1 ton melting furnace emergency troubleshooting method
1. Preparation before the start of the 1 ton melting furnace
1. Check the lining of the melting furnace . When the thickness of the lining (excluding asbestos cloth and refractory clay) is severely worn and corroded and thinned, the lining must be repaired and the lining must be re-knotted.
2. Check the lining for cracks. When the longitudinal crack width exceeds 3 mm, fill the lining material for repair; if there is a transverse crack running through the entire circumference, the lining cannot be used.
3. Ensure that the cooling water of all pipes is unblocked. If you find that a pipe is blocked, you must try to clean it up, otherwise the consequences will be serious.
2 , 1 ton melting furnace safety during smelting
1. The operator in front of the furnace must undergo strict professional training, and the untrained personnel must not go to the furnace for operation.
2. It is strictly forbidden to add a moist charge for smelting. If there is no dry material, it must be dried before it can be put into the furnace.
3. Feed each time evenly. The chip material should be placed on the residual molten iron after the furnace is released.
4. It is strictly forbidden to add a closed tubular or hollow charge to prevent the gas from expanding and causing an explosion.
5. Whenever the material is fed, the second feed must be re-charged on the basis that the previous feed has not been completely melted. To prevent the added charge from splashing the solution.
6. If the rust or the sand with more sand, or when adding too much cold material at a time, it is easy to produce a "bridge" phenomenon, should be checked frequently to avoid the phenomenon of "bridge".
7. Avoid violent mechanical shock to the lining.
8. It is strictly forbidden to connect the molten iron with a defective or wet ladle.
9. It is strictly forbidden to operate without cooling water.
10. The furnace structure should be reliably grounded.
11. Do not operate without normal electrical safety interlock protection.
12. In the process of furnace charging, sampling, alloy addition, temperature measurement, slag removal, etc., if it is necessary to carry out under power-on conditions, appropriate safety measures should be taken. Such as: wearing insulated shoes, with asbestos gloves, wearing insulation, with protective glasses and platform pad insulation.
13. To avoid the temperature of the molten iron from exceeding the required value, the molten iron with too high temperature will greatly reduce the service life of the lining.
14. Always check (at least once a week) whether the hydraulic hose is damaged, leaking or aging. If it is damaged or oily, it should be disposed or replaced in time.
15. Always check if the oil level of the fuel tank is normal. When the oil quantity is insufficient, it should be replenished in case of emergency.
A. P. Keep the hydraulic oil clean and replace it once a year.
3 , 1 ton melting furnace emergency troubleshooting
1. Power failure before smelting, no need to prepare.
2. Power failure during the melting process of the melting furnace , power failure can be, but can not stop the water, such as power outages and water, then you must open the spare water tank to cool the furnace. If the power is stopped for a short period of time (less than 10 minutes), you do not need to use the spare water tank, you can wait for the power to continue.
If the power outage time is long, the moisture in the coil and the hose is easy to form a vapor, which affects the cooling effect of the coil and damages the insulation performance of the hose. Therefore, for a long time of water stoppage, the standby water should be connected. The amount of water is generally about 1/4 of the smelting flow rate.
Within 1 hour of power failure, cover the liquid surface with charcoal to prevent heat dissipation. The power failure time is more than 1 hour. Consider trying to pour out the molten iron.
1. Leakage furnace
Leakage accidents can easily cause damage to equipment and even endanger people. Therefore, we should try our best to maintain and maintain the lining in order to avoid leakage.
When the leaking furnace alarm sends a signal, immediately cut off the power supply, inspect the molten iron around, check whether the molten iron leaks out, if there is leakage, immediately pour out the molten iron; if there is no leakage, the alarm device should be carefully checked. If it is confirmed that the molten iron and the side electrode are in contact, the molten iron should be poured out immediately.
The leaking furnace alarm can only be used as a reference signal for the leaking furnace. Whether it is really leaking or not, according to the actual situation of the site, combined with the change of power in the production record of the melting process, the furnace age of the furnace lining is comprehensively determined.
The thickness of the lining is thinned, the electric efficiency is enhanced, the melting speed is increased, and the material is continuously fed during the production process, and the lining generates rapid cooling and rapid heat, which causes cracks and leaks.
Improper tilting, oven, sintering or improper lining of the furnace can also cause leakage.
4 , cooling water accident
1. The cooling water temperature is too high. Generally for the following reasons:
The sensor cooling water pipe is blocked by foreign matter and the water flow is reduced. At this time, the power is cut off, and the foreign matter is removed by compressed air (the power failure time does not exceed 15 minutes).
Another reason is that the water scale scale seriously affects the flow. Wash once with 1:20 hydrochloric acid. Remove the hose every six months to check the scale. If the scale is clogged, wash it in advance.
B. The sensor water pipe suddenly leaks. The reason for this is that the inductor is formed by the insulation breakdown of the yoke or the surrounding fixing bracket. In the event of such an accident, immediately power off, strengthen the insulation treatment at the breakdown, and seal the surface of the leak with epoxy resin or other insulating glue, and use it under reduced pressure. After the molten iron of the furnace is melted, the molten iron is poured out for repair. If the breakdown area is large, it is impossible to seal with epoxy resin, etc., so that it is necessary to stop the furnace and pour out the molten iron for repair.
