As a core equipment in the fields of chemical engineering, materials science, and new energy, the maintenance quality of synthetic high-temperature and high-pressure reactors directly affects experimental safety, data accuracy, and equipment service life. The following systematically elaborates on the details of professional maintenance from four dimensions: daily maintenance, regular inspection, key component maintenance, and safe operation.
1、 Key points of daily maintenance
1. Cleaning and corrosion prevention
Cleaning of reaction chamber: Immediately rinse the inner wall with deionized water after each experiment, and use specialized cleaning agents (such as acidic solutions or solvents) for stubborn residues. It is strictly prohibited to use hard tools to scrape PTFE or ceramic coatings.
Sealing surface maintenance: Wipe the sealing contact surface between the kettle cover and the kettle body to ensure there are no scratches or foreign objects, and apply a small amount of Vaseline to prevent oxidation and adhesion.
External surface dust removal: Clean the outer shell daily with a dust-free cloth, focusing on cleaning the pressure gauge, temperature controller, and electrical interfaces to prevent dust from entering precision components.
2. Pressure and temperature monitoring
Pressure gauge calibration: Check the pointer return to zero status daily, calibrate it with a standard pressure calibrator every month (error ≤ ± 0.5%), and replace it immediately if any abnormalities are found.
Thermocouple inspection: Calibrate PT100 or K-type thermocouples annually, and replace them when the deviation is greater than ± 1 ℃. The temperature measuring hole should be kept unobstructed.
Overpressure protection test: Verify the popping pressure of the safety valve weekly (usually 1.051.1 times the design pressure), and ensure that the lead seal is intact and undamaged.
3. Maintenance of sealing system
Sealing ring replacement: It is recommended to replace the fluororubber or silicone rubber sealing ring every 50 experiments or 3 months. After replacement, it is necessary to run in and pressure test (hold at 0.8 times the working pressure for 30 minutes).
Flange bolt management: Check the looseness of bolts after each kettle opening, tighten them evenly in diagonal order, and refer to the equipment manual for pre tightening torque (usually 1015N · m).
2、 Regular in-depth maintenance
1. Comprehensive disassembly and inspection
Annual overhaul: Disassemble the reaction kettle, inspect the welding seams of the kettle body, the concentricity of the mixing shaft (deviation ≤ 0.1mm), and the wear of the bearings.
Anti corrosion layer repair: Perform dye penetrant testing on the stainless steel inner liner. If micro cracks or corrosion pits are found, they need to be polished and repaired by welding or sprayed with ceramic coating.
2. Verification of pressure system
Water pressure test: Conduct a water pressure test at 1.5 times the design pressure every six months, and hold the pressure for 30 minutes without leakage to be qualified.
Airtightness testing: Use a helium mass spectrometer leak detector to detect micro leakage points, with a focus on inspecting the valve packing box and pipeline welds.
3. Lubrication of transmission system
Mixing shaft maintenance: Inject high-temperature lubricating oil (such as Mobil SHC 630) into the mechanical seal bellows every month, and replenish molybdenum disulfide grease every 200 hours for the motor bearings.
Belt tension: Adjust the synchronous belt tension to a deviation of ≤ 3mm in the middle of the press to prevent slipping or abnormal wear.
3、 Special maintenance of key components
1. Maintenance of heating sleeve
Resistance wire testing: Use an insulation resistance meter to test the heating element every year, and the ground insulation value should be>100M Ω. Aging resistance wires need to be replaced as a whole.
Insulation layer repair: When the aluminum silicate fiber cotton is damaged, it should be repaired in a timely manner to avoid temperature fluctuations caused by heat dissipation.
2. Maintenance of cooling system
Coil cleaning: Clean the cooling coil with 5% dilute hydrochloric acid circulation every quarter, remove scale, rinse with clean water, and passivate.
Compressor maintenance: Check the pressure of refrigerant (such as R404A), supplement when the pressure on the low-pressure side is lower than the standard value, and remove dust from the condenser fins every month.
3. Control system calibration
PLC program backup: Export temperature control curves and pressure interlock parameters quarterly to prevent program loss or misoperation.
Relay contact polishing: Regularly polish the relay contacts inside the electrical control cabinet with fine sandpaper to prevent oxidation and poor contact.
4、 Safety operation standards
1. Start stop process
Temperature and pressure control: In the initial stage, the temperature is raised at a rate of ≤ 2 ℃/min, and the pressure increase does not exceed 0.1MPa/min to avoid material thermal stress concentration.
Emergency shutdown handling: In case of sudden abnormalities, priority should be given to cutting off the heating power supply, starting the chiller to forcibly cool down, and opening the kettle for inspection after the pressure returns to zero.
2. Hazard prevention
Explosion proof measures: The hydrogen embrittlement sensitivity test requires the introduction of inert gas (such as Ar) for replacement, with oxygen content controlled at<5%.
Corrosion protection: After the strong acid/alkali test, rinse the kettle body with a neutralizing agent in a timely manner to avoid accelerated corrosion caused by residual media.
3. Long term suspension management
Moisture and rust prevention treatment: When the equipment is idle for more than one month, apply rust proof oil to the inner cavity and place silicone desiccant in the control cabinet.
Spare parts reserve: Key spare parts (such as sealing rings, thermocouples, safety valves) need to be stocked in double quantity and stored in anti-static cabinets.