Concrete mixing plant is a large-scale automated production equipment, which is widely used in various construction projects. Compared with the traditional mixer, the concrete mixing plant has high production efficiency, high degree of automation, and good production effect, but the structure is relatively complicated. Then, when we purchase the equipment of the mixing plant, how to install it correctly? What is the installation process of the concrete batching plant?
Preparation
1. Prepare all the necessary parts, remove the debris around the installation site, level the site, and ensure the smooth flow of all kinds of vehicles.
2. Equipment and tool conditions:
⑴. 4 steel wire ropes above φ16, each with a length greater than 6m.
⑵ One φ10 steel wire rope with a length of about 5m.
⑶, 4-6 pieces of U-shaped rings of various specifications, if the area has a wind force of more than six levels all year round, wind-proof measures should be added, and cable wind ropes should be provided.
⑷, 2 12-pound sledgehammers.
⑸ Two sets of 450 pipe wrenches, four sets of open wrenches or box wrenches, one set of 350mm adjustable wrenches, one set of electrician tools, and 10 rolls of insulating and waterproof tape each.
⑹, spare 18 pieces of steel plates with a thickness of 100mm or more of 500㎜×500㎜ (for connecting the bottom plate).
⑺ One truck crane above 25T, equipped with one crane and one hoisting worker and one lifting worker.
(8) One 3t hand chain hoist, two large ropes of 15 meters, 30 meters of 12# iron wire, two electric welders, one oxygen acetylene equipment, four safety belts, and one safety helmet for each person.
3. Personnel: 1 team leader, 2 welders, 2 handymen, and 1 electrician, totaling 6 people.
4. Verification: Prepare a theodolite DJ6 and a DS3 level before construction. Use the theodolite to verify the accuracy of the reference points of the axis of the foundation. Use the level to measure and re-check whether the elevation of each leveling point is accurate, and mark the main parts. Centerline.
2. Layout drawing of the construction site
3. Re-testing of construction foundation drawings
1. Carefully review all the design drawings provided by the manufacturer, determine the position of the foundation axis and the relevant center reference point based on the construction site conditions, and make preparations for the positioning of the embedded parts.
2. According to the design drawings provided by the manufacturer, use the external control method to implement the retest
⑴ Determine the control point, set up the theodolite on each control point and mark the original control punctuation, and use the method of taking the center of the mirror to lead the control line to the center line of the embedded part.
⑵. At the same elevation, form a closed net, measure the distance between each axis with a steel ruler for proofreading. The allowable relative error is not more than 1/2000. The control line after inspection can correspond to whether the central control point of other equipment foundation embedded parts conforms to Design requirements.
3. Use closed transfer to determine elevation control
⑴. Reset the ±0.000 elevation point according to the construction foundation drawing, measure the natural floor elevation of the surface with a level, and simply calculate the absolute elevation, insert steel bars on the foundation embedded parts, and apply red paint as a mark on the control points. As the backsight point of the control elevation.
⑵. Mark more than six ±0.000 elevations evenly around the site, measure ±0.000 to the embedded parts control points of the foundation of each equipment, and use tower rulers to measure the elevations vertically and pass the closed processing to verify compliance Design requirements.
4. The re-measurement of the axis and elevation should be combined with the construction plan, the relevant process of the construction site layout drawing and the relationship between the equipment structure, and the purpose is to reduce errors and ensure the quality and progress of the project.
4. Installation of cement warehouse:
1. The bracket is in place
The bracket is hoisted in place, the diagonal line and the horizontality and verticality of the four legs are corrected, the anchor bolts are installed, and the concrete with a mark higher than the foundation C20 is used for pouring and maintenance, so that the concrete reaches the standard strength. When there are no anchor bolts, the foundation embedded parts should be well connected, and the welding position should be marked.
2. Assembly of warehouse accessories
①Assembly of dust collector
First fix the sealing strip with sealant on the upper part of the cement bin and the inner edge of the connecting flange of the dust collector, and then fix the already installed dust collector assembly with M12X35 bolts.
②Installation of ladder guardrail and top guardrail
Arrange the ladder guardrails from bottom to top in the order of welding numbers 1, 2, and 3, and fix them with M10X40 bolts. Then connect the three guardrails with galvanized sleeves and wear cotter pins. Insert the smallest piece of the top guardrail (three intubated) on the opposite side of the ladder on the top of the warehouse (6th, 7th, and 8th from the ladder), tie the remaining two pieces to the small guardrail, and wait for the warehouse body to be hoisted. After that, install it again.
