TBRED Installation Manual

Transcription

Thoroughbred
Installation
Manual
DC-Colt
Copyright © 2013
THOROUGHBRED & DC-COLT
TABLE OF CONTENTS
SECTION 1: INTRODUCTION
Preface.................................................................................................................... 1
Manual Layout......................................................................................................... 1
Safety & Warning Placards...................................................................................... 1
Safety & Warning Placard Location Diagram........................................................... 2
SECTION 2: PLANNING THE INSTALLATION
Preparations and Considerations............................................................................. 3
SECTION 3: BOLTED CONNECTIONS
Bolt Tightening Requirements.................................................................................. 5
Turn-of-Nut Pre-tensioning Method.......................................................................... 5
Snug-Tightened Joints............................................................................................. 5
Correction of Errors................................................................................................. 6
SECTION 4: INSTALLATION
Prepare for Installation............................................................................................. 7
Placing Plant on Extension Legs.............................................................................. 9
Silo or Cement Batcher Installation........................................................................ 10
Cement Silo Setup..................................................................................................11
Cement Batcher Setup............................................................................................11
Silo Installation (If silo is shipped loose)................................................................ 12
Thoroughbred AGG Bins........................................................................................ 13
Connect Aggregate Bins........................................................................................ 15
Set Up Aggregate Batcher..................................................................................... 15
Connect Electrical Panel........................................................................................ 16
Set-Up Air Compressor.......................................................................................... 17
Set-Up Transfer Conveyor..................................................................................... 18
Set-Up Silo Ladders and Cages............................................................................. 19
Set-Up Water Meter............................................................................................... 19
Service Records.................................................................................................... 20
SECTION 5: CONTACT INFORMATION
STEPHENS MFG................................................................................................... 21
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STEPHENS MFG. PO. BOX 488
TOMPKINSVILLE, KY 42167
PHONE 800-626-0200
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SECTION
SECTION 1: INTRODUCTION
Preface
This manual provides setup and installation instructions for the Thoroughbred and DC-Colt portable
plants for gravity drop cement. Cement is gravity fed from silo to batcher, then, batcher to truck.
The Thoroughbred plant is pre-wired in conduit and the pneumatic lines are pre-plumbed. The
main disconnect and plant power panel are enclosed in a steel cabinet with hinged, lockable steel
doors, positioned to face away from the transfer conveyor for cleaner, safer operation. The plant air
compressor is located on the plant’s tongue above the 5th wheel, away from the transfer conveyor for
a cleaner and safer operation.
Manual Layout
Refer to the manual, images and content to assist with proper setup and installation of the Thoroughbred
and DC-Colt plants. Throughout the manual, safety notices provide help for a successful and safe
installation of the plant. Typical safety notices are defined below:
NOTICE
Highlights information that is of special importance.
CAUTION
Draws attention to anything that could damage the equipment or adversely
affect the installation of the unit.
WARNING
Draws special attention to anything that could cause injury or death.
Safety & Warning Placards
The unit and optional attachments are clearly marked with safety and warning signs, placards, as a
reminder to observe safe installation and operating procedures. Read the instructions and become
familiar with the safety and warning placards. Failure to observe safety and warning placard instructions
can result in serious injury to workers or damage to property.
Always replace worn or missing safety and warning placards. See the Placard Location Diagram for
sign location on page 2, and contact Stephens Manufacturing to order replacement placards.
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SECTION 1: SAFETY & WARNING PLACARDS
Preparations and Considerations
Safety & Warning Placard Location Diagram
This is a typical set of instructions for a standard Stephens’ Thoroughbred or DC-Colt. Please consult
the factory if your plant has any optional equipment not shown in this manual. This manual applies
only to standard Stephens Thoroughbred and DC-Colt equipment.
NOTICE
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Your plant may have some unique or special options that might require
some additional details or instructions.
Stephens may provide instructions that supplement or supersede this manual at any time for standard
or non-standard equipment.
Owner, operator is responsible to ensure the unit installation complies with all applicable local laws,
regulations and codes, and to obtain all necessary permits, inspections and approvals.
Stephens makes no representation or warranty that installation according to these instructions will
comply with any such local requirements. In the event of a conflict between this manual or any other
instructions provided by Stephens and local requirements, contact Stephens.
