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Customer / User:

MAADEN

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Erection Manual D. only for information

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Contract:

Plant:

HSM and TCM

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Year of Supply:

Types of Manuals

Volume

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A - Operating Manual

Volume

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B - Equipment Manual

C - Sub suppliers` Components Manual

Volume

D - Erection Manual

Volume

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Instruction for Erection

Volume
1

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1. General Information for Erection

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2. Erection Measuring Reports

4. Single Function Test

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5. Erection Time Schedule

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3. List of Erection Activities and as-supplied Stage

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The erection manual is a guideline only and has to be adapted to


actual conditions in the field.

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In case of changes this manual will not be considered.

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Table of contents

Table of contents

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General Safety Requirements

1
2

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1.1.

General Information for Erection

1.1.1.

Safety Instructions for Erection, Commissioning, Operation and Maintenance


2
Safety Equipment for Operating Personnel
6
Safety Signs
6
Safety at Site
14
Transfer of risk for fire protection systems
22

1.1.2.
1.1.3.
1.1.4.
1.1.5.

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1.

1.2.

Preconditions for Erection to Start

23

1.3.

Plant Surveys

24

1.4.

Foundation Surveys

Report on foundation acceptance

35

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1.4.1.

30

Preparation of Foundations for Machine Erection

37

1.6.

Levelling/Alignment and Anchoring of Machines and Equipment Units

43

1.7.

Placing Under grouts

47

1.8.

Storage, Slinging, Load Table and Unpacking of Supplied Equipment

50

1.9.

Consumables Needed During Erection

60

1.10. Fitting, bending and welding of piping

63

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1.5.

1.10.1.
1.10.2.
1.10.3.

Execution of fitting work


Bending
Welding

63
80
81

1.11. Chemical Cleaning of Steel Pipes

84

1.12. Flushing of Pipelines for Closed Circuit Lube Oil and Hydraulic Systems

95

1.13. Preassembly of Machines and Components

109

1.14. Pipeline Identification Letters Used for Various Utilities in the Drawings

110

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1.15. Mounting Instructions in Drawings

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1.16. Aligning and Tightening torque for couplings (Information given by Company
FLENDER)
112
114

1.18. Heavy-Duty Cranes and Transport Facilities

117

1.19. Tools, Appliances and Auxiliaries


1.20. Appendix

1.20.3.
1.20.4.

164

Example of Pickling Scheme in Recirculation Process (ZS)


165
Example of Pickling Scheme in Recirculation Process (Hydraulic power
system)
166
Simplified representation in drawings
167
Drawings and bill of material for flushing plates conformable SMS SIEMAG
drawings
168
Off-loading of Mill Housing from flat bottomed vehicle and Positioning
180
Off-Loading of a Mill Housing from well wagon and positioning
182

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1.20.5.
1.20.6.

118

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1.20.1.
1.20.2.

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1.17. Release for Machine Grouting / Open Package Inspection

2.

Erection Measuring Report

3.

Single Function Tests

Precondition for Tests

Mechanical Equipment
Hydraulic Systems (Cylinders, Hydraulic Motors)
Pneumatic Systems (Cylinders, Pneumatic Motors)
Oil Lube Systems
Grease Systems
Cooling Water Systems
High-Pressure Water System

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5
6
7
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3.1.1.
3.1.2.
3.1.3.
3.1.4.
3.1.5.
3.1.6.
3.1.7.

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3.1.

3.2.

Procedure of Tests

3.2.1.
3.2.2.
3.2.3.
3.2.4.
3.2.5.

10

Sense of Rotation of Electric Motors


Electrical Devices such as Proximity Switches, Limit Switches, Brakes,
Photocells etc.
Lubrication to Lube Instructions
Nozzles, Roll Cooling, Descaling
Shear Knife Gap

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3.2.23.
3.2.24.
3.2.25.
3.2.26.
3.2.27.
3.2.28.
3.2.29.
3.2.30.
3.2.31.
3.2.32.
3.2.33.
3.2.34.

Pass Line and Roll Gap


16
Vertical Adjustment
17
CVC Shifting Device
18
Adjustment of Mechanical Equipment such as Rest Bar, Mill Guides etc. 19
Stand Clamping
20
Grease Systems, Control and Function
21
Strokes of Hydraulic Cylinders, Lifting Speed and Cushioning
22
Maintenance Unit for Compressed Air
23
Strokes of Compressed Air Cylinders, Stroke Speed and Cushioning
24
Check of Pressure Limiting Valves for Compliance with Preset Pressure 25
Pressure Setting of Pumps
26
Switch Elements at Oil Tank, Fill Level Indicator, Temperature
27
Filter: Differential Pressure
28
Oil Cooler: Water Flow
29
Accumulator: Pre-Fill Pressure
30
Controls and Functions of the Hydraulic Systems
31
Electrical Switching Elements, Pressure Transducers, Pressure Switches etc.
32
Lubricating-Oil Compact Unit: Filter, Pressure, Temperature
34
Pressure Tank: Pressure
35
Separator: Cup Assembly, Run-off Diameter, Temperature, Safety Device 36
Oil Pressure at the Consumers
37
Water-Inlet Alarm Device
38
Pneumatic Compact Unit: Filter, Pressure, Temperature
39
Hydraulic Lines as to Up tightness
40
Compressed-Air Lines as to Up tightness
41
Water Lines as to Up tightness
42
Grease Lines as to Up tightness
43
Oil-Lubricating Lines as to Up tightness
44
Process Section
45

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3.2.6.
3.2.7.
3.2.8.
3.2.9.
3.2.10.
3.2.11.
3.2.12.
3.2.13.
3.2.14.
3.2.15.
3.2.16.
3.2.17.
3.2.18.
3.2.19.
3.2.20.
3.2.21.
3.2.22.

3.3.

Certificate and Report of Completion of Erection

47

3.4.

Checklist of Water quality and - quantity.

51

3.5.

Check List for Functional Tests

56

3.6.

Certificate for Preliminary Acceptance Test

66

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Erection Time Schedule

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General Information for Erection

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1. General Information for Erection

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1.1.

General Information for Erection

General Safety Requirements

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Attention!
All provisions, regulations and laws issued by the employers liability
insurance associations for safety provisions for workers and prevention of accidents and which shall be applicable to German and European Law as well as to the respective national law and the building
owners rights are basically to be followed.

Safety Instructions for Erection, Commissioning, Operation


and Maintenance

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1.1.1.

In addition to the safety regulations in force in the user country and any in-plant
safety regulations concerning operation, maintenance and erection, the following
general instructions must be observed.

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Accident prevention rules should be conspicuously displayed in a position which is


accessible to everyone working in the plant. Additional instruction should be provided by the safety officer in charge.
Each person having to do with erection, commissioning, operation, maintenance or
repair of plant equipment must have read and understood all corresponding
Manuals A, B, C and D. The provisions furnished by the electrical equipment supplier(s) shall apply in regard to all electrical equipment.

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Alterations/Modifications
Alterations or modifications of plant by the user shall only be carried out after consultation with the supplier company. The supplier will not accept any liability for arbitrary measures or such defects or damage that may result there from.

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Personnel
The plant as supplied is in conformity with what is the current state of technology,
is operationally dependable and safe and will have to be operated by qualified or
at least job trained personnel in conformity with applicable instructions.
Non-compliance will:
Create hazards to the health and life of user or third parties.
Have detrimental impacts on the plant, on individual products or on other property.
Create risks liable to affect efficient performance of the plant.

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Interlocking conditions
The safety of the machine in operation will be ensured by electrical interlocks.
These must be checked at regular intervals.
Responsibility for restarting of machines and equipment:
Machines should only be restarted under the supervision of a person duly authorized by the plant user. Before restarting any machine, this person must ensure that operators are in no way endangered by the machine.
The operating elements of the machine shall only be actuated by suitably
trained personnel.
When the machine is in operation, operators must constantly be present in its
associated control pulpit or station. User will moreover see to it that unauthorized persons will be kept away from the plant.

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Function checks, maintenance work:


User is obliged to have the plant inspected, at least once per shift, for externally
recognizable damages and deficiencies. Changes discovered that may affect
equipment dependability and safety shall be reported and made good without
delay.
User to take care that the plant will be operated while in unobjectionable state
and condition only.
Maintenance, repair and cleaning work is prohibited on machines and equipment in operation.
Inspections and/or checks of individual plant components may only be carried
out in strict compliance with applicable safety regulations and while the respective machine or equipment unit is operating.

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Emergency stop - emergency OFF switch


Emergency stop switch: Movement is stopped by electrically controlled blocking
of drive.
Emergency OFF switch: Movement is stopped by cutting out power supply.

Caution!
Emergency switches should be inspected for functional ability at
regular intervals.

Protective devices:
Existing protective devices may only be removed for repair and maintenance purposes and should be duly refitted after work has been finished.

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Job area safety:


Measures should be taken to ensure the safety of the job area the way existing
conditions may dictate.
Electric power should be switched off and steps should be taken to prevent accidental enclosures.
All responsible executives should be notified in advance.
The name of the responsible executive, date and time should be stated on
signs.

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Transport, Slinging:
Only such transport facilities will be used which are suitable for the intended
purpose and which are in unobjectionable state and condition (chains, ropes,
suspension gears).
All rigging or hang-on aids provided should definitely be used (eyebolts, lugs).
Moving or loose parts on equipment should be reliably secured for transport.
Communication with the crane operator by one person only.

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Working Platforms:
No maintenance and repair work shall be allowed to be performed unless safe
working platforms are provided.
Railings, stairs, platforms, crossovers, gangways and covers are to be kept in a
neat and clean state and checked for safety at regular intervals.
Hard-to-Reach Job Areas
Hard-to-reach job areas are to be fitted with suitable connections such as electric
power receptacles, compressed air and possibly water.

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Fire Endangered Areas


Do not use any open flame in highly inflammable areas and prohibit all smoking.

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Oil Leaks
No saw dust or cotton waste shall be used to remove leak oil due to the fire hazard
this would entail. Use commercial type hazardous neutralizing agents only.

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Utilities
Never have pumps started against closed suction-side shutoff valves.
It is a basic rule that the sense of rotation of all drives shall be checked in inching mode prior to initial start-up of pump units and after each motor change.
The instructions furnished by supplier/manufacturer companies shall basically
be observed for all maintenance/assembly of plant components.
Hydraulic / Pneumatic Systems:
The following procedure is generally to be adopted for all valves, pumps, cylinders etc.:
Un-pressurize systems complete, for instance via measuring hose on
measuring couplings.

Note:
Certain accumulators such as those of the balancing system will
have to be kept under pressure in spite of pressure system relief.

Lock mechanical equipment, for example by Safety pins.


Close shutoff valves in pressure and control oil lines.
Cut out electrical equipment and protect against unforeseen switch-on.

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The position and condition of seals and packing is to be particularly checked


during and after any work on equipment units.
Retightening of pipe screw joints and flange connections as well as any other
sealing measure shall be allowed to be carried out only with the pipeline system
in un-pressurized state.
Mechanical, - welding or soldering work is not allowed to be carried out on hydraulic accumulators.

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1.1.2.

General Information for Erection

Safety Equipment for Operating Personnel


All persons assigned to any job within the plant will have to wear suitable protective garments. Instruction by the safety officer in each case.
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1.1.3.

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Safety signs are intended to ensure safety of people working in the plant. These
signs comprise:
Prohibitive signs
Warning signs
Mandatory signs
Rescue signs
Informative signs
Signs identifying permanent hazard areas
Signs for protection of specific work areas
It is necessary to post these signs during and after assembly in job and hazard areas throughout the plant.

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All persons employed will be informed on the significance of all safety signs prior
to commencement of their activities, and in subsequent periods at adequate intervals, but at least once a year.
The responsibility for posting such signs shall rest with the plant user.

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Caution:
Machine manufacturer shall not be liable in case of non-compliance
with above safety instructions.

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Prohibitive signs

Fire, open flame


and smoking
prohibited

No access for persons with pacemaker

Extinguishing with
water prohibited

Prohibited for floor


vehicles

Do not deposit or
store

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Unauthorized persons keep off

No pedestrians

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No smoking

No drinking water

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Warning:
poisonous
substances

Warning:
radioactive
substances

Warning:
loads passing
substances

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Warning:
corrosive
substances

Warning:
substances
explosive

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Warning:
inflammable substances

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Warning signs

Warning:
high voltage

Warning:
dangerous area

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Warning:
transport vehicles
passing

Warning:
danger of
crushing

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Warning:
danger of
laser beam

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Mandatory signs

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Wear respirator

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Wear ear muffle

Wear protective helmet

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Wear goggles

Wear protective gloves

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Wear safety shoes

For pedestrians

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Use crossover

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Rescue signs

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Escape route

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Arrow of direction *
for first-aid-kits

Side stretcher

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Indication of first aid

Escape route

Emergency exit

* This arrow of direction shall be used only in connection


with another rescue sign for first-aid-kits

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Information signs

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Indication of
fire extinguisher DIN 4066

Signs identifying permanent hazard areas

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Identification of permanent hazard areas for instance


such places which involve the risk of hitting, crushing
and tumbling, stumbling of persons or dropping of loads.
Steps, floor hatches etc.

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General Information for Erection

Board indicating cut-out and reconnection requirements for drives during repair or
no production shifts

Time:

Date:

Time:

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Cutout and Reconnection of drives

Demand - Reconnection
of following drives

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

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Demand - Cutout
of following drives

Signature

Function

Signature

Function

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Request by

Effected by

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Material:
Type:

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Request by
Effected by

Signature

Function

Signature

Function

AlMg3F23
Manufactured to SEO and / or screen printing method,
white background, black characters;
With fixing holes
Size to be determined by user

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Warning Plate:

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Barrier Chain

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Fixed by 3 chain links on every barrier chain,


additionally screwed or hooked on walls and equipment.

30
0
27
0

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Attention!
Hazardous Area

Admittance after Operator's


Permission!

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150

15

12

15

3 thick

10

60
18
M 10

Stretched Length 164

45

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10

10

36
10

R 16
Stretched Length 172

36

Weld on railing or equipment

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Fixed to foundation with dowel

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1.1.4.

General Information for Erection

Safety at Site

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Purpose and Range of Application


These guidelines are applicable to our field staff.
They serve to promote the safety awareness and hence to safeguard the health
and efficiency of our field staff. After having done a good and successful job, they
shall complete each day or shift in good health and in the absence of any injury.
These guidelines are to be understood as supplement to the ruling safety regulations and will be distributed to all the SMS SIEMAG field staff.

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Responsibility for Safety


Our board of management is conscious of its duty to care for and protect the
safety and health of all the staff. It has incorporated in these responsibility supervisors who are authorized to issue directives.
The prevention of dangers of accidents is a legal obligation to which, besides the
contractor, all the staff, too, is subjected without any exception. The responsibility
to implement safe working practices and the proper attitude in regard to safety
hence concerns all of us.
On the basis of our staffs readiness to assume responsibility and their comprehensive cooperation, we aim at creating and maintaining as safe and healthy
working conditions as possible.

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Responsibility of Contractors Management


The ultimate responsibility for safety at the working place and health of our staff
rests with our board of management who is responsible that the ruling safety instructions and/or accident prevention rules are observed and enforced at our work.
For our sites the leader of the organization unit (OE) field assembly/commissioning
is the authorized person for job safety. For the individual site, our respective senior
site manager and/or site manager is in charge of job safety matters. They are authorized to order measures for job safety.
The supervisors at the site are directly responsible for the employees subordinated
to them. They supervise the work and control that the measures ordered are carried out. They take care that the work is done with due observance of the regulations for safety and health of all persons within the site/assembly area.
The executives carry out regular inspections of their sites in regard to job safety.

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Responsibility of Employees
The employees are obliged to take care of their own safety and health as well as
of those of other persons and to cooperate with the supervisors of the contractor to
prevent dangers of accidents. They are also obliged to use the prescribed safety
outfit.
The employees shall use safe working practices and processes, notify practices
and events which endanger the safety and cooperate in the case of investigations
into accidents.
General Safety Instructions:
Make full use of your personal protection outfit!
Make yourself familiar with the first-aid equipment!
Work can be better performed in a tidy and well-arranged area. Keep your working place always in good order, especially the working platforms!
Safe access to and exit from the working area as well as keeping the working
area in a safe state are legal demands for the observance of which you are also
responsible. Abide by this in your own interest!
Keep away from the areas of suspended loads!
Observe warning signs and block off!
Keep traffic routes free!
Do not improvise! Use proper tools and facilities!
Help new fellow workers, especially young workers, by warning them against
dangers and risks known to you! Let other persons benefit from your knowledge
and experience!
Do not improperly use social equipment, site containers, staff containers, sanitary facilities and canteens!
The conditions at site change almost daily. Protect yourself and others by constant vigilance!

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Personal Safety Outfit


It is not always possible to eliminate dangers by technical or organizational measures. The contractor then has to provide personal safety outfits which have to be
used by each worker.
Protection of Head
Whenever there is a danger of head injuries by dropping, toppling over or thrown
away objects or by hitting against edges and obstacles, hard hats are to be worn
which are examined and identified to the valid standard.

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Protection of Eyes
The eyes are our most sensitive and valuable sensory organs.
Everyone should have at least one pair of protective goggles with him at site to
protect his eyes at any time against dust or metal particles flying about.
In the case of danger by infrared, ultraviolet or laser beams appropriate personal safety outfits have to be made available and have to be worn.

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Protection of Hands
The hands are our mostly used tool. They get damaged by cracks, pricks, cuts,
dislocations, bruises, crush injuries, burns and acid burns.
Therefore, always wear suitable hand protection!

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Protection of Feet
The feet are endangered at site especially by falling objects or by stepping into
sharp or pointed objects.
Therefore, always wear appropriate safety shoes!

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Cranes
Observe the applicable safety instructions and accident prevention rules
for cranes.
Possible causes of accidents in conjunction with cranes and hoisting appliances
are as follows:
Human failure of crane operator, attached or other persons involved in the
hoisting procedure; inattentiveness, boredom, readiness for risks, inobservance
of applicable guidelines or faults may be the cause of a failure.
Insufficient attachments - in regard to bad weather conditions such as strong
wind.
Inappropriate load receiving means, unsuitable or damaged sling means.
Improper use and maloperation of hoisting appliances.
Tools or devices dropping from the crane due to detachment by crane movement.
Possible contact with current-conducting collector wires or obstruction by restricted space.
These sources of dangers are to be recognized and secured. Moreover, other
sources of danger have to be considered which may arise in the respective
working area.

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General Information for Erection

Hand-guided Electrical Tools


The following guidelines have to be observed irrespective of whether the tools
have been made available by SMS SIEMAG or others.

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Most accidents are caused by incorrect handling:


The nearest electric connection is to be used to avoid long cable routes.
It has to be ensured that cables are not routed in travelled areas etc. or through
water.
The tools are to be checked carefully prior to being used.
Tools being live are not allowed to be deposited and left unattended.
For certain work the protection of eyes is prescribed and sometimes also the
protection of ears necessary. This protection outfit must absolutely be worn!
Whenever an electrical defect comes up the tools are to be put out of operation.
Repairs are allowed to be done by qualified persons only.
Normally tools for AC with 240 V rated voltage are used. For work to be done in
co fined conductive rooms (for example tanks) only low voltage (12 V) or machines actuated by compressed air under protective measures are to be used.

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Grinding Machines
The use of grinding machines calls for observation of the instructions concerning
grinding bodies and grinding machines. You are also requested to observe the following items applicable for all grinding machines inclusive of portable electrical
and pneumatic grinding devices.
Grinding tools and disks are allowed to be used only after the protective devices
have been fitted.
Grinding bodies are allowed to be clamped only on grinding or abrasive cutting
machines, never on circular saw shafts.
Grinding bodies are permitted to be clamped on by experienced staff only. Defective grinding bodies are not allowed to be used.
The highest permissible circumferential speed of the grinding bodies must not
be exceeded. The data given on the sticker to the grinding body of the max.
Permissible rotational speed must conform to that of the machine as per identification plate. Those grinding bodies not identified by stickers are not allowed to
be used.
It is a must to wear eye protection in the case of grinding work.

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Work in free Heights


A precondition for work to be done in higher elevation is the physical aptitude.
Workers suffering from fainting spells, dizziness or similar weaknesses must not
be charged with such work. Since such ailments are not obvious in most cases,
workers have to inform their superior thereof, even if such ailments are only temporary.

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Ladders:
Examine ladders regularly.
Remove defective ladders from their use immediately and reliably.
Have defective ladders repaired properly.
Secure ladders against:
Sliding
overturning, for instance by lashing the ladder head
excessive deflection

or
m

Ladders at traffic routes are to be particularly protected by blocking offs or warning signs.
Lean-on ladders must extend at least 1,0 m beyond the exit point if there is no
other equivalent holding possibility.
Stepladders are not allowed for climbing over.
Ladders are usually used as accesses to working places only if stairs or other
installed footsteps are missing.
Work of minor extent only is allowed to be done from lean-on ladders.

Fo
r

inf

Scaffolds
Scaffolds are to be installed and maintained by a specialist company. Besides
the legally prescribed acceptances by a competent supervisory person from
SMS SIEMAG no other person is authorized to change the scaffolds or have
them dismounted. Modifications and dismounting are allowed to be done exclusively by the scaffold construction company.
No materials/parts are allowed to be tilted, dropped or thrown down from scaffolds.
Notify weak points to your superior immediately.
Do not overload the scaffold! Keep ladders and gangways free!
Ladders are to be used to enter the scaffolds. Climbing to scaffolds is strictly
prohibited.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

18

D1

General Information for Erection

at
ion

on

ly

Work on Structural Components


Structural components must be sufficiently strong and stable if work has to be
carried out from them.
It must be possible to enter and leave a working place safely and quickly at any
time. A fall of persons or the dropping of objects must be prevented during
work.
At the outer edges of a building and at larger openings on a structural component area at least a 3-part side protection has to be provided if the fall height
exceeds 2.0 m and the distance to strong structural components is more than
0.3 m. Unless a side protection can be fitted, the fall of persons or the dropping
down of subjects must be prevented by providing safety (catcher) stands, protective walls or catcher nets which substantially extend up to immediately underneath the fall-down edge.
For construction work occurring at short notice and suddenly, scaffold construction work or similar technical measures will not be possible for various reasons.
In that case, the safety belts are to be used for personal protection.
A further preventive measure is the installation of danger signs to increase the
safety of persons working in that area or passing underneath.

or
m

Mobile Gear
Only authorized drivers are permitted to operate the mobile gear. This also relates
to the staff of the subcontractors.

Fo
r

inf

Dangers by Electric Current


Defective electrical equipment and materials mean a high risk for life and health.
Defective electrical devices are to be removed from further use immediately and
reliably and to be repaired by an electrical specialist.
Danger by electric current is impending in the case of:
damaged insulation of mobile or firmly installed connection and extension lines
kinks in the lines
exposed single wires at cable entries or in the cable routing
defective plugs
not regular and improper examination of electrical equipment and materials

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

19

D1

General Information for Erection

on

ly

Dangerous Matters
Dangerous matters must be stored and used in line with safety regulations.
Containers and packing containing dangerous working matters must be clearly
identified. Containers normally containing foodstuffs or beverages are never allowed to be used!
Dangerous matters are:
lye solutions
acids
degreasing agents and solvents
bitumen, tear, pitch
PUR painting and insulation materials

at
ion

Attention is directed to the safety instructions Handling of Carcinogenic Materials.

or
m

First Aid
A sufficient first-aid outfit must be available at site at any time. It is to be provided
either by the contractor or by the customer. To render first aid, a completely
equipped First-Aid Kit must be available which will be checked either by the supervisor or the nominated and trained first aid. The first-aid outfit is not allowed to
be used for any purposes other than originally intended.
When establishing a site our senior site manager/site manager clarifies with the
customer and the subcontractors which first-aid measures are taken at the place
of accident and for effective rescue operations from the site via the doctor on
emergency call and transport to a suitable hospital.

inf

For all accidents first aid is to be rendered immediately and the superior to be informed without delay who will possibly initiate rescue measures.

Fo
r

Notification of Accident
All accidents however slight must be notified to the superior immediately since
each documented injury may be important for future determination of a work accident. The senior site manager/site manager is responsible for documentation of
the notification of accident.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

20

D1

General Information for Erection

Fire Protection
Suitable fire extinguishers are made available at site for fire protection.

ly

Pay special attention to the fire protection regulations when welding and abrasive
cutting work is done.
Gas bottles and inflammable materials are to be stored appropriately and checked
regularly to prevent fires.

on

Observe No Smoking signs and do not use any matches or other open flame
near inflammable materials.

at
ion

Special requirements of the customer for fire protection are to be adhered to


strictly.
Behaviour at Customers Site
It is the objective of our company to fulfill the expectations of our customers within
the framework of the agreements reached. We shall not only render our services
promised, but our staff at sites shall also adapt themselves into our customers
works order and organization.

Fo
r

inf

or
m

Please always keep in mind that at site you are the personal representative from
SMS SIEMAG and that your professional qualifications and behaviour are important for the success of your work and consequently for the economic success of
our company and the security of our jobs.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

21

D1

1.1.5.

General Information for Erection

Transfer of risk for fire protection systems


(To be carried out prior to the hot commissioning of "First Coil")

ly

1. Confirmation

on

Of the readiness for operation of all envisaged and installed fire alarm systems and fire extinguishing systems.

The Customer
Represented by

Ms./Mr.

that the

at
ion

hereby confirms

fire alarm systems and fire extinguishing systems

envisaged and installed

or
m

for safe hot commissioning of the plant (plant section)


Designation:

Are ready for operation.


Date

Signature of SMS SIEMAG AG

inf

Signature of Customer

2. Transfer of risk to the Customer

It is hereby confirmed,
that the responsibility for the fire alarm systems and fire extinguishing systems as from

Fo
r

Date:
for the following plants / plant sections

Time:

Designation:

shall be transferred to the Customer and assumed by him


Date:

Signature of Customer

Auft.-Nr. / Order No.

A00226 / MAADEN

Signature of SMS SIEMAG AG

Stand / Revision

2010

Index

--

Blatt / Sheet

22

D1

1.2.

General Information for Erection

Preconditions for Erection to Start

on

ly

Buildings, Foundations:
Roofing of bays completed.
Sidewall panelling closed as far as practicable.
Foundations complete and in broom-clean state.
Anchor and other holes clean, i.e. free from dirt or other impurities.
Embedded parts fitted in accordance with applicable drawings.
Electric rooms complete and fitted with doors and windows.
Floor finishes in electric rooms and cellars will be provided on completed erection and after placing the grouts for main equipment.

at
ion

Bay Cranes:
Bay cranes will be made available in ready-to-operate condition, including qualified crane drivers.
Suitable mobile cranes will be needed for the erection of equipment with single
weights above the load capacity of the bay cranes.
Suitable mobile cranes, chain falls and rope winches are needed for work outside crane reach areas.

