0336筑炉作业指导书eng英文版.docx
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0336筑炉作业指导书eng英文版.docx
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0336筑炉作业指导书eng英文版
WorkInstructionsforCementMachineryandEquipmentInstallation
WorkInstructionsforCalcinerWorks
CBMI.QEMS.03.36
I.Workstepsforcalcinerinstallation
Materialsinspection
Equipmentacceptance
Anchorwelding
Calciumsilicateboardinstallation
Castableplacing
Testblock
Castablemixing
Applicationofwater-proofagent
Inspectionofcastingandbricklaying
Refractorybricklaying
Refractorybrickmortar
Provisionofexpansionjoints
施工过程控制项目
检查内容
II.Qualitycontrolplan
No.
Description
Inspectiontype
Inspectioncategory
Controltype
Documenttype
Documentdescription
1.1
Selfreview/jointreviewofdrawings
Selfreview/jointreviewrecordsfordrawings
1.2
Technicalinstructions
Recordsoftechnicalinstructions
1.3
Equipmentacceptance
DIM
1
Reservedinspectionreportforequipmentinstallation
1.4
Materialsinspection
MTDIM
1
E
N
Checktheex-worksinspectionreports(exceptforsuppliesfromOwner)
1.5
Inspectionofanchoringpartswelding
VC
2
E
N
CBMI––JX––ZL––001
2.1
Installationofcalciumsilicateboards
VC
2
P
N
CBMI––JX––ZL––001
2.2
Applicationofwaterrepellent
VC
2
P
N
CBMI––JX––ZL––001
3.1
Inspectionofrefractorybricklayingandmortarsaturation
DIM
1
P
N
CBMI––JX––ZL––002
3.2
Inspectionofrefractorybrickmasonry
DIM
2
P
N
CBMI––JX––ZL––002
4.1
Inspectionofcastablemixingandwatercontent
DIM
1
P
N
Randomcheckofinstructionmanualsformaterials
4.2
Testblocksofcastable
MT
1
B
R
Inspectionreport
4.3
Inspectionofcastmasonry
DIM
2
P
N
CBMI––JX––ZL––002
5.1
Installationofexpansionjoints
DIM
2
P
N
CBMI––JX––ZL––002
Inspectiontype:
DIM—dimensionscheck,DP—dyepenetrationtest,MP—magneticpowdertest,MT—mechanicaltestforsamples
RD—radiographictest,RT—runningtest,SC—specialcheck,US—ultrasonictest,VC—visualcheck.
Documenttype:
N—inspectionrecord,R—report.
Controltype:
E—ensureditem,B—basicitem,P—itemwithpermissibledeviation.
Inspectioncategory:
1—selfinspection,2—jointinspection.
III.Processcontrolforcalcinerworks
1.Preparationforworks
No.
Content
Inspectionitem
Technicalrequirements
Mainpointsinoperation
Testdevice
1.1
Selfreview/jointreviewofdrawings
CBMI.QEMS.03.07
1.2
Technicalinstructions
CBMI.QEMS.03.09
1.3
Equipmentacceptance
DIM
Asper“Equipmentacceptance”
1.4
Materialinspection
1.4.1
Checktheoveralldimensionsofmaterials
DIM
Dimensiontolerance:
±2%forheight,±2mmforlargeandsmallendwidthofwedges,±1mmforlargeandsmallenddifference,±1%forlength,withthemaximumupto±2mm.
Edgedamage:
damageupto40mminlengthand5mmindepthispermissiblefortwoedgesonthehotandcoldsurfaces,butmustnotexceed.
Cornerdamage:
damageispermissibleonlyatonecorner,withthetotallengthofthreeedgesofthecornernotexceeding50mm.Thatbelow20mmisnotcountedascornerdamage.
Crack:
hair-likefinecracksarepermissibleonthebricksurface,butcracksparalleltowearingplanearenotpermissible;othercracksnotexceeding40mminlengthor0.2mminwidtharepermissible.
Dent,meltingtraceandbulging:
themaximumpermissibledentandmeltingtraceis10mmandthemaximumdepth10mm,themaximumbulging0.5mm.
Theex-worksdateofcastableshallbecheckedforexpiration,andalsocheckifforblockingaftersubjectingtowater.
GradeIsteelplaterule
1.4.2
Checktheex-worksreportofmaterials
MTDIM
Checkthattheparametersintheex-worksreportconformtodesignrequirements,andforimportantparameterssuchassofteningtemperatureunderload,thermalshockingstabilityandresistancetoalkaline,inspectionbyanauthorativethirdpartyshallbepresented.
1.5
Anchoringpartswelding
Theweldingpositionsofanchorsshallconformtodesignrequirements,andbefirmlywelded.Anchorsforcastingarenormallyweldedduringequipmentfabrication,andtheirfirmnesscanbecheckedbyknockingwithahammer.Foranchorsoffieldwelding,thematerialsofelectrodesandpartsmustagree,andtheirfirmnessshallbechecked.
2.Installationofcalciumsilicateboards
No.
Content
Inspectionitem
Technicalrequirements
Mainpointsinoperation
Testdevice
2..1
Installationofcalciumsilicateboardsandwaterrepellent
Mainlythetightnessandfirmnessofcalciumsilicateboardsinstallationwillbechecked,toensuretheywillnotdisengagebeforelayingtherefractorybricks.
Whenmountedonequipmentwithclaspnails,notethetightnessofboardcutdimensionswithmasonry,therootofclaspnailsorseamscanbefilledupusingsmallboardsorceramicfiberwool.Whenmultiplelayersofcalciumsilicateboardsaredesigned,thejointsshallbestaggered.
