Detailed specifications for the technical requirements of ceramic tile installation processes

Surveying and technical discussions on wear-resistant elbows for a client in Guangzhou On March 16, 2018, technical staff went to Guangzhou at the invitation of a coal mine to conduct surveys and hold technical discussions regarding wear-resistant pipes. 　　I learned on the spot that the wear-resistant pipes in coal mines have problems such as lacking wear resistance and durability. 　　Our company recommended ceramic-soldered composite pipes to that company. These pipes boast good toughness, impact resistance, and excellent welding properties; in addition, corundum ceramics offer high hardness, high wear resistance, corrosion resistance, and good heat resistance. Previous solutions: 1. Reduce the air pressure during soot blowing, which can both minimize wear and save energy. This method can indeed extend the lifespan of the ash transfer pipeline a little, but it cannot fundamentally solve the wear problem. 　　2. Construct a square box around the pipeline, fill it with cement or add casting materials and wear-resistant substances; the cost is not high either. This method is no different from applying patches; it can only be used in small areas and cannot solve problems on a large scale. 　　_Recommended method: Given the severe wear on the dust removal pipes, one solution is to choose appropriate pipe materials – materials that are resistant to wear, such as ceramic composite pipe elbows, ceramic-coated pipe elbows, or bimetallic composite pipe elbows. Ceramic-coated pipes can be used at temperatures up to 120°C, and bimetallic composite pipes are also an option; however, they are much more expensive and heavier. It is recommended to use ceramic composite pipes and elbows, which can withstand temperatures of up to 650°C, do not age easily, and do not fall off. 　　If the wear-resistant ceramic elbow wears out after only half a year, it is a design issue; for example, if the concentration of ash gases is low or the velocity of the ash gas mixture is high, check whether the actual inner diameter of the entire pipeline matches the design specifications. Under normal circumstances, the radius of elbows is determined based on technical design; increasing the turning radius of an elbow can help reduce wear to a certain extent.

Ceramic elbows are manufactured using the self-propagating high-temperature centrifugal synthesis method: first, the various segments of the elbow are prefabricated, and then ceramic material is poured into each segment to carry out ceramic molding; once this process is completed, the elbow is considered a qualified product. Combination elbows are considered defective products when the method of prefabricating straight pipes first and then cutting them is used. Pre-fabricated ceramic wear-resistant elbows; assembly of ceramic wear-resistant elbow sections. 2. The dimensional tolerance for the ceramic inner tube of the ceramic elbow is plus or minus one millimeter. 3. The ceramic lining should be firmly attached to the steel pipe, without any defects such as looseness, delamination, cracks, inclusions, pores, or bubbles. 4. Ceramic elbows: At the joints, ceramic powder and high-temperature adhesive of the same material as the base metal are used for sealing; the seams must be filled tightly, with no defects such as missing material or excessive material accumulation. 5. When using ceramic wear-resistant elbows in assemblies, measures must be taken to prevent excessive temperatures at the weld points, which could cause the ceramics to come loose; repaired products with obvious defects are not acceptable.