Fo
r

inf

or
m

Miscellaneous:
Access ways to erection site provided with hard facing.
Bay lighting complete.
Adequate lighting provided in utility cellars.
Sump pumps installed where necessary to keep ducts and cellar spaces free
from rain water.
Ready-to-operate extraction points for site power, compressed air and water
supply in adequate volumes (also see chapter Consumables Needed During
Erection on page 59).
Adequate space for unpacking, cleaning and preassembling of equipment components and interim storage thereof, if any.
Availability of qualified erection personnel in adequate number.
Availability of erection tools and consumables.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

23

D1

1.3.

General Information for Erection

Plant Surveys

ly

Marking of Longitudinal and Transversal Axes as well as Elevations:


The longitudinal and transversal axes of the plant will be fixed by embedded steel
plates (without protection box) to mark respective axis points (Figure 1).
Figure 2 - Figure 4 may also apply.

at
ion

Drawing symbols used and their meaning:

on

Elevation benchmarks will be fitted on operator and drive side to fix all elevation
points (referred to plant floor).

Axis Mark A - A for Longitudinal axes


Axis Mark B - B for Transversal axes

Figure 2:

Elevation benchmarks

Levelling screws

inf

Figure 3:

or
m

Figure 1:

Foundation Recess for Protection Box

Fo
r

Figure 4:

Required points are shown on sketches of axis plan and erection measuring reports.
The locations of axis and elevation points will be laid down in a drawing by purchaser.
Any other axes and elevation points necessary for foundation checks and machine
erection will be determined during field erection (Figure 10 - Figure 13).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

24

D1

Figure 5:

General Information for Erection

Axis Mark (without Protection Box)

on

ly

100

Fo
r

inf

or
m

at
ion

82

16

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

25

D1

Figure 6:

General Information for Erection

Elevation Benchmarks and Axis Marks with


Protection Box and Levelling Spindle

on

ly

260

50

at
ion

or
m

100

1) Grout
2) Epoxy Resin with Quartz Sand
3) Concrete

inf

Legend:

Fo
r

Figure 7:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

26

150

120

D1

Figure 8:

General Information for Erection

Protection Box
140

at
ion

120

on

ly

115

150

200

Figure 9:

Elevation Benchmark and Axis Mark

inf
8

Fo
r

55 min

85 max

or
m

55

80

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

27

D1

General Information for Erection

ly

Figure 10: Setting of Centrelines by means of Theodolit

on

A
C
B

at
ion

inf

or
m

Figure 11: Setting of Centrelines using Piano Wire and Plumb Bob

E
C

Fo
r

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

28

D1

General Information for Erection

Figure 12: Setting of auxiliary Axis by means of Theodolit

on

ly

at
ion

90

inf

or
m

Figure 13: Setting of auxiliary Axis using Piano Wire and Plumb Bob

Fo
r

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

29

D1

1.4.

General Information for Erection

Foundation Surveys

on

ly

Surveys for individual machine foundations will be made with reference to the
foundation drawings to fix:
their position by main longitudinal and transversal axis
the spacing between anchor holes
the elevations of the foundation top surfaces as poured.
It should be observed in this conjunction that the machine grout thicknesses as
given in the foundation drawings will be complied with. This check will be effected
by means of a levelling instrument (Figure 14) and Report on foundation acceptance page 35.

at
ion

Checking of Anchor Holes:


For stone bolts by simple depth measuring with the aid of a measuring rod (Figure 15).
For anchor bolts with embedded anchor plates by insertion of corresponding
bolts, making sure that the correct position of the anchor plates fitted to the bolt
T-head will be ensured. Also checked will be the bolt length with due consideration to under grout thickness.

or
m

It is recommendable to assort the foundation bolts provided in each case with reference to the anchor drawings and to keep them handy close to the respective
place of use. The orientation of T-head anchors is marked in the bolt heads.
Measurement will be effected in accordance with Figure 16 for direct-embedded
anchor bolts.

inf

Construction of Batter boards


Batter boards will be constructed from steel angles or channels in the form of vertical columns with crossbeams welded on top and diagonal braces (Figure 17).

Fo
r

Longitudinal or transversal axis points are to be fixed by transposition to the batter


board transoms, using an adjustable device on the transoms and/or crossbeams
or notches in the latter (Figure 18 and Figure 19).
Longitudinal and transversal axes will be identified by a steel wire of abt. 0.5 mm
dia which is loaded on both ends and which is taken from the above defined fixed
points.
Precision bobs to shall be used for all plumb bob measuring operations.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

30

D1

General Information for Erection

Figure 14: Foundation Check


A

Fo
r

inf

or
m

at
ion

on

ly

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

1) Measuring Rod
2) Dumpy level / Transit

Stand / Revision

2010

Index

--

Blatt / Sheet

31

D1

General Information for Erection

Figure 15: Measuring of Anchor Hole Depth

Legend:

at
ion

on

ly

1) Measuring Rod

inf

or
m

Figure 16: Surveys to determine the Position of Anchor Bolts

Fo
r

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

1) Reference Point

Stand / Revision

2010

Index

--

Blatt / Sheet

32

D1

General Information for Erection

10
00

at
ion

2000

on

ly

Figure 17: Piano Wire fitting Rig

800

Figure 18: Batter board

Fo
r

inf

or
m

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

1) Lock up Band
2) Piano Wire
3) Adjustable Device for taking up of Piano Wire
4) Plumb Bob

Stand / Revision

2010

Index

--

Blatt / Sheet

33

D1

General Information for Erection

Figure 19: Device to receive Piano Wire

on

ly

100

at
ion

1) Piano Wire

Fo
r

inf

or
m

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

34

D1

Report on foundation acceptance

Fo
r

inf

or
m

at
ion

on

ly

1.4.1.

General Information for Erection

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

35

D1

General Information for Erection

ly

Report on foundation acceptance

on

Area according to SMS SIEMAG foundation drawings

at
ion

Foundation meets requirements

Foundation does not meet requirements

inf

or
m

Description of defects / Comments:

Fo
r

Elimination of defects by (date)

Date

Auft.-Nr. / Order No.

A00226 / MAADEN

SMS SIEMAG site management

Customer / Buyer

Stand / Revision

2010

Index

--

Executed by

Blatt / Sheet

36

D1

1.5.

General Information for Erection

Preparation of Foundations for Machine Erection


Smooth foundation surfaces are to be roughened up in order to improve bonding
between concrete and under grouting (Figure 20).

ly

The foundation surface is to be cleaned from loose particles as well as from oil,
grease and other bond affecting residues.

on

Before the machine elements are mounted on top of the foundation, shim plates
are fitted on either side of the anchor bolts (Figure 21 and Figure 22).
Arrangement and positioning of the shim plates is to be performed in the way that
no projections beyond machine elements are exist.

at
ion

After the machines have been levelled and aligned, all shim plates are to be spot
welded with each other to prevent any displacements.

Fo
r

inf

or
m

All shim plates have to be supplied by the erection company are not part of SMS
SIEMAG scope of supply.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

37

D1

General Information for Erection

ly

Figure 20: Chipping of Foundation Surfaces

Legend:

at
ion

on

1) Bush Hammer

Figure 21: Arrangement of Shim Plates

inf

or
m

1) Anchor Hole
2) Shim Plates

Fo
r

Legend:

600

Figure 22: Shim Plates

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

38

D1

General Information for Erection

140

Fo
r

inf

Figure 24:

or
m

20 min

60 max

at
ion

120

on

ly

Figure 23: Formwork for Level Compensation

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

1) Handle

Stand / Revision

2010

Index

--

Blatt / Sheet

39

D1

General Information for Erection

Figure 25:

ly

on

at
ion

Figure 26:

1) Machine/Plant section
2) Shim plates
3) Base plate
4) Existing foundation
5) Grouting mortar
Secure shim plates by weld spot after finish-alignment!

or
m

Legend:

inf

Fo
r

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

1) Machine/Plant section
2) Shim plates
3) Base plate
4) Existing foundation
5) 2 - component plastic material
Secure shim plates by weld spot after finish-alignment!
Stand / Revision

2010

Index

--

Blatt / Sheet

40

D1

General Information for Erection

Figure 27:

ly

at
ion

on

1) Machine/Plant section
2) Inclination 1:100
3) Base plate
4) Grouting mortar
5) Existing foundation
6) Pair of wedges
min.50mm longer Tolerance e. g. Bed plate / Base plate
Secure pair of wedges by weld spot after finish-alignment!

or
m

Legend:

inf

Alignment work in mill stands


Prepare foundation
Shim plates

Fo
r

There are different possibilities of aligning the shim plates on the foundation:
The base plate is laid in a mortar bed into the level surface (Figure 25).
The foundation surface is chiselled out by about 25 mm longer and wider than
the base plate, and around 10 mm deep. Following this, the recess is grouted
with a 2-component plastic material (epoxies resin). After hardening, the material is absolutely plane and ready for receiving the shim plates (Figure 26).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

41

D1

General Information for Erection

Wedges.
Here, the procedure can be similar to that described Shim plates(Figure 27).
Insert anchor bolts.

at
ion

on

ly

Insert anchor bolts


before inserting the anchor bolts, a sketch showing the anchor plate position
should be prepared because it is not sure that the tee-head slots are always oriented towards the same direction.
Alignment of bed plates.
Level height of shim plates.
Deposit bed plates.
Pre-align first bed plate towards axis and height.
Finishing-align bed plate after placing the mill stand housings.

Fo
r

inf

or
m

Alignment of housings.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

42

D1

1.6.

General Information for Erection

Levelling/Alignment and Anchoring of Machines and Equipment Units


Where T-head bolts are used, check to see that these have been fitted into the
foundation anchor holes prior to setting up any of the machine or equipment units.

ly

Install machines on prepared bases or levelling screws and adjust to specified elevation while simultaneously taking surveys by means of level.

on

On this, the machine or equipment unit concerned will be levelled/aligned to defined longitudinal and transversal axes during which operation the anchor bolts will
be tightened down to adjust the unit to specified level and elevation. (It may be
necessary to detach the machine or equipment unit and place additional shims.
This operation can be omitted when levelling is done by means of levelling
screws.)

at
ion

Machines or equipment units anchored by means of stone bolts will be pre-levelled


/ pre-aligned to their defined level and axes. Stone bolt holes will be filled with initial grouts to three quarters of their height. The machine or equipment unit concerned will be finish levelled / finish-aligned after the grout has cured.

Fo
r

inf

or
m

Example
Levelling/alignment of bedplates, bases, roller tables etc. (Figure 28)
Measurement of couplings (Figure 29,29b and Figure 30).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

43

D1

General Information for Erection

Figure 28: Levelling/Alignment of Bedplates, Bases, and Roller Tables etc.

on

ly

at
ion

10

inf

or
m

1 10
1+6
2
3+4
7
8
9
10

Fo
r

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

=
=
=
=
=
=
=
=
=
=

1
2
A

Measuring Points
Parallelism
Position
Coordinate Measurement
Distance Dimension
Levelling
Horizontal Plane
Flatness
Benchmarks
Axis Marks

Stand / Revision

2010

Index

--

Blatt / Sheet

44

D1

General Information for Erection

Figure 29: Measurement of Couplings

inf

Figure 30:

1) Misalignment

or
m

Legend:

at
ion

on

ly

Fo
r

Legend:

Auft.-Nr. / Order No.

A00226 / MAADEN

1) Feeler Gauges

Stand / Revision

2010

Index

--

Blatt / Sheet

45

D1

General Information for Erection

Figure 29 b: Adjustment of couplings with laser units


Adjustment of coupled and uncoupled shafts

Adjustment of cardan and intermediate shafts

on

Adjustment of machine lines

ly

Adjustment of horizontal, vertical and flange-mounted machines

Fo
r

inf

or
m

at
ion

Figure 29 b

Auft.-Nr. / Order No.

A00226 / MAADEN

Copyright by Prftechnik Dieter Busch AG

( Is not in SMS SIEMAG scope of supply )

Stand / Revision

2010

Index

--

Blatt / Sheet

46

D1

1.7.

General Information for Erection

Placing Under grouts

on

ly

Before placing under grouts for individual machine or equipment units or before
bringing in initial grouts for stone bolts, a written request will be sent to the competent contract partner for grout release (see Certificate Release for Initial Grouting /
Under grouting of Machines, Chapter 1.17.).
All anchor holes will be so sealed flush with the foundation top edge before placing
the final under grout of equipment units secured by means of T-head bolts that
penetration of under grout material into the anchor holes will be prevented.

at
ion

Foundation areas mark


in the construction drawings will not be
grouted until after installation and/or erection of the corresponding equipment units
when these have been aligned / levelled and their foundation bolts have been
firmly tightened down. The quality of the under grout material used must at least
be equal to that of the foundation concrete. It is recommended instead of concrete
or mortar to use a special under grout mass which is both shrink-free and also
faster curing.
Where under grout areas are not distinctly identified, the basic rule applies that all
horizontal faces under machine frames will be grouted.

or
m

All concrete surfaces will be thoroughly cleaned and wetted prior to placing the
under grout to ensure a good bond between foundation concrete and grout material.
All anchor bolts will have to be retightened and checked for tight fit after the under
grout has cured.

Fo
r

inf

Release for Machine Grouting see: Chapter 1.17.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

47

D1

General Information for Erection

Examples of Application for Machine grouting:


Figure 31:

on

ly

at
ion

1) Machine part
2) Shims
3) Formwork
4) Foundation
5) Grout
6) Funnel

inf

Figure 32:

or
m

Legend for Figure 31 and Figure 32:

Fo
r

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

48

D1

General Information for Erection

Figure 33:
2

Legend:

at
ion

on

ly

1) Machine part
2) Shims
3) Formwork
4) Foundation
5) Grout

or
m

Preparation of placing grout:

Surface
thoroughly clean, and remove excess cement debris as well as oil and grease.
The surface should be made approx. 6 hours in advance.

inf

Formwork
Tightly secure and seal.

Fo
r

Mixing
Is ready for use, requiring only the addition of water. 7 9 l of water are required for 50 kg of grout.
Grouting
Pour from one side or corner only without interruption.
Note
Open areas are to be protected against premature water evaporation.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

49

D1

1.8.

General Information for Erection

Storage, Slinging, Load Table and Unpacking of Supplied Equipment

ly

Materials and/or equipment can be protected against climatic influences by means


of suitable packaging measures only when the climatic conditions (for instance
temperatures, atmospheric humidity, and precipitations) to be expected during
storage, interim storage, transfer and transport operations are sufficiently known.

Figure 35: Use no hand hooks

inf

or
m

Figure 34: Fragile

at
ion

on

The standard signs shown on all packages are to be observed for storage and
slinging of cases.

Figure 37: Keep away from


sunlight

Fo
r

Figure 36: This way up

Figure 38: Keep away from rain

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Figure 39: Centre of gravity

Index

--

Blatt / Sheet

50

D1

on

ly

General Information for Erection

Figure 41: Do not use hand truck


here

Figure 40: Do not roll

at
ion

....kg max

inf

or
m

Figure 42: Use no forks

Figure 43: Stacking limit by mass

Figure 45: Do not clamp as


indicated

Fo
r

Figure 44: Clamp as indicate

Figure 46: Sling here

Auft.-Nr. / Order No.

A00226 / MAADEN

Figure 47: Temperature limits

Stand / Revision

2010

Index

--

Blatt / Sheet

51

D1

General Information for Erection

Irrespective of the packing medium used, distinction will made between two basic
types of packing for shipment:

at
ion

on

ly

Self - supporting type of packing

Figure 48:

Figure 49:

inf

or
m

Depending type of packing

Figure 51:

Fo
r

Figure 50:

After unpacking, the contents of each package will be checked for completeness
and potential damage with reference to applicable shipping documents.
The conditions and contents of the cases to be confirmed by an appropriate certificate (see Chapter 1.17.).
Storage after unpacking:
Mechanical equipment
Electrical equipment
Structural

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Indoor, dry
Indoor, dry, air conditioned
Outdoor

Index

--

Blatt / Sheet

52

D1

General Information for Erection

Load Table for Slinging Means of Steel Wire Ropes N


This table is only applicable to steel wire slinging ropes N (normal) to DIN 3088
(issue May 1989) featuring a rated strength of the individual wires of 1770 N/mm2.

Single Strand

Double Strand
with inclination angle

from 0 to 45
45

800
1200
1750
2400
3150
4000
5000
6000
7000
8500
9500
12500
16000
19000
24000
28000
33000
37000
44000

560
850
1250
1700
2240
2800
3550
4250
5000
6000
6700
9000
11200
14000
17000
20000
23600
26500
31500

Fo
r

inf

or
m

560
850
1250
1700
2240
2800
3550
4250
5000
6000
6700
9000
11200
14000
17000
20000
23600
26500
31500

from 45 to 60
60

at
ion

mm

8
10
12
14
16
18
20
22
24
26
28
32
36
40
44
48
52
56
60

on

Rope
Rated
Diameter

ly

Load Capacity in kg

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

53

D1

General Information for Erection

Load Table for Slinging Means of Steel Wire Ropes K


This table is only applicable to steel wire slinging ropes K (cable slinging rope) to
DIN 3088 (issue May 1989) featuring a rated strength of the individual wires of
1770 N/mm2.

ly

Load Capacity in kg

directly

from 0 to 45
45

or
m

3150
4000
4750
6000
7100
8000
9500
12500
16000
19000

from 45 to 60
60

at
ion

mm

24
27
30
33
36
39
42
48
54
60

on

Single Strand
with inclination angle

Rope
Rated
Diameter

4500
5600
6700
8500
10000
11200
13200
18000
22400
26500

3150
4000
4750
6000
7100
8000
9500
12500
16000
19000

Fo
r

inf

Due for laying aside; rope types N and K


Slinging ropes are to be taken out of use upon discovery of the following types of
damage or defects:
Fracture of a strand.
Buckles and kinks (cramps).
Slackening of the outer layer in the free length.
Corrosion pits.
Crushing in the free length.
Wire fractures in a large number.
Crushing in the eye depositing area, exhibiting more than 4 wire fractures in
strand ropes or more than 10 wire fractures in cable slinging ropes.
Damage or heavy wear of the ropes or rope-end joints.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

54

D1

General Information for Erection

ly

Load Table for Slinging Means of Chemical Fibre Ropes


The load capacities apply to slinging fibre ropes according to DIN 83 302 (issue
May 1990). The table is applicable to twisted heavy drag ropes from polyester as
per DIN 83 331 and polypropylene type 2 as per DIN 83 332. In case of ropes from
polypropylene type 1 as per DIN 83 329, the load capacity is to be reduced to
about 50 %.
Load Capacity in kg

A00226 / MAADEN

from 45 to
60
60

560
850
1250
1700
2150
2650
3350
4500

450
670
1000
1320
1700
2120
2650
3550

800
1180
1800
2360
3000
3750
4750
6300

560
850
1250
1700
2120
2650
3350
4500

475
710
1000
1320
1700
2120
2500
3550

375
560
800
1060
1320
1700
2000
2800

670
1000
1400
1900
2360
3000
3550
5000

475
710
1000
1320
1700
2120
2500
3550

or
m

Auft.-Nr. / Order No.

from 0 to
45
45

inf

16
20
24
28
32
36
40
48

Fo
r

Polypropylene

Polyester

16
20
24
28
32
36
40
48

braided

at
ion

Fibre material

mm

directly

Double Strand
with inclination angle

on

Single Strand
Rope
Rated
Diameter

Stand / Revision

2010

Index

--

Blatt / Sheet

55

D1

General Information for Erection

Load Table for Slinging Means of Natural Fibre Ropes


The load capacities apply to slinging fibre ropes according to DIN 83 302 (issue
May 1990). The table is applicable to twisted heavy drag ropes from Manila as per
DIN 83 322 and hemp as per DIN 83 325.

Rope
Rated
Diameter

directly

from 0
to 45

at
ion

from 45
to 60
60

250
400
560
750
1000
1250
1500
2120

200
315
450
600
800
1000
1180
1700

355
560
800
1060
1400
1800
2120
3000

250
400
560
750
1000
1250
1500
2120

212
315
450
630
800
1060
1250
1800

170
250
355
500
630
850
1000
1400

300
450
630
900
1120
1500
1800
2500

212
315
450
630
800
1060
1250
1800

or
m

Manila

inf

16
20
24
28
32
36
40
48

braided

45

mm

16
20
24
28
32
36
40
48

Double Strand
with inclination angle

on

Fibre material

Single Strand

Fo
r

Hemp

ly

Load Capacity in kg

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

56

D1

General Information for Erection

on

ly

Due for laying aside; chemical fibre ropes and natural fibre ropes
Fibre ropes (in general) are to be taken out of use upon discovery of the following
types of damage or defects:
Fracture of a strand.
Mechanical damage, heavy wear or slackening.
Damage caused by aggressive matter.
Slackening of splices.
Additionally to be applied to natural fibre ropes:
Dropping-out of fibre flour during untwisting of the rope.
Damage caused by moist storage.

Fo
r

inf

or
m

at
ion

Additionally to be applied to chemical fibre ropes:


Heavy warp age caused by heat, e. g. due to internal and external friction, heat
radiation.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

57

D1

General Information for Erection

ly

Load Tables of Round Steel Chains Grade Class 8


These tables are applicable to slinging chains to DIN 5688 Part 3 Slinging Chains,
Hook Chains, Ring Chains, Grade Class 8.

Load Capacity in kg in Straight strand


Single
Strand

Double Strand
With inclination angle
from 0
to 45

from 45
to 60

45

mm

700
1400
2800
4500
7100
11200
14000
18000
21200
28000
35500
45000
56000
71000
90000

or
m

500
1000
2000
3200
5000
8000
10000
12500
15000
20000
25000
32000
40000
50000
63000

from 0
to 45
45

at
ion

60

inf

4
6
8
10
13
16
18
20
22
26
28
32
36
40
45

Three- and Four Strand


With inclination angle

on

Chain
Nominal
Thickness

500
1000
2000
3200
5000
8000
10000
12500
15000
20000
25000
32000
40000
50000
63000

1050
2100
4250
6700
10000
17000
21200
26500
32000
40000
50000
63000
80000
-----

from 45
to 60
60

750
1500
3000
4750
7500
11800
15000
18000
22400
30000
37500
47500
60000
-----

Fo
r

If several strands are used for slinging, only two of them are allowed to be taken
as carrying means. This does not apply in case it is sure that the load is uniformly
distributed also onto additional strands. Should the load distribution not be uniform, the admissible load of the individual strands must not be exceeded.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

58

D1

General Information for Erection

Load Tables for Round Steel Chains in Grade Class 8

Load Capacity in kg in Lasso position


Chain
Nominal
thickness

Double Strand
with inclination

ly

Single Strand

from 0 to 45
45

60

on

mm

560
1120
2240
3550
5600
9000
11200
14000
17000
22400
28000
35500
45000
56000
71000

or
m

at
ion

400
800
1600
2500
4000
6300
8000
10000
12000
16000
20000
25000
32000
40000
50000

400
800
1600
2500
4000
6300
8000
10000
12000
16000
20000
25000
32000
40000
50000

inf

4
6
8
10
13
16
18
20
22
26
28
32
36
40
45

from 45 to 60

Fo
r

Due for laying aside


Slinging chains are not allowed to be used any longer when the complete chain or
a single link has become elongated by 5 % or more, or when the link thickness
(nominal thickness) has reduced at any point or other by more than 10 %. (see
DIN 685 Tested round steel chains).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

59

D1

1.9.

General Information for Erection

Consumables Needed During Erection

on

KVA

ly

Power for Electric Tools, Welding Machines etc.


Distribution boxes with fuses should be available in adequate number.
Current intensity and frequency to National Standards.
Power consumption to be estimated by erection contractor.

at
ion

Water for Erection Purposes.


Water quality with: pH value 7.
Temperature abt. 20C.
Extraction points in various areas throughout the site as indicated.
Consumption each extraction point to be estimated by erection contractor.
m3/day

or
m

Note:
Water consumption may increase to three to four times the above figure during
chemical cleaning of pipelines.

inf

Compressed Air from Works System for Erection Purposes.


Pressure abt. 5 bar in various Tops throughout the bay above and below mill floor.
Compressed air should be free from oil and water.
Consumption to be estimated by erection contractor.

Fo
r

m3/day

Gas Welding
Gas welding rods, diameter:
2.0 mm
2.5 mm
3.0 mm
4.0 mm
compatible with the parent material to be welded.
Gas welding rods to DIN 8554 (low alloy type).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

60

D1

General Information for Erection

Arc Welding
Stick electrodes, diameter:

ly

2.50 mm
3.25 mm
4.00 mm
5.00 mm

on

compatible with the parent material to be welded.


Stick electrodes to DIN EN 499 (low alloy type).
Stick electrodes to DIN 8556/8555/ISO 3581 (corrosion resistant).

1.6 mm
2.0 mm
2.4 mm
3.0 mm

at
ion

Shielded Arc Welding


Welding rods, diameter:

or
m

or coiled welding rods, diameter:


1.0 mm
1.2 mm
1.6 mm

Welding rods to DIN 8575 (low alloy type)


Welding rods to DIN 8556 (corrosion resistant).

inf

Cored Wire Welding


Cored wire electrodes, diameter
1.6 - 2.8 mm

Cored wire electrodes to DIN EN 440

Fo
r

Chemicals for Pipeline Cleaning


See Chapter Chemical Cleaning of Steel Pipes on page 83.
All consumables and supplies mentioned here shall be made available by the customer in sufficient quantities in close vicinity to the point of consumption.
They are not included in the scope of supply of SMS SIEMAG.
The amount of consumables has to be estimated by the erection sub-contractor.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

61

D1

General Information for Erection

at
ion

on

ly

Sundries
Oils and greases (for assembly of machinery and equipment)
Acetylene
Oxygen
Argon or helium
Sealing tape
Loctite
Liquid surface sealing compound
Filter elements for flushing according to SMS SIEMAG circuit diagrams
Shim Plates
Material: St 37 or similar.
Shims must be plane-parallel and deburred on all sides.
All shim plates have to be supplied by the erection company and are not part of
SMS SIEMAG scope of supply.

Dimensions (mm)
200 x 100 x 40

or
m

200 x 100 x 30
200 x 100 x 25
200 x 100 x 20
200 x 100 x 15

inf

200 x 100 x 10
200 x 100 x 5
200 x 100 x 2

Fo
r

200 x 100 x 1,5


200 x 100 x 1

200 x 100 x 0,5


200 x 100 x 0,2
200 x 100 x 0,1

Packers for bed plates of mill housings refer to SMS SIEMAG drawing:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

62

D1

1.10.
1.10.1.

