Installation method for fire-resistant tiles used to protect boiler water pipes

Abstract

Simply and accurately align and install multiple fire-resistant tiles in their designated positions. [Solution] The process includes: a first step of using one fire-resistant tile 2 as a reference tile 2-1 and hooking it onto a reference hook 5-1 without applying fire-resistant grout; a second step of aligning and fixing one fire-resistant tile 2-2 different from the reference tile 2-1 with the reference tile; a third step of performing either a first branching step after the second step, in which the reference tile 2-1 is removed from the reference hook 5-1 and fixed in alignment with the fire-resistant tile 2-2 fixed in the second step, or a second branching step in which one fire-resistant tile 2-3 different from the fire-resistant tile 2-2 fixed in all the preceding steps of this process is hooked onto an unused hook 5-3 one position away from the hook on which the fixed fire-resistant tile 2-2 was hooked, and fixed while aligning it with the fixed fire-resistant tile 2-2; and a fourth step of repeating the third step a predetermined number of times after the third step.

Description

Technical Field

[0001] The present invention relates to a method for installing refractory tiles for protecting boiler water pipes.

Background Art

[0002] In facilities such as incineration plants that have boilers and generate electricity while incinerating waste, and power plants that burn fuels such as coal, that is, combustion plants equipped with boilers, a plurality of boiler water pipes are installed on the furnace wall of the combustion furnace. The plurality of boiler water pipes are generally each erected in the vertical direction and arranged at equal intervals in the horizontal direction, that is, evenly arranged. And, the space between two adjacent boiler water pipes in the horizontal direction is connected without a gap by a plate-shaped fin, and a water pipe panel is formed by these boiler water pipes and fins.

[0003] In order to protect these boiler water pipes from excessive heat, refractory tiles may be installed on the surface of the boiler water pipes on the side facing the furnace inside the water pipe panel (hereinafter referred to as "installing refractory tiles on the upper surface of the boiler water pipes"). At this time, for example, there is a technique of evenly installing hooks on the fins of the water pipe panel and mechanically supporting the refractory tiles by the hooks (see Patent Document 1). According to this technique, a refractory joint material such as mortar that becomes an adhesive is applied to the back surface of the rectangular refractory tile, the hook is hooked on a depression (hereinafter referred to as "recess") provided near the center of the back surface of the refractory tile, and the refractory tile is pressed toward the water pipe panel, so that the refractory tile is fixed on two adjacent boiler water pipes on both sides of the hook. By repeating this sequentially, a plurality of refractory tiles are installed on the upper surfaces of the plurality of boiler water pipes with gaps having a margin when thermally expanded and opened from each other.

[0004] When installing a large number of refractory tiles, for example, there is a technique of forming a tile group with nine refractory tiles arranged in a rectangular alignment, applying a refractory joint material to the gaps between adjacent refractory tiles within one tile group, and embedding a refractory expansion filler such as fiber cast in the gaps between the tile group and the adjacent tile group (see Patent Document 2). [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Utility Model Registration No. 3176108 [Patent Document 2] Patent No. 3122422 [Overview of the project] [Problems that the invention aims to solve]

[0006] Each of the multiple fire-resistant tiles is sequentially installed by hooking it onto its corresponding hook among multiple hooks that are pre-installed evenly on the water pipe panel, so it is expected that they will be aligned and positioned without any misalignment as designed. However, due to the effect of the fire-resistant jointing material applied to the recesses on the back of the fire-resistant tiles, the positional relationship between the fire-resistant tiles and the hooks may be slightly shifted from their intended positions. In this case, the displacement of each fire-resistant tile is small, so workers may not notice the misalignment, and the installation of the fire-resistant tiles may continue. As a result, the small misalignments of each fire-resistant tile accumulate, and when viewed as a whole after the installation of many fire-resistant tiles, it may result in a large misalignment or distortion, potentially requiring the construction to be redone.

[0007] The present invention has been made in view of the above problems, and aims to provide a construction method for easily and accurately aligning and installing multiple fire-resistant tiles for protecting boiler water tubes in predetermined positions. [Means for solving the problem]

[0008] The present invention is a method for installing fire-resistant tiles for protecting boiler water tubes, comprising arranging and fixing multiple rectangular fire-resistant tiles in an aligned manner to a water tube panel that includes multiple boiler water tubes evenly arranged horizontally, multiple fins connecting two horizontally adjacent boiler water tubes, and multiple hooks provided on the multiple fins. Multiple hooks are fixed to multiple fins in a regular arrangement corresponding to the positions of recesses formed on the back of the fire-resistant tiles that are to be arranged in a line. Then, fire-resistant jointing material is applied to the back of the fire-resistant tiles, and a number of hooks corresponding to the number of recesses in a single fire-resistant tile are hooked into the recesses and fixed in place, so that multiple fire-resistant tiles are arranged in a line with predetermined intervals between them, and one fire-resistant tile is fixed to the top surface of two or more boiler water tubes.

[0009] Furthermore, the present invention is characterized by comprising at least the following steps: The first step involves selecting one of the above multiple fire-resistant tiles as a reference tile, and without applying fire-resistant jointing material to its back surface, hanging it on a number of reference hooks corresponding to the number of recesses formed on the back surface of the reference tile, from among the above multiple hooks. After the first step, a fire-resistant joint material is applied to the back of one of the multiple fire-resistant tiles, which is different from the reference tile. Then, the fire-resistant tile with the fire-resistant joint material is hooked onto a number of hooks corresponding to the number of recesses, including the hook adjacent to the reference hook. After aligning it with the reference tile, the fire-resistant tile with the fire-resistant joint material is pressed and fixed toward the water pipe panel in the second step. After the second step, the reference tile is removed from the reference hook, fire-resistant jointing material is applied to its back surface, and the reference tile is hooked onto the reference hook. Then, while aligning it with the fire-resistant tile fixed in the second step, the reference tile is pressed toward the water pipe panel and fixed in place. The third step involves performing one of the following two branching steps: the first branching step, which involves applying fire-resistant jointing material to the back surface of one of the multiple fire-resistant tiles, which is different from the fire-resistant tiles fixed in all the steps preceding this step; and the third step involves hooking the fire-resistant tile with fire-resistant jointing material applied to a number of hooks that are not yet hooked, including the hook adjacent to the hook to which the fire-resistant tile fixed in the step immediately preceding this step or the step two steps prior to this step was hooked, and a number of hooks corresponding to the number of recesses to which no fire-resistant tiles have yet been hooked. Then, while aligning it with the fire-resistant tile fixed in the step immediately preceding this step or the step two steps prior to this step, the fire-resistant tile with fire-resistant jointing material applied is pressed toward the water pipe panel and fixed in place. The process includes at least a fourth step, in which the third step is repeated a predetermined number of times after the third step. [Effects of the Invention]

[0010] According to the construction method of the present invention, firstly, in the first step, no fire-resistant jointing material is applied to the back surface of the fire-resistant tile that will serve as the reference tile. The reference tile is then hooked onto a number of reference hooks corresponding to the number of recesses formed on its back surface. Since no fire-resistant jointing material is applied, the reference tile is simply hooked onto the reference hooks. As a result, the reference hooks penetrate to the deepest part of the recesses on the back surface and directly contact the reference tile, so that the vertical and horizontal positions of the reference tile are positioned as designed. In the second step, fire-resistant jointing material is applied to the back of a different fire-resistant tile from the reference tile, and this different fire-resistant tile is hooked onto a number of hooks corresponding to the number of recesses on the back of the fire-resistant tile, including the hook one adjacent to the reference hook. Here, the fire-resistant jointing material that has entered the recesses on the back of the fire-resistant tile may prevent direct contact between the fire-resistant tile and the hook in those recesses, and depending on the skill level of the worker, it may be misaligned from the designed position. However, since the reference tile immediately adjacent to the one hooked on the reference hook is in the designed position, the different fire-resistant tile can be aligned and fixed as designed by comparing it with the reference tile. In the third step, the other fire-resistant tile, which was fixed in the position as designed in the second step, can be used as a new reference for alignment. Therefore, the fire-resistant tile placed immediately next to this other fire-resistant tile can also be precisely aligned and fixed in the designed position based on this new reference tile. Then, in the fourth step, by repeating the third step a predetermined number of times, the new standard fire-resistant tile can be sequentially replaced, and multiple rectangular fire-resistant tiles can be aligned and fixed in the order they were designed.

