真空清洗爐檢修內容概述

(1) 編制真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)使用(yong)維(wei)(wei)護(hu)(hu)操(cao)(cao)作規程，建立真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)運行(xing)(xing)記錄和(he)修(xiu)理(li)檔案，統計運行(xing)(xing)累積工(gong)作時(shi)間，加(jia)強真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)日(ri)常(chang)維(wei)(wei)護(hu)(hu)，掌握設(she)備(bei)(bei)技術狀態(tai)變化(hua)趨(qu)勢(shi)，及早發現故(gu)障損壞苗頭，避免屬于(yu)事(shi)故(gu)搶修(xiu)性質的(de)(de)(de)維(wei)(wei)修(xiu)，并根(gen)據真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)工(gong)作負荷和(he)運行(xing)(xing)狀況，提(ti)前有針對性地準備(bei)(bei)真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)修(xiu)理(li)用(yong)零部(bu)件(jian)(jian)，編制真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)運行(xing)(xing)維(wei)(wei)護(hu)(hu)方案。如(ru)真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)加(jia)熱(re)元件(jian)(jian)的(de)(de)(de)使用(yong)壽命長短與工(gong)作溫(wen)度(du)、真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)內產品介(jie)質、產品數量及操(cao)(cao)作情況等許(xu)多(duo)因素有關，在每天24小(xiao)時(shi)加(jia)工(gong)生產的(de)(de)(de)情況下(xia)，真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)加(jia)熱(re)元件(jian)(jian)和(he)隔熱(re)屏(ping)的(de)(de)(de)更換大(da)約每兩(liang)三年進行(xing)(xing)一(yi)次(ci)．這取決(jue)于(yu)釬焊工(gong)作的(de)(de)(de)類型和(he)使用(yong)次(ci)數。真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)一(yi)般(ban)在春(chun)秋(qiu)季(ji)節泄(xie)漏(lou)故(gu)障較多(duo)，長期閑置(zhi)的(de)(de)(de)真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)在才(cai)次(ci)使用(yong)時(shi)真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)爐(lu)(lu)(lu)泄(xie)漏(lou)故(gu)障比較易發生。這時(shi)間就必須進行(xing)(xing)真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)檢(jian)漏(lou)，真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)檢(jian)漏(lou)一(yi)般(ban)采取每月(yue)一(yi)次(ci)測(ce)壓升(sheng)率(在常(chang)溫(wen)下(xia)，關閉所有真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)閥，停止真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)系統運轉，1Omin后(hou)讀(du)一(yi)個數，1h后(hou)再讀(du)一(yi)個數，兩(liang)數之(zhi)差(cha)是壓升(sheng)率的(de)(de)(de)數值)，掌握設(she)備(bei)(bei)泄(xie)漏(lou)變化(hua)趨(qu)勢(shi)，如(ru)真(zhen)(zhen)空(kong)(kong)(kong)(kong)(kong)(kong)設(she)備(bei)(bei)連續停機一(yi)個禮拜，要空(kong)(kong)(kong)(kong)(kong)(kong)運轉一(yi)次(ci)（進行(xing)(xing)烘爐(lu)(lu)(lu)）。 

在(zai)真(zhen)(zhen)空(kong)系統檢(jian)漏(lou)(lou)時(shi)，除臨時(shi)應急維(wei)修用(yong)真(zhen)(zhen)空(kong)泥糊堵外，有氦質(zhi)(zhi)譜(pu)檢(jian)漏(lou)(lou)儀可(ke)用(yong)氦質(zhi)(zhi)譜(pu)檢(jian)漏(lou)(lou)儀進(jin)行真(zhen)(zhen)空(kong)檢(jian)漏(lou)(lou)，如沒氦質(zhi)(zhi)譜(pu)檢(jian)漏(lou)(lou)儀可(ke)用(yong)醫用(yong)針(zhen)管(guan)吸丙酮或乙醚射到所懷疑的(de)(de)漏(lou)(lou)點處，觀察真(zhen)(zhen)空(kong)表讀數有無變(bian)化(hua)。也可(ke)制作(zuo)留有插真(zhen)(zhen)空(kong)硅(gui)管(guan)孔的(de)(de)盲板(ban)，分段封堵真(zhen)(zhen)空(kong)管(guan)路，進(jin)行檢(jian)漏(lou)(lou)。找(zhao)到漏(lou)(lou)點以后進(jin)行維(wei)修（一(yi)般密封圈(quan)老化(hua)比較多），定時(shi)檢(jian)查(cha)真(zhen)(zhen)空(kong)爐的(de)(de)滑閥泵(beng)、羅茨泵(beng)、維(wei)持泵(beng)、擴(kuo)散泵(beng)油，如發現油遇水乳化(hua)，真(zhen)(zhen)空(kong)下跌(die)，必須更換上面4個(ge)泵(beng)油，應每(mei)周檢(jian)查(cha)一(yi)次油位(wei)和油的(de)(de)質(zhi)(zhi)量(liang)。擴(kuo)散泵(beng)油油擴(kuo)散泵(beng)有積炭可(ke)用(yong)化(hua)學(xue)酸洗(xi)的(de)(de)方法清洗(xi)。

