Professional Documents
Culture Documents
MAADEN
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Contract:
Plant:
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Year of Supply:
Types of Manuals
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A - Operating Manual
Volume
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B - Equipment Manual
Volume
D - Erection Manual
Volume
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Table of contents
Table of contents
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1
2
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1.1.
1.1.1.
1.1.2.
1.1.3.
1.1.4.
1.1.5.
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1.
1.2.
23
1.3.
Plant Surveys
24
1.4.
Foundation Surveys
35
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1.4.1.
30
37
1.6.
43
1.7.
47
1.8.
50
1.9.
60
63
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1.5.
1.10.1.
1.10.2.
1.10.3.
63
80
81
84
1.12. Flushing of Pipelines for Closed Circuit Lube Oil and Hydraulic Systems
95
109
1.14. Pipeline Identification Letters Used for Various Utilities in the Drawings
110
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1.16. Aligning and Tightening torque for couplings (Information given by Company
FLENDER)
112
114
117
1.20.3.
1.20.4.
164
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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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2.
3.
Mechanical Equipment
Hydraulic Systems (Cylinders, Hydraulic Motors)
Pneumatic Systems (Cylinders, Pneumatic Motors)
Oil Lube Systems
Grease Systems
Cooling Water Systems
High-Pressure Water System
3
4
5
6
7
8
9
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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.
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Table of contents
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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.
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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.
47
3.4.
51
3.5.
56
3.6.
66
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1.1.
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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.
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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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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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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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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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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.
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1.1.2.
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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
Extinguishing with
water prohibited
Do not deposit or
store
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No pedestrians
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No smoking
No drinking water
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Warning:
poisonous
substances
Warning:
radioactive
substances
Warning:
loads passing
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Warning:
corrosive
substances
Warning:
substances
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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 goggles
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For pedestrians
A00226 / MAADEN
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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Escape route
Emergency exit
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Information signs
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Indication of
fire extinguisher DIN 4066
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Board indicating cut-out and reconnection requirements for drives during repair or
no production shifts
Time:
Date:
Time:
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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
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Request by
Effected by
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Material:
Type:
A00226 / MAADEN
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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30
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27
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Attention!
Hazardous Area
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150
15
12
15
3 thick
10
60
18
M 10
45
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10
10
36
10
R 16
Stretched Length 172
36
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1.1.4.
Safety at Site
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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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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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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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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
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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.
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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.
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Mobile Gear
Only authorized drivers are permitted to operate the mobile gear. This also relates
to the staff of the subcontractors.
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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
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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.
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For all accidents first aid is to be rendered immediately and the superior to be informed without delay who will possibly initiate rescue measures.
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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.
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Fire Protection
Suitable fire extinguishers are made available at site for fire protection.
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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.
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Observe No Smoking signs and do not use any matches or other open flame
near inflammable materials.
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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.
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1.1.5.
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1. Confirmation
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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
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hereby confirms
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Signature of Customer
It is hereby confirmed,
that the responsibility for the fire alarm systems and fire extinguishing systems as from
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Date:
for the following plants / plant sections
Time:
Designation:
Signature of Customer
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1.2.
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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.
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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.
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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.
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1.3.
Plant Surveys
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Elevation benchmarks will be fitted on operator and drive side to fix all elevation
points (referred to plant floor).
Figure 2:
Elevation benchmarks
Levelling screws
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Figure 3:
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Figure 1:
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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).
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Figure 5:
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100
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82
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Figure 6:
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260
50
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100
1) Grout
2) Epoxy Resin with Quartz Sand
3) Concrete
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Legend:
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Figure 7:
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150
120
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Figure 8:
Protection Box
140
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120
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115
150
200
Figure 9:
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8
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55 min
85 max
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55
80
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Figure 11: Setting of Centrelines using Piano Wire and Plumb Bob
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C
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Figure 13: Setting of auxiliary Axis using Piano Wire and Plumb Bob
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1.4.
Foundation Surveys
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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.
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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.
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Legend:
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1) Measuring Rod
2) Dumpy level / Transit
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Legend:
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1) Measuring Rod
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Legend:
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1) Reference Point
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10
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2000
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Legend:
A00226 / MAADEN
1) Lock up Band
2) Piano Wire
3) Adjustable Device for taking up of Piano Wire
4) Plumb Bob
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1) Piano Wire
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Legend:
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1.4.1.
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Customer / Buyer
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1.5.
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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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
37
D1
ly
Legend:
at
ion
on
1) Bush Hammer
inf
or
m
1) Anchor Hole
2) Shim Plates
Fo
r
Legend:
600
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
38
D1
140
Fo
r
inf
Figure 24:
or
m
20 min
60 max
at
ion
120
on
ly
Legend:
A00226 / MAADEN
1) Handle
Stand / Revision
2010
Index
--
Blatt / Sheet
39
D1
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:
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
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
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).
