Instructions for storage in the warehouse of an industrial enterprise. Rational placement of goods in a warehouse: rules and methods. Principles of placement of goods in warehouses
The instruction was developed by the All-Union Research Institute of Economics, Organization of Production and Technical and Economic Information in the Gas Industry (VNIIEgazprom) with the participation of the Equipment Acquisition Department, in accordance with the order of the Ministry of Gas Industry dated 20.08.84 N 175 p.8.
The instruction sets out the procedure for acceptance and storage conditions for equipment and spare parts in warehouses and bases of enterprises and organizations of the Ministry of Gas Industry.
When developing the instructions, the provisions set forth in a similar instruction of the Ministry of Gas Industry (1983), extracts from the "Guidelines for the transportation, acceptance, storage of equipment, electrical products and materials at the bases and warehouses of the USSR Gossnab", Moscow, 1970, "Instructions for loading and storage of equipment in warehouses of associations and compressor stations", developed by Soyuzorgenergogaz and approved by the Deputy Minister of the gas industry comrade. A.N.Kolotilin 02.12.82
1. General Provisions
1. General Provisions
1.1. Bases (warehouses) of departments (trusts) of production and technical services and staffing of departments and production and technical staffing warehouses and storerooms at enterprises and organizations are intended for receiving, accumulating, storing and issuing technical means necessary to ensure capital construction and production activities of enterprises and gas industry organizations.
1.2.1. Acceptance of inventory items should be carried out according to the transport and accompanying documents of the supplier (invoice, specification, waybill, etc.) and consists in determining the conformity of the quantity of received products with the quantity and quality specified in the transport and accompanying documents, as well as in contracts, GOST and TU.
1.2.2. During the acceptance of products, the following operations must be performed:
determination of the quantity and quality of incoming products;
acceptance of products for registration;
preparation for laying products for storage;
storage of products.
1.2.3. Acceptance of products must be carried out by the head of the financially responsible person or a person replacing him, as well as by a person authorized by the head of the organization accepting inventory items.
1.2.4. The warehouse manager, storekeeper - a materially responsible person, before the receipt of production and technical products at the warehouse, base, must prepare for its acceptance:
determine the place for its installation;
instruct workers on the procedure for performing the upcoming unloading work and safety precautions.
1.2.5. Acceptance of inventory items in warehouses should be carried out in batches on the basis of an external examination of the products and a passport, which contains the necessary data provided for by the current standards and specifications.
1.3. Platforms, sheds, warehouses must be provided with reliable drainage of ground and surface waters; open areas, sheds and warehouses where equipment is stored must meet the requirements of SNiP III-A-5-62 "Organization of material and technical facilities. Basic provisions".
Equipment stores should be dry, well ventilated and protected from dust.
Warehouses are ventilated when the absolute humidity of the outdoor air is lower than the absolute humidity of the indoor air. Therefore, before airing the warehouse, the humidity and temperature of the outside air and the air inside the warehouse are measured.
Bases (warehouses) of UPTOiK (trusts), BPTOiK should be organized near railway and waterways, and where this is not the case, have entrances equipped with an asphalt, cobblestone or improved dirt road.
1.4. The territory of the warehouse must have fences that meet local conditions, with a minimum number of passages and passages, but provide access and passage to all storage facilities and sites, have a hard surface that provides water runoff from buildings and from open areas.
Every active passage and passage must be guarded. To accommodate the sentry guards, guard (checkpoint) booths are needed.
There should be a pass system for working and vehicles.
The device and location of entrances and driveways should provide the possibility of convenient passage and work of the fire department.
1.5. Storage of material assets in warehouses should ensure:
- rational placement of goods in warehouses, racks or in stacks;
- quantitative and qualitative safety of all incoming goods;
- the most complete use of warehouse space;
- application of the most rational technological layouts of the territories of the bases for the placement of equipment and places for storing materials;
- use of modern loading and unloading machines, mechanisms and other technological equipment;
- the ability to perform technological operations in all weather conditions;
- in the northern and southern regions, racks, overpasses for open storage of material assets should exclude their filling with snow, sand, etc.;
- Compliance with fire safety and safe working conditions.
1.6. Closed storage areas must have a sufficient number of light openings for daylight. The area and capacity of storage facilities is determined based on the planned cargo turnover.
1.7. The main factors ensuring the fulfillment of the requirements, conditions and storage techniques are the correct choice and rational use of storage equipment (racks, pallets, handling equipment, etc.).
1.8. Methods and procedures for protecting material assets stored in open areas depend on their type, quantity, method of stacking, storage duration, and climatic conditions of the area.
1.9. The base must have a technological plan for the placement of materials and equipment, plan maps of the warehouse facility.
1.10. All inventory items stored in warehouses must be tagged with the name; brands; size type; quantity, price per unit; dates of receipt; warehouse accounting card numbers (Typical interdepartmental form N M-17), see Appendix N 1.
1.11. Ways of laying (in stacks, on racks or on the floor) depend on their shape, weight, packaging, physical and chemical properties and quantity.
1.12. When stacking goods in box pallets, the stacking height should not go beyond the upper edge of the pallet, it should ensure the safety of containers and products from damage.
