D-Erection Manual Vol.1 of 2 Maaden TCM A00226 Rev.0. 2011

ERECTION MANUAL (D)

for

4-stand Tandem Cold Mill

Saudi Arabia

Dsseldorf and Hilchenbach, Germany

Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet A00226.580 / MAADEN 2011 -- 1

Customer / User: Maaden - Alcoa

Ras Az Zawr

Kingdom of Saudi Arabia

Contract: A6RM-4-1002-00 / A6RM100009

Plant: 4-stand Tandem Cold Mill

Year of Supply: 2012

T y p e s o f M a n u a l s

A - Operating Manual Volume

B - Equipment Manual Volume

C - Sub suppliers` Components Manual Volume

D - Erection Manual Volume 1 of 2


Instruction for Erection Volume 1. General Information for Erection 1

2. Erection Measuring Reports 2

3. Single Function Test 1

4. Erection Time Schedule 1

The erection manual is a guideline only and has to be adapted to actual conditions in the field.

In case of changes this manual will not be considered.

Table of contents


Table of contents

1. General Information for Erection 1

1.1. General Safety Requirements 2 1.1.1. Safety Instructions for Erection, Commissioning, Operation and Maintenance

2 1.1.2. Safety Signs 6 1.1.3. Safety at Site 14 1.1.4. Transfer of risk for fire protection systems 22

1.2. Preconditions for Erection to Start 23

1.3. Plant Surveys 24

1.4. Foundation Surveys 30 1.4.1. Report on foundation acceptance 35

1.5. 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 1.10.1. Execution of fitting work 63 1.10.2. Bending 80 1.10.3. Welding 81

1.11. Chemical Cleaning of Steel Pipes 84

1.12. Stainless Steel Pipes 88

1.13. Chemical cleaning of steel pipes by the immersion process 92

1.14. Flushing of pipelines for oil circulation and hydraulic systems 96

1.15. Preassembly of Machines and Components 110

Table of contents


1.16. Pipeline Identification Letters Used for Various Utilities in the Drawings 111

1.17. Mounting Instructions in Drawings 112

1.18. Aligning and Tightening torque for couplings (Information given by Company FLENDER) 113

1.19. Release for Machine Grouting / Open Package Inspection 115

1.20. Heavy-Duty Cranes and Transport Facilities 118

1.21. Tools, Appliances and Auxiliaries 119

1.22. Appendix 165 1.22.1. Example of Pickling Scheme in Recirculation Process (ZS) 166 1.22.2. Example of Pickling Scheme in Recirculation Process (Hydraulic power

system) 167 1.22.3. Simplified representation in drawings 168 1.22.4. Drawings and bill of material for flushing plates conformable SMS SIEMAG

drawings 169 1.22.5. Off-loading of Mill Housing from flat bottomed vehicle and Positioning 181 1.22.6. Off-Loading of a Mill Housing from well wagon and positioning 183

3. Single Function Tests 1

3.1. Precondition for Tests 2 3.1.1. Mechanical Equipment 3 3.1.2. Hydraulic Systems (Cylinders, Hydraulic Motors) 4 3.1.3. Pneumatic Systems (Cylinders, Pneumatic Motors) 5 3.1.4. Oil Lube Systems 6 3.1.5. Grease Systems 7 3.1.6. Cooling Water Systems 8 3.1.7. High-Pressure Water System 9

3.2. Procedure of Tests 10 3.2.1. Sense of Rotation of Electric Motors 11 3.2.2. Electrical Devices such as Proximity Switches, Limit Switches, Brakes,

Photocells etc. 12 3.2.3. Lubrication to Lube Instructions 13 3.2.4. Nozzles, Roll Cooling, Descaling 14 3.2.5. Shear Knife Gap 15

Table of contents


3.2.6. Pass Line and Roll Gap 16 3.2.7. Vertical Adjustment 17 3.2.8. CVC Shifting Device 18 3.2.9. Adjustment of Mechanical Equipment such as Rest Bar, Mill Guides etc. 19 3.2.10. Stand Clamping 20 3.2.11. Grease Systems, Control and Function 21 3.2.12. Strokes of Hydraulic Cylinders, Lifting Speed and Cushioning 22 3.2.13. Maintenance Unit for Compressed Air 23 3.2.14. Strokes of Compressed Air Cylinders, Stroke Speed and Cushioning 24 3.2.15. Check of Pressure Limiting Valves for Compliance with Preset Pressure 25 3.2.16. Pressure Setting of Pumps 26 3.2.17. Switch Elements at Oil Tank, Fill Level Indicator, Temperature 27 3.2.18. Filter: Differential Pressure 28 3.2.19. Oil Cooler: Water Flow 29 3.2.20. Accumulator: Pre-Fill Pressure 30 3.2.21. Controls and Functions of the Hydraulic Systems 31 3.2.22. Electrical Switching Elements, Pressure Transducers, Pressure Switches etc.