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
41
D1
Wedges.
Here, the procedure can be similar to that described Shim plates(Figure 27).
Insert anchor bolts.
at
ion
on
ly
Fo
r
inf
or
m
Alignment of housings.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
42
D1
1.6.
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
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).
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
43
D1
on
ly
at
ion
10
inf
or
m
1 10
1+6
2
3+4
7
8
9
10
Fo
r
Legend:
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
inf
Figure 30:
1) Misalignment
or
m
Legend:
at
ion
on
ly
Fo
r
Legend:
A00226 / MAADEN
1) Feeler Gauges
Stand / Revision
2010
Index
--
Blatt / Sheet
45
D1
on
ly
Fo
r
inf
or
m
at
ion
Figure 29 b
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
46
D1
1.7.
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
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
47
D1
on
ly
at
ion
1) Machine part
2) Shims
3) Formwork
4) Foundation
5) Grout
6) Funnel
inf
Figure 32:
or
m
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
48
D1
Figure 33:
2
Legend:
at
ion
on
ly
1) Machine part
2) Shims
3) Formwork
4) Foundation
5) Grout
or
m
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
49
D1
1.8.
ly
inf
or
m
at
ion
on
The standard signs shown on all packages are to be observed for storage and
slinging of cases.
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
50
D1
on
ly
at
ion
....kg max
inf
or
m
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
51
D1
Irrespective of the packing medium used, distinction will made between two basic
types of packing for shipment:
at
ion
on
ly
Figure 48:
Figure 49:
inf
or
m
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
A00226 / MAADEN
Stand / Revision
2010
Indoor, dry
Indoor, dry, air conditioned
Outdoor
Index
--
Blatt / Sheet
52
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
53
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
54
D1
ly
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
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
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
56
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
57
D1
ly
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
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
58
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
59
D1
1.9.
on
KVA
ly
at
ion
or
m
Note:
Water consumption may increase to three to four times the above figure during
chemical cleaning of pipelines.
inf
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).
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
60
D1
Arc Welding
Stick electrodes, diameter:
ly
2.50 mm
3.25 mm
4.00 mm
5.00 mm
on
1.6 mm
2.0 mm
2.4 mm
3.0 mm
at
ion
or
m
inf
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
61
D1
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
Packers for bed plates of mill housings refer to SMS SIEMAG drawing:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
62
D1
1.10.
1.10.1.
on
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
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
63
D1
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
64
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
65
D1
on
ly
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).
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
66
D1
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
67
D1
at
ion
on
ly
Fo
r
inf
or
m
Figure 55: Welding-nipple coupling with cone, elastic sealing, holding function by
weld seam
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
68
D1
ly
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
69
D1
at
ion
on
ly
inf
or
m
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
70
D1
at
ion
on
ly
Fo
r
inf
or
m
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
71
D1
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
Fo
r
inf
or
m
Figure 60: SAE flange, one-part with O-ring, holding function by bolts
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
72
D1
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
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
73
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
74
D1
on
ly
at
ion
Outer layer
(2) Inner layer
(3) Flange with profile collar
(4) Flange with full profile
Figure 64: Compensator for flange connection
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
75
D1
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
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
76
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
77
D1
Fo
r
inf
or
m
at
ion
on
ly
Figure 67: Clamp stack, e.g. for two pipes arranged one above the other
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
78
D1
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
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
79
D1
1.10.2.
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
80
D1
1.10.3.
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
Square butt
weld
to 2
all
Illustration
on
Wall
thickness Designation
t
ly
s=t
t
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
81
D1
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
inf
Pipeline must be purged with antis lag gas to the following criteria to protect pipe
inner walls and root passes.
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
82
D1
on
ly
Figure 69:
inf
Figure 70:
or
m
Socket welding
at
ion
Fo
r
Note!
SMS SIEMAG does not apply to socket welding!
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
83
D1
1.11.
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
or
m
inf
ON70 (BASF):
1%
10 kg/m3
0,3 %
3 kg/m3
Ammonia NH3OH:
0,9 %
9 kg/m3
0,3 %
3 kg/m3 or
0,5 %
5 kg/m3
55 kg/m3 or
55 kg/m3
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
84
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
85
D1
on
ly
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
86
D1
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
87
D1
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
88
D1
at
ion
on
ly
or
m
Fo
r
inf
The process actually adopted will depend on technical design of the pipe
systems.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
89
D1
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
Degreasing
Acid
Inhibitor
inf
or
m
Pickling Process
Stand / Revision
2010
Index
--
Blatt / Sheet
90
D1
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
A00226 / MAADEN
Degreasing
Acid
inf
or
m
Pickling Process
Stand / Revision
2010
Index
--
Possibly Purge
using Nitrogen or
compressed Air
(No Oxygen!)