③The installation of the level meter
Screw the material level meter and the material level meter cover into the upper and lower limit rib holes respectively, and connect the wires to the junction box.
3. Hoisting of warehouse body
After the foundation support anchor bolts or embedded parts are poured for more than three days, the warehouse body can be hoisted. Use a 25T or more truck crane to connect the warehouse body with M20X80 bolts to the bracket according to the position of the ladder and the exit position of the screw conveyor. Use theodolite to measure the verticality (should be less than or equal to one thousandth), and tighten all bolts after adjustment. Use four M12X40 bolts to connect the feeding pipe with the bin feeding pipe.
Five, the assembly of the host
1. Install the host leg:
Hang the host on a firmly placed cushion block, install the front and rear legs of the host according to the welding number of the host, and fix them with a pin.
2. Installation and walking platform:
Install the walking platform and guardrail in place (if there is an environmentally friendly outer packaging, no guardrail), and install the platform diagonal brace on the platform.
3. In place:
Lift the mainframe, install the mainframe diagonal brace, tighten the bolts and diagonal brace and place them according to the center line of the foundation, and weld the support legs with the embedded parts or connecting bolts.
4. The assembly of the second-tier metering assembly:
Install the walking platform and install the water scale, cement scale, additive scale and collecting hopper, and then hoist the whole to the top of the host, and then tighten it with the assembly bracket with M16X50 bolts.
5. Install the receiving hopper
First put the rubber cylinder into the mouth of the receiving hopper, and fix it with steel belt and M12X60 bolts, and then install the receiving hopper in place with a loader or installation platform.
6. Installation of control room and bracket
1. Put the control room support chassis upside down and raise it about 200mm.
2. Connect the control room platform to the chassis with M16X50 bolts (when there is no bolt, it should be welded with the embedded parts).
3. Connect the outriggers to the chassis with M20X50 bolts (when there are no bolts, they should be welded to the embedded parts).
4. Connect the walking platform and the outriggers with tie rods and pins.
5. Use a crane to turn over the connected bracket.
6. Install the guardrail on the walking platform with M12X35 bolts.
7. Lift the bracket in place according to the base position.
8. Install the climbing ladder, hoist the control room to the bracket and fix it.
Seven, the installation of batching machine
1. Place the batching machine on the center line of the foundation.
2. First, use two wire ropes of the same length (one rope on each side of the enclosure) to fix them on the lifting points, and slowly pull them up with a crane.
3. Fix both ends of the pull rod with pins on the enclosures on both sides.
4. Pull up the end plates at both ends and attach the connecting pins to the two side panels
5. Put on the anchor bolts and carry out secondary irrigation (when there are no bolts, it should be welded with the embedded parts).
8. Hoisting screw conveyor
1. Tie both ends of the screw conveyor with two large ropes to prevent the screw conveyor from swinging during the hoisting process.
2. Choose to use a lifting point, which can form an elevation angle of about 30 degrees after the conveyor is lifted.
3. Move slowly after lifting, align the universal joint to the outlet of the cement silo, add rubber pads between the silo interface flange and the universal joint flange, connect them with M12X50 bolts, and then tighten them.
4. Align the discharge port of the screw conveyor to the powder hopper, and the height is about 300mm away from the powder hopper. After selecting a suitable position, use the screw conveyor bracket to prop up the front of the conveyor and weld it firmly.
5. According to the position of the discharge port of the screw conveyor, match the feed port on the cement scale, and use gas cutting to cut the steel plate in the feed port.
6. Use a canvas tube or rubber tube to connect the conveyor outlet and the cement scale inlet, and fix it with a pipe clamp.
Note: a. During the hoisting process, the crane should move stably; b. When welding the splicing port, pay attention to that the ground wire must be placed directly on the scale, and the sensor must not be bypassed, otherwise the sensor will be easily damaged; c. Canvas tube or rubber tube Do not tie it too tightly, otherwise it will affect the measurement.
