Seam tear in jacketed reactor
Thread Content
The weld between the jacket and the main body of the jacketed reactor has torn; despite two repair welds, leakage persists. Is there any good solution? Considering adding a jacket at the weld seam. I don’t know how effective it is.
Bro, in your case, it’s because the inner or outer cylinder of the reactor is too thin and lacks sufficient strength; this leads to deformation and subsequent weld cracking. It’s best to replace it – it’s better than facing problems later on.
It should be said that the pressure vessel was designed properly, so it must be due to operational reasons. The operations and procedures should be thoroughly checked.
I tend to agree with what the original poster said on the sofa; generally, only when the steel plate becomes thinner will leaks occur no matter how you weld it. Additionally, I’m not aware of the conditions inside your tank. If you know the temperature and the type of medium inside the tank, I can recommend repair materials that will help resolve your immediate problem. If needed, we can also provide on-site service.
That jacket weld crack – this has come up several times on the forum. . Problems with structure, welding, and operating conditions. The root usually has incomplete welding.
Provide detailed parameters: material, internal and external pressure, temperature, etc., to facilitate assessment!
For general leaks, they can be repaired using repair materials such as sealants; we offer on-site service
Most manufacturers are not yet able to do this; it’s probably due to manufacturing issues. There are generally no problems with the drawings. Problems with structure, welding, and operating conditions.
The half-tube jacket, with its inner groove and outer fillet welds, makes it easier to ensure welding quality. The structure featuring an external groove plus external fillet welds is prone to defects such as incomplete fusion at the root, lack of penetration, and burn-through, often due to inappropriate root gap sizes and uneven thickness of the root bevel. Due to the structure of the jacket fillet weld, RT testing is generally not performed, and poor quality of the root pass can easily go unnoticed. Immediately after welding the root pass in the jacket, PT/MT surface inspection is carried out to ensure the quality of the entire weld.
Has this kind of situation already occurred in our unit for a long time? It is estimated that the high temperature of the jacket is to blame; over time, the thermal stress reduces the strength of the fillet welds between the jacket and the cylinder, which leads to this issue. The solution is to install pipe expansion joints at the inlet and outlet after making the repairs; this will at least help improve the situation.