Blatt / Sheet
91
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
92
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
93
D1
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.
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).
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
94
D1
1.12.
Flushing of Pipelines for Closed Circuit Lube Oil and Hydraulic Systems
on
ly
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
95
D1
ly
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
at
ion
Fo
r
inf
or
m
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
96
D1
inf
or
m
at
ion
on
ly
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
97
D1
ly
on
at
ion
Fo
r
inf
or
m
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
98
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
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
Blatt / Sheet
99
D1
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
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
100
D1
ly
300
C
on
200
12/9
at
ion
100
(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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
101
D1
at
ion
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
102
14
14
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
15
06
01
Fo
r
06
01
D1
General Information for Erection
Stand / Revision
Index
--
Blatt / Sheet
103
D1
on
ly
2
G
A00226 / MAADEN
Fo
r
inf
or
m
Flow Direction
at
ion
Stand / Revision
2010
Index
--
Blatt / Sheet
104
D1
A00226 / MAADEN
on
Flow direction
Fo
r
inf
or
m
at
ion
ly
Pump station
supply
Stand / Revision
2010
Index
--
Blatt / Sheet
105
D1
A00226 / MAADEN
on
G
B
Flow direction
Fo
r
inf
or
m
at
ion
ly
Tank
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
A00226 / MAADEN
RI 1 ED x 1 1/2
RI 1 ED x 1 1/2
RI ED x 1 1/2
Stand / Revision
2010
GAV 16 x 2/GAV 25 x 3
GAV 30 x 3/GAV 30 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
GAV 38 x 3/GAV 38 x 3
AFB 2 - 6
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
AFP 2 - 3
at
ion
TV 38 x 6
TV 30 x 4
TV 25 x 3
TV 16 x 2
KHB G
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
RI ED x 1 1/2
RI 1 ED x 1 1/2
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
SN 759
AVIT
Fo
r
B
Socket
A
High pressure hose
D1
General Information for Erection
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
108
D1
1.13.
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
109
D1
1.14.
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
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.
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
111
D1
1.16.
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)
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
112
D1
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
113
D1
Fo
r
inf
or
m
at
ion
on
ly
1.17.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
114
D1
Fo
r
inf
or
m
at
ion
on
ly
Grouting Material:
Date:
A00226 / MAADEN
Remarks:
Stand / Revision
2010
Index
--
Blatt / Sheet
115
D1
ly
_________________________
on
Package:
Completeness /
Delivery complete
Part damaged
Instructions:
Type of Storage
Outdoors
or
m
at
ion
Part missing
Package No.
Additional Requirements
Repackaging
Repeat Preservation Treatment
inf
Fo
r
Remarks:
Date:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
116
D1
1.18.
Designation
Number Provided
at
ion
or
m
Trucks
Load Capacity ( t )
on
Mobile Crane
Tractor-Flatbed
Trailer Units
ly
Fo
r
inf
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
117
D1
1.19.
ly
Site Shop
or
m
at
ion
1.
Specification / Type
on
Item Designation
Fo
r
inf
2.
Figure 78:
3.
Figure 79:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
118
D1
on
ly
4.
Figure 80:
AC motor (variable cutting speeds), complete with 5 m long connecting cable and
plug
at
ion
Power Hacksaw
or
m
5.
Compressor
Fo
r
inf
6.
Figure 81:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
119
D1
Specification / Type
8.
Model F087-127
11.
12.
13.
14.
on
Model B61042005
VT-VETSY-1-1X/1-2-1-1-1
(Rexroth)
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
120
D1
on
ly
16.
Figure 83:
18.
19.
Hydac.
Siemens-Multizet
ARTI / PODS
inf
or
m
20.
at
ion
17.
Figure 84:
Leak detector
22.
Digital thermometer
23.
Fo
r
21.
Figure 85:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
121
D1
ly
Item Designation
Welding Generator
25.
Welding Generator
26.
Welding Generator
at
ion
on
24.
Figure 86:
TIG Welder
inf
or
m
27.
Fo
r
Figure 87:
Note:
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
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:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
123
D1
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.
A00226 / MAADEN
Figure 91:
Figure 92:
Stand / Revision
2010
Index
--
Blatt / Sheet
124
D1
Welders Apron
Leather
on
ly
36.
Figure 93:
Slag Hammer
DIN 5133
at
ion
37.
Figure 94:
Wire Brush
for steel
or
m
38.
Figure 95:
Wire Brush
40.
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.
A00226 / MAADEN
Figure 96:
Stand / Revision
2010
Index
--
Blatt / Sheet
125
D1
Protective Goggles
43.
Lighters
44.
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:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
126
D1
ly
Item Designation
Hydraulic Jacks
46.
Hydraulic Jacks
47.
