首钢京唐焦炉炉组耐火材料砌筑手册+英文译本.doc

Basic Erection ManualForRefractory BrickworkFor theCoke Oven BatteriesOfSGJT(CAOFEIDIAN)首钢京唐焦炉炉组耐火材料基本安装手册Table of Content目录1 . Time Schedule and Sequence of Refractory Brickwork1.耐火砖砌筑进度时间表1 .1 Activities before start of refractory brickwork1.1 砌炉前的准备1 .2 Activities during refractory brickwork1.2 砌炉内容2. Description of Refractory Brickwork2. 耐火砖砌筑说明2.1 Special requirements for refractory brickwork2.1 耐火砖砌筑的特殊要求2.1.1 Axes and elevations2.1.1 轴线和标高2.1.2 Refractory bricks 2.1.2 耐火砖2.1.3 Expansion joints 2.1.3 膨胀缝2.1.4 Mortar joints2.1.4 灰缝2.1.5 Scaffolding for bricking up2.1.5 砌筑用脚手架2.2 Scope of refractory brickwork2.2 耐火砖砌筑范围2.2:1 Regenerator Wall2.2.1蓄热室墙2.2.2 Corbel area2.2.2斜道区2.2.3 Heating wall lower part2.2.3燃烧室墙下部区2.2.4 Regenerator sole flue2.2.4蓄热室底部烟道2.2.5 Checker bricks and regenerator bulkheads2.2.5格子砖和蓄热室堵墙2:2.6 Heating wall upper part2.2.6燃烧室上部区2.2.7 Oven roof2.2.7炉顶2.2.8 Lining of stand pipes2.2.8上升管内衬2.2.9 Work during and after heating-up2.2.9烘炉期间及烘炉后的工作1Time Schedule and Sequence of Refractory Brickwork1.耐火砖砌筑进度时间表The refractory installation shall be executed according to the dates and periods shown in the Project Time Schedule耐火砖的砌筑应该按照工程时间表进行The main refractory brickwork shall be finished before installation of the battery bracing system and the oven closures and before heating up except the upper courses of the oven roof area(The oven roof area will be finished after luting the oven decking shortly before the first coal charge）耐火砖主要砌筑工作将在护炉铁件及炉子封顶前完成。（炉顶密封在第一次装媒前完成） The general sequence of bricklaying activities is as follows： 主要砌筑工作的顺序安排如下：general site measurement of the refractory area with level measurement of the main oven dimensions，the battery main axis，oven pitch，oven length，etc. 耐火材料区域的一组测量数据，包括主炉面积，炉组主轴线，焦炉倾角，焦炉长度等arrangement of the sliding foil on the grouting base 在焦炉底板上铺设滑动箔板bricklaying of the sole flues砌筑炉底烟道bricklaying of the regenerator walls (230 mm and 320 mm)砌筑蓄热室墙（230mm320mm）bricklaying of the 110 mm wall 砌筑110mm墙installation of scaffolds for the up going walls 搭设脚手架用于上部墙体砌筑arrangement of the sliding joint between fireclay and silica brickwork在半硅砖和硅砖之间铺设滑动层bricklaying of corbel area砌筑斜道区bricklaying of heating walls lower part砌燃烧室墙底部bricklaying of heating walls upper part砌燃烧室上部cleaning the heating walls by industry-vacuumed-cleaner用工业用真空清洁器清扫燃烧室墙sealing the inspection .holes by plastic foil（layer 52）用塑料薄膜密封观火孔（52层）inspection of corbel area gas channels by video system and protocol free of obstacles利用视频系统检查斜烟道区煤气通道，并提供清理完成的检测报告installation of oven roof (silica part) 砌筑炉顶（硅砖部分）installation of sliding joint between silica and fireclay砌筑硅砖半硅砖之间的滑动层installation of oven roof (fireclay part)砌筑炉顶（半硅砖部分）installation of base sleeve of ascension pipes砌筑上升管衬转installation of charging hole frames砌筑装煤孔installation of inspection hole frames安装观察孔框架installation of charge car sleepers安装装煤车轨道After the video inspection is complete and successful the works in the regenerator part will commence：当以上工作通过视频系统检查无问题后，以下蓄热室工作将展开：completion of regenerator sole flue完成蓄热室底部烟道installation of checker bricks with the regenerator separation walls安装蓄热室格子砖closing of regenerator front side封闭蓄热室 Remark: Before and during refractory installation mechanical erection has to be performed as described in the Basis Erection Manual for Mechanical Equipment.