32 3.2.23. Lubricating-Oil Compact Unit: Filter, Pressure, Temperature 34 3.2.24. Pressure Tank: Pressure 35 3.2.25. Separator: Cup Assembly, Run-off Diameter, Temperature, Safety Device 36 3.2.26. Oil Pressure at the Consumers 37 3.2.27. Water-Inlet Alarm Device 38 3.2.28. Pneumatic Compact Unit: Filter, Pressure, Temperature 39 3.2.29. Hydraulic Lines as to Up tightness 40 3.2.30. Compressed-Air Lines as to Up tightness 41 3.2.31. Water Lines as to Up tightness 42 3.2.32. Grease Lines as to Up tightness 43 3.2.33. Oil-Lubricating Lines as to Up tightness 44 3.2.34. Process Section 45

3.3. Certificate and Report of Completion of Erection 47

3.4. Check List for Functional Tests 51

3.5. Certificate for Preliminary Acceptance Test 62

4. Erection Time Schedule 1

D 1 General Information for Erection


1. General Information for Erection



1.1. General Safety Requirements

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

1.1.1. Safety Instructions for Erection, Commissioning, Operation and Maintenance

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.

Accident prevention rules should be conspicuously displayed in a position which is accessible to everyone working in the plant. Additional instruction should be pro-vided 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 Man-uals A, B, C and D. The provisions furnished by the electrical equipment suppli-er(s) shall apply in regard to all electrical equipment.

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

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.



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 suit-ably trained personnel.

When the machine is in operation, operators must constantly be pre-sent in its associated control pulpit or station. User will moreover see to it that unauthorized persons will be kept away from the plant.

Function checks, maintenance work: User is obliged to have the plant inspected, at least once per shift, for

externally recognizable damages and deficiencies. Changes discov-ered that may affect equipment dependability and safety shall be re-ported and made good without delay.

User to take care that the plant will be operated while in unobjectiona-ble 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.

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 pur-poses and should be duly refitted after work has been finished.



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 stat-

ed on signs.

Transport, Slinging: Only such transport facilities will be used which are suitable for the in-

tended purpose and which are in unobjectionable state and condition (chains, ropes, suspension gears).

All rigging or hang-on aids provided should definitely be used (eye-bolts, lugs).

Moving or loose parts on equipment should be reliably secured for transport.

Communication with the crane operator by one person only.

Working Platforms: No maintenance and repair work shall be allowed to be performed un-

less 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 inter-vals.

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.

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

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.



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 compo-nents.

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.

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.

Safety Equipment for Operating Personnel All persons assigned to any job within the plant will have to wear suitable pro-

tective garments. Instruction by the safety officer in each case.



1.1.2. Safety Signs

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 ar-eas throughout the plant.

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 inter-vals, but at least once a year.

The responsibility for posting such signs shall rest with the plant user.

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



Prohibitive signs

No smoking Fire, open flame and smoking prohibited

No pedestrians

Unauthorized per-sons keep off

No access for per-sons with pacemak-er

Extinguishing with water prohibited

No drinking water Prohibited for floor vehicles

Do not deposit or store



Warning signs

Warning: inflammable sub-stances

Warning: substances explosive

Warning: poisonous substances

Warning: corrosive substances

Warning: radioactive substances

Warning: loads passing substances

Warning: transport vehicles passing

Warning: high voltage

Warning: dangerous area

Warning: danger of crushing

Warning: danger of laser beam



Mandatory signs

Wear goggles Wear protective helmet

Wear ear muffle Wear respirator

Wear safety shoes Wear protective gloves

For pedestrians Use crossover



Rescue signs

Indication of first aid Side stretcher

Arrow of direction * for first-aid-kits

Escape route

Escape route Emergency exit

* This arrow of direction shall be used only in connection with another rescue sign for first-aid-kits



Information signs

Indication of fire extinguisher DIN 4066 Signs identifying permanent hazard areas

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.



