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10.3


Storage of mechanical and electrical equipment on site
Guidelines for Temporary Storage Facilities on Sites

Erection
Approved date:2007-02-26 Created by: JaK Approved by:SKN

Doc. No.: 39401-01-4.1

Storage of mechanical and electrical equipment on site 39401-01-4.1

List of contents: Page: 1 2 3 Introduction ................................................................................................. 3 General remarks ........................................................................................... 3 Planning the transport and reception of goods .................................................... 4 3.1 Planning ...................................................................................................... 4 3.2 Transport .................................................................................................... 4 Arrangement of storage areas ......................................................................... 5 4.1 Layout of storage areas ................................................................................. 5 4.2 Handling equipment ...................................................................................... 6 4.3 Personnel .................................................................................................... 6 Storage of goods ........................................................................................... 7 General remarks .......................................................................................... 7 Marking of goods .......................................................................................... 8 Placing of goods in the different storage areas .................................................. 9 5.3.1 Goods for outdoor storage type A ........................................................ 9 5.3.2 Goods for outdoor storage type B ........................................................ 9 5.3.3 Goods for storage type C ................................................................... 9 5.3.4 Goods for closed buildings storage type D ............................................ 9 5.3.5 Dangerous goods ............................................................................ 11 5.3.6 Prolonged storage time .................................................................... 11 Store functions ............................................................................................ 12 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 General remarks about shipments ................................................................. 12 Shipping documents ................................................................................... 12 Arrival of goods .......................................................................................... 12 Inspection on arrival of transport damages..................................................... 13 Unloading .................................................................................................. 13 Unpacking and cleaning ............................................................................... 13 Stacking.................................................................................................... 14 Filing ........................................................................................................ 14 Handling of goods on site ............................................................................ 14 5.1 5.2 5.3

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Storage of mechanical and electrical equipment on site 39401-01-4.1

NOTE ! The present instruction manual is concerned with the situations which, according to the experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all conceivable situations, which may occur during manufacture, installation, operation and maintenance of the equipment, cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without undue delay for advice on appropriate action.

1 Introduction
This Instruction Manual gives guidelines for planning, establishing and running of temporary storage facilities for mechanical and electrical equipment on cement plant construction sites. The storage time can vary and may in some cases be up to several months. It is therefore of paramount importance that the below-mentioned guidelines are followed. NOTE! For extreme climate conditions or prolonged storage time project specific storage requirements must be drawn up by FLSmidth and/or sub-suppliers.

2 General remarks
Since more contractors are involved in the on-site installation of the plant, the coordination of the contractors required for working areas on site including internal roads, storage facilities for equipment materials and machines, site offices, workshops of different kind, temporary facilities as for pre – assembling, camps etc. should be done at an early stage in the project. A site installation drawing showing the storage areas etc. should be prepared and updated by the party in charge of the overall project. Furthermore, if special precautions should be taken into account in regard to internal and external factors like health and safety, security, local fire fighting regulations and climate conditions, these factors should be taken into consideration during the coordination of the site installations.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Storage of mechanical and electrical equipment on site 39401-01-4.1

3 Planning the transport and reception of goods
3.1 Planning Based on the general layout the position of the temporary construction site storage facilities must be determined. The storage areas should ideally be placed centrally on the construction site in order to provide short internal transport routes relative to the places of installation or at the place(s) where the preassembly activities are foreseen. The storage areas on site must provide good access conditions, both to the public network of roads and to all sections of the cement plant. If railway transport of goods to the plant is possible, railway wagons must preferably be unloaded directly in the storage area. 3.2 Transport Internal transport routes must be planned as early as possible and shown on the general layout. A free passage must be ensured for the goods to be handled and transported. Provisional supplies of electricity and water and erection equipment must not be allowed to block the roads. Construction (and maintenance) of internal transport roads for the installation activities must be included in the civil works programme. The roads are to be constructed for an axle pressure of min. 10 tonnes allowing transport of heavy goods.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Storage of mechanical and electrical equipment on site 39401-01-4.1

