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AIMS EQUIPMENTS SYSTEMS MANUFACTURING L.L.C.
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INDUSTRAL SHELTERS AND CABINETS MANUFATURING PROCESS Industrial shelters and cabinets are manufactured as per the customer needs depending on the type of analyzer and their necessities. AIMS designs and manufactures shelters and cabinets which have their application all over the world. Years of experiences and knowledge about the industry process and requirements are the foundations of AIMS and help in manufacturing with improved technology. Quality and reliability are the characteristics of the manufactured shelters and cabinets from AIMS. Designing to the customers required specification is where AIMS have strong belief in. The industrial shelters and cabinets manufacturing process mainly involves the following steps as shown:
- Project Confirmation - Engineering Design - Procurement of Raw Materials - Precision Cutting & Drilling - Welding - Installation of Process Analyzers - Pneumatic Tubing Assembly - Electrical Power Distribution Design - Electrical Wiring - Quality Assurance Checking - Factory Acceptance Testing - Packing & Delivery
INDUSTRAL SHELTERS AND CABINETS MANUFATURING FLOW CHART
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Project Confirmation Details:
Engineering Design
Procurement of Raw Materials
Precision Cutting & Drilling
Welding
Electrical grounding
Pneumatic Headers
Shearing and Bending
Quality Assurance Checks
Factory Acceptance Testing
Packing & Delivery
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For preparation of effective production schedule, the following should be developed
- Production database (i.e., type of materials, finishes and dimensions etc.) - Detailed Shop Drawings - Installation Schedule
Engineering Design: As per the project specifications, need to design the analyzer shelters/cabinet system so that the Process Analyzers can be installed and accordingly the final Gas Analyzer Package System can be manufactured as per the Design and Customer requirement.
Design Considerations:
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It’s important to choose the right cabinet depending upon the application and where the product is
going to be used. So to help choose the right shelter or cabinet solution there are some essential design
considerations:
1. Design Standards:
Depending upon the requirements of the customer there are different design standards that can
be applied. These are defined by the government, regulators and standard committee. They are
also dependent on the design specifications and requirements for a particular product or
service.
a. IEC (International Electro technical commission):
IEC develops international standards related to all electrical and electronic related
technologies. They are not necessary to be adopted but they are often mentioned in national
laws and regulations around the world. IEC 60297 is the standard for mechanical structures
for electronic equipment.
b. RoHS (Restriction of Hazardous Substance):
This is from the European Union and restricts the use of six hazardous material which are
found in electrical and electronic products.
2. Weight load capacity:
The weight of the load to be attached in the cabinet varies widely so it’s important to determine
the right type of cabinet for the customer application and requirement. It is difficult to
determine the right weight load capacity because the tests done by using the heaviest
equipment does not necessarily correspond to the final application of the cabinet or shelter.
Another problem with the heavy loads is that dynamic protection will be required which also
might increase the weight. Thus a robust design is necessary depending upon the application.
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3. Thermal management:
Thermal management and cooling is an important design consideration for any type of
enclosure. Cabinets or shelters usually require broad thermal management compatibility and
are often needed to meet tough demands when it comes to performance. Some of the options
which can be used to do thermal management are perforation, fans trays, air conditioners and
heat exchangers.
4. Shock and vibration protection:
Two main tests are carried out: seismic and shock /vibration tests. Both of these have well
defined process to do the tests. It is done twice, once with the cabinet itself and second with the
exact equipment attached so that we know the product offers the shock/vibration and seismic
protection as the required.
a. Shock/Vibration:
This is done by simulation a typical environment in a train or a moving vehicle. The
product is checked so that it can withstand nearby vibration-generating equipment if any on
the field. This is beneficial to customer’s especially overseas or offshore applications.
b. Seismic:
The testing equipment and process are done in multiple labs and is a well-defined and well
known process. It consists of placing a fully loaded cabinet on a platform which can
simulate the earth’s movements as in a seismic activity. If there is a deformation or
movement of the cabinet the test is considered as a failure.
5. Electromagnetic compatibility (EMC):
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This is an area of growing concern as the environment has become more and more susceptible
to electronic emissions. Thus proper tests are required to see that the cabinet or shelter meets
the requirements and can fulfill Electromagnetic Interference protection.
6. Environment and Safety:
IEC 60529 is the standard which classifies the ingress protection (IP) rating of an enclosure. IP
deals with the dust and water protection. The better the product against dust and water the
better the rating. Another standard is the National Electrical Manufacturers Association
(NEMA) defines standards which are compliant in North America for enclosures which are
used in industrial applications. A NEMA certified enclosure is rated to provide protection
against environmental hazards and corrosive agents.
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1. List of the RAW material and the consumed quantity / year (Materials Used for Manufacturing / Fabrication Process)
- Raw material need to be identified as per the project specifications. - Consider the type, area and usage of the cabinet-work as per the defined Engineering Design. - Submit samples of the materials for approval prior to procurement - Procure the raw materials as per the approved samples
S.No Name of the
Material Image
Consumption/year (Approx.)