General Information for Erection

Fitting, bending and welding of piping


Execution of fitting work

on

A distinction is made between:


welded and thus fixed connections and
pipe couplings that can be separated.

ly

Steel piping is normally obtainable on the market in lengths of ca. 6 meters and
must follow the contour of walls and machines during erection work. Pipe connections are therefore inevitable.

at
ion

A piping network has to be manufactured and installed diligently since the reliability of a media supply system depends upon the quality of the design of the network. It is therefore important that the work on the pipeline system be executed in
the necessary quality.
The basis for the manufacture and installation of piping are the plant schematic
and the piping drawings.
In some cases the piping is measured and manufactured on the site after the plant
components have been erected.

inf

or
m

The following must be observed in particular:


split-up into prefabrication and fabrication on the site,
installation of straight, direct, clearly arranged and flow-favourable lines,
cleanness during work,
proper fastening of the piping system,
tension-free installation.

Fo
r

Split-up into prefabrication and fabrication on site


The fabrication of piping systems is performed in accordance with 2 methods that
deviate from each other:
prefabrication in workshop and
fabrication on site.
A mixture of the two types is often chosen out of technical and practical considerations.
Prefabrication
In the case of prefabrication the piping is manufactured in a workshop, separately
in time and place from the activities on the site, and delivered to the site for installation.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

63

D1

General Information for Erection

Fabrication on site

on

ly

In the case of manufacture on the site the piping is manufactured in accordance with the progress
of erection.

at
ion

Figure 52: Saw off pipe at right angles and debur it but do not use a pipe cutter.
Use a sawing machine if possible. Slightly debur pipe ends on inside
and outside. Clean.
Cleanness in work
During the installation work it must be ensured without fail that dirt does not penetrate into the piping system. Piping and components must be delivered to the place
of installation in a properly closed state.

or
m

During the progress of the installation work the connections of the pipes and components must remain closed. Only when they are actually connected, may the
caps be removed. Prior to being fitted the connections and their surfaces must be
checked for cleanness. It is not sufficient to rely solely upon the flushing of the system that may take place after the installation work.

Fo
r

inf

Tension-free fitting
It is very important that the lines be laid tension-free. If lines can only be installed
under tension, they must be aligned or re-fabricated.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

64

D1

General Information for Erection

Fitting of welded connections


Under fixed connections in piping systems in plant engineering we understand
welded connections in which pipes are connected with each other endlessly.

on

ly

Thanks to the use of welded connections leakages can be more easily avoided
and higher pressures mastered due to the fact that there is no elastic sealing. It is
possible to check the quality of the connections by using X-ray and ultrasonic test
methods.
Welding cones, flanges, welding collars, pipes, pipe bends/elbows or other shaped
parts are connected immediately (endlessly) with each other when making welded
connections. Welded piping must be pickled
and flushed in order to prevent the
introduction of dirt into the media system.

Fo
r

inf

or
m

at
ion

Only applies for hydraulic oil circulation systems and special cases

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

65

D1

General Information for Erection

Fitting of pipe coupling systems


In the case of separable connections the pipes are connected with a coupling or
with a flange. This may be done with various systems.

on

ly

Depending on the connection we distinguish at SMS SIEMAG between:


screw connections,
compression-ferrule pipe couplings,
welding-nipple pipe couplings and
flanged connections.

Fo
r

inf

or
m

at
ion

A distinction must be made between the pipe/pipe coupling and the pipe coupling/component connection (valves, base plates, control blocks, pumps).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

66

D1

General Information for Erection

Fitting of connection pipe/pipe coupling


Screw connection (Figure 53)

at
ion

on

ly

The fitting of screw connections is characterized by the fact that the connection
pipe/pipe coupling is executed with the aid of a thread cut onto the pipe. The
sealing here is metal-metal. These threads are normally screwed in with sealing
tape. The holding function is in the thread. Connections of this kind are used for
example with water lines.

Figure 53: Screw connection, metal-metal sealing, holding function using thread,
use in low-pressure range (e.g. on water lines)
Compression-ferrule pipe coupling (Figure 54)

Fo
r

inf

or
m

In the fitting of ferrule pipe couplings a ferrule (bite ring) is pulled onto the pipe. It
cuts into the pipe surface and fulfills at this point the holding and sealing functions. The function sealing to pipe-coupling body is also metal-metal. The holding
function of a ferrule toward the pipe coupling is ensured with the aid of the union
(cap) nut.
Ferrule couplings have to be serviced as they would otherwise tend to leak due to
their metal-metal sealing and to the settling that results there from. Due to the
surface brittleness it is however only possible to tighten within certain limits.
The ferrule should be pulled onto the pipe with particular care, as the ferrule would
slip from the pipe under load if it did not cut sufficiently far into the pipe.
During fitting it should also be ensured that the pipe ends are cut off at right angles
and cleanly deburred.
The fitting instructions of the coupling maker must be observed.

Figure 54: Ferrule pipe-coupling, metal-metal sealing, holding function by a


cutting edge

Auft.-Nr. / Order No.

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Stand / Revision

2010

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--

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67

D1

General Information for Erection

Welding-nipple pipe coupling (Figure 55)

at
ion

on

ly

In the fitting of welding-nipple pipe couplings a welding cone is welded on to the


pipe (butt welding).
The sealing between the welding cone and the coupling is elastic. The holding
function between the cone and the coupling is fulfilled by the union nut.
The fitting instructions of the coupling maker must be observed.

Fo
r

inf

or
m

Figure 55: Welding-nipple coupling with cone, elastic sealing, holding function by
weld seam

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

68

D1

General Information for Erection

ly

Fitting of connection pipe coupling/component


In these pipe couplings the holding function between the coupling and the component is fulfilled with the aid of the thread. Coupling bodies are distinguished by the
kind of sealing of the body toward the components.
Coupling body with sealing edge (Figure 56)

on

With sealing-edge coupling bodies a sealing edge that seals metal-metal on the
components is machined onto the screwed plug. The precondition is that the
screw-on surface is at right angles to the thread and does not display any cross
scoring. The pulsation usual in the hydraulic equipment may lead to material
hardening occurring that necessitates the retightening of the couplings.

at
ion

Normally the threads are however glued in with sealing material, e.g. with Loctite. The sealing function is then in the thread.

or
m

The fitting instructions of the coupling makers and of the sealing-material maker
must be observed.

Fo
r

inf

Figure 56: Coupling body with sealing edge,


Metal-metal sealing,
Countersink at right angles to thread,
Countersink is damaged by cutting edge

Auft.-Nr. / Order No.

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Stand / Revision

2010

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--

Blatt / Sheet

69

D1

General Information for Erection

at
ion

on

ly

Coupling body with U-ring (Figure 57)


With the coupling body with a U-ring the sealing function is fulfilled by the latter.
The precondition for this is also that the securing surface is at right angles to
the thread and that it does not display any cross scoring. The surface roughness of the contact face and of the U-ring compartment should not exceed
RZ 16.
The fitting instructions of the coupling makers must be observed.

Figure 57: U-ring, elastic sealing

inf

or
m

Pipe coupling body with NPT thread (Figure 58)


The NPT threads are tapered. They are inserted in a tapered screw-in thread.
The sealing is metal-metal. Normally speaking these threads are glued in with
sealing material, e.g. with Loctite.
As a result of the slanted thread of the screwed plug there is the danger that
components made of castings or aluminium are burst as the coupling is
screwed in.
The fitting instructions of the sealing-material maker (Loctite) must be observed.

Fo
r

Figure 58: NPT thread,


Metal-metal sealing, only possible with
sealing material,
High bursting forces, undefined position of
coupling body

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

70

D1

General Information for Erection

at
ion

on

ly

Fitting of flange connections


Pipe couplings larger than DN 40 are no longer usual.
From DN 40 flanges upwards are used to connect pipelines with each other and
with components.
With the flange connections the connection flange/pipe is welded in almost all
cases. A butt weld is almost always used.
The type of the flanges used depends essentially on the components used and on
the pressure.
Flanges according to DIN (Figure 59)
Ball valves, butterfly valves and other valves have in some cases the connection pattern for a DIN flange, so that the latter is used for this reason also.

Fo
r

inf

or
m

(1) Gasket to DIN 2690


Figure 59: Flange with sealing, holding function by bolts

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

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71

D1

General Information for Erection

SAE flange one-part (Figure 60)


The one-part SAE flange is made in one piece. Different weld-on plugs for varying pipe dimensions may be equipped with the same SAE connection pattern.
The one-part SAE flange can no longer be adjusted after it has been welded
on.

on

ly

SAE flanges
Many components in hydraulics have screw-on surfaces for so-called SAE
flanges from DN 40. A distinction is made between
one-part SAE flanges and
multi-part SAE flanges.

at
ion

The fitting instructions of the flange maker must be observed.

Fo
r

inf

or
m

Figure 60: SAE flange, one-part with O-ring, holding function by bolts

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

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72

D1

General Information for Erection

SAE flange, multi-part (Figure 61)


The multi-part SAE flange consists of the so-called welding collar, of a turning
part or shaped component in weld able material and of the two flange shoulders
that perform the holding function.

ly

The sealing between the base surface and the SAE flange or between one SAE
flange and another is done elastically with the aid of O-rings.

at
ion

on

The fitting instructions of the flange maker must be observed.

Figure 61: SAE flange, multi-part, elastic sealing, holding function by bolts
Flange connection with square flange (Figure 62)
With flange connections from ca. DN 65 upwards and in the pressure range
from ca. 210 bar upwards so-called square flanges are used. They are two-part
fittings and consist of the welding collar itself and a square flange that performs
the holding function.

or
m

Fo
r

inf

The fitting instructions of the flange maker must be observed.

Figure 62: Flange connection with square flange,


Elastic sealing by O-ring,
Holding function by bolts

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

73

D1

General Information for Erection

ly

Fitting of compensators
Compensators serve in piping systems as elastic pipe connections to compensate
strains, stresses, shifts and movements that are caused by temperature fluctuations, foundation settling, changing loads or vibrations. They are also used to
dampen body sonic transfer and impacts as well as to compensate fitting inaccuracies.

on

The compensators used in hydro systems are made of steel or rubber/artificial rubber in various qualities that is affixed to a rugged carcass of synthetic fibre or steel
wire, depending upon the pressure.

or
m

at
ion

For attachment to the piping system pipe couplings are used from DN 40 upwards
steel flanges in St 37.2 or, if necessary, in other materials
(Figure 63 and Figure 64).

Fo
r

inf

Figure 63: Compensator for flange connection

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

74

D1

on

ly

General Information for Erection

at
ion

Outer layer
(2) Inner layer
(3) Flange with profile collar
(4) Flange with full profile
Figure 64: Compensator for flange connection

Compensators as elastic pipe connections must be installed in such a way that


visual monitoring is possible. The rubber parts must not be coated (painting). No
insulation material may be applied.

or
m

Compensators should be installed in such a way that if possible they are loaded
when pressed together. Stretching in the operating state must be avoided. Torsion
is inadmissible.
Between two fixed points a max. of only one elastic pipe connection must be used.

inf

Rubber compensators should be protected against radiation and heat and if necessary covered or equipped with a protective sleeve.
If electric currents are led through across the piping (e.g. grounding for welding
transformers), the compensator must be sufficiently well bridged. If there is no
such bridge, the compensator may act as an electric resistor and be destroyed.

Fo
r

An eddy current that leads to an increase in the noise level may be caused in the
compensators as a result of the special shape of the latter. A guide pipe must then
be installed.
The fitting instructions of the compensator maker must be observed.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

75

D1

General Information for Erection

Fitting of hose lines


Hose lines are elements for energy transfer in media systems. They are intended
to compensate movements or serve as a length compensation in long piping systems.

ly

Hose lines consist of the actual hose itself and the matching fittings. The fittings
have been adapted to the connecting system within the pipeline.

on

Fitting of hose lines


The lifetime of hose lines is lengthened if they are correctly laid.
Twisting of the hose during fitting should be avoided!

at
ion

Hose lines should be fitted in such a way that there is no tension load, except by
natural weight!
The smallest admissible bending radii must not be gone below!
If a houseline is fitted bent, its length must be selected in such a way that the
bend-free zone is retained!
Fittings should be selected in such a way that the additional loading of the hose is
avoided!

or
m

Hose lines should be protected against external influences. Sharp-edged components should be covered. When necessary, hoses should be protected by suitable
sleeves!

Fo
r

inf

The fitting instructions of the hose line makers must be observed.

Figure 65: Examples for correct laying of hose lines

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

76

D1

General Information for Erection

Fitting of pipe supports


Supports are used to secure piping efficiently. Pipe clamps are made of steel,
aluminium, plastic or plastic with a rubber lining.

or
m

at
ion

on

ly

The clamp base plates are made in weld able steel so that they can be properly
secured to the substructure.

Fo
r

inf

Figure 66: Pipe clamp, heavy-duty series

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

77

D1

Fo
r

inf

or
m

at
ion

on

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General Information for Erection

Figure 67: Clamp stack, e.g. for two pipes arranged one above the other

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

78

D1

General Information for Erection

The piping system is usually secured to the machine structure or to the foundation
walls. A separate substructure must often be created for the piping (Figure 68).
The distance between two clamps depends upon the pipe outer diameter.
See SN 573 for fitting of pipe holders.

inf

or
m

at
ion

on

ly

The fitting instructions of the pipe support makers must be observed.

Figure 68: Substructure to receive piping system

Fo
r

Identification of valves, measuring devices etc.


Valves, measuring devices etc. are identified in the flow diagrams (process schematics, P + I) and in the installation and piping drawings as well as in the layouts
of electrical devices with special identification numbers.
These components must, insofar as they are not already delivered with the identnumber, be labelled provisionally during the fitting of the piping (immediately after
fitting) by means of adhesive tape for example.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

79

D1

1.10.2.

General Information for Erection

Bending

Fo
r

inf

or
m

at
ion

on

ly

For pipe bending radii, minimum dimensions for angled pipes and determination of
pipe lengths with consideration to various bending angles and bending radii also
see SN 740 Part 1 and 2 or DIN 2916.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

80

D1

1.10.3.

General Information for Erection

Welding
Weld preparation of pipelines with reference to DIN 2559/1.

Single V
butt weld

to 20

View

Steepflanked
single V
butt weld

Dimensions
Approximates

2-3

25

To 2

60

25

To 2

10

6 10

10

25

To 2

30 - 40

s=t

Single J
butt weld

inf

s=t

s=t

Fo
r

Fillet weld

all

Note:

s=t

over 20

over 20

Single U
butt weld

Depth of
weld seam
s

s=t

or
m

Butt-type joint

Shape of
groove

at
ion

over 2

Comer joint

Section

Weld joint preparation

Square butt
weld

to 2

all

Illustration

on

Wall
thickness Designation
t

ly

Table 1 ( SN 200 Part 4):

s=t
t

All hydraulic pipelines are to be butt-welded.


Pipelines and welding - neck flanges provided with a 40 m prime coat
must be machined at the welding ends such that a prime coat of
max 20 m is left.
20 m dry coat thickness for the prime coat will permit proper welding.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

81

D1

General Information for Erection

Welding Processes
Gas welding (oxyacetylene welding)
Gases: Oxygen O2 + acetylene C2H2
Filler metal: compatible with pipe material.

ly

Application: All pipes to DIN 2391 and DIN 2448 having wall thicknesses 3 mm.

on

No weld preparation, however with gap corresponding to filler rod diameter. Backhand welding is required basically. Mechanical post treatment of weld by manual
methods is necessary in any case.
Electric Arc Welding
(after root pass has been run by TIG process).

at
ion

Application: All pipes to DIN 2391, DIN 2448, DIN 2462 and DIN 2463 having wall
thicknesses > 3 mm.
Electrodes to be compatible with the material of the parts to be joined by welding.
Electric arc welding always require mechanical inside post treatment by manual
methods.

or
m

Inert Gas Welding


Tungsten inert gas welding, in brief TIG.
Welding gas argon/helium (purity 99 %).
Filler rod selected under the aspect of compatibility with the pipe material.
Application: Universal for all pipelines for reasons of costs to be used for root
passes only. Between-beads and final passes can be provided by
electric arc welding. Weld preparation same as for electric arc welding
(see Table 1).

inf

Pipeline must be purged with antis lag gas to the following criteria to protect pipe
inner walls and root passes.

Fo
r

Required in all cases for pipelines of stainless steels.


Purging where required for pipelines of standard steels.
Antis lag gas N 90 %, H 10 %.
In co action with the welding gas argon and/or helium the antis lag gas inhibits
oxidation and improves on root pass quality.
Metal-bright weld on inside.
Welding Quality Assurance
Note:
Welding work should only be carried out by qualified specialists in
possession of welders qualification certificates to EN 287
Part 1.
The provisions stipulated in ISO 5817 apply in regard to welding
quality assurance.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

82

D1

General Information for Erection

on

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Butt and socket welding


Butt welding:

Figure 69:

One weld seam required for each welded joint


Weld seam up to standard, transferring the same force factor as the actual
pipe
No internal dirt deposits between the pipe ends, resulting in unobjectionable inside purification by way of rinsing in the case of pickling pipes
No additional stress formation in longitudinal direction
Precise alignment of pipe axles necessary
TIG root welding prevents spatters on inner surface

inf

Figure 70:

or
m

Socket welding

at
ion

Fo
r

Two weld seams required for each welded joint


Due to fillet weld, weld seam transfers at best 60 % of the pipe force factor
Due to thermal expansion, axial gap necessary; otherwise additionally
stress formation in longitudinal direction
Undercut in pipe, resulting in reduced wall thickness
Axial gap prevents inside purification during rinsing
Settling of dirt particles in axial gap which detach after start-up and lead to
malfunctions in the valves

Note!
SMS SIEMAG does not apply to socket welding!

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

83

D1

1.11.

General Information for Erection

Chemical Cleaning of Steel Pipes


(Carbon and Stainless Steel Pipes)
(Degreasing, Pickling, Passivating)

on

ly

One of the major preconditions to be satisfied for trouble-free operation and performance is that all utility pipelines are perfectly clean on the inside. To ensure
this, all pipe systems will be degreased, pickled and passivate to defined rules and
criteria prior to commissioning.

at
ion

Following pipelines are to undergo chemical cleaning:


pipelines for Morgoil lubrication systems
pipelines for closed circuit lube oil systems
pipelines for hydrostatic systems
pipelines for hydraulic systems
pipelines for emulsion systems
pipelines for grease systems
pipelines for oxygen systems
pipelines for water systems
pipelines for gas systems

or
m

Chemical cleaning can be done by two different methods:


chemical cleaning by the recirculation process
chemical cleaning by the dipping process
Media to be used

inf

Carbon Steel Pipes:


Degreasing agent Lutensol

0,02 % 200 g/m3

ON70 (BASF):

Inhibitor Rodine A213:

0,02 % 200 g/m3


7 % 210 kg/m3

Ammonium bifluoride (NH4) HF2:

1%

10 kg/m3

Citric acid (GRAN) C6 H8 O7:

0,3 %

3 kg/m3

Ammonia NH3OH:

0,9 %

9 kg/m3

Sodium nitrite NaNO2:

0,3 %

3 kg/m3 or

Hydrogen peroxide H2O2:


Sodium hydroxide NaOH:
Calcium hydroxide Ca(OH)2:

0,5 %

5 kg/m3
55 kg/m3 or
55 kg/m3

Fo
r

33 % hydrochloric acid HCL:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

84

D1

General Information for Erection

Stainless Steel Pipes:


Degreasing agent Lutensol
0,02 % 200 g/m3

ON70 (BASF):
Hydrofluoric acid HF, 71 - 75 %
Nitric acid HNO3, 62 %
Calcium hydroxide Ca(OH)2:

3%

40 kg/m3

on

ly

12 % 200 kg/m3
110 kg/m3

Fo
r

inf

or
m

at
ion

Caution!
The concentration may vary as a function
of the state and condition of the inside surface

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

85

D1

General Information for Erection

Description of Recirculation Process

on

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Caution!
Basically, chemical cleaning should be carried out by a specialized
companies only in due compliance with the safety rules applicable to
handling water-detrimental substances.
Disposal of neutralized pickling solutions will be effected in conformity with official National Rules and Requirements.
Carbon Steel Pipes:

Fo
r

inf

or
m

at
ion

Following installation of pipelines, the specialized company will determine those


interconnecting pipelines that are to be combined into a circuit.
All valves, fittings and equipment units fitted in a circuit which are not pickling
solution-resistant will be removed and replaced by connecting pieces made
from accessory pipe work. Seals made from rubber, or plastics (Viton, Perbunan) are pickling liquor-resistant and will not be removed.
The circuit that has been provided to specific instructions will start off from and
terminate in a tank from which the medium will be fed into the circuit and into
which it finally returns. The length of all pipes combined into a circuit depends
on the inside diameter of pipe and media.
The pickling process commences with filling the closed pipe system with water.
As soon as the water starts flowing inside the circuit, all of the pipe connections
will be leakage-tested. After the circuit has found to be tight, degreasing agent
will be added to the water.
The complete chemical process can be carried out without heating, provided
media temperature is not less than + 20 C.
The next step is to add predetermined quantities of hydrochloric acid with inhibitor and ammonium bifluoride and to recirculation this mixture for 4 to 6 hours.
During the recirculation the chemical reaction will be tested in that the return
hydrochloric acid is measured. Termination of the pickling process will be determined as a function of results from these measurements.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

86

D1

General Information for Erection

Fo
r

inf

or
m

at
ion

on

ly

The pickling solution in the pipelines will by means of clear water be flushed in a
separate neutralization tank and neutralized there to a pH of about 7 by adding
sodium hydroxide or calcium hydroxide.
The pickled pipes will be passivate to preserve their inside faces for a period of
2 to 6 weeks (depending on the ambient humidity). Another recirculation treatment will be made with citric acid with added ammonium and sodium nitrite or
hydrogen peroxide for about 2 hours. This will be followed by draining off the
passivating solution. Pipes up to 50 DN max. will then be purged with dry compressed air or nitrogen (no oxygen!). The passivating treatment provides for
protection of the pipe inside faces against rust film formation for the period of
time mentioned.
It is recommended to fill or to flush the pipe systems with the suitable medias
preferably right after the chemical cleaning process.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

87

D1

General Information for Erection

Stainless Steel Pipes:

ly

The process is the same as described for carbon steel pipes except for the paragraph marked with an asterisk
(refer to sheet 86) which will be amended as
under:

or
m

at
ion

on

The next step is to add predetermined quantities of hydrofluoric acid and nitric
acid and to recirculation this solution for about 4 hours during which period the
chemical reaction will be tested in that the return hydrofluoric acid is measured.
Termination of the pickling process will be determined as a function of results
from these measurements.
The acid carried in the pipelines will be flushed out using demineralised water
(at least drinking water quality) and neutralized to pH 7. Residual clear flush water will be drained off and the pipelines will be purged using dry compressed air
or nitrogen (no oxygen!).
If passivating of certain media is required a 10 % solution of nitride acid should
be used.
It is recommended to fill or to flush the pipe systems with the suitable medias
preferably right after the chemical cleaning process.
It is recommended to fill the pipeline systems with hydraulic fluid or flush oil,
preferably right after the recirculation pickling process has been completed, and
to re-flush same across a suitable filter in closed circuit mode.

Fo
r

inf

Dipping Process:
The same chemicals as defined for the re-circulation process will be used for
treatment by the dipping method.
Short pipe pieces such as reducers, branch offs, distributor pipes, suction
branches etc. will be dipped into the pickling tanks.
Pickling and neutralizing times will be determined on the basis of required purities and may be longer than in case of the re-circulation pickling process. All
sealing faces, threads, etc. have to be protected against damage due to external influences.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

88

D1

General Information for Erection

at
ion

on

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Process Equipment and Facilities


Recirculation Process for Carbon and Stainless Steel Pipes:
1 Tank abt. 1 000 x 1 000 x 800 mm high made from rubber-coated steel
plate of abt. 6 - 8 mm thickness
1 Neutralizing tank, capacity 3 - 15 m3 made from rubber-coated steel plate
of abt. 10 - 12 mm thickness
Sundry rubber-coated shutoff valves (diaphragm valves) DN 32 - DN 80
1 Acid-resistant pump, abt. 25 - 80 m3/hour referred to 25 - 60 m static
head
Sundry interconnecting hoses with hose clips abt. DN 20 - DN 50
Sundry flange sockets for interconnecting hoses, sizes as required
Sundry transition screw joints and flange type reducers, sizes as required.
The actually needed number of connections and reconnections depends on
the size of system to be pickled.

or
m

Dipping Process for Carbon and Stainless Steel Pipes:


3 Tanks abt. 8 000 x 2 000 x 1 000 mm high made from 10 - 12 mm thick
steel plate with stiffener ribs, inside faces rubber or plastic-coated (pickling,
flushing, passivating)
Acid pumps, barrel and submersible type
1 High-pressure cleaner

Fo
r

inf

The process actually adopted will depend on technical design of the pipe
systems.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

89

D1

General Information for Erection

Schematic Representation of Chemical Cleaning Process


Recirculation Process for Carbon Steel Pipes

on

ly

Provision and
Connection of
Pickling Equipment

at
ion

Establishing of
Circuits

Water Leakage
Test

Fo
r

Passivation
to pH 9,5

Caustic Soda or
Calcium Hydroxide

Neutralization
to abt. pH 7

Draining

A00226 / MAADEN

Citric Acid
Ammonia
Sodium Nitrite or
Hydrogen Peroxide

Possibly Purge
using Nitrogen or
compressed Air
(No Oxygen!)

Possibly Flush
With
Oil immediately

Waste Disposal

Auft.-Nr. / Order No.

Degreasing
Acid
Inhibitor

Clear Water Flush


to pH 7

inf

or
m

Pickling Process

Stand / Revision

2010

Index

--

Blatt / Sheet

90

D1

General Information for Erection

Recirculation Process for Stainless Steel Pipes

on

ly

Provision and
Connection of
Pickling Equipment

at
ion

Establishing of
Ciruits

Water Leakage
Test

Passivation using
Nitric Acid
if required

Fo
r

Clear Water
Flush

Caustic Soda or
Calcium Hydroxide

Neutralization
to abt. pH 7

Draining

Waste Disposal

Possibly Flush
with
Oil immediately

Auft.-Nr. / Order No.

A00226 / MAADEN

Degreasing
Acid

Clear Water Flush


to pH 7

inf

or
m

Pickling Process

Stand / Revision

2010

Index

--

Possibly Purge
using Nitrogen or
compressed Air
(No Oxygen!)