4 Arrangement of storage areas
Four different types of storage facilities are generally foreseen: A. Open area near the place(s) of the installation works B. Fenced-in area C. Fenced-in and covered area D. Closed buildings, heated and/or conditioned. 4.1 Layout of storage areas For all storage types the soil must be solid, dry, plane, and free from top soil and vegetation. Where the load capacity of the soil is problematic, it should be considered to cast a concrete slab. In rainy regions the entire storage area must be provided with efficient storm drains and must be protected against disintegration due to heavy downpour, etc. During dry seasons the roads must be sprinkled with water on a regular basis to prevent road dust generation. Close to the Store Office an open area must be established for reception of incoming shipments. Type A: Open area near the place(s) of the installation works In principle, it must be recommended that such store types must not be used for other parts than kiln tubes, mill bodies, and similar large parts, and/or heavy unpacked parts. As a rule, it will be advantageous to transport these large parts and place them directly in such a way that they can slide, be rolled or lifted directly into position and with sufficient space remove them from storage position to final position or to area for pre-assembling. Type B: Fenced-in area The fenced-in storage area must be provided with 6 m wide, clearly marked roads which can carry the total weight of goods, cranes and transportation equipment. Approx. 10,000 m2 of store area are required for every 3,500 tonnes of goods. The area could be divided into numbered sections ranging from 6 x 6 to 10 x 10 metres. All sections must be identified by means of a system of coordinates. Type C: Fenced-in and covered area The covered area is mainly used for lining bricks and insulating materials. As a rule of thumb the efficient storage area in m? is calculated as follows: Kiln diameter x kiln length x 3

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Storage of mechanical and electrical equipment on site 39401-01-4.1 Type D: Closed building, heated and/or conditioned The warehouse should be equipped with air conditioning with heating as well as a dehydration system operating on a 24-hour basis. 25 % of the area must be equipped with shelves and the rest must be divided into sections of suitable size giving access to forklift trucks and Lorries. The storage area may be in an existing building or in a provisional building having a solid floor and furthermore being dry, clean, dust-free and having a non-corrosive atmosphere as well as a suitable temperature: Minimum requirements: Temperature: Temperature variation: Humidity: Dew point: Vibration level: +10 ?C to +40 ?C Max. 5 ?C/h Max. 75% relative Max. 25 ?C A stable support free from excessive vibration and shocks

Suitable action must be taken to protect equipment and packing against vermin, rats etc. The size of the building depends very much on the scope of deliveries and the climatic conditions. ? ? 4.2 As a rule of thumb approximately 400 m? per 3,500 tonnes of equipment is needed for precision mechanics. For electrical equipment approximately 600 m? needed. This area does not include space for cables, cable trays and ladders.

Handling equipment An adequate number of Cranes, Lorries, and Forklift Trucks, etc. must be available on the Temporary Construction Site Storage.

4.3

Personnel Adequate qualified staff should be allocated to the Temporary Construction Site Storage. The daily work includes the following tasks but is not limited to: ? ? ? ? ? ? ? ? ? ? ? Receiving shipments Checking shipments upon arrival Damage reporting Placing equipment on storage Unpacking Retrieving equipment from Storage Updating stock inventory Registration of all store transactions Safety and guarding Reporting to management Filing

The language agreed on in the Contract must be mastered by the head of the storages and one responsible person on each shift. The responsibility for storage operations rests solely with the person in charge of storages who in turn reports to the management.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Storage of mechanical and electrical equipment on site 39401-01-4.1