[0011] Therefore, according to the present invention, it is possible to provide a construction method for easily and accurately aligning and installing multiple fire-resistant tiles for protecting boiler water tubes in predetermined positions. [Brief explanation of the drawing]

[0012] [Figure 1] This is a schematic front view showing a water pipe panel and fire-resistant tiles to which the construction method according to the embodiment is applied. [Figure 2] Figure 1 shows the fire-resistant tile, where (A) is a front view seen from the surface, (B) is a rear view seen from the back, and (C) is a top view seen from arrow A in (A). [Figure 3] The image shows a first-type interlocking fire-resistant tile, where (A) is a front view seen from the surface, (B) is a rear view seen from the back, (C) is a top view, (D) is a bottom view, and (E) is a cross-sectional view of (A) along line BB. [Figure 4] The image shows a fitted type second fire-resistant tile, where (A) is a front view seen from the surface, (B) is a rear view seen from the back, (C) is a top view, (D) is a bottom view, and (E) is a cross-sectional view of (A) along line CC. [Figure 5] The image shows a fitted third-type fire-resistant tile, where (A) is a front view seen from the surface, (B) is a rear view seen from the back, (C) is a top view, (D) is a bottom view, and (E) is a cross-sectional view of (A) along line DD. [Figure 6] This is a schematic front view showing an example of a water pipe panel with interlocking fire-resistant tiles installed. [Figure 7] This is a schematic front view of a water pipe panel after fire-resistant tile installation, showing an example of a different tile arrangement from the one in Figure 6. [Figure 8] This is a schematic front view of a water pipe panel after fire-resistant tile installation, showing an example of a tile arrangement different from that shown in Figures 6 and 7. [Figure 9] The first half-split type fire-resistant tile is similar to the interlocking type first fire-resistant tile, where (A) is a front view seen from the surface, (B) is a rear view seen from the back, (C) is a bottom view, (D) is a top view, and (E) is a cross-sectional view of (A) along line EE. [Figure 10]Figure 1 shows a first half - type refractory tile similar to a combined - type second refractory tile. (A) is a front view as seen from the surface, (B) is a rear view as seen from the back surface, (C) is a bottom view, (D) is a top view, and (E) is a cross - sectional view taken along the F - F line of (A). [Figure 11] Figure 2 shows a first half - type refractory tile similar to a combined - type third refractory tile. (A) is a front view as seen from the surface, (B) is a rear view as seen from the back surface, (C) is a bottom view, (D) is a top view, and (E) is a cross - sectional view taken along the G - G line of (A). [Figure 12] Figure 3 is a schematic front view showing an example of a water - pipe panel constructed with the first and second half - type refractory tiles. [Figure 13] Figure 4 is a perspective view showing a block - type refractory tile. [Figure 14] Figure 5 is a perspective view showing a modified example of the block - type refractory tile. [Figure 15] Figure 6 is a schematic front view showing an example of a water - pipe panel constructed with large - sized refractory tiles. [Figure 16] Figure 7 is a schematic front view showing an example of a water - pipe panel constructed with another type of large - sized refractory tiles. [Figure 17] Figure 8 is a schematic front view showing an example of a water - pipe panel after the construction of refractory tiles used to explain the construction method according to the embodiment.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, with reference to FIGS. 1 to 17, a construction method of a refractory tile for boiler water - pipe protection according to an embodiment of the present invention will be described. In the figures, for the sake of simplicity of explanation, a rectangular coordinate system based on the X - axis, Y - axis, and Z - axis is used for explanation as appropriate. Here, the Z - axis is arranged vertically, and the X - axis and Y - axis are arranged horizontally. The Z - axis indicates the vertical direction, that is, the up - and - down direction in which a plurality of refractory tiles are arranged in alignment. The arrow direction of the Z - axis indicates the upward direction among the up - and - down directions. The X - axis indicates the horizontal direction, that is, the left - and - right direction in which a plurality of refractory tiles are arranged in alignment. The Y - axis indicates the direction perpendicular to the water - pipe panel, that is, the thickness direction of the refractory tile. The arrow direction of the Y - axis indicates the direction from the boiler water - pipe to the refractory tile installed on its upper surface. For the purposes of this explanation, the vertical direction is assumed to be the vertical direction, but any direction along the vertical axis may be inclined relative to the vertical. For example, in some parts of a combustion furnace, the furnace wall may be inclined from the vertical. In such cases, the following explanation can be understood by considering a Cartesian coordinate system in which the X-axis remains horizontal, while the Z-axis and Y-axis are inclined. The embodiments are merely illustrative and do not preclude the application of various modifications or technologies not explicitly stated. Except for the configurations essential to the present invention, each configuration of the embodiments can be selected, modified, or otherwise implemented as needed.

[0014] First, the basic principles of the installation method (hereinafter referred to as "installation method") for the boiler water tube protection refractory tiles of the embodiment (hereinafter referred to as "refractory tiles") will be briefly explained with reference to Figure 1. Then, examples of various refractory tiles used in the installation method will be explained using Figures 2 to 16. Finally, the installation method will be explained in detail with reference to Figure 17.

[0015] [1.Basic matters] Figure 1 is a schematic front view of a combustion plant equipped with a boiler, showing multiple rectangular refractory tiles 2 arranged in a line on the upper surface of multiple boiler water tubes 1, as seen from inside the combustion furnace. In Figure 1, fire-resistant tile 2, which will be detailed in [2. Types of Fire-Resistant Tiles] below, is shown as an example. However, other types of fire-resistant tiles, also detailed in [2. Types of Fire-Resistant Tiles], may be used instead of fire-resistant tile 2. However, when using other types of fire-resistant tiles, the number of recesses 6 on a single fire-resistant tile may differ from those of other types of fire-resistant tiles. Therefore, it is necessary to appropriately position the hooks 5 according to the number and position of the recesses 6 on the fire-resistant tiles. The water tube panel 4 consists of a plurality of boiler water tubes 1, each erected in the Z-axis direction and spaced evenly apart in the X-axis direction, and plate-shaped fins 3 that seamlessly connect two adjacent boiler water tubes 1 in the X-axis direction, i.e., in the lateral direction. In other words, the water tube panel 4 is a rectangular plate-like structure in which each of the plurality of fins 3 fills the space between the plurality of aligned boiler water tubes 1. Since the furnace wall of a combustion furnace is generally rectangular, multiple plate-shaped water tube panels 4 are welded together to form this rectangular shape. However, for the sake of simplicity, this explanation will use water tube panels 4 on one side of the rectangular shape. Multiple hooks 5 are pre-welded to the fin 3 at positions corresponding to the recesses formed on the back surface of multiple fire-resistant tiles that are to be arranged in a line.

[0016] The rectangular refractory tiles are installed to cover the top surfaces of two or more boiler water tubes 1 and are supported by hooks 5 in recesses 6 formed on their backs. Any structure is acceptable, not limited to the various refractory tile examples described later, as long as it allows for the placement of adjacent refractory tiles with a predetermined gap between them. When the refractory tiles are fixed to the water tube panel 4, the side facing the furnace is called the "front surface" of the refractory tile, and the opposite side, i.e., the side facing the boiler water tubes 1, is called the "back surface". The material of the fire-resistant tile should preferably be mainly composed of SiC, in which case the specified width should be, for example, about 4 mm to 8 mm, or more specifically, about 6 mm.

[0017] In Figure 1, the fire-resistant tile 2 has one recess 6 near the center of its back surface. However, like other types of fire-resistant tiles described later, the fire-resistant tile only needs to have at least one recess 6, and may have one or more recesses 6, such as two or three, arranged horizontally. The recess 6 is shaped so that the upper end of the fire-resistant tile is held horizontally when the fire-resistant tile is hooked onto the L-shaped hook 5. Furthermore, in Figure 1, multiple hooks 5 are installed on every other fin 3 in the horizontal direction, and are installed regularly at equal intervals in the vertical direction of the fins 3. However, depending on the type of fire-resistant tile, that is, depending on the number and location of recesses 6 provided in a single fire-resistant tile, the hooks 5 may be arranged regularly as appropriate.

[0018] Furthermore, as shown by the dashed line in Figure 1, multiple tile sets consisting of a predetermined number of refractory tiles are arranged to facilitate the assignment of work areas by multiple workers and to implement measures to prevent thermal expansion of the refractory tiles due to the heat inside the furnace when the combustion furnace is in operation. Specifically, as an example, tile set 7A is shown, which consists of a total of nine refractory tiles 2, three in the vertical direction and three in the horizontal direction, and tile set 7B has the same configuration as tile set 7A but is placed next to tile set 7A. The arrangement of multiple fire-resistant tiles in a single tile set is not limited to arrangements such as tile sets 7A and 7B, where three fire-resistant tiles are arranged vertically and three horizontally (hereinafter referred to as the "first tile set"). It may also include arrangements where two fire-resistant tiles are arranged vertically and two horizontally (hereinafter referred to as the "second tile set"), or arrangements where three or more fire-resistant tiles are arranged vertically and two horizontally (hereinafter referred to as the "third tile set"). Furthermore, the arrangement of multiple fire-resistant tiles in a single tile set may be as follows: two or more fire-resistant tiles arranged vertically and three or more horizontally (hereinafter, this tile set will be referred to as the "fourth tile set"), one arrangement of tiles arranged in a single row only in the vertical direction (hereinafter, this tile set will be referred to as the "fifth tile set"), or one arrangement of tiles arranged in a single row only in the horizontal direction (hereinafter, this tile set will be referred to as the "sixth tile set"). A single water tube panel may have multiple instances of only one type of tile set from the first to sixth tile sets, or it may have a mixture of multiple types of tile sets depending on the shape of the furnace wall of the combustion furnace. Multiple tile sets can be arranged vertically or horizontally. Furthermore, the number of refractory tiles contained within a tile set may be varied as appropriate depending on the location on the furnace wall. Additionally, the same type of refractory tile may be used for all tile sets, or different types of refractory tiles may be used for each tile set.