注意：耐火砖砌筑前及过程中的机械设备的安装必须执行机械安装基本手册1.1 Activities before start of refractory brickwork1.1 砌筑前的准备工作Precondition for the start of the refractory work is the preparation of the even grouting。the battery base stab with the tolerances given in the corresponding civil drawings，the installation of the coke oven gas burner pipes and the temporary oven shedThe temporary oven shed shall be equipped with sufficient light and a heating system to ensure a mintemperature of at least 80 in colder periods. Louvers for ventilation during summer are requiredCrane capacity（5 resp10 t) has to be provided to set in place the oven equipmentcastings on the oven top as well as hoisting features for refractory material transport. Working safety equipment shall be fitted acc. to National Standards砌筑工作开始的前提条件是：焦炉底板灌浆的平整度在图纸给出的允许误差范围内，煤气加热管和临时大棚搭设完毕；临时大棚内应该安装足够的照明设备及采暖设备，采暖设备能保证大棚内温度在冬季不低于8摄氏度；要有夏季通风用的百叶窗；5个10t的起重机，用于安置焦炉设备及铁件，和搬运耐材；按照国家标准配备安全设施。1 .2 Activities during refractory brickwork1.2 砌炉内容For the equipment to be inserted into the refractory brickwork, such as the sole flue frames，regenerator inspection flaps and the oven top closures please refer to the corresponding Basis Erection Manual for Mechanical Equipment for SGJT.嵌入耐火砖结构里的设备，如烟道弯管、蓄热室观察孔挡板等，请参照机械设备基础安装手册中的相关内容。2. Description of Refractory Brickwork2. 砌筑工作描述2.1 Special requirements for refractory brickwork2.1 砌筑工作的特殊要求2.1.1 Axes and elevations2.1.1 轴线和标高Based on the co-ordinates of the existing coking plant the bench marks for the longitudinal and lateral axes are established in all three dimensions as the cold measurement as follows：在已有焦炉平台相关纵坐标的基础上，用于建立焦炉冷态三维横坐标和纵坐标的基准点如下：battery centre line l 炉组中心线oven front on Pusher-Side and Coke-Sidel 机焦侧炉面battery height and oven sole levell 炉高和炉底线 oven axis for two reference ovensl 两座参考炉的轴线 oven axis for the first ovenl 第一座炉的轴线oven axis of last ovenl 最后一座炉的轴线 a marked fixed point for measuring of the elevations shall be determinedl 测量标高的固定点All determination of the measurements shall be recorded所有的测量数据要记录下来The battery must be marked according to these dimensionsDuring the progress of construction work dimensional checks by a surveyors level instrument shall be continuously carried out. 炉组必须按照以上尺寸进行标记在砌筑工作中，尺寸的检查必须有检测员通过水平仪连续的检测。Templates marked which the respective height of the brick course shall be used for observing course heights in the overall structure在整个砌筑过程中，每一层砖的高度都要通过模板进行标定。The bricks in the courses of the regenerator and the heating walls must be bonded all over with packed mortar to ensure that vertical and horizontal joints are completely full of mortar.蓄热室和燃烧室的墙在砌筑时必须保证砖的垂直和水平面填满耐火泥。2.1.2 Refractory bricks2.1.2 耐火砖 After arrival of the refractory material the pallets shall be checked for outer damagesEach single refractory brick has to be checked for damage and be pre-sorted in the brick shedBefore bricklaying into the courses of the wall the bricks shall be checked by the bricklayer once more for damage. In general only undamaged bricks shall be installed. In case of damages at the comer and / or the edge the damage of the bricks have to be analysed with reference to the specification DIN 1089. If bricks meet the requirements according to this specification they can be used耐材运至现场后，要检查整体包装是否损坏，每一块砖都必须进行检查是否有破损然后放入砖库存放。