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BETTER SOLUTIONS
6-1. Installation Press equipments & scheduleitem Equipment name qty wt(Ton) KIA Site arr. install trial
#1 Press 5,400ton Press 1 2,071.0
2005.12
2005.12
~
2006.01
2006.01
~
2006.04
T/F unit 1 20.1
Destacker 1 141.5
Auto Palletizer 1 154.6
Aux. 2,400ton T/O Press 1 643.2
50Ton D/S 1 82.5
B.T.O 1 11.5
600ton Blanking press 1 275.7
Coil line 1 285.9
#2 Press 5,400ton Press 1 2,071.0
2006.03
2006.03
~
2006.05
2006.05
~
2006.07
T/F unit 1 20.1
Destacker 1 141.5
Auto Palletizer 1 154.6
total 13 6,073.2
BETTER SOLUTIONS
6-2. Installation working scope1. General
(1) Schedule Management (2) Safety Management (3) Management of Works (4) Inevitable condition, Disaster (5) Investigation and Technical advise for abnormal condition during installation, assembling and start up. (6) Working time (A) Seven(7) days / week Two shift should be done if not to keep the installation schedule (B) One(1) shifts / days or Two(2) shift / days (C) Eleven(11) hours / shift
2. Unloading and Packaging
(1) Checking quantities and condition (2) Protection cover from rain, flood and snow fall at outdoor (3) Transportation from storage area to erection site (4) Unpacking at installation site (5) Disposal of crate, case, skid and steel, and rubbish to the outside of the plant (6) Removing rust preventives and cleaning
BETTER SOLUTIONS
6-2. Installation working scope3. Preparation of foundation
(1) Checking of dimension of level and center in accordance with drawings and manuals
4. Installation of press equipments and fixture
(1) Base plate (2) Foundation Bolt for Bed (3) Press Proper (Including Crown, Upright, Bed, Die Cushion, Slide, Moving bolster, Platform, Covers, Coil line eqipment, B.T.O ETC) (A) Installation and assembling (including level and center adjust) (B) Assembling of electrical motor and centering (4) Fixture (Auxiliary) * Air tanks * Oil Hydraulic unit with tank * Moving boister and rails, Cable Guides * Safety guards (5) 2,400 Ton Crown Assembly * Assembly work (Refer Packing list) (6) Welding & Cutting work for installation of equipments (7) Welding work for pipe connection between balancer cylinders and air tanks, cushion cylinders and air tanks
BETTER SOLUTIONS
6-2. Installation working scope5. Mechanical pipings
(1) Assembling pipes between press and fixtures (2) Installation and connection of air pipes between air tanks and CTB cylinders (3) Flushing work after piping installation (4) The cutting, bending, welding and etc. for piping work of presss, coil line and etc.
6. Installation of electrical equipment
(1) Drive panel for main motor (2) Control panels (3) Terminal boxes (4) Cable racks & ducts (Cutting, assembly, installation at site) (5) Conduit pipes (6) Wiring (A) Wiring and termination * From panels to termina boxes (TB) * From TB to sensors / actuators * Between each panels (7) The welding, bending, cutting work for electrical pipe installation
BETTER SOLUTIONS
6-2. Installation working scope
8. Installation of scrap chute Carrier railway
9. Installation of the cover for coil line
10. Preparation for Machine Adjustment
(1) Charging of grease to each points (2) Filling up the oils to tanks (3) Cleaning and oil sprinkling to Crown inside and Slide (4) Pickling, cleaning and Flushing of the pipes fabricated at site after inspection of Rotem S/V (5) Air blow cleaning of intemediate air pipes (6) Disposal of dirty and/or used oil (7) Wiring check (Continuity) (8) Power on (9) I/O check for electrical
11. Machine adjustment (1) Assistant Workers during the running test & after running test refer the working schedule (2) Responsibility for bad installation work
BETTER SOLUTIONS
6-3. Organization chart6-3. Organization chart
Main Facility (Rotem)
Press Mechanical Specialist
Press Electric Specialist
PM
Chief PM : Press Specialist (1)
Vice PM : Industrial Facility Specialist (1)
Auxiliary Facility (WIA)
Press Mechanical Specialist
Press Electric Specialist
Installation Master
Specialist Installation Comissioning
Mechanical 20 3
Piping 10 2
Electrical 15 4
Helpers 10 2
Total 55 11
Installation Master
Specialist Installation Comissioning
Mechanical 10 3
Piping 10 2
Electrical 10 4
Helpers 10 4
Total 40 13
BETTER SOLUTIONS
6-4. Installation equipment
Four(4) Point Hydraulic lifter : 400 Tons 1 unit
Mobile Hydraulic crane : 100 Tons 1 unit
BETTER SOLUTIONS
1-5. 1-5. 설비 장비설비 장비
Mobile Hydraulic crane : 50 Tons 1 unit
Fork lifter : 10 ~ 20 Tons 4 units
Remarks : KIA Over-Head Crane (30~50 Tons)
BETTER SOLUTIONS
6-5. Installation basetool list
INSTALLATION BASETOOL LISTNo Machine Name Specification Quantity Remarks
1 Hand tool set
2Arc welder and all necessary welding equipment
3 Helmet for Welding
4 Glove for Welding
5Cutting gas torch and bulbs with all necessary equipment
6 Eye bolt
M8 X 1.25 mm Pitch
M10 X 1.5 mm Pitch
M12 X 1.75 mm Pitch
M16 X 2.0 mm Pitch
M20 X 2.5 mm Pitch
M24 X 3.0 mm Pitch
M30 X 3.5 mm Pitch
7 Shackle
1 ton
2 ton
2.5 ton
5 ton
10 ton
20 ton
BETTER SOLUTIONS
6-5. Installation basetool list6-5. Installation basetool list
INSTALLATION BASETOOL LIST
8 Ratchet lever hoist
0.5 ton
1.0 ton
1.5 ton
9 Chain hoist
1 ton
1.5 ton
3 ton
10 Hydraulic jack
10 ton x 50mm Strok
10 ton x100mm Strok
10ton x 200mm Strok
15ton x 150mm Strok
11 Hand pump for Hydraulic jack
12 Hydraulic jack and distance blocks 50ton
13 Distance block or tube for jack / 15ton /each
Dia 50 - 70mm
Length 1 m
15ton / each
14 Sling for lifting(or Wires)
1 ton x 1 m
1.5 ton x 1 m
3ton x 1 m
3 tons x 2 m
3 tons x 4 m
5 ton x 1 m
5 tons x 2 m
5 tons x 4 m
BETTER SOLUTIONS
6-5. Installation basetool list
INSTALLATION BASETOOL LIST
15 Dial indicator0.01mm / div
0.01 - 10mm
16 Magnet stands for Dial Indicator
17 Oil stone(Fine)
18 Washing Oil(Degreasing equipment)
19 Waste clothes(Scrap rags)
20 Fire extinguisher
21 Fire Blanket
22 Hand saw
23 Craw bar
24 Angle(Disc) grinder Dia 120mm
25 Safety Glasses
26 Hand lamp
27 Garage lamp
28 Extension electric cable 20A, 30m Cable
29 Cold chiselSmall
Medium
BETTER SOLUTIONS
6-5. Installation basetool list6-5. Installation basetool list
INSTALLATION BASETOOL LIST30 Large hammer (Sledge Hammer)