1 Scope This procedure is applicable to the final inspection of wear-resistant heads. 2 Referenced standards: DL/T 680 -1999 Technical requirements for wear-resistant pipes; ASME B16.9-2007 Welded forged pipe fittings manufactured in factories; ASME B31.8-2007 Gas transmission and distribution pipeline systems; GB/T 12459-2005 Steel welded seamless pipe fittings; GB/T 13401-2005 Steel plate welded pipe fittings; ASME B16.5-2009 Pipe flanges and flanged pipe fittings. 3 Finished product inspection: 3.1 The design, manufacture, and acceptance of wear-resistant ceramic elbows shall, in principle, follow the current relevant specifications and standards. The standards followed for design, manufacturing, construction, and acceptance are the Technical Requirements for Wear-Resistant Pipelines DL/T 680. 3.2 Inspection items: 3.2.1 Visual inspection of fittings: 3.2.1.1 The surface quality of wear-resistant elbows is inspected piece by piece by visual inspection; the surface of the fittings should be smooth without any oxide scale. There shall be no defects such as scars, folds, bends, or delamination on the surface of the fittings, with a depth greater than 5% of the nominal wall thickness, and the maximum depth shall not exceed 0.8 mm. 3.2.1.2 The surface quality of wear-resistant elbows is inspected piece by piece by visual inspection; the surface of the fittings should be smooth without any oxide scale. The welds should have a smooth transition, with no cracks, lack of fusion, under-welding, or undercutting, and no slag or spatter should remain. Fittings shall be free from defects such as scars, folds, crushes, and delaminations, whose depth exceeds 5% of the nominal wall thickness and is not more than 0.8 mm. 3.2.2 Inspection of external dimensions: 3.2.2.1 Outer diameter D at the ends: Use a vernier caliper to measure two points at each end of the elbow, in directions perpendicular to each other; the average value of these two points for each end represents the outer diameter of that end. 3.2.2.2 Inner diameter at the ends d: Use a vernier caliper to measure two points at each end of the elbow in directions perpendicular to each other; the average value of these two points constitutes the inner diameter of that end. 3.2.2.3 Inspection of wall thickness s: Use a thickness gauge to take five evenly distributed points on the back arc of the elbow for inspection. 3.2.2.4 Inspection of weld joint groove angle: Measure the groove angle directly using a universal protractor. 3.2.2.5 Inspection of end face deviation X: Place the elbow on a platform, then place a right-angled ruler at the end of the elbow; use a feeler gauge or a straight ruler to measure the distance between the end of the elbow and the ruler – this distance represents the end face deviation X. 3.2.2.6 Inspection of verticality deviation Y: Enlarge the elbow platform, and use a feeler gauge or straight edge to measure the distance between the end part and the non-contacting portion of the platform; this value represents the verticality deviation Y. 3.2.2.7 Inspection of the distance from the center to the end: Place the elbow flat on a platform, with one end against the platform; then position a height gauge against the other end of the elbow and read the height value from the gauge. Subtracting 1/2 of the outer diameter from this value gives the distance from the center to the end. 3.2.3 Non-destructive testing: For the non-destructive testing of steel seamless fittings, tees, crosses made of carbon steel and stainless steel, as well as various types of fittings made of alloy steel, magnetic particle or penetrant testing shall be carried out on each individual fitting. The testing shall be conducted in accordance with the standards specified in JB/T4730-2005; a grade of I indicates compliance, and the fittings must be free of cracks. 3.2.4 Hardness testing: For carbon steel and austenitic stainless steel pipe fittings, 3% of each batch, with a minimum of 2 pieces, shall be selected for hardness testing; if one piece fails the test, additional testing shall be conducted. The hardness of the welds and heat-affected zones of steel seamless pipe fittings shall meet the requirements of relevant standards or specifications, but their hardness value shall not exceed 120% of the hardness of the pipe fitting itself. 3.2.5 In cases where the user has special requirements, it shall be carried out in accordance with the user’s requests, the agreements reached between both parties, relevant responses, and industry standards. 3.3 The product comes with a certificate of conformity, packing list, and shipping list. 3.4 The markings shall be in accordance with the relevant product standard requirements.

