Square silo
Manual type: Instalation instruction Version Master, No.: 01, GB
Date issued: March 2016 Distribution: Machine documentation
Contact:Andritz Feed & Biofuel A/S Division: Machine documentation Machine responsible: Engineering Glentevej 5-7 6705 Esbjerg, Denmark Phone: +45 72 16 03 00 Fax: +45 72 16 03 01 www.andritz.com
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the written consent of ANDRITZ
TABLE OF CONTENTS
Contents INTRODUCTION 5 1.1 Installation instructions
5
1.2 Guidelines for the use of the manual
5
1.3 Instructions in the use of the manual
6
1.4 Guarantee
6
1.5 Manufacturer
6
SAFETY 7 2.1 General safety regulations
7
2.2 User obligations
7
2.3 Warning and mandatory signs
8
2.4 Safety precautions
9
2.5 Personal safety at the assembly site
10
COMPONENT LIST
11
3.1 Delivery
11
3.2 Foundation
11
3.3 Support structure
12
3.4 Corner brackets
13
3.5 Hopper
13
3.6 Panels
14
3.7 Roof
14
3.8 Handrails
15
3.9 Ladders
16
EQUIPMENT LIST 17 4.1 Hand tools
17
4.2 Lifting equipment
22
4.3 Various equipment and accessories
25
4.4 Equipment and accessories for welding
27
ASSEMBLY 28 5.1 Installation instructions
28
5.2 General assembly instructions
28
5.3 Foundation
29
5.4 Mounting of support structure
30
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TABLE OF CONTENTS 5.5 Assembly of hopper
31
5.6 Mounting of corner brackets
32
5.7 Mounting of hopper panels
32
5.8 Mounting of side panels
33
5.9 Mounting of corner panels
34
5.10 Optionel
34
5.11 Mounting of roof
35
5.12 Mounting of handrail
36
5.13 Mounting of ladders
37
DISMANTLING 38 6.1 Dismantling and scrapping
38
APPENDIX 39 7.1 Documents
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39
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TABLE OF CONTENTS
EXPLANATION OF CHAPTERS AND SYMBOLS = General
= Safety
= Component list
= Equipment list
= Assembly
= Dismantling
= Appendix
Subject to all rights! ANDRITZ reserves the right to make changes in the illustrations and information in this manual as a consequence of further technical development. Furthermore, any translation is subject to reservations. © Copyright ANDRITZ
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INTRODUCTION
INTRODUCTION 1.1 Installation instructions This manual is a assembly manual, which forms part of ANDRITZ’ technical documentation. The manual is intended to facilitate the process of getting to know and utilize the assembly in the best way possible. The assembly manual contains important instructions regarding safe assembly of the silo. Observance of these instructions will minimize risks, repair costs and wasted time and also increase the reliability and the operational life of the silo.
1.2 Guidelines for the use of the manual The assembly manual should be read and used by all the persons, who work with the silo, e.g. in the following areas: • • •
Assembly: (erection, remedy of errors during the working procedure, maintenance, removal of operational and auxiliary equipment etc.). Safety: (lifting etc.). Appendix: (Assembly drawings etc.)
In addition to this manual, national and local safety prescriptions in force are to be observed. Some of the illustrations in this manual may show various additional equipment.
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INTRODUCTION
1.3 Instructions in the use of the manual The user manual has been divided into chapters and sections. Therefore, the table of contents or the index pages at the back of the manual should be consulted in order to provide a general view of the manual.
Means: Assembly instruction.
Means: Important information about the most efficient use of the silo.
Means: Reference to another section or appendix.
Means: Safety information/warning regarding provisions and prohibitions in order to avoid serious injuries or damage.
1.4 Guarantee The sales contract specifies the guarantee, which ANDRITZ, grants from the date of delivery. Wear parts and general wear of the equipment shall not be covered by this guarantee. The standard guarantee does not cover equipment, which has been damaged due to the fact that it has been used for other purposes or in other conditions than those, for which it was offered. The standard guarantee does no cover damage, misuse or lack of maintenance, which infringe the recommendations given in the manuals composed by ANDRITZ. ANDRITZ has been very attentive to fabrication and design in order to make the product as safe and reliable as possible. Should you, contrary to expectation, experience problems with your product from ANDRITZ, please contact the company, which is responsible for the installation of the equipment, or ANDRITZ. At the inquiry the serial number placed on the silo nameplate should be indicated.
1.5 Manufacturer DENMARK
Andritz Feed & Biofuel A/S Glentevej 5-7 6705 Esbjerg, Denmark Phone: +45 72 16 03 00 Fax: +45 72 16 03 01 www.andritz.com
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SAFETY
SAFETY 2.1 General safety regulations ANDRITZ cannot be held responsible for damage due to incorrect use of the silo. To avoid serious accidents, it is extremely important to observe the indicated safety regulations. The silo may not be used, until these regulations have been fully understood. Before use the buyer is responsible for the correct installation of the silo in accordance with the safety and health rules in force at the time in question. The silo may not be modified without previous written agreement with ANDRITZ. •
The construction site must be kept in order.
