Method for repairing cracking of smelting slag ladle and slag ladle based on multilateral beveling

Abstract

The invention discloses a method for repairing cracking of a smelting slag ladle and a slag pot based on multilateral beveling, and relates to the technical field of welding maintenance, and the key points of the technical scheme are as follows: in the repairing method, firstly, the damage degree of the slag ladle and the slag pot needs to be analyzed, and the damage degree analysis needs to analyze an opening part, a body part, a trunnion, a reinforcing rib and a ladle bottom one by one; judging whether the part is cracked, deformed or perforated; according to the method, the problems that in an existing smelting enterprise, the purchasing cost of slag ladles and slag ladles is very high, the slag ladles and the slag ladles are prone to being scrapped due to cracking and piercing deformation in the using process, the production cost is low, and the like are solved. The service life is greatly prolonged, the purchase cost and the waste steel inventory cost are saved for enterprises, and the enterprise pressure is relieved.

Description

Technical Field

[0001] The present invention relates to the technical field of welding repair, and more specifically, it relates to a method for repairing cracks in smelting slag ladles and slag pots based on multi-sided beveling. Background Art

[0002] The repair and maintenance of smelting slag ladles and slag pots can effectively maintain their normal operation and extend their service life. During the use of smelting slag pots, various problems may be encountered, such as cracks, steel sticking, etc. If these problems are not repaired in time, it may lead to the scrapping of the slag pots and increase production costs. Therefore, it is crucial to repair and maintain the slag pots in a timely manner. During the repair process, the selection and application of repair technologies are the key, including but not limited to manual arc welding repair technology, which can effectively repair the damaged parts of the slag pots and restore their use functions.

[0003] In addition, the repair of smelting slag pots also includes regular inspection and maintenance of the slag pots to ensure their structural integrity and performance stability. For example, the inspection system is one of the important measures to ensure the safe operation of the slag pots. Through regular inspections, potential problems can be discovered and processed in time to avoid accidents.

[0004] In the repair practice of smelting slag pots, it also involves the analysis and treatment of the causes of slag pot damage. For example, since the smelting slag pots will experience frequent rapid cooling and heating during use, this will cause the flake graphite in the cast iron matrix to undergo relative slip or fracture, thereby leading to cracks in the slag pots. Therefore, when repairing, these factors need to be considered and corresponding measures need to be taken to reduce the influence of thermal stress, such as using appropriate materials and structural designs, and taking appropriate cooling measures during the repair process. Summary of the Invention

[0005] The purpose of the present invention is to provide a method for repairing cracks in smelting slag ladles and slag pots based on multi-sided beveling, which is a repair process that combines multiple technologies such as damage degree analysis, double-sided beveling, shaping, riveting, steel buckle installation, and reinforcement plate welding. According to the damage degree of different materials, the best repair measures are adopted to achieve the purpose of repair and use, greatly extending the service life and saving the enterprise's procurement cost and scrap steel inventory cost, reducing the enterprise's pressure.

[0006] The above technical purpose of the present invention is achieved through the following technical solutions: A method for repairing cracks in smelting slag ladles and slag pots based on multi-sided beveling. In this repair method, first, the damage degree of the slag ladles and slag pots needs to be analyzed. The damage degree analysis needs to analyze the mouth part, body part, trunnion, stiffening rib, and bottom of the ladle one by one to judge whether these parts are cracked, deformed, or perforated; then, according to the results of the damage degree analysis, one or more steps of hole repair, shaping, V-groove cutting, material cutting, steel buckle installation, and reinforcement plate installation are selected to repair it.

[0007] The present invention is further configured as follows: The specific repair steps for the internal cracking of the mouth part, body part, reinforcing rib or bottom package are as follows:

[0008] (1) Clean the steel slag at the crack;

[0009] (2) Make a 45° V-shaped groove;

[0010] (3) Perform multi-layer and multi-pass welding;

[0011] (4) Turn over the repair part;

[0012] (5) Make a single-sided V-shaped groove;

[0013] (6) Perform multi-layer and multi-pass single-sided welding.

[0014] The present invention is further configured as follows: The specific repair steps for the cracking of the trunnion and its surrounding are as follows:

[0015] (1) Make a deep V-shaped groove;

[0016] (2) Perform multi-layer and multi-pass welding.

[0017] The present invention is further configured as follows: For the cracking of the trunnion, a V-shaped groove needs to be polished by a polishing device first and then multi-layer and multi-pass welding is performed.

[0018] The present invention is further configured as follows: The specific repair steps for the deformation of the slag ladle and slag pot are as follows:

[0019] (1) Cut and shape the irregular module;

[0020] (2) Fix it;

[0021] (3) Make a V-shaped groove;

[0022] (4) Perform multi-layer and multi-pass welding.

[0023] The present invention is further configured as follows: The specific repair steps for the perforation of the slag ladle and slag pot are as follows:

[0024] (1) Cut into a square or rectangular hole;

[0025] (2) Cut the material;

[0026] (3) Fix it;

[0027] (4) Make a V-shaped groove;

[0028] (5) Perform multi-layer and multi-pass welding.

