AIMS EQUIPMENTS SYSTEMS MANUFACTURING L.L.C. Cabinets and Shelters final.pdfAIMS EQUIPMENTS SYSTEMS MANUFACTURING L.L.C. Page 1 of 23 INDUSTRAL SHELTERS AND CABINETS MANUFATURING PROCESS

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.

https://en.wikipedia.org/wiki/Burr_(metal)


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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.

Documents

AIMS EQUIPMENTS SYSTEMS MANUFACTURING L.L.C. Cabinets and Shelters final.pdfAIMS EQUIPMENTS SYSTEMS MANUFACTURING L.L.C. Page 1 of 23 INDUSTRAL SHELTERS AND CABINETS MANUFATURING PROCESS