[0019] In a single tile set, fire-resistant jointing material such as mortar or castable is applied to the gaps around each of the multiple fire-resistant tiles, and fire-resistant expansion-allowance filler such as fibercast is embedded in the gaps around a single tile set. In Figure 1, a fire-resistant expansion filler is embedded in the gap between tile set 7A and the adjacent tile set 7B, and a fire-resistant jointing material is applied to the gaps between the multiple fire-resistant tiles contained within tile set 7A and the multiple fire-resistant tiles contained within tile set 7B.

[0020] [2. Types of fire-resistant tiles] Next, we will describe specific examples of fire-resistant tile types to which the construction method of the present invention can be applied. [Seagull-shaped fire-resistant tile (non-interlocking type)] Figures 2(A) to (C) show the fire-resistant tile 2 illustrated in Figure 1. Specifically, it is a single rectangular fire-resistant tile 2 with a single recess 6 formed in the center of the X-axis direction and slightly above the center in the Z-axis direction on the back surface, and it covers two boiler water tubes 1. The rectangular fire-resistant tile 2, when viewed in the XZ plane, has a rectangular central section 2A located in the center in the X-axis direction, with one rectangular side section 2B on each side that covers one boiler water tube 1. That is, one side section 2B is located to the right of the central section 2A, and one side section 2B is located to the left of the central section 2A. When viewed in the XY plane, the side section 2B has a curved shape that follows approximately half of the outer circumference of the boiler water tube 1. The thickness of this curved shape is substantially the same at all points and is thinner than the thickness of the central section 2A. A recess 6 is formed in the central section 2A. On the back surface of the fire-resistant tile 2, multiple spacers 2C are formed on each side portion 2B, protruding toward the boiler water tube 1. The spacers 2C have the function of leveling the thickness of the fire-resistant joint material, such as mortar, applied to the back surface of the fire-resistant tile 2 to strengthen adhesion and to equalize heat transfer performance. In Figure 2, three spacers 2C are formed on one side portion 2B, but there may be four or more, or two or fewer. Furthermore, when viewed in the XY plane, the fire-resistant tile 2 is described as a "seagull-shaped" fire-resistant tile, as the sides 2B on both sides of the central part 2A resemble the wings of a flying seagull.

[0021] [Seagull-shaped fire-resistant tiles (interlocking type)] The fire-resistant tiles 8 to 10 shown in Figures 3 to 5 are a type of "seagull-shaped" fire-resistant tile, similar to fire-resistant tile 2. The only difference between fire-resistant tiles 8 to 10 and fire-resistant tile 2 is that they are "interlocking" type fire-resistant tiles. Therefore, the same numbering is used for components identical to those of fire-resistant tile 2, and their explanations are omitted. Fire-resistant tile 8 is a "first interlocking fire-resistant tile" equipped with both the interlocking projection 8D and the interlocking recess 8E described later, fire-resistant tile 9 is a "second interlocking fire-resistant tile" equipped only with the interlocking projection 8D described later, and fire-resistant tile 10 is a "third interlocking fire-resistant tile" equipped only with the interlocking recess 8E described later. Fire-resistant tile 9 has the same shape as fire-resistant tile 8, except that the interlocking recess 8E is not formed. Similarly, fire-resistant tile 10 has the same shape as fire-resistant tile 8, except that the interlocking projection 8D is not formed. The interlocking projection 8D and the interlocking recess 8E are shaped to fit together. Therefore, the interlocking projection 8D of the fire-resistant tile 8 can be fitted into the interlocking recess 8E of the fire-resistant tile 10, and the interlocking recess 8E of the fire-resistant tile 8 can be fitted into the interlocking projection 8D of the fire-resistant tile 9. Similarly, the interlocking projection 8D of the fire-resistant tile 9 can be fitted into the interlocking recess 8E of the fire-resistant tile 10.

[0022] The rectangular fire-resistant tile 8, when viewed in the XZ plane, has a rectangular central section 8A located in the center in the X-axis direction, with one rectangular side section 2B on each side to cover one boiler water tube 1. That is, one side section 2B is located to the right of the central section 8A, and one side section 2B is located to the left of the central section 8A. A single recess 6 is formed in the center of the central section 8A in the X-axis direction and slightly above the center in the Z-axis direction. Viewed in the XZ plane, the central portion 8A has a fitting projection 8D that protrudes rectangularly above the upper end of the side portion 2B, and a fitting recess 8E that is recessed rectangularly above the lower end of the side portion 2B and is sized to accommodate the fitting projection 8D.

[0023] The rectangular fire-resistant tile 9, when viewed in the XZ plane, has a rectangular central section 9A located in the center in the X-axis direction, with one rectangular side section 2B on each side to cover one boiler water tube 1. That is, one side section 2B is located to the right of the central section 9A, and one side section 2B is located to the left of the central section 9A. A single recess 6 is formed in the center of the central section 9A in the X-axis direction and slightly above the center in the Z-axis direction. When viewed in the XZ plane, a fitting projection 8D is formed in the central part 9A, protruding in a rectangular shape above the position of the upper end of the side part 2B.

[0024] As shown in Figures 5(A) to (E), the fire-resistant tile 10 has a rectangular central section 10A located in the center in the X-axis direction when viewed in the XZ plane, with one rectangular side section 2B on each side that covers one boiler water tube 1. That is, one side section 2B is located to the right of the central section 10A, and one side section 2B is located to the left of the central section 10A. A single recess 6 is formed in the center of the central section 10A in the X-axis direction and slightly above the center in the Z-axis direction. Viewed in the XZ plane, the central portion 10A has a rectangular recessed area 8E that extends above the lower end of the side portion 2B, and is sized to accommodate the fitting projection 8D.

[0025] Figure 6 shows an example where the fire-resistant tile 2 in Figure 1 is installed on the water pipe panel 4 instead of the interlocking fire-resistant tiles 8 to 10. As mentioned above, both tile sets 7A and tile sets 7B are first tile sets with three fire-resistant tiles installed in the vertical direction, so they can be arranged in the order of fire-resistant tile 9, fire-resistant tile 8, and fire-resistant tile 10 from bottom to top in the Z-axis direction. Here, the interlocking projection 8D of the fire-resistant tile 8 is interlocked with the interlocking recess 8E of the fire-resistant tile 10, and the interlocking recess 8E of the fire-resistant tile 8 is interlocked with the interlocking projection 8D of the fire-resistant tile 9. As shown in Figure 6, when using interlocking fire-resistant tiles, two adjacent fire-resistant tiles are interlocked with each other. Therefore, compared to using non-interlocking fire-resistant tiles 2, it is more resistant to shaking such as earthquakes, and the peeling and falling of fire-resistant tiles can be more firmly prevented.

[0026] Furthermore, as mentioned above, the number of refractory tiles included in a single tile set may be changed as appropriate depending on the location on the furnace wall. Figure 7 shows an example of a third tile set in which a total of six refractory tiles are arranged, three vertically and two horizontally. Specifically, starting from the bottom to the top in the Z-axis direction, rows are formed by fitting two adjacent refractory tiles together in the order of refractory tile 9, refractory tile 8, and refractory tile 10, and two such rows are arranged in the X-axis direction to form one tile set. Figure 7 shows an example in which two of these tile sets are arranged horizontally, namely tile set 7A' and tile set 7B'. In Figures 6 and 7, the lower end of the tile assembly is designated as fire-resistant tile 9, and the upper end as fire-resistant tile 10. Two or more fire-resistant tiles 8 may be aligned vertically between fire-resistant tile 9 and fire-resistant tile 10, and two adjacent fire-resistant tiles may be fitted together vertically. As another example, Figure 8 shows a fourth tile set in which a total of six fire-resistant tiles are arranged in a vertical direction (two) and a horizontal direction (three). Specifically, starting from the bottom to the top in the Z-axis direction, rows are formed by fitting two adjacent fire-resistant tiles together, such as fire-resistant tile 9 and fire-resistant tile 10, and three such rows are arranged in the X-axis direction to form one tile set. Figure 8 shows an example in which two of these tile sets are arranged horizontally, namely tile set 7A′′ and tile set 7B′′.