Blatt / Sheet

91

D1

General Information for Erection

Dipping Process for Carbon Pipes

ly

Provision of Tanks
and filling with
Water

on

Degreasing
Acid
Inhibitor

Clear Water
Sprayoff

HP Unit

Passivation
to pH 2 - 3

Citric Acid

Passivation
to pH 9,5

Ammonia
Sodium Nitrite or
Hydrogen Peroxide

inf

or
m

at
ion

Pickling Process

Caustic Soda or
Calcium Hydroxide

Fo
r

Neutralization
to abt. pH 7

Waste Disposal

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

92

D1

General Information for Erection

Dipping Process for Stainless Steel Pipes

on

ly

Provision of Tanks
and filling with
Water

at
ion

Pickling Process

or
m

Clear Water
Sprayoff

Degreasing
Acid

HP Unit

Passivation using
Nitric Acid
if required

inf

Clear Water
Flush

Caustic Soda or
Calcium Hydroxide

Fo
r

Neutralization
to abt. pH 7

Waste Disposal

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

93

D1

General Information for Erection

Comparison of Recirculation- and Dipping Process

Usual Dipping Process

Recirculation Process
Assembly:
pipes are welded max. endless.

Dismantling:
pipelines must be dismantled for pickling.
Disadvantage:
large expenditure of labour and time.

Dismantling:
deleted.
Advantage:
time- and money saving.

Transport to pickling:
transport equipment necessary.
Disadvantage:
large expenditure of labour and time.

Transport to pickling:
deleted.
Advantage:
time- and money saving.

ly

Assembly:
pipes must be flanged in lengths of
approx. 6 m.
Disadvantage:
max. material in terms of flanges, screws,
washers and welding substances as well as corresponding assembly time.

at
ion

on

Advantage:
decrease in flanges, screws, washers and
welding material as well as shortened
assembly time.

Pickling:
pipes are pickled in recirculation process.
Advantage:
low requirements of jobs, decreased pickling time,
since pickling takes place in large
circuits and with adapted circulation.
Contaminations dissolve faster.
Pipelines can be put into operation immediately
after pickling.

Transport to the assembly place:


transport necessary.
Disadvantage:
large expenditure in terms of transport,
manpower, time. Pipes can contaminate again.

Transport to the assembly place:


deleted.
Advantage:
time- and money saving no danger of contamination.

Maintenance of pipeline:
many flange connections.
Disadvantage:
many flange connections = many sources of error,
continuous employ of time and material as well as
large store of spare parts necessary.

Maintenance of pipeline:
minimum number of flange connections.
Advantage:
less flange connections = less sources of error,
decreased employ of time and material, minimized stock of spare parts.

Fo
r

inf

or
m

Pickling:
pipes are pickled in containers.
Disadvantage:
size of containers limited for technical
reasons. Because of continuous shifting from
container to container, large expenditure of
labour and time, crane necessary, pickling
liquid is circulated only in container, the
contaminations dissolve relatively slow.

Decision on which process is the more favourable one in each case must be made
with due consideration to location of site, type of pipe installation and possible
ways of chemical disposal.
Example of Pickling Scheme in Recirculation Process (ZS).
Example of Pickling Scheme in Recirculation Process (Hydraulic power system).

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

94

D1

1.12.

General Information for Erection

Flushing of Pipelines for Closed Circuit Lube Oil and Hydraulic Systems

on

These purities apply to pipelines of:


Morgoil lubricating systems
Closed circuit lube oil systems
Hydraulic systems.

ly

Degree of Cleanliness of Pipelines:


All inside faces will have to be cleaned to purity BE or Sa 3 corresponding to by
suitable treatments (pickling) prior to flushing the pipelines.

at
ion

Caution!
For pressure, temperature etc. please observe
manufactures guidelines on flame-inhibiting fluids.

Fo
r

inf

or
m

Work for flushing closed circuit lube oil systems with flush oil:
Carefully clean all tanks and pressure vessels in conformity with
One tank per system will be filled with flush oil about 80 % through associated filler line, followed by heating the oil to a temperature of 70 C.
All oil feed lines will be short-circuited to the return flow lines upstream the
consumer while bypassing bearings and gear units.
The entire system will be rinsed with hot flush oil.
All pumps are operating (incl. standby pump) to deliver the flush oil in recirculation with the duplex filters set for full passage.
In case of filter clog up the system will be switched back to 1 handling
pump and 1 filter half, followed by cleaning the deactivated half of the filter
unit.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

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Blatt / Sheet

95

D1

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The flushing operation must be performed continuously, if possible at different temperatures between 30 C and 70 C. The di fferential pressure at
the filter provided with clean filter elements must not exceed the admissible
working range of the filter flow curve in case of an 8-hours flushing time.
Pump off flush oil, making sure that lower-level pipe pieces will be drained.
Flange connections will be detached and dirt between flange sealing strip
and sealing bore will be removed.
Defective seals will be replaced.
Clean oil tank and pipe connections. Make measuring and control instruments ready for operation.
Fill in operating oil and start up system
(see Maintenance Manual B).

on

General Information for Erection

at
ion

Flush Oil Specifications - See SN 180


Viscosity ISO VG 46 for instance
HLP 46
hydraulic fluid to DIN 51524/2 or
CL 46
flushing oil to DIN 51502

Fo
r

inf

or
m

Compatibility of flush oil with operating oil must be ensured.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

96

D1

General Information for Erection

inf

or
m

at
ion

on

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Work to be Performed for Flushing Hydraulic Systems


Preliminaries
Disconnection of hoses from cylinders and short closing.
Removal of all filter elements and installation of envisaged operational
flushing elements.
Setting of:
Pressure switches
Thermostats on oil tank
Cooling water regulating valves
Pressure reducers and safety valves
Work to be Performed:
Fill oil into system through filling filter, cleanliness rate of filled oil should be
NAS 1638, class 10.
Before flushing commences, the filled-in oil needs to be pre filtered to at
least the purity degrees of the operating oil by means of recirculation (recirculation pumps).
None of the servo and proportional valves will be fitted, provide flush valve
plates instead.
Pre flushing should be done by a separate flushing unit (pumps and tank).
Final flushing across filters may be done using existing main pumps. Replace elements as filters are getting clogged.
Flow velocities should be 6-10 m/sec. for which purpose it may be necessary to operate several pumps simultaneously.
Filter elements of 8 m mesh size will be used in systems with directional
valves, filter elements of 5 m mesh size will be used in systems with proportional valves and filter elements of 3 m mesh size will be used in systems with servo valves.
Oil temperature: 50 C
Pressure:
pre flushing ranging between 5 - 20 bar
final flushing up to 100 bar

Fo
r

Where hydraulic accumulators exist, the pipelines will have to be intermittently pressurized through these accumulators after the continuous flushing
process.
Samples will be taken in the following areas:
in the suction line
upstream the servo-valves
upstream the return line filter

Auft.-Nr. / Order No.

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Stand / Revision

2010

Index

--

Blatt / Sheet

97

D1

General Information for Erection

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Following purities must be ensured:


NAS 1638 Group 6 - 8 for systems with directional valves
NAS 1638 Group 5 - 6 for systems with proportional valves
NAS 1638 Group 4 - 5 for systems with servo valves.
Purities will be demonstrated and can be taken from attached Tables.
After flushing, the hydraulic fluid will have to be tested as to serviceable state and
condition.

on

For flushing oil specification - see SN 180


Operating oil is to be used as flushing medium for the hydraulic system.

at
ion

Operation on Water Glycol HFC


Conditions: Flushing with water glycol only
Temperature max. 40 C
Compensate evaporation losses by
fully de mineralized water

Fo
r

inf

or
m

Using of flushing plates see Simplified representation in drawings.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

98

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

50 100

25 50

Over 100

44

22

10 25

250

125

Over 100

16

89

380

2680

9700

56

21

225

1510

10700

32000

41

430

3130

11

12

11

6
1

63

356

32

178

22

126

712

45

253

16

90

506

1425 2850

32

180

1012

5700

64

360

2025

128

720

4050

256

1440

8100

11400 22800 45600

512

2880

16200

91200

1024

5760

32400

182400

ly

92

1000

6500

42000

128000

on

10

21400

87000

at
ion

Class

to NAS 1638

11

110

780

5360

24000

or
m

inf
2

Class

to SAE 749

1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000

28

210

500

16

50 100

93

25 50

670

10 25

Particle
Size
m
-5

4600

2700

1340

Particle
Size
m
-5

Fo
r

D1
General Information for Erection

Purities Required for Hydraulic Systems


(Number of foreign particles per 100 cm3 oil for system classification)

Blatt / Sheet

99

D1

General Information for Erection

Table of Pollution Degrees and Related Codes (to ISO 4406)


Number of Particles in 100 ml
Particle Size over 15 m

from

to

From

20/17
20/16
20/15
20/14

* 500k
500k
500k
500k

** 1M
1M
1M
1M

64k
32k
16k
8k

19/16
19/15
19/14
19/13

250k
250k
250k
250k

500k
500k
500k
500k

18/15
18/14
18/13
18/12

130k
130k
130k
130k

17/14
17/13
17/12
17/11

64k
64k
64k
64k

To

ly

Particle Size over 5 m

Code

Purity
to
NAS 1638
Pollution
Class
11 10

32k
16k
8k
4k

64k
32k
16k
8k

10 9

250k
250k
250k
250k

16+-k
8k
4k
2k

32k
16k
8k
4k

98

130k
130k
130k
130k

8k
4k
2k
1k

16k
8k
4k
2k

87

32k
32k
32k
32k

64k
64k
64k
64k

4k
2k
1k
500

8k
4k
2k
1k

76

16k
16k
16k
16k

32k
32k
32k
32k

2k
1k
500
250

4k
2k
1k
500

65

8k
8k
8k
8k

16k
16k
16k
16k

1k
500
250
130

2k
1k
500
250

54

13/10
13/9
13/8

4k
4k
4k

8k
8k
8k

500
250
130

1k
500
250

43

12/9
12/8

2k
2k

4k
4k

250
130

500
250

32

11/8

1k

2k

130

250

at
ion

or
m

Fo
r

14/11
14/10
14/9
14/8

inf

16/13
16/12
16/11
16/10
15/12
15/11
15/10
15/9

on

130k
64k
32k
16k

* k = x 10

** M = x 10

Proposed Purity for Acceptable Service Life

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

100

D1

General Information for Erection

Pollution Degrees to ISO 4406


Code figures: Number of particles each 100 ml

ly

300
C

on

200

12/9

at
ion

100

13/9 14/10 15/11 16/12 17/13 18/14 19/15 20/16 21/17

(first figure for particles up to 15 m, second figure for particles over and above
15 m).
Working pressure (bar)

Fo
r

inf

or
m

A - Very delicate hydraulic components (servo-valves, HP pumps)


B - Normal hydraulic components inclusive most pump types
C - Rugged components

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

101

D1

General Information for Erection

Material for flushing of pipe lines

at
ion

Figure 71 Flushing header


Figure 72 Header connection to and from cylinder lines
Figure 73 Header connection to pressure line P
Figure 74 Header connection to tank T
Table 1 Code of parts in flushing diagrams
Table 2 Flushing volume and velocity

Fo
r

inf

or
m

on

ly

Note!
All material for flushing is not in SMS SIEMAG scope of supply.
Material of loops at machines should be determined at site.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

102

14

14

Auft.-Nr. / Order No.

A00226 / MAADEN

2010

15

15

05

02

15

04

04

15

or
m

02

inf

05

15

07

07
08
08

ly

13

10

on

12

09
11

ATTENTION:
All components should be
suitable for working pressure
PN 210 bar (3000 psi)

at
ion

15

03

03

01 = 1 1/2" SAE butt weld flange (2 off)


02 = 2" SAE butt weld flange (2 off)
03 = 1 1/2" SAE butt weld flange + blind flange tapped 1/2" BSP
04 = 1 1/2" SAE butt weld flange + blind flange tapped 3/4" BSP
05 = 1 1/2" SAE butt weld flange + blind flange tapped 1" BSP
06 = 1 1/2" SAE butt weld flange + blind flange tapped 1 1/4" BSP
07 = 1 1/2" SAE butt weld flange + blind flange
08 = 3" SAE butt weld flange + blind flange tapped 1/2" BSP
09 = 3" SAE butt weld flange + blind flange tapped 3/4" BSP
10 = 3" SAE butt weld flange + blind flange tapped 1" BSP
11 = 3" SAE butt weld flange + blind flange tapped 1 1/2" BSP
12 = 3" SAE butt weld flange + blind flange tapped 2" BSP
13 = 3" SAE butt weld flange + blind flange tapped 2 1/2" BSP
14 = 3" SAE butt weld flange + blind flange
15 = TEE 3" x 1 1/2" ANSI B 16.5 ( 3000 psi )
16 = TEE 3" x 2" ANSI B 16.5 ( 3000 psi )

15

06

01

Fo
r

06

01

D1
General Information for Erection

Material for Flushing Header (Hydraulic only)


Figure 71:

Stand / Revision

Index

--

Blatt / Sheet

103

D1

General Information for Erection

on

ly

2
G

Auft.-Nr. / Order No.

A00226 / MAADEN

Fo
r

inf

or
m

Flow Direction

at
ion

Connection to cylinder line 1 or 2

Header Connection to and from Cylinder Lines


Figure 72:

Stand / Revision

2010

Index

--

Blatt / Sheet

104

D1

General Information for Erection

Auft.-Nr. / Order No.

A00226 / MAADEN

on

Flow direction

Fo
r

inf

or
m

at
ion

Connection to pressure line 1 or 2

ly

Pump station
supply

Header Connection to Pressure Line


Figure 73

Stand / Revision

2010

Index

--

Blatt / Sheet

105

D1

General Information for Erection

Auft.-Nr. / Order No.

A00226 / MAADEN

on

G
B

Flow direction

Fo
r

inf

or
m

at
ion

Connection to tank line 1 or 2

ly

Tank

Header Connection to Tank Line


Figure 74:

Stand / Revision

2010

Index

--

Blatt / Sheet

106

inf

C
Socket type
Reducer pipe
SN 455
or
FKB-AVIT
PN 250, Ser. 3
SN 591

D
Socket type
Reducer pipe

Auft.-Nr. / Order No.

A00226 / MAADEN
RI 1 ED x 1 1/2

RI 1 ED x 1 1/2

ST2 P DN 16 X...AS/AS GUV 20 x 2,5-G A RI 1 ED x 1

ST2 P DN 20 X...AS/AS GUV 25 x 3 G1A

RI ED x 1 1/2

ST2 P DN 40 X...AS/AS GUV 50 x 7 G A

Stand / Revision

2010

GAV 16 x 2/GAV 25 x 3

GAV 30 x 3/GAV 30 x 3

1 2500 psi GAV 30 x 5/GAV 25 x 3

4 150 psi

Index

--

FKB 32

AFB 1 - 6

107

Blatt / Sheet

AFB - 6

AFB - 6

AFB - 3

GEV 30 (UNF)

GEV 25 (UNF)

GEV 20 (UNF)

KHB G 2

ly
FKB 80

AFB 1 - 3

FKB 80

AFB - 3

5 150 psi

AFB 4 - 6

FKB 100

on

GAV 38 x 6/GAV 20 x 3

4 2500 psi

AFB 3 - 6

FKB 65

GEV 16 (UNF)

GAV 26 x 2,5/GAV 12 x 2

2 2500 psi GAV 20 x 2,5/GAV 20 x 2,5

GAV 38 x 3/GAV 38 x 3

AFB 2 - 6 3 2500 psi

AFB 2 - 6

AFB 1 - 6 2 2500 psi

AFB 1 - 6 1 2500 psi GAV 16 x 2,5/GAV 16 x 2,5

AFP 4 - 3

AFP 3 - 3

G 1 A

G A

KHB G 1 G 1 A

KHB G 1

KHB G

G 1 A

DIN 2990
(SN 718)

K
Doublenipple

G 2 A

GAV 16 x 3/GAV 12 x 1,5 KHB G 1 G 1 A

2 150 psi GAV 25 x 3/GAV 25 x 3

AFP 2 - 3 3 150 psi

AFP 2 - 3

AFP 1 - 3 2 150 psi

AFP 1 - 3 1 150 psi GAV 20 x 3/GAV 25 x 3

at
ion

TV 38 x 6

TV 30 x 4

TV 25 x 3

TV 16 x 2

KHB G

AFP 1 - 3 1 150 psi GAV 25 x 3/GAV 38 x 5

J
Straight flow
valve
HYDAC

AVIT
ANSI B 16.5
AFKB=
or
3000 / 6000
FKB-AVIT
psi
PN 320, Ser. 4

FKB 50

FKB 40

RI ED x 1 1/2

ST2 P DN 32 X...AS/AS GUV 38 x 5 G A

RI ED x 1 1/2

RI 1 ED x 1 1/2

ST2 P DN 25 X...AS/AS GUV 30 x 4 G A RI 1 ED x 1

RI ED x 1 3/4

TV 20 x 3

AVIT
Part 1 only

G
Blind flange

H
Special part
2 x GAV AVIT part1
or
1 x GEV part 1

E
F
Equal TEE Blind flange

or
m

ST2 P DN 13 X...AS/AS GUV 16 x 2 G A RI 1 ED x 1 1/4 RI 1 ED x 1 1/2

SN 759

AVIT

Fo
r

B
Socket

A
High pressure hose

D1
General Information for Erection

Code of Parts in Flushing Diagrams (Table 1)

D1

General Information for Erection

Flushing volume and velocity


Table 2
l/min
(4 m/sec)

l/min
(6 m/sec)

l/min
(8 m/sec)

DN 8

12

18

DN 10

18

28

DN 12

24

40

55

DN 15

42

63

85

DN 17

55

80

110

DN 20

75

115

150

DN 24

115

160

220

DN 26

135

195

260

DN 28

150

220

300

DN 30

170

255

345

ly

Pipe inside

24

or
m

at
ion

on

38

190

295

390

DN 40

300

450

600

DN 50

480

700

950

DN 60

690

1000

1350

Fo
r

inf

DN 32

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

108

D1

1.13.

General Information for Erection

Preassembly of Machines and Components


It is due to specific erection sequences that some of the machines and components have to be assembled before being placed on top of their foundations.

on

ly

All faces machined for assembly are to be carefully cleaned from anticorrosion
coatings applied. Moreover, such faces are to be checked for damage that may
have been caused during transport. Damage or defects, if any, are to be eliminated with the aid of suitable tools, such as files, scrapers, emery paper etc. prior
to assembly.
Assembly as well as matching of machines and components will be effected in due
compliance with applicable drawings.

Fo
r

inf

or
m

at
ion

After preassembly, all machined faces are to be protected against corrosion by


applying a film of oil or grease thereto.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

109

D1

1.14.

General Information for Erection

Pipeline Identification Letters Used for Various Utilities in the Drawings

on

at
ion

MC
IC
DC
SW
HW
PW
EW
HP
DI
SO
IW
WW
FF
MW
SL

ly

Abbreviation

CA
PN
NI
AR
NG
OX
HA
CG
LP
MG
IA

Fo
r

inf

or
m

Water
Mould Water
Indirect Cooling Water
Direct Cooling Water
Scale Water
Hot Water
Potable Water
Emergency Water
High Pressure Water / Descaling
Dematerialized Water
Soft Water
Industrial Water
Waste Water
Fire Fighting Water
Make Up Water
Sludge
Gas
Compressed Air/Works line system
Pneumatics
Nitrogen
Argon
Neutral Gas
Oxygen
Halon
Coke Oven Gas/Converter Gas
LP-Gas
Mixed Gas
Instrument Air
Lubrication
Grease Lubrication
Lubrication Oil
Emulsion
Rolling Oil
Spent Emulsion
Waste Oil
Hydraulic
Hydraulic general
Hydraulic oil
Hydraulic emulsion
Syn. hydraulic fluid
Steam / Condensate
Steam
Condensate
Chemicals
Acid
Alkaline Solution

Auft.-Nr. / Order No.

A00226 / MAADEN

GR
LO
EM
RO
SE
WO
HY
HM
HE
HS
ST
CO
AC
AL

Stand / Revision

2010

Index

--

Blatt / Sheet

110

D1

1.15.

General Information for Erection

Mounting Instructions in Drawings


Particular attention is invited to the notes and instructions given in various drawings for field erection.

ly

These activities are the responsibility of the erection contractor in charge of erecting corresponding plant components.

on

Required tools, appliances and consumables are not included in the SMS
SIEMAG extent of supplies.

Field - Welds

Figure 75:

or
m

Field-attached
Field-drilled
Adapted during field erection
Exact dimension determined and adapted during field erection
Bolted joints secured with LOCTITE
Faces sealed with sealing compound etc.

Fo
r

inf

at
ion

Example:
Field-welded

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

111

D1

1.16.

General Information for Erection

Aligning and Tightening torque for couplings


(Information given by Company FLENDER)

ly

Aligning
The couplings compensate for positional variations of the shaft ends to be connected up to the data refer to page 113.

on

When aligning, keep the radial and angular misalignment of the shaft ends as
small as possible because hereby the service life of the flexible is increased under
otherwise the same operating conditions.

at
ion

Alignment is to be carried out in two axial planes vertical to each other. This is
possible by means of a ruler (radial misalignment) and feeler gauge (angular misalignment) according to the figure 77.
By using a dial gauge, the alignment precision can be increased.

or
m

Ruler

inf

Feeler gauge

Figure 76:

Fo
r

Caution!
Check the tightening torque of the screws after re-establishing the
connection (refer to page 113)

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

112

D1

General Information for Erection

Possible misalignments for couplings

S2 max

S2 max

S2 min

ly

Kw

Kw

on

Ka

S2 min

Coupling Type

Axial misalignment
Ka
+ 1 mm

H 110 - 140

+ 1 mm

H 160 - 140

+ 1 mm

H 95 - 100

+ 1 mm

H 110 - 140

+ 1 mm

B 125

+ 1 mm

H 95 - 100

Angular misalignment
Kw

Radial misalignment
Kr

Tightening torques
TA

0,24 mm

0,24 mm

29 Nm

0.18 mm

0.18 mm

14 Nm

0.27 mm

0.27 mm

35 Nm

0.15 mm

0.15 mm

10 Nm

0.18 mm

0.18 mm

14 Nm

0.21 mm

0.21 mm

17.5 Nm

+ 1 mm

0.15 mm

0.15 mm

10 Nm

B 125

+ 1 mm

0.21 mm

0.21 mm

17.5 Nm

H 140 - 180

+ 1 mm

0.24 mm

0.24 mm

29 Nm

H 95 - 100

+ 1 mm

0.15 mm

0.15 mm

10 Nm

H 110 - 100

+ 1 mm

0.18 mm

0.18 mm

14 Nm

+ 1 mm

0.18 mm

0.18 mm

14 Nm

+ 1 mm

0.38 mm

0.38 mm

89 Nm

+ 1 mm

0.34 mm

0.34 mm

67 Nm

+ 1 mm

0.30 mm

0.30 mm

44 Nm

H 225 - 180
H 200 - 180

inf

H 110 - 100

or
m

H 140 - 180

at
ion

Figure 77:

Fo
r

H 180 - 180
H 110 - 100

+ 1 mm

0.18 mm

0.18 mm

14 Nm

B 125

+ 1 mm

0.29 mm

0.21 mm

17.5 Nm

Caution!
Angular and radial misalignments may occur at the same time.
The sum of both misalignments must not exceed the max.
permissible value of the angular or radial misalignment.
(Kw + Kr)existing Kw X Sn or Kr X Sn

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

113

D1

Release for Machine Grouting /


Open Package Inspection

Fo
r

inf

or
m

at
ion

on

ly

1.17.

General Information for Erection

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

114

D1

General Information for Erection

Grouting of Stone Bolts Machine Under grouting

Fo
r

inf

or
m

at
ion

on

Area acc. to Foundation Drawing

ly

Release for Machine Grouting

Grouting Material:

Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Remarks:

SMS SIEMAG Site Management: Contractor:

Stand / Revision

2010

Index

--

Blatt / Sheet

115

D1

General Information for Erection

Open Package Inspection


_________________________

ly

Delivery Note No.:

Part-Consignment No. / Package

_________________________

on

Package:

Completeness /

Delivery complete

Description of State and Condition:

Equipment in proper State

Part damaged

Quantity SMS SIEMAG Complaints Report


No.

Instructions:
Type of Storage
Outdoors

or
m

at
ion

Part missing

Package No.

Additional Requirements
Repackaging
Repeat Preservation Treatment

inf

Outdoors plus covered up


Under roof shelter
Dry room

Fo
r

Temperature controlled room

Remarks:

Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

SMS SIEMAG Site Management: Contractor:

Stand / Revision

2010

Index

--

Blatt / Sheet

116

D1

1.18.

General Information for Erection

Heavy-Duty Cranes and Transport Facilities

Designation

Number Provided

at
ion

or
m

Trucks

Load Capacity ( t )

on

Mobile Crane

Tractor-Flatbed
Trailer Units

ly

For intermediate transport if necessary. To be defined by erection contractor according to mobilization.

Fo
r

inf

Fork Lift Trucks

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

117

D1

1.19.

General Information for Erection

Tools, Appliances and Auxiliaries


(Is not part of SMS SIEMAG scope of supply).

ly

Site Shop

Upright Drilling Machine

Morse taper 3, 100 - 1000 RPM with motor


for direct-on-line starting and
5 m long connecting cable complete with
plug

or
m

at
ion

1.

Specification / Type

on

Item Designation

Bench Drilling Machine

Morse taper 2, 430 - 4500 RPM with motor


for direct-on-line starting and 5 m long
connecting cable complete with plug

Fo
r

inf

2.

Figure 78:

3.

Figure 79:

Dual Tool Grinding

Auft.-Nr. / Order No.

A00226 / MAADEN

Wheel size 300 x 40 x 76 mm with standard


Machine, Upright Design tip, tool rests,
spark protector as well as 5 m long connecting cable complete with plug (refer to
Figure 80)

Stand / Revision

2010

Index

--

Blatt / Sheet

118

D1

Dual Tool Grinding

Wheel size 150 x 20 x 32 mm with standard


Machine, Bench Design tip, tool rests,
spark protector as well as 5 m long connecting cable complete with plug

on

ly

4.

General Information for Erection

Figure 80:

AC motor (variable cutting speeds), complete with 5 m long connecting cable and
plug

at
ion

Power Hacksaw

or
m

5.

Compressor

Mobile screw type compressor 4.00 m3/min


referred to 7 bar, max. operating pressure
8 bar
Figure 82:

Fo
r

inf

6.

Figure 81:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

119

D1

General Information for Erection

Test- and Checking devices for Hydraulic Equipment


Item Designation

Specification / Type

Test kit for proportional

Type G040-123-001 with Accessories

8.

