How to replace the coil inside a reaction kettle
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There are multiple leaks in the internal coil of the reactor, and it cannot be repaired – it must be replaced. Does anyone have good experience with replacing coils in existing kettles? I have replaced it before, using welding in half-circles; fortunately, there is some distance between the coil and the wall of the reactor, so it’s still possible to weld on the opposite side【the side closer to the reactor wall】using a mirror. The distance is quite small now, making welding difficult. For the skylight, is it okay to weld half a circle on the reverse side [near the reactor wall] on the inside?
This doesn’t comply with the regulations, right? Is it a pressure vessel? In the case of leakage in such coils, it’s best to replace them; it’s likely that the leakage will persist even after repairs are made. The company has encountered similar problems before – the area that was repaired stopped leaking after a few weeks, but leakage occurred in the surrounding areas, which caused a lot of trouble. In the end, the coils had to be taken to the factory for replacement, and since then there has been no more leakage. It’s recommended to check the medium used, as coil leakage is often related to the type of medium involved.
It is not a pressure vessel, and the medium contains a small amount of chloride ions.
Buy a new one and replace it; chloride corrosion is very severe
May I ask about your heat exchange temperature, pressure, and pipe diameter? Thank you!
Generally, it is welded outside first, then fixed to three iron rods using clamps; it is placed inside the tank, and the ends of the iron rods are welded to the tank to secure it. The inlet and outlet of the coiled tube extend out from the tank opening, with valves installed there
Cut open the end cap, replace the entire coil at once, in one go
Use semi-circle welding, carrying out the welding from bottom to top; do not fix it yet. During welding, lift the coiled tube to create a certain slope, which provides sufficient space for welding. I have used this method, and after welding, the distance between the outside of the coiled tube and the tank wall is less than five centimeters. You can give it a try
Use half-circle welding, carrying out the welding from bottom to top; the coil at the bottom does not need to be fixed – during welding, simply lift the coil by an appropriate distance to create a slight slope. I have used this method, and after welding, the distance between the outside of the coil and the tank wall was less than 5 centimeters. You can give it a try.
It’s possible to replace it inside; however, it requires a lot of labor, there are many welding points, making the process difficult, and the quality is not very good. The cost of cutting off the end cap and replacing it is roughly the same. What’s needed is to take the equipment to the manufacturing factory where the quality will be better