoreA) | 38+5 | 37-38 |
| 8 | TENSILE STRENGTH in kg/cm2(min) | 255 | 260 |
| 9 | ELONGATION ATBREAK %(min) | 900 | 960 |
| 10 | ABRASION TEST (mm3) | 80 | 75 |
| 11 | QUANTITY (ROLLS) | 10 | |
| 12 | QUANTITY (kgs) | 1821 | |
| CONCLUSION: – ABOVE MATIERLA MEETS ALLREQUIRMENTS AS PER SPECIFICATION. | |||
| THIS IS TO CLEATIFY THAT THE WHOLE OF THE SUPPLIES DETALED HERE ON HAVE BEEN INSPERCTED, TESTED AND UNLESS OTHERWISE STATED ABOVE CONFIRM IN ALLRESPECTS WITH THE REQUIRMENTS OF THE CONTRACT OF THE ORDE. THE QUALITY ARRANGEMENTS ADOPTED IN RESPECT O THERE. | |||
Case Study 1
Spools Fabrication & Rubber lining
Details
| Project Name | Rubber Lining of Spools with Rexline Rex Premium |
| Project No. | PO4500095536 & PO4500095543 |
| Asset | 650NB Spools – Various sizes |
| Document ID | #01 |
| Date Produced | 22/10/17 |
Project scope performance
Deliverables
Fabricate and Paint to Spec. System E, Beige and Rubber Line with 25MM Thick REXLINE REX
- SPOOL, T,985MM,215-1382/0135-R7L1-650-SPP -7 no’s
- SPOOL,2737MM,215-1382/0135-R7L1-650-SPP -6 no’s
- SPOOL, T,849MM,215-1382/0135-R7L1-650-SPP -5 no’s
AG Mill Concentrator Suction Spool Set
| Process Parameters | Explanations |
| Application of these pipes | Slurry piping |
| Mode of failure | Normal wear and tear – Liner worn |
| Areas of failure | Near flange areas, elbows and tee off points. |
| Current Life of the pipe | Varies from pipe to pipe refer attached spread sheet |
| Material/particle size | Max particle size 12 – 25mm, no size distribution data available |
| Velocity | Pumped velocity not available |
| Pump discharge pressure | 3500Kpa |
| Density | 50% 1472 kg/m3 |
| Normal flow rate | 5500 m3 |
| Maximum flow rate | 8000m3 |
| Pipe size used | DN550, 600 & 650 in various lines |
Note: These pipe lines are feeding cluster of cyclones where min required pressure is 35kpa and flow rate is 3800m3.
Major scope changes
Replacement of Premium Red Rubber 25mm by 24mm Thick REXLINE REX Premium.
Comments
REXLINE REX Premium has better wear life compared to Premium Red Rubber. Overall cost saving of 40% on the Rubber Lining and better life.
Project benefits review
| Proposed Changes / Benefits | |
| Life | Expected life on the market premium red rubber was exceeded by 30% upon installation of REXLINE Rex Premium. |
| COST | Cost involved in maintenance of these set of spools was reduced by a minimum of 40% on a projection of 1 year. |
Case Study in Pictures
Case Study 2
Feed Distributor
Details
| Project Name | BACK LOADING OVERSIZED DISTRIBUTOR BOX #1 |
| Project No. | PO4500108943 |
| Asset | BACK LOADING OVERSIZED DISTRIBUTOR BOX #1 |
| Document ID | #05 |
| Date Produced | 29/10/17 |
Project scope performance
Deliverables
Project benefits review
| Scope of Work | |
| Dismantle and Inspection | A.Unload the distributor box from transport vehicle B.Unload the Distributor box from transport frame C.Dismantle the distributor box D.Clean the distributor box E.Visual inspection of the distributor box F.Thickness measurements and submit report G. General condition report on supported with photos |
| Removal of Existing Lining | A.Blast and remove the rubber lining |
| Repair and Welding | A. Cut out the workout section, subject to thickness of plate retaining existing nozzle B. Re weld and blend for rubber lining C. Cut out and replace the entire nozzle section D. Weld patches of external compensation plates. Thickness of 20mm |
| Surface Treatment and Rubber Lining | A. Internal blast of the distributor box B. Application of Chemlok 205 C. Rubber Lining 25m REXLINE REX PREMIUM D. Replace existing seals/flange rubber on the endplate sealing faces E. Internal blast of the distributor box F. Application of Chemlok 205 G. Rubber Lining 25m REXLINE REX PREMIUM H. Replace existing seals/flange rubber on the endplate sealing faces |
| Assembly | A. Reassemble the distributor box B. Record the assembly data C. Fasteners replacement |
| Blast and Painting | A. Blast and Painting to specifications B. Inspection reports and quality tests |
Note: The distributor had few of the nozzles blow out due to the excessive wear on the outlets. The issue was found to be caused by wear on the previous rubber sheeting which was worn out and subsequently causing damages to parent metal.
Major scope changes
Replacement of existing rubber lining with REXLINE Rex Premium of equivalent thickness
Project benefits review
| Proposed Changes / Benefits | |
| Life | Life of the distributor was increased by 25% without any significant wear on the outlet rubber lining providing complete protection for parent metal |
| COST | Overall cost of the maintenance was reduced by 25% |
Case Study in Pictures
