General process rules for reactor processing

### Guidelines for Operating and Maintaining Reactors

#### **Operational Guidelines**

1. **Documentation and Compliance**:

- Read and adhere to all instructions in drawings and process documents.

- Strictly follow design drawings, process procedures, and technical requirements. Avoid arbitrary changes.

2. **Tool and Equipment Checks**:

- Verify that borrowed measuring tools meet process and usage requirements.

- Inspect reactor blanks before processing to ensure allowances meet process requirements.

3. **Inspection Protocols**:

- Perform first-piece inspections in a free-standing state, avoiding clamps or fixtures.

- Conduct inspections after tool changes and during continuous processing to prevent batch scrapping.

4. **Chamfering and Blunting**:

- Deepen or enlarge chamfers and undercuts as per allowances.

- Blunt edges unless specified otherwise, especially for die edges.

5. **Workplace Organization**:

- Keep workpieces clean, rust-free, and neatly arranged.

- Use magnetic tables for holding workpieces and demagnetize them after processing.

#### **Cleaning and Maintenance**

1. **Scale Removal**:

- **Pickling**:

- Optimal temperature: 60°C.

- Solution: 81% formic acid, 17% water, 1.2% buffer, 0.8% surfactant.

- Duration: 2 hours static immersion, followed by 3–4 hours of circulation.

- Passivation treatment required after pickling.

- **Flushing**: Remove impurities before pickling to enhance effectiveness.

- **Alkaline Cleaning**: Use NaOH and NaHPO₄ after acid cleaning to neutralize and prevent corrosion.

- **Water Cleaning**: Rinse thoroughly with softened water to remove residue.

2. **Recording**:

- Document all steps during cleaning for verification and process control.

By following these guidelines, reactor operations can be conducted efficiently and safely, ensuring high-quality processing and maintenance.