Technical specifications and standards for equipment relocation (Part II)

5、 Commissioning of equipment:

5.1 general technical requirements for commissioning:

(1) The fluid medium pipeline and chamber (box) body shall be free of running, emitting, dripping, leakage and seepage;

(2) Check the transmission part, and the operating parts shall be flexible without jamming, plug, vibration and shaking;

(3) For the equipment requiring pressure test during commissioning, the pipeline shall be vented after the test.

(4) The safety braking system must be sensitive;

(5) The action of electrical components shall be sensitive and reliable, and there shall be no ignition and leakage;

(6) The temperature and noise of main bearing and pressure parts of the equipment (such as bearing, gearbox, motor, etc.) shall not exceed the factory design requirements of the equipment;

(7) Grounding protection must be tested in accordance with national and industrial standards;

(8) Machine wiring, pipe laying and electrical wiring shall be standardized and reasonable without binding, pulling, lifting and binding;

(9) The completion data shall be complete (including various changes, installation records and commissioning records).

5.2 commissioning procedure

Commissioning procedure: comprehensive inspection - unit (vehicle) inching air test - unit (vehicle), continuous air test - system linkage air test - comprehensive inspection and rectification - load commissioning preparation - system load commissioning - completion acceptance

5.3 installation and commissioning of hydraulic and pneumatic systems

5.3.1 the pipeline construction of hydraulic and pneumatic system shall be correct and reasonable according to the equipment technical documents.

5.3.2 when the hydraulic and pneumatic pipelines need to be bent, they shall be cold bent. Before construction, they shall be purged with compressed air and pre pickled if necessary to keep degreasing.

5.3.3 when the hydraulic system pipeline needs to be welded, argon arc welding shall be adopted. When flaw detection is required, the random inspection amount shall reach 50%.

5.3.4 when filling the hydraulic system, check the cleanliness, fill the oil according to the specification, variety and characteristics, and open the exhaust to exhaust the air.

5.3.5 conduct pressure test on the system, disconnect the motor, servo valve, proportional valve, pressure sensor and pressure relay in the system, slowly pressurize to the test pressure during pressure test, maintain the pressure for 10 minutes, and check whether there is pressure drop and whether there is leakage at the weld interface.

5.3.6 turn on the hydraulic pump or air source, adjust the safety valve, pressure maintaining valve, pressure relay and other valve unit elements in the system to reach the specified value, check the correct action and reliability, and check the stroke, speed and operation condition of the driving parts.

5.4 single machine test run

5.4.1 the single machine operation shall be carried out after the secondary grouting strength of the equipment is more than 90% and the pipeline and circuit are all constructed.

5.4.2 the equipment pipeline test and circuit test are qualified, and the single machine test shall be prepared after the construction records and data are complete.

5.4.3 single unit test run conditions:

(1) The required energy, media, materials, machines and tools, testing instruments, safety protection facilities and appliances shall meet the needs of commissioning. Lubricating oil, grease, emulsion, hydraulic oil, etc. have been added.

(2) Personnel participating in the test run shall disclose or train the equipment structure, performance, technical documents and operating procedures in advance.

(3) Clean the surrounding environment of the equipment.

5.4.4 equipment commissioning steps:

(1) Check the installation condition of the equipment, the movement of the machine tool and the movement and stability of the rotating parts, the manual turning is flexible, light and free of blocking, and the belt tension shall be consistent and meet the technical requirements of the equipment; The adjustment of safety device is correct and reliable, and the adjustment of braking and locking mechanism is appropriate.

(2) The installation accuracy shall meet the technical requirements of the equipment.

(3) The anchor bolts shall be fastened evenly and in good contact with the equipment.

(4) The inspection and adjustment of lubrication, hydraulic, air cooling and other systems shall meet the requirements of the equipment technical documents. According to the equipment technical documents, the parts to be lubricated shall be filled with lubricant and the cleanliness shall be inspected.

(5) The pressure, oil temperature and pipeline exhaust of lubricating oil, liquefied oil, gas and coolant shall meet the provisions of equipment technical documents after single system startup.

(6) The action adjustment of valves and mechanisms of lubrication, hydraulic, gas and cooling systems shall be correct, reliable and sensitive. The working medium of each system shall not be interrupted and leaked, and the specified pressure, temperature and flow shall be maintained.

