"From the outset, the customer's preference was to replace their old acid converter with a Mueller converter because of our longstanding reputation for quality. But they were delighted to discover that they could also entrust the entire expanded scope project to us and we could make it happen with minimal downtime."
Jeremy Rogles,
Mueller Field Operations President
A specialty chemical company needed to upgrade and replace an old acid converter but feared that resolution would require an extended outage. Because of the limits of space and time, they were looking for a partner that could not only provide the converter and the expertise required to implement an entirely new system, but also help ensure that they could deploy the solution without dramatically impacting their production schedule. They were leery of an extended outage, and knew they had to avoid any disastrous surprises that could further impact their ability to deliver to their customers.
Initially assuming they would have to hire an outside general contractor to decommission the old system and to design, engineer, and build the new acid converter, the customer was pleased to discover that their preferred tank manufacturer, Paul Mueller Company, could also provide the expertise to design, engineer, and construct the entirely new acid converter system onsite.
"From the outset, the customer's preference was to replace their old acid converter with a Mueller converter because of our longstanding reputation for quality. But they were delighted to discover that they could also entrust the entire expanded scope project to us and we could make it happen with minimal downtime."
Jeremy Rogles, Mueller Field Operations President
Mueller Field Operations committed to fully execute a two-part plan within a tiny one-month outage window. First, the existing converter and supporting infrastructure had to be deconstructed and removed. Then, the new state-of-the-art stainless system had to be moved into place, with piping, electrical, and ducts all reconnected.
Built over an eight-month period and then moved into place after demolition of the old 35-foot-tall converter, the new 70-foot-tall, all stainless-steel construction with internal heat exchangers and internal ceramic and catalyst beds, created the perfect technical solution. But the project was not without its challenges.
"We had to demolish the existing converter, existing duct work, existing electrical, and scoot our new tank into place, reconnect all the new duct work, all the new fans, new electrical, and get this process up and running, keeping the customer down for only about 28 days,"
Project Manager, Kirk Grantham.
With 6000 feet of welds, 800 feet of duct work, and testing with X-Ray and dye penetration inspections, specialists in each area kept things moving, constantly aware of the pressing schedule.
Although the Chemical Company team was well aware that the project was no small endeavor, they considered the completed effort to be a huge success. The project took months of planning, not just for the erection of the new converter, but also for the shutdown. The Mueller Field Operations team did a lot of planning—and a lot of practice—to ensure that it had all the procedures, processes, and expertise in place to maintain their standard of exceptional quality and safety throughout. While Paul Mueller Company is proud to be known for quality manufacturing of stainless steel tanks, vessels, and converters, the Mueller Field Operations team is also extremely proud of their reputation as a general contractor who can reliably design, engineer, plan, and execute huge construction projects onsite and do so in compressed timeframes to minimize downtime and negative impact on its customers.
See how our Field Operations team can come onsite and help with your expanded scope project
Paul Mueller Company Headquarters
Missouri, USA
The Americas:
+1-417-575-9000
Europe, Africa, Middle East:
+31 (0)88-6830000
Asia Pacific:
+84 982 071 506
At Paul Mueller Company we are united by a belief that the only quality that matters is quality that works for life. With every piece of processing equipment we build, our goal is to have lasting impact. From solar milk coolers in rural Africa, to lifesaving medical technology we are making an impact across the globe.