•
Crane operators and forklift drivers must have the required certificates
•
All hoist equipment need to be inspected before use
•
Secure lines and safety harnesses must be CE marked.
•
Local laws and safety regulations must be respected
2.2 User obligations •
Read and understand the assembly manual and the related drawings.
•
Take care of audible or otherwise perceptible operating troubles immediately, no matter if these can be remedied by the customer on site, or if they require assistance from a service engineer from ANDRITZ.
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SAFETY
2.3 Warning and mandatory signs WARNINGS AND SYMBOLS
P3
The following safety and mandatory signs are used for the assembly and in the user manual:
131852702
Wear cut-resistant safety gloves.
P4
131852751
P6
131186608
Wear safety shoes.
Obligatory safetyglasses. Risk of eye injury. Eye protection required.
Hearing protection
Welding helmet
P12 132503030
Safety harness must be worn. Use fall protection when working on the silo
P7 132507232
Obligatory helmet
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SAFETY
2.4 Safety precautions The following safety and mandatory equipment are used in the assembly manual: Assembly platform
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SAFETY
2.5 Personal safety at the assembly site During assembly of the silo, there is a risk of dropping heavy parts. Due to the tare weight of the items, even small mishaps may cause injuries. There is a risk of rupture, wound injuries, fractures and crushing. Furthermore, there is a risk of straining injuries. Therefore, it is important to observe the above instructions. It is important to wear a helmet and use fall protection gear during installation of the silo.
During welding, wear approved welding helmet.
Use safety glasses to prevent eye injuries
Due to noise, wear hearing protection.
There must be used safety boots at the construction site
Wear cut-resistant safety gloves.
Furthermore, reference is made to the factory instructions concerning the use of personal protective equipment in the working area. • •
Do not handle heavy parts manually. Use appropriate lifting tools.
The crane operators is responsible for lifting in accordance with local laws and regulations
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Component list
COMPONENT LIST 3.1 Delivery ALL PARTS ARE DELIVERD IN A CONTAINER
Any product from ANDRITZ has to be stored as safely and reliably as possible. • All exposed and unprocessed metallic parts must be protected against damage and corrosion.
3.2 Foundation
1
2
Description 1
Concrete
2
Embedded bolts
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Component list
3.3 Support structure SUPPORT STRUCTURE DEPENDS ON THE MODEL
4
3 2
1
Description 1
Side legs
2
Horizontal beams, mid
3
Diagonal beams
4
Horizontal beams, top
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Component list
3.4 Corner brackets Description 1
Corner bracket
2
Shims
1
2
3.5 Hopper
2
1
Description 1
Upper hopper
2
Lower hopper
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Component list
3.6 Panels
3
2
1
Description 1
Side panel half hight
2
Full size side panels
3
Corner panels
3.7 Roof THE APPEARANCE DEPENDS ON THE MODEL
2
1 Description 1
Indlet
2
Manhole
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Component list
3.8 Handrails
1 2 3
Description 1
Handrail
2
Knee rail
3
Foot rail
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Component list
3.9 Ladders
1
2
3
Description 1
Top ladder
2
Middel ladder
3
Buttom ladder
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Tools list
EQUIPMENT LIST 4.1 Hand tools Measure tape Size: 5 m
Measure tape Size: 30 m
Impact sockets Size: From 6mm to 36mm
Impact wrench
Wrench/spanner set Size: From 6mm to 36mm
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Tools list
Level Length: Approx 3m
Chipping hammer
Hammer 1,5 kg
Hammer 5 kg
Center punch
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Tools list
Heavy drilling machine
Drilling machine
Steel drill Size: From 4mm to 20mm
Crowbar
Grinding machine
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Tools list
Screwdriver set
Lockpliers
Duct tape
Nose pliers
Wood clamp
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Tools list
Allen keys Size: From 6mm to 20mm
Galvanizing spray
Ladder Height: Approx 3m
Moveable towerscaffolding Hight: 3m
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Tools list
4.2 Lifting equipment Lifting chain with four legs Lifting capacity: 5 tons
Lifting chain with two legs Lifting capacity: 5 tons
Lifting straps. Size: 4 x 1 tons 4 x 2 tons 4 x 5 tons
Beam clamp Lifting capacity: 5 tons
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Tools list
Manual lifting hoist Lifting capacity: 5 tons
Manual horisontal hoist Lifting capacity: 5 tons
D-clamp Size: 4 x 1 tons 4 x 2 tons 4 x 5 tons
Plate clamp Lifting capacity: 5 tons
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Tools list
Concrete skip
Tower crane Lifting capacity is determined on site
Forklifts Lifting capacity: 2T
Cherry picker Height: 20m to 30m
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Tools list
Personnel Crane Baskets For 2 persons
4.3 Various equipment and accessories Theodoliet
Work light
Extension cords extension cords 220Vac lenght 20m extension cords 220Vac lenght 100m
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Tools list
Electrical distribution cabinet for construction site 220Vac 32 amp 380Vac 63 amp
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Tools list
4.4 Equipment and accessories for welding Welding equipment
Cables for welding equipment
Welding rods
Welding helmet
Extension cords 380Vac lenght 10m
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ASSEMBLY AND INSTALLATION
ASSEMBLY 5.1 Installation instructions BUILDING FLOOR
All supporting structure for ANDRITZ equipment shall be calculated according to relevant building codes, with required safteyfactors: It shall be verified that all loads informed by ANDRITZ can be obtained in the structure. Tolerance: Steel structure according to EN 1090 Concrete structure according to EN 13670 •
The structure shall correspond to minimum Execution Class 2 unless otherwise specified.