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

Material: AlMg3F23

Type: Manufactured to SEO and / or screen printing method, white background, black characters;

With fixing holes Size to be determined by user

Cutout and Reconnection of drives

Date: Time:

Demand - Cutoutof following drives

1. 2. 3. 4. 5. 6. 7. 8. 9.10.

Request by

Effected bySignature Function

Signature Function

Date: Time:

Demand - Reconnectionof following drives

1. 2. 3. 4. 5. 6. 7. 8. 9.10.

Request by

Effected bySignature Function

Signature Function



Warning Plate:

Fixed by 3 chain links on every barrier chain, additionally screwed or hooked on walls and equipment.

Weld on railing or equipment Fixed to foundation with dowel

Barrier Chain

300

270 15

12

150

15 Attention!

Hazardous Area

Admittance after Operator's Permission!

3 thick

10 10

36

Stretched Length 164

45

M 1

0

60 18 10 36

R 16 Stretched Length 172

10



1.1.3. Safety at Site

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 regula-tions and will be distributed to all the SMS SIEMAG field staff.

Responsibility for Safety Our board of management is conscious of its duty to care for and protect the safe-ty 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 compre-hensive cooperation, we aim at creating and maintaining as safe and healthy working conditions as possible.

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 in-structions 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 au-thorized 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 car-ried out. They take care that the work is done with due observance of the regula-tions 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.



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 plat-forms!

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 contain-ers, sanitary facilities and canteens!

The conditions at site change almost daily. Protect yourself and others by constant vigilance!

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.



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 appropri-ate personal safety outfits have to be made available and have to be worn.

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!

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!

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. Moreo-

ver, other sources of danger have to be considered which may arise in the respective working area.



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.

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 ab-solutely 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 pro-tective measures are to be used.

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 fol-lowing 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 protec-tive devices have been fitted.

Grinding bodies are allowed to be clamped only on grinding or abra-sive 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.



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 tem-porary.

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

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.

Scaffolds

Scaffolds are to be installed and maintained by a specialist company. Besides the legally prescribed acceptances by a competent supervi-sory 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 con-struction 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.



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 fit-ted, the fall of persons or the dropping down of subjects must be pre-vented by providing safety (catcher) stands, protective walls or catcher nets which substantially extend up to immediately under-neath 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 in-crease the safety of persons working in that area or passing under-neath.

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

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 exten-sion 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 ma-

terials



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 al-lowed to be used! Dangerous matters are:

lye solutions acids degreasing agents and solvents bitumen, tear, pitch PUR painting and insulation materials

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

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 su-pervisor 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.

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

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 acci-dent. The senior site manager/site manager is responsible for documentation of the notification of accident.



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

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.

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

Special requirements of the customer for fire protection are to be adhered to strict-ly.

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.

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



1.1.4. Transfer of risk for fire protection systems

(To be carried out prior to the hot commissioning of "First Coil") 1. Confirmation Of the readiness for operation of all envisaged and installed fire alarm systems and fire extinguish-

ing systems. The Customer Represented by Ms./Mr. hereby confirms that the

fire alarm systems and fire extinguishing systems envisaged and installed for safe hot commissioning of the plant (plant section) Designation:

Are ready for operation. Date

Signature of Customer Signature of SMS SIEMAG AG 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 Date: Time: for the following plants / plant sections Designation:

shall be transferred to the Customer and assumed by him Date:

Signature of Customer Signature of SMS SIEMAG AG



1.2. Preconditions for Erection to Start

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 com-

pleted erection and after placing the grouts for main equipment.

Bay Cranes: Bay cranes will be made available in ready-to-operate condition, in-

cluding 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.

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 equip-ment components and interim storage thereof, if any.

Availability of qualified erection personnel in adequate number. Availability of erection tools and consumables.



1.3. Plant Surveys

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.

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

Drawing symbols used and their meaning:

Figure 1: Axis Mark A - A for Longitudinal axes Axis Mark B - B for Transversal axes

Figure 2: Elevation benchmarks

Figure 3: Levelling screws

Figure 4: Foundation Recess for Protection Box Required points are shown on sketches of axis plan and erection measuring re-ports.

