DaimlerChrysler Construction Standards
AME-PT Plants
Date11/20/05
SECTION 15198 – CHIP HANDLING SYSTEMS
PART 1 - GENERAL
1.1 Submittals
1.2 Quality Assurance
1.3 Delivery, Storage, and Handling.
PART 2 - DESIGN AND PRODUCT
2.1 Chip Conveyors – Aluminum, Cast Iron and Steel
2.2 Aluminum and Steel Processing
2.3 Pneumatic Conveying System
2.4 Cast Iron Processing
2.5 Electrical Controls
2.6 Work Platforms
2.7 Painting
2.8 Supervision/Service
2.9 Training.
2.10 Sound Level/Noise Abatement
PART 3 - DOCUMENTATION
3.1 Drawings
3.2 Coordination
3.3 Operation and Maintenance
3.4 Spare Parts Lists
3.5 Delivery
3.6 Payment Terms and Conditions
3.7 Installation
Related Sections include the following:
- Division 15 Section 15050 “Basic Mechanical Materials and Methods”
- Division 15 Section 15185 “Cutting Machine Coolant Piping”
- Division 15 Section 15110 “Valves”
- Division 15 Section 15060 “Hangers and Supports”
- Division 15 Section 15815 “Metal Ducts.”
- Division 15 Section 15889 “Oil Mist / Dust Collector Units”
- Division 15 Section 15970 “Machine Tool and Process Equipment Installation”
- Division 05 Section 05500 “Metal Fabrication”
- Division 15 Section 15980 “Total Maintenance Spare Parts”
- SMI-148 “Maintenance of Water Based Coolant”
- Division 17 Section “ Safety “
- Division 3 Section 03300 “ Cast In Place Concrete “
- Division 3 Section 03305 “ Concrete Floor Slabs “
14. A. M. E. P. T. Control Standards
PART 1 - GENERAL
1.1 SUBMITTALS
A. Drawings & Manuals: Within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AME-PT engineer for DaimlerChrysler‘s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with machine and one CD of drawings and operation and maintenance manuals to the responsible AMEPT engineer. Once installed and qualified, the OEM shall update and ship three (3) paper sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. to the plant representative as directed by the responsible AME-PT engineer. A signed copy of the Letter of Transmittal and a CD containing all “as installed” drawings of the equipment, operational maintenance manuals, and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists to the responsible AMEPT Engineer.
B. DaimlerChrysler will supply the brass tag and drawing numbering system when the purchase order is issued.
C. All floor plan drawings must show the complete plan view of the entire machine as it sets on the floor. Its base, including projections for leveling or anchoring, shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including tanks, housing, platforms, conveyors, load and unload locations, panels or any other part of the machine. Clearance for service, including panel and access doors (open position) shall be shown in the proper location. Show all locations of piping, drains, exhaust stacks, and air intakes. Ancillary equipment such as electrical panels and filters shall be shown in correct relation to machine and dimensioned. In no case shall the equipment be located so as to prevent ease of access for service or repairs of any component of the machine or ancillary equipment.
D. The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to DaimlerChrysler prior to altering the machine, ancillary equipment or orientation.
E. All engineering drawings shall be developed using the CAD software and version agreed upon in CAA. All engineering drawings, upon successful completion of this project become the property of DaimlerChrysler Corporation.
F. Maintenance Manuals in English shall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked.
G. The OEM shall provide a recommended spare parts list for all of the supplied machines. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per DaimlerChrysler TMS electronic format (contact DCX plant engineer).
H. Field Utility routing to equipment and gages including planned placement of all cranes, pull boxes, disconnects, control panels, isolation valves, (including lockout valves), supports, flow balancing valves, flow meters, gages and anchors and sway bracing. Do not route utilities in the path of the automation such as gantries or in the path of any cranes.
I. Wiring diagrams in controls submittals for all field-installed wiring showing panel terminated insulation labels and color of wire
J. All installation submittals must show code clearances such as 42 inches from front of a panel to any obstruction and 48 inches from the fronts of two opposed facing panels. Supplier shall designate all utility hook-ups (i.e.: water, air, gas, etc.) refer to Appendix 6 in Machine & Tool Specification.