[0029] The present invention is further configured such that: before welding, the oxidation slag and other impurities in the weld seam need to be cleaned; when multi-layer and multi-pass welding is adopted, the surface welding slag needs to be removed after each layer of welding to prevent the occurrence of pores caused by inclusions. If there are slag inclusions or pores, cutting treatment is required before re-welding. For the trunnion welding, if there are slag inclusions or pores, grinding is required first and then welding.

[0030] In summary, the present invention has the following beneficial effects:

[0031] 1. The repair method provided by the present invention can adopt the best repair measures according to different degrees of damage to achieve the purpose of reuse, greatly extending the service life and saving the procurement cost and scrap steel inventory cost for enterprises, reducing the pressure on enterprises;

[0032] 2. The repair method provided by the present invention solves the problem that the procurement cost of slag ladles and slag pots in existing smelting enterprises is very high, and they are prone to scrapping due to cracking, piercing and deformation during use, resulting in high industrial costs. Specific Embodiments

[0033] The following further details the present invention.

[0034] Embodiment 1: A repair method for cracking of smelting slag ladles and slag pots based on multi-sided beveling. In the repair method, first, the degree of damage to the slag ladle and slag pot needs to be analyzed. The degree of damage analysis needs to analyze the mouth part, body part, trunnion, stiffening rib and bottom of the ladle one by one to judge whether the above parts are cracked, deformed or pierced; then, according to the results of the degree of damage analysis, one or more steps of hole repair, shaping, V-groove cutting, blanking, steel buckle cutting and reinforcement plate are selected to repair it.

[0035] 1. The specific repair steps for cracking inside the mouth part, body part, stiffening rib or bottom of the ladle are as follows:

[0036] (1) Clean the steel slag at the crack;

[0037] (2) Cut a 45° V-groove;

[0038] (3) Multi-layer and multi-pass welding;

[0039] (4) Turn over the repair part;

[0040] (5) Cut a single-sided V-groove;

[0041] (6) Multi-layer and multi-pass single-sided welding.

[0042] 2. The specific repair steps for cracking of the trunnion and its surrounding areas are as follows:

[0043] (1) Cut a deep V-groove;

[0044] (2) Multi-layer and multi-pass welding.

[0045] For the cracked trunnion, it is necessary to first grind a V-shaped groove with a polishing equipment and then perform multi-layer and multi-pass welding.

[0046] 3. The specific repair steps when the slag ladle and slag pot are deformed are as follows:

[0047] (1) Cut and shape the irregular module;

[0048] (2) Fix it;

[0049] (3) Make a V-shaped groove;

[0050] (4) Perform multi-layer and multi-pass welding.

[0051] 4. The specific repair steps when the slag ladle and slag pot have holes are as follows:

[0052] (1) Cut into a square or rectangular hole;

[0053] (2) Cut the material;

[0054] (3) Fix it;

[0055] (4) Make a V-shaped groove;

[0056] (5) Perform multi-layer and multi-pass welding.

[0057] 5. Before welding, it is necessary to clean the oxidation slag and other impurities in the weld; when using multi-layer and multi-pass welding, the surface welding slag needs to be removed after each layer of welding to prevent the occurrence of pores caused by inclusions. If there are slag inclusions or pores, it is necessary to cut and process them before welding. For the trunnion welding with slag inclusions or pores, it is necessary to first grind and then weld.

[0058] Example 2. Quality assurance measures in the actual implementation of the repair method provided by the present invention

[0059] (1) If there are waste residues, cold steel, etc. inside, it is necessary to clean them up before repair. Conduct a comprehensive inspection on it before repair, determine the deformed, cracked, perforated and pitted parts and make marks.

[0060] (2) Develop corresponding repair measures specifically according to the damaged parts, and make a repair process table for each spare part.

[0061] (3) Arrange repair personnel to prepare the equipment and consumables required for repair.

[0062] (4) During repair, it is necessary to use flame cutting to clean the slag at the damaged part and make a double-sided V-shaped weld.

[0063] (5) For the deformed parts, it is necessary to perform cutting, shaping, straightening and reinforcement welding.

[0064] (6) The weld area should be cleaned thoroughly to prevent the generation of pores and slag inclusions during welding.

[0065] (7) When welding, multiple layers and multiple passes should be used. The slag of the current layer should be cleaned up before welding the next layer.

[0066] (8) When the welding is completed, the surface should be smooth, flat, without slag inclusion and pores. Ensure that the height of the smooth and flat welding surface is < 3 mm.

[0067] (9) After welding is completed, the site should be cleaned up to keep it tidy.

[0068] (10) After the repair is completed, a comprehensive quality inspection should be carried out to ensure that the repair quality meets the requirements, and the repair process record form should be filled out and filed.

[0069] (11) It can be put into use only after passing the quality acceptance of Party A.