在砌筑前筑炉人员应再对每一块砖进行检查。通常只有没有破损的砖才能被使用。如果破损在角上或者边缘，可以参照DIN1089标准进行分析，如果满足要求可以使用。2.1.3 Expansion joints2.1.3 膨胀缝Expansion joints shall be laid by using adequate strong joint fillers.膨胀缝在砌筑时要用足够的高强度填充物进行填塞。The dimension of the expansion joints shall be executed exactly according to the refractory drawings. The expansion joints must not be smaller than shown in the drawings！膨胀缝的尺寸要严格安照图纸砌筑，绝对不能小于图纸所标注的尺寸！No mortar residues shall remain in the expansion joints prior to the installation of ceramic fibre mats or polystyrene在安装陶瓷纤维毡或聚苯乙烯泡沫前要保证膨胀缝里没有残留的耐火泥。Prior of bricking-up the next brick course the mortar free joint will be inspected by the refractory supervisors and ceramic fibre mats or polystyrene is filled into the joint and the expansion joints are to be covered by adhesive tape in order to avoid mortar entering from the next course into the expansion joint.在砌筑下一层之前，自由缝要进行检查，陶瓷纤维毡要被填进缝中，膨胀缝还要用胶布覆盖防止耐火泥从上层进入缝里。2.1.4 Mortar Joints2.1.4 灰缝The refractory bricks are put into place with mortar as specified in the mortar drawingsThe thickness of the joints is acc. to the drawings with respect to the tolerances，given under chapter 2143耐火砖被置在耐火泥上。砖缝厚度在图纸上给出，注意允许误差，厚度在2.1.4.3中给出。2 .1.4.1 Preparation of the mortar2.1.4.1 耐火泥的准备The mortar is mixed with pure tap water in such a way that it remains pliable and bonds well during application. The mortar pans should be made of plastic so that tempering water with binding agents and fine grain cannot escape. 用干净的自来水和泥，这样在使用时耐火泥会有较好的韧性和粘度。选用塑料材质的耐火泥托板，这样粘合剂中的水和一些小的颗粒就不会站在托板上面。With our correspondence（NoTisco 02-0309 / TISCO-UHDE E 0106) we explained to utilise only silica mortar type KS91 for the whole refractory brickwork.我们在信件（NoTisco 02-0309 / TISCO-UHDE E 0106）中解释了为什么在整个耐火砖砌筑工程中只采用KS91型号的硅石耐火泥。Before bricking up the individual brick courses we suggest to lay out the courses without mortar in order to match with the joint thicknessIn order to obtain a uniform joint distribution it may then be necessary to replace bricks with minus or plus tolerances每层砖在砌筑之前，我们建议先在不放泥的情况下摆放以下，以匹配合适的砖缝厚度。为了得到一个统一的砖缝分布，可以用在误差范围内的不同的砖替换。2.1.4.2 Bricking,-up2.1.4.2 砌砖In bricking-up，the mortar of a part of the horizontal joints can be drawn up onto the previously bricked course prior to laying of the bricksThe mortar of the vertical joint is applied onto the respective brick to be laid砌砖时一部分水平缝可以先在前一层砖上画下线然后再铺耐火泥，垂直缝的泥再分别抹。Following laying of the brick it is then tapped with a rubber hammer so that the mortar bubbles come out of the horizontal and vertical joint.铺好砖后用橡胶锤子轻敲，以便将耐火泥的气泡从水平和垂直的缝里挤出来。 Alignment can take place once the required joint thickness has been obtained through tapping可以通过敲打得到要求的砖缝厚度，从而对齐整列的砖。Subsequently tapped and aligned bricks may not be subjected to a further correction of the joint since this causes porosity. 随后进一步敲打或较直砖，不能有效的改进砖缝，这样会导致多孔性。If the required thickness of the horizontal and vertical joints has not been achieved due to insufficient application of mortar, the brick shall be removed，re-applied with mortar and re-laid如果由于耐火泥放的不够多导致砖缝到不到要求，砖应该拿掉重砌。