Kit for checking, maintenance and adjustment for


Moog-servo valves
Valve tester for Moog
valves
Tools kit

Model F087-127

11.

12.
13.

14.

on

Model B61042005

Valve tester for energizing


of servo- and proportional
valves
Servo valve tester II

Test kit for checking and


adjustment of proportional
pressure valves and directional valves
O-Ring kit
R-Ring kit

VT-VETSY-1-1X/1-2-1-1-1
(Rexroth)

Testing Equipment for


proportional valves,
Servo-valves + Solenoid
valves

Type 4
Service for following valves
D661 MOOG
WRZ Rexroth
DER Rexroth

Type 828293
Type 828294

Fo
r

inf

15.

Model G040-119

at
ion

10.

or
m

9.

ly

7.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

120

D1

Pressure testing set

Complete (HGM 2020)

on

ly

16.

General Information for Erection

Figure 83:

18.
19.

Hydac.

Digital measuring instrument for voltage, current


and resistor
Oil-contamination control
device

Siemens-Multizet

0 - 250 bar, 0 - 400 bar

ARTI / PODS

inf

or
m

20.

Portable nitrogen preloading devices with oil aggregate


Filling and testing device

at
ion

17.

Figure 84:

Leak detector

Complete (SPM instrument)

22.

Digital thermometer

D 700 (Impact Tastotherm)


with Sensor OT 1301

23.

Digital manual speed indicator

HT 4100 (Dr. Horn)

Fo
r

21.

Figure 85:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

121

D1

General Information for Erection

Electric Welding Machines


Specification / Type

ly

Item Designation
Welding Generator

up to 200 A welding power

25.

Welding Generator

up to 300 A welding power

26.

Welding Generator

up to 450 A welding power

at
ion

on

24.

Figure 86:

TIG Welder

inf

or
m

27.

up to 350 A welding power


(shielded arc welding)

Fo
r

Figure 87:

Note:

Auft.-Nr. / Order No.

A00226 / MAADEN

All welding machines complete with connecting cable and plug as well
as welding and earthling cable (VDE tested)

Stand / Revision

2010

Index

--

Blatt / Sheet

122

D1

General Information for Erection

Oxy/Acetylene Welding and Cutting Torches

Cutting Torch Kit

Complete with handle, cutting tips size


3 - 8, torch guide, radius rod, torch wrench
and tip cleaner. Preheat orifices / tips of all
sizes (cutting torch DIN EN ISO 5172)

at
ion

on

28.

Specification / Type

ly

Item Designation

Figure 88:

Oxygen Hose

DIN EN 559
dia. 6.3 blue, complete with hose coupler
and connection to DIN EN 560

30.

Gas Hose

DIN EN 559
dia. 10 red, complete with hose coupler and
connection to DIN EN 560

31.

Pressure Reducer

DIN EN 385
with pressure gauge for gas bottles
1 - 25 bar

inf

or
m

29.

Pressure Reducer

DIN EN 385
with pressure gauge for oxygen bottles
1 200 bar

Fo
r

32.

Figure 89:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

123

D1

General Information for Erection

Accessories to Oxy/Acetylene Welding and Cutting Torches

Hand Shield

DIN 58214
Complete with light and dark panes,
DIN EN 169, protection class 13

at
ion

on

33.

Specification / Type

ly

Item Designation

Figure 90:

Fixed Shield

DIN 58214
Complete with light and dark panes,
DIN EN 169, protection class 13

inf

or
m

34.

Protective Gloves

DIN EN 374
Leather, with long cuffs

Fo
r

35.

Auft.-Nr. / Order No.

A00226 / MAADEN

Figure 91:

Figure 92:

Stand / Revision

2010

Index

--

Blatt / Sheet

124

D1

Welders Apron

Leather

on

ly

36.

General Information for Erection

Figure 93:
Slag Hammer

DIN 5133

at
ion

37.

Figure 94:

Wire Brush

for steel

or
m

38.

Figure 95:

Wire Brush

for stainless steel


(refer to Figure 95)

40.

Protective Gloves for Argon gas welders

DIN EN 379
Soft leather, with long cuffs
(refer to Figure 92)

Protective Goggles

DIN EN 1836
Welders goggles with dark glasses,
DIN EN 169, protection class 4

inf

39.

Fo
r

41.

Auft.-Nr. / Order No.

A00226 / MAADEN

Figure 96:

Stand / Revision

2010

Index

--

Blatt / Sheet

125

D1

General Information for Erection

Protective Goggles

DIN EN 1836,with light glasses,


DIN EN 169, protection class 4
(refer to Figure 96)

43.

Lighters

for welding and cutting torch

44.

Bottle Cart for 2 bottles

load capacity 500 kg, sturdy tubular structure, high stability, bottle shovel angle ironframed on 3 sides, wheels arranged on ball
bearings, dia. 400, solid rubber-tired

at
ion

on

ly

42.

Fo
r

inf

or
m

Figure 97:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

126

D1

General Information for Erection

Tackles and Appliances (incl. Spare Parts)


Specification / Type

ly

Item Designation
Hydraulic Jacks

HP 100/250 (t / stroke in mm)

46.

Hydraulic Jacks

HP 50/200 (t / stroke in mm)

47.

Hydraulic Jacks

HP 20/150 (t / stroke in mm)

48.

Hydraulic Jacks

HP 20/50 (t / stroke in mm)

49.

Hydraulic Jacks

HP 20/400 (t / stroke in mm

50.

Hydraulic Jacks

51.

Hydraulic Jacks

52.

Hydraulic Jacks

at
ion

on

45.

HP 10/150 (t / stroke in mm)


HP 10/50 (t / stroke in mm)

or
m

HP 5/20 (t / stroke in mm)

Figure 98:

Hand Pumps for Hydraulic


Presses, incl. Hydr. Fluid

4.5 l
(refer to Figure 99)

54.

Hand Pumps for Hydraulic


Presses, incl. Hydr. Fluid

1.3 l

inf

53.

Fo
r

Figure 99:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

127

D1

General Information for Erection

Steel Winch

DIN 7355
5 tons with safety crank

56.

Steel Winch

DIN 7355
10 tons, with safety crank

57.

Chain fall with Articulated


Chain
Chain fall with Articulated
Chain

1.5 tons

on

3.0 tons

Draw Winch

Figure 100:
3.2 tons, complete with 25 m rope
Figure 101:

Fo
r

inf

59.

or
m

at
ion

58.

ly

55.

60.

Deflector Pulley

Auft.-Nr. / Order No.

A00226 / MAADEN

for draw winch, refer to item 59

Stand / Revision

2010

Index

--

Blatt / Sheet

128

D1

General Information for Erection

Mechanics and Pipe Fitters Tools

Mechanics Work-Pipe
Bench, incl. Sub cabinets

Vice up to 3" and parallel vice 150 mm jaw


width

on

61.

Specification / Type

ly

Item Designation

at
ion

Figure 102:
Pipe Bending Machine

Hydraulic pipe bending unit with bending


bocks for pipes 1/2" - 3" and standardwalled boiler tubes up to max. 60,3x8.

63.

Electro hydraulic Universal Pipe Bending Machine

Complete with accessories Pipe Bending


Machine

Metal Saw Frame

inf

64.

or
m

62.

66.

DIN 6473
300 mm long, complete with saw blades

Figure 104:

Electric Hand Sawing Machine

Fo
r

65.

Figure 103:

Complete with saw blade for stainless steel

Figure 105:

Water Pump Pliers

DIN ISO 8976

Figure 106:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

129

D1

67.

Pipe Pliers

General Information for Erection

1/2" - 4"

68.

Elbow Pipe Pliers

1/2" - 4"

on

Figure 108:

ly

Figure 107:

Pipe Cutter

1/8" - 2" (refer to Figure 109)

70.

Pipe Cutter

1 1/4" - 4"

at
ion

69.

Figure 109:

Pipe Die Stock for


Threads to

DIN ISO 228


(refer to Figure 110)
1/8", 1/4", 3/8", 1/2", 3/4"
incl. ratchet and dies

72.

Pipe Die Stock for


Threads to

DIN ISO 228


(refer to Figure 110)
1", 1 1/4", 1 1/2", 1 3/4", 2"
incl. ratchet and dies

73.

Pipe Die Stock for


Threads to

DIN ISO 228


2 1/4", 2 1/2", 2 3/4", 3", 3 1/2", 4"
incl. ratchet and dies

Fo
r

inf

or
m

71.

74.

Figure 110:

Steel Tape Rule

DIN 6403
2 m long

Figure 111:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

130

D1

75.

Folding Rule

General Information for Erection

DIN 2268 (graduation)


2 m long, wood

Wood Spirit Level

400 mm long

on

76.

ly

Figure 112:

Figure 113:
Pipe Welder - Grip Pliers

at
ion

77.

Figure 114:

250 x 165 mm

Back square

inf

79.

Engineers Square

or
m

78.

DIN 875
300 x 175 mm

Figure 116:

Centre Square

Fo
r

80.

Figure 115:

300 x 180 mm

Figure 117:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

131

D1

Bevel Steel Square

Universal type bevel steel square, 300 mm

Vernier Callipers

DIN 862
Measuring range 250 mm, with nibs, stainless

at
ion

82.

on

Figure 118:

ly

81.

General Information for Erection

Fo
r

inf

or
m

Figure 119:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

132

D1

General Information for Erection

Measuring and Testing Equipment

Dumpy Level / Transit

Precision 0.1 mm, incl. stand


Type NA2 with micrometer GPM3
Wild Leica

at
ion

on

83.

Specification / Type

ly

Item Designation

Figure 120:

Levelling Rod

85.

Levelling Rod

DIN 18703
3 m long, foldable to 1.50 m, graduation to
match level

86.

Theodolite

incl. stand
Type: T16E
Wild Leica

Fo
r

inf

or
m

84.

87.

Figure 121:

Collimator marks kit

Auft.-Nr. / Order No.

A00226 / MAADEN

DIN 18703
3 m long, graduation to match level

1 Stand GDF 21
1 Collimator plate GZT 1
1 Beam GZR 1
Wild Leica

Stand / Revision

2010

Index

--

Blatt / Sheet

133

D1

External Micrometer

DIN 863
Range 0 - 300 mm, 25 mm increments

Internal Micrometer

DIN 863
Range 0 - 300 mm, 25 mm increments

at
ion

89.

on

Figure 122:

ly

88.

General Information for Erection

Figure 123:

90.

Extensions for Inside

DIN 863 Range up to 500 mm Micrometer

Figure 124:

Straightedge

92.

Straightedge

DIN 874 Part 1


4.0 m long (refer to Figure 125)

93.

Straightedge

DIN 874 Part1


3.0 m long (refer to Figure 125)

inf

or
m

91.

DIN 874 Part 1


5.0 m long (refer to Figure 125)

Straightedge

DIN 874 Part 1


2.0 m long (refer to Figure 125)

95.

Straightedge

DIN 874 Part 1


1.5 m long (refer to Figure 125)

Fo
r

94.

96.

Straightedge

DIN 874 Part 1


1.0 m long (refer to Figure 125)

97.

Straightedge

DIN 874 Part 1


0.5 m long

Figure 125:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

134

D1

Gauge Blocks

DIN 861
150 x 130 x 75 mm, size 2, class 1

Surface Plate

DIN 876, Part 2


200 x 300 mm, size 4, class 1

at
ion

99.

on

Figure 126:

ly

98.

General Information for Erection

Figure 127:

inf

or
m

100. Electric Alignment


Checker, complete
101. Phosphor Bronze Wire
(Piano Wire) or Steel Wire
102. Gradient Indicator

dia. 0.3 mm, 0.5 mm, 1.0 mm

DIN 877
200 mm, accuracy 0.10 mm/m
(Frame Spirit Level)

Figure 128:
DIN 877
200 mm, accuracy 0.04 mm/m

104. Gradient Indicator (Shaft


Spirit Level)

DIN 877
200 mm, accuracy 0.10 mm/m

Fo
r

103. Gradient Indicator (Frame


Spirit Level)

Figure 129:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

135

D1

DIN 862
Range 250 mm, with nibs, stainless

on

Figure 130:

ly

105. Vernier Callipers

General Information for Erection

DIN 862
Range 250 mm, stainless Gauge

at
ion

106. Sliding Depth

Figure 131:

107. Dial Gauge

DIN 878
Accuracy 1/100 mm, range 0 - 10 mm

or
m

Figure 132:

inf

108. Magnetic Stand

for dial gauge (refer to 107)

Figure 133:
DIN 6403
50 m, stainless

110. Measuring Tape

DIN 6403
30 m, stainless

111. Measuring Tape

DIN 6403
20 m, stainless

Fo
r

109. Measuring Tape

Figure 134:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

136

D1

Complete with cord


Removable Tip

Figure 135:
DIN 6403
2 m long

on

113. Steel Tape Rule

ly

112. Plumb Bob with

General Information for Erection

Figure 136:

DIN 2268 (graduation)


2 m long, wood

115. Feeler Gauge

DIN 2275
100 mm long, 0.05 - 1.0 mm
(refer to Figure 137)
DIN 2275
600 mm long, 0.05 - 1.0 mm

or
m

116. Feeler Gauge

at
ion

114. Folding Rule

inf

117. Screw Pitch Gauge

Fo
r

118. Graduated Steel Straightedge


however s = 1

Figure 137:
for Metric and With worth threads

Figure 138:
DIN 866
however s = 1 500 x 30 x 1 mm, graduations 0.5 mm and 1 mm
(refer to Figure 139)

119. Graduated Steel Straightedge


however s = 1

DIN 866
1000 x 30 x 1 mm, graduations 0.5 mm
and 1mm (refer to Figure 139)

120. Graduated Steel Straightedge


however s = 1

DIN 866
however s = 1 2000 x 30 x 1 mm, graduations 0.5 mm and 1mm
Figure 139:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

137

D1

General Information for Erection

DIN 874 Part 2


100 mm long, with case (Figure 140)

122. Bevel Steel Straightedge

DIN 874 Part 2


200 mm long, with case

Fo
r

inf

or
m

at
ion

on

Figure 140:

ly

121. Bevel Steel Straightedge

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

138

D1

General Information for Erection

Pneumatic Machine Tools


Specification / Type

ly

Item Designation
123. Hand Drilling Machines

on

Morse taper 1 - 3

Figure 141:
124. Angle Type Drilling Machines

at
ion

Morse taper 1 - 3

Figure 142:

or
m

125. Magnetic Standard Drilling


Machines
126. Taper Sleeves

Morse taper 1 - 3

DIN 1808
Morse taper 2/1, 3/2, 4/3
DIN 6349
Opening 1 mm - 13 mm

128. Drift Pins

DIN 317
for the drilling machines

129. Grinding Machine

with roughing and abrasive cutter wheel


attachment

inf

127. Drill Chuck

Fo
r

Figure 143:
130. Rubber Grinding Disk
elements

for above grinding machine, with fixing

Figure 144:
Note:

Auft.-Nr. / Order No.

A00226 / MAADEN

All pneumatic machine tools with suitable hoses and hose connectors.

Stand / Revision

2010

Index

--

Blatt / Sheet

139

D1

General Information for Erection

Electric Hand-Operated Machine Tools


Specification / Type
with drill chuck to DIN 6349, drilling capacity for steel up to 32 mm

at
ion

on

131. Electric Multi-speed Handoperated, Drilling Machine

ly

Item Designation

Figure 145:

132. Electric Two-speed Drilling Machine

or
m

capacity for steel up to 16 mm

inf

133. Electric Angle Type Grinding Machine

Figure 146:
Grinding wheel dia. 178 / 125 mm and rubber disk

Fo
r

Figure 147:
134. Electric Grinding Machine
(High-Speed Type)

for abrasive pencils, rotating milling cutters


etc. shank, dia. 6 mm

Figure 148:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

140

D1

135. Magnetic Standard

General Information for Erection

on

ly

for electric hand drilling machines

All electric units with connecting cable and plug, VDE-tested.

Fo
r

inf

or
m

Note:

at
ion

Figure 149:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

141

D1

General Information for Erection

Sundries
Specification / Type
DIN 14711 Part 2
4 m and 6 m long

at
ion

on

136. Aluminium Assembly Ladder

ly

Item Designation

Figure 150:

with connection for 3 x 220 V, 3 x 380 V,


incl. fusing and feeder cable

or
m

137. No stationary Work-site


Distribution Board

with 50 m cable, 3 receptacles, 220 V

Fo
r

inf

138. Cable Drum

Figure 151:

Figure 152:

139. Hand lamp 100 Watt

with 50 m cable complete with plug

Figure 153:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

142

D1

Complete with cells and bulbs (spare bulbs


and cells must be available)

Figure 154:

with safety ropes to DIN EN 354, holding


belts to DIN 7470, catch belts to DIN 7478

at
ion

on

141. Safety Belt

ly

140. Flashlights

General Information for Erection

Figure 155:

142. Scaffold Planks

abt. 4 m long

or
m

143. Assembly Timber Assembly Pedestals


144. Pails
145. Pails

Plastics, abt. 10 l

Galvanized, abt. 11 l

146. Sundry Brushes

Graduated polyethylene collecting bottle


200 ml capacity (refer to Figure 156)

148. Bottle

Graduated polyethylene collecting bottle


850 ml capacity

Fo
r

inf

147. Bottle

Auft.-Nr. / Order No.

A00226 / MAADEN

Figure 156:

Stand / Revision

2010

Index

--

Blatt / Sheet

143

D1

M 24, M 30, M 36, M 42, M 48, M 56, M 64,


M 72 x 6, M 80 x 6, M 90 x 6, M 100 x 6,
M 110 x 6, M 120 x 6 M 125 x 6, M 140 x 6,
M 160 x 6

on

ly

149. Hydr. pre-stressing Device


with pump and pressure
gauge, refer to SN 403
(turning)

General Information for Erection

Figure 157:

M 24, M 30, M 36, M 42, M 48, M 56, M 64,


M 72 x 6, M 80 x 6, M 90 x 6, M 100 x 6,
M 110 x 6, M 120 x 6 M 125 x 6, M 140 x 6,
M 160 x 6

151. Power Screwdriver

for Sizes SW 17 - SW 42
(SW = width across flats)

or
m

at
ion

150. Hydr. pre-stressing Device


with pump and pressure
gauge, refer to SN 403
(drawing)

0 - 10 bar, (DIN EN 837)


0 - 160 bar, (DIN EN 837)
0 - 600 bar, (DIN EN 837)

Fo
r

inf

152. Pressure Gauges

Figure 158:

Figure 159:

153. Minimess Box

Auft.-Nr. / Order No.

A00226 / MAADEN

Hydrotechnik

Stand / Revision

2010

Index

--

Blatt / Sheet

144

D1

DIN ISO 6789


0 - 500 Nm with various torques
Type RAHSOL
GEDORE
Figure 160:

abt. 1000 bar with accessories such as


hoses and fittings

on

155. SKF HP Oil Pump

ly

154. Torque Wrench

General Information for Erection

Type Hilti with drill holder and drills


dia. 10, 12, 14, 18, 20, 25, 28

or
m

156. Drill Hammer

at
ion

Figure 161:

Compressed-air driven, incl. accessories for


various grease nipples

Fo
r

inf

157. Mobile Grease Pump

Figure 162:

Note:

Auft.-Nr. / Order No.

A00226 / MAADEN

Figure 163:

Spares and wearing parts in adequate number must be available at site


for all machines and devices. (Electric parts corresponding to VDE
0100, Part 704)

Stand / Revision

2010

Index

--

Blatt / Sheet

145

D1

General Information for Erection

General Tools
Specification / Type

ly

Item Designation

DIN 580
M 10, M 12, M 16, M 20, M 24, M 30, M 36

159. Crowbar

dia. 20 mm, 1000- and 2000mm long

on

158. Eyebolt

Figure 164:

DIN 6453
200- 250 mm long

at
ion

160. Flat Chisel

Figure 165:

DIN 6451
200- 250 mm long

or
m

161. Cape Chisel

inf

162. Groove Chisel

Figure 166:
DIN 6455
200 mm long x 6,
200 mm long x 8
200 mm long x 10
Figure 167:

Shank dia. 15 mm, 150 mm long


Shank dia. 19 mm, 170 mm long
Shank dia. 25 mm, 200 mm long

Fo
r

163. Check Plug

Figure 168:

164. Hand-Operated Plate


Shear

300 mm long

Figure 169:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

146

D1

165. Pincers

General Information for Erection

Figure 170:
166. Rubber Mallet

on

DIN 5128

ly

250 mm long

167. Plastic Mallet

at
ion

Figure 171:

Figure 172:
2 - 12"

or
m

168. Chain Pipe Tong

inf

169. Wheel Puller

Two-armed 250- and 700 mm

Fo
r

Figure 173:

170. Tool Case

Lockable, empty

Figure 174:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

147

D1

DIN 5254, Form A

dia. 10 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm

at
ion

comprising:
Pliers
Pliers
Pliers
Pliers
Pliers

on

Figure 175:

or
m

172. Set of Pliers for Shaft Retaining Rings

inf

comprising:
Pliers
Pliers
Pliers
Pliers
Pliers

Fo
r

173. Set of Pliers for Bore Retaining Rings

A00226 / MAADEN

DIN 5254, Form B

Figure 176:
dia. 10 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm
DIN 5256, Form C

Figure 177:

comprising:
Pliers
Pliers
Pliers
Pliers
Pliers

Auft.-Nr. / Order No.

ly

171. Set of Pliers for Shaft Retaining Rings

General Information for Erection

dia. 8 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm

Stand / Revision

2010

Index

--

Blatt / Sheet

148

D1

DIN 5256, Form C

on

ly

174. Set of Pliers for Borex Retaining Rings

General Information for Erection

Figure 178:

dia. 8 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm

at
ion

comprising:
Pliers
Pliers
Pliers
Pliers
Pliers

175. Set of Screwdrivers

Cross point Screw DIN 5262 and


Slotted Head / Grub Screw DIN 5265

or
m

Figure 179:

inf

comprising:
Screwdriver
Screwdriver
Screwdriver
Screwdriver
Screwdriver
Screwdriver

176. Square Scraper

4.0 mm
5.5 mm
6.5 mm
10.0 mm
12.0 mm
14.0 mm
DIN 8350, Form A
with handle, 250 mm long

Fo
r

Figure 180:

177. Three-Square Flat Ground


Scraper

DIN 8350, Form B


with handle, 250 mm long

178. Three-Square Hollow


Ground Scraper

DIN 8350, Form C


with handle, 250 mm long
Figure 181:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

149

D1

179. Set of Hand Files

General Information for Erection

DIN 7261, Form A

ly

Figure 182:
comprising:
Hand File
Hand File
Hand File
Hand File
Hand File
Hand File
Hand File

on

Cut 1, 350 mm long


Cut 2, 350 mm long
Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long

180. Set of Square Files

at
ion

DIN 7261, Form D

Figure 183:

or
m

comprising:
Square File
Square File
Square File
Square File
Square File
Square File

inf

181. Set of Three-Square Files

comprising:
Three-Square File
Three-Square File
Three-Square File
Three-Square File
Three-Square File
Three-Square File

A00226 / MAADEN

DIN 7261, Form C

Figure 184:
Cut 1, 350 mm long
Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long

Fo
r
Auft.-Nr. / Order No.

Cut 2, 350 mm long


Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long

Stand / Revision

2010

Index

--

Blatt / Sheet

150

D1

182. Set of Bastard Files

General Information for Erection

DIN 7261, Form E


Figure 185:

ly

comprising:
Bastard File
Bastard File
Bastard File
Bastard File
Bastard File
Bastard File

on

Cut 1, 350 mm long


Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long

183. Set of Round Files

at
ion

DIN 7261, Form F


Figure 186:

or
m

comprising:
Round File
Round File
Round File
Round File
Round File
Round File

inf

184. Flat Rasp

185. Half-Round Rasp

Cut 1, 350 mm long


Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long
DIN 7263, Form A
Cut 1, 300 mm long

Figure 187:
DIN 7263, Form C
Cut 1, 300 mm long
Figure 188:
DIN 7264, Form A
A 300 - 3, A 400 - 1

Fo
r

186. Milled File

Figure 189:

187. File Hand

DIN 395
100-, 140- and 160 mm long

Figure 190:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

151

D1

188. Oil Can

General Information for Erection

on

Figure 191:

ly

0.25 l and 0,5 l

189. Grease Gun

at
ion

with hand lever and accessories

Figure 192:

190. Set of Double Head Box


Wrenches

with flat offset DIN 897 and


with deep offset DIN 838

Figure 193:

inf

or
m

comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench

191. Set of Double Head OpenEnded Wrenches

Fo
r
A00226 / MAADEN

14/17 mm
16/18 mm
19/22 mm
24/27 mm
30/32 mm
36/41 mm

DIN 3110, Series C

Figure 194:

comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench

Auft.-Nr. / Order No.

SW
SW
SW
SW
SW
SW

SW
SW
SW
SW
SW
SW

Stand / Revision

2010

14/17 mm
16/18 mm
19/22 mm
24/27 mm
30/32 mm
36/41 mm

Index

--

Blatt / Sheet

152

D1

DIN 3114, Series C

Figure 195:
30 mm
34 mm
36 mm
41 mm
46 mm
55 mm
65 mm
75 mm
85 mm
90 mm

on

SW
SW
SW
SW
SW
SW
SW
SW
SW
SW

at
ion

comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench

ly

192. Set of Single-Ended Open


Jaw Wrenches

General Information for Erection

193. Set of Slugging Ring


Wrenches

or
m

DIN 7444

Fo
r

inf

comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench

194. Open Jaw Slugging


Wrenches

Figure 196:
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW

30 mm
34 mm
36 mm
46 mm
55 mm
65 mm
75 mm
85 mm
95 mm
105 mm
115 mm
180 mm

DIN 133

Figure 197:
Jaw
Jaw

Auft.-Nr. / Order No.

A00226 / MAADEN

SW 170
SW 180

Stand / Revision

2010

Index

--

Blatt / Sheet

153

D1

DIN 896

with bin handle, dia. 6, SW 8/ 9 mm


with bin handle, dia. 6, SW 10/11 mm
with bin handle, dia. 8, SW 12/13 mm
with bin handle, dia. 10, SW 14/17 mm
with bin handle, dia. 10, SW 16/18 mm
with bin handle, dia. 12, SW 19/22 mm
with bin handle, dia. 14, SW 24/27 mm
with bin handle, dia. 16, SW 30/32 mm
with bin handle, dia. 18, SW 36/41 mm
with bin handle, dia. 20, SW 46/50 mm

at
ion

comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench

on

Figure 198:

ly

195. Set of Tee-Handled Double-Ended Socket


Wrenches

General Information for Erection

196. Set of Tee-Handled


Socket Wrenches

DIN 3112

or
m

Figure 199:

inf

comprising:
Wrench
Wrench
Wrench
Wrench
Wrench

197. Set of Hook Wrenches

DIN 1810, Form A

Fo
r

Figure 200:

comprising:
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench

Auft.-Nr. / Order No.