The locations of axis and elevation points will be laid down in a drawing by pur-chaser.

Any other axes and elevation points necessary for foundation checks and machine erection will be determined during field erection (Figure 10 - Figure 13).



Figure 5: Axis Mark (without Protection Box)

100

7

82 16



Figure 6: Elevation Benchmarks and Axis Marks with Protection Box and Levelling Spindle

Legend: 1) Grout

2) Epoxy Resin with Quartz Sand 3) Concrete

Figure 7:

260

120

150

100

50

1

2

3

1



Figure 8: Protection Box

Figure 9: Elevation Benchmark and Axis Mark

140

115

120

150

200

55

80

8

55 m

in

85 m

ax



Figure 10: Setting of Centrelines by means of Theodolit

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

A

B C

D

E

A B C D E

A E

B

C

D



Figure 12: Setting of auxiliary Axis by means of Theodolit

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

90

B B

B B

A A

A

A

B B



1.4. Foundation Surveys

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 ac-ceptance page 35.

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 corre-

sponding 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.

It is recommendable to assort the foundation bolts provided in each case with ref-erence 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.

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

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.



Figure 14: Foundation Check

Legend: 1) Measuring Rod 2) Dumpy level / Transit

A

B B

A

1

2



Figure 15: Measuring of Anchor Hole Depth

Legend: 1) Measuring Rod

Figure 16: Surveys to determine the Position of Anchor Bolts

Legend: 1) Reference Point

1

1



Figure 17: Piano Wire fitting Rig 20

00

8001000

Figure 18: Batter board

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

1

2

3

4



Figure 19: Device to receive Piano Wire

Legend: 1) Piano Wire

10

0

1



1.4.1. Report on foundation acceptance



Report on foundation acceptance

Area according to SMS SIEMAG foundation drawings

Foundation meets requirements

Foundation does not meet requirements

Description of defects / Comments:

Elimination of defects by (date)

Date SMS SIEMAG site man-

agement Customer / Buyer Executed by



1.5. 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).

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

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.

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

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



Figure 20: Chipping of Foundation Surfaces

Legend: 1) Bush Hammer

Figure 21: Arrangement of Shim Plates

Legend: 1) Anchor Hole 2) Shim Plates

Figure 22: Shim Plates

1

600

1 2



Figure 23: Formwork for Level Compensation

Figure 24:

Legend: 1) Handle

140

120

60 m

ax

20 m

in

1



Figure 25:

Legend: 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!

Figure 26:

Legend: 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!

1

2

3

4

5

1

2

3

5

4



Figure 27:

1

2

4

6

5

3

Legend: 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!

Alignment work in mill stands Prepare foundation Shim plates

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 mate-rial is absolutely plane and ready for receiving the shim plates (Figure 26).



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

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.

Alignment of housings.



1.6. 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.

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

On this, the machine or equipment unit concerned will be levelled/aligned to de-fined 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.)

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 ini-tial grouts to three quarters of their height. The machine or equipment unit con-cerned will be finish levelled / finish-aligned after the grout has cured.

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



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

7

8

10

9

0

3

4

A

A

B

B

B

A

12

6

Legend: 1 10 = Measuring Points

1 + 6 = Parallelism 2 = Position 3 + 4 = Coordinate Measurement 7 = Distance Dimension 8 = Levelling 9 = Horizontal Plane 10 = Flatness = Benchmarks = Axis Marks



Figure 29: Measurement of Couplings

Legend: 1) Misalignment

Figure 30:

Legend: 1) Feeler Gauges

1

1



Figure 29 b: Adjustment of couplings with laser units Adjustment of coupled and uncoupled shafts

Adjustment of horizontal, vertical and flange-mounted machines Adjustment of cardan and intermediate shafts

Adjustment of machine lines

Figure 29 b

Copyright by Prftechnik Dieter Busch AG ( Is not in SMS SIEMAG scope of supply )



1.7. Placing Under grouts

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 compe-tent 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.

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 firm-ly 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.

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 mate-rial.

All anchor bolts will have to be retightened and checked for tight fit after the under grout has cured.

Release for Machine Grouting see: Chapter 1.17.



