焚烧炉衬里施工要点.doc

F-4940 COMBUSTION TREATMENT REFRACTORY INSTALLATION MANUAL FOR FIELD WORKF4940 COMBUSTION TREATMENT REFRACTORYINSTALLATION MANUALFORFIELD WORK1. Outline of construction 施工概要This manual applies to the application method of the refractories lining work applied the F-4940 combustion treatment. 本手册用于F-4940焚烧炉耐火内衬施工。This manual describes the lining method based on experience up to the present; proceed with the construction work after discussion with our installation instructing engineers every time any problem occasion in this manual. 本手册描述的衬里方法是基于至今为止的工程经验；每次发现手册内有任何问题应与我们的施工指导工程师讨论后，才再继续施工。2. Provisional construction 施工临时设施A field office, a bunkhouse, a shed for mortar mixing and a shed for preparing forms would be necessary. Sites for these constructions shall be supplied. Facilities such as provisional power outlet or hoists shall be planned in advance and be provided. 现场应提供：一间现场办公室，一间工棚，一个配耐火泥用的棚和预砌筑用的棚。要预先配备例如象临时电源或卷扬机等设备或工具。3. Storage of refractory materials 耐火材料保管Satisfactory measures against humidity shall be provided, because humidity is detrimental to refractories. 要放在湿度应尽量小一些的环境内，因为湿气对耐火材料有害。In case of outdoor storage, the ground is leveled up, materials are covered with water-proof sheets and roped up. 万一要放在室外，应垫高并盖好防雨布。4. Tools and equipments for lining installation 衬里用工具和设备Tools and equipments shall be prepared with care. There shall be exhaustive discussions about the selection, considering local conditions and the method of installation. 工具和设备应认真准备。根据当地条件和施工方法，仔细考虑和挑选。Electrical tools shall be regulated with particular care to prevent electric shock or leakage. Also, materials for safety measures shall be considered and provided in advance detail refer to tools list for refractory installation. 电动工具应有防漏电保护。同样应充分预先考虑安全性，详细细节参考耐火材料安装工具清单。5. Checkup on dimensions of the shell 壳体尺寸检查Every dimension of the shell shall be checked up before the start of lining installation. If the shell has warped significantly, the progress of installation work is impeded because much brick cuttings are necessary. 开始衬里施工前应检查壳体的每个尺寸。如果壳体有明显变形，就会妨碍衬里施工进度，因为会增加许多砖加工量。Besides, a warped shell would affect the life of lining because of anomalous stresses that arise at high temperatures. In order to have no trouble after the start of the installation work, the location of openings and the installation method around openings shall be checked up in detail. 此外，壳体变形会影响衬里的使用寿命，因为在高温时会产生不正常的应变。为了开始施工后没有麻烦，开口位置和开口位置的施工方法应详细地检查。Main confirmation item 主要确认项目(1) shell inside diameter and strain.(+-10mm) 壳体内径和损伤(2) position of brick retainer, shape, members rib. 托砖板位置，外形，筋板。(3) Other hole 其它孔洞6. Use and workability control of mortar 耐火泥的使用和可用性控制Mortar is used to bind bricks firmly together to build a strong structure that bears mechanical impact, and to correct irregularities of lining surfaces, enabling the lining to carry the load uniformly. 耐火泥把砖连成一个坚固的整体，以抵抗机械冲击和修正衬里表面，使衬里受力均匀。Also, mortar is used for the purpose of preventing brickwork form the leakage of furnace gases, flames or ambient air. Therefore, it is most important to perform careful mixing and to maintain the optimum water content and workability. 