In order to ensure the installation progress and reduce the installation workload, the installation is carried out simultaneously with the help of a crane and a loader to improve efficiency.
Check whether the foundation meets the installation requirements. If so, installation can be carried out.
The installation sequence of the mixing station is as follows:
- Installation of the main frame
(1) Bolt and connect the mixing layer beam with the connecting plate, lift the mixing layer beam with an 8t crane, and then rotate it 180° so that the lower surface of the mixing layer beam faces upward. Lift the lower legs with an 8t crane, bolt them together with the mixing layer beam, connect the mixing layer beam with the four columns on the ground, install the hopper under the mixing layer beam with bolts, and then rotate it 180° so that the columns face downward. Lift it on the foundation with a large crane and fix it with anchor bolts.
(2) Lift the mixing main machine on the beam and connect it with bolts.
(3) Lift the weighing layer, bolt the weighing layer together, connect the weighing layer with the mixing layer on the ground, and then rotate it 180° so that the columns face downward. Lift it with a large crane and fix it on the mixing layer beam.
(4) Connect the door platform and mixing layer ladder with bolts; then connect the mixing layer unloading pump, unloading pipe, powder pipe and other accessories with bolts.
(5) Lift the temporary storage bin with the door opening device installed to the metering bin and connect it with bolts.
(6) Lift the pressure relief pipe into place and connect it with bolts.
(7) Lift and connect the powder metering system and liquid metering system, and make each metering hopper free without interfering with other components.
(8) Lift the dust collector into place and install it as required.
- Belt conveyor installation
There are two types of inclined belt conveyors, one is a high-end side trough belt conveyor, and the other is a ring belt conveyor. The following are the installation methods of the two conveyors:
Since the inclined belt conveyor is long, the frame is easy to deform, the upper installation height is high, and the crane arm is too long, it is easy to cause safety accidents. Therefore, you must pay attention to the lifting method and position.
(1) Installation of high-retaining side trough belt conveyor
① Bolt the frames of each section of the belt conveyor together; connect the inclined platform and the middle bracket as one, set up the middle bracket, install the belt, install the upper and lower roller groups, and install the legs
② Use two cranes to lift it into place, calibrate it, and connect the anchor bolts.
③ Adjust the tensioning device to make the belt tight and appropriate.
④ Install the belt beating device.
⑤ Install the empty section cleaner.
⑥ After normal operation, install the guide trough, collection barrel, tile edge plate support, and tile edge plate.
(2) Installation of circular flat belt conveyor
① Bolt the frames of each section of the belt conveyor together.
② Connect the inclined platform and the conveyor frame as one, hoist it into place with two cranes, install the support feet, calibrate and connect the anchor bolts.
③ Install the platform guardrail.
④ Hoist the collecting barrel into place and connect the bolts.
⑤ Install the upper and lower roller groups.
⑥ Install the belt.
⑦ Install the active roller, driven roller and steering roller.
⑧ Install the heavy hammer tensioning device.
⑨ Install the tile edge plate support and tile edge plate.
- Aggregate batching system installation
(1) Hoist the batching system in transport state onto the laid foundation and secure it with anchor bolts.
(2) Hoist the upper bin into place and secure it to the frame.
(3) Install the sensor and adjust the distance between the upper surface of the metering hopper and the discharge door to an appropriate level. It is strictly forbidden to subject the sensor to torque when installing the sensor. For floor-type batching machines, the transport hinge should be loosened, but not removed, so that it is no longer subjected to force.
- Operation room installation
(1) After connecting the operation room to the bracket, hoist it onto the laid foundation and secure it with anchor bolts.
(2) Install the lower ladder and upper ladder.
- Installation of cement silo and screw conveyor
(1) Assemble the components of the supporting cement silo one by one on the ground (install the upper and lower level meters and their circuits, dust collector cables, ladders and railings, air breaker pipes, solenoid valves and air filters, cement feed pipes, screw conveyor suspension ropes, etc.), then lift the cement silo and put it in place, and tighten the anchor bolts. (Note: For areas where the wind force is often greater than level 6, a wind rope should be added).
(2) Assemble the screw conveyor on the ground, hang the feed end on the cement silo discharge port, align the discharge port with the metering hopper feed port, tighten the suspension rope, install the screw conveyor bracket, and then connect the feed port with the cement silo discharge port. Connect the discharge port with the metering hopper feed port with a soft rubber sleeve. Note that the soft rubber sleeve should not be stretched too tight to avoid affecting the metering accuracy.
