Induction melting furnace furnace lining maintenance content

Maintenance and repair project

Maintenance and repair content

Inspection time and frequency

Remarks

furnace

lining

Does the lining have cracks?

See if there is any crack

Cold furnace before each furnace

If the crack width is less than 22 mm , if the chips or the like are not embedded in the crack, they do not need to be repaired and can still be used.Otherwise it needs to be patched before it can be used.

Repair of the taphole

Observe whether there is crack at the junction of the side refurbishment lining and the taphole

When tapping

If there is a crack, repair it

Repair of furnace bottom and slag line lining

Observe whether the lining of the bottom of the furnace and the slag line is partially corroded.

After tapping

If there is obvious erosion, it needs to be repaired.

sense

should

line

ring

Visual inspection

( 1 )            Is the coil insulation part bumped and carbonized?

( 2 ) Whether there is adhesion to the surface of the coil

( 3 ) Does the insulation pad between the coils protrude?

( 4 ) Is the mounting bolt of the top tight coil loose?

1 time / day

1 time / day

1 time / day

1 time / 3months

Purge with compressed air in the workshop

Tighten the bolt

Coil compression screw

Visually check if the coil compression screw is slack

1 time /week

rubber tube

( 1 )            Is there any leakage at the rubber pipe joint?

( 2 )            Check if the rubber tube is cut

1 time / day

1 time /week

Coil corrosion joint

Remove the rubber hose and check the corrosion resistance of the corrosion joint at the end of the coil

1 time / 6months

When the corrosion joint is corroded by 1/2or more, it needs to be replaced with a new one.Usually changed every two years

Cooling water temperature at the coil outlet

Under the rated amount of molten iron and rated power, record the maximum and minimum cooling water temperature of each branch of the coil

1 time / day

Dust removal

There is compressed air in the workshop to blow off the dust and molten iron on the surface of the coil.

1 time / day

Pickling

Pickling of the sensor water pipe

1 time / 2years

can

scratch

Sex

guide

line

Water cooled cable

( 1 ) Whether there is leakage

( 2 ) Check if the cable is in contact with the pit

( 3 ) Record the cable outlet temperature at rated power

( 4 ) Preventive measures taken to prevent accidents

( 5 ) Check if the connection bolts at the terminal end are discolored

1 time / day

1 time / day

1 time / day

1 time / 3years

1 time / day

According to the number of tilting, the life of the water-cooled cable is determined to be three years. It needs to be replaced after three years. If the bolt is discolored, re-tighten.

Maintenance and repair project

Maintenance and repair content

Inspection time and frequency

Remarks

furnace

cover

Dry cable

( 1 ) Eliminate dust on the busbar splint of insulating rubber

( 2 ) Check if the chain of the suspension busbar is broken

( 3 ) Is the busbar copper foil disconnected?

1 time / day

1 time /week

1 time /week

When the copper foil area is 10% of the busconductive area , a new busbar needs to be replaced.

Refractory pouring material

Visual inspection of the refractory lining inspection lid watering a layer thickness

1 time / day

When the thickness of the refractory potting material is 1/2, the lining of the furnace cover should be rebuilt.

Hydraulic furnace cover

( 1 ) Whether there is leakage at the sealing part

( 2 ) Leakage of piping

( 3 ) Leakage of high pressure pipe

1 time / day

1 time / day

1 time / day

If so, repair it

Exchange

High pressure pipe

( 1 ) There are traces of iron scald on the high-pressure pipe, etc.

( 2 ) To ensure safety, exchange

1 time /week

1 time / 2years

Lubricating

( 1 ) Manual type: part of the fulcrum of the furnace cover

( 2 ) Electric type: sprocket drive bearing for shaft adjustment chain for shaft cover wheel

( 3 ) Hydraulic type: guide bearing

pour

move

oil

Cylinder

Cylinder lower bearing and high pressure pipe

( 1 ) There are traces of iron scald on the bearing part and the high pressure pipe

( 2 ) oil leakage

1 time /week

1 time /month

Remove the cover for inspection

Cylinder

( 1 ) Whether there is leakage at the sealing part

( 2 ) abnormal sound

1 time / day

1 time / day

Observe the cylinder block when tilting the furnace

When a sound such as a knocking cylinder is issued, most of the bearings are short of oil.