K. All means of egress between equipment must have a minimum of 28 inches.
1.2 QUALITY ASSURANCE
A. Fabricator Qualifications: A firm experienced in producing metal fabrications similar to those indicated for this Project and with a record of successful in-service performance, as well as sufficient production capacity to produce required units.
B. Any and all sub-contractors to be used on this project must be approved by DaimlerChrysler.
C. Installations shall comply with all national and local codes.
D. Installations shall comply with DaimlerChrysler standards.
E. Provide survey results from datum’s and benchmarks.
1.4 DELIVERY, STORAGE, AND HANDLING
A. A designated contractor or plant personnel must, prior to unloading inspect all equipment and all damage must be reported on the shipper and to the appropriate DaimlerChrysler project engineer and supplier.
B. All equipment delivered to the project site must be unloaded and unpackaged promptly without any damage and placed in its intended rough in location or at a minimum inside of a facility which provides protection from the elements.
C. All equipment must be inspected by supplier at time of delivery to assure that the equipment drawings and required set up tools and software are included with the shipment, which identifies the required information to allow a quick and accurate installation.
PART 2 - DESIGN AND PRODUCT
2.1 CHIP CONVEYORS – ALUMINUM, CAST IRON AND STEEL
A. Drives shall be non-overloading, with link-belt helical worm gear reducer (selected at 1.5 service factor) martin style – SP bolt or shear pin sprocket at head shaft.
B. Bearings and take-ups shall be link belt series 22400 spherical roller bearings, use minimum 6T 12’ P.D. sprocket for head shafts.
C. All new conveyors with inclined discharges will use WD-110 chain and sprockets.
D. All conveyors will discharge 72 inches (min.) above existing floor with a removable chute designed to discharge into a below grade conveyor or a portable dumper.
E. All concrete work will be done by others, therefore, trench design must be verified prior to fabrication of conveyors.
F. Discharge section of conveyor above floor must be enclosed with expanded metal door.
G. Conveyor discharge and drive must be mounted on H beam frame and legs.
H. Electrical controls will include start, stop and manual forward and reverse jog buttons and appropriate indicator lights, motors.
I. All chip conveyors with disposal paper media systems shall be designed with rewinders to separate chips for proper reclamation.
J. Supplier shall design filter pit chip removal systems that correlate to a maximum load of chips and maintain a balanced working system. The goal will be to achieve maximum settling time and minimal indexing. The rough part vs. finish part weight will be a starting point to develop this system.
K. All chip conveyors shall have a means of stopping and holding foreign objects to prevent damage to chain and flight or pan conveyors and drives, the method used will not slow down or stop the flow of chips or coolant.
L. A reverse and jog control option bust exist from the manual mode and from the location near the drive system via a momentary contact
2.2 ALUMINUM AND STEEL PROCESSING
A. Primary conveyor to Crusher – primary conveyor shall receive the turnings and boring from the final collection conveyor discharge and convey them to the inlet of a chip crusher. Provisions shall be made in this conveyor to install an automatic parts separator.
B. An automatic parts separator is to perform the function of removing bar ends, tools and machined parts form the turnings before they reach the crusher to reduce wear and tear on the crusher.
C. Chip Crusher – The chip crusher is to be a heavy duty shredder ring type chip crusher, equipped with an inlet trap and ejection chute as well as an apron type tramp metal ejector and grate bars sized to reduce the turnings to a size suitable for pneumatic conveying. The crusher shall be equipped with an electric motor drive of sufficient horsepower to process the volumes of chips that will be stated in engineers Scope of Work. The crusher in automatic mode, upon sensing a jam shall reverse to remove the jam and attempt a restart. If a second jam happens, the unit will reverse and shut down, alarm will sound indicating a foreign part jam up. All guarding, structural supports and access ladders and platforms shall be provided. The crusher chamber liners, grate bars, grind plates and shredder rings shall be made of manganese steel for wear resistance. Quality shall be equivalent to units manufactured by the American Pulverizer Co. or greater.