9. Install water, gas and additive lines
It depends on the construction conditions on site;
Please refer to the drawing to install the waterway. (Omitted)
Please refer to the diagram to install the gas circuit. (Omitted)
Please refer to the drawings to install the additive pipeline. (Omitted)
10. Wiring debugging
1. Please refer to the electrical manual for wiring and debugging
2. Note:
⑴. Before testing the machine, first check whether the power supply voltage and capacity meet the requirements, whether there is a leakage protection device, whether the equipment has short circuit or leakage, and there should be no debris in the mixing drum and on the belt conveyor.
⑵. During the test, the idle personnel are required to leave the scene. One debugger will operate and the other will observe the implementation of each organization. The two must ensure good communication.
⑶. When adjusting the deviation of the belt conveyor, keep your body away from the body as much as possible.
⑷. When adjusting other facilities, the power should be cut off and be supervised by special personnel.
⑸. When adjusting and maintaining the air circuit, the compressed air should be vented after the power is cut off to cause danger.
⑹. Each time the equipment is started, the bell must be pressed to warn, and it can be started after inspection by the inspectors.
⑺. During shutdown or maintenance, no material should be stored in the collecting hopper to prevent the air pressure from falling into the main engine after release, causing unnecessary trouble and danger.
11. Acceptance of measurement system
1. The mixing metering system (cement, sand, stone, water, admixtures) must undergo metering inspection and a certificate of inspection must be issued. The metering system equipment should be reported to the local quality inspection department for review and acceptance before being used.
2. The allowable deviation of measurement is not greater than the following regulations
⑴, cement, water, admixtures, admixtures are ±2% (waterproof concrete is ±1%).
⑵±3% for sand and stone (±2% for waterproof concrete).
3. Before commissioning and starting production, the operator must conduct a recheck of the metering equipment inspection and calibration, and the production can be put into production only after inspection and calibration.
12. Emergency plan
1. Emergency rescue team and responsibilities
⑴. The on-site commander is the first person in charge of the emergency rescue team, who serves as the team leader and is responsible for the command work of emergency handling. The members are composed of installers. The on-site technical instructor (person in charge of safety) is the first executor of emergency rescue and serves as the deputy team leader, responsible for the specific implementation and organization of emergency handling.
(2) The work team leader is the second person in charge of the accident emergency team, responsible for the implementation of emergency response (electric shock, fall from height, electric welding injury, vehicle fire accident, traffic accident, fire and explosion) and other accidents. If accidents occur, they should promptly report The person in charge of the scene reports and cooperates with the team leader to handle the corresponding accident rescue organization and accident investigation cooperation.
2. Measures to prevent accidents
For the identified major hazards, targeted preventive measures shall be taken to avoid accidents according to the ways they may lead to accidents, and various preventive measures must be implemented to the team leader and individuals. Especially during the hoisting process, if an emergency occurs that affects hauling, the person on duty should immediately stop the operation, protect the site, and report to the emergency organization to send someone to rescue. After the emergency is properly handled, the construction can be carried out.
3. Accident handling
⑴ When an accident or emergency occurs, the person in charge of the construction site should immediately report to the company and the emergency rescue headquarters of the construction site, and leave a special person to keep in touch with the superior.
(2) Arrive at the scene, issue notices and instructions according to regulations, and immediately call emergency rescue personnel to gather.
(3) Understand the situation on the scene and actively participate in the rescue.
⑷Cooperate with superiors and coordinate external support personnel to organize on-site rescue.
⑸ On-site restoration.
⑹ Investigation of the cause of the accident.
⑺ Summarize experience and lessons, remediate and revise accident emergency rescue plan.
13. Safety protection measures
1. All installers should wear safety helmets before performing on-site operations.
2. On-site personnel and machinery must obey the deployment and command of the commander.
3. During the hoisting process, the crane must be stable and obey the command of the ground commander.
4. When hoisting, it must be fixed firmly to prevent decoupling. During the hoisting process, the staff shall not work under the hoisted objects.
5. It is forbidden to hoist in bad weather. Safety protection ropes must be configured during elevation operations. Hands should be grasped firmly when climbing. If the cement warehouse is higher than other surrounding buildings, lightning rods should be installed.
14. Equipment maintenance
1. The normal use and service life of the equipment are closely related to daily maintenance. Please refer to the manufacturer's instructions for comprehensive maintenance.
2. Maintenance must be carried out when the power is cut off and people are supervised.
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