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Vacuum Pumps Common Problems and Troubleshooting
Vacuum Pumps Common Problems and Troubleshooting
Vacuum Pumps Common Problems and Troubleshooting
2009.02.18
1 FEB. 18, 2009 ISSUED FOR APPROVAL MYUNG SUK KIM MYUNG SUK KIM
CONTENTS
1 GENERAL
2 PROJECT
4 LOCATION
5 MATERIALS
6 INSTALLATION GENERAL
8 INSTALLATION PROCEDURE
9 CURING
10 TESTING
11 INSPECTION
12 REPAIRS
13 DRY-OUT
*ATTACHMENT
# 1. REFRACTORY INSTALLATION LOG - FORM --------------- 1 SHT
# 2. INSPECTION REPORT- FORM --------------- 2 SHTS
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 2 OF 14
1. GENERAL
1-1 This specification describes their methods of application for brick lining & plastic/castable installation.
1-2 This specification shall be used by the brick / castable lining applicator to
prepare , if required , for approval by the owner or his authorized
representative prior to start of work.
2. PROJECT
PROJECT : 17223 THERMAL OXIDIZER
5 MATERIALS
5-4
5 4 LIGHT WEIGHT BRICK, GT
GT-23
23
5-8
5 8 LIGHT WEIGHT CASTABLE, INCT
INCT-120
120
6 INSTALLATION GENERAL
1)) Upon
p receiptp of the materials,, check the q
quantity
y with p
packing
g list
and inspect the appearance to make sure of no damage to the materials.
7) Handle the materials with care since they are apt to be damaged with a rough handling.
8 INSTALLATION PROCEDURE
A PREPARATION
1) Field measure the steel dimensions to verify that they match the construction drawings.
2) All equipment for mixing and handling must be thoroughly cleaned before use.
4) During hot weather, the refractory lining and the surface to which it is applied shall not exceed a
temperature of 95℉(35℃) during application. If required, the exterior surface of the incinerator shall be
cooled by shading spraying with cold water, air conditioning, or other means before and while the
refractory lining is being applied. Installation at night, when it's cooler and there is no radiant heat
from the sun, may be considered. After refractory application, cooling of shell in no longer required.
1) All water used for mixing refractory must be clean, potable, have between
PH 6.5~8.35 and may vary between 10℃ ~ 21℃.
5) C
Castable
t bl can bbe iinstalled
t ll d within
ithi 20 minutes
i t from
f the
th adding
ddi off water.
t In
I no circumstances
i t castables
t bl
shall be remixed after they have started to set.
6) Check the anchroage system, clean the surface of the area to be refractoried by a steel brush
Apply the coat of plistix mix #464.
8) Mixing and the addition of water shall be in accordance with instructions found on the bags of
the refractory using a paddle type mixer of adequate capacity.
11) The amount of water to be added to the refractory mateiral shall be sufficient to produce proper hydration.
Under no circumstances should more water be and the mix retempered as per material manufacturer's
recommendation.
12) Use castable as soon as possible after mixing. Do not use material that has started to stiffen.
C PLASTIC LINING
1) Job sequence
① ②
③ ④
2) Placeing plastics
3) Air pressure
An air pressure of 5~6 bars should be maintained at the manifold with 0.55m3/min supply.
Air pressure
4) Wall
The positioning of anchors is critical. Before starting any work in the furnace, the position of every anchor should
be set out on the enclosure and clearlyy marked. Fix the specified
p g
insulation material to a convenient height
having marked out and drilled or welded attachment points for anchors in the proper places.
Lay slabs of plastic on the wall with the long direction parallel with the face of the wall. Similar to a stretcher
Every 4 to 5 courses lay the plastic slabs as headers. Lay the slices tight together with one face in line with the
wall hot face, fit the small pieces and trimmings in gap behind the full slices.
5) Ramming
Thoroguhly ramm each 50/75mm course before laying succeeding courses. Hold the rammer in a vertical position.
Start ramming midway between the hot face and cold face of the wall. Move the rammer in the direction of the wall
length at a rate that ensures that each succeeding impact of the head covers approximately half the area of the
previous impact. Move the rammer back and forth from the centre of the wall to the cold face metal cases or
insulation. When all voids in this portion of the wall are closed up, start again and work from the centre line of the
wall to the hot face in the same manner.
