Casting Crane High Temp Maintenance | Tips, Troubleshooting & Service

Casting workshop is always in high temperature, high dust, strong corrosion environment, molten steel temperature of more than 1500 ℃, the workshop room temperature peak can reach 60 ℃, casting Crane High Temperature Maintenance has always been the core of the maintenance team of the steel plant difficulties.

Equipment to withstand long-term heat radiation, heavy load impact and dust erosion, component aging much faster than ordinary lifting equipment, maintenance is not in place to trigger brake failure, wire rope breakage, electrical insulation aging and other problems, light stop production, or cause safety accidents.

As a professional metallurgical casting crane manufacturer, Henan Mine Casting Crane Industrial has served hundreds of steel mill projects around the world, and has seen too many premature equipment scrapping and production losses due to irregular maintenance.

This casting crane high-temperature maintenance guide combined with front-line project experience, from component maintenance, troubleshooting, spare parts selection to intelligent upgrading to organize the practical methods to help companies do a good job of high-temperature lifting maintenance in steel mills, to lengthen the service life of the equipment.

High-temperature environment on the core impact of equipment

High temperature is not a single factor, but and dust, corrosive gases, high-frequency heavy load together to accelerate the loss of components, which is the molten metal Crane maintenance program is different from the fundamental reason for ordinary overhead crane.

Strong heat radiation continues to bake the steel structure, wire rope and electrical components, reducing material strength and accelerating fatigue aging. Metal dust adheres to the surface of electrical components, affecting heat dissipation and insulation, but also wear and tear transmission components. The corrosive vapor and smoke produced by smelting will accelerate the corrosion of steel structure and deterioration of electrical insulation.

Coupled with the casting Crane is usually 24 hours of continuous operation, heavy load start and stop frequently, lubrication and cooling system long-term high-load operation, it is easy to lubrication failure, overheating of components. Maintenance can not copy the general lifting equipment maintenance standards, must be adapted to the metallurgical industry lifting maintenance standards to do special design.

Key components of high-temperature maintenance points

Steel structure and thermal protection

The main beam, end beams, spreader beams are exposed to heat radiation for a long time, which is easy to appear local stress concentration and micro-cracks. Clean the dust on the surface in a timely manner, regularly check the integrity of the anti-corrosion coating and heat insulation boards, replace the coating damage in time, repair and replace the heat shield deformation in time, and do a good job of casting the Crane heat insulation protection maintenance.

Focus on the weld and overhanging stress area, regularly with Crane non-destructive testing maintenance to detect hidden cracks, high-temperature radiation can be additional workstation installed reflective insulation to reduce the impact of heat radiation. Do a good job of Crane heat shield maintenance, can effectively extend the life of the steel structure, is the converter workshop ladle crane maintenance of the basic items.

Wire rope system

Casting Crane high temperature maintenance of steel wire rope is the most important, ordinary steel wire rope by the heat of the rapid decline in strength, must choose metal core high temperature resistant special steel wire rope.

Do high-temperature wear testing of wire rope every shift, verification of broken wire, wear and rope diameter changes, more than the end-of-life standard replacement immediately. Regular maintenance with high-temperature resistant grease to keep the rope lubricated to reduce wear. Regularly check the barrel wear and weld status of the reel, and the height of the end flange meets the safety standard to prevent rope removal.

Replacement of high-temperature-resistant models with ordinary steel wire rope, not only short life, but also the risk of fracture, is a mandatory item in the high-temperature safety inspection of casting cranes, but also the core control points of the refinery lifting equipment maintenance.

Brake system

Brake is the last safety barrier for molten metal transportation, friction pads are easy to overheat and wear out under high temperature environment, resulting in longer braking distance and lower braking force.

Check the wear of friction pads every shift, and replace them if they are more than 50% of the original thickness. Priority is given to the use of high-temperature-resistant friction materials, and the replacement cycle of high-temperature brake friction pads is carried out in accordance with the standard. Regularly calibrate the braking force and brake clearance to ensure that the two sets of independent braking systems can work normally. Hydraulic brakes are regularly checked for fluid leakage and air mixing to ensure reliable braking response.

Master the correct brake high temperature maintenance methods, brake high temperature failure check, can significantly reduce the risk of brake failure. Crane emergency stop system maintenance should also be synchronized to ensure that the emergency can be reliable action.

Henan Mine  Overhead Rotating Electromagnetic Beam Crane

Bearing and reducer

High temperature will accelerate the loss of grease failure, resulting in overheating bearings, gear wear increased.

Landing professional high-temperature lubrication technology for Crane, selecting high-temperature special grease with high drip point, replenishing and replacing it regularly, monitoring the oil temperature and vibration on a daily basis, and shutting down immediately for investigation when the oil temperature exceeds the threshold. Regularly do Crane vibration analysis maintenance, early detection of bearing wear, gear meshing abnormalities and other problems, to avoid failure expansion.