5 Storage of goods
5.1 General remarks The goods shall be stored in the relevant storage facility described in 4.1. In general, the goods must only be sorted with respect to the required storing conditions. Do not try to sort the goods according to the order number, machine number, department, etc., because this will mean delays, possibly confusion, and prevent optimum utilisation of the store area. The Packing Lists, which contain detailed information about the contents of each case/package, must possibly be reviewed in co-operation with the Chief Erection Engineer to ascertain the correct storing method for the goods. When updating the store files it should be checked that the position of the goods in the store is in compliance with the classification agreed upon. Goods not placed in accordance with this Instruction Manual must be moved to the correct place before any damage occurs. The store files must subsequently be updated. Cases and other packing must not be opened, unless there is reason to believe that packing or contents have been damaged. Normally cases and other packing offer good protection against rough handling and therefore opening of the cases is not recommended until the parts are to be mounted. It is normally also recommended to leave the goods in the containers unless the goods in the container require storage conditions according to category D (5.3.4). If, however, the cases have been opened for the reasons mentioned above, periodical inspections are required during the storing period so as to make sure that the inside of the cases is still dry. If this is not the case, the parts must be dried immediately and further measures be taken to safeguard against the formation of moisture and to repair any damaged equipment. If the equipment is to be stored for more than 6 months, arrangements must be made to ventilate the cases. Drill holes at the top of one side of the case and at the bottom of the case on the opposite side. Cover the holes with wire netting to protect against vermin. Cases containing electric and electronic equipment must not normally be stacked. The cases are often, but not always, provided with the permissible stacking weight of the machine. On delivery to the plant site each type of goods is placed at its respective storage area as per the below-mentioned guidelines so that each type of goods can be identified in accordance with the marking described.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Storage of mechanical and electrical equipment on site 39401-01-4.1 5.2 Marking of goods The goods are, as a rule, marked as follows if no other marking is agreed upon in the contract: ? ? ? ? ? ? Purchase Order Number Equipment Number Name of plant Port of destination Weight Dimensions

Furthermore each package will be provided with the international symbols for handling and storing, see ISO standard 780 marking below.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Storage of mechanical and electrical equipment on site 39401-01-4.1 5.3 Placing of goods in the different storage areas 5.3.1 Goods for outdoor storage type A Heavy parts such as mill bodies, kiln sections and live rings should preferably be transported directly to the place of installation and be stored in such a way as to facilitate the later installation. As concerns kiln sections, attention is drawn to the fact that the sections are marked with an arrow pointing towards the kiln outlet. The kiln section closest to the smoke chamber is marked No. 1 and the other sections are marked in increasing numerical sequence towards support I which is the support closest to the burner platform. The heavy goods and all unprotected goods as well as steel structures must be kept out of contact with the ground by means of sleepers or similar supports. 5.3.2 Goods for outdoor storage type B All goods not requiring protection against weather influences or goods which do not require special storage conditions can be placed in the open fenced-in storage area. The heavy goods and containers must be kept out of contact with the ground by means of sleepers or similar supports. For practical reasons, only goods which can be handled with ordinary transportation equipment must be placed in this part of the store. Heavy parts must be placed in the store area dealt with in sub-section 5.3.1. Voluminous goods like rolled cables or cable drums can be stored in storage type B. Allocation of area amount to at least 2500 m? in order to facilitate handling and working with cables. Material delivered in shippers’ own containers can be stored inside the fenced area type B. 5.3.3 Goods for storage type C This storing method is useful for most of the delivery. The cover protects against sun and rain and is suitable for storing of voluminous goods such as lining bricks, lining and insulating materials, grinding media, belt conveyors (steel parts) etc. Short-time storage of oil and grease: If oil and grease supplied in drums (600-1000 drums for first filling) cannot be stored in closed buildings type D, the drums should be kept under a lean-to roof. The drums must be stored in a reclining position i.e. not upright and on rails or timber. 5.3.4 Goods for closed buildings storage type D Equipment that should be stored in type D warehouse comprises mainly electrical, hydraulic and precision-mechanical equipment as such goods may be destroyed by moisture and corrosion as well as castables, special mortars, monolithic refractories, Densit, vulcanisation materials etc. Furthermore, all closed cases and equipment marked with a symbol indicating that the goods must be stored inside in a temperature and/or moisture regulated area must be stored in the warehouse. As a general rule, oil and grease should be stored in closed buildings. Moisture and frost may cause deterioration of the products. Electric and hydraulic equipment Electric and hydraulic equipment is normally packed in cases or containers, and the most common reason for damage is moisture. Therefore it is