1.13. The warehouse manager should check daily:
temperature in the warehouse;
correct storage of products in racks and stacks;
serviceability of the electrical network, water supply, heating, sewerage, ventilation installations, external drains;
shelter of equipment stored in open areas and under a canopy;
no leaks in the roof;
the condition of the glazing on the windows.
1.14. Warehouse workers must be able to work with fire-fighting inventory and equipment, know the rules of care and use when extinguishing a fire.
1.15. Warehouses for storing equipment should be of the following types:
Table N 1
|
Warehouse type |
Equipment characteristic |
An error has occurred The payment was not completed due to a technical error, funds from your account | ||
The process of storing goods begins with placing them in the warehouse. The placement method is chosen depending on the tasks, the purpose of the goods, the chosen storage method, the need to maximize the use of the warehouse volume with a rational arrangement of sections, protect goods from damage, the availability of any warehouse cell for mechanisms in large warehouses, and quickly find the necessary goods.
There are the following methods of placement and storage of goods:
High-quality - goods of various types and varieties are placed separately from each other;
Batch - each batch of goods received at the warehouse is stored separately, while the composition of the batch of goods may include goods of various types and names;
Batch-sorted - each batch of goods received at the warehouse is stored separately, while within the batch the goods are disassembled by type and grade and are also placed separately;
By name - goods of each name are stored separately.
For quick placement and selection, ensuring the required storage modes, they develop schemes for the placement of goods, providing for permanent storage places, the possibility of monitoring their safety and caring for them. When developing schemes, the frequency and volumes of receipt and shipment of goods, the optimal methods of stacking, the conditions for their shipments, and for some types of goods, the “right neighborhood” are taken into account. In some cases, if freedom of maneuver is needed, variable storage locations for goods are used.
When placing goods, one should adhere to the principle "more often demand - closer to the passage (passage)". Daily demand items are stored in close proximity to the shipping or pick-up area.
It is practiced to allocate areas for short-term and long-term storage. Fast-turning goods are located in short-term storage areas. In the areas of long-term storage, both goods of low demand and goods of frequent demand are placed, which make up insurance stocks in addition to the operational ones located in the area of short-term storage.
In large warehouses with a large turnover, each cell is made in such a size that it can accommodate a batch of goods in it together with a pallet or in a box in which it arrived, and the passages between the racks must be sufficient for the operation of forklifts with lateral movement of the forks.
In warehouses for small wholesale and retail trade, goods are most often placed in accordance with the grouping by size. Warehouses have sections for large and small goods. For different products, different ratios of the quantities of small, medium and large cells in the warehouse, different cell sizes in depth are needed. Firms specializing in the manufacture of warehouse equipment develop standard schemes and models of collapsible racks for different goods, so it’s cheaper to buy ready-made collapsible racks with variable cell height than to make them according to your own sketches, and subsequently either redo them or put up with uneconomical placement of goods on stock.
To increase the number of cells, improve the method of storage, accelerate the selection of goods of a specific shape, stands with pins are installed on the free sections of the walls, on the columns and ends of the racks. Stands are used to place flexible goods in a suspended state - hoses, cables, i.e. goods whose storage in the supine position does not allow, due to their shape, to economically use the volumes of the cells and is inconvenient for selection.
Regardless of whether the warehouse is large or small, it is imperative to maintain a single address system for placing goods, otherwise loss of goods, regrading and losses are inevitable. This is important to ensure an increase in turnover, avoid errors in the placement of goods and quickly find them even for new employees after a short briefing.
The essence of this system is that each storage location is assigned a code (address) indicating the number of the rack (stack), the number of the vertical section and the number of the shelf. The address can have 4-5 characters or more. Programmatically provide automatic indication of addresses in labels, checks, availability specifications and inventory sheets. Inventory sheets and packing lists for the selection of goods are printed sorted by address.
In the warehouse, everything has its place and only in this place should be.
The most common address system is as follows. Cell number: A1739, where A, B, C - storage area (warm, cold warehouse or part of the warehouse); 17 - serial number of the rack; 3 - serial number of the vertical section of the rack; 9 is the serial number of the shelf.
Obviously, this numbering is suitable for a zone of 99 racks and that each rack can have no more than 10 vertical sections and no more than 10 shelves. For a larger number of vertical sections and shelves, two-digit numbers are used, but more often they tend to use a conditional division of the warehouse into zones and use an alphabetic zone index.
The introduction of an address system includes marking on layout plans, making and fixing numbers or applying them with paint, entering addresses into product specifications, entering numbers from specifications into a computer database or accounting cards.
Addresses are applied with bright paint on the design of racks, compartments, on the floor. A space without shelving can also be divided into zones and compartments, either constructively or conditionally using markup.
A warehouse worker must find a product by name and address, even without knowing its appearance. The use of permanent addresses provides the possibility of quick selection or placement of goods, as well as effective control over their movement. New employees, after a short briefing, having at hand a statement of the availability of goods in the warehouse with addresses, will be able to cope with this work without errors.
Shelving or stacking schemes with storage addresses are posted on the walls so that warehouse employees can study them and easily navigate.