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For supervision during installation and further unit operation training, contact Stephens MFG. It is the
owners responsibility to meet local and federal government guidelines and codes, to include acquiring
registered engineer design documents for footings, anchor bolts, shims and grout to complete the
installation and operation of the plant.
NOTICE
If your equipment has additional options, or the place where it will be
installed differs from standard in any way, contact Stephens for additional
instructions.
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DESCRIPTION
Caution, LockOut - Decal
Caution, Live Circuit - Decal
Caution, Batch Plant Disconnect - Decal
Caution, Check Lubrication - Decal
480 Volt, Three Phase - Decal
120 Volt, Single Phase - Decal
Danger, High Voltage - Decal
Warning, Arc Flash & Shock Hazard - Decal
Caution, Not Suitable Work Platform - Decal
CPMB - Decal
Serial Number - Plate
Remove Scale Bracket - Decal
Conveyor Guard - Decal
The manufacturer warranty does not apply to plants that have not been properly installed, operated
or maintained according to Stephens’ drawings, specification, instructions or manuals. During
installation, if a contradiction between any said documents and the customer engineered design plans
becomes apparent, stop the installation and contact a Stephens representative.
QTY
The owner is responsible to coordinate (hire) certified crane services to unload and erect the plant.
It is the owners responsibility to arrange utilities, water and electrical services to the proposed plant
site. The customer must enlist a certified scale servicemen, before plant operation, to calibrate and
certify scale systems.
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WARNING
Failure to install equipment according to the instructions of Stephens or
any other manufacturer can cause injury or death.
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Bolt Tightening Requirements
Unless noted otherwise, all structural connections using 5/8 inch diameter or larger bolts shall be
installed as pre-tensioned joints without washers. Smaller bolts or joints, as designated may be
installed to a snug-tight condition.
CAUTION
Use the “Turn-of-Nut” method for tightening all structural connections
that require 5/8 inch diameter or larger bolts. See detailed explanation of
the “Turn-of-Nut” method when tightening structural connections.
NOTICE
Stephens Engineers only recommend minimum size anchor bolts.
Turn-of-Nut Pre-tensioning Method
All bolts shall first be installed to a snug-tight condition. Subsequently, the nut or head rotation specified
in Table 1 shall be applied to all fastener assemblies in the joint, progressing systematically from the
most rigid part of the joint in a manner that will minimize relaxation of previously pre-tensioned bolts.
The part not turned by the wrench shall be prevented from rotating during this operation.
CAUTION
Use the “Snug Tight” method for tightening all smaller bolts or joints as
designated. Additionally, this method is used for anchoring the plant to
the concrete foundation. See detailed explanation of the “Snug Tight”
method when tightening these various connections.
Snug-Tightened Joints
All bolt holes shall be aligned to permit insertion of the bolts without undue damage to the threads. Bolts
shall be placed in all holes with nuts threaded to complete the assembly. Compacting the joint to the snugtight condition shall progress systematically from the most rigid part of the joint.
The snug-tightened condition is the tightness that is attained with a few impacts of an impact wrench or
the full effort of an ironworker using an ordinary spur wrench to bring the connected piles into firm contact.
More than one cycle through the bolt pattern may be required to achieve the snug-tightened joint.
Disposition of Outer Face of Bolted Parts
Bolt Lengthc
Both faces
normal to bolt
axis
One face normal to
bolt axis, other sloped
not more than 1:20d
Both faces sloped not more than 1:20
from normal to bolt axisd
Not more than 4db
1/3 turn
1/2 turn
2/3 turn
Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For required nut
rotations of 1/2 turn and less, the tolerance is plus or minus 30 degrees; for required nut rotations of
2/3 turn and more, the tolerance is plus or minus 45 degrees.
Applicable only to joints where all material within the grip is steel.
When the bolt length exceeds 12db, the required nut rotation shall be determined by actual testing in a
suitable tension calibrator that simulates the conditions of solidly fitting steel.
Beveled washer not used.
Table 1 - Nut Rotation from Snug-Tight Condition and Turn-of-Nut Pretension,b
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SECTION: BOLTED CONNECTIONS
Correction of Errors
Prepare for Installation
Normal erection operations include the correction of minor misfits by moderate amounts of reaming,
chipping, welding or cutting, to align elements through the use of drift pins. Refer to AISC Code of
Standard Practices for Steel Buildings and Bridges.
Prepare for installation and setup of your plant. Begin by positioning the plant adjacent to the concrete
piers and then proceed with the steps as indicated below.