(IV) Pipeline installation
Water pipeline installation: Place the water pump in place and install the water supply pipe as required. Users can build their own water
pools, the water pool capacity should not be less than 10m³, or directly connect the water pump to the tap water pipeline.
- The pipeline flow should not be less than 50m³/h.
- Admixtures: Place the admixture storage bin in place and install the admixture pipeline.
(V) Gas system installation
- Fix the air compressor and gas tank in place.
- Connect the pipelines between the air compressor, gas tank, various gas control boxes, cylinders, etc. according to the diagram.
(VI) External decoration installation
(Install the various bending parts on the olive fan fruit and the weighing layer fire fruit).
- Install the doors and windows.
- Install the axial flow fan.
(VII) Electrical system installation
- The control electrical appliances of the mixing and metering systems are installed in the main electrical cabinet and the control console respectively. Before external wiring, first check whether the electrical components of each part are intact and firmly fixed. The wiring screws must not be loose, and the welding points must not fall off or corrode.
- Connect the wiring between the electrical cabinet, the operating table, and each motor, solenoid valve, travel switch, sensor, etc., and review according to the electrical schematic diagram. The system uses grounding protection as a safety protection, requiring good grounding protection measures at the installation site. The protection line of the motor cable, the shell of the electrical box, the main grounding bolt of the equipment, and the main grounding electrode are electrically connected, and the protection line is not allowed to be connected in series. If the external power supply allows zero protection, the protection line PE is connected to the protection line of the motor cable, the shell of the electrical box, and the main grounding bolt of the equipment; the grounding wire connected to the main grounding terminal of the equipment, the grounding terminal of the cement silo, and the grounding terminal on the main control room leg can be a wire that meets the corresponding grounding requirements or a bare conductor such as flat steel, which can be installed by the user. After the equipment is installed, the installer should check that the pure resistance is not greater than 4 ohms and the equipment is grounded at the same potential. If the requirements are not met, the pole should be immediately entered for rectification.
- The layout of the external building line should be reasonable, beautiful and generous. The power line and the signal line shall not be laid in parallel. The wiring of each part should be arranged neatly and shall not contact oil, water and corrosive substances. All money and power distribution to the concrete mixing station shall comply with the relevant provisions of GB5226.1-1996 and factory power design technology; products with requirements shall comply with the regulations of this industry or department.
(VIII) Lightning protection device
According to the natural conditions such as geography, geology, soil, meteorology, environment and the law of lightning activity of the equipment use site, the user shall install the lightning protection device according to the "GB50057-1994 Building Lightning Protection Design Code" and other requirements.
(IX) Safety guarantee measures
- All installers shall wear safety helmets before on-site operations.
- On-site personnel and machinery must obey the deployment and command of the commander.
- During the hoisting process, the crane should move steadily and obey the command of the ground commander. The crane hoisting operation should be commanded by a dedicated person and no illegal operation should be performed.
- The hoisting should be fixed firmly to prevent unhooking. During the hoisting process, workers are not allowed to work under the hoisted objects.
- Hoisting is prohibited in bad weather. Safety ropes must be configured for high-altitude operations. Hands should be held firmly when climbing. If the cement silo is higher than other surrounding buildings, lightning rods should be installed.
- The verticality of the cement tank must be ensured when installing the cement tank.
- After the installation is completed, the bell should be pressed three times before starting the mixer and belt conveyor each time, with an interval of 10 seconds each time. The equipment can only be started after 5 seconds after the third bell.
- It is strictly forbidden to enter the mixer without reason. If it is really necessary for maintenance, the power supply should be disconnected, and a warning sign of "Someone is working, it is strictly forbidden to close the switch" should be hung, and a dedicated person should be assigned to guard to prevent accidental closing of the switch. The mixer can only be started after confirming that there is no one in the mixing tank to prevent casualties.
- It is strictly forbidden for people to put their hands into the screw conveyor. If it is really necessary, the power supply should be disconnected and a warning sign "Someone is working, it is strictly forbidden to close the switch" should be hung to prevent accidental closing of the switch. The screw conveyor can be started only after it is confirmed to be safe.
Precautions for the installation of mixing station equipment:
① Under the premise that the lifting capacity allows, the ground assembly should be hoisted together as much as possible;
② Before installation, each component must be counted and numbered, and a dedicated person should be responsible for command during hoisting to prevent rework due to wrong hoisting and ensure hoisting safety;
③ During installation, the installation dimensions should be checked at any time and deviations should be corrected in time;
④ After installation, the surface paint should be repainted if it is damaged.
⑤ All installers must wear safety helmets and safety belts.
⑥ Non-installation personnel are not allowed to enter the construction site.