(2)真(zhen)空爐(lu)(lu)維(wei)修好后的使(shi)用(yong)初期要經常進(jin)行(xing)檢查，檢查使(shi)用(yong)后的真(zhen)空爐(lu)(lu)表溫度(du)和爐(lu)(lu)子實際溫度(du)是(shi)否一致(定期進(jin)行(xing)真(zhen)空計、溫控(kong)儀、熱(re)電偶、電壓表、電流(liu)表的檢定、校準工作），檢查三相(xiang)加(jia)熱(re)體是(shi)否存在過(guo)熱(re)損傷情況、溫度(du)不均或發(fa)白等現象。對于三相(xiang)高溫真(zhen)空爐(lu)(lu)，以及真(zhen)空電阻爐(lu)(lu)容量超過(guo)100kW時，每相(xiang)、每一個加(jia)熱(re)區都應安(an)裝(zhuang)有電流(liu)表，發(fa)現真(zhen)空爐(lu)(lu)溫與儀表指示(shi)不正常，及時分析處理(li)。 

(3)要避免加(jia)(jia)(jia)熱(re)元件和產品(pin)發生反應，尤(you)其(qi)足銅、鋁、鋅(xin)、錫、鉛等與真空加(jia)(jia)(jia)熱(re)元件接(jie)觸(chu)，無論是細粉、熔液或蒸汽等，防(fang)止在電(dian)加(jia)(jia)(jia)熱(re)體表面(mian)侵蝕形成“麻(ma)坑”，截面(mian)變小(xiao)，*過熱(re)而燒斷。

(4)不(bu)(bu)能超負(fu)荷使(shi)用真(zhen)(zhen)空(kong)爐，真(zhen)(zhen)空(kong)爐的(de)*使(shi)用溫(wen)(wen)(wen)度(du)是指元(yuan)件(jian)在真(zhen)(zhen)空(kong)中允許的(de)本身(shen)表面(mian)溫(wen)(wen)(wen)度(du)，并不(bu)(bu)是指加(jia)熱(re)物質的(de)溫(wen)(wen)(wen)度(du)或(huo)加(jia)熱(re)元(yuan)件(jian)周圍(wei)的(de)溫(wen)(wen)(wen)度(du)。要注意(yi)真(zhen)(zhen)空(kong)電熱(re)元(yuan)件(jian)本身(shen)的(de)溫(wen)(wen)(wen)度(du)一股(gu)比(bi)它(ta)周圍(wei)的(de)介質溫(wen)(wen)(wen)度(du)或(huo)被加(jia)熱(re)溫(wen)(wen)(wen)度(du)高100℃。

(5)真(zhen)空爐(lu)子升溫(wen)后，不(bu)能突然(ran)破壞(huai)真(zhen)空系統，更不(bu)可打開真(zhen)空爐(lu)爐(lu)門(men)。注意充(chong)大(da)氣進去前(qian),應關閉真(zhen)空計開關,防止真(zhen)空計老化。當溫(wen)度(du)高于400

℃時，不得急劇冷卻。對(dui)于真空(kong)加(jia)熱元件在溫度高、真空(kong)度不好以及冷熱變化(hua)大情況下(xia)，容易引(yin)起氧化(hua)。對(dui)于鉬加(jia)熱爐，正常使用維護(hu)中注(zhu)意應冷卻至200℃以下(xia)方可(ke)停(ting)送保(bao)護(hu)氮氣。80℃以下(xia)才能(neng)打開爐門。

