Equipment Installation Program
In order to ensure the effectiveness of our efforts, it is often necessary to develop a well-thought-out program in advance, which refers to a planned instrument for a particular action. Programs should be how to develop a good? The following is my collection of equipment installation program, for reference only, I hope to be able to help you.
I. Preparation for installation
1, technical preparation.
2, organizational preparation.
3, supply work preparation.
(1) before the construction must be prepared for the technical preparations proposed in the required machinery and materials, and timely delivery of the installed machinery and equipment to the site, unpacking and inspection, disassembly, cleaning, lubrication.
(2) equipment unpacking inspection.
(3) Equipment disassembly, cleaning and lubrication.
(1) equipment cleaning. Equipment out of the box inspection, disassembly, to remove the coated rust inhibitor and internal residual iron filings, rust and transportation, storage of dust and other filth accumulated, cleaned before assembly.
Installation projects commonly used cleaning agents are alkaline cleaning agents, cleaning agents containing non-ionic surfactants, petroleum solvents, cleaning gas-phase anti-corrosion solvents.
Cast iron platform equipment processing surface of the rust layer, shall not use the sand cloth or metal scraper to remove, only allowed to use clean cotton gauze, cotton cloth, wood scraper or ox horn scraper, etc. to remove. Dry oil can be cleaned with kerosene. Antirust paint can be cleaned with banana water, alcohol, turpentine and acetone. Processing the surface of the rust, with oil can not be wiped off, available cotton cloth dipped in acetic acid to wipe off; rust removal and neutralization with lime water wipe, and finally dry with clean cotton gauze or cloth. Gear box gears coated with anti-rust dry oil is too thick, available 70 ~ 80 ℃ hot oil or 30 ~ 40 ℃ hot kerosene poured into the box to clean. Has been hardened or more difficult to clean the ball bearing, can be used 70 ~ 80 ℃ hot oil rinse, then kerosene cleaning, and finally cleaned with gasoline. Cleaning bearings shall not use cotton yarn, only allowed to use clean cotton cloth; such as cotton inconvenient to clean, can be used in the oil gun into kerosene or hot oil cleaning.
② equipment lubrication. Equipment inside and outside the ministries clean, before refueling lubrication. Lubricants must be tested to determine compliance with the requirements before use. Join the equipment before the lubricant must be filtered, the oil refueling should reach the specified oil position; all lubrication parts and oil holes should be filled with lubricant.
The use of grease sealing is simple, not easy to dirty, reduce the loss, do not have to often change the grease. Especially for high-speed motors, automatic devices and equipment that are not easy to refuel lubrication is of great practical significance. At the same time, the grease is not affected by the temperature, the nature of the load, the speed of movement has a greater range of adaptability, in the vertical lubrication surface is not easy to lose. Add appropriate amount of graphite powder in the grease, can form a tougher film, can play a slow moving role in the reciprocating mechanism, to avoid crawling, eliminate vibration. Because of the poor fluidity and low thermal conductivity of the grease, it cannot be used as a circulating lubricant.
Second, the foundation work
1, the construction of the foundation. Foundation construction includes about several processes: digging pit, installing templates, tying reinforcement, installing footing laurel and pre-hole templates, pouring concrete, maintenance, removal of templates and so on.
2, acceptance of the foundation.
(1) machinery and equipment in place before the equipment foundation concrete strength must be measured. Generally should wait until the concrete strength of 60% or more, the equipment can be installed in place. Equipment leveling adjustment, tighten the ground bolts must be until the concrete design strength can be carried out. Small and medium-sized machinery and equipment foundation can be used "steel ball impact mark method" to determine the strength of concrete. Large machinery and equipment foundation must be pre-pressurized before installation, the weight of the pre-pressurized weight and allow the maximum weight of the processing parts of the sum of 1.25 times.
(2) The geometric dimensions of the equipment foundation should be in accordance with the design provisions, the baseline for equipment positioning should be the vertical and horizontal center line of the workshop columns or the edge of the wall as a baseline (should be required by the design drawings).
(3) Ground bolts.
① The role of the foot bolt is to firmly connect the mechanical equipment with the foundation base to prevent displacement, vibration and overturning of the equipment during operation.
② The length of the foot bolt should be in accordance with the provisions of the construction drawings, when the construction drawings are not specified, can be determined in accordance with the following formula:
L = 15D + S + (5 ~ 10)
where L - the length of the foot bolt (mm);
D - the diameter of the foot bolt (mm);
S - the height of the pad iron and the seat, the thickness of the nut and the amount of reserve (the amount of reserve is about the foot bolt 3 to 5 pitches) of the sum.
③ Vertical buried footbolt, the laying of the lead should be guaranteed, the vertical deviation should be less than 1%.
