Dokumen Teknis
Panduan instalasi, manual operasi, prosedur perawatan, dan dokumentasi pemecahan masalah untuk peralatan pembuatan pipa semen.
HLY-INS-01: Suspension Roller Pipe Machine Foundation & Installation Manual
1. Scope & Equipment Overview This manual governs the civil foundation construction, mechanical alignment, and anchoring of HLY single-station and dual-station suspension roller co...
HLY-INS-02: CNC Rebar Cage Welding Machine Commissioning & Wiring Guide
1. Machine Bed & Rail Installation - Longitudinal Rail Straightness: The total straightness deviation of the servo carriage travel rails must be $\le$ 1.0 mm over full length, with...
HLY-INS-03: JS Series Twin-Shaft Mixer Assembly & Pneumatic Calibration
1. Structural Leg Positioning & Anti-Overturning Bracing - Elevate mixer legs (clearance 3.8m or 4.5m for batch transfer hopper) with verticality deviation $\le$ 1/1000. - Perimete...
HLY-INS-04: Gantry Crane Track Foundation Leveling & Festoon Cable Installation
1. Crane Rail Foundation & Alignment Tolerances - Heavy-duty P43 or P50 crane rails fastened upon continuous concrete grade beams. - Span Gauge Tolerance: Actual track gauge vs nom...
HLY-OP-01: Suspension Roller Machine Console Dual-Speed & Auto-Feeding SOP
1. Pre-Shift 5-Minute Safety Checklist 1. Verify hydraulic tank oil level is at 2/3 of sight glass and temperature is between 20°C and 50°C. 2. Check main reducer oil level and con...
HLY-OP-02: CNC Rebar Cage Welder Touchscreen Programming & Resistance Welding SOP
1. HMI Touchscreen Recipe Programming 1. Navigate to "Recipe Setup", load target standard profile (e.g., DN1000-GB2.5M). 2. Input dimensional parameters: - Total cage length (e....
HLY-OP-03: 4-Stage Steam Curing Thermal Valve Control & Recording SOP
1. Pit Enclosure & Pre-Steaming Delay - Place green pipes into pit; lower insulated covers; verify water-trough perimeter seals are flooded to prevent steam escapes. - Mandatory De...
HLY-OP-04: Hydraulic Collapsible Box Culvert Mold Stripping & Clamping SOP
1. Pre-Pour Setup & Mechanical Wedging 1. Spray bio-based release oil over inner core and outer formwork panels. 2. Start hydraulic station (set to 18 MPa); shift lever to "Expand"...
HLY-MNT-01: Precast Concrete Pipe Mold Daily Cleaning & End-Ring Alignment Protocol
1. Mandatory 15-Minute Post-Demolding Cleaning Rule - Within 15 minutes of pipe stripping, crews must remove cement paste with pneumatic scrapers and curved brass blades. - Zero Ha...
HLY-MNT-02: Twin-Shaft Mixer Wear Liner Replacement, Clearance Adjustment & Seal Greasing
1. Blade-to-Liner Operating Clearance Adjustment - Inspect gap between blade tips and curved wear liners weekly; maintain between 3.0 and 5.0 mm. - If clearance exceeds 8.0 mm, loo...
HLY-MNT-03: Suspension Roller Main Drive Shaft NDT Inspection & Roller Bearing Greasing
1. Ultrasonic Non-Destructive Testing (NDT) of Roller Shaft - The 42CrMo forged alloy steel roller shaft endures multi-ton alternating dynamic loads. - Conduct ultrasonic flaw dete...
HLY-MNT-04: Specialized C-Hook Pipe Lifter & Spreader Beam Rigging NDT Inspection
1. Monthly Magnetic Particle Testing (MT) of Welded Roots - The 90° re-entrant throat corner of counterbalanced C-hooks endures peak tensile concentrations. - Inspect all critical ...
HLY-TS-01: Pipe Delamination, Spiral Cracks & Mold Jumping Troubleshooting Guide
Fault 1: Severe Mold Hopping & Impact Noise on Roller Shaft - Root Causes: 1. Non-uniform longitudinal feeding causing dynamic mass imbalance; 2. Runner rings worn out-of-round...
HLY-TS-02: CNC Cage Welder Weld Failures, Pitch Drift & Servo Alarm Diagnosis
Fault 1: Cold Welds, Lack of Fusion & Brittle Joint Separation - Root Causes: 1. Low pneumatics (<0.4 MPa) providing inadequate squeeze pressure; 2. Heavy rust scale, drawing o...
HLY-TS-03: Steam Curing Thermal Shocks, Crazing Cracks & Strength Retrogression Fixes
Fault 1: Spiderweb Crazing Cracks on Pipe Surfaces Post-Curing - Root Causes: 1. Pre-steaming delay too short; pore water flashes to steam prior to initial set; 2. Superheated ...
HLY-TS-04: Hydraulic Core Jamming, Sync Cylinder Pressure Drop & Release Manual
Fault 1: Inner Core Locked Solid During Collapse Cycle (Pump Stalls at Relief) - Root Causes: 1. Cement slurry intruded into corner wedge slider grooves and set rock-hard; 2. M...
HLY-GEN-01: Three-Edge Bearing Load Testing & Hydrostatic Proof Standards
1. Three-Edge Bearing Test (TEBT, ASTM C497 / GB/T 16752) - Apparatus Setup: Rigid loading frame, upper loading beam, lower parallel hardwood timber strips (width 50 mm, spaced at ...
HLY-GEN-02: Dry-Cast Zero-Slump Concrete Mix Design & Vebe Consistency Norms for Precast Plants
1. Binder Quantity & Water-Cement Ratio Redlines - Cement Grade: Ordinary Portland Cement (OPC Grade 42.5 or 52.5), dosage 320–380 kg/m³. - Water-Cement Ratio (W/C): Strictly maint...
HLY-GEN-03: Trenchless Jacking Pipe Manufacturing Tolerances & Steel Collar Inspection Protocol
1. Jacking Pipe Manufacturing Tolerance Limits - End Face Squareness: Perpendicularity deviation must be $\le$ 0.8 mm (exceeding 1.0 mm causes catastrophic edge spalling under high...
HLY-GEN-04: Pipe Storage Yard Grade Leveling, Safe Tier Stacking & OSHA Safety Protocol
1. Storage Yard Concrete Paving & Drainage - Yard foundation must be compacted (compaction ratio $\ge$ 0.95) and paved with $\ge$ 180 mm Grade C25 concrete slab, rated for $\ge$ 15...
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