[0070] (12) After passing the acceptance and being put into use, a ledger should be established.

[0071] (13) According to the ledger, record the on-site tracking usage situation.

[0072] (14) If the trunnion and its installation part are repaired, invite a qualified unit to conduct flaw detection separately and issue a flaw detection report.

[0073] Example 3. Management of the equipment used in the actual implementation of the repair method provided by the present invention

[0074] (1) Regularly inspect and maintain the cutting torch and welding machine.

[0075] (2) Regularly check the gas source point valve box and joints. If there is a potential gas leakage hazard, it is prohibited to use and report it to the factory for handling.

[0076] (3) Before operation, carefully check the operation of the welding machine, grounding wire, power switch, coal and oxygen pipe belts for no air leakage.

[0077] (4) Before hot work, the on-site environment must be confirmed. If there are flammable sundries on-site during operation, they need to be cleaned up before operation.

[0078] (5) After operation, turn off the power, coal and oxygen point valve box valves, and put the welding machine cutting auxiliary equipment into the toolbox.

[0079] Example 4. Hazards existing in the actual implementation of the repair method provided by the present invention and related preventive measures

[0080] Hazard sources: dust, noise, electrical leakage, operating vehicles, oxygen backfire, overhead crane lifting;

[0081] Potential hazards: occupational diseases, electric shock, vehicle injuries, burns and explosions, object strikes;

[0082] Preventive measures:

[0083] Dust: Wear dust-proof masks;

[0084] Leakage of mobile electrical appliances: Turn off the power supply in time. If leakage is found, report for repair and handling in time;

[0085] Moving vehicles: Pay attention to observing the on-site environment and avoid operating vehicles in time;

[0086] Oxygen backfire: Check the clamp joints and hoses to ensure that the joints and hoses are intact. Wear protective glasses correctly;

[0087] Lifting objects by overhead crane: It is strictly prohibited to work, pass through or stay under the lifted objects by overhead crane. The operators should evacuate to a safe distance of more than 5 meters.

[0088] This specific embodiment is only an explanation of the present invention, and it is not a limitation of the present invention. After reading this specification, those skilled in the art can make modifications to this embodiment without creative contributions as needed, but as long as it is within the scope of the claims of the present invention, it is protected by the patent law.

Claims

1. A method for repairing cracks in smelting slag ladles and slag pots based on multilateral beveling, characterized by: In the repair method, the damage degree of the slag bag and the slag pot must first be analyzed. The damage degree analysis requires analyzing the mouth, body, ear axis, reinforcement rib and bag bottom one by one to determine whether the above parts are cracked, deformed or punctured; Then, according to the result of damage degree analysis, one or more steps including hole repair, shaping, V-shaped groove, material cutting, steel buckle installation and reinforcement plate are selected to repair it.

2. The method for repairing cracks in smelting slag ladles and slag pots based on multilateral beveling according to claim 1 is characterized by: The specific steps for repairing cracks in the mouth, body, ribs or bottom of the bag are as follows: (1) Clean the steel slag from the cracks; (2) Make a 45° V-shaped groove; (3) Multi-layer and multi-pass welding; (4) Turning over the repaired part; (5) V-shaped single-sided groove; (6) Multi-layer and multi-pass single-sided welding.

3. The method for repairing cracks in smelting slag ladles and slag pots based on multilateral beveling according to claim 1 is characterized by: The specific repair steps for the cracks in the trunnion and its surroundings are as follows: (1) Make a deep V-shaped groove; (2) Multi-layer and multi-pass welding.

4. The method for repairing cracks in smelting slag ladles and slag pots based on multilateral beveling according to claim 3 is characterized by: The cracked ear shaft needs to be polished with a polishing device to grind the V-shaped groove and then welded in multiple layers and passes.

5. The method for repairing cracks in smelting slag ladles and slag pots based on multilateral beveling according to claim 1 is characterized by: The specific repair steps when the slag bag or slag pot is deformed are as follows: (1) Cutting irregular modules into shapes; (2) Fixation; (3) V-shaped groove; (4) Multi-layer and multi-pass welding.

6. The method for repairing cracks in smelting slag ladles and slag pots based on multilateral beveling according to claim 1 is characterized by: The specific repair steps when the slag bag or slag pot is punctured are as follows: (1) Cut into square or rectangular holes; (2) Cutting materials; (3) Fixation; (4) V-shaped groove; (5) Multi-layer and multi-pass welding.

7. A method for repairing cracks in a smelting slag ladle or slag pot based on multilateral beveling according to any one of claims 2 to 6, characterized in that: Before welding, the oxidized slag and other impurities in the weld need to be cleaned; when multi-layer and multi-pass welding is adopted, the surface welding slag needs to be removed after each layer is welded to prevent the occurrence of pores caused by inclusions. If there are slag inclusions or pores, they need to be cut and processed before welding. If there are slag inclusions or pores in the ear shaft welding, they need to be polished before welding.