Marking the numbers (articles, codes) of goods on boxes should be large so that employees can see them from afar and quickly choose a route.
Labels with names are better to be mounted on shelves, and not on boxes, because. the product must have a permanent place. If the box is taken away, it will be seen that you need to bring or order the goods.
For packaged and piece goods, stacked and rack stacking methods are usually used.
Stacking is used to store goods packed in bags, bales, coolies, boxes, barrels. Forming a stack, ensure its stability, allowable height and free access to goods. The height of the stack is determined by the properties of the product and its packaging, the capabilities of the stacker, the maximum load per 1 m 2 of the floor, the height of the warehouse.
Stacking is used in three versions: straight, cross-checked, reverse-checked.
In straight stacking, more commonly used for stacking crates and drums of the same size, each crate is placed strictly and evenly on top of the crate in the bottom row. Improving the stability of the stack provides a direct pyramidal stacking:
in each top row there is one less place and each top place is set on the two bottom ones.
Boxes of various sizes are placed in a cross cage. In this case, the upper boxes are laid across the lower ones.
As a rule, goods packed in bags are placed in the reverse cage. The top row of bags is placed on the bottom row in reverse order.
When stacking goods in stacks, ensure that normal air circulation, sanitary and fire safety requirements are ensured in the warehouse. Stacks are placed no closer than 0.5 m from walls and 1.5 m from heating appliances. Between the stacks leave passages about 1.5 m wide.
Stacked storage of goods stacked on rack and box pallets allows for more rational use of premises and the use of mechanisms.
With the rack method of storage, goods on pallets, unpacked, as well as goods in individual packaging are placed in the cells of the racks.
Rack storage of goods on pallets is convenient, since with the help of stackers, pallets are stacked on shelves located at any height accessible to the mechanisms. On the lower shelves, you can store goods, the selection of which is carried out manually, on the top - goods shipped entirely on a pallet.
When packing goods, the following requirements must be observed:
Container places are laid with markings towards the aisle;
Homogeneous goods are stacked in racks on both sides of one aisle, so that the transportation path is shorter during stacking and picking;
If one cell is not enough for the entire quantity of goods of one name, the goods are placed higher, in the following cells of the rack in the same vertical section, so that when stacking and picking, the travel path is shorter, and the storage address differs only by the shelf number.
Consider the principles of stowage of cargo for storage:
Use of address storage system;
Economical use of storage space;
Allocation of a zone of short-term and long-term storage;
Seasonal storage goods - on the last tiers of racks or in remote places of the warehouse;
Goods with high turnover - at the entrance-exit;
Oversized cargo - at the exit;
With the rack method - changes in the load along the depth of the inter-rack aisle;
Vertically - a homogeneous product;
On opposite sides - a homogeneous product;
On the upper tiers of the racks, long-term storage goods are placed, as well as goods released from the warehouse in batches of at least a whole package or pallet.
Mechanized hangers are used to store outerwear in warehouses. Bulk cargo is stored in bulk. Tanks, tanks and barrels are used to store liquids.
Goods are stacked on racks, pallets, in stacks, etc. The weight of the load on the pallet must not exceed the design capacity of a standard pallet.
When placing goods in rooms, the dimensions of the indents should be: from the walls of the room - 0.7 m, from heating devices - 0.5, from light sources - 0.5, from the floor - 0.15-0.30 m. Clearances in the stack should be: between boxes - 0.02 m, between pallets and containers - 0.05-0.10 m.
It is allowed to install shelving or stack goods in piles with an indent from walls and wall columns of 0.05-0.10 m in cases where the indents are not used for evacuation of people.
The dimensions of the indents from the heating devices should be increased if this is required by the storage conditions of the goods.
When stacking loads, ensure the stability of the stack and the safety of people working on or near the stack. It is not allowed to stack loads in damaged silt and in oversized containers, in containers with slippery surfaces, in packaging that does not ensure the stability of the package.
Stowage of goods should ensure their stability during storage and transportation, unloading of vehicles and dismantling of stacks, as well as the possibility of mechanized loading and unloading. Unstacking of goods must be carried out from top to bottom.
Cargoes in boxes and bags, not formed into packages, should be stacked in a bandage. For the stability of the stack, it is necessary to lay rails every 2 rows of boxes, and boards every 5 rows of bags.
The height of storage of packaged and piece goods is determined based on the height of the room, floor load, technical characteristics and mechanization, technological rules and storage conditions. The height of the stack when manually stacking packaged goods in boxes weighing up to 50 kg, in bags up to 70 kg should not exceed 2 m.
The height of stacking barrels in a horizontal position (lying) should be no more than 3 rows with obligatory laying of gaskets between rows and wedging of all extreme rows. When installing barrels while standing, the laying height is allowed in no more than 2 rows in a dressing with laying boards of equal thickness between the rows.
Barrels with gasoline and other flammable liquids must be laid only lying down, in one row with the stopper up.
The stack should not be stacked close to the stack in order to avoid collapses when dismantling the adjacent stack. The distance between the rows of stacks should be determined taking into account the possibility of installing containers in a stack, removing them from the stack with load gripping devices and providing the necessary fire breaks.