Vertical joints on the last brick to be laid must be given a double application of mortar, i.e. both the vertical joint surfaces of the bricks already laid and the vertical joint surfaces of the last brick to be laid must be provided with mortar.最后一块砖的垂直缝必须用双倍的耐火泥，也就是已经铺上的那块砖和将要铺上的砖的垂直面都要抹耐火泥。When laying the last brick it must be driven into the mortar bed so that the mortar fillings of the vertical joint surfaces combine together. Then the brick is tapped on and the remaining mortar drawn off with the trowel最后一块砖被敲进耐火泥里，使泥填满垂直缝使两个垂直面粘牢，然后轻敲砖，多余的泥用铲刮掉。In case no drawings are available for the brickwork bonding of brickwork parts which are made of standard bricks, the following must be observed:如果砌筑的结合处，图纸中没有给出，且是标准砖，观察以下几点：Continuous joints have to be avoided：要避免连续的缝；Vertical joints shall overlap with each other to prevent penetration of air and gas垂直缝要相互错开，防止空气和煤气的渗漏。The joints of brickwork remaining visible shall be pointed with mortar prior to completion of each shift在完成每班工作时，砌筑中可见的缝用耐火泥溜缝。Installation of checker bricks：格子砖的安装Before the checker bricks are laid in the regenerator chamber the heating flues shall be cleaned carefully by industry vacuum cleaner in order to find and remove any remaining，obstacles，displacements or contaminationUhde suggests to utilise a video camera system to investigate each single airgas channel and to record the results in a minutes.在将格子砖放入蓄热室前，燃烧室烟道必须用工业真空清洁器进行清理。伍德建议使用视频摄像系统检查每一个空气/煤气通道，并且立即记录结果。2.1.4.3 Permissible Tolerances of mortar joints2.1.4.3灰缝允许公差Taking into account a justifiable joint thickness, brickwork must be bricked with suitable bonding. The following joint thickness must be applied:砌砖用灰浆必须有合适的粘度，用来确保砖缝合适。下面列出了各部位的砖缝尺寸要求：l Regenerator wall and Corbel area 3-8mm, max10mml 蓄热室墙和斜道区 3-8mm, 最大不能超过10mml Heating walll 燃烧室墙Coal connecting face 3-7mm炭化室面墙 3-7mmBinder wall/taper compensation 3-10mm各火道隔墙/锥度补偿 3-10mmOther brickwork 3-8mm, max10mm 其他墙面 3-8mm，最大不超过10mml Regenerator inlet and oven roof 3-10mm, max12mml 蓄热室与废气瓣结合部和炉顶区 3-10mm，最大不超过12mml Chamber cover bricks, tapered joint 2-10mm, max12mml 砖保护层之间，接缝锥度 2-10mm, max12mm2.1.4.4 Permissible Tolerances of brickwork2.1.4.4 砌砖允许公差The following tolerances have to be kept during bricking up(cold condition).砌砖时，必须遵循下列标准（冷态条件下）。l For the chamber width +2/-1mml 炭化室宽 +2/-1mml For heating wall width +1/-2mml 燃烧室宽 +1/-2mml Oven chamber height 5mml 炭化室高 5mml Oven sole elevation 3mml 炉底标高 3mml Oven roof elevation 5mml 炉顶标高 5mml Perpendicular of wall heads 2mml 炉头垂直度 2mmMeasured at the outer wall face 外部墙面的处理方法l Back setting of bricks in the layers over a height of 1 m should not be more than 1mml 1米高以上的砖层的调节量不应该超过 1mml Tolerance of one(1) oven pitch 1mml 炭化室中心距 1mmll Tolerance of five (5) oven pitches 3mml 相隔5个炭化室中心距 3mm l Tolerance of more than 5 oven pitches 5mml 相隔5个以上炭化室中心距 5mml Distance between charging holes 3mml 装煤孔中心距 3 mml Distance between rail chairs 2,5mml 装煤车轨道基础间距 2,5mmIf the tolerances are not met, the brickwork must be demolished and rebuilt.如果超出以上偏差，必须拆除重新砌筑。2.1.5 scaffolding for bricking up2.1.5砌砖用脚手架的搭设When erecting working scaffolding between the regenerator walls or between the heating walls, the scaffolding trestles and chamber posts may not be wedged or screwed too tightly against the brickwork to prevent deformation of the bricked walls.