Inclined limit switch

( 1 )            Action check

Press the limit switch by hand and the pump motor should stop running.

( 2 ) Whether there is splashing molten iron on the limit switch

1 time /week

1 time /week

Lubricating

All the fuel filler ports

1 time /week

High pressure control

cabinet

Cabinet inspection

( 1 ) Check the operation of each indicator bulb

( 2 ) Whether the parts are damaged or burned out

( 3 ) Clean the inside of the tray with compressed air in the workshop

1 time /month

1 time /week

1 time /week

Circuit breaker vacuum switch

( 1 ) Cleaning pass is the contact

The vacuum tube is milky white, blurred, and the vacuum is reduced.

( 2 ) Measuring electrode consumption

1 time / 6months

1 time /month

If the gap exceeds 6 mm,replace the vacuum tube

Main switch cabinet

Electromagnetic air switch

( 1 ) The roughness of the main contact, the amount of wear

( 2 )            Come on

( 3 ) Whether the fire extinguishing board has carbonization

1 time / 6months

1 time / 6months

1 time / 6months

Grinding with a trowel, sand, etc.

When the contact wear exceeds 2/3 , change the contact

Adding spindle oil to each bearing and link

The carbonized part is ground with sand

Maintenance and repair project

Maintenance and repair content

Inspection time and frequency

Remarks

Main switch cabinet

( 4 ) Dust removal

1 time /week

Clean with compressed air in the workshop and wipe off the dust on the insulator with a cloth

Insulation resistance

Use a 1000 volt megger to measure the main loop with greater than 10M Ωbetween

Converter switch

Transfer switch

( 1 ) Measuring insulation resistance

( 2 ) switch main joint rough

( 3 ) The main circuit connecting bolt is loose and overheated

1 time / 6months

1 time /month

1 time / 3months

Measuredbetween the conductor and the ground with a 1000volt megger

1M Ω

Polish or exchange

control

system

cabinet

station

Cabinet inspection

( 1 ) Whether the component is damaged or burned out

( 2 ) Whether the component is slack or falling off

1 time /week

1 time /week

Action test

( 1 ) Check if the indicator light is on

( 2 ) Alarm circuit

Should check the action according to the alarm condition

1 time /week

1 time /week

Dust removal inside the cabinet

Use workshop compressed air to clean

1 time /week

Auxiliary machine contactor

( 1 ) Check the roughness of the joint, and use a fine sand to smooth it when it is rough.

( 2 ) Exchange contacts

Replace when the contact is worn out

1 / March

1 time / 2years

In particular, the contactor for the furnace cover that is often used

Transformer reactor

Check appearance

( 1 ) Is there any oil leakage?

( 2 ) Whether the insulating oil is added to the specified position

1 time /week

1 time /week

Transformer and reactor temperature

Check the daily thermometer indication, below the specified value

1 time /week

Sound and vibration

( 1 ) usually check by listening and touching

( 2 ) Instrument measurement

1 time /week

1 time /year

Insulating oil pressure test

Should meet the specified value

1 time / 6months

Tap changer

( 1 ) Check the tap conversion for offset

( 2 ) Check the roughness of the tap adapter

1 time / 6months

1 time / 6months

Change the new one when it is severely rough with fine sand

Capacitor bank

Check appearance

( 1 ) Is there any oil leakage?

( 2 ) Whether the terminal screws are loose or not

1 time / day

1 time /week

If slack occurs , theterminal part will change color due to overheating.