The organization of storage should provide:
Preservation of the quantity of goods, their consumer qualities and the performance of the necessary loading and unloading operations;
Conditions for inspection and measurement of goods, sampling and samples of goods by the relevant regulatory authorities, repair of damaged packaging, performance of loading and unloading operations,
Ensuring the safety of the properties of goods is achieved by creating an appropriate hydrothermal storage regime for goods, a convenient system for their stacking and placement, and organizing constant monitoring during storage.
Goods in warehouses must be constantly monitored and maintained. Their condition should be regularly checked, control for the appearance of signs of damage, traces of rodents or insects.
With proper storage organization:
Do not place goods in the aisles, do not block fire extinguishers and sockets with them,
Do not stack pallets or goods too high;
The uppermost shelves are used as a reserve for goods that do not have enough space on the lower shelves;
If the goods protrude from the cells, they are corrected, and if the goods do not fit in the cells, they are placed in deeper racks;
Provide a permanent place for the storage of material handling equipment and move it there if it is not occupied during placement and selection;
Maintain optimal modes of storage of goods - temperature and humidity; air temperature is controlled by means of thermometers or remote control systems, and hygrometers are used to measure air humidity;
Set the required air temperature and humidity by regulating heating and ventilation, as well as the use of moisture-absorbing substances;
Goods stacked in piles are periodically shifted: top - down, bottom - up;
Bulk goods are shoveled;
Fur and woolen goods protect against moths;
Damp goods are dried and aired;
To maintain the necessary sanitary and hygienic regime, a thorough cleaning of the premises is regularly carried out, as well as its deratization, disinfestation, disinfection and deodorization.
Methods of storage of individual product groups and goods
| Products and product groups | Type of product packaging | Storage method |
| Non-grocery goods |
||
| 1. Outerwear on brackets | Without packaging | On hangers, brackets |
| 2. Hats | Boxes, boxes | On pedestals, racks |
| 3. Toys | Consumer packaging | On the shelves |
| 4. Leather goods | Boxes, bundles, packages | |
| 5. Forest and building materials |
||
| sheet metal | On pedestals |
|
| Thermal insulation building materials and products | Without packing Bales | Lined |
| Roll roofing and waterproofing materials | Without packaging | In containers, on pallets |
| On pedestals |
||
| Sawn timber, roundwood | Without packaging | Lined |
| Roof tiles | ||
| piece materials | Barrels, packs | On shelves |
| 6. Small-capacity cylinders with liquefied gas | On pedestals |
|
| 7. Motorcycle and bicycle equipment on racks | ||
| Carton boxes | Hv racks |
|
| rubber | On pedestals |
|
| 9. Porcelain and faience dishes | On the shelves |
|
| 10. Fur and sheepskin coats | Without packaging | On hangers, racks, brackets |
| 11. Textile products | On shelves |
|
| 12. Televisions, radios, other large-sized radio products | Carton boxes | On pedestals, racks with gaskets |
| 13. Knitwear | Packs, boxes, crates | On shelves |
| 14. Sewing products | Without packaging | |
| 15. Electrical goods |
||
| Household lamps | Carton boxes | On the shelves |
| Cable products | Bays, paper | On shelves |
| Vacuum cleaners, polishers | Carton boxes | |
| Refrigerators, washing machines, sewing machines | Carton boxes | On shelves |
| Electric lamps, electric heaters | ||
| Foodstuffs |
||
| 16. Alcoholic and non-alcoholic drinks | Boxes, baskets, bulk | On pedestals, racks |
| 17. Sausages, smoked meats, frankfurters, sausages | On hooks |
|
| 18. Confectionery | Boxes, corrugated boxes | On pedestals, racks |
| 19. Canned food | ||
| 20. Dairy and margarine products | Boxes, boxes, flasks, barrels | |
| 21. Meat products | Lined |
|
| Meat chilled | Without packaging | On hooks |
| Meat ice cream | On pedestals |
|
| Semi-finished products, by-products | Trays, trays | On the shelves |
| On pedestals, racks |
||
| Without packaging | On racks, flooring with gaskets |
|
| 23. Bread and baked goods | On trays, in equipment containers, on racks |
|
| 24. Fruit and vegetable products | Boxes, trays, baskets, barrels, cans, consumer packaging | On linings, podtovarniki, racks |
In the process of storing goods, preparing them for release and performing other operations for some types of goods, commodity losses may occur. There are allowable commodity losses, for which the norms of natural loss are established, and unacceptable, which are referred to as actuated losses. Unacceptable losses include losses resulting from damage, battle, scrap, theft of goods or unsatisfactory storage conditions.
Natural wastage rates are scientifically developed and duly approved limit values for the loss of mass or volume of transported goods or stored inventory items under the influence of natural wastage (shrinkage, shrinkage, etc.), for which the carrier, trading company or warehouse does not is responsible. Attrition rates usually depend on the distance of transportation, the number of transshipments, the type of packaging, the time of year and are calculated separately for each type of transport involved in the transportation. The norms of natural loss, established as a percentage of the turnover, are attributed to the costs of circulation.
Losses in excess of the norms of natural attrition are attributed to financially responsible persons and written off during inventories.