1 SS Metal Sheets
1.0 mm Thick flat
sheets - 1 Ton.
1.2mm Thick flat
sheets - 2 Ton
2.0mm Thick flat
sheets - 6 Ton
2.5mm Thick flat
sheets - 5 Ton
3.0mm Thick flat
sheets - 6 Ton
5.0mm Thick flat
sheets - 3 Ton
2 SS angles and Channels
50 x 50 x 3 Box
section – 1 Ton
50 x 50 x 5 Angles –
1 Ton
100 x 50 x 6 Channel
section – 1 Ton
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3 Schedule 40 and 80 SS Pipes
100 Length – 0.5 Ton (1 Length = 6 Meters)
4 SS tubes
200 Length – 0.25 Ton (1 Length = 6 Meters)
5 Ex-Junction Boxes
300 to 350 units
6 Mounting Uni Studs
500 lengths (1 length = 3 meters)
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7 Plain Strut Channels
500 lengths (1 length = 3 meters)
8 Bolts
1 Lot (1 lot = 3000 pieces)
9 Nuts and Washers
1 Lot (1 lot = 3000 pieces)
10 Miscellaneous Fittings
1000 pieces
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11 Hinges
200 pieces
12 Locks
50 pieces
13 Rubber Beadings
100 meters
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2. List of the machineries and equipment's or production lines with the
following details
Precision Cutting & Drilling: Precision Cutting needs to be performed on the metal sheets as per the approved engineering design and necessary care will be taken and exact lengths will be cut as per the requirement. Drilling will be performed as per the requirement as defined in the engineering design and necessary holes will be made for the manufacturing of the Gas analyzer cabinet. Positions of Openings and alignment are within specified tolerances. Cutting:
Specification Details:
Model : BOSCH GCO 2000 Professional
Motor : 2000W Cutting capacity at rectangle 0º: 180 x 85
mm
Cutting capacity at square 0º : 110 x 110 mm
Cutting capacity at L-profile 0º : 130 x 130 mm
No-load speed : 3.500 rpm
Cutting disc diameter : 355 mm
Cutting disc bore : 25,4 mm
Weight : 180Kg
Angle Grinder: An angle grinder, also known as a side grinder or disc grinder, is a handheld power tool used for cutting, grinding and polishing. Angle grinders can be powered by an electric motor, petrol engine or compressed air.
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Specification Details: Angle grinder
Disc Size : 115mm
Model Number : GWS 8-115
Plug Type : Type C – EuroPlug
Speed : 11000rpm
Voltage Rating: 240V
Wattage: 800W
Weight : 1.9kg
Drilling: Drilled holes are characterized by their sharp edge on the entrance side and the presence of burrs on the exit side, unless they have been removed.
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Specification Details: Drilling Machine
Model No : SCHEPPACH RDM-3201FN
Power : 1100 W
Speed Range 50Hz: 200-1990rpm
60Hz: 240-2400rpm
Max. spindle travel : 120mm
Max. drilling capacity : 32mm
Overall height : 1700mm
G.W. / N.W. : 135/129Kg
Welding: Welding needs to be performed by certified welders as per the approved design and procedure to attach the metals and make lengths.
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Specification Details: Welding Machine
Voltage : 230V , 50/60 Hz
Absorbated Power : 70 KVA
No Load Voltage Vo : 90V
Welding Current : 25-200 A
Duty Cycle I2max : 200 A
Normal Use : 200 A , 40%
Min-Max Electrode : 1,6-4mm
Insulation Class : H
Protection Degree : IP 21S
Master Box weight : 6.9 Kg
Specification Details: Air compressor
Screw Compressor : SK 22 T
Material No : 101961.00510
Serial No : 1021
Rated Power : 110KW
Motor Rotated Speed 2960 1/min
Max work press : 11,0 bar
Ambient Temperature : 45 C
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Specification Details: Hacksaw Model: AJPH-280 Motor power: 2Hp(1.5 kW) Cutting capacity: 280 DIA Size: 1350 x 800 x 950
Specification Details: Hydraulic swing beam shearing machine Model No. : HGS 16x40K Max Shearing thickness: 16mm Max Shearing width: 6000mm Shearing angle: 2 Degree Back gauge stroke: 20 – 1000 mm Throat Depth: 150mm Main Power: 37 kW
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Specification Details: CNC Press Brake: Model No: WA67-DKS (320 X 3200) Nominal Pressure: 3200 KN Max Bending: 3200mm Distance between uprights: 2700mm Cylinder stroke: 250mm Main Power: 22 KW Oil Volume: 580L Approaching speed: 80 mm/s Working speed: 9mm/s Returning speed: 90mm/s Weight: 17100 Kg
Specification Details: Heavy Duty Power Drill machine: Model No: M820 Max Work piece: 520x220x490 Max grinding length: 530mm Max grinding width: 220mm Side way: V-type rail with Steel-ball: 200 Spindle Speeds: 2850 rpm, 50Hz Spindle Motor: 1.1 KW Gross weight: 0.8 T
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Specification Details: Lathe Machine Model No. : CS6180C Max swing dia over bed: 800mm Max swing dia over cross slide: 560mm Max turning dia: 540mm Max swing dia over gap: 1000mm Effective length in gap: 240mm Max workpiece length: 2000/3000mm Max turning length: 1950/2950 mm Spindle bore diameter: 104mm Main motor power: 7.5 KW Rapid Travel motor power: 0.37 KW Coolant pump motor power: 0.12 KW
Factory Acceptance Testing: After the completion of the final product, internal tests takes place and is witnessed by the customer if the system is ready to be shipped. Packing & Delivery:
- Shelter and cabinet manufactured are checked once to ensure that they are in accordance with specifications
- The mounting brackets and lifting hooks (eye-bolts) are attached to the cabinet or shelter for lifting.