Examples of Application for Machine grouting:

Figure 31:

Legend for Figure 31 and Figure 32: 1) Machine part 2) Shims 3) Formwork 4) Foundation 5) Grout 6) Funnel

Figure 32:

1

2

3

4

5

6

1

5

3

2

4



Figure 33:

Legend: 1) Machine part

2) Shims 3) Formwork 4) Foundation 5) Grout

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 ad-vance.

Formwork Tightly secure and seal.

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 evapora-tion.

4

2 1

5

3



1.8. Storage, Slinging, Load Table and Unpacking of Supplied Equipment

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.

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

Figure 34: Fragile Figure 35: Use no hand hooks

Figure 36: This way up Figure 37: Keep away from sunlight

Figure 38: Keep away from rain Figure 39: Centre of gravity



Figure 40: Do not roll Figure 41: Do not use hand truck here

Figure 42: Use no forks Figure 43: Stacking limit by mass

Figure 44: Clamp as indicate Figure 45: Do not clamp as indicated

Figure 46: Sling here Figure 47: Temperature limits

....kg max



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

Self - supporting type of packing

Figure 48: Figure 49:

Depending type of packing

Figure 50: Figure 51:

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 certifi-cate (see Chapter 1.17.). Storage after unpacking: Mechanical equipment - Indoor, dry Electrical equipment - Indoor, dry, air conditioned Structural - Outdoor



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.

Rope Rated

Diameter

mm

Load Capacity in kg Single Strand Double Strand

with inclination angle

from 0 to 45 from 45 to 60

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

560 850 1250 1700 2240 2800 3550 4250 5000 6000 6700 9000

11200 14000 17000 20000 23600 26500 31500

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

45 60



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.

Rope Rated

Diameter

mm

Load Capacity in kg Single Strand


directly from 0 to 45 from 45 to 60

24 27 30 33 36 39 42 48 54 60

3150 4000 4750 6000 7100 8000 9500

12500 16000 19000

4500 5600 6700 8500

10000 11200 13200 18000 22400 26500

3150 4000 4750 6000 7100 8000 9500

12500 16000 19000

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 frac-

tures in strand ropes or more than 10 wire fractures in cable slinging ropes.

Damage or heavy wear of the ropes or rope-end joints.

45 60



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 %.

Fibr

e m

ater

ial Rope

Rated Diameter

mm



directly braided from 0 to 45

from 45 to 60

Pol

yest

er

16 20 24 28 32 36 40 48

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

Pol

ypro

pyle

ne

16 20 24 28 32 36 40 48

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

45 60



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.

Fibr

e m

ater

ial

Rope Rated

Diameter

mm


with inclination angle directly braided from 0

to 45 from 45

to 60

Man

ila

16 20 24 28 32 36 40 48

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

Hem

p

16 20 24 28 32 36 40 48

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

45 60



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.

Additionally to be applied to chemical fibre ropes:

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



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.

Chain Nominal

Thickness

mm

Load Capacity in kg in Straight strand Single Strand

Double Strand With inclination angle

Three- and Four Strand With inclination angle

from 0 to 45

from 45 to 60

from 0 to 45

from 45 to 60

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

500 1000 2000 3200 5000 8000

10000 12500 15000 20000 25000 32000 40000 50000 63000

700 1400 2800 4500 7100

11200 14000 18000 21200 28000 35500 45000 56000 71000 90000

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

--- ---

750

1500 3000 4750 7500

11800 15000 18000 22400 30000 37500 47500 60000

--- ---

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 uni-form, the admissible load of the individual strands must not be exceeded.

45 60 45 60



Load Tables for Round Steel Chains in Grade Class 8

Chain Nominal thickness

mm

Load Capacity in kg in Lasso position

Single Strand Double Strand with inclination

from 0 to 45 from 45 to 60

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

400 800 1600 2500 4000 6300 8000

10000 12000 16000 20000 25000 32000 40000 50000

560 1120 2240 3550 5600 9000

11200 14000 17000 22400 28000 35500 45000 56000 71000

400 800 1600 2500 4000 6300 8000

10000 12000 16000 20000 25000 32000 40000 50000

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).

45 60



1.9. Consumables Needed During Erection

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. KVA

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

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

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.

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).



Arc Welding Stick electrodes, diameter:

2.50 mm 3.25 mm 4.00 mm 5.00 mm

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).