In insurance and claim work, attrition rates are used to determine the insurance value of goods and material assets in the event of insured events. If such cases occurred in the warehouse, the amount of natural loss can be calculated as a percentage of the amount of products sold for the inter-inventory period or to the amount of product stocks at the end of the inventory period, taking into account the guaranteed shelf life. Attrition rates are not applied if there are signs of theft, deliberate damage, etc.
Recognize as invalid Instructions for the storage of food and feed grains, oil seeds, flour and cereals N 9-2, approved by Order of the USSR Ministry of Procurement of November 21, 1977 N 397.
2. The ministries of grain products of the Union republics to organize the study of this by the employees of elevators and grain receiving enterprises, flour and cereal factories, grain factories, sales and grain depots, departments of grain products and departments of the state grain inspection and ensure its implementation.
1.2. The instruction provides for the procedure for acceptance, placement, post-harvest processing and storage of grain, oilseeds, flour and cereals (except for castor beans and soybeans), ensuring high-quality preservation and their rational use.
1.3. The instruction takes into account the provisions of the current regulatory and technical documentation aimed at the safety of grain: Instructions for drying food, feed grains, oilseeds and operation of grain dryers; Instructions for cleaning and separating the fine fraction of grain, operating grain cleaning machines at elevators and grain-receiving enterprises; Instructions for active ventilation of grain in warehouses and sites; Instructions for combating pests of grain stocks; Rules for organizing and conducting the technological process at elevators and grain-receiving enterprises; Rules for the technical operation of elevator structures; Rules for the technical operation of prefabricated elevators; Guidelines for monitoring and assessing the state of elevator structures, etc.
1.4. Accounting and registration of transactions with grain, flour and cereals is carried out in accordance with the requirements of the Instruction on the procedure for keeping records and registration of transactions with grain and products of its processing at the enterprises of bakery products of the system of the USSR Ministry of Procurement and the Instruction on the procedure for settlements with collective farms, state farms and other farms for sold state grain, oilseeds and grasses.
1.5. The financial responsibility of officials for the quantitative and qualitative preservation of grain, flour and cereals is regulated by the Regulations on financially responsible persons of grain receiving and grain processing enterprises of the system of grain products and the feed industry.
2.1. The territory of the enterprise with all buildings, structures and devices related to it must be fenced and kept in order with strict observance of the Safety and Industrial Sanitation Rules at enterprises, organizations and institutions of the USSR Ministry of Procurement.
2.2. The territory of the enterprise must be planned with an appropriate drainage system that ensures the removal of atmospheric and groundwater from the territory to the drains. The roadway of the territory, as well as all sites and places of work with grain and products of its processing must be asphalted and provided with lighting at night in accordance with established standards.
Along the perimeter of granaries and product warehouses, asphalt blind areas 1.0 m wide (up to 2.0 m are recommended for loess soils) with a slope of at least 10 ° and drainage ditches should be arranged.
2.3. Enterprises should implement a set of measures for industrial aesthetics, including the issues of planning and landscaping, interior design and color finishing of equipment.
2.4. Granaries and warehouses of products in technical and sanitary terms must meet the following basic requirements: not have an odor unusual for grain and products and not be infected with pests; be dry, isolated from groundwater penetration; warehouses - plastered from the inside, elevators - not to have unfinished vertical and horizontal joints; doors - close tightly, floors and walls - smooth, without cracks; roofs - in good condition; doorways of warehouses are sealed with embedded boards; windows must be sealed from the inside of the warehouse; lamps - protected by protective caps with nets; inlets of active ventilation channels - have tight-fitting lids to prevent atmospheric precipitation from entering them.
2.5. Flour and cereals are stored in warehouses built for their storage. When placing products in grain warehouses, the latter must meet the sanitary requirements for product warehouses.
2.6. Warehouses with concrete, asphalt floors, intended for the storage of flour and cereals, are equipped with wooden pallets or special solid or removable (portable) decks 10–15 cm high.
2.7. Under the condition of a low level of groundwater, it is allowed to store packaged products for current consumption directly on the asphalt floor (correctly made, serviceable).
2.8. Storage of containers and tarpaulins, as well as their cleaning and gassing for the purpose of disinfection, is carried out in separate rooms isolated from granaries and product warehouses.
2.9. By-products and wastes of all categories should be stored in separate containers, isolated from granaries and warehouses for products.
2.10. Litter, dust, obtained during the cleaning of granaries and the territory and when working with grain, must be removed outside the territory of the enterprise, burned or buried in the ground.
Destruction or use of category III waste is carried out in accordance with the Instruction on the procedure for keeping records and registration of operations with grain and products of its processing at the enterprises of bakery products of the system of the USSR Ministry of Procurement.
2.13. Only service personnel and persons exercising control and supervision over stored grain, flour or cereals are allowed into granaries and product warehouses.
2.14. During the operation of granaries, it is necessary to systematically clean the premises and keep the equipment clean, preventing the accumulation of dust, litter, dirt, spills, and foreign objects. It is prohibited to leave unused mobile equipment and portable devices in warehouses.
This instruction is intended for organizing the storage of general engineering equipment at the bases, warehouses and sites of the enterprise. In case of non-compliance with the requirements of this manual, as well as the instructions of the equipment manufacturers, the responsibility for possible damage to the equipment (Goods) during storage lies with the Customer.