NOTICE
Place the “Stephens Thoroughbred or DC-Colt” as close to the concrete
piers as possible to reduce crane time erecting of the plant on its piers.
Figure 1: DC-Colt
Figure 2: Thoroughbred w/ silo shipped loose
WARNING
Maintain safe clearance from power and overhead lines when orientating the unit
for transfer and erection. Contact with overhead lines could cause serious injury,
death, and/or damage to equipment.
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Placing Plant on Extension Legs
Use 7/8” x 2-1/2” Bolts* at column connections.
Use 7/8” x 2” Bolts* at bracing.
1. Prepare for lifting the plant onto the extension legs. Hook the crane cables to the lifting eyes/lugs
and/or at stable braced areas as shown above.
2. Align plant with the top of the lower extension legs (already fastened to concrete piers). While
plant is suspended, bolt connection plates together with applicable bolts.
WARNING
Use only certified lifting chain for crane lifting assignments as broken
attachments can cause serious injury or death.
Figure 3: Thoroughbred with silo attached
1. Bolt the six (6) bottom extension legs to the concrete piers, refer to Figure 4. (hand tighten only)
2. Bolt the cross bracing (hand tighten only). The minimum size anchor bolts are listed in the base plate
layout prints, per Stephens Engineer Recommendations. Stephens supplies bolts for connection
plates and leg support braces with the unit.
3. Refer to prints for approximate weight specifications of equipment. It is recommended that you use
an oversized crane to eliminate any unnecessary lifts and moves with the smaller cranes. Contact
factory for exact weights.
4. Axles can be returned for credit. Remove axles assemblies before the plant is raised. With proper
support for the axles, loosen all the bolts that hold the axles to the transportation frame. If the
axles, tires, wheels and brake air tank are in good working order they can be returned to the
factory for credit. Customer is responsible for delivery freight to factory in Tompkinsville, KY.
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Figure 5: Sketch Shows Thoroughbred
WARNING
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Maintain safe clearance of power and overhead lines when orientating the unit for
transfer and erection. Contact with overhead lines could cause serious injury,
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Figure 4: Lifting Diagram
*Bolt size/length increases for some seismic plants, consult factory.
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Silo or Cement Batcher Installation
Cement Silo Setup
1. Set crane position to hinge the silo or cement batcher section into the up position.
Customer will need to use the job specific electrical prints to properly connect wires, bindicators, and vents.
Always use proper lock-out/tag-out procedures before working on electrical system, customer may also
have to connect some pneumatic components. See specific customer prints for more details.
2. Remove the bolts from the bottom section of silo legs from the travel position.
3. Position the crane for lifting the silo in place. Use of a spreader bar/beam may be desirable to
connect cables to outside lifting lugs of silo.
WARNING
Danger, 120 volt, single phase.
4. With the crane, slowly raise the silo frame and/or silo up into position.
5. While silo frame is suspended by crane, bolt legs to foundation and connection plates (hand tighten only).
6. Install all applicable braces between silo legs (hand tighten only).
CAUTION
Disconnect power and “Lock-Out” before servicing.
WARNING
CAUTION
More than one live circuit.
Column Connections use 7/8” x 2-1/2” Bolts*
Cement Batcher Setup
Bracing uses 7/8” x 2” Bolts*
Normally all electrical and pneumatic items will be wired and connected to the cement batcher. The
customer will be responsible to remove all shipping brackets before operation the plant. The work platform
around the cement batcher is an optional item; caution will need to be taken while removing brackets.
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CAUTION
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Figure 6: Thoroughbred with silo loose.
WARNING
Maintain safe clearance of power and overhead lines when orientating the unit for
transfer and erection. Contact with overhead lines could cause serious injury,
Figure 7: Thoroughbred and/or DC-Colt with silo attached
*Bolt size/length increases for some seismic plants, consult factory
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Silo Installation (If silo is shipped loose)
Thoroughbred AGG Bins
1. While silo is lying on the ground, install ladders, cages, platforms, etc., included in the order of
this plant. Use a 12’-0” spreader bar to pick silo up (spread bar to clear handrails and any vents).
1. Install the middle aggregate partitions. (If bins are welded up type skip no. 1 thru no. 3 of this section.)
2. Lift the silo onto the connection plates as shown in Figure 8.
3. Install the two side partitions.
3. Install cement batcher scale bolts and safety chains prior to un-securing cement weight batcher.
(Weight batcher is secured during shipping.)
