Technical Specification for Installation of Asphalt Mixing Plants

I. General Provisions 1.1 Purpose To ensure the safety, quality, and efficiency of asphalt mixing plant installation work, and to guarantee the stable operation of the equipment after commissioning, this procedure is formulated. 1.2 Scope of Application This procedure applies to the equipment installation projects of newly built, relocated, or substantially modified asphalt mixing plants. 1.3 General Safety Principles • Installation work must adhere to the principle of "Safety First, Prevention Foremost." • All personnel involved must receive safety training. Personnel for special operations (lifting, welding, electrical work, etc.) must hold valid qualification certificates. • Necessary safety protection facilities and personal protective equipment (PPE) must be provided at the construction site. II. Pre-installation Preparation 2.1 Site Planning & Foundation Construction 2.1.1 Site Selection • Choose level ground with good drainage, away from sensitive areas such as residential zones and schools. • Ensure convenient transportation access to meet the needs of raw material and finished product logistics. • Conduct a geological survey to ensure the foundation bearing capacity meets design requirements. 2.1.2 Foundation Design & Construction • Construct according to the precise foundation drawings provided by the manufacturer. • Concrete strength grade ≥ C25. • Key control points: The position, elevation, and levelness (error ≤ ±5mm/m) of anchor bolts/embedded parts must be precise. • The foundation must be adequately cured. Installation can only proceed after it has reached the specified strength. 2.2 Equipment & Document Acceptance • Unpacking and Inventory: Conduct a joint unpacking by the manufacturer, installer, and user. Verify the quantity and model of equipment, components, and accessories against the packing list, and check for any visible damage. • Document Review: Receive and properly archive the complete set of technical documents (manuals, drawings, certificates, quality inspection reports). 2.3 Personnel, Tools & Materials • Personnel Organization: Establish an installation team with clearly defined roles (team leader, technician, safety officer). • Tool Preparation: Prepare a complete set of lifting, hoisting, measuring (level, theodolite), electrical, and general tools, ensuring they are in good condition. • Material Preparation: Prepare all standard parts and auxiliary materials (e.g., high-strength bolts, sealant, lubricating oil, etc.). III. Main Equipment Installation Core Principle: Install underground parts before above-ground, main structure before auxiliary components, framework before pipelines. 3.1 Mixing Tower Installation • Base Installation: Position, preliminarily level, and tighten anchor bolts. • Tower Assembly: Hoist sections sequentially, monitor verticality throughout using a theodolite, ensuring overall vertical deviation ≤ ±10mm. • Mixer Placement: Hoist the mixer to its designated position, secure it, and connect relevant inlet/outlet pipes. 3.2 Dryer Drum System Installation • Drum Installation: Hoist the dryer drum onto the support rollers and adjust it to level. • Burner Installation: Position accurately, securely connect fuel lines and control system. A leak test is mandatory. • Drive System Installation: Install the motor and reducer, adjust chain/belt tension to the appropriate level. 3.3 Vibrating Screen Installation • Frame Fixation: Ensure the foundation is level and solid, with frame levelness error ≤ ±2mm/m. • Screen Mesh & Motor Installation: Properly tension the screen mesh; install vibration motors according to markings and adjust eccentric blocks to the required angle. IV. Auxiliary Equipment & Pipeline Installation 4.1 Batching & Conveying System • Aggregate Bins & Feeders: Install bins stably; position feeders (e.g., belt scales, screw conveyors) accurately to ensure smooth material discharge. • Belt Conveyors: Level and align the frame, install rollers and idlers properly, focusing on adjusting the belt to prevent running off-track. 4.1.1 Pipeline Installation • Mineral Filler Pipelines: Ensure tight connections to prevent leakage. • Asphalt Pipelines: Must be insulated throughout, connected using specialized fittings, ensuring no leakage. 4.2 Dust Collection System Installation • Dust Collector Placement: Foundation must be level; position should allow easy maintenance access. • Duct Connection: Ensure reasonable duct routing, airtight sealing at connections to guarantee the system's designed air volume. • Fan Installation: Verify fan rotation direction, secure firmly, ensure effective vibration damping measures. V. Electrical System Installation Core Requirements: Compliance, Safety, Reliability. • Control Cabinet Installation: Cabinets must be vertical, stable, with levelness ≤ ±1mm/m. Internal wiring should be neat and compliant, with clear wire markings. • Motor Wiring: Measure motor insulation resistance before wiring. Wire strictly according to diagrams, ensuring correct phase sequence and reliable grounding. • Lighting & Grounding System: Ensure adequate lighting in work areas. The grounding system is critical for safety; grounding resistance must be ≤4Ω. VI. Equipment Commissioning 6.1 No-load Commissioning • Individual Jogging: Briefly jog each device separately to confirm correct rotation direction. • Individual No-load Run: Run each device independently for 2-4 hours, checking for temperature rise, vibration, and abnormal noise. • Linked No-load Run: Simulate the production sequence for startup/shutdown, testing if electrical interlocks and signal feedback function correctly. 6.2 Load Commissioning (Hot Commissioning) • Gradual Material Feeding: Start trial production at low output, gradually increasing to rated capacity. • Parameter Optimization: Monitor and adjust parameters of each system (drying temperature, weighing accuracy, mixing time, etc.). • Finished Product Testing: Sample and test the asphalt mixture for gradation, asphalt-aggregate ratio, temperature, and physical properties. Fine-tune equipment based on results until qualified products are consistently produced. VII. Final Acceptance & Handover 7.1 Acceptance Content • Installation Quality Acceptance: Check installation dimensions, accuracy, tightness, and sealing against drawings and this procedure. • Electrical Safety Acceptance: Inspect wiring, insulation, grounding, and protection. • Performance Acceptance Test: Operate continuously under rated conditions to assess if equipment capacity, energy consumption, and product qualification rate meet contract specifications. 7.2 Handover Documents After successful acceptance, compile and hand over the following documents: • As-built drawings and modification records. • Certificates for key components and materials. • Installation process inspection records. • Final acceptance report. • Complete set of equipment technical documents (manuals, maintenance guides, software backups, etc.). 7.3 Operator Training Provide systematic on-site training for the user's operators and maintenance personnel to ensure they can safely and correctly operate and maintain the equipment. VIII. Supplementary Provisions This procedure serves as the fundamental guideline for installation work. On-site installation must also comply with the specific technical documents provided by the equipment manufacturer, national standards, and safety regulations. Any adjustments or changes to installation steps require written confirmation from the responsible technical personnel.