Thermal Shop Design

Contents

Contents

Introduction

1 Architectural - structural part

1.1 Process

1.2 Master Plan

1.2.1 Shape and dimensions of the site, its construction, orientation

1.2.2 Vertical reference of the building on the ground

1.2.3 Landscaping and landscaping of the built-up area

1.2.4 Technical and economic indicators of the general plan

1.3 Space-planning solutions of the building

1.3.1 Building configuration and parameters

1.3.2 Structural diagram of the building. Providing Spatial

rigidity

1.3.3 Ensuring evacuation of people from the building

1.3.4 Technical and economic parameters of the building

1.4 Calculations for Architectural and Structural Part

1.4.1 Calculation of domestic premises

1.4.2 Thermal calculation of coatings

1.4.3 Definition of EEC

1.5 Structural solution of the building

1.5.1 Foundations. Substantiation of foundation depth

Foundation beams

1.5.2 Building framework

1.5.3 Walls. Partitions

1.5.4 Windows. Doors. Gates

1.5.5 Coating. Drainage. Protection

1.5.6 Floors

1.5.7 Ladder

1.6 Finishing of the building

1.6.1 Exterior Finishes

1.6.2 Interior Finishes

1.7 Engineering Equipment

1.7.1 Water supply

1.7.2 Heating

1.7.3 Sewerage

1.7.4 Power supply

1.7.5 Low current devices

1.7.6 Ventilation

Introduction

In accordance with the decisions of the Russian Government, it is now necessary to ensure further economic progress of society, accelerate scientific and technological progress, increase the efficiency of public production in order to quickly get the country out of the crisis. Currently, special attention is paid to the need for the operational development of the Engineering Field of Industry. To do this, it is necessary to develop and implement high-efficiency methods for improving the strength properties, corrosion resistance, heat and cold resistance of the metals and alloys used. The use of automated lines and machines, automatic manipulators with software control will eliminate manual low-skilled labor, especially in difficult and harmful conditions for humans.

The continuous expansion of automation is one of the main features of industry at this stage.

Automation of production processes is the main and decisive direction of modern technical development. The developing industry is characterized by a continuous expansion of the field of automation.

In the field of thermal metal processing, automatic lines and machines based on complex mechanization and automation are widely developed and introduced in the machine building industry.

Automation in thermal workshops is carried out in two ways:

modernization of existing equipment and equipping it with modern automation equipment;

design of new automated equipment.

The introduction of automation leads to a significant increase in productivity and quality of products and a decrease in cost, a decrease in production area, and an increase in the overall culture of production.

One of the most important problems of our time is the improvement of the quality and efficiency of public production based on its intensification, planning and management. At the same time, the issues of organization, planning and production management, which carry out a targeted impact on the facility to ensure the most effective solution of tasks, have a significant impact on the implementation of this problem. One of the conditions of technological progress in mechanical engineering is the continuous improvement of production through the application of new technological means, technologies and methods of organization of production.

Optimal technological solutions in specific production conditions should ensure high quality of products and labor productivity, minimum production costs.

1 Architectural - structural part

1.1 Process

The thermal workshop of the procurement production can be compared with a sharp intersection where the main technological flows of the automobile plant converge. Products manufactured in other workshops are brought here for volumetric heat treatment. From here, processed parts are delivered along the factory technological route to the places of assembly of bridges, reduction gears, transfer boxes, to the belt of the main conveyor. That is why it is so important that only high-quality products come out of the thermal workshop. And on time.

The quality of the product is a set of properties of the products, which make it fully suitable to meet specific needs in accordance with its purpose.

In order to improve the quality of products and strengthen technological discipline in production, high requirements for products have been established. Quality control is an integral function of production personnel. The wizard conducts a periodic quality check.

Selection of main equipment.

In the designed workshop of thermal treatment of large-sized parts from corrosion-resistant steels for heating of parts for hardening, annealing, tempering, decarburization and tempering, aging, it is proposed to use electric chamber furnaces of PIZ type 11.22.7.

Selection of auxiliary equipment

Internal and inter-shop transportation of parts is carried out using electric cars, which in turn are unloaded by a bridge crane, which is also necessary for installation work.

Selection of control equipment.

To measure the hardness of parts, we choose a device of the TS type, the principle of which is based on pressing a hardened ball into the tested sample under a certain load and then measuring the diameter of the print

Technological process of heat treatment of steel of brands 12XH3A, 20H2NCh, 18XHBA, 18HGT:

Quenching: for each steel a certain temperature, holding time, cooling in water at the required temperature, then in air to room temperature.

Cold treatment: exposure at negative temperatures, exposure in air.

Tempering: heating and aging, cooling in air.

Control: grades of material by knocked-out cipher of process mode smelting are operational; control of microstructure in TSL.

Decarbonizing tempering: heating, aging, cooling in air.

Aging: heating steel to optimal temperature, aging, cooling in air.

Dry grinding on a grinding machine, grinding depth up to 0.2 mm.

Control: grades of material according to knocked-out cipher, process mode of heat treatment in operation, control of hardness of HVotr = 3.053 .2mm and mechanical properties in ZP αv = 12501400 MPa, δ≥10%, Ψ≥55%.