Wear-resistant ceramic elbows: Domestic and international bituminous coal contains a high amount of impurities, including stones, etc., and its quality is very low. When used in the air ducts of swirl coal-fired burners in power plant boilers, they suffer from severe wear and have a short service life. A wear-resistant ceramic air duct, whose components include: a duct body made of steel sheet rolls, a ceramic lining, and flanges for connection. 1. Wear-resistant ceramic air ducts require a steel body made by rolling carbon steel plates, which is then assembled according to the angle of the elbows; the error allowed must not exceed 0.5 degrees. The inner diameter of the steel pipe elbows must also meet the specified requirements. II. After the steel frame of the ceramic duct has been welded, flanges need to be installed; generally, the ceramic tiles are applied after the welding of the steel frame between the two holes of the flanges is completed. Once the ceramic has been bonded, it cannot be welded anymore, to avoid affecting the strength of the bond. III. The wear-resistant ceramic tiles used as the lining for ceramic air ducts must be flat, and the adhesive filling between the ceramic tiles should be sufficient to ensure a strong bond between the steel pipe and the ceramic tiles. The wear-resistant ceramic tiles should be applied at the inlet of the wear-resistant ceramic duct, following the flow direction of the medium. Wear-resistant elbows, wear-resistant ceramic elbows, manufacturers of pipes with ceramic linings _ Hebei Tengtai Pipe Manufacturing Co., Ltd. Wear-resistant ceramic air ducts

The severe wear of the elbow at the end of the pump pipe poses a difficult problem for pump trucks. Many companies previously used ceramic mosaics for this purpose, as special ceramics have good wear resistance. However, regardless of the high impact forces and pressures involved, if one piece of such ceramic breaks off, it creates a weak point in the elbow, leading to rapid wear and leakage. Based on the characteristics of pump pipe usage, these companies developed a ceramic interlocking elbow. Corundum wear-resistant ceramics are used in an interlocking process that binds them together into a single unit, and specialized ceramic adhesives with high strength are employed to ensure that the ceramics do not come apart. Ceramic wear-resistant elbow fittings have advantages such as light weight and high hardness; tests have shown that they can be used for transporting over 20,000 cubic meters of concrete without any problems

Hebei ceramic elbows – welcome to Hebei Elbows. As a manufacturer of ceramic elbows, we adhere to the principles of quality and integrity, striving to provide you with better, higher-quality products at more competitive prices. The ceramic elbows produced by our company come in a wide range of specifications; they feature an outer steel tube with a composite ceramic layer on the inside. The ceramic layer possesses high hardness and excellent performance, resulting in a longer service life. These elbows are suitable for use in pneumatic conveying systems, offer easy installation, and have low operating costs. They are widely used in power plants, steel mills, cement factories, ore processing plants, as well as in various pipeline systems related to pneumatic conveying, ash removal, and dust elimination. Elbows are pipe fittings in pipeline systems that experience significant wear; the degree of wear on elbows is more than 6 times that of straight pipe sections. If ordinary steel elbows are used, their service life is short, requiring frequent maintenance and replacement. In contrast, ceramic elbows extend the service life by more than 10 times, thereby extending the lifespan of the pipelines and achieving energy savings. Ceramic elbows are formed by shrimp-waist welding and sintered at high temperatures in a centrifugal casting machine. 2.1. The medium transported inside the pipeline is air or a coal powder mixture. The normal operating temperature ranges from 80°C to 100°C; in special cases, it can reach 350°C. The normal operating velocity is 22–28 m/s, while the normal wind pressure is 5–15 kPa. Elbows are suitable for use in environments where there is gas-powder erosion at a velocity of 35 m/s. 2.2 Ceramic elbows ensure a service life of over 10 years. 2.3 Ensure that the internal flow diameter is 610 mm. 2.4. The ceramics will not crack, age over time, or fall off. If such issues as falling off or cracking occur within the guaranteed service life, the winning bidder shall replace them at no cost. 2.5. After the ceramic tiles are bonded, the surface irregularity between the two tiles shall not exceed ±1.0 mm. 2.6. The lining is made of 95-alumina ceramic, with a hardness of HRA≥90; the thickness of the ceramic is not less than 12 millimeters. The ceramic uses a dovetail fitting design, with each piece having edges on all four sides to ensure interlocking. Each piece also has welding holes, and after welding, ceramic welding plugs are placed over them. 2.7. To ensure smooth flow in the pipeline, seamless steel pipes (with a wall thickness of not less than 10 mm) are used for medium-frequency overall extrusion; the ceramic-coated section of the pipe must be seam-free, and the shrimp-shaped design is not permitted.