D. The chip deck shall receive chips that are generated in other areas of the plant. They will be delivered to the chip deck in hoppers and either manually or mechanically fed to the conveyor as determined as most efficient for the performance of the down-stream equipment.
E. Conveyor and Oily Hopper – An apron or drag type conveyor shall be provided to convey the chips from the discharge of the crusher to the oily storage hopper. The Chip Hopper serves as oily storage for feeding a batch type wringer.
F. The oily chip hopper is to be constructed of heavy gauge steel plate and structural members supported from the floor. The hopper discharge is to be connected to a helical conveyor to lead chips into a chip wringer. The wet chip hopper shall contain two electrical level probes located at a high and low position. The function of the probes is to control the operation of the wringer as described in the section 2.5 on electrical controls. The helical conveyor is to be of the trough type with removable covers, anti-friction bearings and heavy duty helicoid sections.
G. Chip Wringer – The chip wringer is to be an automatic or manual controlled floor supported vertical unit, which is a centrifugal programmed two speed continuous batch type, starting at low speed during the load cycle and automatically go to high speed for the wring cycle. The capacity of the wringer shall be adequate to handle the volume of chips previously stated, and produce chips with not more than 2% moisture content. Chip wringer separation units shall be supplied with a pump for removal of dirty coolant with a tie-in to the nearest waste treatment line for disposal.
H. Wringer – The wringer is to handle aluminum or steel chips as presented to it from a chip crusher or conveyor. Wringer operation shall be continuous with a minimum downtime required for screen cleaning. Dried chips shall be conveyed to a live bottom storage hopper. The oil and sludge removed from the chips are to be directed to the plant process waste. Connection to the process waste shall be by the installer.
I. The wringer shall be provided with a structural steel frame and stand rigidly constructed to withstand the dynamic forces involved, including ladders, railing, access platforms and clean outs.
J Sludge Removal System – All conveyors and chip wringers shall be provided with a means of positively separating sludge and liquid. The sludge must be deposited in a “V” dump, and the liquid must flow by gravity to the process waste system. The liquid must be free of any contaminate which might plug the process waste system.
K Electrical Panel and Controls – The electrical panel shall be complete with the appropriate power distribution, PLC, all push buttons, lights, and circuits to provide control of all components as specified in electrical section of this specification. The controls shall include, but not limited:
1. High and low level controls and interlocks to and from wet chip hopper.
2. Interlocks to shut down wringer feed in the event of valve malfunction.
3. Interlocks to shut down wringer from an out of balance condition, or motor overheating.
4. Interlocks to shut down chip system on a high level condition in the final storage hopper.
5. The drive to be an electric motor TEFCBB 1750 R.P.M. or equivalent , “V” Belt connected to a worm gear reducer with roller chain drive from reducer to helicoid shaft. All drives to be guarded to O.S.H.A. requirements.
6. Refer to Controls Specifications.
L General Note: All concrete work will be done by others; therefore, trench design must be verified prior to fabrication of conveyors. Chip wringer foundation dimensions to be provided to DaimlerChrysler for installation by others.
2.3 VACUUM CONVEYING SYSTEM
A. Vacuum Conveying System is allowed for chip processing – Blower unit to incorporate the use of a rotary piston blower driven by a 1750 R.P.M., T.E.F.C.B.B. motor or equivalent. The blower shall have the capability to vacuum the chip through a vacuum pipe system at the rate of 1 gr/min to 50 kg/min. up to a distance of 500 meters.
B. The vacuum system shall be able to detect and warn or indicate plugging between the collection and disposal points.
C. The blower unit enclosure muat be removable for servicing the unit amd limiting the noise level to 80 DB as an integrated system on the “A” scale at 3 feet from the unit.
D. The vacuum conveying piping system should have straight runs of approx. 5 inches in diameter steel pipe
E. All elbows to be long radius type of case NI-hard metal with gasketed cleanout.
2.4 2.4 CAST IRON PROCESSING
A. Primary Conveyor and Separator – Turnings and boring will discharge from a final collection conveyor into a screw or flight type conveyor that will feed the chips to a part separator. The part separator shall be of the electrically driven vibrating screen type. The separator shall be super imposed above or may be an integral part of the wet chip storage hopper.