"Identifying Safety Risks in Intermediate Frequency Furnace Coil Castable Cement"

胶泥受潮、含水率过高，烘炉不彻底，高温水汽汽化引发匝间击穿、打火、线圈短路烧毁。

The coil cement is damp with excessive moisture and incomplete baking; water vapor vaporizes at high temperature, causing inter-turn breakdown, arcing and short-circuit burnout of the coil.

胶泥冷热循环、振动开裂脱落，线圈绝缘裸露，金属粉尘及铁豆嵌入造成接地或匝间短路。

Cement cracks and falls off due to thermal cycling and vibration, exposing coil insulation; embedded metal dust and iron pellets lead to earthing or inter-turn short circuit.

劣质胶泥杂质多、电阻率低，高温下绝缘性能急剧衰减，引发漏电、爬电、打火。

Inferior cement contains many impurities and low resistivity; its insulation performance drops sharply at high temperature, causing electric leakage, creepage and arcing.

线圈绝缘漆破损未修复，直接敷胶泥，造成匝间绝缘缺失。

Damaged coil insulating varnish without repair before cement coating results in loss of inter-turn insulation.

配比加水过多、搅拌不均、养护不足，干燥后产生干缩网状裂纹。

Excessive water proportion, uneven mixing and insufficient curing produce dry shrinkage mesh cracks after drying.

炉体频繁启停、温差过大，胶泥热膨胀系数不匹配，热震开裂、崩落。

Frequent furnace start-stop and excessive temperature difference, mismatched thermal expansion coefficient of cement cause thermal shock cracking and collapse.

筑炉、拆炉、清渣过程机械撞击刮擦，造成胶泥局部破损脱落。

Mechanical impact and scraping during furnace building, dismantling and slag cleaning cause local damage and spalling of cement.

炉衬受热膨胀挤压胶泥，炉口、顶部易翘边剥离，钢水渗入诱发漏炉。

Thermal expansion of furnace lining extrudes cement; warping and peeling easily occur at furnace top and furnace mouth, leading to molten steel infiltration and furnace leakage.

新抹胶泥养护时间不足，直接升温烘炉，水汽急剧膨胀造成鼓包、爆裂、绝缘崩坏。

Insufficient curing time for newly coated cement before direct heating; rapid expansion of water vapor causes bulging, bursting and insulation collapse.

烘炉低温段升温过快，内部水汽无法正常排出，胶泥疏松、裂纹增多。

Excessively fast heating at low temperature stage of baking makes internal water vapor unable to discharge normally, resulting in loose cement and increased cracks.

水冷系统渗漏，冷却水渗入胶泥长期吸水饱和，绝缘电阻趋近于零。

Water cooling system leakage makes cooling water infiltrate into cement and reach long-term water saturation, with insulation resistance approaching zero.

劣质胶泥耐火度偏低，高温下软化粉化、流失，失去绝缘防护作用。

Low refractoriness of inferior cement leads to softening, pulverization and loss at high temperature, losing insulation protection function.

粘结强度不足，长期高频振动下整体剥离，线圈匝间失稳、短路。

Insufficient bonding strength causes overall peeling under long-term high-frequency vibration, resulting in inter-turn instability and short circuit of coil.

抗渣侵蚀性差，炉渣、铁水逐步侵蚀穿透胶泥，烧损线圈。

Poor slag erosion resistance makes slag and molten steel erode and penetrate cement gradually, burning out the coil.

长期高温热震工况，胶泥脆化老化、强度下降，轻微振动即脱落开裂。

Long-term high temperature and thermal shock condition cause cement embrittlement and aging with strength decline, cracking and spalling under slight vibration.

线圈匝间胶泥未填满压实，存在空隙，积尘积铁形成导电通路。

Cement not fully filled and compacted between coil turns with gaps left; accumulated dust and iron form conductive paths.

胶泥涂抹厚度偏薄、厚薄不均，绝缘防护厚度不足易被高温应力击穿。

Uneven and too thin cement coating leads to insufficient insulation thickness, easily broken down by high temperature stress.

线圈同心度偏差大，炉衬膨胀应力集中，局部挤压开裂。

Large deviation of coil concentricity causes concentrated expansion stress of furnace lining and local extrusion cracking.

长期超温熔炼，加速胶泥绝缘老化、性能劣化。

Long-term over-temperature smelting accelerates insulation aging and performance deterioration of cement.

线圈固定松动、磁轭紧固失效，高频振动加剧胶泥疲劳开裂。

Loose coil fixation and failed yoke fastening aggravate fatigue cracking of cement by high-frequency vibration.

线圈周边铁豆、导电粉尘堆积，形成跨接短路隐患。

Accumulated iron pellets and conductive dust around the coil bring hidden danger of bridging short circuit.

日常巡检不到位，未及时排查裂纹、脱落、渗水隐患，小故障演变为设备及安全事故。

Inadequate daily inspection fails to detect hidden dangers such as cracking, spalling and water seepage in time, leading minor faults to equipment and safety accidents.