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Storage of mechanical and electrical equipment on site 39401-01-4.1 important to protect the parts against moisture and condensation during storage. Even minor moisture and corrosion attacks can damage the equipment. Main motors must have heating elements energized and main motor shafts must be turned every second month. Some parts are packed in aluminium foil which is sealed by airtight welding. However, even the smallest hole in the foil can in connection with high relative humidity and temperature fluctuations create a kind of "pumping" action of the air into and out of the packing, thus constantly increasing the moisture which condenses inside the packing when the temperature drops. Short-term storage of electrical equipment (less than 2 months) Equipment shall be stored in a proper warehouse with a controllable environment in accordance with requirements set up in chapter 4.1. If the equipment is equipped with anti-condensation heaters they should be energized if the seaworthy packing has been penetrated. Operation of anticondensation heaters must be verified periodically. If seaworthy packing is intact, the heater needs not to be energized. If the anti-condensation heaters are energized on electric motors, and the surrounding air is above 50?C (120?F), it must be confirmed by supplier that the motor is not overheated. If the seaworthy packing has been penetrated on electric motors and these are not with anti-condensation heaters, an alternative method of heating the equipment must be used for preventing condensing of moisture inside the equipment. This method is subject to agreement with motor supplier. Protection must be provided against harmful insects and vermin. If electrical motors are equipped with condensate drain holes the sealing plugs shall be removed at regular intervals. The condensate shall be drained off and the plugs refitted. Long-term storage of electrical equipment (more than 2 months) In addition to the measures described for short-term storage, compliance with the following must be ensured: ? For electric motors the insulation resistance and winding temperature shall be measured every three months and verified in accordance with the appropriate maintenance manual. The condition of painted surface shall be checked every three months. If corrosion is observed it must be removed and the surface repainted. The condition of anti-corrosive coating on blank metal surface (e.g. shaft extensions) shall be checked every three months. If corrosion is observed it must be removed with a fine emery cloth and anticorrosive treatment must be performed. If the equipment is stored in a wooden box small ventilation openings must be arranged. To prevent water, insects and vermin from entering the box a fine meshed net can be mounted on the openings.

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Electronic equipment i.e. instruments, panels, printed circuits, etc. is highly sensitive to shocks and moisture and requires a warehouse type D.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Storage of mechanical and electrical equipment on site 39401-01-4.1 Computer and X-ray equipment are particularly sensible to moisture and temperature changes and generally it is recommended not to forward such equipment to the plant site until such time when the equipment can be installed finally in the control room. Other equipment such as rubber conveyor belts also requires special storage considerations. 5.3.5 Dangerous goods Particular attention is needed when storing inflammable, explosives, radioactive or etching materials in storage type D and according to local regulation. 5.3.6 Prolonged storage time If for some reason, the installation of equipment should be postponed, the stored goods must be inspected, not later than 6 months after delivery and subsequently every 6 months. Check that the paint or rust protection applied to machines and parts before shipment is still intact. If necessary, apply a new protective coating. Check expiry date of chemical products such as glue for vulcanising, Epoxy, paints, Densit, castables, etc.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Storage of mechanical and electrical equipment on site 39401-01-4.1

6 Store functions
6.1 General remarks about shipments The instructions provided on the goods and in FLSmidth instruction manuals must be strictly adhered to. The forwarding documents may serve to decide where the goods must be stored and entries made on the documents. Unless specifically stated in the contract, FLSmidth does not assume any responsibility for damage resulting due to physical abuse during transport and unloading or due to inappropriate storage. 6.2 Shipping documents These documents are very important for the working routines on site and for the storage and handling of goods. For satisfactory store operation it is an absolute necessity that the shipping documents arrive at site before the goods. First of all, the shipping documents are required for planning, checking and unloading. Moreover, they are required for establishing/updating the store files which is part of the actual store system. 6.3 Arrival of goods When goods arrive, the haulier shall be held liable in writing for visible damage to goods delivered, e.g. by endorsement of the vehicle operator's report. Immediately when the goods arrive at the plant, checks must be conducted to determine whether the cases are undamaged and whether unpacked parts are damaged or attacked by rust. Damage to rust-proofing must be repaired. The contents of damaged cases must be checked against the packing list, and missing or damaged parts must be recorded and a report must be submitted to the insurance company as well as FLSmidth. If the goods are to remain stored in the cases, they must be repaired. Special tools for opening of boxes and cases must be used to avoid damage to the packing materials and the contents. Undamaged cases must not be unpacked, unless special instructions exist or there is a suspicion of e.g. internal damage (moisture, vermin attack) or divergence between the dimensions and weight of the case and the Packing Lists. Unpacking will increase the risk of parts disappearing before erection begins. On the other hand, general insurance terms require that claims for damages must be made immediately on arrival of the goods. On this background it is impossible to give general instructions as to the opening of cases. The final decision on the procedure to be adopted must be made on site. However, it must be emphasised that the transport insurance normally ceases to cover against concealed damages 60 days after arrival. Losses and damage that have occurred at site will not be covered by the transport insurance but must be claimed under the Contractors All Risk Insurance (C.A.R.) if taken out for the purpose.

