Unpacking of the machine needs to be allowed for in the installation estimate as well as the removal of packing and surface protection films. Only those components ready for the installation at any specific time should be unpacked, do not unpack all items and prepare as surfaces and bright finished can be damaged prior to installation.  man-hours 40.

Total Hours Mechanical Installation; 2640 Man-Hours

1. Locate all items and Check all supplied items against equipment list.
2. Before installation, all parts shall be thoroughly cleaned, dirt, grit and foreign matter shall be removed. Grease or other protective coatings supplied for protection of the equipment in shipment and/or storage, except prime coating, shall be removed by using suitable solvents or cleaners which will not damage the finish of the equipment..
3. All foundation elevations and bolt locations shall be verified and accepted by the erection contractor prior to the start of installation of equipment
4. Levelling and alignment of all equipment shall be within the tolerance specified on the drawing or as specified in the manufacturer’s instructions. Where equipment is received as a shop assembly unit, alignment shall be checked and adjusted where necessary.

Unpack Prepare for installation 130 Man-hours

 

Civil Concrete Structure check

1. Check all the levels top of concrete for and record the exact RL’s.
2. Check bolt locations to drawings.
3. After Checking against civil drawings note any discrepancies in the mechanical check sheet
4. Once RL’s have been checked Scabble all the Plinths.

Civil Preparation              60 man-hours

 

2. Baseplates
   1. Baseplates shall be correctly levelled, aligned, set and adjusted on packers and shims.
   2. Packers shall be of sufficient size to sustain an effective load bearing area.
   3. Shims shall be of the same size as the packer. The maximum thickness of shim shall be used to reduce the number of shims required at any one point to a minimum.
   4. Form up around Base plates and pour 2 pack impact resistant Epoxy grout to the base plates and allow 12 hours before applying any load.
   5. Check center lines measurements to ensure square ( piano wire)
   6. Remove Polystyrene formers from Concrete and install hold down bolts in holes in concrete casting. Secure plate with the bolts flogged down but do not tension.
   7. Recheck for level and recheck center lines

120  Man-hours

 

Press Frame installation.

The press frame is generally supplied pre-assembled.

 

Check dimensional tolerances of the Slides and ensure they are parallel to the sides of the press frame, check for horizontal alignment and ensure it is perfectly level. Check bearing levels and contact surfaces of the fixed bearings.

Lower the press frame into place and secure but do not tension down.

The roller alignment shims are generally installed and set by the factory, ensure that the alignment accuracy is checked against the installation and operating manual before moving to the next procedure.

 

The roller housing is generally installed in the factory, dimension and accuracy must be checked, to do this remove the hoods on both sides.

Locate Haul to install location                           36 man-hours

Prepare for lifting                                              12 man-hours

Installation                                                       240 Man-hours

 

Placing the rollers

Using the lifting frame place both rollers fixed and floating on the slide on the hinged down head ends.

First stage is to push the fixed roller into the frame until it touches the Shim plates, close the head end up and fix the locking pins into place, press the floating roller into place in the same manner but leave the head ends open.

Moving the two rollers into the press frame is done using the roller pulling device to move the rollers into place in a parallel motion.

 

Locate Haul to install location                           64 man-hours

Prepare for lifting                                              72 man-hours

Installation                                                       330 Man-hours

 

Cylinder Blocks and hydraulics

Place the cylinder blocks into position on each side of the machine slide into the location against the bearing housings of the floating roller. Remove safety device, lock into position using the locking screws

 

Install Cylinder Blocks                                       64 man-hours

 

Gravity Feeder

 

Place the gravity feeder into position on the press frame and bolt in place, hang the cheek plates in position, bolt the bottom of the cheek plate by hand securing the top bolts latter, this allows for adjustment of the cheek plates to meet the feeder operating parameters, continue on to fit the cover plates.

 

Install Gravity feeder                                        120 man-hours

 

Gear Boxes.

 

The gear boxes have protective cover plates on the machined surfaces, these must be removed just prior to installation.

The gear boxes are generally built with lifting lugs in place to allow correct installation, a soft sling is required to balance the load  and should be slung just behind the torque arm, this sling should be attached to the lifting rig with a chain block to allow for adjustments when aligning the drive unit couplings.

 

The roller shaft and hollow shaft on the gear box must be cleaned of any protective coating applied for transport, then attach the Gear box to the roller shaft using a levelling devise to assist with alignment and adjust the level with the chain block attached to the sling. Air will be released through the small grove on the journal, the insertion of the roller drive shaft must be slow to allow for the air to escape.  Support the gear box using blocks.

Repeat this procedure for the second gear box.

Once both units are in position secure the torque arms using the intermediate struts, fit the Shrink disk guards in place on the gear box, mount sensors in place.

Connect the universal joint coupling to the gear box, connect oil lines and install guards.

 

Install gearboxes                                              160 man-hours each – 320 man-hours

 

Motors

Motors are mounted on base frames which are mounted on base plates installed during the setup stages on the installation, each motors connects to the Gear box via a the input shaft and clutch mechanism.

Install Motor Frames                                        24 Man-hours each 48 man hours

Install Drive Motors                                           120 man-hours each -240 Man-hours

 

Hydraulic Power Pack

 

The Hydraulic power pack is located away from the Roller  unit and the oil supply is hard piped to the unit. The grease unit is generally part of the oil and lube skid, this also requires piping to be run to a close proximity of the roller unit them the final connection utilises flexible tube.

 

Install Hydraulic Skid unit                                  84 Man-hours

Install Hydraulic hard piping                              340 Man-hours

 

Cooling Water system

A cooling system is required to provide cool water to the Rollers, Bearings and Oil cooler, this is generally located at ground level with hard piping to the unit

Connect cooling water System                         60 Man-hours

Hard pipe Cooling Water                                  240 Man-hours

Final hook up                                                   60 Man-hours