Equipment installation graduation thesis

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Brief Discussion on Mechanical Equipment Installation Abstract This article focuses on the coking project to introduce the concept of coking equipment installation, and discusses the causes and characteristics of common problems in the installation of mechanical equipment, how to rectify their hazards, and the installation procedures. Whether a piece of machinery and equipment can be put into production smoothly, whether it can give full play to its performance, extend the service life of the equipment and improve the quality of the produced products, largely depends on the quality of the installation of the machinery and equipment. Keywords machinery, coking, equipment Introduction Mechanical equipment installation engineering is an important process between civil engineering and production. It is also the only way for mechanical equipment to go from factory manufacturing to operation and production. During use, mechanical equipment will gradually age, malfunction, and even cause accidents, affecting production. Therefore, the installation quality of mechanical equipment has become a top priority. With the huge economic losses caused by damage to mechanical equipment affecting production, mechanical equipment installation has also entered the stage of history. The quality of mechanical equipment installation determines the rest of the mechanical equipment. 1. Characteristics of Equipment Installation Mechanical equipment installation refers to the transportation of equipment from the production plant to the construction site. After a series of necessary construction processes, the main body of the mechanical equipment and ancillary components are installed in the correct process position, and the conditions for production and use are achieved through adjustment and trial operation. This entire process is the mechanical equipment installation process. Mechanical equipment installation engineering is an important process between civil engineering and production. It is also the only way for mechanical equipment to go from factory manufacturing to operation and production. The installation of mechanical equipment is also a complex project. It includes many types, different technical requirements, and various installation procedures and methods. Therefore, a high degree of attention must be paid to its construction methods and installation quality. With the upgrading of mechanical equipment, its technical content is getting higher and higher, and the installation of mechanical equipment also stands out. Prevent possible failures of mechanical equipment in advance and handle various failures in a timely manner before accidents occur or have no economic impact, thereby maintaining and extending their service life to varying degrees. ； If the mechanical equipment is reasonably installed and of high quality, unnecessary equipment failures will be prevented and unnecessary economic expenditures will be reduced from the most essential principle. Mechanical equipment is similar to people to a certain extent. For example, in order to save money, a person does not pay attention to his own nutritional supplement. For this reason, he often goes to the hospital for check-ups to prevent life-threatening diseases, which will cause a lot of damage to the economy and body. “It’s not too late to make up for it.” Although it is not life-threatening, if you pay attention to all aspects of nutrition and exercise of the body from the beginning, then there will be no need to go to the hospital, and the body’s resistance to the disease will not be reduced. For timely and high-quality mechanical equipment, if there are problems in the installation of the mechanical equipment that are not dealt with or not handled properly, then during the operation of the mechanical equipment, vibration may occur due to a screw not being tightened, causing damage to the outer shell or internal parts of the mechanical equipment, shortening the service life of the mechanical equipment. Although screws are inconspicuous and unimportant, they can cause damage to mechanical equipment. If the screws are tightened a few more times when installing mechanical equipment, all unnecessary losses may be avoided. Tightening the screws a few times does not require a waste of money and is not troublesome, but neglecting it will result in a greater investment of money and time. As the saying goes, "losing your wife and losing your army". If a person pays attention to physical exercise, controls his diet, has a regular daily life, is cheerful and generous, and focuses on strengthening the body's resistance, the so-called "three-point cure and seven-point nourishment" will reduce the chance of this person getting sick. “"If you don't enter the tiger's den, you won't get the tiger's cubs." Spending small money is to protect big money. Starting from the root of the problem will save a lot of unnecessary trouble. 2. The main manufacturers of coke oven machinery and equipment have stable and low-accident production. The quality of the machinery and equipment itself is unquestionably important. Domestic machinery and equipment technology is developing steadily, and the quality of machinery and equipment is also constantly improving. Excellent quality and low price are the advantages of domestic machinery and equipment production in the world. As a factory area, there are countless manufacturers of special equipment, but among the 360 ​​lines, the top manufacturers stand out. Major manufacturers of coking machinery and equipment: The coke oven vehicle is Dalian Huarui Heavy Industry Coke Oven Vehicle Equipment Co., Ltd. ； The furnace protective iron parts are from Shandong Zibo Vermicular Graphite Cast Iron Co., Ltd., Wuxi Coking Equipment Factory, Jiangdu Suxing Metallurgical Machinery Co., Ltd. and Botou Valve Gas Chemical Equipment Manufacturing Co., Ltd. ； The blower is from