1.Key points for preparation before installation
Brick Selection and Quality Inspection
Select the appropriate inlaid outlet nozzle block based on the specific size, shape, and operating environment of the outlet nozzle. Different industries, such as metallurgy and chemical engineering, may have different requirements for the block’s material, temperature resistance, and corrosion resistance. For example, in steelmaking, the ability of the block’s outlet nozzle in a continuous casting machine to withstand the high temperatures and chemical corrosion of molten steel is crucial. High-alumina block materials, with an alumina content of up to 70%-80%, are generally selected.
Carefully inspect the block for defects such as cracks and pores. Minor cracks can cause leakage of molten steel or other molten metal during use, while excessive pores can compromise the block’s strength and sealing. Non-destructive testing methods, such as ultrasonic testing, can be used to verify the internal quality of the block.
Installation Tools and Site Preparation
Gather the necessary tools for installation, such as specialized lifting equipment, positioning tools, and sealing materials. For large pedestal blocks, appropriate lifting equipment will ensure safe and accurate installation. For example, in large foundries, a crane is used to lift pedestal blocks.
Clean the installation site and ensure the foundation surface is flat and clean. An uneven foundation surface will affect the installation accuracy and stability of the pedestal blocks, potentially causing them to tilt during use. Grind the foundation surface with a grinding tool to achieve the required flatness.
2.Key points during installation
Precise Positioning and Installation
Precise positioning is crucial for block installation. Use positioning tools, such as a laser locator or specialized molds, to ensure that the block aligns with the center axis of the outlet nozzle. The deviation should generally be controlled within ±1-2mm. During installation, place the block slowly and steadily into position to avoid collisions that could damage or shift the block.
For blocks with specialized shapes, such as those with complex flow channels or grooves, ensure that these structures perfectly align with the corresponding equipment components. For example, in the outlet nozzle block of some chemical reactors, the internal flow channels must precisely align with the reactor’s internal piping system to ensure smooth material flow.
Sealing
Proper sealing between the base brick and surrounding equipment components is crucial. Select appropriate sealing materials, such as high-temperature sealant and ceramic fiber gaskets. For applications in high-temperature environments, the sealing material must be able to withstand the corresponding temperatures and maintain good sealing performance over extended use.
When applying sealant or installing gaskets, ensure that the sealing material is evenly distributed, free of bubbles and gaps. For example, when applying high-temperature sealant, the thickness of the adhesive layer should generally be around 1-2 mm, and the specified curing time and conditions must be followed to ensure a good seal.
3.Maintenance points during use
Temperature and Pressure Monitoring
During the use of embedded outlet nozzle blocks, the temperature and pressure they are subjected to must be monitored. For blocks operating in high-temperature environments, such as those used for molten steel outlets in the metallurgical industry, temperature sensors should be used to monitor temperature changes in real time. Excessive temperatures can degrade the material properties of the blocks or even damage them.
Also, monitoring pressure changes is crucial. This is especially true in high-pressure environments, such as outlet nozzles in high-pressure chemical pipelines, where sudden pressure fluctuations can affect the sealing and stability of the blocks. A pressure alarm should be installed to provide a prompt alert when pressure exceeds a safe range.
Regular Inspection and Cleaning
Inspect the block blocks regularly to check for wear, erosion, cracks, and other signs of damage. Minor wear and erosion can be repaired, such as by applying a protective coating. For example, in environments subject to mild chemical attack, a corrosion-resistant coating can be applied to the block blocks to extend their lifespan.
Clean debris and sediment from around the block blocks. In some applications, such as the outlet block blocks of sewage treatment equipment, debris may accumulate around the block blocks, affecting their proper function. Regularly clean this debris to ensure a clear outlet.
4.Points to note when replacing seat bricks
Safe Removal
When a seat brick needs to be replaced, it must be removed safely. First, shut down the relevant equipment and ensure that all materials and liquids are drained from the equipment. During removal, exercise caution to avoid damaging surrounding equipment components. Use appropriate tools, such as specialized disassembly tools or cutting equipment, to remove the old seat brick.
When removing sealing materials or connecting components that are tightly bonded to the seat brick, be mindful of the removal method. For example, when removing a ceramic fiber gasket, be sure to prevent any remaining fibers from entering the system after breaking, potentially interfering with the installation of the new seat brick and the normal operation of the equipment.
Commissioning the New Seat Brick
After installing the new seat brick, commissioning is required. Start the equipment and gradually increase flow and pressure parameters to observe the operation of the seat brick. Check for leaks, abnormal temperature increases, and other issues. During commissioning, fine-tune the seat brick’s installation position and sealing, based on actual conditions, to ensure proper and stable operation.