[0027] [Seagull-shaped fire-resistant tiles (interlocking and half-split type)] The fire-resistant tiles 11 to 13 shown in Figures 9 to 11 differ from the interlocking fire-resistant tiles 8 to 10 shown in Figures 3 to 5 only in that one side 2B of the interlocking fire-resistant tiles 8 to 10 is split along the Z-axis near its center. Therefore, the same numbering is used for components identical to those of fire-resistant tiles 8 to 10, and their explanations are omitted. The interlocking and split-type fire-resistant tiles 11, 12, and 13 shown in Figures 9(A), 10(A), and 11(A) have a configuration in which, when viewed from the surface of the fire-resistant tile, one side section 2B is positioned to the right of the central sections 8A, 9A, and 10A, and one split side section 11F is positioned to the left of the central sections 8A, 9A, and 10A. These are called "first split-type" fire-resistant tiles. On the other hand, fire-resistant tiles with a shape symmetrical to the first split-type fire-resistant tiles are called "second split-type" fire-resistant tiles. The split side section 11F is a structure in which side section 2B is split along the Z-axis and side section 2B is made smaller laterally. When viewed in the XY plane, it has a curved shape that follows approximately 1 / 4 of the outer circumference of the boiler water tube 1.

[0028] As the first half-split type fire-resistant tile, here we show fire-resistant tile 11 in Figure 9 (a first half-split type fire-resistant tile similar to the interlocking first fire-resistant tile), which differs from fire-resistant tile 8 in Figure 3 only in the split side portion 11F; fire-resistant tile 12 in Figure 10 (a first half-split type fire-resistant tile similar to the interlocking second fire-resistant tile), which differs from fire-resistant tile 9 in Figure 4 only in the split side portion 11F; and fire-resistant tile 13 in Figure 11 (a first half-split type fire-resistant tile similar to the interlocking third fire-resistant tile), which differs from fire-resistant tile 10 in Figure 5 only in the split side portion 11F. As second-half-type fire-resistant tiles, Figure 12 shows fire-resistant tile 14 (a second half-type fire-resistant tile similar to the interlocking first-type fire-resistant tile) which has a shape symmetrical to fire-resistant tile 11, fire-resistant tile 15 (a second half-type fire-resistant tile similar to the interlocking second-type fire-resistant tile) which has a shape symmetrical to fire-resistant tile 12, and fire-resistant tile 16 (a second half-type fire-resistant tile similar to the interlocking third-type fire-resistant tile) which has a shape symmetrical to fire-resistant tile 13. However, unlike the first half-type fire-resistant tiles, individual illustrations are omitted.

[0029] As shown in Figure 9(A), the first half-split fire-resistant tile 11 has a structure in which, when viewed from the surface, the left side portion 2B of the central portion 8A of the interlocking fire-resistant tile 8 shown in Figure 3 is replaced by a half-split side portion 11F. Therefore, similar to the interlocking fire-resistant tile 8, the central portion 8A of the first half-split fire-resistant tile 11 is provided with an interlocking projection 8D above it and an interlocking recess 8E below it. As shown in Figure 10(A), the first half-split fire-resistant tile 12 has a structure in which, when viewed from the surface, the left side portion 2B of the central portion 9A of the interlocking fire-resistant tile 9 shown in Figure 4 is replaced by the half-split side portion 11F. For this reason, similar to the interlocking fire-resistant tile 9, the central portion 9A of the first half-split fire-resistant tile 12 is provided with an interlocking projection 8D above it. As shown in Figure 11(A), the first half-split fire-resistant tile 13 has a structure in which, when viewed from the surface, the left side portion 2B of the central portion 10A of the interlocking fire-resistant tile 10 shown in Figure 5 is replaced by a half-split side portion 11F. Therefore, similar to the interlocking fire-resistant tile 10, the central portion 10A of the first half-split fire-resistant tile 13 is provided with an interlocking recess 8E below it.

[0030] On the other hand, although not shown individually, the second half-split type fire-resistant tile 14 has a structure in which the right side portion 2B of the central portion 8A of the interlocking type fire-resistant tile 8 shown in Figure 3 is replaced with a half-split side portion 11F when viewed from the surface. For this reason, the central portion 8A of the second half-split type fire-resistant tile 14 is provided with an interlocking projection 8D above it and an interlocking recess 8E below it. Furthermore, the second half-split type fire-resistant tile 15 has a structure in which, when viewed from the surface, the right side portion 2B of the central portion 9A of the interlocking type fire-resistant tile 9 shown in Figure 4 is replaced with the half-split side portion 11F. For this reason, the central portion 9A of the second half-split type fire-resistant tile 15 is provided with an interlocking projection 8D above it. Furthermore, the second half-split type fire-resistant tile 16 has a structure in which, when viewed from the surface, the right side portion 2B of the central portion 10A of the interlocking type fire-resistant tile 10 shown in Figure 5 is replaced with the half-split side portion 11F. For this reason, the central portion 10A of the second half-split type fire-resistant tile 16 is provided with an interlocking recess 8E below it.

[0031] As shown in Figure 12, the first half-split fire-resistant tile and the second half-split fire-resistant tile can be placed facing each other with their respective split sides 11F facing each other, thereby covering the three boiler water tubes 1. As mentioned above, multiple hooks 5 are pre-installed on the fin 3 at positions corresponding to the recesses formed on the back surface of multiple fire-resistant tiles that are to be arranged in a line. When using half-split fire-resistant tiles, unlike the water tube panel 4 shown in Figure 1, the hooks 5 are installed on two adjacent fins 3 on either side of one boiler water tube 1 of the water tube panel 4', and are installed regularly at equal intervals in the vertical direction of the fins 3. Figure 12 shows an example in which, starting from the bottom to the top in the Z-axis direction, a first row 18 is formed by fitting together two adjacent fire-resistant tiles vertically in the order of fire-resistant tile 12, fire-resistant tile 11, and fire-resistant tile 13, and a second row 19 is formed to the right of the first row 18 by fitting together two adjacent fire-resistant tiles vertically in the order of fire-resistant tile 15, fire-resistant tile 14, and fire-resistant tile 16, with the first row 18 and the second row 19 forming a single tile set 17. The tile set 17 is the third tile set. Here, a configuration is shown in which adjacent fire-resistant tiles are fitted together in the vertical direction. However, these fire-resistant tiles may also be of the half-split type, without the fitted protrusions 8D and fitted recesses 8E.

[0032] [Block-type fire-resistant tiles] Figure 13 shows an example of the configuration of block-type fire-resistant tiles 20. The only difference between fire-resistant tiles 20 and the seagull-shaped fire-resistant tiles 2 in Figure 2 is that their surfaces are formed as flat surfaces. Therefore, the same numbering is used for components identical to those of fire-resistant tiles 2, and their explanations are omitted. The surfaces of the central portion 2A, its right-side portion 2B, and its left-side portion 2B are all located at the same position in the Y-axis direction, i.e., in the thickness direction. Therefore, the refractory tile 20 can be formed by cutting off two U-shaped grooves 20A that cover two boiler water tubes 1 and recesses 6 for attaching hooks 5 from a single rectangular prism-shaped refractory tile raw material and then firing it. The block-type fire-resistant tile 20 is heavier than the seagull-type fire-resistant tile because its side section 2B is thicker, but it can be used in furnace walls depending on the design. Figure 14 shows an example of the configuration of a fire-resistant tile 21, which is a modified version of the block-type fire-resistant tile 20. Unlike the block-type fire-resistant tile 20, the block-type fire-resistant tile 21 does not have two U-shaped grooves 20A that cover the two boiler water tubes 1. Therefore, the fire-resistant tile 21 can be formed by cutting off only the recess 6 for attaching the hook 5 from a single rectangular prism-shaped fire-resistant tile raw material and firing it. The block-type refractory tile 21 has the advantage of being easier to manufacture than the block-type refractory tile 20, and like the refractory tile 20, it can be used in furnace walls depending on the design.