同样，耐火泥使用的目的是防止砖结构炉内气体，火焰或周围空气的泄漏。因此，耐火泥的混合，加水量和可使用性是最重要的。Mortar mixing shall be performed mechanically with mortar mixers or hand mixers. Air setting mortar shall be used immediately after mixing or breaking seal.耐火泥的混合应使用灰浆搅拌机或搅拌器。气硬性灰浆混合后应立即使用或保持密封。If a portion is to be stored overnight, precautions such as covering the surface with water, shall be taken. 如果一部份灰浆要过夜放置，应采取象在灰浆表面撒水的预防措施。7. Brick cutting 砖切割Cutting of insulating brick shall be made with great care, using a cutting machine or an insulating brick saw. If there is on other way but hand cutting, a masons cutting blade is used. 保温砖的切割要特别小心，应用切割机械或保温砖专用锯。还可以有其它方法但是不能用瓦刀砍切。Out surface is finished with a disc-sander planer to obtain a good finish. 外表面用砂轮机加工可以得到满意的表面质量。8. Brick installation 砌砖(1) A quantity of mortar corresponding to the joint thickness is spread on the brick surface. This spreading operation should uninterruptedly performed to ensure that all unfilled joints are eliminated. 根据灰缝厚度涂敷相应数量的灰浆到砖表面。所有灰缝必须抹灰浆，保证无任何砖缝漏涂灰浆。(2) After the brick spread with mortar, is placed in position, it is tapped with a hammer with plastic-coated head to correct the joint thickness. Forced-out mortar is scraped off with a trowel. 只能用橡胶锤砌砖，挤出的灰浆及时用泥刀刮掉。(3) Every brick is required to be laid accurately in regard to the vertical and horizontal directions. 每块砖都要砌得横平竖直。(4) The width of cut bricks shall be larger than 1/2 width of a regular brick. To keep this rule, often, two or three bricks must be cut instead of one. 砖加工后的尺寸必须保证大于原尺寸的一半。如果不能保证，就加工两块或三块。(5) Mortar shall always be used between insulating bricks and the shell. 保温砖与壳体之间应始终抹灰浆。(6) Also mortar shall be used between bricks and metal fittings such as brick retainers and ribs to avoid their direct contact. 同样砖与金属结构例如托砖板，筋板之间应抹灰浆，避免砖与它们直接接触。(7) Brickwork around a cleaning hole shall be built taking the frame center point as the basis, and necessary cuttings shall be made on bricks in the lower part.砌砖根据底部法兰中心砌筑，如有必要应加工砖。9. Finishing of joints 勾缝This is performed before mortar becomes too hard. 在灰浆完全干硬前勾缝。Surplus mortar is scraped off and a lack of mortar is made up with new mortar. 多余的灰浆刮掉， 不足处用新灰浆补上。Mortar surface is compressed with a joint trowel so as to recede by about 1mm from the brick face. 勾缝时要用泥刀用力挤压，使灰缝表面低于砖表面1mm。10. Mortar kind 灰浆种类Kind of brick 砖种类 Kind of mortar灰浆种类 Used section 使用部位CX-ALZM-AZCombustion chamber燃烧室CX-BSZM-AZUpper conical (top 2 layer)上锥（顶上2层）ER1681RNM-MLS1ZNaOH inlets nozzles NaOH喷嘴ML- S1ZM-MLS1ZStraight shellupper conical直筒到上锥SA-36SZM-SA36SZLower conicalstraight shell 下锥到直筒C1JT-32-DZAll backup lining 所有衬里内层11. Working procedure 工作程序(1) Covering for care 做好遮盖保护The cooling tank shall be covered by plastic sheet and plywood board. After some layers of lower conical part brick lining, cover these parts with plywood board. 冷却槽内要铺一层塑料布和夹合板。下锥部位内衬完后也要铺一层夹合板。Those are for cooling tank protection by some failing object at the time of brick works. The inlet position of refractory materials is manhole of cooling tank. 这是为了防止砌砖时掉落物体损坏冷却槽。耐火材料由冷却槽人孔进入。(2) Low conical 下圆锥For the first step, at the combination in brick SD-1 and SD-1-A, up to approximately 1600 millimeter inner diameter, in circumference direction. 