A00226 / MAADEN

without bin handle, dia. 26, SW 55 mm


without bin handle, dia. 32, SW 60 mm
without bin handle, dia. 32, SW 70 mm
without bin handle, dia. 40, SW 80 mm
without bin handle, dia. 40, SW 95 mm

for nut outer dia. 16 - 20 mm


for nut outer dia. 25 - 28 mm
for nut outer dia. 30 - 32 mm
for nut outer dia. 34 - 36 mm
for nut outer dia. 40 - 42 mm
for nut outer dia. 45 - 50 mm
for nut outer dia. 52 - 55 mm
for nut outer dia. 58 - 62 mm
for nut outer dia. 68 - 75 mm
for nut outer dia. 80 - 90 mm
for nut outer dia. 95 - 100 mm
for nut outer dia. 110 - 115 mm
Stand / Revision

2010

Index

--

Blatt / Sheet

154

D1

DIN ISO 2936

ly

for nut outer dia. 120 - 130 mm


for nut outer dia. 135 - 145 mm
for nut outer dia. 155 - 165 mm
for nut outer dia. 180 - 195 mm
for nut outer dia. 205 - 220 mm

on

Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
198. Set of Hex. Socket Screw
Keys

General Information for Erection

Figure 201:

inf

199. Set of Allan Keys with


Spigot

DIN 6911

SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW

Fo
r
A00226 / MAADEN

3 mm
4 mm
5 mm
6 mm
8 mm
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
24 mm

Figure 202:

comprising:
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key

Auft.-Nr. / Order No.

SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW

at
ion

or
m

comprising:
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key
Screw Key

Stand / Revision

2010

4 mm
5 mm
6 mm
8 mm
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
27 mm
32 mm
36 mm

Index

--

Blatt / Sheet

155

D1

200. Set of Straight Shank


Twist Drills

General Information for Erection

Figure 203:

on

201. Set of Twist Drills with


Morse Taper 1

inf

comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill

A00226 / MAADEN

Standard DIN 345 and Long DIN 341


(refer to Figure 204)
dia. 10.5 mm
dia. 11.0 mm
dia. 11.5 mm
dia. 11.8 mm
dia. 12.0 mm
dia. 12.5 mm
dia. 13.0 mm
dia. 13.5 mm
dia. 14.0 mm

Fo
r
Auft.-Nr. / Order No.

dia. 2.0 mm
dia. 2.5 mm
dia. 3.0 mm
dia. 3.3 mm
dia. 3.5 mm
dia. 4.0 mm
dia. 4.2 mm
dia. 4.8 mm
dia. 5.0 mm
dia. 5.5 mm
dia. 6.0 mm
dia. 6.4 mm
dia. 6.8 mm
dia. 7.0 mm
dia. 8.0 mm
dia. 8.4 mm
dia. 9.0 mm
dia. 9.5 mm
dia. 10.0 mm

at
ion

or
m

comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill

ly

Short DIN 338 and Long DIN 340

Stand / Revision

2010

Index

--

Blatt / Sheet

156

D1

on

dia. 14.50 mm
dia. 15.25 mm
dia. 16.00 mm
dia. 16.50 mm
dia. 17.00 mm
dia. 17.50 mm
dia. 18.00 mm
dia. 18.50 mm
dia. 19.00 mm
dia. 19.50 mm
dia. 20.00 mm
dia. 21.00 mm
dia. 22.00 mm
dia. 22.50 mm
dia. 23.00 mm

at
ion

comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill

Standard DIN 345 and Long DIN 341


(refer to Figure 204)

203. Set of Twist Drills with


Morse Taper 3

Standard DIN 345 and Long DIN 341


(refer to Figure 204)

inf

or
m

comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill

204. Set of Twist Drills with


Morse Taper 4

Fo
r
A00226 / MAADEN

dia. 23.5 mm
dia. 24.5 mm
dia. 25.0 mm
dia. 26.5 mm
dia. 27.0 mm
dia. 28.0 mm
dia. 29.5 mm
dia. 30.0 mm
dia. 30.5 mm
Standard DIN 345 and Long DIN 341

Figure 204:

comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill

Auft.-Nr. / Order No.

ly

202. Set of Twist Drills with


Morse Taper 2

General Information for Erection

dia. 32.0 mm
dia. 33.0 mm
dia. 37.5 mm
dia. 39.0 mm
dia. 45.0 mm

Stand / Revision

2010

Index

--

Blatt / Sheet

157

D1

205. Set of Taper Pin Twist


Drills

General Information for Erection

DIN 1898
Figure 205:

ly

comprising:
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill

on

with cyl. shaft, dia. 4 mm, Form A


with Morse taper, dia. 5 mm, Form B
with Morse taper, dia. 6 mm, Form B
with Morse taper, dia. 8 mm, Form B
with Morse taper, dia. 10 mm, Form B

206. Set of Taper Pin Twist


Drills

DIN 1898 ,Form B


(refer to Figure 205)

at
ion

comprising:
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill
Taper Pin Twist Drill

with Morse taper 2, dia. 12 mm


with Morse taper 2, dia. 14 mm
with Morse taper 2, dia. 16 mm
with Morse taper 3, dia. 20 mm
with Morse taper 3, dia. 25 mm
with Morse taper 4, dia. 30 mm
with Morse taper 4, dia. 40 mm

or
m

207. Set of Hand Reamers


each

inf

comprising:
Hand Reamer
208. Set of Taps, 3-part

DIN 206, Form A/B,


dia. 5, dia. 8, dia. 10, dia. 16, dia. 20,
dia. 25, dia. 30,dia. 40, dia. 50
Figure 206:

DIN 352
for Metric ISO Standard
M 4, M 5, M 6, M 8, M 10, M 12, M 16,
M 20, M 24, M 30, M 36, M 42

Fo
r

comprising:
Threads

Figure 207:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

158

D1

DIN 5157
for Pipe

Figure 208:

on

comprising:
Threads

ly

209. Set of Taps, 2-part

General Information for Erection

1/8", 1/4", 3/8", 1/2", 3/8", 1", 1 1/4", 1 1/2",


1 3/4" , 2", 2 1/2", 3"
DIN EN 22568
for Metric ISO

at
ion

210. Set of Round Threading


Dies,

Figure 209:

comprising:
Standard Threads

or
m

M 5, M 6, M 8, M10, M 12, M 16,


M 20, M 24

inf

211. Set of Round Threading


Dies

comprising:
Threads

DIN EN 24231
for Pipe G-DIN/ISO 228

Figure 210:
G 1/8", G 1/4", G 3/8", G 1/2", G 3/4"
DIN EN 22568
(refer to Figure 211)

Fo
r

212. Set of Die Holders


comprising:
Die Holder

dia. 20, dia. 25, dia. 30, dia. 38, dia. 45,
dia. 55

213. Set of Die Holders

DIN EN 22568

Figure 211:
comprising:
Die Holder

Auft.-Nr. / Order No.

A00226 / MAADEN

G 1/8", G 1/4", G 3/8", G 1/2", G 1/2"

Stand / Revision

2010

Index

--

Blatt / Sheet

159

D1

214. Tap Wrenches, with Movable

General Information for Erection

DIN 1814
Jaws Size 5, 6 and 7

215. Set of Tap Extensions

ly

Figure 212:

on

DIN 377
Figure 213:

comprising:
Tap Extension

4.5 mm, 5.6 mm, 7.1 mm, 9.0 mm,


11.2 mm,12.5 mm, 14.0 mm, 16.0 mm,
18.0 mm, 20.0 mm, 22.4 mm, 25.0 mm
DIN 1041
DIN 1042
300 g, 500 g, 1000 g, 2000 g, 4000 g,
8000 g, 12000 g

or
m

at
ion

216. Hand Hammer Round Set


Hammer

217. Screwdrivers for


Slotted Head / Grub
Screw

inf

Screws

DIN 5265

Figure 215:
3, 5, 8, 11 mm
DIN 3113
SW 6, 7, 8, 9, 10, 11, 12, 13, 14, 16, 17, 18,
19, 21, 22, 24, 27, 34 mm

Fo
r

218. Combination Wrenches

Figure 214:

Figure 216:

219. Hex. Socket Screw


Wrenches

DIN ISO 2936


SW 3, 4, 5, 8, 9, 10, 12, 14 ,17, 18,
20, 24 mm

Figure 217:
220. Wire Rope

Auft.-Nr. / Order No.

A00226 / MAADEN

DIN 3088
with loops, dia. 8 x 1.5 m
Stand / Revision

2010

Index

--

Blatt / Sheet

160

D1

General Information for Erection

DIN 3088
with loops, dia. 10 x 1.5 m

222. Wire Rope

DIN 3088
with loops, dia. 12 x 1.5 m

223. Wire Rope

DIN 3088
with loops, dia. 14 x 1.5 m

224. Wire Rope

DIN 3088
with loops, dia. 16 x 1.5 m

225. Wire Rope

DIN 3088
with loops, dia. 12 x 4.0 m

226. Wire Rope

DIN 3088
with loops, dia. 12 x 6.0 m

228. Wire Rope

on

DIN 3088
with loops, dia. 12 x 8.0 m
DIN 3088
with loops, dia. 16 x 4.0 m

or
m

229. Wire Rope

at
ion

227. Wire Rope

ly

221. Wire Rope

DIN 3088
with loops, dia. 16 x 6.0 m
DIN 3088
with loops, dia. 16 x 8.0 m

231. Wire Rope

DIN 3088
with loops, dia. 20 x 8.0 m

232. Wire Rope

DIN 3088
with loops, dia. 20 x 10.0 m

233. Wire Rope

DIN 3088
with loops, dia. 36 x 8.0 m

234. Wire Rope

DIN 3088
with loops, dia. 36 x 10.0 m

Fo
r

inf

230. Wire Rope

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

161

D1

General Information for Erection

DIN 3088
with loops, dia. 36 x 12.0 m

236. Wire Rope

DIN 3088
with loops, dia. 42 x 8.0 m

237. Wire Rope

DIN 3088
with loops, dia. 42 x 10.0 m

238. Wire Rope

DIN 3088
with loops, dia. 24 x 6.0 m

239. Wire Rope

DIN 3088
with loops, dia. 24 x 8.0 m

241. Wire Rope


242. Hemp Rope

on

DIN 3088
with loops, dia. 24 x 10.0 m
DIN 3088
with loops, dia. 24 x 12.0 m
DIN EN 1261
endless, dia. 20

or
m

243. Hemp Rope

at
ion

240. Wire Rope

ly

235. Wire Rope

DIN EN 1261
endless, dia. 30

DIN EN 1261
endless, dia. 40

245. Rope Protectors

25.0 t

246. Rope Protectors

50.0 t

inf

244. Hemp Rope

DIN 82101
1.0 t

248. Shackles

DIN 82101
2.0 t

Fo
r

247. Shackles

249. Shackles

Auft.-Nr. / Order No.

A00226 / MAADEN

DIN 82101
4.0 t

Stand / Revision

2010

Index

--

Blatt / Sheet

162

D1

DIN 82101
6.0 t

251. Shackles

DIN 82101
8.0 t

252. Shackles

DIN 82101
10.0 t

253. Shackles

DIN 82101
12.0 t

254. S-Hooks

0.2 t

255. S-Hooks

0.5 t

257. S-Hooks

1.0 t
2.0 t
5.0 t

Fo
r

inf

or
m

258. S-Hooks

at
ion

256. S-Hooks

on

250. Shackles

ly

General Information for Erection

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

163

D1

Appendix

Fo
r

inf

or
m

at
ion

on

ly

1.20.

General Information for Erection

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

164

D1

1.20.1.

General Information for Erection

Example of Pickling Scheme in Recirculation Process (ZS)

on

ly

Legend:
1 Oil tank
2 Lubrication oil pump
3 Double screen filter
4 Oil cooler
5 Air vessel
6 Consumer

7 Pickling tank
8 Pickling pump

6
6
6

at
ion

6
6

Provisional connection
with hoses

or
m

Fo
r

inf

1
3

Figure 218

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

165

D1

1.20.2.

General Information for Erection

Example of Pickling Scheme in Recirculation Process (Hydraulic power system)

LP

ly

LP

1 Oil tank
2 High pressure pump
3 Circulation pump
4 Filter
5 Cooler
6 Accumulator
7 Valve stand
8 Hydraulic cylinder

on

Legend:

at
ion

or
m

9 Pickling pump
10 Pickling tank

P
Y

inf

Fo
r

10

Provisional connections with hoses:


Pickling circuit 1
Pickling circuit 2
Pickling circuit 3

Dismantling of pipes
and tank pickling

Figure 219

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

166

D1

1.20.3.

General Information for Erection

Simplified representation in drawings

120 x 30

ly

38 x 140
50 x 60
7 x80

on

19 x 6
G 1/4 x 12/80

19 x 6
G 1/4 x 12/18
7 x 100

M10 x 15/23

at
ion

7 x 100

or
m

Figure 220
All bores located on a common centre should be dimensioned from the upper edge of the mounting
plate.
Exceptions are as follows:
Thread and core hole depths commencing centrically or none centrically in a centring point as well
as bores commencing none centrically in a centring point. These are dimensioned from the lower
surface. If this cannot be clearly shown in a simplified representation, the situation should be represented in a section.
All flushing plates have to be supplied by the erection company are not part of SMS SIEMAG
scope of supply.
Upper edge
Mounting plate =
datum surface

inf

Bores commencing)
non centrically in
a centering point

Bores and countersinks


situated at a centre

Fo
r

15

Thread and core


hole depths

0
0

0
6

30
0

50

12

18

12
60

23

100
80

80
38

140

Core hole bores


also serving
as hydr. bore

Figure 221

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

2010

--

Blatt / Sheet

167

D1

1.20.4.

General Information for Erection

Drawings and bill of material for flushing plates conformable SMS SIEMAG drawings

ly

Flushing Plate for D 760 (SMS Drwg. 2/5929970)


For fastening of flushing plate screws of valve can be used Material of flushing plate St
0

on

G 1/8 x 8/13
8 x 81
20
30

at
ion

56

40,5

G 1/4 x 12/36

G 3/8 x 12/30
G 1/8 x 8/18

G 1/8 x 8/13
8 x 61

81,6

C2

69,2

67,1
G 1/4 x 12/30

47
35,9

G 1/4 x 12/30

C1

0
51,6

30

0
45

59,6

73

inf
37,5

C1

55

G 1/8 x 8/13
8 x 39

14- 0,2

1,5 0,05

Fo
r

40,5

15,4

7,9

30

81

24,8

47

4x 15 x 22 / 9

20

58,1

29,4

40,5

47

47

C2

4x G 3/8 x 12 / 18
11 x 33

or
m

5,3 x 14

4x 8 x 30
81,6

16,3

94

0,

45

G 1/4 x 12/36

G 3/8

G 3/8

G 3/8

C1

G 3/8

D 760

30

0,

G 1/8

1,6

C2

39

20,3

5x A - A

Figure 222:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

168

D1

General Information for Erection

Additional Parts for Flushing Plate of Valve Block D 760


as per SMS SIEMAG Draw. 2/5929970
Description

Material

Socket head screw


ISO 4762 M8 x 50

O-Ring
SN 430 10 x 2 - N
similar to DIN 3771

Plug screw
SN 870 VSTI G 1/8 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 1/4 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 3/8 A-ED

ST / Viton

Plug screw
SN 869 G 1/8 A

ST

Socket
SN 759 GUV 12 / G 3/8

ST

High pressure hose


DN 8 x 800 - 2 x M 20 x 1,5 - 490 bar
Supplier: Aeroquip
Type: 2755 - 6 - 00800
2 x GC 3471 - 6
2 x 41.721 - 12 - 6

ly

Amount

129

Fo
r

inf

or
m

at
ion

on

Viton / 70

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

2010

--

Blatt / Sheet

169

D1

General Information for Erection

Flushing Plate for NG 16XY (SMS Drwg. 2/5929990)


For fastening of flushing plate screws of valve can be used Material of flushing plate St

ly

108

G 3/4

G 3/4

G 3/4

G 3/4

on

NG 16 XY

G 1/8

G 1/8 x 8/13
6,8 x 50
M8 x 42

4x G 3/4 x 16/25

M8

95

2x 7 x15

84,1

82,5

or
m

26,9
B

25,3

11

0,
2
R

0,
2

0,
3

0,
2
R

39,3

55,1

28 - 0,2

2,3 + 0,05

14 - 0,2

71

109,1

G 1/8 x 8/13
7 x 45

98

0
0

39

142

93

71
80

inf

Fo
r

55,1

39

21

40

G 1/8 x 8/13
7 x 45

40

48

0
0

55

122,6

12,6

26

23

T
68,2

66,6

86,9

64

97,6

50

73

1,5 0,05

G 3/8 x 12/52
G 1/8 x 8/13
7 x 55

1.6

4x 18 x 33

4x 18 x 12/11

at
ion

2x 11 x 12/6,6

2x A - A

4x B - B

Figure 223:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

170

D1

General Information for Erection

Additional Parts for Flushing Plate of Valve Block NG 16 XY


as per SMS SIEMAG Draw. 2/5929990
Description

Socket head screw


ISO 4762 M6 x 60

Socket head screw


ISO 4762 M10 x 60

O-Ring
SN 430 10 x 2 - N
similar to DIN 3771

O-Ring
SN 430 22 x 3 - N
similar to DIN 3771

Viton 70

Plug screw
SN 870 VSTI G 1/8 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 3/8 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 3/4 A-ED

ST / Viton

Grub screw
ISO 4027 M8 x 12

45 H

Plug screw
SN 869 VSTI G 1/8 A

ST

Socket
SN 759 GUV 20 / G 3/4

ST

on

129

at
ion

Viton 70

inf

129

or
m

Material

ly

Amount

High pressure hose


DN 16 x 800 - 2 x M 30 x 2 - 400 bar
Supplier: Aeroquip
Type: 2755 - 10 - 00800
2 x GC 3471 - 10
2 x 41.721 - 20 - 10

Fo
r

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

2010

--

Blatt / Sheet

171

D1

General Information for Erection

Fo
r

inf

or
m

at
ion

on

ly

Flushing Plate for NG 10XY (SMS Drwg. 2/5929980)


For fastening of flushing plate screws of valve can be used Material of flushing plate St

Figure 224:
Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

172

D1

General Information for Erection

Additional Parts for Flushing Plate of Valve Block NG 10 XY


as per SMS SIEMAG Draw. 2/5929980
Description

Material

Socket head screw


ISO 4762 M6 x 60

O-Ring
SN 430 12 x 2 - N
similar to DIN 3771

Plug screw
SN 870 VSTI G 1/8 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 1/4 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 1/2 A-ED

ST / Viton

Grub screw
ISO 7434 M8 x 12

14 H

Socket
SN 759 GUV 16 / G 1/2

ST

High pressure hose


DN 12 x 800 - 2 x M 24 x 1,5 - 420 bar
Supplier: Aeroquip
Type: 2755 - 8 - 00800
2 x GC 3471 - 8
2 x 41.721 - 16 - 8

ly

Amount

129

Fo
r

inf

or
m

at
ion

on

Viton / 70

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

2010

--

Blatt / Sheet

173

D1

General Information for Erection

ly
at
ion

120

G1/8 x 8/13
6,8 x 135

G1/8 x 8/13
6,8 x 63
M8 x 50

58

31

Fo
r

31

131,5

22 - 0,2

2
0,

2
0,

G1

G1

NG 25 XY
M8

M8

0,

Y
1,6

G1

2
0,

38 - 0,2

G1

33
31,5

X
B

87

inf

195

151

124,5

104

98

74

68

47,2

21

B
4x 22 x 33

14

133,5

27,5

or
m

2x 10 x 30

58

33,5

88,5

38,3

6x 20 x 16
13,5

50,2

4x G1 x 18/35

P
Y

74

92,5
86,5

98

1,5 0,05

31

on

G1/8 x 8/13
6,8 x 79
M8 x 72

121,6

2,3 0,05

40,3

Flushing Plate for NG 25 XY (SMS Drwg. 2/5193810)


For fastening of flushing plate use screws M12 x 60 Material of flushing plate St

2x A - A

4x B - B

Figure 225

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

174

D1

General Information for Erection

Additional Parts for Flushing Plate of Valve Block NG 25 XY


as per SMS SIEMAG Draw. 2/5193810
Description

Socket head screw


ISO 4762 M12 x 55

O-Ring
SN 430 18 x 2 - N
similar to DIN 3771

O-Ring
SN 430 32 x 3 - N
similar to DIN 3771

Plug screw
SN 870 VSTI G 1/8 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 1 A-ED

ST / Viton

Socket
SN 759 GUV 25 / G1

ST

Grub screw
ISO 4027 M8 x 12

45 H

129

on

Viton / 70

or
m

at
ion

Viton 70

High pressure hose


DN 20 x 800 - 2 x M 36 x 2 - 420 bar
Supplier: Aeroquip
Type: GH 506 - 12 - 00800
2 x GH 10243 - 12
2 x GH 10235 - 12

Fo
r

inf

Material

ly

Amount

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

2010

--

Blatt / Sheet

175

D1

General Information for Erection

Flushing Plate for D079 1 (SMS Drwg. 2/5193730)


For fastening of flushing plate use screws M10 x 70 Material of flushing plate St

4 x 18 x 13,5
11

4 x G3/4 x 16/24
19 x 55

ly

140

on

C1

at
ion

110,4
106,5

70

4 x 16 x 15

2 x 4,5 x 38

X
A

95,4

C1

70

50

2
0,

9,6

29,6

80,4

100,4

55

G 3/4

G 3/4

G 3/4

G 3/4

C1

C2

D079 -1

4x B - B

98,5

2x A - A

55

11,5

2 x 16 x 45
G1/8 x 8/13
6,8 x 50

2
0,

1,9 0,05

2
0,

0,
3

34

25 - 0,2

12 - 0,2
R

Fo
r

54

1,5 0,05

G1/2 x 14/49

1,6

69

inf

110

97,8

80,4

55

29,6

12,2

34

C2

or
m

33,5
29,6

44,6

C2

G1/8 x 8/13
6,8 x 100

Figure 226:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

176

D1

General Information for Erection

Additional Parts for Flushing Plate of Valve Block D 079 - 1


as per SMS SIEMAG Draw. 2/5193730
Description

Socket head screw


ISO 4762 M10 x 70

O-Ring
SN 430 8 x 2 - N
similar to DIN 3771

O-Ring
SN 430 20 x 2,5 - N
similar to DIN 3771

Plug screw
SN 870 VSTI G 1/8 A-ED

ST / Viton

Plug screw
SN 870 VSTI G 1/2 A-ED

ST / Viton

Plug screw
SN 869 VSTI G 3/4 A-ED

ST / Viton

Socket
SN 759 GUV 20 / G 3/4

ST

129

on

Viton / 70

or
m

at
ion

Viton 70

High pressure hose


DN 16 x 800 - 2 x M 30 x 2 - 400 bar
Supplier: Aeroquip
Type: 2755 - 10 - 00800
2 x GC 3471 - 10
2 x 41.721 - 20 - 10

Fo
r

inf

Material

ly

Amount

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

2010

--

Blatt / Sheet

177

D1

General Information for Erection

on

44,9

73,5

ly

102,1

53

147

132,2

106,6

73,5

40,4

14,8

Flushing Plate for D079 2 (SMS Drwg. 2/5193740)


For fastening of flushing plate screws of valve can be used Material of flushing plate St

4 x G1 x 18/35

at
ion

34,6
45,9
C2

66,1

or
m

113,9

145,4

38- 0,2

0,
2

Fo
r

8 x 26 x 17,5
17,5

129,6

C1

G1

G1

G1

G1

D079 - 2

0,
3

1,6

90

4 x 28 x 25

2,3 0,05

C1

180

50,4

inf

134,1

C2

C1

C2

4x A - A

Figure 227:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

178

D1

General Information for Erection

Additional Parts for Flushing Plate of Valve Block D 079 - 2


as per SMS SIEMAG Draw. 2/5193740

Description

Material

Socket head screw


ISO 4762 M16 x 65

O-Ring
SN 430 32 x 3 - N
similar to DIN 3771

Plug screw
SN 870 VSTI G 1 A-ED

ST / Viton

Socket
SN 759 GUV 25 / G1

ST

High pressure hose


DN 20 x 800 - 2 x M 36 x 2 - 420 bar
Supplier: Aeroquip
Type: GH 506 - 12 - 00800
2 x GH 10243 - 12
2 x GH 10235 - 12

ly

Amount

129

Fo
r

inf

or
m

at
ion

on

Viton / 70

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

179

D1

1.20.5.

General Information for Erection

Off-loading of Mill Housing from flat bottomed vehicle and Positioning


Overhead travelling crane 2

Overhead travelling crane 1

Fig. 1

Fig. 2

Flat-bottomed vehicle
Mill housing

or
m

Wooden plank

at
ion

on

ly

Drive side (outside)

Minimum load - carrying


capacity of cranes:
weight of mill housing
plus
weight of lifting device

Fig. 3

Lifting device
Bed plate

Fo
r

inf

Fig.4

Fig. 6

Fig. 5

Drive side (outside)

Center line of mill

Center line of mill

Figure 230:
Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

180

D1

General Information for Erection

Overhead travelling crane 1

Overhead travelling crane 2

on

ly

Operating side (inside)

Fig. 2

at
ion

Fig. 1

Minimum load - carrying


capacity of cranes:
weight of mill housing
plus
weight of lifting device

Flat-bottomed vehicle

Fig. 3

Mill housing

Wooden plank

or
m

Lifting device
Bed plate

Fig. 6

inf

Fig. 7

Fo
r

Fig.4

Fig. 5

Operating side (inside)


Center line of mill

Center line of mill

Center line of mill

Figure 231
Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

Index

Blatt / Sheet

2010

--

181

D1

on

Minimum load - carrying capacity


of overhead travellingcrane:
weight of mill housing
plus
weight of lifting device

Fo
r

inf

or
m

at
ion

Lifting device

ly

Off-Loading of a Mill Housing from well wagon and positioning

Mill housing

1.20.6.

General Information for Erection

Figure 232:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

182

Fo
r

A00226 / MAADEN

Auft.-Nr. / Order No.

