TL;DR
Iron contamination in the product or a failed spark test confirms glass lining damage. Schedule a spark test inspection during the next cleaning cycle and assess for repair or re-lining.
What you might see
- product discoloration from iron contamination
- pH drift in batch product
- spark test indicating holiday in lining
- visible chip or crack on glass surface
Likely causes
Mechanical impact from a foreign object or overfill causing chips in the glass
Thermal shock from rapid temperature cycling beyond the glass design limit
Chemical attack from pH outside the glass rating, typically below pH 1 or above pH 12
Abrasion from high-viscosity or abrasive slurry over extended operation
Required tools
- Spark tester (calibrated, high voltage)
- Confined space entry kit: supplied air, gas detection, rescue line
- Chemical PPE appropriate to last product
- Flashlight or LED inspection lamp
Safety first
- Confined space entry requires a permit, atmospheric gas test, and a rescue team on standby. Never enter a reactor without a confined space permit.
- The spark tester uses high voltage. Keep the probe away from personnel and metallic reactor internals that are grounded.
- Reactors that previously held toxic or flammable materials must be decontaminated and certified gas-free before entry.
Procedure
- 1
Empty, clean, and decontaminate the reactor. Confirm the interior is safe for entry.[1]
- 2
Enter the reactor using a confined space permit. Wear chemical PPE appropriate to the last product.
- 3
Perform a visual inspection of the glass surface under good lighting. Look for chips, cracks, blisters, or areas of discoloration.[1]
- 4
Perform a spark test (holiday test) using a calibrated high-voltage spark tester. Move the probe across the entire glass surface in overlapping passes.
- 5
Mark any holiday locations with a non-contaminating marker. Record location and size for the repair log.
- 6
Holidays smaller than 3 mm in an area remote from process nozzles may be repaired with an approved glass repair compound. Larger defects require professional re-lining.
- 7
If iron contamination in the product is the trigger, trace the source by testing multiple batch samples against the suspected holiday locations.
Sources
Pfaudler Pfaudler RA / RT glass-lined Reactor / Pressure Vessel general technical documentation, Pfaudler
Pfaudler RA / RT glass-lined reactor general glass lining inspection and spark test procedures (general)
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