[0033] [Large fire-resistant tiles] As mentioned above, among multiple tile sets, one set may consist of several specific types of fire-resistant tiles, while another set may consist of fire-resistant tiles of a different type than those specific types. Figure 15 shows tile set 7B, which is the first tile set, in which a total of nine fire-resistant tiles 2 are arranged in a row of three vertically and three horizontally, and tile set 7A′′′, which is the fifth tile set, in which three large fire-resistant tiles 23 are arranged in a row only in the vertical direction. Typically, one side of the furnace wall of a combustion furnace is formed by welding together multiple rectangular water tube panels. A linear mark remains where two adjacent water tube panels are welded, and this is called a weld line. Because weld lines are uneven, it may not be possible to attach hook 5 to fins with weld lines. On the other hand, depending on the size and design of the combustion furnace, if refractory tiles 2 are installed horizontally on a single water tube panel, it may not be possible to cover one boiler water tube 1 at the end of the water tube panel with the refractory tiles 2. Figure 15 illustrates this situation. In Figure 5, water pipe panels 4'' are arranged on both the left and right sides. Similar to the water pipe panel 4 in Figure 1, the water pipe panel 4'' has multiple hooks 5 installed on every other fin 3 in the horizontal direction, and the hooks 5 are regularly installed at equal intervals in the vertical direction of the fins 3. However, in Figure 15, the left end of the right water pipe panel 4'' and the right end of the left water pipe panel 4'' are welded to each other, so when attempting to install only the fire-resistant tiles 2, a weld line 26 is formed on the fins 3 where the hooks 5 should be installed, making it impossible to properly attach the hooks 5. Therefore, a large fire-resistant tile 23 is used that can straddle the weld line 26 and simultaneously cover the boiler water tubes 1 of these two water tube panels 4′′.

[0034] The large fire-resistant tile is rectangular in shape, has two or more recesses 6 formed in it, and can cover three or more boiler water tubes 1. The large fire-resistant tile 23 shown as an example in Figure 15 has a structure in which three fire-resistant tiles 2 are connected horizontally and integrally formed. However, in the fire-resistant tile 23, the recess 6 located at the weld line 26 is unnecessary and therefore not formed. Accordingly, in Figure 15, the fire-resistant tile 23 has a total of two recesses 6: one that can be hooked onto a hook 5 installed on the left water pipe panel 4′′ and another that can be hooked onto a hook 5 installed on the right water pipe panel 4′′. In this description, the large fire-resistant tile is a large fire-resistant tile 23 in which three fire-resistant tiles 2 are connected horizontally and formed as a single unit. However, it is not limited to this, and may also be a large fire-resistant tile with a structure in which four or more fire-resistant tiles are connected horizontally and formed as a single unit. Furthermore, the large fire-resistant tile is not limited to a configuration in which multiple fire-resistant tiles 2 are connected horizontally. For example, it may be a structure in which multiple interlocking fire-resistant tiles 8 are connected horizontally and formed as a single unit, or a structure in which multiple block-type fire-resistant tiles 20, 21 are connected horizontally and formed as a single unit. In addition to the conventional method of applying fire-resistant joint material to address areas with weld lines 26, large fire-resistant tiles can now be installed across the weld lines 26, thereby strengthening the protection of the boiler water tubes 1 in the water tube panel 4′′.

[0035] Furthermore, the large fire-resistant tiles are not limited to being installed only where they straddle the weld lines 26, but may also be installed within a single water tube panel. As mentioned above, the large fire-resistant tiles are rectangular in shape, and it is sufficient that they have two or more recesses 6 and can cover three or more boiler water tubes 1. Therefore, as shown in Figure 16, the fire-resistant tiles 28 may be formed as a single unit with a structure in which the first half-type fire-resistant tile and the second half-type fire-resistant tile, which are adjacent to each other on the left and right in Figure 12, are connected. Figure 16 shows an example of a fifth tile set in which large fire-resistant tiles 28B (connecting fire-resistant tiles 12 and 15 in Figure 12), large fire-resistant tiles 28A (connecting fire-resistant tiles 11 and 14 in Figure 12), and large fire-resistant tiles 28C (connecting fire-resistant tiles 13 and 16 in Figure 12) are installed in a line in this order from bottom to top in the Z-axis direction. The two interlocking protrusions 8D on the large fire-resistant tile 28A are interlocked with the two interlocking recesses 8E on the large fire-resistant tile 28C, and the two interlocking recesses 8E on the large fire-resistant tile 28A are interlocked with the two interlocking protrusions 8D on the large fire-resistant tile 28B. Figure 16 shows interlocking large fire-resistant tiles 28A, 28B, and 28C. However, the design is not limited to these; a single type of non-interlocking large fire-resistant tile may be used without forming the interlocking protrusions 8D and interlocking recesses 8E.

[0036] [3. Construction method] The above shows examples of rectangular fire-resistant tiles to which the construction method of the present invention can be applied. The construction method of the present invention using these fire-resistant tiles will now be described below. For the sake of simplicity, this explanation will proceed using an example of installing fire-resistant tile 2, which is a "seagull-type fire-resistant tile," from among the various types of fire-resistant tiles mentioned above, namely, "seagull-type fire-resistant tile (non-interlocking type)," "seagull-type fire-resistant tile (interlocking type)," "seagull-type fire-resistant tile (interlocking and half-split type)," "block-type fire-resistant tile," and "large fire-resistant tile." However, by fixing the hooks 5 to the fins 3 in a regular arrangement corresponding to the number and position of recesses formed on the back surface of the fire-resistant tiles that are to be arranged in a line on the water pipe panel, the construction method of the present invention can be applied not only to "seagull-shaped fire-resistant tiles (non-interlocking type)" but also to any of the following types of fire-resistant tiles: "seagull-shaped fire-resistant tiles (interlocking type)", "seagull-shaped fire-resistant tiles (interlocking and half-split type)", "block-shaped fire-resistant tiles", and "large fire-resistant tiles".

[0037] Figure 17 shows the fire-resistant tiles 2 shown in Figure 1, numbered 2-1, 2-2, 2-3, ..., 2-18. These numbers are used in the following explanation to indicate the order in which the fire-resistant tiles 2 are installed. In Figure 17, tile sets 7A and 7B are the first tile sets, so three rows of fire-resistant tiles 2 are arranged horizontally, that is, from bottom to top, in the order of bottom row, middle row, and top row. Also, horizontally, tile sets 7A and 7B, which are the first tile sets, are placed next to each other, so tile set 7A has three vertical columns and tile set 7B has three vertical columns, for a total of six columns of fire-resistant tiles 2. Therefore, a total of (3 × (3 + 3)) = 18 fire-resistant tiles 2 are installed by combining tile sets 7A and 7B. Therefore, the six fire-resistant tiles 2 placed in the bottom row were numbered from left to right as 2-1, 2-2, 2-3, 2-4, 2-5, and 2-6; the six fire-resistant tiles 2 placed in the middle row were numbered from left to right as 2-7, 2-8, 2-9, 2-10, 2-11, and 2-12; and the six fire-resistant tiles 2 placed in the top row were numbered from left to right as 2-13, 2-14, 2-15, 2-16, 2-17, and 2-18. In addition, the hooks 5 were numbered to correspond to the numbering of each fire-resistant tile 2. Specifically, the six hooks 5 in the bottom row were numbered 5-1, 5-2, 5-3, 5-4, 5-5, and 5-6 from left to right; the six hooks 5 in the middle row were numbered 5-7, 5-8, 5-9, 5-10, 5-11, and 5-12 from left to right; and the six hooks 5 in the top row were numbered 5-13, 5-14, 5-15, 5-16, 5-17, and 5-18 from left to right.

[0038] Now, let's begin the explanation of the construction method. In Figure 17, the water pipe panel 4 has multiple hooks 5 regularly fixed by welding or other means to every other fin 3 in the horizontal direction. We will begin the explanation from the state where no fire-resistant tiles 2 have been placed yet. (1) First step The worker will proceed with the explanation that they will be responsible for installing fire-resistant tiles 2 in tile sets 7A and 7B. In the first step, one of several fire-resistant tiles is designated as a reference tile, and without applying fire-resistant jointing material to its back surface, it is hung on a number of reference hooks corresponding to the number of recesses formed on the back surface of the reference tile. Therefore, the worker first selects a reference tile from the fire-resistant tiles 2 that are to be installed. Considering the ease of the work, it is desirable to start installing the fire-resistant tiles 2 that are to be located at the lower end of the tile arrangement and at the horizontal end. Here, we will proceed assuming that the worker has first selected fire-resistant tile 2-1, which is planned to be located at the leftmost end of the bottom row of tile set 7A, as the reference tile. Although we will proceed with fire-resistant tile 2-1 as the reference tile, the worker may select any fire-resistant tile 2 at any location as the reference tile at their discretion.

[0039] Since fire-resistant tile 2-1 has only one recess 6, the number of standard hooks corresponding to the number of recesses 6 is only hook 5-1. If, for example, a "large fire-resistant tile" has multiple recesses 6, then the number of horizontal hooks 5 corresponding to the number of recesses will be the standard hooks. Therefore, the number of standard hooks can be one or more.

