BETTER SOLUTIONS 6-1. Installation Press equipments & schedule itemEquipment nameqtywt(Ton)KIA Site arr.installtrial #1 Press5,400ton Press12,071.0 2005.12

BETTER SOLUTIONS

6-1. Installation Press equipments & scheduleitem Equipment name qty wt(Ton) KIA Site arr. install trial

#1 Press 5,400ton Press 1 2,071.0

2005.12

2005.12

~

2006.01

2006.01

~

2006.04

T/F unit 1 20.1

Destacker 1 141.5

Auto Palletizer 1 154.6

Aux. 2,400ton T/O Press 1 643.2

50Ton D/S 1 82.5

B.T.O 1 11.5

600ton Blanking press 1 275.7

Coil line 1 285.9

#2 Press 5,400ton Press 1 2,071.0

2006.03

2006.03

~

2006.05

2006.05

~

2006.07

T/F unit 1 20.1

Destacker 1 141.5

Auto Palletizer 1 154.6

total 13 6,073.2

BETTER SOLUTIONS

6-2. Installation working scope1. General

(1) Schedule Management (2) Safety Management (3) Management of Works (4) Inevitable condition, Disaster (5) Investigation and Technical advise for abnormal condition during installation, assembling and start up. (6) Working time (A) Seven(7) days / week Two shift should be done if not to keep the installation schedule (B) One(1) shifts / days or Two(2) shift / days (C) Eleven(11) hours / shift

2. Unloading and Packaging

(1) Checking quantities and condition (2) Protection cover from rain, flood and snow fall at outdoor (3) Transportation from storage area to erection site (4) Unpacking at installation site (5) Disposal of crate, case, skid and steel, and rubbish to the outside of the plant (6) Removing rust preventives and cleaning

BETTER SOLUTIONS

6-2. Installation working scope3. Preparation of foundation

(1) Checking of dimension of level and center in accordance with drawings and manuals

4. Installation of press equipments and fixture

(1) Base plate (2) Foundation Bolt for Bed (3) Press Proper (Including Crown, Upright, Bed, Die Cushion, Slide, Moving bolster, Platform, Covers, Coil line eqipment, B.T.O ETC) (A) Installation and assembling (including level and center adjust) (B) Assembling of electrical motor and centering (4) Fixture (Auxiliary) * Air tanks * Oil Hydraulic unit with tank * Moving boister and rails, Cable Guides * Safety guards (5) 2,400 Ton Crown Assembly * Assembly work (Refer Packing list) (6) Welding & Cutting work for installation of equipments (7) Welding work for pipe connection between balancer cylinders and air tanks, cushion cylinders and air tanks

BETTER SOLUTIONS

6-2. Installation working scope5. Mechanical pipings

(1) Assembling pipes between press and fixtures (2) Installation and connection of air pipes between air tanks and CTB cylinders (3) Flushing work after piping installation (4) The cutting, bending, welding and etc. for piping work of presss, coil line and etc.

6. Installation of electrical equipment

(1) Drive panel for main motor (2) Control panels (3) Terminal boxes (4) Cable racks & ducts (Cutting, assembly, installation at site) (5) Conduit pipes (6) Wiring (A) Wiring and termination * From panels to termina boxes (TB) * From TB to sensors / actuators * Between each panels (7) The welding, bending, cutting work for electrical pipe installation

BETTER SOLUTIONS

6-2. Installation working scope

8. Installation of scrap chute Carrier railway

9. Installation of the cover for coil line

10. Preparation for Machine Adjustment

(1) Charging of grease to each points (2) Filling up the oils to tanks (3) Cleaning and oil sprinkling to Crown inside and Slide (4) Pickling, cleaning and Flushing of the pipes fabricated at site after inspection of Rotem S/V (5) Air blow cleaning of intemediate air pipes (6) Disposal of dirty and/or used oil (7) Wiring check (Continuity) (8) Power on (9) I/O check for electrical

11. Machine adjustment (1) Assistant Workers during the running test & after running test refer the working schedule (2) Responsibility for bad installation work

BETTER SOLUTIONS

6-3. Organization chart6-3. Organization chart

Main Facility (Rotem)

Press Mechanical Specialist

Press Electric Specialist

PM

Chief PM : Press Specialist (1)

Vice PM : Industrial Facility Specialist (1)

Auxiliary Facility (WIA)

Press Mechanical Specialist

Press Electric Specialist

Installation Master

Specialist Installation Comissioning

Mechanical 20 3

Piping 10 2

Electrical 15 4

Helpers 10 2

Total 55 11

Installation Master

Specialist Installation Comissioning

Mechanical 10 3

Piping 10 2

Electrical 10 4

Helpers 10 4

Total 40 13

BETTER SOLUTIONS

6-4. Installation equipment

Four(4) Point Hydraulic lifter : 400 Tons 1 unit

Mobile Hydraulic crane : 100 Tons 1 unit

BETTER SOLUTIONS

1-5. 1-5. 설비 장비설비 장비

Mobile Hydraulic crane : 50 Tons 1 unit

Fork lifter : 10 ~ 20 Tons 4 units

Remarks : KIA Over-Head Crane (30~50 Tons)

BETTER SOLUTIONS

6-5. Installation basetool list

INSTALLATION BASETOOL LISTNo Machine Name Specification Quantity Remarks

1 Hand tool set 　　　

2Arc welder and all necessary welding equipment

　　　