第一步，砌砖SD-1和SD-1-A，内径约1600mm，沿圆周方向砌筑。Next, execute the brick work by SD-2, in circumference direction for the second step, and confirm inner diameter 1600 millimeter, same as the first step. 第二步砌SD-2，内径和砌筑方法同第一步。A footline (a) layer and (k) layer positions brick cut at site. There after, low conical shall be worked with combination table. As for the brick materials, C1 for back lining, and SA-36SZ for surface lining. 背衬砖在 (a) 和（k）处要在现场加工。然后按下锥砌砖表砌筑。背衬砖材质是C1向火面砖材质是SA-36SZ。The refractory brick shall be applied to 11 layers (a-k) for back lining and 14 layers for surface. 背衬砖砌11层，向火面砖砌14层。(3) Scaffolding 脚手架After low conical execution completion, firmly fasten the single pipes with scaffolding board. Then place the plywood to completion of scaffolding. The space between the low conical and scaffolding shall be covered with plastic sheets. With the progress of brick works at straight shell of furnace, raise scaffolding sequentially. 下锥砌完后，扎牢单管脚手架板。然后这个位置铺夹合板，脚手架搭完后。下锥和脚手架之间要铺塑料布。炉直筒砌砖，应升一层脚手架，砌一段砖。The bricks through the manhole shall be raised to proper level by using winch or hoist, to the working level of straight shell lining position. 砖应通过卷扬机或电动葫芦提升到直筒内衬工作面。(4) Straight shell No.1 直筒段下段Apply first back lining with S brick in a circumference direction. Then apply brick B1-76 and B2-76 under the brick support for one ring, up to 3850 millimeter inside diameter. 首先沿圆周方向砌背衬S 砖。然后砌托砖板下一圈砖B1-76 和B2-76，内径3850mm.。Then work of surface brick lining B1-A and B2-A on the brick support. After these, with the instruction drawings, apply insulating bricks followed by surface lining and back lining. 托板板上向火面砖是B1-A 和 B2-A。根据结构图，跟着向火面砖砌保温砖。The B1-74 and B2-74 shall be used to under of upside brick support. As for the brick materials, C1 for back lining, and SA-36SZ for surface lining. The space between the brick and brick support shall be filled with blanket for expansion. 砖B1-74 和 B2-74 用于上部托砖板下面。至于砖材质，背衬砖是C1, 向火面砖是SA-36SZ。砖与托砖板之间的膨胀间隙用纤维毯填滿。At manhole outer layer lining, apply Y22 for Y23 for 2 ring for 484 millimeter inner diameter. Then the back lining and surface lining shall be shaped cut at site. Nozzle parts shall be seted with brick SD-8 and SD-9. 人孔处用砖Y22 和Y23 砌两圈，内径484mm.。背衬砖和向火面砖需现场切割。管嘴部位砌砖SD-8和SD-9。Attention: for manhole brick, and nozzle part brick, any portion of direct contact with straight shell shall be shaped cut at site. 注意：人孔和管嘴部位的砖直接接触壳体处需现场切割。(5) Straight shell No.2 直筒段上段Apply brick B1 and B2 in a circumference up to 3850 millimeter inside diameter. After these, with the instruction drawings, apply insulating bricks followed by surface lining and back lining. 沿圆周方向砌B1和B2，保证内径3850mm。然后根据结构图砌向火面砖和背衬砖，保温砖依向火面砖砌筑。Then work of surface brick lining B1-A and B2-A on the brick support. 托砖板上部向火面砖是B1-A和B2-A。Then work of surface brick lining B1-74 and B2-74 under the brick support. 托砖板下向火面砖是B1-74和B2-74。As for the brick materials, C1 for back lining, and ML-S1Z for surface lining. The space between the brick and brick support shall be filled with blanket for expansion. 至于砖的材质，背衬砖是C1，向火面砖是ML-S1Z。砖与托砖板之间的膨胀间隙用纤维毯填滿。(6) Upper conical 上圆锥A footline (a) layer and (g) layer positions brick cut at site. （a）和（g）