Shielded Arc Welding Welding rods, diameter:

1.6 mm 2.0 mm 2.4 mm 3.0 mm

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).

Cored Wire Welding Cored wire electrodes, diameter

1.6 - 2.8 mm

Cored wire electrodes to DIN EN 440

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 cus-tomer 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.



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

200 x 100 x 30

200 x 100 x 25

200 x 100 x 20

200 x 100 x 15

200 x 100 x 10

200 x 100 x 5

200 x 100 x 2

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



1.10. Fitting, bending and welding of piping

1.10.1. Execution of fitting work

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 connec-tions are therefore inevitable.

A distinction is made between: welded and thus fixed connections and pipe couplings that can be separated.

A piping network has to be manufactured and installed diligently since the reliabil-ity of a media supply system depends upon the quality of the design of the net-work. 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.

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.

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 considera-tions.

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 instal-lation.



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

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 pene-trate into the piping system. Piping and components must be delivered to the place of installation in a properly closed state.

During the progress of the installation work the connections of the pipes and com-ponents 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 sys-tem that may take place after the installation work.

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.



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.

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.

Only applies for hydraulic oil circulation systems and special cases



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.

Depending on the connection we distinguish at SMS SIEMAG between: screw connections, compression-ferrule pipe couplings, welding-nipple pipe couplings and flanged connections.

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



Fitting of connection pipe/pipe coupling Screw connection (Figure 53)

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)

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 func-tions. 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



Welding-nipple pipe coupling (Figure 55)

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.

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

weld seam



Fitting of connection pipe coupling/component In these pipe couplings the holding function between the coupling and the compo-nent 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) 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. Normally the threads are however glued in with sealing material, e.g. with Loctite. The sealing function is then in the thread. The fitting instructions of the coupling makers and of the sealing-material maker must be observed.

Figure 56: Coupling body with sealing edge,

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



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

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.

Figure 58: NPT thread,

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



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.

(1) Gasket to DIN 2690 Figure 59: Flange with sealing, holding function by bolts

1



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.

SAE flange one-part (Figure 60)

The one-part SAE flange is made in one piece. Different weld-on plugs for vary-ing 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. The fitting instructions of the flange maker must be observed.

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



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. 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. 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. 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



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

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.

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).

Figure 63: Compensator for flange connection



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.

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.

Rubber compensators should be protected against radiation and heat and if nec-essary 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.

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.



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 sys-tems.

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

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!

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!

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

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

Figure 65: Examples for correct laying of hose lines



Fitting of pipe supports Supports are used to secure piping efficiently. Pipe clamps are made of steel, al-uminium, plastic or plastic with a rubber lining.

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

Figure 66: Pipe clamp, heavy-duty series



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



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.

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

Figure 68: Substructure to receive piping system Identification of valves, measuring devices etc. Valves, measuring devices etc. are identified in the flow diagrams (process sche-matics, 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 ident- number, be labelled provisionally during the fitting of the piping (immediately after fitting) by means of adhesive tape for example.



1.10.2. Bending

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.



1.10.3. Welding

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

Table 1 ( SN 200 Part 4):

Wall

thickness t

Designation

Illustration Shape of groove

Weld joint preparation

Section View Depth of

weld seam s

Dimensions Approximates

Butt-

type

join

t

to 2

Square butt weld

s = t b 2 - 3

over 2

to 20

Single V butt weld

c

bt

s = t

b 2 5

c

To 2

60

over 20

Single U butt weld

r

bct

s = t

b 2 5

c To 2

r 4

10

over 20

Steep-flanked

single V butt weld

b

t

s = t

b 6 10

10

Com

er jo

int

all

Single J butt weld

t

c

b

s = t

b 2 5

c To 2

30 - 40

all

Fillet weld

t

t

s = t

Note: 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.



Welding Processes Gas welding (oxyacetylene welding)

Gases: Oxygen O2 + acetylene C2H2 Filler metal: compatible with pipe material.

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

No weld preparation, however with gap corresponding to filler rod diameter. Back-hand 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).

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.

Inert Gas Welding Tungsten inert gas welding, in brief TIG.

Welding gas argon/helium (purity 99 %). Filler rod selected under the aspect of comp

Documents

D-Erection Manual Vol.1 of 2 Maaden TCM A00226 Rev.0. 2011