Notes:

With an unsatisfactory structure, all parts are returned for additional heat treatment, in this regard, hardening of the part is allowed no more than three times.

Parts coming to aging must not have draft surfaces.

It is necessary to load parts into the refrigerating compartment when it is cooled to a temperature of 50 ° C. To ensure hardening of steel during cold treatment, it is necessary to prevent heating of parts after hardening before cold treatment in the temperature range of 200500 ° C, as well as prolonged exposure to low temperatures (0 - -40 ° C). The time between quenching and cold treatment should not be more than three days.

The time between cold treatment and aging is not limited.

Microstructure control should be carried out after hardening, cold treatment and tempering on samples cut from the central part.

You can edit the part after hardening, cold treatment, tempering, and after a full heat treatment cycle.

1.2 Master Plan

1.2.1 Shape and size of the plot, its development

The area on which the designed rectangular building is located is 72 by 144.5 meters in size.

Absolute ground elevation H0 = 75.45 m.

On the site, in addition to the designed building, there are :

- administrative - household building ;

- garage building;

- two security posts;

- building of repair and assembly shop;

- warehouses of component parts;

- car park;

- transformer substation;

- open storage area.

The site complies with all sanitary and fire safety standards based on SNiP II8980 *.

Asphalt roads with entrances to the building are provided on the designed site. Landscaping is provided along roads, walkways, around the building, as well as in vacant areas. The distance between the trees is taken at least 3.5 meters.

1.2.3 Landscaping and landscaping of the built-up area

On the territory of the outbuilding zone there are subsidiary outbuildings, entrances for trucks. Entry to the territory of the yard is provided from a secondary street.

Utility networks are placed within the cross-section of the road: under sidewalks. The width of the roads is taken to be 6 m.

Asphalt roads with entrances to the building are provided on the designed site. Landscaping is provided along roads, walkways, around the building, as well as in vacant areas. For the purpose of landscaping, trees are planted, flower beds and lawns are arranged. Shrubs are given various forms. Recreation grounds are included in the area of ​ ​ individual sections of the landscaped territory. The distance between the trees is taken at least 3.5 meters.

For the movement of workers and employees in the territory of the plant there is a network of pedestrian and transport routes.

Space planning solutions

1.3.1 Plan layout and parameters of the building

The designed building in the plan has a rectangular shape with dimensions of

axes "1 - 11" - 114 m., And axes "A - G" - 72 m. The building is one-story, since production with a horizontal technological process is characterized by heavy and bulky equipment, with significant dynamic loads. The height of the floor is 8 m. The building with a full frame with a grid of columns 12 × 24 m. Pitch - 12 m, span - 24 m.

The administrative-household building also has a rectangular configuration in plan with dimensions in the axes "14-16" - 12 m, in the axes "V-Z" - 48 m. The connection of the production workshop with the administrative-household building is provided through the gallery-type transition. The building is two-story with a floor height of 3.3 m.

1.3.2 Structural diagram of the building. Provision of spatial stiffness.

The project proposes a frame and panel diagram of a building with a full frame. The designed workshop has a frame with a column grid of 1224 m. The spatial rigidity of the frame is provided in the horizontal plane by foundation beams, crane beams, railway trusses and coating plates acting as rigid horizontal diaphragms, in the vertical plane spatial rigidity is provided by walls and vertical stiffness connections.

1.3.3 Ensuring evacuation of people from the building

Evacuation of people from the workshop is provided through the gates and doors, which open in the direction of evacuation.

Evacuation of people from the administrative and domestic building is provided through the lobby, central entrances. Evacuation of people from the second floor is carried out by stairs. The width of the flight of stairs is set according to SNiP based on the throughput and is taken equal to 1350 mm. The escape doors open towards the exit.

1.6 Finishing of the building

1.6.1 Exterior Finishes

Panels are covered with water-emulsion paints. Painting is made under the color of brick. The basement is plastered with the addition of decorative marble crumbs.

1.6.2 Interior Finishes

Toilet and shower rooms are lined with glazed ceramic tiles to maintain cleanliness. Tile lining is made for the entire height of the room. Tiles are laid on cement sand mortar of 50 grade, for which their rear part has corrugation. For each tile room, different colors, shapes, sizes are used, which gives the facing surfaces a very attractive appearance. In the transformer room, equipment room, electrical panel and other production departments, the walls are plastered with the addition of colored cements of warm tones.

Process equipment that constantly falls into the field of view of workers is also painted in light tones. Open steel structures are carefully painted with oil paints or covered with other anti-corrosion compositions.

Columns in the administrative and household housing are lined with clean-cut granite on M100 cement-sand mortar using fasteners.

Steps and risers of stairs are lined with marble polished slabs on cement-sand mortar M 100. Sill marble slabs are laid.