Do a good job of monitoring the high temperature oil temperature reducer, can effectively extend the life of transmission components, but also metallurgical cranes in the regular maintenance cycle of the core testing items, while the focus of the Crane maintenance of the electric furnace workshop.

Electrical system

High temperature accelerates the aging of cable and component insulation, which is the main cause of electrical failure.

Do a good job of casting crane motor high temperature protection, must be equipped with H-class insulation metallurgy special motor, do a good job of motor H-class insulation maintenance, regular testing of insulation resistance, below the safety value of timely disposal. All cables are selected high-temperature fire-resistant models, do a good job of high-temperature cable aging test, the joints to do thermal insulation protection. Electrical room sealing insulation, with air conditioning cooling, regular cleaning of dust to ensure smooth heat dissipation.

Electrical maintenance is the key work of continuous casting workshop Crane maintenance, do a good job can significantly reduce the probability of electrical failure downtime.

Core components maintenance cycle

Common high-temperature faults quickly troubleshooting

Mastering the basic casting Crane high temperature fault detection methods, can reduce a lot of unnecessary downtime waiting, is a steel plant high temperature equipment operation and maintenance management of the necessary skills.

Hook openings become larger, cracks, mostly caused by long-term high temperature radiation plus overload, must be scrapped and replaced, high temperature workstation can be installed heat shield to protect the hook.

Braking distance becomes long, priority check friction plate wear, oil pollution and spring fatigue, corresponding replacement of clean adjustment can be.

Frequent overheating motor tripping, first check whether the ventilation and cooling blockage, and then measure the insulation resistance, to confirm whether the insulation is aging, ventilation is not smooth to clean up the cooling ducts, insulation down to do the drying or replacement process.

Hydraulic system slow action, oil temperature is too high, first of all, do the hydraulic system high temperature oil testing, check the deterioration of the oil, filter blockage, replace the high temperature hydraulic oil, clean the oil circuit can be restored.

Spare parts selection and cost control

Do a good job of casting Crane high-temperature spare parts selection is the key to controlling maintenance costs. Don't choose common parts for cheap, under high temperature working conditions, common parts have short life, frequent replacement, and higher long-term costs.

Priority selection of high-temperature wire rope, high-temperature lubricating grease, H-class insulated motors, high-temperature seals, these special parts, although the unit price is high, but the service life is long, comprehensive and more cost-effective. Clearly casting Crane wearing parts replacement cycle, the establishment of the key spare parts inventory, to avoid temporary procurement when the failure of production delays.

Reasonable preventive maintenance program for casting cranes can nip the failure in the bud, significantly reducing the cost of repair and downtime losses of sudden failure. Do a good job of casting Crane maintenance cost analysis will find that the standardized maintenance can pull down the full cycle cost.

We provide casting crane maintenance services for steel mills, can help customers build a scientific maintenance system, control long-term operation and maintenance expenditures, but also supports metallurgical crane maintenance SOP customization, adapted to the needs of different workshop conditions.

Henan Mine  Overhead Rotating Electromagnetic Beam Crane

Intelligent monitoring upgrade direction

Many steel mills are now beginning to land casting Crane intelligent monitoring and maintenance, using digital means to improve maintenance efficiency.

Installation of temperature, vibration and stress sensors in key parts of the motor, bearings, wire rope, steel structure, with lifting equipment stress monitoring, real-time data collection, abnormal automatic alarm. With infrared thermal imaging lifting detection and vibration analysis, hidden faults can be detected without dismantling the machine.

High-order predictive maintenance system for Crane can also project the remaining life of components through data trends, and arrange maintenance programs in advance, without having to blindly maintain according to a fixed cycle.

For continuous production of steel mills, reduce the production losses saved by an unplanned shutdown, can cover the investment in intelligent upgrades, which is also a cost-effective option in the high-temperature life extension program for casting Cranes.

Conclusion

Crane maintenance in high temperature working conditions, rely on standardized cycle inspection, suitable special spare parts and scientific maintenance methods. The daily maintenance to do a solid, and then with reasonable intelligent monitoring upgrade, not only can reduce the safety risk, but also can lengthen the life of the equipment, control the full cycle of maintenance costs.

Henan Mine Crane, as a professional foundry crane supplier, not only provides high-temperature casting cranes in line with metallurgical standards, but also provides molten metal lifting equipment maintenance, spare parts supply, intelligent monitoring and upgrading of the whole chain of support.

If you have a high-temperature workshop crane maintenance plan construction, equipment high-temperature transformation, spare parts selection needs, welcome to contact our technical team, we will issue a customized program according to your working conditions.