Shenyang Turbo Machinery Co., Ltd. ； Belt conveyor: Jiaozuo Yuxin Machinery Co., Ltd., Henan Tianlong Conveying Equipment Co., Ltd. ； Reducer: Taixing Reducer Co., Ltd., Tailong Reducer Co., Ltd. 3. Mechanical equipment installation content Mechanical equipment installation means that the equipment is transported from the production plant to the construction site. After a series of necessary construction processes, the main body of the mechanical equipment and ancillary components are installed in the correct process position, and the conditions for production and use are achieved through adjustment and trial operation. This entire process is the mechanical equipment installation process. (1) Preparation work before installation of mechanical equipment 1. Technical preparation mainly includes preparing construction technical plans in accordance with design documents, construction and acceptance standards and specifications, and equipment instructions, arranging the sequence of construction processes and dividing the levels of process quality control points, selecting advanced, practical, economical, and safe construction machinery and measurement tools to create orderly construction conditions and quality control conditions for mechanical installation. 2. Preparation of on-site construction conditions In accordance with the provisions of the technical plan for installation and construction of mechanical equipment, organize and implement the leveling of the site, the construction of parts storage places, parts and assembly places, construction water, points, roads, lighting, fire-fighting measures, and the preparation of lifting and transportation machinery and equipment to create a good production and operating environment for the installation of mechanical equipment. 3. Foundation acceptance: In accordance with the provisions of the design documents, retest measurements of the elevation, center line, anchor bolt holes, equipment coordinates of the equipment foundation, and settlement observation points of the main machines and equipment are carried out. Any foundation surface that requires secondary grouting should be pre-levelled and dirt removed so that the mechanical equipment and foundation can be accurately and densely combined. (2) Composition of mechanical equipment installation organization plan 1. Composition of construction personnel: Project managers, material purchasers, installation personnel (professionals such as aerial operators, crane workers, welders, etc.), and safety officers can mobilize personnel at any time based on the actual construction conditions. 2. Installation and configuration of mechanical equipment: Welding machines, oxyacetylene cutting tools and other tools 3. Construction procedures: Material procurement—→Construction preparation—→Organization plan—→On-site construction. 4. Quality standards and acceptance standards for installation and execution of mechanical equipment: Professional skills performed in machinery and equipment * * Standards and Mechanical Department Standards. 5. Mechanical equipment progress plan 6. Safety technical measures: Protection measures for special operations, on-site fire management, etc. (3) The installation of mechanical equipment is restricted by the following points: 1. Design drawings: The process installation drawings of coking machinery and equipment are designed based on the process flow of the factory, the needs of each branch plant, and the working principles and performance parameters of various mechanical equipment. The dimensions of the mechanical equipment civil engineering foundation drawings must be consistent with the dimensions of the mechanical equipment installation drawings. 2. Reasonable mechanical equipment: Select the model and specifications of mechanical equipment based on the working principle of the mechanical equipment and the performance parameters of the mechanical equipment, in line with the "reasonable structure and simple manufacturing" ； Easy to transport and install ； Easy to operate, control and maintain. ” 3. Installation team of mechanical equipment: From the causes of damage to mechanical equipment, it can be seen that it is very important to select an installation team. An installation team that is relatively professional and has the ability to independently complete the installation project should be selected based on the specialty of the equipment. There should be no phenomenon of inflating the numbers. (4) Installation problems and solutions of mechanical equipment 1. Problems in the installation of mechanical equipment (1) The installation team is a non-professional team. Most of the installation personnel are migrant workers summoned temporarily. They do not know how to install the slant iron for leveling during installation. Some even do not know how to install it and directly let the mechanical equipment come into contact with the foundation, resulting in uneven foundations of mechanical equipment, damaged bearings or broken anchor bolt holes during the operation of mechanical equipment. (2) The basic elevation of the mechanical equipment of the civil construction team did not match the drawings, which caused the mechanical equipment to be modified during the installation process, affecting the appearance of the mechanical equipment and posing hidden dangers to the operation of the mechanical equipment. 