THALE-mail www.thaletec.

com

REPAIR METHOD
NE
W

THALETEC LOCAREP page 2

COMPENSATING SYSTEM
SHIMMING SYSTEMS FOR
FLANGE GASKETS page 4

NEVER SHIM AGAIN

NE
W

SHIMFREE page 7

FROM ONE PIECE

GLASS-LINED HIGH PRESSURE
REACTOR page 10

EVENTS
GLASS-LINING FOR
BEGINNERS page 11

CLEAN MEANS SAFE

DECONTAMINATION page 12

THALETEC GmbH
Steinbachstraße 3 | D - 06502 Thale
Telefon: + 49(0)3947 778-0
Telefax: + 49(0)3947 778-110

85
newsletter@thaletec.com
www.thaletec.com
Hotline: + 49(0)3947 778-111

e
1 Ausgabe 60 • 2014 www.thaletec.com
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THALETEC LocaRep
Repair method facilitates local reglassing of damaged
THALETEC on YouTube components

Optimal CIP cleaning in glass-lined apparatus

can be carried out with the THALETEC CIP
systems, RotoCIPPY and StatiCIPPY (see Flyer
K082 ).

Videos on YouTube demonstrate the spray

pattern of StatiCIPPY and RotoCIPPY .

Workshops:
2017 registration In addition to the repair methods previ- Fig. 1:
ously available (see Table 1), THALETEC Local reglassing
THALETEC Workshops Registration for now offers a new solution, LocaRep: local
reglassing of damaged components.
Termine 2017 und Anmeldung
Appointment 2017 and Registration
our workshops in
2017 has already
commenced. More In particular, built-in glass-lined compo- LocaRep process. In this way, only the
information on nents, such as stirrers, agitating elements, damaged site is repaired and reglassed.
dates, prices as well baffles, dip pipes and valve parts, which The properties of the repaired site are
as the registration have localised damage (e.g. Fig. 2), in comparable to a new glass-lining following
form can be found many cases can be reglassed quickly the local reglassing.
in our new flyer and safely "locally" using the THALETEC
K108 .

Process Flyer

MiniScrew K090
THALETEC heat exchanger
RepCap K091
in the Deutsches Museum
EmPad K092
From 15th February you can visit and expe-
rience the special exhibition about energy EmRep K093
transition "energie.wenden" in the Deutsches
Museum on the Museum Island in Munich. A RepDisk K094
THALETEC heat exchanger (see cover photo)
forms part of this exhibition on the theme of RepSet K095
energy revolution.
PTFE repair sleeve K096
At the centre of the exhibition there is a mul-
timedia interactive game in which the visitor LocaRep K112
makes decisions about energy revolution. The
Welding repair THALE-mail 80, Page 5
exhibition has been conceived as an interna-
tional touring exhibition. It will be in Munich
until 19.08.2018. Table 1: Repair process by THALETEC for glass-lined equipment and components from all
manufacturers

2 Issue 85 • 2017
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With "LocaRep" THALETEC offers you

an all-round service package from one
provider which can be tailored to your
requirements:

1. (High voltage) test of every component

2. Removal of the defective part
3. Transport of the defective part to a
suitably equipped THALETEC GmbH
service centre
4. Repair of the damage, for example by
application welding, grinding, repla-
cing parts of the defective component
(Figure 3) and subsequent local glass-
lining (Figure 1 and 4)
5. Quality control of the repaired area
6. Transportation of the repaired compo-
nent to the customer Fig. 2:
7. Fitting of the repaired component and Impact damage on agitator shaft
delivery of all requisite parts, such as
flange gaskets (Flyers K025 , K099 ,
K100 ), relining materials (THALETEC
QuickShim as per Flyer K105 ) and
other materials (Flyer K048 )
8. Commissioning support

For the local reglassing with LocaRep,

THALETEC uses repair glass-lining
which meets the requirements of DIN
EN ISO 28721 and is compatible with the
glass-linings of the European manu-
facturers of glass-lined apparatus and
components.

For this reason, glass-lined components of

other manufacturers can also be repaired
using LocaRep.
Fig. 3:
You can find further details about the new Preparation
LocaRep method from THALETEC in Flyer
K112 .

Fig. 4:
Local glass-lining coating

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Compensating System
THALETEC shimming systems for flange gaskets
Flanges on glass-lined, process enginee-
ring apparatus can exhibit unevenness,
flange sheet inclination and an angu-
larity by contrast with the ideal axis of
the opening (Fig. 5) as specified in the ted as a result of reglassing glass-lined
applicable quality standards DIN 28005-2 apparatus, which can even exceed the
(tanks), DIN 28006-2 (reactors) and DIN values specified by the standards, where
28007-2 (columns). Flanges can be distor- applicable.

