Summary of Inspection and Repair of Induction Melting Furnace to Avoid Major Accidents

Maintenance and repair items		Maintenance and repair content	Maintenance time and frequency	Remark
furnace lining	Whether the furnace lining has cracks	Check for cracks in the crucible	Before the furnace starts every time	If the crack width is less than 22 mm , it is not necessary to repair it when chips and other things will not be embedded in the crack, and it can still be used. Otherwise, it needs to be patched before it can be used
	Repair of taphole	Observe whether there are cracks at the junction of the side avoiding furnace lining and the tap hole	At the time of tapping	If cracks appear, repair them
	Furnace lining repair at furnace bottom and slag line	Visually observe whether the furnace lining at the bottom of the furnace and the slag line is locally corroded	After casting	If there is obvious corrosion, it needs to be repaired
feel answer String lock up	Visual inspection	(1 ) Whether the insulation part of the coil is bruised or carbonized (2 ) Is there any foreign compound attached to the surface of the coil? (3) Whether the insulating backing plate between the coils protrudes (4) Whether the assembly bolts of the tightening coil are loose	1 time / day 1 time / day 1 time / day 1 time /3 months	Purge with compressed air in the workshop Tighten the bolts
	Coil compression screw	Visually check whether the coil compression screw is loose	1 time / week
	rubber tube	(1) Whether there is water leakage at the rubber tube interface (2 ) Check whether the rubber tube is cut	1 time / day 1 time / week
	Coil anti-corrosion joint	Remove the rubber hose and check the corrosion degree of the anti-corrosion joint at the coil end	1 time /6 months	When this anti-corrosion joint corrodes more than 1/2 , it needs to be replaced with a new one. Usually changed every two years
	Cooling water temperature at coil outlet	Under the conditions of rated molten iron volume and rated power, record the maximum and minimum values of the cooling water temperature of each branch of the coil	1 time / day
	Dust removal	The compressed air in the workshop blows away the dust and molten iron splashes on the surface of the coil	1 time / day
	Pickling	Pickling of sensor water pipes	1 time /2 years
Can scratch sex guide String	Water-cooled cable	(1 ) Whether there is electricity leakage (2 ) Check whether the cable is in contact with the furnace pit (3 ) Record the temperature of the cable outlet water under the rated power (4 ) Preventive measures taken to prevent accidents (5 ) Check whether the connecting bolts at the terminals are discolored	1 time / day 1 time / day 1 time / day 1 time /3 years 1 time / day	According to the number of tilts, determine the life of the water-cooled cable as three years, and need to be replaced after three years. If the bolt changes color, re-tighten it
Maintenance and repair items		Maintenance and repair content	Maintenance time and frequency	Remark
furnace cover	Dry cable	(1) Eliminate dust on the insulating bakelite busbar splint (2 ) Check whether the chain hanging the busbar splint is broken (3 ) Whether the copper foil of the bus bar is disconnected	1 time / day 1 time / week 1 time / week	When the area of the disconnected copper foil accounts for 10% of the conductive area of the bus, it needs to be replaced with a new bus
	Refractory castable	Visually inspect the thickness of the refractory pouring layer of the furnace cover lining	1 time / day	When the thickness of the refractory castable remains 1/2 , the furnace cover lining must be rebuilt
	Oil pressure furnace cover	(1 ) Whether there is leakage in the sealing part (2 ) Leakage of piping (3 ) Leakage of high pressure pipe	1 time / day 1 time / day 1 time / day	If yes, repair it Swap
	High pressure pipe	(1 ) Whether there are traces of molten iron scald on the high-pressure pipe, etc. ( 2 ) To ensure safety, exchange	1 time / week 1 time /2 years
	Add lubricating oil	(1 ) Manual type: Furnace cover fulcrum part (2) Electric type: sprocket drive bearing for shaft adjustment chain for furnace cover wheel (3 ) Hydraulic type: guide bearing
pour move Oil Cylinder	Lower bearing and high pressure pipe of oil cylinder	(1 ) Whether there are traces of molten iron scald on the bearing part and the high-pressure pipe (2 ) Oil leakage	1 time / week 1 time / month	Remove the cover for inspection
	Cylinder	(1 ) Whether there is leakage in the sealing part (2) Abnormal sound	1 time / day 1 time / day	When tilting the furnace, observe the cylinder block When making sounds such as knocking on the cylinder, the bearings are mostly out of oil