Should there be specific issues on requirements, of steel and concrete structures please contact ANDRITZ.
5.2 General assembly instructions This is a assembly instruction for further details see the drawings.
SEALING: Sealing mass (Tec7 or eq.) will be applied to every surface which are bolted together (unless otherwise indicated).
Bolt torque chart (dry) GRADE
8.8
10.9
27,3 Nm
41,1 Nm
M12
93 Nm
137 Nm
M16
230 Nm
338 Nm
DIM
M8
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ASSEMBLY AND INSTALLATION
5.3 Foundation EMBEDDED BOLTS
THE FOUNDATION IS LEVELED TO A HIGHT DIFFERENCE OF MAX 10MM
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ASSEMBLY AND INSTALLATION
5.4 Mounting of support structure THE TWO SIDES ARE ASSEMBLED LAYING FLAT ON THE GROUND
ERECT THE SUPPORT PARTS AND FASTEN ON THE FOUNDATION
THE HORIZONTEL AND DIAGONAL BEAMS (MARKT BLUE) ARE MOUNTED
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ASSEMBLY AND INSTALLATION
5.5 Assembly of hopper THE HOPPER IS ASSEMBLED ACCORDING TO DRAWING
2
1
3
4
THE HOPPER IS TURNED AND PLACED ON THE SUPPORT STRUCTURE
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ASSEMBLY AND INSTALLATION
5.6 Mounting of corner brackets THE CORNERS IS ALLIGNED WITH SHIMS TO A MAX HIGHT DIFFERENCE OF 1MM
5.7 Mounting of hopper panels THE HOPPER PANELS ARE MOUNTED ON THE SIDE
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ASSEMBLY AND INSTALLATION
5.8 Mounting of side panels (1) 2 HALF HIGHT SIDE PANELS AND (2) 2 FULL SIZE SIDE PANELS ARE USED FOR THE FIRST AND LAST ROWE FOR LIFTING OF THE SIDE PANELS USE EYEBOLTS AND SLINGS
2
1
THE SIDE PANELS ARE ASSEMBLED WITH SEALING MASS
2
1
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ASSEMBLY AND INSTALLATION
5.9 Mounting of corner panels THE CORNER PANELS ARE BOLTET TO THE SILO
5.10 Optionel THE CORNER PANELS CAN BE FILLED WITH CONCRETE
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ASSEMBLY AND INSTALLATION
5.11 Mounting of roof THE ROOF ARE MOUNTED ACCORDING TO DRAWING
USE SLINGS FOR LIFTING
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ASSEMBLY AND INSTALLATION
5.12 Mounting of handrail HANDRAIL IS ASSEMBLED AND MOUNTED ACCORDING TO DRAWING USE SLINGS FOR LIFTING
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ASSEMBLY AND INSTALLATION
5.13 Mounting of ladders THE 3 LADDER PARTS IS MOUNTED ON THE SILO ACCORDING TO DRAWING, STARTING WITH THE LOWEST LADDER (1) THEN THE MIDDEL LADDER (2) AND THEN THE TOP LADDER (3)
3
USE SLINGS FOR LIFTING
2
1
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DISMANTLING AND SCRAPPING
Dismantling 6.1 Dismantling and scrapping The dismantling has to take place in the opposite order of the mounting. It is important to suspend/support the individual component properly before loosening its bolted connections. In case of scrapping the silo, all environmentally damaging parts should be isolated and sent to destruction. The rest can be cleaned and sent to a scrapdealer. In case the silo is resold to another party than ANDRITZ, the seller is responsible that the present manual accompanies the machine to its new owner. For the remounting, it is important to read chapter 5, assembly.
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Appendix
APPENDIX 7.1 Documents Document number
Description
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Silo March 2016 EN rev. 01 Page 39