2. Equipment for general engineering. General requirements
2.1. General engineering equipment includes: compressors, pumps, cooling towers, dehumidifiers, turbines and other process equipment (hereinafter referred to as equipment).
2.2. Depending on the duration of storage of equipment in warehouses, there are short-term and long-term storage.
2.3. During short-term storage, the equipment is stored unpacked in an open area under a canopy or in a closed room.
2.4. For long-term storage, the equipment in warehouses is unpacked.
2.5. Outdoor equipment is stored outdoors.
2.6. Equipment intended for work in closed premises (compressors, pumps, fans, electric motors, etc.) is stored in closed heated premises (not lower than +5).
2.7. The equipment is stored separately from acids, gases, alkalis, combustible materials, as well as materials that emit dust: chalk, alabaster, etc.
2.8. Heavy and bulky equipment (pumps, compressors, electric motors, etc.) can be stored directly on the floor, or on special wooden decks.
2.9. Equipment of small weight and overall dimensions should be stored on ordinary shelf racks, or in stacks if it is in packaging that allows it to be stacked in several rows.
2.10. Reinforcement is stored in closed warehouses on stands or pallets.
2.11. In places of storage, the equipment is placed systematized on linings. Passages to the equipment must be free and provide the possibility of carrying out loading and unloading operations.
3. Special requirements
3.1 Compressor installations
3.1.1. The place of storage of compressor units must be clean, dry and heated (not lower than +5), protected from weather fluctuations, as well as from precipitation and direct sunlight.
3.1.2. Compressors are stored separately from acids, gases, alkalis, combustible materials.
3.1.3. If the compressor is stored for a long time, it is necessary to re-preserve it.
Preservation must be done as follows:
- provide constant pressurization with compressed dry air or nitrogen;
- lubricate all external surfaces with galvanized coatings with conservation oil.
3.1.4. For short term outdoor storage, it is the customer's responsibility to completely cover the equipment with a tarp and purge with dry air or nitrogen to prevent water damage and periodically inspect for signs of corrosion or damage. In very humid climates and/or high humidity environments, it is the customer's responsibility to purge the equipment (at least the compressor housing(s) and oil reservoir) with dry air or nitrogen.
3.2. Heat exchangers and other capacitive equipment
3.2.1. If during the storage period it is expected that the temperature will drop below the freezing point, then in this case it is necessary to make sure that there is no water (liquid) in the tank equipment and, if necessary, remove all water through the drain fitting or plugs for draining and ventilation. Add approximately one liter of ethylene glycol or standard automotive antifreeze to the heat exchangers through the vent hole, after closing the drain plug. This will prevent the remaining moisture from freezing and damaging the pipes.
3.2.2. For a closed loop cooling water system, there is no need to empty the heat exchangers of this system because the coolant already contains some form of antifreeze. However, it is recommended to run the heating medium for 15-20 minutes every 3-4 weeks to reduce the growth of biological elements (algae) in the heat exchanger tubes.
3.3. Distribution cabinets and cabinets of control systems
3.3.1. For long-term storage, the storage place must be clean, dry and heated (not lower than +5), protected from weather fluctuations and precipitation.
3.3.2. For short-term storage of cabinets mounted on site, it is necessary to leave the cabinet with power applied to it during the entire period of storage. The heat generated by the power supply prevents condensation. Close all entry openings of the cabinet with nets to prevent insects from entering it.
3.3.3. Control boxes must be wrapped with non-rust vapor barrier material, also called VCI paper, before closing, after which the control boxes must be wrapped with polyethylene or shrink wrap to protect against water ingress. All special requirements of the customer are carried out at his expense.
3.3.4. Electrical switches mounted on the outside of control boxes must be wrapped to protect them from water ingress.
3.3.5. All instruments and devices with faceplates must be protected with bubble wrap, foam or other suitable material to prevent accidental damage during transport.
3.3.6. The closing clips of the control boxes must be securely tightened.
3.4 Air intake filter
It is allowed to store these devices both indoors and outdoors, but it is necessary to seal the inlet and outlet pipes of the air filter.
3.5 Storage log
- The lube oil heater operates at 80°F.
- The auxiliary oil pump has been running for 15-20 minutes.
- Rotation of the compressor and electric motor when the pump is running.
- Required oil level in the motor bearing reservoirs (only for motors with sleeve bearings).
- Interwinding space heaters are working.
- The control cabinet heater is working.
3.6. Electric motors and electrical equipment
3.6.1. Electric motors in explosion-proof design, electric motors in moisture-dustproof design should be stored under a canopy on the floor and on pallets. Shelf life in warehouses is not more than six months.
3.6.2. Asynchronous electric motors of open design must be stored in closed heated rooms at an air temperature of at least +5 °C and humidity not higher than 70%.
3.6.3. It is not allowed to store electric motors in dusty rooms and in the presence of acid and alkali vapors in the environment.
3.6.4. For storage, electric motors are installed on flat pallets with their placement in rack cells.
3.6.5. All electrical equipment supplied from manufacturers in their original packaging may be stored in open areas for a period of not more than two months from the date of receipt.