2. Solutions to mechanical equipment installation problems (1) Solutions for direct contact between mechanical equipment and the ground. When the foundation flatness is relatively flat, use a pair of inclined pads to level the mechanical equipment. ； When the surface of the foundation is rough, smooth the contact surface first, then use inclined pads to level it, and use grouting to stabilize the mechanical equipment. (2) Solutions for civil construction foundation inconsistencies a. When the civil construction foundation elevation does not meet the requirements, if the foundation is too high, a chisel can be used to lower it. ； If it is too low, the original foundation surface can be shoveled and then filled with concrete or a metal bracket can be added to solve the problem. b. When the foundation deviation is too large, the center of the foundation can be adjusted by changing the position of the anchor bolts. c. Deviation of anchor bolts: In the case of primary grouting, if the deviation is small, the anchor bolts can be baked red by gas welding and corrected to the correct position. ； If the deviation is too large, smaller anchor bolts can be dug out and re-buried. ； For larger anchor bolts, cut them off after digging to a certain depth, and weld a steel plate in the middle. The thickness of the steel plate is equal to the deviation size. (3) Conduct air tightness tests on storage tanks containing toxic gases or liquids, and check the quality of welds if necessary. If there is leakage, it is required to grind the welds flat and then repair the welds. For welding of some steel plates with a thickness greater than 8mm, a 45° groove should be made on the welding surface, and the welding is required to be full, and the weld height must meet the requirements. 4. The core of mechanical equipment installation lies in people 1. In addition to designing and manufacturing the correct installation of mechanical equipment, before installing mechanical equipment, the mechanical equipment installation management personnel should ask the constructor to check the installation instructions of the equipment. The mechanical equipment installation management personnel should pay attention and resolutely prevent speculation and cutting corners. Install correctly according to the mechanical equipment installation procedures to lay a good foundation for the operation of the mechanical equipment. 2. Equipment storage and transportation Some parts will fail due to improper storage. For example, a machinery factory in a coastal city processed and automatically welded 400 sections of Cr18Ni9Ti with a wall thickness of 12-14mm and a diameter of 600-1200mm for a user. The stainless steel pipe was of very good quality after welding. One year after being placed in the warehouse, a large number of welding cracks were found on the surface of the weld. After analysis, it was found that stress corrosion cracks in the weld area were caused by ocean moisture and Cl- and SO2+ in the atmosphere, so care should be taken when choosing a storage location. Heavy rain, floods, sunlight, vibration, impact, ocean moisture, and improper measures during transportation will cause undue damage to the equipment, and all of these can be avoided or minimized by humans. 3. Collect a large amount of feedback information and use advanced technology to transform equipment. According to the continuous occurrence of faults caused by improper design, manufacturing, and installation during operation of the equipment, use advanced technology to install mechanical equipment in a targeted manner to fundamentally solve the problems that existed in the operation of the equipment in the past. For example, a firewall in a modern network system can put a site in a proactive position in system maintenance. The firewall provides a barrier. 4. Train workers, engineering technicians and construction leaders at all levels who are engaged in mechanical equipment installation projects. They must be proficient in the basic requirements of installation projects.: Contents, organization and preparation of the installation ； Installation technical standards and testing methods, types and characteristics of various equipment foundations ； Commonly used material types and requirements in engineering ； Transportation, lifting, storage and acceptance of equipment ； Installation methods and commissioning rules for various types of typical mechanical equipment ； Basic knowledge of mechanics, mechanics, and applied chemistry commonly used in installation engineering, etc., as well as the skills to analyze faults and difficult problems that occur during the installation of various mechanical equipment. Only with such qualities can one be competent in the construction of mechanical equipment installation projects. People-oriented, training comes first. Looking at the above, the key lies in people. We need high-level installation managers with formal education and rich practical experience, and a large number of professional installation teams and supervisors with certain technical theory and process knowledge. We will not let go of any hidden dangers that may affect production, laying a solid foundation for the factory's commissioning and daily service life. 5. Conclusion In summary, if we install mechanical equipment in strict accordance with the equipment installation procedures in the initial stage from the beginning of the equipment's life cycle to the end of its life, it will delay the service life of the equipment, improve the reliability of the system and equipment utilization, reduce downtime, reduce the large amount of money occupied by maintenance and reserve parts, and significantly reduce maintenance costs. Some people estimate that most of the damage to mechanical equipment is mainly caused by improper installation or cutting corners. The practice of some units has also proved that paying attention to the installation of mechanical equipment and monitoring and controlling the root parameters is a "fundamental" approach. Taking precautions can achieve twice the result with half the effort. References 1. Gong Kechong, Gai Renbai, Equipment Installation Technology Manual. China Building Materials Industry Press. 1995 2. Li Zhuang, Chemical Machinery Equipment Installation and Debugging, Fault Diagnosis, Maintenance and Overhaul Technical Specification Manual. Jilin Electronic Press. 2003 3. Fan Zhaofu, Mechanical Equipment Installation Engineering Manual. Beijing Metallurgical Industry Press. 2004 4. Chen Guanguo, Mechanical Equipment Maintenance. Machinery Industry Press. 2000