As the rammer nears the hot face of the wall, rotate the wrist so that the rammer turns through 90ㅇ down to a
horizontal position and peen over the edge of the wall. Then return the rammer to the vertical position and run it
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 7 OF 14
10 to 15mm beyond the line of the hot face. This allows for trimming or shaving the wall. Should the wall become
excessively bulged beyond the line of the hot face (due to careless ramming) the material must be shaved off rather
than forced back with the air rammer. The wall should be built up evenly from end to end.
Each installer should work a 1 to 3m length of wall depending on thickness and anchor pitching.
Continue in this manner to the top of the wall if possible. When no longer possible to do so (due to the proximity of
the roof) start at each end, placing the slices on edge against the end walls so that they reach from the last course
to the top level of the wall (approx. 12in or 300mm). Ram sideways or against the ends of the wall. Work to the
centre of the wall
wall. Close in by laying the slab vee fashion,
fashion finally ramming the last square foot (300 x 300mm)
on the hot face.
6) Trimming
Prior
P i to trimming
i i the
h surface,
f ram lilightly
h l around
d each
h anchor
h fface to completely
l l fill the
h corrugations
i off the
h anchor.
h
Place the back of the trimming spade against the plastic at an angle which will prevent the point digging in beyond
the hot face line. Shave off the surplus material using the anchor faces as guides.
7) Venting
Vent the surface immediately after trimming. Stream evolved during heat up can force slabs of material off the hot
face of the lining unless vent holes provide a means of escape. Use a 5mm diameter rod. Make rod into the full
depth of the plastic up to 230mm. For thicker wall make vent holes to minimum 230mm depth : alternatively to half
the wall thickness. Where plastic is rammed directly onto a steel casing, make vent holes the full depth of
the plastic.
8) Joints
Joints- surface expansion cuts
Where these are required by the designer, they should be formed and located as shown on drawings.
They should never coincide with the anchor positions.
Surface expansion cuts should be made using a bolster to the depth required. Thus work must always be
l db f l f kf h d Ah d f h fi i h d f i h
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 8 OF 14
A PREPARATION
2) Inspect inside and outside of shell and make sure is no damage or stain on the surface.
3) If the steel shell is damaged, report it to owner so as to have field construction repair it.
B BRICK LAYING
1) Apply the plistix mix #464 by means of trowel up to the 3mm thickness.
Also the hardening of this mortar shall be completed within 24 hours.
2) Apply GT-26 brick in the bottom part of the Incinerator , after having wet the same with plistix #464 coating.
3) Brick and shapes will be installed with jointing cement, maximum thickness of joint between bricks : 2mm.
4) Refer to the refractory lining drawing which show quantity and the sizes of bricks to be used in each area.
6) The layer of insulating brick shall be applied starting from the bottom part for 210o extension.
7) The upper part of the lining for 150o extension shall be made by using a formwork to support the bricks.
The top part, bricks shall be installed with a free space from the surfaces as radial joint.
8) The gap shall be filled by ceramic blanket, gradually inserted during the bricks installation.
9) Adjusting bricks, no more than two for each ring and no thinner than 40mm , shall be installed at 30o at least
from the top, and positined alternately at right in first ring, and at left in the next one.
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 9 OF 14
10) Near the nozzles, the bricks shall be cut to suit the shapes shown in the drawing.
At the elliptical head the insulating bricks shall be installaed in circular rings, starting from the bottom part of
the periperical ring. After the completion of the first ring, the installation proceeds with the internal rings.
11) If cutting is necessary in order to position the keystone, cutting must not, in any case, exceed one third
of the relevant part, otherwise cutting must be performed on the last two parts positioned in the roll.
13) Insulation bricks shall be dry cut when required, using an abrasive saw.
14) The closing of the brick rows shall not be done at the top of the furnace but at 30o at least from the top.
16) Any mortar excess shall be scraped by means of a trowel after a short drying period.
17) Each brick shall be positioned by hammering, in order to remove any excess quantity of bonding mortar
18) Special care shall be given in the positioning of any performed block. A trial fit up of each block
near the nozzles shall be made in order to minimise the cut of the adjacent bricks.