3.7. Circulating cooling towers
For long periods of storage (greater than six months), rotate tower fan and motor shafts monthly. In addition, the fan shaft bearings must be purged and relubricated before starting.
3.8 Dryers
Store indoors unless the unit has been specially prepared for outdoor use. In addition, the air inlet and outlet pipes must not be opened in order to prevent contamination of the embedded adsorbent with ambient moisture before installation.
3.9 Pumps
3.9.1. Pumps aggregated with electric motors, starters and other electromechanical products are stored indoors at a temperature not lower than 5 °C and a humidity of 80%.
3.9.2. If the technical conditions provide for the possibility of disconnecting the electric motor component from the pump at the time of transportation or storage, then the electric motor and electrical components are stored separately from the pump in a closed room, the pump is stored under a canopy or in an open area.
3.9.3. Stacking of pumps, regardless of the types of packaging, is not allowed.
3.9.4. Large pumps in the original packaging are stored under a canopy or in an open area.
After storage, before installation, the following steps must be taken:
|
Assembly or part |
Action names |
|
Multiplier ** |
|
|
Intermediate** and end heat exchangers** |
|
|
Lube oil system ** |
|
|
Control cabinet |
|
|
Control valves ** |
|
|
Compressor drive motor |
|
|
** Parts required for inspection (gaskets, O-rings, etc.). See "Owner's Manual".
4. Instrumentation
4.1. A large group of devices includes: devices for measuring and controlling temperature, pressure, control, regulation of technological processes; electrical measuring instruments, machines and instruments for measuring mechanical quantities; devices for physical research and others.
4.2. All this nomenclature requires careful handling, storage in dry, clean rooms with a constant temperature from +5 °C to 25 °C and a relative humidity of no more than 70%.
4.3. Devices during storage must be placed in the position provided for by the Instructions, passport or marking.
4.4. Devices arriving at the warehouses in the manufacturer's containers are not unpacked, they are packaged on flat pallets and stacked in a pile or in rack cells.
4.5. It is not allowed to open devices sealed by the factory in warehouses.
4.6. Small devices and devices, supplied in individual packaging, are stored in box pallets with installation in a stack.
4.7. Devices and devices without individual packaging should be stored in the cells of the racks no more than five rows in height with the use of gasket materials between them.
4.8. Small devices and products that arrive without packaging can be stored in small-mesh racks and cabinets, while devices or products of the same type should be stored in one cell.
4.9. To protect from sunlight, the cells of the racks for storing devices without packaging should be covered with curtains.
5. Pipeline industrial fittings
5.1. Steel and cast iron gate valves, valves, cocks, bronze, cast iron and steel valves, injectors and steam traps, level gauges, regulators, gates constitute a group of industrial pipeline fittings.
5.2. According to their purpose, valves are divided into shut-off valves (taps, valves, gate valves), control valves (double adjustment valves, three-way valves, pressure reducing valves), special valves (condensate traps, injectors, elevators, gate valves) and safety valves (level gauges, safety and check valves) .
5.3. Depending on the size, purpose and complexity, industrial pipeline fittings are stored in closed, unheated rooms or under a canopy. The electric drive, solenoid, start-up equipment from it, if it can be dismantled, is stored indoors.
5.4. Pipe fittings, received at the warehouse of the base in their original packaging, up to 50 mm in size, should be stored in a dry, closed, unheated room, on pallets in racks, separately by type, standard size, material of the product.
5.5. Arrived rebar without packaging is placed in box pallets and stored in the cells of the racks.
5.6. Control and safety valves of all sizes are stored in closed warehouses on pallets or on linings.
5.7. Fittings of 80 mm and above are stored under a canopy on pallets in racks or on the floor on linings.
5.8. All unpackaged equipment stored in open areas or under a canopy must have plugs.
Created climatic conditions - and make sure not to be dragged away.
In fact, there are many more tasks. It is necessary to provide access to all items, leave room for the movement of a forklift and other equipment. Form a convenient search system. And at the same time, space should be used as efficiently as possible.
How to properly organize the work of the warehouse? There is no universal recipe. It is necessary to consider the parameters of a particular room, and take into account the properties of specific goods.
Placement of goods in the warehouse
Products in the warehouse can not lie randomly. We need a unified system.
The most common ways to group products are:
- By type
Products are sorted by kind or type. We can see an example of such a division in any supermarket: cheese is put on top of cheese, sugar on top of sugar.
- By party
All incoming batches are stored separately. In this case, one lot can contain both the same and different items.
- By party and type
The parties are also stacked separately from each other. Within a batch, products are divided into species, types, or grades.
- By name
Products are sorted by article or name. This grouping method is useful when the cargo consists of many similar items.
After you have decided on the general principle of placement, you can start drawing the diagram.
Division of the warehouse into zones
First of all, it is necessary to determine the areas of short-term and long-term storage. Typically, short-term storage areas are located near the place where the goods are loaded. They keep products that are in high demand. The greater the demand, the higher the turnover, and the more often you have to look there.
You can lay heavy loads near the entrance. This solution is considered especially successful in warehouses intended for retail and small wholesale traders. Often there all goods are sorted by size.
