Keeping Production on Track: 5,000-Gallon Glass-Lined Series 60 Lighnin Reactor &Shaft Repair
Six months after installation, a 5,000-gallon Series 60 Lighnin reactor’s agitator shaft and drive system experienced an unexpected failure. The mechanical seals had been destroyed, and the agitator shaft showed visible damage. The OEM technician, after disassembling the unit, advised the customer to order a brand-new shaft and seals before departing the plant, leaving production at a standstill and a costly replacement looming.
That’s when Glasslined Technologies, Inc. was called in.
With a replacement reactor already scheduled for installation during the plant’s 3rd quarter 2025 shutdown, our client needed a fast, reliable, and cost-effective interim solution. After inspecting the damage, our team offered three options to return the reactor to service quickly and safely, without unnecessary spending or downtime.
The Chosen Solution: Repair Over Replacement
The selected repair approach involved several key steps:
• Installing FEP boots on the agitator shaft just below the honed glass area.
• Re-seating the large tantalum patch using a new gasket.
• Installing new mechanical seals.
• Verifying shaft runout and performing a test run on the drive system.
Visual inspections showed clear signs of wear on the shaft, most notably, a damaged area just above the seal journal that had narrowly avoided impacting the honed surface. Additional damage was also discovered on the larger diameter section of the shaft.
Our team carefully smoothed worn areas using 320-grit emery cloth and applied FEP over both damaged sections. Once the drive system was reassembled with the new seals, we confirmed shaft runout was within spec. The seals were rigorously pressure tested statically and then subjected to a three-hour run test under load—with all readings confirming a leak-free operation.
Back in Action—On Time and On Budget
Thanks to our strategic repairs and fast response, the customer was able to keep this reactor in production until the scheduled Q3 2025 shutdown, when the permanent replacement will be installed.
At Glasslined Technologies, Inc., we specialize in practical, cost-saving solutions for glass-lined processing equipment. Whether it’s a proactive maintenance plan or an emergency repair, our expert team is ready to respond with precision, reliability, and results that last.