当在蓄热室墙之间或者燃烧室之间安装脚手架时，脚手架高架桥和柱架构成的空间布置不能是楔形，或者对着砌砖的螺钉不能拧的太紧，否则不能预防砖墙的变形。Scaffolds shall not be supported by the regenerator walls and/or heating walls.脚手架不能用蓄热室墙/或燃烧室墙作为支撑。2.2 Scope of fefractory brickwork2.2耐火砖砌筑范围The scope of refractory brickwork can be estimated from the corresponding drawings. The quantities for each layer is shown on drawing UDO-FKTB-00-000-Part3 3. 砌砖范围能从相应图纸中查到，而且每层砖的数量在UDO-FKTB-00-000-Part3 3图纸中也标出来了。In general the work comprises of the following activities:一般情况下，砌砖工作包括以下内容：2.2.1 Regenerator Wall2.2.1 蓄热室墙Bricking-up of the regenerator walls (courses 1-32as per the drawings)蓄热室墙砌体（如图纸所示1-32层）Course 1 to 21 executed with fireclay bricks, course 22 to 32 in silica 1-21层用半硅砖，22-32层用硅砖。Execution of a sliding/mortar joint between the nozzle deck (concrete) and the first regenerator wall courses。在焦炉基础顶板和第一层蓄热室砖间铺设滑动层/灰缝。Application of approx. 5% blastfurnace-cement for the first 15 courses to the refractory mortar. It has to be checked by trial that the addition of the selected cement has no negative affect to the tightnees of the joints.开始的15层砌筑火泥中应添加5的矿渣水泥，同时矿渣水泥应该进行检验其对灰缝的收缩没有负面影响。Installation of 72 cast iron frames for the waste gas boxes, on CS。在焦侧安装用于与废气瓣连接的72个小烟道衬套。Installation of 72regenerator inspection frames, PS and CS.在机、焦侧各安装72个蓄热室检查孔座。Due to stability reasons it is recommended to brick the regenerator sole flue wall after the regenerator chamber is finished.为了稳固，建议在蓄热室砌筑完成后再砌筑小烟道。The checker bricks will be installed later after finishing the heating wall and the inspection of the channels in the corbel area.在砌筑完燃烧室墙和斜道清扫完成后，再进行格子砖的安装。2.2.2 Corbel area2.2.2斜道区Bricking-up of the corbel area, courses 33 to 40 as per the drawings. 斜道区砌体（如图纸所示33-40层）Special care has to be taken to the different expansion joints in the corbel area as described under item 2.1.3我们要按照第2.1.3条所述那样，对斜道区膨胀缝的不同应该尤其注意。Arrangement of sliding joints between course 36 and 38 acc. to the drawing.根据图纸铺设36层和38层间的滑动缝。Installation of cast iron oven sole plates安装炉底铸铁板。2.2.3 Heating wall lower part2.2.3 燃烧室墙下部区Bricking-up of the heating walls(courses 1 to 59 as per the drawings).燃烧室砌体（如图纸所示1-59层）Adjustment of burner level:烧嘴高度调节：First slide bricks in the burner level have to be installed according to the drawing and have to be fixed after that in order to avoid moving during ongoing bricking up.根据图纸在烧嘴高度处设置滑动砖，滑动砖必须固定，防止其在继续往上砌砖过程中移动。During bricking up of the heating flue it must be ensured by temporary protection plates that no mortar is falling down to the burner level. If this by accident happens the burner level has to be cleaned before continuing the upper part of the heating wall.在立火道的砌筑过程中，必须采用临时保护板防止灰浆进入烧嘴，一旦发生灰浆流入烧嘴内时，必须清理干净后才能继续向上砌筑。After finishing course 51 (before closure of the heating wall) a thorough cleaning of the heating wall by special powerful industry vacuum cleaners shall take place.(It is not recommended to use compressed air blower because mortar will be blown out of the joints).在砌筑完51层（燃烧室封顶前）后，用特制大功率工业真空泵对燃烧室墙面进行彻底清理。（不推荐用压缩空气吹扫，以免将砖缝中灰浆吹出）2.2.4 Regenerator and regenerator bulkheads2.2.4蓄热室及蓄热室封墙For the bricklaying of the