It is desirable to place things close in function in the neighborhood. Do the same with "related" food products.
It is necessary to distinguish between areas of permanent storage and temporary. Only predetermined products can be stored in permanent sites, and any product can be stored in temporary sites.
For valuable items, places are allocated next to the watchman or under the video surveillance camera.
Shelving installation
Racks are placed at some distance from each other so that goods can be easily reached. If a forklift is operating on site, this distance should be at least 3 m.
Pay attention to the shelves (cells). Their size determines how ergonomically the space will be used.
In large complexes, racks with large cells are often installed. The consignment of goods is placed there as a whole, right in the package (pallet or box). And in warehouses where products are stored for retail, they prefer to use structures consisting of cells of various heights and depths. Collapsible racks are very convenient here - the parameters of the cells can be adjusted in them.
Address storage system
To make the search for goods less time, various systems of accounting and storage of products are used in warehouses. Let's take a closer look at one of them - address.
With this system, each shelf is marked with a symbol (letter or number). The sign is painted with bright paint right on the rack, or a large sign is hung up. The racks themselves, as well as sections and zones, receive similar designations. Together, these characters form the cell address.
More or less like this:
Upon receipt of the cargo, the address of the corresponding cell is entered in a special journal. Subsequently, the desired item can be easily found.
Address storage is of two types:
- static
Each product is assigned to a specific place. Such a system significantly speeds up the process of unloading products. Warehouse workers clearly know where to put what. True, if someday the goods do not fit on the shelf, difficulties may arise.
- dynamic
The load is placed on any unoccupied place. Immediately fix the address in the database. Goods are accounted for electronically. The statistics are immediately visible: you can find out the demand for products, the volume of trade. But, alas, the slightest computer glitch can lead to a logistical disaster.
With an address system, the layout of the warehouse plays a very important role. The drawing should be bright, visual, informative. All zones, compartments, racks are marked there.
For example, like this:
With a static type of storage, the names of goods are also indicated on the plan.
The scheme is hung in a conspicuous place so that all employees can navigate by it.
Goods storage
Most often, goods in a warehouse are stacked or kept on racks.
Stacks stack products in bags, bales, boxes and other large containers. And on the racks is placed piece or packaged goods.
There are also alternative storage methods. So, clothes are hung on special structures made of poles - hangers. Bulk loads are formed from bulk cargoes. Liquid substances are poured into tanks, cisterns and barrels.
Stacking
The product may only be stored in stacks in well-ventilated areas. It can not be laid close to the wall, step back at least half a meter. Wide aisles (at least 1.5 m) are left between the stacks.
Do not place the product near heating devices (recommended distance is 1.5 m). It is enough to move away from light sources by 50 cm.
It is better to stack stacks on pallets. Firstly, it promotes air circulation (the optimal pallet height is 15-30 cm). Secondly, it will be more convenient to ship goods.
Types of stacking:
- Straight
Structural elements are installed clearly one above the other. A variety of direct laying is pyramidal (with each row, the number of elements is reduced by one).
- cross
It is used when the width of two elements is equal to the length of the third. The top row is laid out across the bottom.
- Reverse
Most often, bags are laid in this way. The cargo is located in a "troika" (and in some cases - "five" or "seven"). The next layer is formed in reverse order.
The stack will be more stable if a layer of slats or boards is placed between the rows of objects. Bags are laid through five rows, boxes - through two.
The size of the masonry depends on many factors. The most important of them are the weight of the cargo and the type of container. Knowing these parameters, you can calculate the maximum height of the stack. Let's say the box structure weighs 50 kg. Then its height should not be more than 2 meters.
Do not stack products in damaged or slippery packaging.
All elements of the stack must be similar in shape and size. If the goods differ significantly, they form the so-called cargo packages, equal in volume.
You can also make a stack of barrels. Two rows of standing barrels are tied together and laid with boards. Also, the barrels can be laid - then the structure is reinforced with wedges from the sides. The height of such a stack should not exceed 3 rows. Each row must be laid.
If the liquid is flammable, then there can be only one row. The barrels are laid on their side, turning the cork up.
Unload stacks exclusively from top to bottom.
Shelving
Items on the rack can be stored in pallets, boxes, bags, boxes, etc. If loading is automatic, it is still better to use pallets. They are often installed on the upper shelves: the mechanism does not care where to get the products from. And at the bottom of the rack they leave those objects that are going to be loaded manually. Some of the cells on the upper tier are kept "in reserve".
In addition, long-term storage products are removed upstairs. And goods that require frequent care are placed at eye level.
Loads are deployed so that the marking is on the side of the passage. At the same time, goods of the same type are placed on both sides of the aisle, thereby reducing the path of the loader.
If the cell turned out to be small and the goods did not fit, the remains are placed in the same section, on the next shelf - then the address will differ slightly.
Basic storage rules
- Control air parameters (temperature, humidity);
- Provide good ventilation;
- Regularly clean the premises;
- Comply with fire safety regulations;
- Do not leave goods in the aisles;
- Keep loading equipment in a designated area;
- Timely service and inspect all mechanisms;
- Do not overload racks and stacks.