As a core equipment in industries such as chemical, pharmaceutical, and food, the stable operation of stainless steel reaction vessels directly affects production efficiency and product quality. However, due to factors such as medium corrosion, mechanical wear, and operating standards, the reaction kettle often experiences failures such as leakage, abnormal stirring, and uncontrolled heating during use. The following discusses from three levels: common types of faults, cause analysis, and solutions, providing systematic guidance for equipment maintenance:

1、 Sealing leakage fault

1. Flange seal leakage

-Reason: Uneven tightening of bolts or long-term vibration leading to loosening; Aging or damage of gaskets (such as rubber gaskets being corroded by media) or improper selection (such as ordinary gaskets coming into contact with highly corrosive media).

-Solution: Tighten the bolts in diagonal order in stages; Replace polytetrafluoroethylene (PTFE) gaskets or metal wrap gaskets.

2. Mechanical seal leakage

-Reason: Wear of sealing surface, failure of spring, or deviation of coaxiality of mixing shaft.

-Solution: Minor wear can be repaired by polishing with metallographic sandpaper; Severe damage requires replacement of the entire mechanical seal, and the coaxiality of the shaft should be calibrated during installation.

3. Leakage of packing seal

-Reason: Aging of the packing or uneven tightness of the gland.

-Solution: Adjust the gland bolts and replace the packing if there is still leakage.

2、 Mixing system malfunction

1. The mixer stops running

-Reason: Motor malfunction, bearing jamming, or magnetic coupling failure.

-Solution: Check the power supply and wiring; Dismantle the mixing shaft to clean foreign objects; If the internal magnetic steel demagnetizes at high temperature, a new magnetic steel needs to be replaced.

2. Abnormal noise and vibration

-Reason: Bearing wear, blade scraping or loose transmission components.

-Solution: Replace the bearing and adjust the clearance; Check the gap between the blade and the kettle wall to ensure there is no friction.

3、 Heating and temperature control malfunction

1. Decreased heating efficiency

-Reason: scaling of heating rod, short circuit of solid-state relay (SSR), or sensor drift.

-Solution: Remove scale; Detecting circuit signals; Re calibrate the temperature sensor.

2. Temperature runaway

-Reason: Temperature controller parameter error or poor cooling cycle.

-Solution: Restore factory settings; Inspect the circulation pipeline to avoid air burning.

4、 Abnormal pressure malfunction

1. Fluctuations in pressure gauge readings

-Reason: Loose sensor wiring or gas leakage inside the kettle.

-Solution: Tighten the circuit connectors; Use soapy water to detect leaks and repair them.

2. Overpressure risk

-Reason: Blockage of the pressure relief valve or uncontrolled release of heat from the reaction.

-Solution: Regularly verify the safety valve; Optimize the feeding rate and add cooling intervention.

The troubleshooting of stainless steel reaction vessels requires a logical chain of "precise diagnosis targeted repair systematic prevention". By strengthening daily maintenance, standardizing operating procedures, and promptly eliminating hidden dangers, the equipment failure rate can be significantly reduced, ensuring production safety and efficiency. For complex faults such as intergranular corrosion and stress cracking, it is recommended to contact a professional team for in-depth inspection and repair.