1、F4940 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. 本手冊用于F-4940焚燒爐耐火內(nèi)襯施工。This manual describes the lining method based on experience

2、up to the present; proceed with the construction work after discussion with our installation instructing engineers every time any problem occasion in this manual. 本手冊描述的襯里方法是基于至今為止的工程經(jīng)驗(yàn)；每次發(fā)現(xiàn)手冊內(nèi)有任何問題應(yīng)與我們的施工指導(dǎo)工程師討論后，才再繼續(xù)施工。2. Provisional construction 施工臨時(shí)設(shè)施A field office, a bunkhouse, a shed for morta

3、r 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. 現(xiàn)場應(yīng)提供：一間現(xiàn)場辦公室，一間工棚，一個(gè)配耐火泥用的棚和預(yù)砌筑用的棚。要預(yù)先配備例如象臨時(shí)電源或卷揚(yáng)機(jī)等設(shè)備或工具。3. Storage of refractory material

4、s 耐火材料保管Satisfactory measures against humidity shall be provided, because humidity is detrimental to refractories. 要放在濕度應(yīng)盡量小一些的環(huán)境內(nèi)，因?yàn)闈駳鈱δ突鸩牧嫌泻?。In case of outdoor storage, the ground is leveled up, materials are covered with water-proof sheets and roped up. 萬一要放在室外，應(yīng)墊高并蓋好防雨布。4. Tools and equipments f

5、or lining installation 襯里用工具和設(shè)備Tools and equipments shall be prepared with care. There shall be exhaustive discussions about the selection, considering local conditions and the method of installation. 工具和設(shè)備應(yīng)認(rèn)真準(zhǔn)備。根據(jù)當(dāng)?shù)貤l件和施工方法，仔細(xì)考慮和挑選。Electrical tools shall be regulated with particular care to prevent

6、electric shock or leakage. Also, materials for safety measures shall be considered and provided in advance detail refer to tools list for refractory installation. 電動(dòng)工具應(yīng)有防漏電保護(hù)。同樣應(yīng)充分預(yù)先考慮安全性，詳細(xì)細(xì)節(jié)參考耐火材料安裝工具清單。5. Checkup on dimensions of the shell 殼體尺寸檢查Every dimension of the shell shall be checked up be

7、fore the start of lining installation. If the shell has warped significantly, the progress of installation work is impeded because much brick cuttings are necessary. 開始襯里施工前應(yīng)檢查殼體的每個(gè)尺寸。如果殼體有明顯變形，就會(huì)妨礙襯里施工進(jìn)度，因?yàn)闀?huì)增加許多磚加工量。Besides, a warped shell would affect the life of lining because of anomalous stress

8、es 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，殼體變形會(huì)影響襯里的使用壽命，因?yàn)樵诟邷貢r(shí)會(huì)產(chǎn)生不正常的應(yīng)變。為了開始施工后沒有麻煩，開口位置和開口位置的施工方法應(yīng)詳細(xì)地檢查。Main confirmation item 主要確認(rèn)

9、項(xiàng)目(1) shell inside diameter and strain.(+-10mm) 殼體內(nèi)徑和損傷(2) position of brick retainer, shape, members rib. 托磚板位置，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 t

10、o correct irregularities of lining surfaces, enabling the lining to carry the load uniformly. 耐火泥把磚連成一個(gè)堅(jiān)固的整體，以抵抗機(jī)械沖擊和修正襯里表面，使襯里受力均勻。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 carefu

11、l mixing and to maintain the optimum water content and workability. 同樣，耐火泥使用的目的是防止磚結(jié)構(gòu)爐內(nèi)氣體，火焰或周圍空氣的泄漏。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.耐火泥的混合應(yīng)使用灰漿攪拌機(jī)或攪拌器。

12、氣硬性灰漿混合后應(yīng)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. 如果一部份灰漿要過夜放置，應(yīng)采取象在灰漿表面撒水的預(yù)防措施。7. Brick cutting 磚切割Cutting of insulating brick shall be made with great care, using a cutting machine or an insulating brick saw. If there is

13、 on other way but hand cutting, a masons cutting blade is used. 保溫磚的切割要特別小心，應(yīng)用切割機(jī)械或保溫磚專用鋸。還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. 外表面用砂輪機(jī)加工可以得到滿意的表面質(zhì)量。8. Brick installation 砌磚(1) A quantity of mortar corresponding to the joint thickness is spread

14、on the brick surface. This spreading operation should uninterruptedly performed to ensure that all unfilled joints are eliminated. 根據(jù)灰縫厚度涂敷相應(yīng)數(shù)量的灰漿到磚表面。所有灰縫必須抹灰漿，保證無任何磚縫漏涂灰漿。(2) After the brick spread with mortar, is placed in position, it is tapped with a hammer with plastic-coated head to correct t

15、he joint thickness. Forced-out mortar is scraped off with a trowel. 只能用橡膠錘砌磚，擠出的灰漿及時(shí)用泥刀刮掉。(3) Every brick is required to be laid accurately in regard to the vertical and horizontal directions. 每塊磚都要砌得橫平豎直。(4) The width of cut bricks shall be larger than 1/2 width of a regular brick. To keep this rul