Fig. 5:
Table 3 from DIN 28006-2; Shape/angle/incline tolerances for openings and their covers

4 Issue 85 • 2017
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Fig. 6:
Methods to compensate for flange uneven-
ness and their fields of application

There are various methods available to

compensate for the deviations in respect
of evenness, incline and angle of the nozz-
les which have differing areas of applica-
tion, options and limitations.

QuickShim shimming material

Gaskets can be lined to compensate for
leaky flange gaskets as a result of flange
sheet inclines and unevenness.

To this end the sealing element is filled (a)

with a hardening paste (THALETEC
QuickShim ). This process can be
applied quickly and compensates
deviations of up to 8 mm.

(b) (c)

(d)

Fig. 7:
THALETEC QuickShim-System: (a) com-
pressed air-driven gun, (b) double cartridge,
(c) mixing tube, (d) cap nut

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Fig. 8:
Lining a manhole seal with the THALETEC
shimming system, QuickShim

Lining with triangular shaped inserts

It is also possible to line gaskets using consuming and requires a high degree
customised inserted elements. of competence and experience from the
This method, however, is very time- employees carrying out the work.

Seals with twistable, wedge-shaped inserts

Specifically to compensate for incorrect gaskets are used with two wedge-shaped shaped inserts against each other, angle
angles on agitator nozzles of glass-lined sealing inserts which can be twisted defects of up to 3 degrees (depending on
reactors in compliance with DIN 28136 flat against each other. By twisting the wedge- the nozzle size) can be corrected.

Fig. 9:
Seal with wedge-shaped inserts to correct
the angle setting of the agitator nozzle

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Glass-lined angle spacers

Angle spacers are wedge-shaped rings
made of glass-lined steel. They are available
up to a nominal diameter of 500 mm and
can compensate for angles up to 3 degrees.
Angle spacers are built onto the skewed
nozzles and sealed with a standard flange
seal in compliance with DIN 28148.
In addition to the methods to date, the
ShimFree system developed by THALETEC is
now available. This is presented below.

Fig. 10:
Angle spacer to rectify angle errors up to 3°
on nozzles up to DN 500

ShimFree – The intermediate ring which saves on

shimming – once and for all!
All the methods mentioned up to now
have certain limitations in respect of the
operating range, availability and applica-
tion. For this reason, THALETEC has deve-
loped the ShimFree intermediate ring (see
Flyer K104 ) as a universal component
to compensate for all kinds of deviations of
glass-lined nozzles.
ShimFree intermediate rings are produced
individually on the basis of an exact mea-
surement of the nozzle to be corrected. Af-
ter a service engineer from THALETEC has
measured the actual existing deviations
of the nozzle to be rectified or of a tank Fig. 11: Fig. 12:
aperture up to a nominal diameter of DN Setting up the machine to work on a Shim- ShimFree intermediate ring. It can be seen
600 (larger diameters up to DN 2000 upon Free intermediate ring that the circumference thickness of the in-
request), this data is then used to manu- termediate ring varies, thus compensating
facture a geometrically accurate ShimFree for flange deviations
intermediate ring. For this, THALETEC uses
a 3D manufacturing process. intermediate rings ensure that after the for, or correct, the angle of the nozzle to
By contrast with other compensating ring is fitted onto the (deformed) nozz- a great extent. If a ShimFree intermediate
methods, with the ShimFree interme- le, it covers the complete sealing sur- ring should be damaged in operational
diate ring the incline of the sealing face width and there is no contact with use, a new ShimFree intermediate ring
surface is also corrected in addition to the lines which could lead to damage or can easily be manufactured again on the
the unevenness of the flange surface. destruction of the flange gasket. basis of the measurements already held by
The measuring method used and the Besides the flange unevenness, a ShimFree THALETEC.
manufacturing concept of ShimFree intermediate ring can also compensate

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ShimFree intermediate ring as manhole protection

One special application of the ShimFree
intermediate ring is its use as a protection
ring for the manhole opening of glass-
lined apparatus.

The ShimFree intermediate ring ensures for

manhole openings that after it has been
fitted, no additional lining of the manhole
cover seal is required.

