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In an industrial enterprise, the installation of technological equipment can be a difficult task if the installation work is performed by a contractor without experience and qualification. The applied machines and devices differ in size, weight, design, their installation requires specially trained personnel and competently selected lifting mechanisms and machines.
Terms and definitions
Equipment of a machine-building enterprise depends on the type and volume of products. The structure of the plant includes the main and auxiliary workshops that perform certain functions and require installation of in-house equipment of various types.
The procurement workshops are made for the production of blanks from which the finished product will be assembled. For machine-building enterprises, the main one is forging-press, producing parts from metal sheets, and metalworking equipment that performs the processing of blanks by cutting.In press buildings, cold stamping, cutting, cutting of parts is performed. It uses disc and vibration guillotines and scissors, stamping hammers, crank, pneumatic and hydraulic presses. For machining, various milling and lathes, automatic lines are installed.
In the shops of auto assembly production, the knot and complete assembly of the product is carried out. They carry out the installation of metal cutting lines, equipment for welding and assembly. These are lines for spot and suture welding, conveyor lines, stands, platforms with lifting tables, various robots.
Background data
To perform the installation of the workshop equipment, the supplier provides the necessary information for assembly: passports for equipment, recommendations for placement and fastening on the foundation, requirements for the construction readiness of the installation site and premises. The supplier attaches a list of devices and tools recommended for installation of equipment, options for filling foundation seams.
Location of installation sites and equipment location are determined in the PPR during the construction or reconstruction of the workshop. During the development of the project of production of works, technological planning is carried out. To ensure the production of energy, steam water, points of connection to existing engineering networks are identified, based on the production capabilities of the enterprise, free capacities are allocated for the operation of new units. By the time the installation of workshop equipment begins, production, technical and organizational issues are solved.
Features and differences
Installation work is necessary for the construction of a new workshop, reconstruction of an existing one, repair of machines or replacement with modern ones. In some cases, it may be necessary to dismantle the equipment, which will increase the complexity of the installation and costs. Depending on the parameters and technical characteristics, the installation of equipment received from the supplier is carried out by different methods, and the mechanisms used for this are different in carrying capacity and overall dimensions.
The equipment supplied in the assembly practically does not require improvement and is installed on the foundation in a short time, but causes difficulties in delivery and movement on the site. Lifting and transport and rigging devices are calculated on a sufficient carrying capacity, high qualification of line workers and work culture are required.
The solution will be the use of conveyor assembly, in which at the same time at several installation sites, large-assembly of parts received from the manufacturer is performed. The equipment is installed fully assembled or assembled from separate units.The conditions of the construction site, the complexity of the units, the presence and features of the resources involved affect the choice of the assembly method. If the foundation device and underground works for the equipment are performed before the construction of the frame of the building, then the method of the completed zero cycle is applied. With a closed method, preparation for installation of equipment is carried out in an already built building, and with a combined method, both methods are used.
Timing and sequence of work
Installation of industrial equipment is performed according to SNIP 3.05.05-84 “Technological equipment and technological pipelines”, guided by the project of production of works (PPR), design and estimate documentation, manufacturer’s requirements. When assembling simple equipment enough technological map.
Work is carried out in several stages:
- Based on the needs of the enterprise, the need for equipment is determined. The design task includes the installation of conveyors, machines and other units. The project lays down the type of equipment, the conditions for its installation and connection. Schedules are compiled that determine the timing of work.
- The RWP is approved and agreed upon. It contains mounting schemes, statements of equipment for the performance of works, equipment, tools, determines the engineering support for the site intended for assembly.
- Preparatory work is carried out, the site is leveled, earthworks are performed, the foundation and steel foundation structures are laid. To connect to engineering networks, cables, pipelines, channels for laying engineering systems are laid.
- The equipment is delivered from the supplier, its unloading, inspection, visual inspection and acceptance are carried out.
- Large-node assembly is carried out on installation sites, equipment is installed on the foundation, exposed and fastened with the help of foundation bolts. Before the start of work, the foundations are accepted, the planned and high-altitude position is checked, selective geodetic control is carried out.