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

Storage of mechanical and electrical equipment on site 39401-01-4.1 6.4 Inspection on arrival of transport damages All packages, cases and contents of containers must be inspected for visible transport damage when the parts arrive at site. Closed cases must be opened carefully and examined immediately if damaged or if there is a risk that the actual goods have suffered damage. Unpack thoroughly dry and clean parts which have been damaged by moisture or rust. Do not remove the identification tags. Apply a new rust-proofing coating and re-pack the parts in the same cases when the cases have dried thoroughly. Sealed parcels containing e.g. electrical equipment, must not be opened, but must be checked for holes. If the packaging has holes or is damaged, there is a risk that the equipment has been damaged by moisture. If electrical parts and instruments have been exposed to moisture, they must be cleaned and dried out, and FLSmidth shall be consulted and further instructions should be awaited. If the boxes are equipped with Tilt Indicators or Moisture Indicators the figures should be noted and reported if the boxes have been tilted or exposed to moisture. 6.5 Unloading At early stage prior to the arrival of the goods, procedures must be made for unloading the goods and necessary lifting gear, forklifts, cranes, personnel, etc. must be in place. Also prepare a Transport Damage Claims Procedure. Check up the conditions and time limits for claim advice of the insurance company or the local insurance agent concerned before the shipment arrives so that all conditions for any claim advice can be complied with. In order to avoid accidents the goods must be unloaded using the lifting logs arranged by Packing/Shipping at the workshops or other specified and properly suited equipment. Undamaged slings and other certified equipment must be used to avoid accidents. 6.6 Unpacking and cleaning Just prior to erection of a given piece of equipment the Chief Installation Supervisor should be consulted regarding unpacking and cleaning of the equipment. If required, clean machined parts in a suitable solvent. Do not use paraffin oil, because it promotes corrosion. Apply a thin coat of oil to the goods after cleaning and maintain this protection until the machines are put into operation. It will normally not be necessary to remove the rust-proofing coating on supporting rollers and tyre paths. In case of doubt consult FLSmidth. The anti-corrosion treatment on Collecting Plates for Electrostatic precipitators must not be removed.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Storage of mechanical and electrical equipment on site 39401-01-4.1 6.7 Stacking If packages/cases and/or goods cannot withstand stacking or only a limited stacking weight, this is usually indicated on the packing. Special care should be taken when stacking Refractory Bricks. NOTE! However, it will always be up to the personnel in charge of unloading and storing to determine goods not marked can be stacked without attendant risk of damage. 6.8 Filing The store files may either be controlled manually or by means of a suitable software programme. Either system has proved effective for controlling store functions. Using a software the store handling system information about the actual store condition is permanently available and if online or included in the intranet on site it could be useful when planning the actual installation works as fast and complete store survey is available including search facility for: ? ? ? ? ? ? ? 6.9 Total stock Order number Position (store section) Plant department Field of responsibility Supplier Weight

Handling of goods on site In accordance with the time schedule for the installation works the machines and equipment are taken out from the respective storage areas and placed in the vicinity of the installation area and/or at the preassembly area. An intermediary storage area in each department of the plant is typically constructed prior to the start of the installation activities including a covered area for tools, consumables, spare parts, instruments, bolts, nuts, welding electrodes, steel plates, pipes and fittings, lubricants and oil, lifting gear such as shackles, slings, hoists, wires etc. for the safe handling of the equipment. These covered and guarded storages should as a minimum fulfil the same criteria as for all other storage areas taking into account that the delay of installation work might take several months. When the installation of the single plant departments has been finished it is very important that erection tools, spare parts and instruments, etc. are returned and signed for at the main storage for later use during maintenance. ---o0o---

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The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.


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