Pruner Three-Piece Repair Plug Instruction Manual IM83-201-5 IMPORTANT: The folowing instructions descroe a method of repairing the glass lining only of Plaudler® glass-ined sae! vessels. Repairs te the steel substrate ate not descrited here ‘When steel damage |s to be repaired, consult your local authorized Boller and Pressure Yesse! Inapecter 1. DESCRIPTION Preudler Threepiece Repair Plugs are used in glass-ined siee! ‘equipment to cover areas where glass has been damaged and/or tea! Is exposed. [A standard Three-pioce Ropair Plug consists oF ametal stud and ut a metal alloy dise, several potous PTFE filer gaskets (tf needed) anc one sola FIFE Sealing gasket, Refer to Plouder MB3.001 for materials, oF call ler A filer material is used wnen fsialing a Three-piece Revair Plug. See Plaudler IMBSOO1 for a isting of filler materials available from Praudler 2, TOOLS & MATERIALS REQUIRED BY USER, Tools required for installing @ Threepiece Repair Plug are as follows Eloctrie han¢ dil (nigh-epeea) for use in non-hazardous areas only Ar grinder (25,000 rpm) for use In nazardous areas Mounted grincing whee! Mounted grinding point Drils: Only one size required, depending on size of repair slug (Gee Table 1) Starting and bottoming taps: Only one size required, depending on size of repair plug (Gee Table 1) ap wrenches: 938 and 938 Chip biowor fair eyringo) No. 3 sereworivar Grescent wrenen (6 inch) Ball peen hammer (% Ib) 3. PRELIMINARY STEPS Surface preparation, plug size selection, plug disc shaping 1, DANGER: DO NOT ENTER A PROCESS VESSEL WITHOUT Figure 1. Threepiece Reoair Pug 2 inches or less are no ritbed Porous PrFE TABLE 1 - PLUG SIZES Disc Stud Drill Diameter Thread Required we 103221 " 122814 We" 2B 56-24 31824 sie2d 8 20 20/64 420 29164 %20 20164 FIRST PREPARING IT FOR SAFE ENTRY. FAILURE TO DO SO CAN RESULT IN SERIOUS. INJURY OR DEATH. CONSULT. YOUR PLANT SAFETY PERSONNEL FOR PERMISSION ‘TO ENTER VESSEL AND FOR ESTABLISHED SAFETY GUIDELINES. 2. Non-damaged gass areas musi be protecied betore starting work 8 Thoroughly clean damaged 2703 and surrounding glass-coated ares, 4. Remove all loose and cracked glass: Grind out from cenier of ‘aroa to sound glass, leaving smooth bevel at edges. . Any product build-up andiot Corroded steel In the camaged ‘area shoud be rerroved by ‘grinding down te sound rota. Ste¢l is corroded, consul your local authorized Boler and Pressure Vessel Inspector ‘or proper repar tectniques and any required reduction in the allowable pressure rating of the vessel 5. Seiect a plug that has a disc diameter atleast % inch greater that the area that was ground and beveled in step 4. I the appreariate size is not avaiable, solact a plug one size laroer, ‘space permitting, from the list in Table t 66. In tho area where the stud wit be located. grind glass to bare metal excosing a spet sightly larger (1/16 inch) than the stud diameter. 7. Drill and tap a hole for the plug stud using the appropriate size starting and bottoming taps. Make the hole at least 2s deep as the lameter of the stud. Make sure tho holo is square to the sto! substrate before proceeding to tap it WARNING: Dull should not penetrate more than 759% of the Initial vessel wall thickness. 8. Remove all chips trom rote with 2 chip blower (air syiinge) then Clean area with alcohol or a sutatie sovert. CAUTION: Handle alcohol or solvent with proper caution. 8. Insert stud into hele. Do nat tightenPRUphGr Three-Piece Repair Plug Instruction Manual IM83-201-5 10, Siide disc onto stuo. ‘a. With a crayon make a retoranea matk on dice and Glass so that disc can be Felumed to the same position alter each removal. Bb. Determine the locations where the dise des not th against ihe glass properly and rmark with a crayon . Remove disc and shape it with two crescent wrenches, Vie grins, oF pliore (covered to prevent metal damage) to form the disc to the glass contour Use @ pointed feeler gauge 0 Make sule the gep between disc and glass ie 'ocs than 10005 inch, 4. Make sure edges of disc are ‘ot jagged. If the sealing edge Of the dsc Is jagged, it must be filed emooth before fina! Instalaton. Eoge must make Continuous contact all arounc. 