[0040] The worker hooks the recessed area 6 on the back of the fire-resistant tile 2-1, which has been selected as the reference tile, onto the reference hook, hook 5-1, without applying fire-resistant jointing material such as mortar to the back of the tile. Because the fire-resistant tile 2-1 is simply hooked onto hook 5-1 without applying fire-resistant jointing material to the back of the fire-resistant tile 2-1, gravity allows the tip of the L-shaped hook 5-1 to naturally penetrate as far as possible into the recessed area 6. In other words, it can reach as far as possible into the uppermost part of the recessed area 6. Next, the top edge of fire-resistant tile 2-1 is aligned horizontally. The position of the top edge and the position of the side edge aligned in this way become the reference position in the row and column where the reference tile is placed. Here, the position of the top edge of fire-resistant tile 2-1 becomes the designed position relative to the top edges of each of the multiple fire-resistant tiles 2 placed in the bottom row. Also, the position of the side edge of fire-resistant tile 2-1 becomes the designed position relative to the side edges of each of the multiple fire-resistant tiles 2 placed in the vertical column of fire-resistant tile 2-1.

[0041] (2)Second process In the second step, after the first step, fire-resistant jointing material is applied to the back of one fire-resistant tile from among several fire-resistant tiles, which is different from the reference tile. Then, the fire-resistant tile with the fire-resistant jointing material is hooked onto a number of hooks corresponding to the number of recesses, including the hook adjacent to the reference hook. Finally, while aligning it with the reference tile, the fire-resistant tile with the fire-resistant jointing material is pressed towards the water pipe panel to secure it. Therefore, the worker first selects which fire-resistant tile 2 to fix to the reference tile, fire-resistant tile 2-1, from among the fire-resistant tiles 2 adjacent to it in the vertical, horizontal, and vertical directions. In this case, since the reference tile is fire-resistant tile 2-1, the candidates for the fire-resistant tile 2 to be fixed are either fire-resistant tile 2-7, which is planned to be located one position above fire-resistant tile 2-1, or fire-resistant tile 2-2, which is planned to be located one position to the right of fire-resistant tile 2-1. When a worker selects fire-resistant tile 2-2 for the fire-resistant tile 2 to be fixed, the worker applies a fire-resistant jointing material such as mortar, which will serve as an adhesive, to the back of fire-resistant tile 2-2, and hooks the single recess 6 that fire-resistant tile 2-2 has onto hooks 5-2, which are "numbered by the number of recesses, including the hook immediately adjacent to the standard hook 5-1." In this case, since fire-resistant tile 2 has only one recess 6, the number of hooks 5 corresponding to the recess 6 is also one. However, as mentioned above, if the fire-resistant tile has multiple recesses 6, the number of hooks 5 corresponding to the recess 6 will also be multiple. Since fire-resistant jointing material is filled into the recess 6 of the fire-resistant tile 2-2, the fire-resistant tile 2-2 is positioned so that its upper end aligns with the upper end of the reference tile, fire-resistant tile 2-1, and while vibrating the fire-resistant tile 2-2 vertically in the longitudinal direction of the boiler water tube 1 to ensure that the thickness of the fire-resistant jointing material is uniform to a predetermined thickness of approximately 10 to 20 mm, the fire-resistant tile 2-2 is pressed and fixed toward the water tube panel 4. At this time, since the lateral dimension of the recess 6 of the fire-resistant tile 2 is substantially the same as the lateral dimension of the tip of the L-shaped hook 5, the position of the side end of the fixed fire-resistant tile 2-2 naturally coincides with the designed position. Since the upper and side edges of the fixed fire-resistant tile 2-2 coincide with the designed positions, fire-resistant tile 2-2 can be treated as a new reference tile for aligning fire-resistant tiles 2 to be installed in subsequent processes to their designed positions. As mentioned above, since spacer 2C is placed on the back of fire-resistant tile 2, the fire-resistant joint material can be made to the specified thickness simply by pressing fire-resistant tile 2-2 toward the water pipe panel.

[0042] If a worker selects fire-resistant tile 2-7 to be fixed, the worker applies fire-resistant jointing material such as mortar to the back of fire-resistant tile 2-7 and hooks the single recess 6 on fire-resistant tile 2-7 onto hooks 5-7, which are "numbered by the number of recesses, including the hook adjacent to the standard hook 5-1." If a fire-resistant tile has multiple recesses 6, the number of hooks 5 corresponding to the recesses 6 will also be multiple, as described above. Since fire-resistant jointing material is filled into the recess 6 of fire-resistant tile 2-7, align it so that the position of the side edge of fire-resistant tile 2-7 matches the position of the side edge of the reference tile, fire-resistant tile 2-1. However, even if the side edges are aligned, it is difficult to position the top edge of the fire-resistant tiles placed in the vertical rows of the reference tile at the designed position. Therefore, we utilize the fact that two adjacent fire-resistant tiles in the vertical, horizontal, or vertical directions are designed to have a predetermined width of space between them. In other words, when aligning the fire-resistant tile 2-7 so that its side edge aligns with the side edge of the reference tile, fire-resistant tile 2-1, the distance between the upper edge of fire-resistant tile 2-1 and the lower edge of fire-resistant tile 2-7 is measured to be the predetermined width, and while vibrating the fire-resistant tile 2-7 vertically in the longitudinal direction of the boiler water tube 1, the fire-resistant tile 2-7 is pressed and fixed toward the water tube panel 4. Since the upper and lower ends and side ends of the fixed fire-resistant tile 2-7 coincide with the designed positions, fire-resistant tile 2-7 can be treated as a new reference tile for aligning the fire-resistant tile 2 to be installed in subsequent processes to the designed positions. Furthermore, all fire-resistant tiles 2 fixed in subsequent processes will be fixed in their designed positions, and can therefore be treated as new reference tiles.

[0043] (3) Third step In the third stage, after the second stage, one of the following branching processes—the first branching process or the second branching process—is performed. The first branching process is performed only once throughout the entire process. (3-1) First branching process In the first branching process, the reference tile is removed from the reference hook, fire-resistant jointing material is applied to its back surface, and then the reference tile is hooked onto the reference hook. In the second process, the reference tile is aligned with the fire-resistant tile that was fixed, and then pressed and fixed toward the water pipe panel. Therefore, the worker first removes the reference tile, fire-resistant tile 2-1, from the reference hook, hook 5-1. Since fire-resistant tile 2-1 is simply hooked onto hook 5-1 without applying fire-resistant jointing adhesive, it can be easily removed. Then, after applying fire-resistant jointing material to the back of fire-resistant tile 2-1, the recess 6 of fire-resistant tile 2-1 is hooked onto hook 5-1 again. Then, fire-resistant tile 2-2 or fire-resistant tile 2-7, which has already been fixed in the designed position, is treated as a new reference tile, and while aligning it with fire-resistant tile 2-2 or fire-resistant tile 2-7, fire-resistant tile 2-1 is pressed and fixed toward the water pipe panel 4. Specifically, the fire-resistant tile 2-1 is fixed to the water pipe panel 4 as follows.

[0044] If fire-resistant tile 2-2, located one tile to the right of fire-resistant tile 2-1, is fixed, the upper end of fire-resistant tile 2-1 is aligned with the upper end of fire-resistant tile 2-2, which is the new reference tile, and while fire-resistant tile 2-1 is vibrated vertically along the length of the boiler water tube 1, it is pressed and fixed toward the water tube panel 4. The upper and side ends of the fixed fire-resistant tile 2-1 then coincide with the designed positions. Although fire-resistant tile 2-1 was originally a reference tile, by being fixed to the water pipe panel 4 in the first branching process, it can be treated as a new reference tile for aligning the fire-resistant tiles 2 to be installed in subsequent processes to their designed positions.

[0045] If fire-resistant tile 2-7, located one position above fire-resistant tile 2-1, is fixed, when aligning the fire-resistant tile 2-1 so that its side edge aligns with the side edge of the new reference tile, fire-resistant tile 2-7, the distance between the lower edge of fire-resistant tile 2-7 and the upper edge of fire-resistant tile 2-1 is measured to be the predetermined width, and while vibrating fire-resistant tile 2-1 vertically in the longitudinal direction of the boiler water tube 1, fire-resistant tile 2-1 is pressed and fixed toward the water tube panel 4. The upper and side edge positions of the fire-resistant tile 2-1 fixed in this way coincide with the designed positions. Although fire-resistant tile 2-1 was originally a reference tile, by being fixed to the water pipe panel 4 in the first branching process, it can be treated as a new reference tile for aligning the fire-resistant tiles 2 to be installed in subsequent processes to their designed positions.