2. Install the two outside partitions.
Column Connections use 7/8” x 2-1/2” Bolts*
Bolt up heap plates 7/8” x 2” Bolts
Bolt up Bins 7/8” x 2” Bolts
4. Now go back and tighten all bolts on the cement section by using the “Turn of Nut” method. Refer
to Section 3, page 5 for bolt torque table and guidelines.
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CAUTION
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WARNING
Figure 8: Thoroughbred with silo shipped loose
WARNING
CAUTION
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*Bolt size/length increases for some seismic plants, consult factory
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Connect Aggregate Bins
Use the specific electrical customer prints to determine if your plant has any special bin level indicators
or vibrators for the aggregate bins. Stephens will normally ship the necessary air cylinders for the
aggregate bin gates, strapped to the horizontal beam above the aggregate batcher. Customer should
remove the cylinders from the beam and install them on the overhead bin gates.
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Figure 11: AGG Bin
NOTICE
DC-Colt will not have overhead bins.
CAUTION
4. Lift the bin and cone up and install four stub legs.
5. Set the bin and cone back on top of aggregate frame and install angle leg braces.
WARNING
6. If bins are welded up type, set them on top of cone section.
7. Now go back and tighten all bolts on the aggregate section by using the “Turn of Nut” method.
WARNING
Set Up Aggregate Batcher
All electrical and pneumatic items should be connected to the batcher. Customers will have to remove
shipping brackets to allow Aggregate Batcher to swing freely.
WARNING
Figure 12: AGG Bin Shipping Bracket
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Connect Electrical Panel
Set-Up Air Compressor
Stephens will normally supply a main disconnect with each new plant. Unless specified otherwise
the size disconnect and all starters will only cover items supplied by Stephens Mfg. The customer will
need a certified electrician to use the job specific electrical plans to connect main voltage and test/
operate the new plant. Consult the factory if additional prints are required. Follow all safety labels and
always use the proper lock-out/tag-out procedures for service and maintenance.
Compressor is normally shipped on the tongue of the plant, away from moving parts. Unless optional
work platform is selected at purchase, the tongue area is not to be a work platform area and caution
should be taken. To start up compressor use the manufacturers start up instructions located in the
maintenance manual, and double check fluid levels and rotation.
WARNING
Danger, 480 volt circuit.
WARNING
Danger, high voltage!
CAUTION
Check lubricant levels in all gear reducers prior to start up.
Figure 13: Electrical Panel
Figure 14: Electrical Panel
WARNING
Danger, 120 and 480 volt circuits.
WARNING
Danger, high voltage!
WARNING
Arc flash, electrical shock hazard. Appropriate PPE and tools required
when working on this equipment.
Figure 15: Unit Tongue Platform Caution Placard
CAUTION
Batch Plant Disconnect
CAUTION
CAUTION
CAUTION
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17
Set-Up Silo Ladders and Cages
Customer will need to look at specific customer prints to determine the number of cage sections, their
locations and the locations of rest stops.
Ladders, cages, and platforms are
unit specific. Verify unit plans to
determine quantities and location
of included equipment.
Figure 16: Conveyor Guard
WARNING
Danger, 480 volt circuit.
CAUTION
CAUTION
CAUTION
Set-Up Transfer Conveyor
The transfer conveyor is normally already pre-wired at the factory and run for conveyor tracking purposes.
The customer should bolt the collection hopper to the frame of the conveyor. The customer should check
fluid level in reducer. The customer should double check the rotation and accuracy of the belt tracking. The
conveyor belt should be tightened after initial use. (3-4 weeks after start up) Always use proper lock-out/
tag-out procedures before performing service or maintenance on conveyor.
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Figure 17: Conveyor Guard
Set-Up Water Meter
The water meter normally travels with the Thoroughbred and Colt plants. The customer will need to
connect the water line/hose to the truck collection hopper.
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SECTION 5: CONTACT INFORMATION
Service Records
SERVICE PERFORMED
DATE
INITIALS
STEPHENS MFG.
PO. BOX 488
TOMPKINSVILLE , KY 42167
PHONE: 800-626-0200
OUTSIDE the USA:
270-487-6774
FAX: 270-487-8368
Proud Member of:
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TBRED Installation Manual

Transcription

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