- The final installation is performed, all removable parts and components are installed. Technological pipelines and systems are connected.
- A visual inspection is carried out, the reliability of the mounting of the nodes, the quality of the welded seams is checked. Acceptance tests are being carried out. The unit is connected in the factory networks. Based on the results, acceptance by the working commission is carried out.
- Commissioning works are carried out, including adjustment of electrical and thermal power systems and ICS, individual tests and comprehensive testing of the unit. At each stage, defects are eliminated, parameters are checked and adjusted to the values specified in the technical passport.
- The service of operation of the enterprise, and, if necessary, the state acceptance commission takes the equipment into operation.
Special requirements
When performing the work, the dimensions of the room where the installation or dismantling is carried out, the configuration of the openings, the height of the ceilings, the load on the base, the access roads are taken into account, otherwise the transportation and rigging of large-sized equipment can cause difficulties. It should be sufficiently spacious and a platform for installation and storage. It should be freely accommodated and work installation equipment. In cramped conditions, the use of mobile portal systems helps. When installing press lines, they will allow large nodes to install in the unloading position and move them to the installation site.
To save space and ensure free movement will allow the arrangement of channels in the floor for laying power cables and pipelines. After installation, the channels for engineering systems should be closed and protective fences removed.
Adjustment and adjustment of equipment at the first run does not always guarantee the necessary quality of products. A limited batch shall be made to check the accuracy and tolerances and checked for dimensionality. If there is a large percentage of low-quality parts in the trial batch, additional adjustment is necessary.
Why the service is necessary for the customer
Only specialists with the necessary qualifications are able to make a design and manufacture task, perform all surveys and surveys. On the basis of pre-project studies, the project is being implemented, the PPR is being developed.
Construction works for installation of technological equipment are carried out by contractors, a team of installers assembles in accordance with the drawings. For rigging and transportation of oversized and heavy units, certified workers with cargo permits and high-altitude work are required. Special skills are needed to connect to engineering networks.
To carry out adjustment works, acceptance tests, equipment configuration, you need knowledge of the features of the machine or press, the ability to bring the parameters to the requirements of the manufacturer. The result will be the execution of executive documentation and the delivery of equipment into operation.
What is the uniqueness of our offer
For competent selection and high-quality installation of technological equipment, special knowledge in a number of areas and experience in performing such works are needed. Consistency is difficult when involving multiple organizations and contractors.
Sintez TMK offers a comprehensive solution to complex problems thanks to the necessary experience. The specialists working in the company have different knowledge and are able to perform work in a short time.
Engineers, builders, designers are a close-knit team capable of providing high-quality results. Success guarantees a positive business reputation, the necessary admissions, certificates and experience.
Mistakes and problems. Possible and frequent
The main mistakes in installation work are caused by the incompetence of the performers. If due to non-punctuality during the installation of industrial equipment, a start is carried out without testing and adjustment, this can lead to equipment breakdown. The absence of RRP causes haphazardness and increase in the cost of installation, without incoming control of project documentation, the quality of work of units deteriorates.
Difficulties in translating technical documentation or its absence make the assembly by eye. As a result, the assembly is performed with errors, and there is a high probability that the machine will work incorrectly.
Rigging is an important component of installation work. An incorrect logistics decision will lead to a violation of delivery times to the facility when transported from abroad or an increase in the cost of the object caused by the wrong choice of transport and lifting mechanisms, delays during movement or transshipment.
Mistakes in installation lead not only to the loss of money. A malfunctioning machine will be a source of potential danger and can cause accidents and injure people. Work must be done by professionals.
Regulatory instruments
GOST 9045-93 Rent thin sheet cold rolled from low-carbon quality steel for cold stamping. Technical specifications
GOST 18970-84 Pressure treatment of metals. Forging and stamping operations. Terms and definitions
SNIP 3.05.05-84 Technological equipment and technological pipelines
VNIR B6-16 Release 16. Machinery and forging and press equipment