[0046] (3-2) Second branching process In the second branching process, fire-resistant jointing material is applied to the back of one fire-resistant tile from among several fire-resistant tiles, which is different from the fire-resistant tiles fixed in all the preceding processes of this process. Then, the fire-resistant tile coated with fire-resistant jointing material is hooked onto a number of hooks that are not yet hooked, including the hook adjacent to the hook to which the fire-resistant tile fixed in the process immediately preceding or two processes prior to this process was hooked, and a number of hooks corresponding to the number of recesses are used. Finally, the fire-resistant tile coated with fire-resistant jointing material is pressed toward the water pipe panel and fixed in place while aligning it with the fire-resistant tile fixed in the process immediately preceding or two processes prior to this process. Therefore, the worker first selects one fire-resistant tile 2 that is different from the fire-resistant tile 2 fixed in all the preceding steps of this process. As will be described later, in the fourth step which is carried out after the third step, the third step is repeated, so when the second branching step of the third step is carried out for the first time, the first branching step of the third step may have already been carried out. Therefore, when the second branching process is first carried out, the "fire-resistant tile 2 fixed in all preceding processes of this process" can be in two states: (A) fire-resistant tile 2-2 fixed in the second process, or (B) fire-resistant tile 2-2 fixed in the second process and fire-resistant tile 2-1 fixed in the first branching process. However, in case (A), fire-resistant tile 2-1 is not fixed but remains hooked onto hook 5-1. In this process, namely the second branching process, the "different fire tile" is attached to the "hook that does not yet have any fire tile attached to it." Therefore, in light of (A) and (B), fire tile 2-1 and fire tile 2-2 are excluded from the target of the "different fire tile 2." However, since the process involves "aligning with the fire-resistant tile fixed in the process immediately preceding this process or the process two steps prior to this process," ultimately, when the second branching process is performed for the first time, the "one different fire-resistant tile" mentioned above will be either fire-resistant tile 2-3, located one position to the right of fire-resistant tile 2-2, or fire-resistant tile 2-8, located one position above fire-resistant tile 2-2, in the case of (A). Also, in the case of (B), when the second branching process is performed for the first time, the "one different fire-resistant tile" mentioned above will be either the two fire-resistant tiles in the case of (A), namely fire-resistant tile 2-3 and fire-resistant tile 2-8, or fire-resistant tile 2-7, located one position above the fixed fire-resistant tile 2-1. Furthermore, in the construction method of the present invention, the positions of the upper and lower ends and the side ends of the "fixed fire-resistant tiles" coincide with the designed positions, so all "fixed fire-resistant tiles" can be treated as the new reference tiles described above. Accordingly, not only the fire-resistant tiles fixed in the "step immediately preceding this step," but also the fire-resistant tiles fixed in the "step two steps prior to this step" can be treated as the new reference tiles.

[0047] In cases (A) and (B), if the worker selects fire tile 2-3 as the "one different fire tile" described above, the worker applies a fire-resistant jointing material such as mortar, which will serve as an adhesive, to the back of fire tile 2-3, and hooks the single recess 6 that fire tile 2-3 has onto hooks 5-3, which include "the hook one position away from the hook on which the fixed fire tile is hung, and the number of hooks corresponding to the number of recesses on which no fire tile has yet been hung." Then, the fixed fire-resistant tile 2-2 is treated as a new reference tile, and while aligning it so that the upper end of fire-resistant tile 2-3 coincides with the upper end of fire-resistant tile 2-2, and while vibrating fire-resistant tile 2-3 vertically in the longitudinal direction of the boiler water tube 1, fire-resistant tile 2-3 is pressed and fixed toward the water tube panel 4. Since the upper and side edges of the fixed fire-resistant tiles 2-3 coincide with the designed positions, fire-resistant tiles 2-3 can be treated as new reference tiles for aligning fire-resistant tiles 2, which are to be installed in subsequent steps, to their designed positions.

[0048] In cases (A) and (B), if the worker selects fire tile 2-8 as the "one different fire tile" described above, the worker applies a fire-resistant jointing material such as mortar, which will serve as an adhesive, to the back of fire tile 2-8, and hooks the single recess 6 that fire tile 2-8 has onto hooks 5-8, which include "the hook one position away from the hook on which the fixed fire tile is hooked, and a number of hooks corresponding to the number of recesses on which no fire tile has yet been hooked." Then, treating the fixed fire-resistant tile 2-2 as a new reference tile, and aligning it so that the side edge of fire-resistant tile 2-8 coincides with the side edge of fire-resistant tile 2-2, the distance between the upper edge of fire-resistant tile 2-2 and the lower edge of fire-resistant tile 2-8 is measured to be the predetermined width, and while vibrating the fire-resistant tile 2-8 vertically in the longitudinal direction of the boiler water tube 1, the fire-resistant tile 2-8 is pressed and fixed toward the water tube panel 4. Since the upper and lower ends and side ends of the fixed fire-resistant tile 2-8 coincide with the designed positions, fire-resistant tile 2-8 can be treated as a new reference tile for aligning the fire-resistant tile 2 to be installed in subsequent processes to the designed positions.

[0049] In case (B), if the worker selects fire tile 2-7 as the "one different fire tile" mentioned above, the worker applies a fire-resistant jointing material such as mortar, which will serve as an adhesive, to the back of fire tile 2-7, and hooks the single recess 6 that fire tile 2-7 has onto hooks 5-7, which include the hook adjacent to the hook on which the fixed fire tile is hooked, and which are a number of hooks corresponding to the number of recesses on which no fire tile has yet been hooked. Then, although the fixed fire-resistant tile 2-1 was a reference tile before being fixed, it is treated as a new reference tile, and when aligning it so that the position of the side edge of fire-resistant tile 2-7 matches the position of the side edge of fire-resistant tile 2-1, the distance between the position of the upper edge of fire-resistant tile 2-1 and the position of the lower edge of fire-resistant tile 2-7 is measured to be the predetermined width, and while vibrating fire-resistant tile 2-7 vertically in the longitudinal direction of the boiler water tube 1, fire-resistant tile 2-7 is pressed toward the water tube panel 4 and fixed in place. Since the upper and lower ends and side ends of the fixed fire-resistant tile 2-7 coincide with the designed positions, fire-resistant tile 2-7 can be treated as a new reference tile for aligning the fire-resistant tile 2 to be installed in subsequent processes to the designed positions.

[0050] (4) Fourth step In the fourth step, after performing the third step for the first time, the third step is repeated a predetermined number of times. Here, the predetermined number of times can be arbitrarily determined by the worker. In other words, the construction method of the present invention may be performed multiple times on a single tile set. However, generally speaking, from the viewpoint of improving construction speed, the predetermined number of times should be the number of times required to install all the fire-resistant tiles contained in at least one tile set. In other words, it is desirable to perform the construction method of the present invention on one or more tile sets. When a worker is responsible for multiple adjacent tile sets, and the type of fire-resistant tile contained within these tile sets is the same, each tile set may be treated as a single tile set, and the prescribed number of times may be the number of times until all the fire-resistant tiles contained within that treated single tile set have been installed. Furthermore, since the predetermined number of times is the number of times the third process is repeated after being performed once, the predetermined number is obtained by subtracting 1 from the total number of times the third process has been performed.

[0051] For example, when installing fire-resistant tiles 2 in units of tile assembly 7A, and in the case of (A) above, fire-resistant tile 2-2 of tile assembly 7A, which was fixed in the first step immediately preceding the third step, is treated as a new reference tile. Fire-resistant tile 2-3 is fixed in the second branching step (1st time) of the third step, fire-resistant tile 2-9 is fixed in the second branching step (2nd time) of the third step using the fixed fire-resistant tile 2-3 as a new reference tile, and fire-resistant tile 2-8 is fixed in the second branching step (3rd time) of the third step using the fixed fire-resistant tile 2-9 as a new reference tile. Fire-resistant tiles 2 can then be installed sequentially in this manner. Subsequently, fire-resistant tile 2-7 is fixed in the second branching step (4th time) of the third step, fire-resistant tile 2-13 is fixed in the second branching step (5th time) of the third step, fire-resistant tile 2-14 is fixed in the second branching step (6th time) of the third step, and fire-resistant tile 2-15 is fixed in the second branching step (7th time) of the third step. Finally, by fixing fire-resistant tile 2-1 in the first branching step of the third process (the first time, but the eighth time in the third process), all the fire-resistant tiles 2 contained within the tile assembly 7A can be installed. Therefore, in this case, the above-mentioned number of times is (8-1)=7.