5.4.3 after the adjustment and inspection of equipment electrical, pipeline, working medium and other systems are qualified, the joint adjustment test of machinery and each system shall be carried out.

5.4.3 the joint commissioning starts from components to components, to single machine, to complete set of equipment, and shall be carried out according to the equipment technical documents and operating procedures.

(1) Adjust the stroke and limit of reciprocating parts, and observe the operation of the whole stroke. There shall be no vibration, crawling and stagnation.

(2) Conduct operation test at all speeds of main motion and feed speed, observe start, stop and braking, and there shall be no abnormality in manual operation and automatic operation.

5.4.4 the no-load commissioning of the system shall be carried out after the joint adjustment test of machinery and each system is qualified.

5.4.5 no load commissioning shall be carried out according to equipment technical documents and national standards.

5.4.6 check the temperature rise of guide rail joint surface and lubricating oil.

5.4.7 after no-load test run, cut off the power supply and other power sources, deflate, drain and apply anti rust oil, recheck the geometric accuracy of equipment installation, check the cleanliness of lubricating oil, and replace new oil if necessary.

6、 Detection and measurement of equipment:

6.1 the elevation of the tested surface of the equipment passes through the precision level S-1 (the reading error is controlled within 0.03mm).

6.2 the plane position of the equipment is led from the datum point by the theodolite.

6.3 equipment datum detection method:

(1) Straightness test: select measuring points equidistantly along the direction of the measured surface with a frame level or precision level. At least three measuring points shall be selected for the full length to measure the readings respectively, and the deviation shall be calculated according to the maximum algebraic difference of the readings.

(2) For levelness test, the measuring points shall be selected around the center of the measured surface or 50mm away from the edge, measured with a ruler, contour block or special detection tool and frame level, and measured in two directions of 90 degrees to each other, and the deviation shall not exceed the value specified in the equipment documents.

(3) For perpendicularity test, select measuring points on the measured surface with a frame level and take readings, or calculate the readings with two levels through the measured qualified level:

(4) Plane parallelism measurement: select the measuring points between the two planes with an inner micrometer according to the equipment shape, and the deviation is the maximum algebraic difference of the two measured readings.

(5) Detection of movement parallelism between the central axis of the rotating body and the moving part: the measurement shall be conducted in two directions where the test mandrel is 90 degrees to each other, and the measurement deviation shall be half of the algebraic sum of the measurement results in two directions.

(6) The equipment shall be tested according to the technical documents of the equipment, or the measurement method shall be discussed in accordance with relevant specifications or with the representative of Party A.

7、 Equipment commissioning and acceptance:

7.1 commissioning inspection items:

(1) Operation of mechanical transmission system;

(2) Temperature rise, vibration and noise of motor;

(3) Noise, temperature and vibration of reducer;

(4) Brand, quantity, oil temperature and circulation of lubricating grease;

(5) Action sensitivity of safety braking protection system;

(6) Automatic detection and control system action;

(7) Temperature and noise changes of main bearing;

(8) Sealing point inspection;

(9) Electrical wiring and grounding protection inspection;

(10) Inspection of various fastening connections (couplings);

(11) Inspection of environmental protection indicators.

7.2 commissioning and acceptance:

(1) Before the equipment commissioning, the cleanliness of the main lubricating parts shall be checked, and the unclean parts shall be cleaned.

(2) For equipment commissioning, the lubrication system shall be started first. After confirming that the lubrication is in place, the single vehicle (yuan) air test shall be carried out. The system linkage air test can be carried out only after the single vehicle (yuan) air test is qualified. During the test run, the temperature, noise and vibration changes of the bearing, pressure bearing and heating parts of the equipment (motor, bearing, gearbox, etc.) shall be closely monitored. If they exceed the regulations, they shall be eliminated in time. Equipment problems and equipment faults (mechanical and electrical) during commissioning shall be rectified immediately.

(3) The installation contents that fail to meet the technical requirements shall be rectified, and the acceptance of rectification shall meet the technical requirements.

(4) Fill in commissioning records (Annex 3)

7.3 equipment processing parts and acceptance

7.3.1 when the equipment commissioning is normal, the parts shall be processed, and the first inspection (all dimensions) shall be carried out according to the quality assurance requirements. If there are unqualified dimensions, they shall be adjusted;

7.3.2 batch processing can be carried out only after the first inspection is qualified;

7.3.3 during the processing, the quality assurance department shall track the inspection and make inspection records.