Fig. 13:
Measuring a manhole nozzle

Features
• Approved for -1/+10 bar and -60°C to
230°C
• Available as standard for nozzles up to
DN 600; other dimensions upon request
• Manufacture of the ShimFree interme- • Fitting the ShimFree intermediate ring
diate ring after measuring the flange using a new type of clip bolt which can
unevenness on the existing glass-lined be freely positioned on the circumfe-
equipment rence

Advantages
• ShimFree intermediate rings avoid the
necessity of lining flange gaskets; parti-
cularly useful for flange gaskets which
are frequently changed
• In manhole openings the ShimFree
intermediate ring replaces the manhole
protection ring used previously
• Compensation for flange deviations
(angle and/or flange unevenness) in a
large range
• ShimFree intermediate rings make it
possible to keep equipment with gre-
ater flange deviations securely sealed,
even those which have been reglassed
multiple times
• Universal solution for all glass-lined
equipment from all manufacturers
• Complies with the requirements of
TA-Luft (German emission standards)
in connection with THALETEC flange
gaskets AGR Premium (Flyer K025 ) or
GRX Premium (Flyer K099 )

More often reglassing possible with ShimFree

When tanks are reglassed, sometimes the
nozzle deviations increase as a result of the
reglassing temperatures. Often apparatus
has to be discarded only because the flan-
ge deviations have become so great that it
is no longer possible to secure a tight seal.
ShimFree intermediate rings solve this
problem. Based on their significant com-
pensatory capacity for all kinds of flange
deviations, it is possible in many cases to
provide a secure seal in operation, even
for apparatus whose nozzles are severely
deformed following multiple reglassing. In
these cases the affected nozzles, as descri-
bed above, are measured at THALETEC and
the corresponding ShimFree intermediate
rings are manufactured, lined with glass
and fitted to the respective nozzle.

8 Issue 85 • 2017

Fig. 14 shows a ShimFree intermediate ring
for a nozzle DN 600, with which a flange
unevenness of 8 mm on a manhole nozzle
was rectified. Without the Shim-Free pro-
tection ring the corresponding glass-lined
apparatus, which even before reglassing
Once and for all
ShimFree protection rings, as described
above, are adjusted to fit the two flange
surfaces to be sealed in terms of their
geometry in respect of the unevenness
and distortion. As long as the intermedi-
ate ring is undamaged, this can be sealed
Any requirements?
If you are looking to solve difficult sealing
problems in your company, contact
THALETEC.
We will be delighted to advise you on
suitable sealing systems and especially
www.thaletec.com
already had a flange deviation of almost 8 Fig. 14:
mm, would no longer have been usable. Manufactured and glass-lined
ShimFree protection ring
again and again and with normal, reaso- suitable intermediate ring – should this
nably priced and unlined flange gaskets. ever be damaged – can be done promptly
at any time.
As the geometric data of the ShimFree
protection ring is stored at THALETEC and
can be accessed repeatedly, reordering a
regarding compensating processes for
nozzle deviations. Just talk to us!
Issue 85 • 2017 9
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From one piece – glass-lined high pressure

reactor with tempering channel made using
additive manufacturing
This innovative AM glass-lined high pressure reactor was recently nominated for the
"Best of Industry Award". Together with its partner, SLM Solutions Group AG, THALETEC
GmbH was one of the potential award winners in the category of "Additive Manufactu-
ring" (Fig. 15). Even a nomination is considered a particular honour as there are strict
criteria to be met, such as a high degree of technical innovation, significant benefits for
industry, the environment and society.

High pressure reactors are used in process

engineering to carry out chemical reactions
at pressures up to 200 bar. Previously, these
were manufactured and machined from
materials such as refined steel or Hastelloy.
To date, high pressure reactors were used
with an inliner made of PTFE for use with
chemically highly aggressive products.

THALETEC has developed the prototype of

a glass-lined high pressure reactor (Fig. 16).

The high pressure reactor is approx. 300

mm long, with an internal diameter of 60
mm and volume of approx. 0.5l.

This new solution is particularly innovative

because the high pressure reactor was
made in one piece using an additive manu-
facturing method, "Selective Laser Melting".

The use of this manufacturing method

allows the high pressure reactor to be
equipped with an integrated tempering
channel for heating or cooling the interior
of the reactor (see Fig. 17).

Fig. 15:
Nomination certificate for THALETEC and
SLM Solutions for the "Best of Industry
Award – Additive Manufacturing"

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In so doing, the entire component is

made "from one piece" without any
welding joints.