16、e, often, two or three bricks must be cut instead of one. 磚加工后的尺寸必須保證大于原尺寸的一半。如果不能保證，就加工兩塊或三塊。(5) Mortar shall always be used between insulating bricks and the shell. 保溫磚與殼體之間應(yīng)始終抹灰漿。(6) Also mortar shall be used between bricks and metal fittings such as brick retainers and ribs to avoid their direct

17、 contact. 同樣磚與金屬結(jié)構(gòu)例如托磚板，筋板之間應(yīng)抹灰漿，避免磚與它們直接接觸。(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.砌磚根據(jù)底部法蘭中心砌筑，如有必要應(yīng)加工磚。9. Finishing of joints 勾縫This is performed before mortar becomes too hard

18、. 在灰漿完全干硬前勾縫。Surplus mortar is scraped off and a lack of mortar is made up with new mortar. 多余的灰漿刮掉， 不足處用新灰漿補(bǔ)上。Mortar surface is compressed with a joint trowel so as to recede by about 1mm from the brick face. 勾縫時(shí)要用泥刀用力擠壓，使灰縫表面低于磚表面1mm。10. Mortar kind 灰漿種類Kind of brick 磚種類 Kind of mortar灰漿種類 Used se

19、ction 使用部位CX-ALZM-AZCombustion chamber燃燒室CX-BSZM-AZUpper conical (top 2 layer)上錐（頂上2層）ER1681RNM-MLS1ZNaOH inlets nozzles NaOH噴嘴ML- S1ZM-MLS1ZStraight shellupper conical直筒到上錐SA-36SZM-SA36SZLower conicalstraight shell 下錐到直筒C1JT-32-DZAll backup lining 所有襯里內(nèi)層11. Working procedure 工作程序(1) Covering for ca

20、re 做好遮蓋保護(hù)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. 冷卻槽內(nèi)要鋪一層塑料布和夾合板。下錐部位內(nèi)襯完后也要鋪一層夾合板。Those are for cooling tank protection by some failing object at the time of brick works. The inl

21、et position of refractory materials is manhole of cooling tank. 這是為了防止砌磚時(shí)掉落物體損壞冷卻槽。耐火材料由冷卻槽人孔進(jìn)入。(2) Low conical 下圓錐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，砌磚SD-1和SD-1-A，內(nèi)徑約1600mm，沿圓周方向砌筑。Next

22、, 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，內(nèi)徑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.

23、As for the brick materials, C1 for back lining, and SA-36SZ for surface lining. 背襯磚在 (a) 和（k）處要在現(xiàn)場加工。然后按下錐砌磚表砌筑。背襯磚材質(zhì)是C1向火面磚材質(zhì)是SA-36SZ。The refractory brick shall be applied to 11 layers (a-k) for back lining and 14 layers for surface. 背襯磚砌11層，向火面磚砌14層。(3) Scaffolding 腳手架After low conical execution c

24、ompletion, 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

25、. 下錐砌完后，扎牢單管腳手架板。然后這個(gè)位置鋪夾合板，腳手架搭完后。下錐和腳手架之間要鋪塑料布。爐直筒砌磚，應(yīng)升一層腳手架，砌一段磚。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. 磚應(yīng)通過卷揚(yáng)機(jī)或電動(dòng)葫蘆提升到直筒內(nèi)襯工作面。(4) Straight shell No.1 直筒段下段Apply first back lining with S brick

26、 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. 首先沿圓周方向砌背襯S 磚。然后砌托磚板下一圈磚B1-76 和B2-76，內(nèi)徑3850mm.。Then work of surface brick lining B1-A and B2-A on the brick support. After these, with the instruction drawings

27、, apply insulating bricks followed by surface lining and back lining. 托板板上向火面磚是B1-A 和 B2-A。根據(jù)結(jié)構(gòu)圖，跟著向火面磚砌保溫磚。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 suppor

28、t shall be filled with blanket for expansion. 磚B1-74 和 B2-74 用于上部托磚板下面。至于磚材質(zhì)，背襯磚是C1, 向火面磚是SA-36SZ。磚與托磚板之間的膨脹間隙用纖維毯填滿。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

29、be seted with brick SD-8 and SD-9. 人孔處用磚Y22 和Y23 砌兩圈，內(nèi)徑484mm.。背襯磚和向火面磚需現(xiàn)場切割。管嘴部位砌磚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：人孔和管嘴部位的磚直接接觸殼體處需現(xiàn)場切割。(5) Straight shell No.2 直筒段上段Apply brick B1 and B2

30、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. 沿圓周方向砌B1和B2，保證內(nèi)徑3850mm。然后根據(jù)結(jié)構(gòu)圖砌向火面磚和背襯磚，保溫磚依向火面磚砌筑。Then work of surface brick lining B1-A and B2-A on the brick support. 托磚板上部向火面磚

31、是B1-A和B2-A。Then work of surface brick lining B1-74 and B2-74 under the brick support. 托磚板下向火面磚是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. 至于磚的材質(zhì)，背襯磚是C1，向火面磚是ML-S1Z。磚與托磚板之間的膨脹間隙用纖維毯填滿。(6) Upper conical 上圓錐A footline (a) layer and (g) layer positions brick cut at site. （a）和