Stand / Revision

2010
Bed plate

or
m

inf
on
Wooden plank

Mill housing

at
ion

ly

Minimum load - carrying capacity


of overhead travelling crane:
weight of mill housing
plus
weight of lifting device

Lifting device

D1
General Information for Erection

Figure 233:

Index

--

Blatt / Sheet

183

D2

Erection Measuring Report

2. Erection Measuring Report

Fo
r

inf

or
m

at
ion

on

ly

The protocols are to be understood only as measuring protocols, but not


as erection drawings.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D2

Erection Measuring Report

Shape and Position Tolerances - Symbols for Field Erection

ly

Symbol ISO 1101


Examples of Application
with SN 200 Expansion *1 Tolerance Zone Drawing EnDrawing Entry
and Tolerance Quality
try

on

*2

at
ion

0,2/1000

1,0

Shape

*1
Horizontal
Plane
SN200

The tolerance horizontal line


must be between two parallel
lines spaced
t = 0, 2 mm.
*2 If a reference length is
not specified, the tolerance
always related to the
overall length.

Flatness

1,0 A

or
m

The tolerance surface must


lie between two parallel
planes a distance of
t = 1 mm apart.
The tolerance axis must lie
within a cylinder of diameter
t = 1 mm lying parallel to the
datum axis.

Parallelism

inf

2,0

50

50

Position

100

100

Fo
r

Position

1,0

1,0 A
A

Symmetry

Perpendicularity

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

The tolerance surface must


lie between two planes
t = 1 mm apart and parallel
to the datum axis.
The axis of the hole must lie
within a cylinder of diameter
t = 2 mm, the axis of which is
located at the geometrically
ideal position (dimensions
shown in boxes)
The central plane of the
groove must lie between two
parallel planes t = 1 mm
apart and lying symmetrically
to the central plane of the
datum element.
The tolerance axis of the cylinder must lie between two
parallel planes which are
perpendicular to the reference surface and 0,1 apart.

0,1

Index

--

Blatt / Sheet

Fo
r
or
m

inf

at
ion

on

ly

Fo
r
or
m

inf

at
ion

on

ly

Fo
r
or
m

inf

at
ion

on

ly

Fo
r
or
m

inf

at
ion

on

ly

Fo
r
or
m

inf

at
ion

on

ly

Fo
r
or
m

inf

at
ion

on

ly

Fo
r
or
m

inf

at
ion

on

ly

D3

Single Function Tests

Fo
r

inf

or
m

at
ion

on

ly

3. Single Function Tests

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.

Single Function Tests

Precondition for Tests

Fo
r

inf

or
m

at
ion

on

ly

All machine components, especially skid ways, rails, rollers, rolls and piston
rods are to be carefully cleaned from remaining preservatives and other contaminations.
All electrical functions inclusive of interlocking are to be tested by the responsible electrical equipment supplier.
All auxiliary media are available in a function-tested state.
All erection work has been checked for unobjectionable completion as
for instance:
tight fit of all screw joints (especially on universal joint shafts, couplings and
other rotating parts)
tight fit of all pipe fastenings
tight fit of all anchor bolts

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.1.

Single Function Tests

Mechanical Equipment

on

ly

The following energy carriers and utilities are available:


current
hydraulic medium
compressed air
lube oil and grease
cooling water
high-pressure water

Fo
r

inf

or
m

at
ion

All grease/lube points to be greased/lubricated according to the lube instructions as given in the Special Manual B1.
The mounted machine components were surveyed and a measuring protocol
was drawn up.
All integrated switch gears (limit switches, light barriers, level switches etc.)
were installed, cabled and their functions electrically tested.
Release present for the electrical control system including voltage supply to motors.
Drive couplings to be properly mounted, this work including proper alignment
according to the instructions of the manufacturer and proper filling with grease /
oil in compliance with the lube instructions as given in the Special Manual B1.
Prior to the first start of a drive motor, the latter has to be turned by hand as far
as possible or by means of mechanical aids to ensure its freedom of movement.
In case of drives running in one sense of rotation only the rotational sense is to
be checked by a short jog control.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.2.

Single Function Tests

Hydraulic Systems (Cylinders, Hydraulic Motors)

at
ion

on

ly

Check to see whether:


tanks and pipelines are free from inadmissible contaminations
filter inserts are free from inadmissible contaminations
tank is filled with hydraulic oil, level indicators and monitors are in a functional
state
pipelines have been:
pickled
pressure-tested
connections established in accordance with control circuits
vented

Fo
r

inf

or
m

release is present for the electrical control including voltage supply to motors
and heaters;
the hydraulic station is ready for operation up to the individual control panels
and has been pressurized;
accumulators have been filled with nitrogen

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

Pneumatic Systems (Cylinders, Pneumatic Motors)

on

Check to see whether:


compressed air system has been pressurized
connecting pipelines have been:
pressure-tested
connections established as per control circuits
free from inadmissible contaminations

ly

3.1.3.

Single Function Tests

at
ion

pipelines at the machines are:


free from inadmissible contaminations
connections have been established as per circuit diagram

Fo
r

inf

or
m

compressed air control panels are ready for operation (for instance oil atomizer
filled, pressure reducer set to operating pressure, filter free from inadmissible
contaminations )
pipelines are free from any inadmissible humidity
function of the automatic filter de-watering is ok
release of electrical control

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.4.

Single Function Tests

Oil Lube Systems

Fo
r

inf

or
m

at
ion

on

ly

Check to see whether:


cooling water is present for oil cooler
compressed air is present for pressure tank and controller
oil tank and pipeline system are free from inadmissible contaminations
filter inserts are free from inadmissible contaminations
controllers are preset to their service data
tank is filled with lube oil, the level indicator and monitor are in a functional state
all pressure switches, level switches etc. are set to special instructions and their
functions have been tested
release is present for the electrical control including voltage supply to motors
and heaters

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.5.

Single Function Tests

Grease Systems

at
ion

on

ly

Check to see whether:


grease tank on pump is filled with grease and is free from inadmissible contaminations
filter insert at pump is free from inadmissible contaminations
pipeline system:
free from inadmissible contaminations
pressure-tested
connections have been established to circuit diagram
filled with grease
vented

Fo
r

inf

or
m

all pressure switches, level switches etc. are set to special instructions and their
functions have been tested
release is present for the electrical control including voltage supply to motors

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.6.

Single Function Tests

Cooling Water Systems

on

ly

Check to see whether:


cooling water is available from water treatment plant
compressed air is available for pneumatically pilot-controlled valves
connecting pipelines and spray headers have been:
flushed and are free from inadmissible contaminations
pressure-tested
connections established to control circuits
vented

at
ion

all movable valve elements are clean and freely movable


filter inserts are free from inadmissible contaminations
signal transducers preset to their service data.
release is present for the electrical control including voltage supply to motors

Fo
r

inf

or
m

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

3.1.7.

Single Function Tests

High-Pressure Water System

on

ly

Check to see whether:


water from the water treatment plant is present
compressed air is available for pneumatically controlled valves
connecting pipelines and spray headers have been:
flushed and are free from inadmissible contaminations
pressure-tested
connections established as per circuit diagram
vented

at
ion

all movable valve elements are clean and freely movable


filter inserts are free from inadmissible contaminations
signal transducers preset to their service data.
release is present for the electrical control inclusive of voltage supply to motors

Fo
r

inf

or
m

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

D3

Procedure of Tests

Fo
r

inf

or
m

at
ion

on

ly

3.2.

Single Function Tests

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

10

D3

3.2.1.

Single Function Tests

Sense of Rotation of Electric Motors


Visual check of sense of rotation of the electric motors.

ly

Checks to be made:

at
ion

on

Sense of rotation of the electric motors after completed electrical check. The
uncoupled electric motor is to be started in secured state to suit operational
conditions. If and when the sense of rotation on the machine input shaft conforms to that of the electric motor output shaft, the test is considered passed
and completed. In case of a wrong sense of rotation the specialist responsible
for electrical matters is to be informed and a new test to be made after corresponding measures for a rotational sense reversal have been completed.
In case of drives with two rotational senses care will be taken to ensure that the
correct sense of rotation is allocated to the control element (for instance starting
button).
When maxi- or main drives (for instance stand/reel drives) are concerned, the
sense of rotation has to be ensured by the electrical specialist including compliance of these drives with special rules and safety instructions.

Fo
r

inf

or
m

If, for technical or other reasons, the electrical drive cannot be uncoupled from
the working unit (pump, gear unit, rolls ....), the check for a proper rotational
sense is to be carried out only in inching mode, or by starting and instantaneous switch-off.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

11

D3

3.2.2.

Single Function Tests

Electrical Devices such as Proximity Switches, Limit Switches, Brakes,


Photocells etc.
Visual check of electrical switch elements.

ly

Checks to be made:

on

The mechanical function and, if necessary in this conjunction, the electrical


function of the electrical switch elements as stated with due consideration to the
technical data contained the set values and positions possibly indicated in the
equipment arrangement drawing.

Fo
r

inf

or
m

at
ion

So the following items are checked for instance as far as proximity limit switches
are concerned:
correct attachment of limit switch
passage of switch flag
working clearance of switch flag
presence of inadmissible impairment of the magnetic field
switching or rather moving positions for which purpose the relevant switch
points have to be approached, if possible, and the response behaviour of the
switch-off device to be checked. In case of conspicuous limit switches the function can be checked by means of a light-emitting diode at the limit switch. Is the
function not conspicuous, the proper function can be tested in the terminal box
locally or at the light-emitting diode of the centralized PLC. If this is not possible
either, the electrical specialist can check this function by making measurements
or on the display of the plant control pulpit. During testing, special care will be
taken to ensure conflict- and collision-free functioning of the transducers and
sensors with regard to their attachments.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

12

D3

3.2.3.

Single Function Tests

Lubrication to Lube Instructions


Visual check of lube points at the machine.

on

ly

Checks to be made:
Lubrication as per lube instructions in conjunction with the lube chart - relubricate if so required.

Fo
r

inf

or
m

at
ion

See also Manual B, Chapter .1

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

13

D3

3.2.4.

Single Function Tests

Nozzles, Roll Cooling, Descaling


Visual check of nozzles.

on

ly

Checks to be made:
Jet direction, spray angle of nozzles, proper application of nozzle jet to the part
to be sprayed, sufficient spray jet intensity and attachment of spray nozzles.

Fo
r

inf

or
m

at
ion

The reference values are contained in the technical data or rather equipment arrangement drawing.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

14

D3

3.2.5.

Single Function Tests

Shear Knife Gap


Visual check of shear knife gap

ly

Checks to be made:
Spacing between the closed shear knives.

at
ion

on

Check will be made by use of a feeler gauge. Shear knives to be brought into cutting position in the absence of material and with due consideration to safety instructions. During measurement, the tooth backlash must be eliminated in a possibly existing shear gear unit whereupon the knife gap is checked for compliance
with the reference value range by inserting a feeler gauge into the knife gap. If the
knife gap is not within the specified range, it must be corrected using shims.

Fo
r

inf

or
m

The reference value is indicated in the technical data or rather equipment arrangement drawing.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

15

D3

3.2.6.

Single Function Tests

Pass Line and Roll Gap


Visual check of pass line

on

ly

Checks to be made:
Horizontal and vertical alignment of the machines and devices involved in the
rolling process.

Visual check of roll gap

at
ion

The pass line will be checked by use of a Theodolite. The check will be made with
reference to the measuring points for the longitudinal and transversal axes as well
as to the level marks as determined during the design, mechanical manufacture,
construction of foundations and field-assembly. How these measurements are to
be carried out in practice is described in detail in Chapters 1.3 to 1.6 of this Erection Manual.

Checks to be made:
Distance between top and bottom roll.

or
m

The roll gap will be measured through measurements of the work roll positions by
means of a position transducer at the mill stand in connection with the electrical
control. In case of mill stands without roll gap control, these measurements will
take place by means of a feeler gauge directly in the roll gap. The demanded roll
gap dimension will be input at the electrical control system.

inf

For checking, the bottom or the top work roll will be positioned to the required level
in the mill stand by use of the respective mechanical, vertical adjustment or, if not
available, by means of shims and with due consideration to the pass line, as a
function of the design.
The other work roll in each case will then be moved to the proper height in the mill
stand by means of the hydraulic or rather mechanical, vertical adjusting system so
that the desired roll gap is produced. For this purpose, the position control of the
electrical control system is used when hydraulic vertical adjustments take place.

Fo
r

Subsequently, a feeler gauge can be pushed between the top and bottom roll for
finding out the actual dimension.
Measurements to be made on the drive and operator side of the stand to ensure
that the top and bottom rolls are parallel.
To compensate a possible clearance in the top roll adjusting system, the top roll
balancing system must be active.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

16

D3

3.2.7.

Single Function Tests

Vertical Adjustment
Visual check of the adjusting system

ly

Checks to be made:
Traversing stroke of top or rather bottom roll

at
ion

on

The vertical adjustability of the top or rather bottom roll will be checked for which
purpose the respective rolls will be moved into the upper or rather bottom end position by means of the hydraulic or mechanical vertical adjusting system. The other
end position in each case is not allowed to be reached while the traversing stroke
of the vertical adjusting system is being performed as otherwise the top roll will
contact the bottom roll and could damage same.

Fo
r

inf

or
m

In case of hydraulic vertical adjusting systems, the vertical shifting stroke is


checked by means of an electro-hydraulic position control, i.e. through position
measurements by position transducers at the mill stand.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

17

D3

3.2.8.

Single Function Tests

CVC Shifting Device


Visual check of the CVC shifting device

on

ly

Checks to be made:
Axial shifting stroke of the top and bottom work roll in connection with the hydraulic system.
For checking the axial shifting stroke, the shifting blocks of the CVC equipment
have to be coupled in their operator-side end positions with the roll chocks through
a hydraulically shift able bolt.

at
ion

Only in coupled position can the work rolls axially be shifted according to the requirements of the CVC technology.
Coupling has been effected unobjectionably only when the end position of the roll
set, after having been shifted into the stand, exactly accords with the End Position
Operator Side of the shifting blocks.

or
m

For checking the axial shifting stroke of the work rolls, the hydraulic system with its
pump is switched on through the electrical control system and, with due consideration to the safety instructions, shifting strokes are manually performed via the electrical control. At the same time the shifting stroke and the shifting position are being measured by a magnetostrictive position transducer at the mill stand and compared with the demanded set value or rather reference value for checking.

Fo
r

inf

The max. shifting stroke is indicated in the technical data, the equipment arrangement drawing or rather in the plant layout.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

18

D3

3.2.9.

Single Function Tests

Adjustment of Mechanical Equipment such as Rest Bar, Mill Guides etc.


In the mechanical equipment, adjustments and positions are visually checked.

Fo
r

inf

or
m

at
ion

on

ly

Checks to be made:
Set values stated in the technical data and possibly in the equipment arrangement drawing. Part of the set values will also result from the desired rolling program. The set values and positions of the mechanical equipment will be
checked for their reference value range using measuring rulers, slide gauges,
feeler gauges, test mandrels, visual or rather electronic measuring and testing
devices etc. dependent on the requirement of the respective test procedure.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

19

D3

3.2.10.

Single Function Tests

Stand Clamping
Both the mechanical and the hydraulic systems of the stand clamping device will
be visually checked.

on

ly

Checks to be made:
Opening and closing of the stand clamping mechanism.

Fo
r

inf

or
m

at
ion

The first step is to open the stand clamping device by pressurization. It will be
checked if the clamping device is fully opened and thus allows the stand housing
to be shifted or rather removed. Then, the clamping device is disconnected from
the hydraulic pressure and relieved. If existing, the other connection is then pressurized for closing the clamping device. There is to be checked whether the
clamping faces of the housing and the stand clamping device have closed. This
check can additionally be made by use of a feeler gauge. Even the thinnest feeler
gauge is not allowed to be inserted between the closed clamping faces.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

20

D3

3.2.11.

Single Function Tests

Grease Systems, Control and Function


Grease systems are subjected to a visual check.

ly

No check of the pump pressure and control system is necessary in case of manually driven grease systems.

on

Checks to be made:
Overall function of the manual grease system.

When operating the grease pump, check some grease points for escape of
grease.

at
ion

In case of automatic, electrically driven grease systems the electrical control system is switched on and the automatic operation switched off for checks. Thereafter, the first half of the greasing cycle is initiated manually.

or
m

Checks to be made:
Pump pressure on pump pressure gauge;
Grease distributors (visual check) for escape of grease in the connected grease
points. However, in each half greasing cycle only half of the grease points connected to a grease distributor are greased as a function of system design.
The limit pressure switches by disconnecting the grease pump when the set absolute operating limit pressure is attained at the main line end or the required
differential pressure between the two main lines at the line end.
Immediately after automatic switch-off of the grease pump through the limit
pressure switch, the system operating pressure can be read on the pressure
gauge at the main line end.

inf

After a pause of at least half an hour, the second half of the greasing cycle is
started manually. Same as in the first half of the greasing cycle, Items 1 to 4 will
again be checked, but this time for the other main line.

Fo
r

In grease facilities in the progressive system the check of Items 3 and 4 and of the
second half of the greasing cycle is omitted.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

21

D3

3.2.12.

Single Function Tests

Strokes of Hydraulic Cylinders, Lifting Speed and Cushioning


Check of technical data and set values of the hydraulic cylinders will be done visually.

at
ion

on

ly

Checks to be made:
Cylinder stroke by approaching the two cylinder end positions by means of the
switched-on hydraulic control. In both end positions the extension length of the
piston rod is measured by use of a measuring ruler. The difference between the
values results in the cylinder stroke. Due to the machine design it is not possible to move all hydraulic cylinders into their stroke end positions. In these cases
it is not necessary to check the cylinder stroke.
Stroke speed. It is calculated from the time for one cylinder stroke and the
length of the cylinder stroke. The time needed to perform a cylinder stroke is
measured by means of a stop watch.
End position damping will be checked visually. The reduction of the stroke
speed in the cylinder end positions is distinctly recognizable with correct setting
of the damping.

Fo
r

inf

or
m

The reference values are indicated in the technical data or rather equipment arrangement drawing.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

22

D3

3.2.13.

Single Function Tests

Maintenance Unit for Compressed Air


Visual check of maintenance unit for compressed air.

Fo
r

inf

or
m

at
ion

on

ly

Checks to be made:
Operating pressure according to technical data or rather system diagram. The
operating pressure is read on the pressure gauge. If this pressure is not within
the reference value range it can be corrected by setting the compressed air reducing valve.
Filter contamination and water separation can be checked after shutoff of the
compressed-air feed and the opening of the filter.
Oil metering in oiler. The number of drops must be set such that about one drop
of oil per minute is dispensed. The right oil volume can be checked in that one
piece of clean white paper is held against the vent port of a way valve for the
duration of 3 to 4 switch cycles. The silencer is to be removed for this purpose.
The paper must then feature a slight decolouration.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

23

D3

3.2.14.

Single Function Tests

Strokes of Compressed Air Cylinders, Stroke Speed and Cushioning


Checking of technical data and set values of the pneumatic cylinders is visual.

at
ion

on

ly

Checks to be made:
Cylinder stroke by approaching both cylinder end positions by means of the
switched-on pneumatic control. In both end positions the extension length of the
piston rod will be measured by use of a measuring ruler. The difference between the values produces the cylinder stroke. Due to the machine design it is
not possible to move all pneumatic cylinders into their stroke end positions. In
these cases, the cylinder stroke need not be checked.
Stroke speed. It is calculated from the time for one cylinder stroke and the
length of the cylinder stroke. The time needed to perform a cylinder stroke is
measured using a stop watch.
End position damping will be checked visually. The reduction of the stroke
speed in the cylinder end positions is distinctly recognizable with correct setting
of the damping.

Fo
r

inf

or
m

The reference values are indicated in the technical data or rather product arrangement drawing.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

24

D3

3.2.15.

Single Function Tests

Check of Pressure Limiting Valves for Compliance with Preset Pressure


Visual check of the opening pressure set on the pressure limiting valve
(safety valve).

at
ion

on

ly

Checks to be made:
At which oil pressure in the hydraulic system or rather in the lube-oil recirculation system the pressure limiting valve opens. The pressure reference value is
stated in the technical data or rather system diagram.
A deviating pressure set value might be determined and set during trial operation and later during commissioning in order to adapt the opening pressure to
the operating conditions of the hydraulic system or rather the lube-oil recirculation system.
It is reasonable to check the opening pressure on an appropriate test stand. If
there is none this test can also be carried out by a short-time increase of the
system operating pressure.
For checking the opening pressure at the pressure limiting valve, a pressure
measuring instrument featuring an appropriate measuring range is connected to
the corresponding test-point connection by means of a hose with Test-point coupling.

or
m

Then, the pump of the hydraulic system or rather the lube-oil recirculation system
is switched on through the electrical control system. On this, the set system operating pressure can be read on the pressure measuring instrument and recorded.

inf

To assess the set opening pressure of the pressure limiting valve, the previously
read and recorded system operating pressure = pump pressure is slowly and cautiously increased by raising the operating pressure setting for the pump until the
pressure limiting valve opens.
In so doing care has to be taken to ensure that the max. admissible operating
pressure of all incorporated hydraulic devices and pipelines will not be exceeded
to avoid damage to the hydraulic system.

Fo
r

The opening of the pressure limiting valve is audibly distinguished by flowing


noises since opening is accompanied by heavy noise emission. Moreover, valve
opening is recognized by the fact that the pressure indicated by the pressure meter does not increase any further despite rising of the operating pressure setting
for the pump.
Now, the pressure setting of the pressure limiting valve on the pressure meter can
be read and recorded.
Prior to disconnecting the hydraulic system or rather the lube-oil recirculation system, the system operating pressure has to be reset to the normal operating pressure assessed at the commencement of the measurements.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

25

D3

3.2.16.

Single Function Tests

Pressure Setting of Pumps


Visual check of pressure setting at the pressure-controlled main pumps.

ly

Checks to be made:
Operating pressure in hydraulic system

on

The operating pressure reference value is indicated in the technical data or rather
system diagram.
A deviating pressure set value might be determined and set during trial operation
and later during commissioning in order to adapt the operating pressure to the operating conditions of the hydraulic system.

at
ion

For checking the operating pressure in the hydraulic system a pressure measuring
instrument featuring an appropriate measuring range is first connected to the corresponding test-point connection by means of a hose with test-point coupling.

Fo
r

inf

or
m

Then, the hydraulic system pump is connected with the electrical control system.
On this, the set operating pressure = pump pressure will be read on the pressure
measuring instrument and recorded.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

26

D3

3.2.17.

Single Function Tests

Switch Elements at Oil Tank, Fill Level Indicator, Temperature


Visual check of electrical switch elements.

on

ly

Checks to be made:
The mechanical function and, if necessary in this conjunction, the electrical
function of the electrical switch elements as stated with due consideration to the
technical data contained the set values and positions possibly indicated in the
equipment arrangement drawing.

Fo
r

inf

or
m

at
ion

For this purpose the relevant switch points have to be approached, if possible, and
the response behaviour of the switch-off device to be checked. In case of conspicuous switches the function can be checked by means of a light-emitting diode
at the switch. If the function is not conspicuous, the proper function can be tested
in the terminal box locally or at the light-emitting diode of the centralized PLC. If
this is not possible either, the electrical specialist can check this function by making measurements or on the display of the plant control pulpit. During testing, special care will be taken to ensure conflict- and collision-free functioning of the transducers and sensors with regard their attachments.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

27

D3

3.2.18.

Single Function Tests

Filter: Differential Pressure


Visual check of differential pressure at filter.

on

ly

Checks to be made:
Filter contamination by check of the electrical differential pressure switch or a
mechanical clog-up indicator at the filter casing.

Fo
r

inf

or
m

at
ion

For the purpose of checking the differential pressure, the respective system with
the associated pump is switched on via the electrical control system. On response
or changeover of the electrical differential pressure switch (pilot lamp) or if and
when the indicator is within the red range in case of mechanical clog-up indication, it will be necessary to clean or change the filter. If duplex filters are used,
change-over to the other filter cartridge can be made.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

28

D3

3.2.19.

Single Function Tests

Oil Cooler: Water Flow


Check by sensor of the water flow in the oil cooler.

ly

Checks to be made:
Water flow in oil cooler.

on

For the purpose of checking the water flow, the cooling water system and the hydraulic system with its associated pumps have to be connected via the electrical
control system.

at
ion

When the hydraulic system has reached its operating temperature, the cooling water feed to the oil cooler will be opened via the electrical control system either
automatically or manually.
For water flow checking, the temperature will then be measured outside at the
cooling water lines by use of a contact thermometer or even by hand.
If and when the temperature of the cooling water return line is distinctly higher than
the temperature of the cooling water feed line, water flow is ensured.

Fo
r

inf

or
m

If the operating temperature in the hydraulic system has not been attained, a
screw joint in the cooling water return line of the oil cooler can be somewhat
slackened cautiously as an alternative to check the water flow. If cooling water escapes under pressure, water flow is ensured.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

29

D3

3.2.20.

Single Function Tests

Accumulator: Pre-Fill Pressure


Visual check of the nitrogen pre-fill pressure in the accumulator.

on

ly

Checks to be made:
Nitrogen pressure in the hydraulic accumulator relieved by the hydraulic system
service pressure.
To check the nitrogen pre-fill pressure the first step is to close the oil-pressure-side
shutoff valve at the safety shutoff block whereupon the oil pressure relief valve will
be opened at the safety shutoff block. Now, the accumulator oil side is discharged
by the leak oil line in the tank.

Fo
r

inf

or
m

at
ion

On this, the accumulator fills and test device on top at the nitrogen connection of
the accumulator is connected. Now, the pre-fill pressure can be read at the pressure meter of the fill and test device and compared with the reference value in the
technical data or rather the system diagram. If necessary, the pressure can also
be corrected using the fill and test device by refilling or discharging nitrogen.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

30

D3

3.2.21.

Single Function Tests

Controls and Functions of the Hydraulic Systems


Visual and/or electromechanical function checks of the solenoid valves and/or the
proportional valves and servo valves.

on

ly

Checks to be made:
Way valves: the alternating stroke movements of the respective hydraulic cylinder. Proportional valves and/or servo valves: the stroke speed and/or the position control of the respective cylinder.

at
ion

It is convenient, however, to check the hydraulic valves on a suitable test stand. If


no such stand is available, the hydraulic valves can be checked in installed state,
too.
For checking the way valves, the hydraulic system is cut on with its pump via the
electrical control. Then the way valve to be checked is actuated manually under
special observance of the safety instructions via the electrical control and monitored to test the alternating stroke movement of the associated hydraulic cylinder.
If the function of a valve is not selectable separately, appropriate aids are to be
used for triggering, as a substitute even hand operation of the valve.

or
m

The hydraulic system is cut on with its pump via the electrical control likewise for
checking the proportional valves and servo valves.
As regards those valves that control the cylinder stroke speed, cylinder strokes are
manually performed via the electrical control under special observance of the
safety instructions. For checking, the stroke speed of the hydraulic cylinder is
monitored by means of a stopwatch. The stroke speed is calculated from the time
needed for one cylinder stroke and the length of the latter.

inf

In case of valves which cause a position control, the position actual value is
measured, when the position control has been cut on, by use of suitable electronic
and/or visual measuring facilities, and is for checking compared with the demanded set point and/or nominal value.