The combination of glass-lining and inte-

grated tempering channel offers a clearly
improved thermal transfer between the
product and the tempering medium com-
pared with the previous usual solutions and
thus it is possible to influence the heat tone
of the process better. Furthermore, a grea-
ter pressure sustainability despite thinner
walls, a guaranteed impermeable and
chemically highly resistant coating in the
interior in contact with the media as well
as a weight reduction, which is important
when handling reactors in the laboratory,
are all rendered possible. Fig. 16:
Glass-lined high pressure reactor (cross-section) with integrated tempering channel
Selective Laser Melting, for example, per-
mits the manufacture of interior structu-
res such as channels, cavities in complex
components, which would not be possible
using normal manufacturing methods such
as turning, milling and drilling.
In Selective Laser Melting the component
is developed in the 3D CAD system and the
geometrically optimised component is then
digitally refined and then passed to the SLM
unit (Fig. 18).

The component is then built up in layers in

the unit. The materials system developed
by THALETEC for Selective Laser Melting
can also be glass-lined. In order to use high
pressure reactors, these must be designed
and equipped in compliance with Pressure
Equipment Directive 97/23 (PED) and in Fig. 17:
accordance with a valid set of rules, e.g. Detailed view of the tempering channel
AD 2000.

In close cooperation with a notified body

THALETEC high pressure reactors made
using additive manufacturing can be produ-
ced accordingly as approved pressure appa-
ratus since THALETEC has a tried and tested
method which permits the certification of
AM pressure apparatus in accordance with
the pressure apparatus directive.

Fig. 18:
Result of the building process in a SLM
plant of SLM-Solutions, Lübeck

Issue 85 • 2017 11

Workshop:
Glass-lining for beginners
Do you recognise these situations? You as-
sume technical responsibility in a new pro-
duction plant, in which there is glass-lined
equipment. Or you are at the start of your
career and land in a company with glass-
lined apparatus? Or you have colleagues
or employees who are new to glass-lining?
But unfortunately, you or your "newbies"
only know enamel from Grandma's coo-
king pots and the bath tub?
Glass-lined process engineering ap-
paratus, such as stirred-tank reactors,
tanks, recipient vessels, heat exchangers,
columns and glass-lined pipe lines do not
have much in common with that which
you perhaps know at home. Even if the
basic concept, namely putting a layer of
"glass" - the glass-lining material - on top
of a basic body of metal, is similar whether
household enamel or technical glass-lining
is involved.
12 Issue 85 • 2017
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Especially for those new to the topic of You will find the dates for these and other
"glass-lined equipment" THALETEC offers the workshops in our Flyer K108 .
newly conceived workshop "Engineering" as
in Flyer K102 . In addition, it is also possible to hold
a workshop at your premises which is
The workshop will teach in a condensed tailored to your specific requirements
form the fundamental basis of glass-lined and criteria. Just speak to us to agree on
apparatus engineering. The content of the content and dates.
workshop is divided into two sequential
events. In the first part of the workshop,
aspects of plant planning and the specifi-
cation of glass-lined apparatus for process
engineering plants will be discussed on
the one hand. On the other hand, the fun-
damental basics of the "glass-lining" ma-
terial system will be taught as well as the
impact of the properties of the material
on the potential design and limitations. In
the second part of the workshop, the most
important principles of process enginee-
ring construction as well as the design of
glass-lined apparatus will be discussed and
comprehensively worked through.
 www.thaletec.com

Clean means safe

Process engineering glass-lined components and equipment can be reconditioned
particularly economically through reglassing and prepared for further use. The
components are thereby dismantled at THALETEC, the worn glass layer removed
by sand blasting and the components then reglassed. After sand blasting even
damage to the steel body of the component can be repaired or modifications can
be realised.
For us as a DIN ISO 9001-certified manu-
facturer the health of our employees is
extremely important. For that reason, we
ensure that the components we receive
from our customers for reglassing or recon-
ditioning are clean and safe to handle. With
a so-called decontamination certificate
which you are required to provide with the
respective component, you declare that the
component was thoroughly cleaned prior
to dispatch and has no substances which
are poisonous, harmful to health, corrosive,
irritating, flammable, explosive or environ-
mentally hazardous or could develop one of
these characteristics when heated.

Please understand that we cannot com-

mence the reconditioning of components
until we have this certificate.

You can request a form for this decontami-

nation certificate at any time by emailing
service@thaletec.com.

Fig. 19:
THALETEC form for the decontamination
certificate

Issue 85 • 2017 13