Fault Phenomenon: Shell Damage (Corrosion, Cracking, Perforation)

Reason for the Failure:

1. Exposure to medium radiation (pitting corrosion, intergranular corrosion)

2. Thermal stress can lead to cracking or alkali brittleness.

3. Wear thinning or uniform corrosion.

Methodology:

The shell lined with corrosion-resistant materials requires relining or partial welding repairs.

2. Stress relief is required after welding, and cracks should be repaired.

If the thickness exceeds the allowable limit, the body needs to be replaced.

Symptom: Over-temperature and over-pressure

Reason for the Fault:

Instrument failure, inadequate control.

2. Mistake in operation; improper raw material ratios; severe reaction.

Due to poor thermal conductivity or mixing performance, secondary reactions occur.

4. Intake valve malfunction leading to excessive intake pressure and high pressure.

Approach:

Inspect and repair the automated control system, strictly adhere to operational procedures.

2. In accordance with the operational procedure, implement emergency pressure release and strictly adhere to the specified quantity and timing of material feeding, vigilantly prevent any misoperations.

Increase the heat transfer area or remove scale to enhance heat transfer efficiency; repair agitators to improve mixing efficiency.

4. Close the main steam valve, and perform repairs on the steam cutoff valve.

III. Fault Phenomenon: Seal Leakage

Cause of the failure:

Filler Sealing

The agitator shaft is worn or corroded at the filling point, resulting in excessive gaps.

2. Incorrect oil ring positioning or clogged oil pathways prevent the formation of an oil seal.

3. The cap is not tightly sealed, the filling material is of poor quality, or it has been used for too long.

4. Filling box corrosion.

Mechanical Seal

1. End face deformation and damage due to impact

2. Excessive face-to-face pressure leads to thermal deformation in the frictional components.

3. Incorrect material selection for sealing rings, insufficient clamping force, or incorrect installation of the V-shaped sealing ring, leading to loss of sealing properties.

4. Excessive perpendicular error between the shaft axis and the static ring end face.

5. Operational pressure fluctuations, unstable temperatures, and hard particles entering the frictional components.

6. Axle string quantity exceeded the target.

7. Sealing leakage in the fitting or bonding of dynamic and static rings.

Methodology:

Filler Sealing

1. Replace or repair the agitator shaft, and machine it on the lathe to ensure the surface roughness.

2. Adjust the oil ring position and clean the oil passages.

3. Tighten packing material or replace it.

4. Repairs or replacements

Mechanical Seal

1. Replace friction pairs or resurface anew.

Adjust the pressure appropriately, strengthen the cooling system, and promptly dissipate heat.

3. Selecting the correct sealing ring material and ensuring proper installation with sufficient clamping force is essential.

4. Shutdown for realignment, ensuring the verticality is no less than 0.5mm.

严格控制 process specifications to ensure no particles or crystalline matter enters the frictional components.

6. Adjustments and maintenance ensure the shaft's axial displacement meets the standard.

7. Improved installation techniques, with appropriate interference fit or a reliable, strong adhesive.

Four: Abnormal noise inside the kettle

Root Cause:

1. Scraper or scraper blade for agitator pot attachments (serpentine pipes, thermometer tubes, etc.)

2. Blender detachment.

3. Lining bulging, impacting with the agitator.

4. Blender bend or bearing damage.

Approach:

1. Shutdown for maintenance: align the mixer with its accessories to maintain a certain gap.

2. Shutdown inspection and bolt tightening.

3. Repair drum bubbles, or replace the lining.

4. Inspection or replacement of shafts and bearings.

Five: Fault Phenomenon: Enamel agitator detachment

Reason for the failure:

Material corrosion and fracture.

2. The motor's rotation direction is reversed.

Method of Handling:

1. Replace porcelain shafts or repair with fiberglass.

2. Shifting Gears with Downtime

Six: Fault Phenomenon: Enamel pot flange gas leakage

Root Cause:

1. The porcelain surface of the法兰 is damaged.

2. Incorrect selection of gasket material, improper installation of joints, gaps, misalignment.

Bolted nuts are loose or insufficient in quantity.

Approach:

1. Repair, coat with anti-corrosion paint or resin.

2. Select the gasket material according to the process requirements, ensuring that the gasket interfaces are aligned and evenly spaced.

3. As per design specifications, there should be an adequate number of clips, which must be securely fastened.

Issue: Ceramic surface experiencing scale burst and micropores

Root Cause of the Issue:

1. The presence of acidic impurities within the jacket or agitator shaft tube leads to hydrogen embrittlement.

2. The porcelain layer is not dense, presenting a potential隐患 of micro-pores.

Method of Handling:

After neutralizing with sodium bicarbonate, rinse or repair; replace if corrosion is severe.

2. Minor holes are repairable; severe cases require an update.

Issue: Motor current exceeds rated value

Cause of the Failure:

Bearings damaged.

2. Low internal pot temperature, material is thickened.

3. The spindle rotates at a high speed.

The impeller diameter is too large.

Approach:

1. Replace bearings.

2. Adjust temperatures according to operational procedures; ensure that material viscosity does not exceed a certain level.

Maintain the spindle speed within a specific range.

4. Adjust Appropriately.