- Shelter and cabinet are packed and labelled after quality inspection indicating the cabinet dimensions and project details.
- Finished goods are send to client through our logistics system
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3. Proposed factory layout
Please see attached separate in Annexure 1
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4. List of final products with the yearly actual production capacity
including some clear pictures for each final products
SS Cabinet Manufactured Galvanized Steel Cabinet Manufactured
Shelter Package installed at a refinery Shelter Outer look
Total number of shelter units produced: 22 Nos Total number of cabinet units produced: 43 Nos
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5. Number of employees per shift and no of shifts
Shift timing (1) Working hours : 8:30 am to 12:30 pm Lunch Break : 12:30 pm to 1:30 pm Working hours : 1:30 pm to 5:30 pm
Number of Employee are around 27: Factory In charge - 2 Nos, Senior Supervisor - 2 Nos, Safety office - 1 Nos, Store keeper - 1 Nos Fore men’s - 2 Nos, Fabricators - 4 Nos, Welders - 4 Nos, Helpers - 8 Nos, Drivers -2 Nos Overhead crane and Fork lift operator - 1 Nos
ORG CHART
Wielder 2
Project Supervisor Quality & Safety Engineer
Technician 5
Electrician 2
Project Manager
Fitter 3
Helper
Engineers 2
Driver
Draftsman
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6. Brief on the manufacturing process
The unique, in-depth fabrication process used for industrial used cabinets ensures that every piece of
cabinetry that leaves our facility is flawless and built to last. We inspect our craftsmanship and double-
check our measurements continuously to make sure the standard or custom metal cabinet you order
will exceed your expectations, and we do it by following these steps:
Step 1: Cabinet Specification:
Since the cabinet we manufacture are specifically designed to incorporate online process Analyzer
System mainly for Oil & Gas Industry it has to be designed as per specification provided by the
customers. Generally, the specification will cover,
Size of the Shelters and/or cabinets (depends on the equipment size installed and
customer requirement)
Material of Construction is Stainless Steel 316, 316L and (304 is used only for internal
purpose)
Entry & Exit Ports Requirements
Ingression Protection Rating (IP Rating)
Hazardous Area Classification
Load Capacity (Cabinet load capacity, Lifting load capacity)
Cooling Requirement (AC, HVAC or Vortex cooler)
Shelter Safety system (Emergency exit, panic bolts and bars)
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Step 2: Drawing Approval
Based on the specification provided by the customers, a set of drawings covering all the aspects is
produced. All the drawing and relevant documents are approved by the customer prior to start
manufacturing.
Step 3: Bill of Material (BOM)
Once the drawings are approved, a list of material required to manufacture the
shelters/cabinet/enclosure is finalized and purchased. A typical cabinet will required following
material, Sheets (Stainless Steel 316 etc.)
Step 4: Construct the Components – Every part of the manufacturing process of our industrial metal
cabinets is done in-house. The design process is built around what our customer is going to use the
product for. Once the design is approved we will produce a sample to make sure the product is correct
in fit and function.
Step 5: Weld the Joints – To guarantee the custom metal cabinetry we create will be able to
withstand rigorous use and harsh environments the product was designed for, we spot weld, tig weld
or mig weld depending on the type of material and to meet certain criteria addressed in the design
phase of the metal cabinet.
Step 6: Installation of Pneumatic tubing
Step 7: Installation of electric power grounding
Step 8: Powder Coat the Surfaces – Once the product is completed and inspected it is thoroughly
degreased and iron phosphate is applied in our 3 stage degreasing system. This assures that all surfaces
are completely clean and ready for the industrial high grade powder coating we apply. The powder
coated finish is highly durable and can be had in virtually any color.
Step 9: Insulation – Rockwool insulation is used based on design density
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Step 10: Inspection
Step 11: Perform Final Assembly and Packaging – The final assembly stage may include screen
printing your company’s brand, or message on the cabinet to proudly represent your products and
image in the marketplace. Final assembly will also include installing hardware, locks, door handles,
hardware packs, instructions, etc. Every finished product will then go through a final inspection and
packed and skidded for shipment.
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