In basements, rooms, walls are plastered. Curved and flat window and door slopes are also plastered. Lime painting is carried out on plastered surfaces, whitening of ceilings with thick-grained beliles. Individual rooms are painted with water-emulsion and pentaphthalic paints. Decorative decoration of door canvases. Walls, ceilings and internal structures of thermal shops shall be painted with refractory paint of light tones. Finishing of production rooms shall exclude the possibility of dust accumulation, absorption of vapors and gases and allow systematic cleaning of the surface in a wet way.

Engineering equipment

1.7.1 Water supply

Water in an industrial enterprise is used for household, industrial and fire-fighting needs. Water supply is carried out from the networks of the industrial site, the head at the inlet is 24 m. The enterprise provides for a supply of clean water in the tanks. Employees of the hot areas of the workshop should be supplied with salted carbonated water with a content of 0.5% table salt at a rate of 4-5 liters per person per shift, for which it is necessary to install saturator units., Drinking water supply devices should be kept clean, have a glass rinse unit, drain shells or special water drains.

In the production rooms of thermal workshops, where work is carried out with harmful substances (acids, alkalis, etc.), fountains are arranged for washing the eyes and skin in an amount and in places that ensure their use no later than 612 seconds after the lesion.

1.7.2 Heating

The heating system is arranged in the premises of the administrative-household building and the central two-pipe heating system from the city networks is accepted. Type of coolant - water with parameters 150 - 700 С.

1.7.3 Sewerage

Sewerage - separate: production, household and rain in the city network. Waste water is discharged via closed gravity pipes. All toilets in the toilets are equipped with individual drain tanks. Shower pallets are provided in showers located on interstage floors. For the building of the thermal workshop, several sewage systems are provided for the disposal of water requiring preliminary treatment or treatment and differing in composition, aggressiveness and other indicators, taking into account which mixing of these wastewater is unacceptable.

Sewage pipes located in clandestine channels are laid below water supply pipes by at least 10 cm.

Acid solution pipelines are made of acid resistant materials (e.g. ceramics, vinyl plastic, etc.); for cyanide alkaline solutions - from steel and cast iron.

Acid and alkaline solutions are lowered via separate channels and pipelines.

Water from the parts washing tanks after their treatment in melts and spent caustic melts are periodically drained into a special tank and sent for neutralization to local treatment facilities.

1.7.4 Power supply

Power supply - from the city network with voltage of 380/220V. All wiring is laid in plastic bags according to safety requirements. In thermal workshops, the general lighting system is used as working lighting. Organized combined lighting at workplaces, where additional lighting is required for high-quality and safe performance of production operations.

Luminaires with fluorescent lamps are used to illuminate working rooms, as well as with lamps of DRL, DRS type. Filament lamps are used for lighting passages, for local lighting of workplaces, as well as for emergency or evacuation lighting.

Bridge cranes are equipped with crane lighting made with incandescent lamps and providing illumination level in areas shaded by cranes of at least 150 lx. Lighting fixtures on cranes are installed on shock-absorbing devices. In the cockpits of bridge cranes there are screens that protect the crane operator from the blinding effect of general lighting lamps installed above the crane.

Emergency lighting, which is automatically switched on in the event of an emergency shutdown of working lighting, is provided at workplaces, process areas where it is impossible to immediately stop work (work in gas furnaces, plants for obtaining controlled atmospheres, work with cyanide salts, acids), and in areas where a sudden termination of the technological process involves a danger to human life or large economic losses.

1.7.5 Low current devices

As low-current devices in the building, the following are provided: distribution complex network, radio broadcasting network, local, city, operational telephone communication, fire alarm.

1.7.6 Ventilation

In the premises of thermal workshops, both natural and artificial ventilation is used.

Aeration of production rooms is performed by opening of windows and light-aeration lights, holes of ventilation shafts. Opening is carried out according to the instructions specially developed in the organization, taking into account the time of year and the direction of winds, as well as taking into account the exclusion of the possibility of ingress of harmful substances from one room to another.

Light-aeration lights have devices for remote opening of frames and frames from control points in the shop room.

Flaps in window bindings of lower layers of glazing, available for opening from floor or working platform, have handles for opening manually.

Plenum ventilation supplies air to the working area and exhaust ventilation is removed from the upper area of the room.

The air removed from the production premises and equipment shall be cleaned of harmful substances before being released into the atmosphere in accordance with the requirements of SNiP 2.04.05.

Emergency remote ventilation is provided

Ventilation equipment, pipelines and air ducts located in rooms with aggressive environment or intended for air transportation with aggressive gases, vapors and dust shall be made of anti-corrosion materials or protected with appropriate coatings.

Summary

The explanatory note contains pages, including 3 figures, 12 tables, 13 sources. The graphic part is made on 4 sheets of A1 format.

This project contains the main provisions and selection of structures of the thermal workshop of the automobile plant. The explanatory note provides a description of the object and a detailed description of the structural elements. Process of thermal treatment of parts is described. Thermal calculation of coatings, lighting calculation, calculation of domestic premises were carried out.

The project provides for the use of automated progressive and high-performance equipment.

The new Rubimast roll roofing material is used in the project, which meets operational requirements, improves the quality of work performed, and increases the life of the roof.

PROVEDAL aluminum sliding windows made according to Spanish technology are also used.