Replacing the contactor of the capacitor

Dust removal

( 1 )            Rough joint

1 ) Smooth the rough part with a trowel sand

2 ) When the wear is severe, change the joint

( 2 ) Contact temperature rise

Wipe the insulator with a cloth using a compressed air in the workshop

1 time / 6months

1 time /week

1 time /week

At least 1 time/ month

Temperature around the capacitor bank

Mercury thermometer measurement

1 time / day

Ventilated, so that the surrounding temperature does not exceed 40 ℃

Oil pressure device

Hydraulic oil

( 1 ) Whether the oil level of the oil level indicates the color of the oil changes

( 2 ) Check the amount of dust in the hydraulic oil and the quality of the oil

( 3 ) Measuring temperature

1 time /week

1 time / 6months

1 time / 6months

If the oil level drops ,the circuit leaks

When the quality is poor , change the oil.

pressure gauge

Whether the pressure of the tilting furnace is different from normal, when the pressure drops, adjust the pressure to normal value.

1 time /week

Maintenance and repair project

Maintenance and repair content

Inspection time and frequency

Remarks

oil

Pressure

Loading

Set

Pump

Check if the noise of the pump is abnormal

1 time /week

When the pump is noisy , there are the following reasons :

(1) Inhaling air from a suction filter

(2) Inhaling air on the suction side of the pump

Pressure regulating valve

(1) When the time lag occurs from the start of the pump to the pressure rise and the noise of the pressure regulating valve becomes louder ,disassemble the pressure regulating valve for cleaning.

(2) When the speed of the tilting furnace is too slow , increase the setting of the pressure regulating valve within the maximum operating pressure range of the device . The set pressure does not rise , and the cleaning is performed for cleaning.

Pipeline filter

Disassemble the filter for cleaning

Exchange parts

The first time a month laterfor the 1/3months

1 time / 2years

Piping

Emergency generator

Petrol Engine

Hand pump

Visually check for oil leaks on the piping

Prevent rust , start engine pump

Check by attached inspection book

Take measures to prevent rust and start the hand pump

1 time /month

1 time /month

1 time /month

Blower

Fan belt

Whether the belt is slack

Whether the belt is disconnected

The first time is one month , and thefuture is

1 time / 6months

Gas filter

Visually check the vacuum status and clean it with compressed air in the workshop

1 time /month

Noise, vibration

The noise and vibration of the blower are different from usual.

1 time /week

Lubricating

Blower bearing

1 time / 3months

Cooling water circuit

Cooling water pump

(1) Bearing temperature and motor case temperature

(2) When the pump bearing has water leakage , thereinforced bearing

(3) The noise and vibration of the motor and pump are different from usual.

(4) after long-term operation, or in the winter, night stops running, should be excluded from surplus water

(5) gland seal electrical wear

1 time /week

1 time /month

1 time /month

1 time / 1.5to 2 years

Cooling Tower

(1) Blockage of the nozzle

(2) Filtration of the filter :

Clean or exchange when there is serious pollution

(3) Whether the fan belt is slack

(4) Fan bearing lubrication

Initialinspectionis a once a month,after 1/3months

1 time / 3months

Check the nozzle for blockage from the inspection window during operation

Maintenance and repair project

Maintenance and repair content

Inspection time and frequency

Remarks

Cooling water circuit

Cooling water circuit

(1) Is the flowmeter flow different from usual?

(2) Cleaning filter

(3) Water pressure gauge

Whether the alarm value is normal or not, the pressure indication is different from usual.

(4) Thermometer

The thermometer indicates whether it is normal

Whether the alarm contact point is abnormal

(5) Piping

Whether the piping has leaked

1 time / day

1 time / 3months

1 time /week

1 time /month

1 time /week

1 time / day

Emergency equipment

(1) Gasoline engine pump

Run weekly, half-hour time

(2) Gasoline engine inspection according to subsidiary inspection

(3) Emergency solenoid valve

1 time /week

1 time / day

Leakage alarm device

Electrode lead line inspection

(1) Is the electrode lead wire connected normally?

(2) Whether the electrode lead wire is grounded

1 time / day

Check with a test stick

Coil check

When removing the furnace :

Whether the coil is burnt out due to molten metal

Whether there is bump in the coil

Is there any other damage to the coil?

It is more appropriate tofill the coil insulation with asbestos plaster for 3 to5 years.