3 Helmet for Welding 　　　

4 Glove for Welding 　　　

5Cutting gas torch and bulbs with all necessary equipment

　　　

6 Eye bolt

M8 X 1.25 mm Pitch 　　







7 Shackle

1 ton 　　

2 ton 　　

2.5 ton 　　

5 ton 　　

10 ton 　　

20 ton 　　

BETTER SOLUTIONS

6-5. Installation basetool list6-5. Installation basetool list

INSTALLATION BASETOOL LIST

8 Ratchet lever hoist

0.5 ton 　　

1.0 ton 　　

1.5 ton 　　

9 Chain hoist

1 ton 　　

1.5 ton 　　

3 ton 　　

10 Hydraulic jack

10 ton x 50mm Strok 　　

10 ton x100mm Strok 　　

10ton x 200mm Strok 　　

15ton x 150mm Strok 　　

11 Hand pump for Hydraulic jack 　　　

12 Hydraulic jack and distance blocks 50ton 　　

13 Distance block or tube for jack / 15ton /each

Dia 50 - 70mm 　　

Length 1 m 　　

15ton / each 　　

14 Sling for lifting(or Wires)

1 ton x 1 m 　　

1.5 ton x 1 m 　　

3ton x 1 m 　　

3 tons x 2 m 　　

3 tons x 4 m 　　

5 ton x 1 m 　　

5 tons x 2 m 　　

5 tons x 4 m 　　

BETTER SOLUTIONS



15 Dial indicator0.01mm / div 　　

0.01 - 10mm 　　

16 Magnet stands for Dial Indicator 　　　

17 Oil stone(Fine) 　　　

18 Washing Oil(Degreasing equipment) 　　　

19 Waste clothes(Scrap rags) 　　　

20 Fire extinguisher 　　　

21 Fire Blanket 　　　

22 Hand saw 　　　

23 Craw bar 　　　

24 Angle(Disc) grinder Dia 120mm 　　

25 Safety Glasses 　　　

26 Hand lamp 　　　

27 Garage lamp 　　　

28 Extension electric cable 20A, 30m Cable 　　

29 Cold chiselSmall 　　

Medium 　　

BETTER SOLUTIONS


INSTALLATION BASETOOL LIST30 Large hammer (Sledge Hammer) 　　　

31 Hammer 　　　

32 Copper hammer

Small 　　

Medium 　　

Large 　　

33 Rubber hammer 　　　

34 Files 10" 　　　

35 Open end spanner

6mm,8mm,10mm, 12mm,14mm,15mm, 17mm,18mm,19mm, 20mm,22mm,24mm,27mm,29mm,30mm,32mm,36mm,46mm,50mm,55mm.

　　

36 Ring Spanner

6mm,8mm,10mm, 12mm,14mm,15mm, 17mm,18mm,19mm, 20mm,22mm,24mm,27mm,29mm,30mm,32mm,36mm,46mm,50mm,55mm.

　　

37 Sledge Spanner24mm, 30mm, 36mm,41mm,50mm,55mm.

　　

38 Ring Spanner

M30 　　

M36 　　

M41 　　

M46 　　

M55 　　

BETTER SOLUTIONS



39 Socket & Socket wrenct 8mm - 55mm 　　

40 Tie-Rod Jack 　　　

41 Torque Wrenches 60kg/m 　　

42 Hexagon Wrenches MAX 27mm 　　

43 Hanger Metal 　　　

44 Combination Spanner 　　　

45 Adjustable Wrench 　　　

46 Chain Clamp 　　　

47 Grip Plier 　　　

48 Screwdriver 　　　

49 Super Lift 　　　

50 Heavy Equipment

- Hydro Crane 500t 이상 or hydro gantry Crane 300t 이상(Rail type)

　　

- Hydro Crane 200T 　　




- Fork lift 10 ton 　　

- Fork lift 20 ton 이상 　　

- Hydro Gentry Crane 　　

(Tire Type) 　　

BETTER SOLUTIONS


INSTALLATION ELECTRICAL BASETOOL LIST

1 Heart maker 　　 Numbering type

2 Hydraulic pusher 250SQ 　　

3 Hydraulic puncher 　　　

4 Testor 　　 Digital type

5 A Meter 　　　

6 Drill 　　　

7 Hand welder 　　　

8 Pipe bender 　　　

9 Hole maker 　　　

10 Mega ring testor 　　　

11 O-ster 　　　

12 Laptop & PLC programmer 　　　

13 　　　　

14 　　　　

15 　　　　

BETTER SOLUTIONS


정도 측정 공구1 Cylinder gauge 　　　

2 Dial gauge 　　　

3 Fineness gauge 　　　

4 Oxygen cutter 　　　

5 Laser thermamometer 　　　

6 Level reader 　　　

7 Torque gauge 　　　

8 Bolt doubler 　　　

9 Oil injector 　　　

10 Flatness finder 　　　

11 Piano wine, turn buckle 　　　

12 　　　　

13 　　　　

BETTER SOLUTIONS

6-6. Spare Parts & maintenance6-6. Spare Parts & maintenance

Spare part : Rotem

location : BMI Slovakia s.r.o in Rosina, Slovakia (8km from KIA site) Mlynska 813, 013 22 Rosina capa. : 1,500m2, Yard 5,000m2

scope : Press equipment Spare Parts

Documents

BETTER SOLUTIONS 6-1. Installation Press equipments & schedule itemEquipment nameqtywt(Ton)KIA Site arr.installtrial #1 Press5,400ton Press12,071.0 2005.12