Fo
r

The stroke speed or the position set point is indicated in the Technical Data, in the
Equipment Arrangement Drawing and/or in the Plant Layout and may also depend
on the selected production program.
During trial operation and later during start-up, yet possibly deviating valve setting
values have been and/or will be fixed and set in order to tune the valves to the operating conditions of the hydraulic system.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

31

D3

3.2.22.

Single Function Tests

Electrical Switching Elements, Pressure Transducers, Pressure


Switches etc.
Visual check of electrical switching elements.

ly

Checks to be made:

on

The mechanical function and, if necessary in this connection, the electrical function of the electrical switching elements as stated with due consideration to the
technical data, contained the set values and possibly indicated in the equipment
arrangement drawing.

at
ion

To this end, the relevant switching points are, if possible, to be approached and
the response of the cut-off equipment to be tested. As regards observable
switches, the function can be checked by means of the LED on the switch. Should
the function not be observable, the proper function can be tested in the terminal
box locally or at the LED of the centralized PLC. If this fails to be possible as well,
then the person in charge of the electrics may check that function by way of
measurement or on the display of the plant control. Particular attention should be
paid to conflict- and collision-free function of the transducer and sensor attachment.

or
m

In case of pressure switches for example, the following features are checked:
the correct fixture of the pressure switch
the switching-pressure presetting
the tightness against the escape of media
the pressure switching points

inf

A check is made as to the oil pressure in the hydraulic system at which the pressure switch will be operative. The pressure set point is stated in the Technical
Data and/or in the Plant Layout.

Fo
r

During trial operation and later during start-up, a yet possibly deviating pressure
setting value will be fixed and set in order to tune the pressure switching points to
the operating conditions of the hydraulic system.
It is convenient to check the pressure switches on a suitable test stand. If no such
stand is available, the check can also take place through short-time boosting of the
operating pressure of the system.
For checking the pressure switching points at the pressure switch, a pressure
measuring device with a suitable measuring range is connected by means of a
hose with test-point coupling to the corresponding test-point connection.
Following this, the pump of the hydraulic system is cut on with the electrical control. Thereafter, the set operating pressure of the system may be read at the pressure measuring device and recorded.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

32

D3

Single Function Tests

So as to establish the set pressure switching points of the pressure switch, the
previously read and recorded system operating pressure = pump pressure is
slowly and carefully increased by way of raising the operating-pressure setting for
the pump until the pressure switch has become operative.

on

ly

When doing so, it is to be observed that the admissible maximum operating pressure of all installed hydraulic devices and pipelines will not be exceeded to avoid
damage to the hydraulic system.
Now the switching-pressure setting of the pressure switch can be read and recorded at the pressure measuring device.

Fo
r

inf

or
m

at
ion

The operating pressure of the system has, prior to cutting-off of the hydraulic system, to be reset to the regular operating pressure determinate at commencement
of the measurements.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

33

D3

3.2.23.

Single Function Tests

Lubricating-Oil Compact Unit: Filter, Pressure, Temperature


Visual check of filter, pressure and temperature of the compact unit
(lube-oil recirculation system).

on

ly

Checks to be made:
The contamination inside the filter of the compact unit.
Also see the check: Filter: Differential pressure.
The operating pressure in the lubricating-oil circulation system.

The pressure set point is indicated in the Technical Data and/or in the
Plant Layout.

at
ion

During trial operation and later during start-up, a yet possibly deviating pressure
setting value will be fixed and set in order to tune the operating pressure to the
operating conditions of the machines (consumers).
Measurements of the operating pressure in the lube-oil recirculation system are effected by the firmly integrated operating pressure measuring system of the lube-oil
recirculation system.

or
m

For checking, the lube-oil recirculation system with its pump is switched on
through the electrical control system whereupon the system operating pressure
can be read on the pressure-measuring device, and recorded.

inf

If there is no such firmly integrated pressure measuring device available at the


lube-oil recirculation system, a pressure measuring device with a suitable measuring range is, for checking of the operating pressure in the lube-oil recirculation system, connected to the corresponding test-point connection by means of a hose
with test-point coupling and the operating pressure read thereon.
The operating temperature of the lube-oil recirculation system.

Fo
r

The temperature set point is stated in the Technical Data and/or in the Plant
Layout. For checking the operating temperature of the lubricating-oil circulation
system, the system with its pump is cut on via the electrical control and the
temperature measured at the outside of the oil-tank wall after lapse of several
hours of oil circulation by use of a contact-type thermometer. Should the lubricating-oil circulation system avail of a firmly installed temperature measuring
device, the operating temperature can also be read there.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

34

D3

3.2.24.

Single Function Tests

Pressure Tank: Pressure


Visual check of the pressure in the pressure tank.

on

ly

Checks to be made:
The oil pressure in the pressure tank of the lubricating-oil circulation system
when having been cut on.
The pressure set point is indicated in the Technical Data and/or in the Plant
Layout.

at
ion

During trial operation and later during start-up, a yet possibly deviating pressure
setting value will be fixed and set in order to tune the operating pressure of the
pressure tank to the operating conditions of the machines (consumers).
Measurements of the operating pressure in the pressure tank of the lube-oil recirculation system are effected by the firmly integrated operating pressure measuring
system at the pressure tank.
For checking, the lube-oil recirculation system with its pump is switched on
through the electrical control system whereupon the operating pressure in the
pressure tank can be read on the pressure-measuring device, and recorded.

Fo
r

inf

or
m

If there is no such firmly integrated pressure measuring device available at the


pressure tank, a pressure measuring device with a suitable measuring range is, for
checking of the operating pressure in the pressure tank, connected to the corresponding test-point connection by means of a hose with test-point coupling, and
the operating pressure in the pressure tank read thereon.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

35

D3

3.2.25.

Single Function Tests

Separator: Cup Assembly, Run-off Diameter, Temperature, Safety Device


Visual check of the separator.

ly

Checks to be made:
The faultless mounting of the cup assembly and its balancing.

on

To check the cup assembly, the hood of the drum is opened and the correct installation as well as a the visual condition of the cup assembly are inspected in
accordance with the Operating and Maintenance Instruction. Following this, the
hood must be reclosed carefully.

at
ion

For checking the balancing, the separator is cut on via the electrical control and
examined as to vibrations. Should abnormal vibrations or noises occur, the machine is to be cut off at once.
The temperature of the oil feed as well as the temperature between flow-heater
and separator drum.
The heating and the oil feed to the flow-heater are cut on to check the temperature of the oil feed. The separator drum has to be switched on previously.

inf

or
m

For checking the temperature of the oil feed, the temperature is then measured
at the outside of the oil feed pipe to the separator, either by use of a contacttype thermometer. Should a firmly installed temperature measuring device be
available at the flow-heater, the temperature of the oil feed to the separator can
also be read there. The reference value of the separating temperature is about
90 C - 100 C. Attention: risk of burning!
The brake as a safety device.

Fo
r

For checking the brake, the separator is cut on via the electrical control and cut
off as soon as the operating speed has been achieved. The brake is applied
immediately upon cutting-off of the separator. When the brake is operating
properly, the run-out time of the drum will be intensely shortened, thus passing
the critical speed of the drum faster.
Notice:
For all checks, the operating instructions of the separator have to be
additionally adhered to.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

36

D3

3.2.26.

Single Function Tests

Oil Pressure at the Consumers


Visual check of the operating pressure at the machines (consumers).

on

ly

Checks to be made:
The operating pressure of the lubricating-oil circulation system at the machines
(consumers).
The pressure set point is indicated in the Technical Data and/or in the Plant
Layout.

at
ion

During trial operation and later during start-up, a yet possibly deviating pressure
set point will be fixed and set in order to tune the operating pressure to the operating conditions of the machine (consumers).
Measurements of the operating pressure at the machine (consumers) are effected
by the firmly integrated pressure measuring system at the machine (consumers).
For checking, the lube-oil recirculation system with its pump is switched on
through the electrical control system whereupon the operating pressure at the machine (consumers) can be read on the pressure-measuring device, and recorded.

Fo
r

inf

or
m

If there is no such firmly integrated pressure measuring device available at the


machine (consumers) , a pressure measuring device with a suitable measuring
range is, for checking of the operating pressure at the machine (consumers), connected to the corresponding test-point connection by means of a hose with testpoint coupling, and the operating pressure read thereon.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

37

D3

3.2.27.

Single Function Tests

Water-Inlet Alarm Device


Visual check of the electrical switching elements of the water-inlet alarm device.

on

ly

Checks to be made:
The mechanical function and, if necessary in this connection, the electrical function of the electrical switching elements as stated with due consideration to the
technical data, contained the set values and possibly indicated in the equipment
arrangement drawing.

Fo
r

inf

or
m

at
ion

To this end, the relevant switching points are, if possible, to be approached and
the response of the cut-off equipment to be tested. As regards observable
switches, the function can be checked by means of the LED on the switch. Should
the function not be observable, the proper function can be tested in the terminal
box locally or at the LED of the centralized PLC. If this fails to be possible as well,
then the person in charge of the electrics may check that function by way of
measurement or on the display of the plant control. Particular attention should be
paid to conflict- and collision-free function of the transducer and sensor attachment.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

38

D3

3.2.28.

Single Function Tests

Pneumatic Compact Unit: Filter, Pressure, Temperature


Visual Check of filter, pressure and temperature of the compact unit.

on

ly

Checks to be made:
The contamination inside the filter of the compact unit.
Also see the check: Filter: Differential Pressure.
The operating pressure of the pneumatic system.

The pressure set point is indicated in the Technical Data and/or in the Plant
Layout.

at
ion

During trial operation and later during start-up, a yet possibly deviating pressure
setting value will be fixed and set in order to tune the operating pressure to the
operating conditions of the pneumatic system.
For checking the operating pressure in the pneumatic system, a pressure measuring device with a suitable measuring range is connected by means of a hose with
test-point coupling to the corresponding test-point connection.

or
m

Following this, the pneumatic system with its compressor is cut on via the electrical control. Thereafter, the operating pressure of the system may be read at the
pressure measuring device and recorded.
Since the compact unit avails of a firmly installed pressure measuring device, the
operating pressure can also be read there.
The compressed-air temperature of the pneumatic unit.

Fo
r

inf

A maximum temperature figure might be specified in the Technical Data and/or


in the Plant Layout. For checking the temperature of the pneumatic unit, the
system with its compressor is cut on via the electrical control and the temperature measured at the outside of the wall of the compressed-air accumulator after lapse of several hours either by use of a contact-type thermometer or by
hand. Should the compressed-air accumulator avail of a firmly installed temperature measuring device, the temperature can also be read there.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

39

D3

3.2.29.

Single Function Tests

Hydraulic Lines as to Up tightness


Visual check of the hydraulic pipelines.

ly

Checks to be made:
As to any escape of hydraulic oil.

Fo
r

inf

or
m

at
ion

on

For this purpose, the oil-filled and vented hydraulic-oil lines are pressurized with
operating pressure through switch-on of the pump. Weld seams, screw joints and
connections to pumps, hydraulic cylinders and control elements are especially
critical locations.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

40

D3

3.2.30.

Single Function Tests

Compressed-Air Lines as to Up tightness


Acoustical check of the compressed-air lines.

ly

Checks to be made:
As to inadmissible escape of compressed air.

Fo
r

inf

or
m

at
ion

on

Uptight locations can be recognized by a sizzling noise. To this end, the compressed-air lines are pressurized. Weld seams, screw joints and connections to
pneumatic cylinders and control elements are especially critical locations.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

41

D3

3.2.31.

Single Function Tests

Water Lines as to Up tightness


Visual check of the water pipelines.

ly

Checks to be made:
As to inadmissible escape of water.

Fo
r

inf

or
m

at
ion

on

To this end, the water-filled and vented water lines are pressurized through switchon of the pump. Weld seams, screw joints and connections to nozzles and control
elements are especially critical locations.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

42

D3

3.2.32.

Single Function Tests

Grease Lines as to Up tightness


Visual check of the grease pipelines.

ly

Checks to be made:
As to inadmissible escape of grease.

on

To this end, the grease-filled and vented grease lines are pressurized through
switch-on of the pump. Screw joints and connections to grease metering blocks
and control elements are especially critical locations.

Fo
r

inf

or
m

at
ion

Also see the test features: Grease Systems, Control and Function.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

43

D3

3.2.33.

Single Function Tests

Oil-Lubricating Lines as to Up tightness


Visual check of the oil-lubricating pipelines.

ly

Checks to be made:
As to inadmissible escape of lubricating oil.

Fo
r

inf

or
m

at
ion

on

To this end, the oil-filled and vented oil-lubricating lines are pressurized through
switch-on of the pump. Weld seams, screw joints and connections to control elements are especially critical locations.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

44

D3

3.2.34.

Single Function Tests

Process Section

The components listed are to be checked as under:

ly

The function trial runs/tests as described below are generally applicable to various
components of the process section. A complete list of all components providing
important additional info is in each case given after each chapter.

Condensate discharge device


Direction of mounting to be checked

B...

Vessels and tanks


Vessels/tanks to be checked inside for cleanliness

E...

Q... Agitators
Agitator vanes to be checked for freedom of movement

F...

Filters and strainers


Filter inserts/strainers to be checked for cleanliness/damage

H...

Ball valve (manually operated)


Manual function (Open/Close) to be checked
Limit switch operation possibly to be checked

H...

Ball valve (pneumatically operated)


Electric (switching) function to be checked
Emergency/manual function to be checked
Limit switch operation to be checked (LED)
Switching speed to be preset (2 sec.)

at
ion

or
m

inf

Measuring and switching devices


Presetting of measuring range to be checked
Zero point to be checked/adjusted if so required
Local display to be checked for readability and function.
Special Function Tests of Measuring and Switching Devices
(details in each case given in Manual C of the relevant
manufacturer).
Measurements of conductivity, empty tube calibration,
pH measurement, calibration of probe, level switch/overfill
measuring instrument, switch point to be tested (dismounting,
plunge into vessel, LED), flow sensors I 3500, 3505, 3510,
function to be tested after dismounting, flow and temperature
monitor to be checked, switch point setting to be checked

Fo
r

I...

on

A...

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

45

D3

Single Function Tests

Butterfly valves (hand lever)


Manual function test (open/close)
Limit switch operation to be checked if required

K...

Butterfly valves (pneumatically operated)


Electric (switching) function , function, freedom of movement to be
checked
Emergency/Manual function to be checked
Limit switch operation to be checked
Switching speed to be preset (5 sec. each direction)
Position indication to be checked

K...

Butterfly valves (driven by electric motor)


Butterfly valves to be opened/closed via local remote control
Check to see if in Close direction the Butterfly Valve Closed limit
switch is operated before the torque switch
Manual function to be checked
Position indication to be checked

P...

Pumps
No pump test to be carried out without medium in the pump!
Check of rotational sense of motor with disconnected pump only!

R...

Check valves
Direction of mounting to be checked
Feeding screw
Sense of rotation to be checked
Freedom of movement to be checked

or
m

inf

T...

at
ion

on

ly

K...

Valve in general
Checks to be made analogously to butterfly valves (K...)
VT... Fan
Fan to be started, pressure build-up to be checked
Vibration monitoring to be checked if required
VT... Vacuum pump
No test without medium, test to be carried out during commissioning of
the evaporator
W... Measurement of weight
Zero balance to be carried out with empty tanks

Fo
r

V...

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

46

D3

Certificate and Report of Completion of Erection

Fo
r

inf

or
m

at
ion

on

ly

3.3.

Single Function Tests

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

47

D3

Single Function Tests

Drawing-No.

Remarks

Fo
r

inf

or
m

at
ion

on

Contract Item / Equipment Designation /


Functional Unit

ly

Certificate of Completion of Erection

Confirmation:

Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

It is hereby confirmed that above-mentioned equipment / functional


units have been completely delivered and installed in line with
associated drawings, documents and contract-specification.
Purchaser / Inspector:

Stand / Revision

2010

Seller:

Index

--

Blatt / Sheet

48

D3

Single Function Tests

Report on the end of erection

SMS Siemag Aktiengesellschaft

ly

Customer:

57271 Hilchenbach

Contractor:

on

Wiesenstrasse 30

...................................................

at
ion

...................................................
...................................................

Agreement item:
Plant designation:

......................................

or
m

SMS Siemag Code:

......................................

SMS Siemag Order No.


SMS Siemag Order

......................................

No.

......................................

inf

dated ......................................

It is hereby certified that the overall erection has been carried out
with the exception of the cases listed below
...................................... and

Fo
r

in accordance with our Order No.


the pertaining drawings.

Adherence to deadlines
The erection was completed on ...............
The contractually stipulated date was ..............
This results in an erection delay of ............... days.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

49

D3

Single Function Tests

Acceptance reports
The acceptance reports for all machines for which a report had to be prepared

ly

have been submitted and have been signed by the site manager of the erection

on

company and the site manager of SMS Siemag.

Functional tests

at
ion

All functional tests have been carried out. The corresponding reports have been
submitted and have been signed by the site manager of the erection company and
the site manager of SMS Siemag.

or
m

Outstanding work

According to the list of outstanding items dated ................................

Warranty

Fo
r

inf

The warranty period begins on................................

............................., ................................

_______________________

_______________________
On behalf of SMS Siemag

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

50

D3

3.4.

Single Function Tests

Checklist of Water quality and - quantity.

Media: Cooling water system DC 2 (direct cooling water)


Flow sheet draw. No.:____________

m3/h

measurement:

m3/h

Pressure:
design:

at
ion

Water data of supply line


Flow rate:
design:

on

Item No.:___________

ly

Checking and Regulation of Water quality and - quantity.


During functional tests the water quantities have to be checked and regulated at
the T.O.P. and at the valves of hot strip mill.

bar ()

measurement:

m3/h

or
m

Water data of return line


Flow rate:
design:

bar ()

measurement:

m3/h

Pressure:
design:

bar ()

measurement:

bar ()

Fo
r

inf

A sample of the water of hot strip mill send for checking to SMS SIEMAG Hilchenbach / AWW or to a local laboratory or clients WTP - laboratory.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

51

D3

Single Function Tests

Checking and Regulation of Water quality and -quantity.


During functional tests the water quantities have to be checked and regulated at
the T.O.P. and at the valves of hot strip mill.

ly

Media: Cooling water system DC 3 (direct cooling water)


Flow sheet draw. No.:____________

m3/h

measurement:

m3/h

Pressure:
design:

bar ()

measurement:

at
ion

Water data of supply line


Flow rate:
design:

bar ()

m3/h

measurement:

m3/h

or
m

Water data of return line


Flow rate:
design:

Pressure:
design:

on

Item No.:___________

measurement:

bar ()

bar ()

Fo
r

inf

A sample of the water of hot strip mill send for checking to SMS SIEMAG Hilchenbach / AWW or to a local laboratory or clients WTP - laboratory.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

52

D3

Single Function Tests

Checking and Regulation of Water quality and -quantity.


During functional tests the water quantities have to be checked and regulated at
the T.O.P. and at the valves of hot strip mill.

ly

Media: Cooling water system DC 4


(laminar cooling, indirect cooling water)
Flow sheet draw. No.:____________

m3/h

measurement:

m3/h

Pressure:
design:

at
ion

Water data of supply line


Flow rate:
design:

bar ()

measurement:

bar ()

m3/h

measurement:

m3/h

or
m

Water data of return line


Flow rate:
design:

Pressure:
design:

on

Item No.:___________

measurement:

bar ()

bar ()

Fo
r

inf

A sample of the water of hot strip mill send for checking to SMS SIEMAG Hilchenbach / AWW or to a local laboratory or clients WTP - laboratory.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

53

D3

Single Function Tests

Checking and Regulation of Water quality and -quantity.


During functional tests the water quantities have to be checked and regulated at
the T.O.P. and at the valves of hot strip mill.

ly

Media: Cooling water system IC 4 (indirect cooling water)


Flow sheet draw. No.:____________

m3/h

measurement:

m3/h

Pressure:
design:

bar ()

measurement:

at
ion

Water data of supply line


Flow rate:
design:

bar ()

m3/h

measurement:

m3/h

or
m

Water data of return line


Flow rate:
design:

Pressure:
design:

on

Item No.:___________

measurement:

bar ()

bar ()

Fo
r

inf

A sample of the water of hot strip mill send for checking to SMS SIEMAG Hilchenbach / AWW or to a local laboratory or clients WTP - laboratory.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

54

D3

Single Function Tests

Checking and Regulation of Water quality and -quantity.


During functional tests the water quantities have to be checked and regulated at
the T.O.P. and at the valves of hot strip mill.

ly

Media: Cooling water system DC 7


(roll gap lubrication, direct cooling water)
Flow sheet draw. No.:____________

m3/h

measurement:

m3/h

Pressure:
design:

at
ion

Water data of supply line


Flow rate:
design:

bar ()

measurement:

bar ()

m3/h

measurement:

m3/h

or
m

Water data of return line


Flow rate:
design:

Pressure:
design:

on

Item No.:___________

measurement:

bar ()

bar ()

Fo
r

inf

A sample of the water of hot strip mill send for checking to SMS SIEMAG Hilchenbach / AWW or to a local laboratory or clients WTP - laboratory.

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

55

D3

Check List for Functional Tests

Fo
r

inf

or
m

at
ion

on

ly

3.5.

Single Function Tests

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

56

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

Lubrication to lube instructions

on

Item No.:

ly

Mechanical Equipment

not appl.

Remarks

at
ion

Electrical motors sense of rotation

or
m

Strokes of hydraulic cylinders, stroke


rates and cushioning
Strokes of compressed air cylinders,
stroke rates and cushioning
Compressed air unit
Electrical facilities such as proximity
switches, limit switches, brakes, photocells, etc.
Hydraulic pipelines for leak test
Compressed air lines for leak test
Water lines for leak test

inf

Grease lines for leak test

Lube oil lines for leak test

Fo
r

Nozzles, roll cooling, etc.

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

57

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

Lubrication to lube instructions

on

Item No.:

ly

Mill Stand

not appl.

Remarks

Pass line and roll gap


Radial screw down

at
ion

Electrical motors sense of rotation

or
m

Vertical adjustment
Strokes of hydraulic cylinders, stroke
rates and cushioning
Strokes of compressed air cylinders,
stroke rates and cushioning
Compressed air unit
Electrical facilities such as proximity
switches, limit switches, brakes, photocells, etc.
Hydraulic pipelines for leakage

inf

Compressed air lines for leakage


Water lines for leakage

Grease lines for leakage

Fo
r

Lube oil lines for leakage


Nozzles for de-scaler box, roll cooling,
etc.
Adjustment of mechanical equipment
such as rest bars, mill guides, etc.
Basic adjustment of spindle chairs
Stand and roll clamping

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

58

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

not appl.

Remarks

or
m

at
ion

Electrical motors sense of rotation


Pressure limiting valves for specified
pressure
Pump pressure setting
Switching elements on oil tank:
Level indication
Temperature
Filter:
Differential pressure
Oil cooler:
Water flow volume
Accumulator:
Pre-charge pressure
Controls and functions

on

Item No.:

ly

Hydraulic Equipment

Hydraulic lines for leakage

Fo
r

inf

Water lines for leakage


Electrical switching elements:
Pressure transducer
Pressure switch
Position transducer
Limit switch
Water alarm
Water ingress alarmed device

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

59

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

Lube oil lines for leakage

not appl.

Remarks

at
ion

Electrical motors sense of rotation

on

Item No.:

ly

Oil Lubrication System

Compressed air lines for leakage

inf

or
m

Water lines for leakage


Switching elements on oil tank:
Level indication
Temperature
Compact unit:
Filter
Pressure
Temperature
Pressure tank:
Pressure
Compressed air for instruments
Separator:
Plate pack, outgoing dia
Temperature
Safety facilities
Oil pressure at consumers

Fo
r

Water ingress alarm device

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

60

D3

Single Function Tests

Check List for Functional Tests

Equipment:

Compressed air lines for leakage

not appl.

Remarks

inf

or
m

Compressed air unit:


Filter
Pressure
Lubricator

yes

at
ion

CHECK

on

Item No.:

ly

Pneumatic System

Fo
r

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

61

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

not appl.

Remarks

or
m

at
ion

Electrical motors sense of rotation


Pressure limiting valves for specified
pressure
Pump pressure setting
Switching elements on tank:
Level indication

on

Item No.:

ly

Grease Equipment

Controls and functions

inf

Grease lines for leakage

Note: Technical Data see Manual - B.


Buyer:

Fo
r

Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

62

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

Hydraulic pipelines for leakage

on

Item No.:

ly

Piping

not appl.

Remarks

Water lines for leakage


Grease lines for leakage

inf

or
m

Lube oil lines for leakage

at
ion

Compressed air lines for leakage

Note: Technical Data see Manual - B.


Buyer:

Seller:

Fo
r

Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

63

D3

Single Function Tests

Check List for Functional Tests

Equipment:

CHECK

yes

Lubrication to lube instructions

on

Item No.:

ly

Water Pumps

not appl.

Remarks

at
ion

Electrical motors sense of rotation

or
m

Electrical facilities such as proximity


switches, limit switches, brakes, photocells, etc.

inf

Water lines for leakage

Fo
r

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

64

D3

Single Function Tests

Equipment:

yes

not appl.

Remarks

Fo
r

inf

or
m

at
ion

CHECK

on

Item No.:

ly

Check List for Functional Tests

Note: Technical Data see Manual - B.


Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

Buyer:

Seller:

Stand / Revision

2010

Index

--

Blatt / Sheet

65

D3

Certificate for Preliminary Acceptance Test

Fo
r

inf

or
m

at
ion

on

ly

3.6.

Single Function Tests

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet

66

D3

Single Function Tests

Drawing-No.

Remarks

Fo
r

inf

or
m

at
ion

on

Contract Item / Equipment Designation /


Functional Unit

ly

Preliminary Acceptance Certificate

Enclosures:

Confirmation:

Date:

Auft.-Nr. / Order No.

A00226 / MAADEN

This is to confirm that above mentioned equipment / functional units


were completely supplied, installed and tested in accordance with the
Contract
Purchaser / Inspector:

Stand / Revision

2010

Seller:

Index

--

Blatt / Sheet

67

D4

Erection Time Schedule

Fo
r

inf

or
m

at
ion

on

ly

4. Erection Time Schedule

Auft.-Nr. / Order No.

A00226 / MAADEN

Stand / Revision

2010

Index

--

Blatt / Sheet