[0052] Furthermore, since the fire-resistant tiles contained within adjacent tile sets 7A and 7B in Figure 17 are the same type of fire-resistant tile 2, if tile sets 7A and 7B are considered as a single tile set and the installation of fire-resistant tile 2 is carried out, and in case (B) above, since the first branching step of the third process has already been carried out once, only the second branching step of the third process will be repeated. In this case, for example, similar to the example in the tile assembly 7A unit described above, the fire-resistant tile 2-2 of tile assembly 7A, which was fixed in the previous step, is treated as a new reference tile, and the fire-resistant tile 2-3 is fixed in the second branching step (1st time) of the third step, the fire-resistant tile 2-4 of tile assembly 7B is fixed in the second branching step (2nd time) of the third step, the fire-resistant tile 2-5 is fixed in the second branching step (3rd time) of the third step, the fire-resistant tile 2-6 is fixed in the second branching step (4th time) of the third step, the fire-resistant tile 2-12 is fixed in the second branching step (5th time) of the third step, the fire-resistant tile 2-11 is fixed in the second branching step (6th time) of the third step, the fire-resistant tile 2-10 is fixed in the second branching step (7th time) of the third step, and the fire-resistant tile 2-9 of tile assembly 7A is fixed in the second branching step (8th time) of the third step, thus allowing the fire-resistant tiles 2 to be installed sequentially across the two tile assemblies, from the lower row to the upper row. Then, after installing all the fire-resistant tiles 2 in a row, the process is repeated, and all the fire-resistant tiles 2 in the row above are installed. By performing the second branching step of the third process a total of 16 times, the fire-resistant tiles 2-18 of tile assembly 7B can be fixed in place by the second branching step of the third process (the 16th time, however, the 17th time as part of the third process). This allows all the fire-resistant tiles 2 contained within tile assembly 7A and tile assembly 7B to be installed. In this case, the predetermined number of times is (17 - 1) = 16.

[0053] (5) Post-processing After all the fire-resistant tiles within each tile set assigned to the worker have been fixed in place, as mentioned earlier, the worker applies fire-resistant jointing material such as mortar or castable to the gaps between two adjacent fire-resistant tiles in the vertical, horizontal, or vertical directions within a single tile set. In addition, the worker fills the gaps between two adjacent tile sets with fire-resistant expansion-allowance filler such as fibercast. In Figure 17, fire-resistant jointing material is applied between two adjacent fire-resistant tiles 2 in tile set 7A, and also between two adjacent fire-resistant tiles 2 in tile set 7B. Fire-resistant expansion filler material is then embedded between tile set 7A and tile set 7B, around tile set 7A, and around tile set 7B. This improves the protective performance of the boiler water tubes 1 and prevents cracking and detachment of the refractory tiles 2 due to thermal expansion, thereby extending the lifespan of the combustion furnace.

[0054] As described above, according to the construction method of the invention, in the second step, the fire-resistant tile is fixed to the water pipe panel after being aligned using a reference tile that was simply hooked in the first step, in the third step, the fire-resistant tile fixed in the second step is treated as a new reference tile and aligned, and another fire-resistant tile is fixed to the water pipe panel, and in the fourth step, the third step is repeated a predetermined number of times. In other words, by sequentially changing the fire-resistant tile that serves as the reference for alignment, multiple fire-resistant tiles can be easily and accurately aligned and installed in their designated positions. [Explanation of Symbols]

[0055] 1. Boiler water tube 2, 8, 9, 10, 11, 12, 13, 14, 15, 16, 20, 21, 23, 28 Fire-resistant tiles 2A, 8A, 9A, 10A central part 2B Side 2C Spacer 3 fins 4, 4′, 4′′ Water pipe panel 5 hooks 6 recesses 7A, 7B, 7A′, 7B′, 7A′′, 7B′′, 7A′′′ Tile set 8D Mating protrusion 8E Mating recess 18 First row 19 Second row 20A U-shaped groove 26 Welding lines

Claims

1. In order to align and fix a plurality of rectangular refractory tiles to a water tube panel comprising a plurality of boiler water tubes evenly arranged horizontally, a plurality of fins connecting two horizontally adjacent boiler water tubes, and a plurality of hooks provided on the plurality of fins, the plurality of hooks are fixed to the plurality of fins in a regular arrangement corresponding to the positions of recesses formed on the back surface of the aligned refractory tiles. In a method for installing fire-resistant tiles for protecting boiler water tubes, in which a fire-resistant jointing material is applied to the back surface of the fire-resistant tile, and the recesses are hooked onto a number of hooks corresponding to the number of recesses to secure the tiles, so that a plurality of the fire-resistant tiles are arranged in a line with predetermined intervals between them, and one fire-resistant tile is fixed to the upper surface of two or more boiler water tubes, The first step involves using one of the multiple fire-resistant tiles as a reference tile, and without applying fire-resistant jointing material to its back surface, hanging it on a number of reference hooks corresponding to the number of recesses formed on the back surface of the reference tile, After the first step, a second step is taken in which fire-resistant jointing material is applied to the back surface of one fire-resistant tile from among the plurality of fire-resistant tiles, which is different from the reference tile, and the fire-resistant tile with the fire-resistant jointing material applied is hooked onto a number of hooks corresponding to the number of recesses, including the hook adjacent to the reference hook, and then the fire-resistant tile with the fire-resistant jointing material applied is pressed toward the water pipe panel and fixed in place while being aligned with the reference tile. After the second step, the reference tile is removed from the reference hook, fire-resistant jointing material is applied to its back surface, and then the reference tile is hooked onto the reference hook. Then, while aligning it with the fire-resistant tile fixed in the second step, the reference tile is pressed toward the water pipe panel and fixed in a first branching step. Of the multiple fire-resistant tiles, fire-resistant jointing material is applied to the back surface of one fire-resistant tile that is different from the fire-resistant tile fixed in all the steps preceding this step, and of the multiple hooks, the step immediately preceding this step or the two steps of this step A third step involves performing one of two branching steps: a second branching step in which, after hooking a fire-resistant tile coated with fire-resistant joint material onto a number of hooks corresponding to the number of recesses, which have not yet had any fire-resistant tiles hooked onto them, and then pressing and fixing the fire-resistant tile coated with fire-resistant joint material toward the water pipe panel while aligning it with the fire-resistant tile fixed in the step immediately preceding this step or the step two steps prior to this step; A fourth step is performed in which the third step is repeated a predetermined number of times after the third step. A method for installing fire-resistant tiles for protecting boiler water tubes.

2. The fixed multiple fire-resistant tiles are divided into multiple rectangular tile sets in which multiple fire-resistant tiles are arranged vertically or horizontally. The process involves filling the predetermined interval between two adjacent tile sets among the multiple tile sets with a fire-resistant expansion filler material, The process of applying fire-resistant jointing material to the predetermined interval between two fire-resistant tiles that are included in one tile set and are adjacent to each other. A method for installing fire-resistant tiles for protecting boiler water tubes according to claim 1, further comprising the above.

3. The method for installing fire-resistant tiles for protecting boiler water pipes according to claim 2, wherein the reference hook is located at the lowest level inside the tile assembly, or is a hook for hooking a fire-resistant tile fixed to either the lowest level or one of its ends.

4. The method for installing fire-resistant tiles for protecting boiler water tubes according to claim 3, wherein the tile arrangement consists of multiple tile arrangements of only one type, such as a first tile arrangement in which three fire-resistant tiles are arranged vertically and three horizontally, a second tile arrangement in which two fire-resistant tiles are arranged vertically and two horizontally, a third tile arrangement in which three or more fire-resistant tiles are arranged vertically and two horizontally, or a fourth tile arrangement in which two fire-resistant tiles are arranged vertically and three or more horizontally, a fifth tile arrangement in which tiles are arranged in a single row only vertically, or a sixth tile arrangement in which tiles are arranged in a single row only horizontally, or a mixture of multiple types of tile arrangements from the first to sixth tile arrangements.

5. The fire-resistant tile comprises a first fitted fire-resistant tile having a fitting projection protruding from above the central part and a fitting recess formed below the central part that can fit the fitting projection of another fire-resistant tile, a second fitted fire-resistant tile having the same shape as the first fitted fire-resistant tile except that the fitting recess is not formed, and a third fitted fire-resistant tile having the same shape as the first fitted fire-resistant tile except that the fitting projection is not formed. In the first tile set, the third tile set, or the fifth tile set in which three or more fire-resistant tiles are fixed in the vertical direction, the interlocking second fire-resistant tile is fixed to the lowest level in the vertical direction, the interlocking third fire-resistant tile is fixed to the uppermost level in the vertical direction, and the interlocking first fire-resistant tile is fixed to the second level or higher in the vertical direction and below the uppermost level. A method for installing fire-resistant tiles for protecting boiler water tubes according to claim 4, wherein in the second tile set, the fourth tile set, or the fifth tile set in which two of the fire-resistant tiles are fixed in the vertical direction, the interlocking second fire-resistant tile is fixed to the lowest position in the vertical direction, and the interlocking third fire-resistant tile is fixed to the uppermost position in the vertical direction.

6. The method for installing a fire-resistant tile for protecting boiler water tubes according to any one of claims 1 to 4, wherein the fire-resistant tile has multiple recesses formed near the center for hooking hooks and covers the upper surfaces of three or more boiler water tubes.

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