(6)測量真空爐(lu)溫均勻(yun)性(xing)時，應注意測溫觸點的定位捆綁方式(shi)，以(yi)及距加(jia)熱元(yuan)件的遠近。真空爐(lu)內經(jing)常(至(zhi)少每天或每班使(shi)(shi)前(qian))用毛刷、掃帚(zhou)或壓縮空氣、吸塵(chen)器等清(qing)潔爐(lu)膛，要防止(zhi)爐(lu)內氧(yang)(yang)化(hua)皮等雜質(zhi)掉在(zai)電熱元(yuan)件上(shang)，發(fa)(fa)生短路，甚至(zhi)燒(shao)壞鉬加(jia)熱棒。底板、鉬加(jia)熱棒、爐(lu)保(bao)溫層等耐熱鋼構件每使(shi)(shi)用一段時間，應該進行清(qing)理，嚴禁敲擊，可小(xiao)心清(qing)除其氧(yang)(yang)化(hua)皮。氧(yang)(yang)化(hua)鐵皮等雜質(zhi)如不及時清(qing)除，就會熔融處與保(bao)溫層發(fa)(fa)生打火，使(shi)(shi)鉬絲熔化(hua)。

(7)冷(leng)卻系統(tong)(tong)是真空(kong)(kong)爐(lu)的重要(yao)部分。冷(leng)卻水(shui)(shui)(shui)(shui)(shui)路(lu)應保持暢(chang)透(tou)，否則(ze)水(shui)(shui)(shui)(shui)(shui)溫(wen)升高造(zao)成停機。這是真空(kong)(kong)爐(lu)工作(zuo)時(shi)常披忽視的問題當(dang)(dang)無人管(guan)(guan)理時(shi)可(ke)能(neng)會(hui)導致真空(kong)(kong)爐(lu)的重大毀壞。用(yong)生物(wu)(wu)分解化(hua)學輔助方法處(chu)(chu)理冷(leng)卻水(shui)(shui)(shui)(shui)(shui)，目的是保持礦物(wu)(wu)質呈懸浮態，減少橡皮(pi)管(guan)(guan)、蛇形(xing)管(guan)(guan)和水(shui)(shui)(shui)(shui)(shui)套內沉(chen)淀物(wu)(wu)累積(ji)，以使水(shui)(shui)(shui)(shui)(shui)流暢(chang)通。這一(yi)般采用(yong)一(yi)種自動(dong)裝置來完成，它(ta)可(ke)以監測水(shui)(shui)(shui)(shui)(shui)的導電性(xing)，自動(dong)補(bu)充化(hua)學劑(ji)，沖冼(xian)水(shui)(shui)(shui)(shui)(shui)路(lu)，添(tian)加新鮮水(shui)(shui)(shui)(shui)(shui)。與附屬蒸氣過濾系統(tong)(tong)配合，這種方法還可(ke)以保證水(shui)(shui)(shui)(shui)(shui)的pH值控制，防止在(zai)(zai)冷(leng)卻水(shui)(shui)(shui)(shui)(shui)系統(tong)(tong)中(zhong)多余礦物(wu)(wu)質沉(chen)積(ji)。在(zai)(zai)系統(tong)(tong)工作(zuo)穩(wen)定后，至少應每月一(yi)次(ci)(ci)進行水(shui)(shui)(shui)(shui)(shui)質試驗以防過處(chu)(chu)理或(huo)欠過理。真空(kong)(kong)爐(lu)外殼和熱(re)交換器(qi)材料的試驗樣(yang)品(pin)也應放在(zai)(zai)水(shui)(shui)(shui)(shui)(shui)路(lu)系統(tong)(tong)中(zhong)，每年做(zuo)一(yi)次(ci)(ci)重量損失檢(jian)驗以檢(jian)查(cha)處(chu)(chu)理的效果。對(dui)擴(kuo)散泵的蛇形(xing)管(guan)(guan)冷(leng)卻器(qi)必須特別注意。應該經常檢(jian)查(cha)。如果堵(du)塞了，擴(kuo)散泵將(jiang)會(hui)過熱(re)并喪失功能(neng)，而且還進一(yi)步引(yin)起擴(kuo)散泵加熱(re)器(qi)燒毀，造(zao)成昂貴的、費時(shi)的修理。當(dang)(dang)蛇形(xing)冷(leng)卻水(shui)(shui)(shui)(shui)(shui)管(guan)(guan)堵(du)塞時(shi)，將(jiang)水(shui)(shui)(shui)(shui)(shui)路(lu)同水(shui)(shui)(shui)(shui)(shui)源斷開，排(pai)水(shui)(shui)(shui)(shui)(shui)并用(yong)壓縮空(kong)(kong)氣吹通或(huo)用(yong)稀醋酸溶液沖洗。