C EXPANSION JOINTS
1) Expansion joints have to be done according to the indications shown on the refractory lining drawing.
2) Expansion joints will be lined with ceramicfiber blanket without mortar addtion.
9 CURING
During the curing period , the castable lining shall be treated as follows;
1) The curing shall begin immediately upon lining application for min 24hrs
until hard set has developed
developed.
4) one pound hammer at about one foot intervals over the entire surface.
Any voids of dry filled spaces will emit a dull sound.
5) After the curing period has been completed, the castable lining shall be air dried for at least another 24 hours
by natural or forced ventilation.
10 TESTING
1) Mixing of castable lining materials and water to ensure that correct materials and procedures
are used, that containers are clean and water is drinkable.
2) Application of castable lining materials to ensure that full lining thickness is attained
with proper application.
5) The hammer test shall consist of striking the entire refractory surface with a hammer
at about 12 inchs ( 305 mm ) intervals. When areas with voids, laminations or areas filled with dry material
are struck with the hammer, a dull sound will be produced.
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 11 OF 14
11 INSPECTION
1) MATERIALS
2) SHELL
a. inspection.
a Make sure of no damage or stain on the lining by visual inspection
The following works will be carried out paying attention to the respective points listed below.
A . BRICKLAYING
In case any damage is found, take total measurment of A+B+C or D+E shown in fig.22
and discard the brick which has a damage of 50mm or over in the measurements
such brick, however, may be used for cutting or installed where out of sight.
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 12 OF 14
② Surface
S f breakage
b k
CORNER
a+b+c < 30mm
Note : when a,b, or c< 10mm
EDGE
b c
d+e+f < 30mm
Note : when d,e,or f < 10mm
We don't regard it as a defect.
Fig.22
③ CRACK
d Bricks
d. B i k are to
t be
b laid
l id h
horizontally
i t ll and
d vertically.
ti ll
f. Width and position of each expansion joints are to be in accordance with dwg.
g. Expansion joints for accessories such as nozzle are to be provided in accordance with dwg.
1) BRICK LAYING
C . All expansion joints are to have been filled with ceramic fiber blanket.
12 REPAIRS
12-1 CASTABLE
1) Repair portion shall be cut out to steel plate of first layer, and made
the following shapes.
More than three(3) anchors are required at one repair portion.
2) Make the space around repair portion to become wet sufficiently prior to
castable insalltation.
3) Materials to be used for repair shall be same one installed previously.
DOC. NO. CERA - 17223 - 01
CERA REFRACTORY LINING PROCEDURE
PAGE 14 OF 14
12-2 BRICK
1) Replace the damage brick with new brick of the same material.
2) Fill insufficient mortar joints with new mortar of the same material as original.
Where joint mortar is separated from a brick, remove applicable bricks and lay them again
13 DRY-OUT
3) Raise
R i ttemperature
t to
t 260℃ att a rate
t off 30℃ per hour.
h
6) Thermocouple q'ty
q ty & Location (See the dryout sequence)
- one(1) thermocouple at refractory surface per each item.
7) Check outlet temperature per the 30 minutes interval during the holding time.
TEMP(℃)
4 Hrs Holding
260℃
8Hrs Holding
g 30℃/Hr
110℃ l
lower temp. slowly
l l
30℃/Hr
Curing
3 11 16 20 Time(Hour)
CASTABLE INSPECTION REPORT
P.O. NO. :
INSTALLATION METHOD :
ITEM NAME :
ITEM NO. :
INSPECTION DATE :
1 Used Materials
2 g Thickness
Lining c ess
4 Check Of Dimension
8 Internal Clearing
WITNESSED /
PREPARED BY REVIEWED BY APPROVED BY
REVIEWED BY
P.O. NO. :
INSTALLATION COMPANY :
INSTALLATION METHOD :
ITEM NAME :
ITEM NO. :
N N DATE :
INSPECTION
1 Used Materials
3 Lining Thickness
4 Mortar Condition
6 Vi l Examination
Visual E i i After
Af H
Heat D
Dryout
WITNESSED /
PREPARED BY REVIEWED BY APPROVED BY
REVIEWED BY
WITNESSED
PREPARED BY REVIEWED BY APPROVED BY
/REVIEWED BY