11. after forming ine ase dotermine the number of porous PTFE gaskets needed to fil the Space under the disc while ‘maintaining the cisc in contact with tne giass surtace. 412. Romove stud and clean damaged ares, tapped hale and ppg paris with aicohol or any suitable sovent 113, Blow out solvent from hole, Using a chip blower (air syringe) and wipe area dry with a clean bth. 44, Make sure nut turns freely over stud before proceeding with installation Pomener WeAUS EDs” Praudler-US., Inc PO. Box 1600 Rochester, NY 14692 716-235-1000 2eMR 3M 4, INSTALLATION OF PLUG 1. Insert stud inte tapped tole and Bl itup snug with properly sized screwdriver Do not overtichten, Damage may occur 10 the sioited fend of the stud making impossible for the nut to be placed aver me stud 2. Mik filer material following instructions supplied wity it. See Praudier 1M83-001 for use of corroct recommended flier material 3, Fill in area around stud with filer, extencing a thin layer over edge of grounc glass. 4. Clean ood PTFE gackot with alcohol er suitable solvent ana a Clean cleth. Then insiall by screwing it onto the stud pressing firmly against me damageo area, 8. Prees down on acid PTFE ‘gasket, forcng extra tiller material from under t. Wipe away extra ‘material with a clean cloth in the area where a seal to gless Is going to be mode, 6. Aply a thin ayer of ler to the top of the gasket near the stud. Be coaretul rot io eppy t20 thickly 7. Install a porous PTFE gasket by screwing it onto stud and eppiying 2 thin layer a iller to the tap af the gasket 8. Repeat step 7 untl the required umber of gaskets nave been assembled, 8. Cover inside of mataldise with a thin layer of filer material (do ‘not completely fill the disc with filer material) ang slo it orto stu Make sure reference marks on dise and glass are algnod. Figure 2. Plug Shaped To Fit ‘Curved Surface 10. Install a nex nut (concave side toward metal disc) on stud and pull itup tight, 411. If the filler squeezes out arund the edge of repair, remove disc ard nut, wipe off excess, 42. Rensiall ise end nut. Make cute disc compresses PTFE gasket all around its edge 48. Cure the filer h accordance with instructions provided with the filet. Co not place vessel in eenice until filler ie fully cured. 5. PERIODIC INSPECTION Repairs to the glass tining of equpmen: must be inspected periodically. While a correctly installed plug will provide years of senice in mest chemical ‘envronments that are sutable for glass, plugs may be disturbed ‘during normal use, maintenance or cleaning operations. In such cases premature failure may occur ‘cepencing on the severity of tne sence. Therefore, repairs of this type shauld be inspected shortly after being exposed to the ‘operating environment, and as fen thereatier as i feasible Plugs exposed to severe corrosive conditions, high temperatures, etc should receive more frequent inspection than those exposed to ralatively mild Service conaitions CAUTION: If the plug material has ‘deteriorated in any way or become loose, it must be replaced. Do not retighcen existing pltg. ‘Tho information recommendations, andopiionsseitorhneren ae "| fered sll foryour conseraten, | Inquiry and verifeaton ane arene, in par or ta, obo construed as constiuting « warranty or representa tion for which The Pauder Companies, ine. assumes legal esponsbity. Copyright Plauder US, Inc, 1989 llrightsreserved, Printed inUS.A,