Completenessofwaterrepellent
Waterrepellentisusedtopreventtooearlyabsorptionofwaterbycalciumsilicateboardsaftercastingwhichwillresultinloweringofstrength,thereforecalciumsilicateboardsatportionsforcastingmustbefullycoatedwithwaterrepellent,anditisnotnecessarywherebrickswillbelaid.
3.Layingrefractorybricks:
No.
Content
Inspectionitem
Technicalrequirements
Mainpointsinoperation
Testdevice
3.1
Mortarpreparationandwork
Mortarsaturation
Greaterthan90%
Refractorymortarofthesametypeasrefractorybricksmustbeused,andtheiradhesivenessshouldbeadjustedaccordingtothejointsizeandapplication.Duringworkthemortarsaturationmustmeetthestandardsinthespecifications,andrandomcheckswillbemadeduringtheworks
Grid
3.2
Refractorybrickmasonrywork
Brickjointthickness
±1mm
Thebrickjointsinverticaladjacentlayersofmasonrymustbestaggered,2-4placesshallbecheckedonasamplingbasisonthemasonry,andateachplace5pointsshallbecheckedoverasurfaceareaof2m2.
Feelergauge
Straightwall
Horizontality
Perm
5mm
Themasonryhorizontalitywillbecontrolledwithahorizontallineduringwork.
1.Level
2.Ruler
3.Backplate
Lineandrule
500mmlevel
Fulllength
10mm
Verticality
Laying
3mm/m
Theverticalitywillbecontrolledbyaplumbandlineduringwork.
1.Plumb
2.Lineattachplate
3.Brickwall
Lineand0.5kgweight
Fulllength10mm
Hangbricks
5mm/m
Fulllength15mm
Surfaceflatness
Laying
5mm
Checkthemasonryevery3-5m,withtheruletightlyagainstthewall,tofindthemaximumgap
2000mmwoodenrule
Hangbricks
7mm
Roofsuspendedbricks
5mm
Adjusttheroofsuspendingframetomakeitflatandtoachievegoodmatchingbetweenbricksandframe
Straightrule
Circulararchedwall
Deviationoflongitudinaljointineachsectionofmasonry
2mm/m
Circlescanbedrawnbysectionsasacontrolmeanstopreventdeviationofmasonryfromcenterline.
(Thispracticeisnormallynotused.)
Tape
Fulllength10mm
Circularlaying:
theparallelismofcirculararchtocenterline
8mm
Itismainlyforthebricklayingofrotarykilnandcircularducts.Drawthecenterlinesinthelengthdirectiononthecircumsference,andthenmakesectionsonthecenterlines,tomeasureandcontrolthedeviationbetweenbrickringsofeachsection
Tape
Individualsurfaceunevenness
3mm
Checkforindividualsurfaceunevenness.
Rule
4.Workwithcastmaterial
No.
Content
Inspectionitem
Technicalrequirements
Mainpointsinoperation
Testdevice
4.1
Mixingandwatercontentincastmaterial
1.Thewaterforcastmaterialmixingmustbepotablewater.
2.Theamountofwaterformixingmustbecontrolledinstrictaccordancewiththeworkinstructionsfromthemanufacturer,andmustnotexceedthelimit.Theamountofwaterwillbeaslittleaspossiblewhileensuringtheworkperformance.
3.Themadecastmaterialmustbeplacedwithin30minutes.
Measuringcup
4.2
Testblocksforcastmaterial
1.Asetoftestblocksshallberetainedforevery20cu.m.ofcastmaterial(includingthatlessthan20cu.m.),forinspectionofstrengthandothermainperformance.
2.Themeanvalueofcompressionlimitstrengthofthesamebatchoftestblocksmustnotbebelowthedesignrequirement;andtheminimumvalueinanysetofblockmustbenolessthan85%ofthedesignvalue.
Testblockmoulds
4.3
Inspectionofcastbody
Surfaceflatness
8mm
Checkthemasonryevery3-5m,withtheruletightlyagainstthewall,tofindthemaximumgap
2000mmwoodenruler
Surfacecurvature
+8mm,-5mm
Placeacurvedformtightlyagainstthebodysurface,tomeasurethemaximumgapwitharuler.
Curvedform
Sectionaldimensions
+8mm,-5mm
Measurethedifferencebetweendesigndimensionsandactualdimensionswitharuler.
Tape
5.Installationofexpansionjoints
No.
Content
Inspectionitem
Technicalrequirements
Mainpointsinoperation
Testdevice
5.1
Provisionofexpansionjoints
Expansionjointsshallbeprovidedinawayandatpositionsinconformitywithdesignrequirements.Thejointsshallbefilledwithrefractoryfibers(wool)thatcanwithstandtheworkingtemperatureattheposition,andinternalcavitymustbeavoided.
Dimensionalcheck
Width
+5mm,-2mm
Thedimensionaldeviationcanbecontrolledusingformswiththesamedesignthickness,andminustoleranceshouldbeminimized.
Feelergauge
隐蔽工程会检记录CBMI––JX––ZL––001
jointinspectionRecordforconcealmentworks编号No
单位工程名称
Sub-item/code
分部分项工程名称
Partofworks
筑炉
Refractory
工程编号
Item.No/Dwg.No.
会检日期
Dateofjointinspection
检查内容(InspectionItem/sketchordescription):
锚固件的焊接位置应符合设计要求,并且焊接牢固,并涂有沥青漆;()
Theweldingpositionsofanchorsshallconformtothedesignrequirements,andtheyshal
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