Revitalizing 4000 Gallon SA Series Reactors: A Reglass & Rebuild Success Story

At GTI, we pride ourselves on transforming challenges into opportunities, and our recent reglass and rebuild project for two 4000-gallon reactors is a prime example. We received one De Dietrich glass-lined reactor and one Pfaudler glass-lined reactor, both destined for a comprehensive overhaul that not only restored functionality but also enhanced system performance.

Initial Inspection & Preparation

Upon arrival, both reactors underwent a thorough inspection. Our team evaluated the glass integrity and the steel substrate of each reactor. For the reactor jackets, a complete replacement was necessary, ensuring each component met ASME code design pressure requirements. The old PTE-drive system was scrapped, paving the way for a complete modernization.

The Reglass Process: Cost-Effective & Efficient

Reglassing has become an invaluable option for reducing both cost and delivery time in many industrial projects. Here’s how we approached the reglassing of these reactors:

⦁ Old Glass Removal: The outdated glass lining was carefully removed to expose the steel substrate.

⦁ Steel Inspection and Repair: We conducted a detailed evaluation of the substrate, measuring steel thickness and repairing any corrosion or damage in compliance with ASME code requirements. During this phase, modifications such as nozzle additions can be performed—in this case, side nozzles were added to enhance the reactor’s utility.

⦁ Firing & Inspection: During the firing process, each vessel underwent multiple stages of inspection. After each firing cycle, we performed a detailed glass thickness inspection, ensuring consistency and reliability. Once the firing cycles were completed, final thickness measurements and a rigorous spark test at 20,000 volts were conducted to verify the quality of the new glass lining.

⦁ Jacket and Shell Evaluation: While the vessel was in the enameling area, the reactor jacket received equal attention. Precise steel thickness calculations were performed to verify that both the jacket and shell met the necessary design pressures. In specific cases, this evaluation might also result in a down-rating of the shell or jacket based on the findings.

⦁ Install 12” Side Nozzles: Each reactor required 12” side nozzles through the shell and jacket. ASME code calculations were performed, Nozzles were swagged in the shell with new sealer ring installed on the jacket.

Our reglassing process adheres to ASTM B08.12 standards, ensuring that every piece of equipment shipped is pinhole free. Every reactor comes with a comprehensive quality control dossier that includes ASME U-1 reports, vessel maps detailing statistical glass thickness, spark test and pressure test results, and drive system run test data—all stored electronically for ongoing maintenance and future reference.

Drive System Rebuild: Precision & Performance

Modernizing the drive system was as critical as the reactor refurbishment itself. Our team meticulously rebuilt the drive system, which included:

⦁ Inspection & Replacement: The entire drive system—comprising the case, gearset, and bores—was inspected. All bearings, shims, and seals were replaced.

⦁ Precision Shimming: Special attention was given to the worm drives, which were shimmed to within .001” to ensure the wear patterns met or exceeded OEM specifications.

⦁ Agitation System Upgrade: Both reactors were outfitted with new CryoTech Agitation systems. The agitator shafts and hubs were glassed and honed to an impressive .0005” tolerance.

⦁ Integration with New Systems: The reactors were rebuilt with RW drive systems and agitators that are fully compatible with the existing plant configurations. Enhancements included new John Crane mechanical seals, a new pedestal bearing, and a 25hp explosion-proof motor.

⦁ ASME Code Calculations: Our engineering team performed detailed ASME code calculations to install side entering nozzles with sealer rings, ensuring everything was engineered for safety and optimal performance.

Final Quality Checks & Documentation

Before shipping, every reactor underwent a series of final quality checks:

⦁ Comprehensive Testing: Each unit was pressure tested, and the drive system underwent a run test to confirm peak performance.

⦁ Complete Documentation: Units were shipped complete with all gaskets, split flanges, support legs, and full ASME code documentation. Additionally, each vessel’s dossier includes detailed testing and inspection reports, ensuring transparency and traceability.

⦁ Confidence in Quality: With our rigorous inspection and rebuilding processes, our customers can trust that their regenerated reactors are built to perform and last.

Conclusion

Our reglass and rebuild project for the 4000-gallon SA Series reactors is a testament to GTI’s commitment to quality, precision, and innovation. By combining expert reglassing techniques with state-of-the-art drive system upgrades, we not only extended the service life of these reactors but also delivered significant value in terms of cost savings and reduced downtime. Whether you are seeking a refurbishment solution or a complete system upgrade, Glasslined Technologies, Inc. is your trusted partner in glass-lined processing equipment solutions.

For more information on our services or to discuss your project needs, contact us today!