Newsletter:  November 16, 2009 

PATCH FURNACE REPAIRS 

In this issue of our newsletter we present a little known enameling method that can be used to save thousands of dollars on a single piece. Downtime can be cut from months to less than a week for a critical item.

For decades all manufacturers have used the patch furnace, muffle furnace, or localized repair to save time and money on projects. Occasionally, while enameling a pinhole may develop or damage can occur within the production facility. Rather than reglass the entire piece, manufacturers use the patch furnace to perform a localized repair. This technique is utilized to enamel the area where the drive end has been welded to the agitator, repair damaged areas on shafted pieces, or repair hubs. Most idle or slightly damaged agitators, baffles, or hubs can be repaired using this method.  The cost is a fraction of replacement or even reglass. Delivery can be in less than a week compared to 6-8 weeks or longer to reglass some items.

This process requires a furnace that is designed with a temperature gradient curve that prevents thermal shock or stress to surrounding areas and a delta T of 20F/minute.

The end result of a localized glass repair is the ability to return an otherwise unusable item back to service with confidence it will not fail. Prior to committing a piece to a localized repair it must undergo a complete inspection to determine the glass condition. A complete detailed inspection is performed. Glass thickness is recorded followed by a 6000 volt spark test.

There are times when the patch furnace is not the correct choice for your repair. We can not make repairs to items that have holes through the steel and have been contaminated by process chemicals. We also highly recommend items with thin or worn glass be completely reglassed.

It is a great option to have for pieces with impact damage in a few areas on a shaft, hub, or impeller. Damage near the drive end of an agitator can also be repaired. The patch furnace can be used to convert an obsolete agitator to a useable spare rather than scrap the item. It is possible to repair Non standard glasslined items that would otherwise have a long delivery.

For more information on patch furnace repairs please call or email our office.

10% discount for all patch furnace repair orders placed by Jan 15, 2010

Below are some examples of items repaired using the patch furnace.

The photos below depict the repair of a damaged 8000 gallon beavertail baffle. Replacement cost for this baffle approached $30,000 with a 12 week delivery. The repair was $3250 with 2 week delivery. This item has been in service for 26 months since date of repair.

Before Repair:

After Repair:

The photos below are of a 2000 gallon agitator with damage near the drive end. This agitator exhibited excellent glass thickness below the damaged area. The agitator was verified as straight in the lathe. A new drive end was installed on the agitator within a week at a cost of $4150 rather than $8200 for reglass of the entire piece.

Before Repair:

After Repair:

EQUIPMENT SPECIALS

500 Gallon Reactor:

Reconditioned Pfaudler 500 gallon RA series reactor

National Board # 3839

Internal 50psi/FV @ 500F

Jacket 90psi@ 500F

Nozzles: (4) 4", (1) 6", (1) 24" access opening with reglassed 24" cover w/ (2) 2", (1) 4" drive nozzle, and (1) reglassed 12X16 manway cover.

Drive system: Reconditioned 4DTW drive w new 3" mechanical T8/T9 seals, new 5hp explosion proof motor, reglassed retreat curve agitator, reglassed "h" style baffle.

Vessel is supplied with new gaskets for all nozzles, inspection report detailing glass thickness and spark test results. Vessel will ship with installation maintenance, and operation manuals.

12 month warranty on vessel and all parts.

Price: $28,800

30 Gallon Reactor:

Vessels Ratings:

Internal 30/FV @ 650F

Jacket 115psi @ 350F

Drive system: 2.5DTW with: 2hp explosion proof motor, new 1 1/2" mechanical seals, reconditioned seal housing, reglassed retreat curve agitator, reglassed fin baffle. Unit is supplied with new gaskets, reconditioned clamps, reglassed access cover. Vessel has been reglassed, blasted and painted with an industrial epoxy coating. This unit will ship with installation, maintenance and operation manuals.

12 month warranty on all parts.

Price: $21,550  

Phone: (706) 454-1701 | Fax: (706) 454-1705 | Email: info@southernglass.com