④ Exclusion of deviation of foot bolt. Center distance deviation processing. When the center distance deviation of the ground foot bolt exceeds the permissible value, first use the chisel to pick up the concrete around the threads, pick the depth of the bolt diameter of 8 to 15 times, and then use the oxygen-acetylene flame to heat the bolt to correct the bending part of the 850 ℃ or so, with a sledgehammer and a jackhammer for correction. After meeting the requirements, in the bending part of the additional welding steel plate, in order to prevent the bolt is straightened again after the force. Finally, fill the concrete.
Treatment of elevation deviation. Positive deviation of the bolt elevation exceeds the allowable range, should be cut to a part, and re-processed out of the thread. If the negative deviation of the bolt elevation and not more than 15mm, should be chiseled to part of the concrete, and then use the oxyacetylene flame to bolt threads outside the part of the baked red elongation, in the elongation of the diameter of the reduced part of the sides of the welded on the two reinforcing steel or thin tube. If the negative deviation exceeds 15mm, the bolt should be cut off and re-welded with a new bolt, and then weld four steel bars in the butt weld, and re-pour good concrete after processing.
Foot bolt "live plate" processing. When tightening the foot bolt, due to excessive force, the bolt from the equipment foundation pulled out, so that the equipment installation can not be carried out. At this time, the bolt in the middle of the concrete chiseled away, and then welded on two cross U-shaped rebar, make up for the concrete, the bolt can be re-fixed.
(4) pad iron. In the equipment base placed under the pad iron group, through the pad iron group thickness adjustment, so that the equipment to achieve the installation requirements of the elevation and level, and at the same time to facilitate the second grouting, so that all parts of the base of the equipment can be in full contact with the foundation, and so that the foundation uniformly withstand the weight of the machinery and equipment and the force generated during the operation.
① Classification and scope of application of the pad iron. Rectangular pad iron (also known as flat pad iron) used to bear the main load and strong continuous vibration of the equipment; oblique pad iron (also known as oblique inserted pad iron) is mostly used to not bear the main load (the main load basically borne by the grouting layer) of the parts, oblique pad iron should be flat under the pad iron; open pad iron is often in the form of a standoff mounted on a metal structure or ground plane, and is to support the situation of the area of the smaller, the equipment is supported by more than two feet! ; Hook head paired slanting washers.
② pad iron placement should meet the following requirements: each foot bolt should normally be placed at least one set of pad iron. Does not bear the main load of . Matting group, only the use of flat pads and a sloping pad can be; bear the main load of the pad iron group, should be used in pairs of sloping pad iron, leveling with welding; bear the main load and produce strong continuous vibration in the operation of the equipment, the pad iron group can not be used to sloping pad iron, can only be used to use the flat pad iron. The total number of pad iron in each group shall not exceed 3, in the pad iron group, thick pad iron on the bottom, thin pad iron on the top, the thinnest placed in the center.
Third, equipment installation
1, equipment operation level and find the right. Mechanical equipment installation of the base with the point, that is, the factory zero point as a standard, with the measurement method to mark the base with the point of the accurate elevation
2, mechanical assembly.
(1) bolt connection of the anti-loosening device. Bolt connection itself has self-locking, bear static load, in the case of relatively stable working temperature is reliable. But in the impact, vibration and alternating loads, self-locking is damaged. Therefore, the need to increase the anti-loosening device.
(2) key connection. Key is used to connect the shaft and shaft parts, key connection is characterized by simple structure, reliable, easy to install and disassemble. Keys are usually divided into loose keys, tight keys and splines according to the structure and use.
(3) plain bearing installation. Sliding bearing is a kind of sliding friction bearing, which is characterized by reliable work, smooth, no noise, oil film vibration absorbing ability, so it can withstand large impact load.
(4) Rolling bearing installation includes cleaning, inspection, installation and clearance adjustment steps.
(5) gear drive mechanism installation. The gear transmission mechanism has the advantages of accurate and reliable transmission, compact structure, small size, high efficiency, easy maintenance and so on.
(6) worm gear drive installation. Worm gear transmission mechanism is characterized by a large transmission ratio, transmission ratio accuracy, smooth transmission, low noise, compact structure, can be self-locking. The shortcomings are low transmission efficiency, frictional heat generated when working, the need for good lubrication.
(7) coupling installation. Coupling is divided into two categories of fixed and movable.
Fourth, equipment inspection, adjustment and test run of mechanical equipment test run steps are: first no load, after the load, the first single machine, after the system, and finally linkage.
Trial run first from the beginning of the components, from components to components, from components to a single (set) equipment. Several pieces of equipment linked into a set of linkage unit, should be a single piece of equipment, and then systematically linkage test run.