	Tilting furnace limit switch	(1) Action check Press the limit switch by hand, the oil pump motor should stop running (2 ) Whether there is molten iron splashing on the limit switch	1 time / week 1 time / week
	Add lubricating oil	All fuel ports	1 time / week
High pressure control cabinet	Appearance inspection inside the cabinet	(1) Check the operation of each indicator light bulb (2 ) Whether the parts are damaged or burned out (3 ) Clean the pan with compressed air in the workshop	1 time / month 1 time / week 1 time / week
High pressure control cabinet	Circuit breaker vacuum switch	(1 ) The cleaning pass is a contact The vacuum tube is milky white and fuzzy, the vacuum degree is reduced (2 ) Measuring electrode consumption	1 time /6 months 1 time / month	If the gap exceeds 6 mm, replace the vacuum tube
Main switch cabinet	Electromagnetic air switch	(1 ) Roughness and wear of the main contact (2 ) Come on (3 ) Whether the fire extinguishing board is carbonized	1 time /6 months 1 time /6 months 1 time /6 months	When the roughness is severe, grind it with a file, sand skin, etc. When the contact wear exceeds 2/3 , replace the contact Add spindle oil to each bearing and connecting rod Use sanding to remove the carbonized part
Maintenance and repair items		Maintenance and repair content	Maintenance time and frequency	Remark
Main switch cabinet		( 4) Dust removal	1 time / week	Clean with compressed air in the workshop, and wipe the dust on the insulators with a cloth
Main switch cabinet	Insulation resistance	Use a 1000 volt megger to measure the main circuit and greater than 10M Ω
Converter switch	Transfer switch	(1) Measure insulation resistance (2 ) Rough switch main connector (3) The main circuit connecting bolts are loose and overheated	1 time /6 months 1 time / month 1 time /3 months	Between the conductor and the ground, use a 1000 volt megohmmeter to measure greater than 1M Ω Polish or exchange
control system cabinet tower	Appearance inspection inside the cabinet	(1) Whether the components are damaged or burned out (2 ) Whether the components are loose or fall off	1 time / week 1 time / week
	Action test	(1 ) Check whether the indicator light can be on (2 ) Alarm circuit Action should be checked according to alarm conditions	1 time / week 1 time / week
	Dust removal in the cabinet	Clean with compressed air in the workshop	1 time / week
	Contactor for auxiliary machine	(1) Check the roughness of the contact, if the roughness is severe, polish it smoothly with fine sand (2) Exchange contacts Replace the contacts when they are badly worn	1 time / 3 months 1 time /2 years	Especially the frequently used contactor for tilting furnace lid
Transformer reactor	Check appearance	(1 ) Whether there is oil leakage (2 ) Whether the insulating oil is added to the specified position	1 time / week 1 time / week
	Transformer and reactor temperature	Check the daily thermometer indication, which is lower than the specified value	1 time / week
	Sound and vibration	(1 ) Usually check by listening and touching (2 ) Instrument measurement	1 time / week 1 time / year
	Insulating oil withstand voltage test	Should meet the specified value	1 time /6 months
	Tap changer	(1 ) Check whether the tap changeover is offset (2 ) Check the roughness of the tap adapter	1 time /6 months 1 time /6 months	Use fine sand to polish and replace it with a new one when it is severely rough
Capacitor bank	Check appearance	(1 ) Whether there is oil leakage (2 ) Whether each terminal screw is loose	1 time / day 1 time / week	If slack occurs , the terminal part will be discolored due to overheating
	Exchange capacitor contactor Dust removal	(1) The roughness of the contact 1 ) Use a file to smooth the rough part 2 ) When the wear is severe, replace the joint (2 ) The contact temperature rises Use compressed air in the workshop to clean the insulators with a cloth	1 time /6 months 1 time / week 1 time / week	At least 1 time / month
	The temperature around the capacitor bank	Measure with mercury thermometer	1 time / day	Ventilated , so that the surrounding temperature does not exceed 40 deg.] C
Hydraulic device	Hydraulic oil	(1 ) Whether there is any change in the color of the oil at the height of the oil level displayed by the oil level gauge (2) Check the amount of dust in the hydraulic oil and the quality of the oil (3) Measuring temperature	1 time / week 1 time /6 months 1 time /6 months	If the oil level drops , there is a leak in the circuit When the quality is poor , change the oil
Hydraulic device	pressure gauge	Whether the tilting pressure is different from usual, when the pressure drops, adjust the pressure to the normal value	1 time / week