Hydraulic Jacks
48.
Hydraulic Jacks
49.
Hydraulic Jacks
HP 20/400 (t / stroke in mm
50.
Hydraulic Jacks
51.
Hydraulic Jacks
52.
Hydraulic Jacks
at
ion
on
45.
or
m
Figure 98:
4.5 l
(refer to Figure 99)
54.
1.3 l
inf
53.
Fo
r
Figure 99:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
127
D1
Steel Winch
DIN 7355
5 tons with safety crank
56.
Steel Winch
DIN 7355
10 tons, with safety crank
57.
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
128
D1
Mechanics Work-Pipe
Bench, incl. Sub cabinets
on
61.
Specification / Type
ly
Item Designation
at
ion
Figure 102:
Pipe Bending Machine
63.
inf
64.
or
m
62.
66.
DIN 6473
300 mm long, complete with saw blades
Figure 104:
Fo
r
65.
Figure 103:
Figure 105:
Figure 106:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
129
D1
67.
Pipe Pliers
1/2" - 4"
68.
1/2" - 4"
on
Figure 108:
ly
Figure 107:
Pipe Cutter
70.
Pipe Cutter
1 1/4" - 4"
at
ion
69.
Figure 109:
72.
73.
Fo
r
inf
or
m
71.
74.
Figure 110:
DIN 6403
2 m long
Figure 111:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
130
D1
75.
Folding Rule
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:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
131
D1
Vernier Callipers
DIN 862
Measuring range 250 mm, with nibs, stainless
at
ion
82.
on
Figure 118:
ly
81.
Fo
r
inf
or
m
Figure 119:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
132
D1
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:
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.
Figure 123:
90.
Figure 124:
Straightedge
92.
Straightedge
93.
Straightedge
inf
or
m
91.
Straightedge
95.
Straightedge
Fo
r
94.
96.
Straightedge
97.
Straightedge
Figure 125:
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
at
ion
99.
on
Figure 126:
ly
98.
Figure 127:
inf
or
m
DIN 877
200 mm, accuracy 0.10 mm/m
(Frame Spirit Level)
Figure 128:
DIN 877
200 mm, accuracy 0.04 mm/m
DIN 877
200 mm, accuracy 0.10 mm/m
Fo
r
Figure 129:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
135
D1
DIN 862
Range 250 mm, with nibs, stainless
on
Figure 130:
ly
DIN 862
Range 250 mm, stainless Gauge
at
ion
Figure 131:
DIN 878
Accuracy 1/100 mm, range 0 - 10 mm
or
m
Figure 132:
inf
Figure 133:
DIN 6403
50 m, stainless
DIN 6403
30 m, stainless
DIN 6403
20 m, stainless
Fo
r
Figure 134:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
136
D1
Figure 135:
DIN 6403
2 m long
on
ly
Figure 136:
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
at
ion
inf
Fo
r
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)
DIN 866
1000 x 30 x 1 mm, graduations 0.5 mm
and 1mm (refer to Figure 139)
DIN 866
however s = 1 2000 x 30 x 1 mm, graduations 0.5 mm and 1mm
Figure 139:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
137
D1
Fo
r
inf
or
m
at
ion
on
Figure 140:
ly
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
138
D1
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
Morse taper 1 - 3
DIN 1808
Morse taper 2/1, 3/2, 4/3
DIN 6349
Opening 1 mm - 13 mm
DIN 317
for the drilling machines
inf
Fo
r
Figure 143:
130. Rubber Grinding Disk
elements
Figure 144:
Note:
A00226 / MAADEN
All pneumatic machine tools with suitable hoses and hose connectors.
Stand / Revision
2010
Index
--
Blatt / Sheet
139
D1
at
ion
on
ly
Item Designation
Figure 145:
or
m
inf
Figure 146:
Grinding wheel dia. 178 / 125 mm and rubber disk
Fo
r
Figure 147:
134. Electric Grinding Machine
(High-Speed Type)
Figure 148:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
140
D1
on
ly
Fo
r
inf
or
m
Note:
at
ion
Figure 149:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
141
D1
Sundries
Specification / Type
DIN 14711 Part 2
4 m and 6 m long
at
ion
on
ly
Item Designation
Figure 150:
or
m
Fo
r
inf
Figure 151:
Figure 152:
Figure 153:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
142
D1
Figure 154:
at
ion
on
ly
140. Flashlights
Figure 155:
abt. 4 m long
or
m
Plastics, abt. 10 l
Galvanized, abt. 11 l
148. Bottle
Fo
r
inf
147. Bottle
A00226 / MAADEN
Figure 156:
Stand / Revision
2010
Index
--
Blatt / Sheet
143
D1
on
ly
Figure 157:
for Sizes SW 17 - SW 42
(SW = width across flats)
or
m
at
ion
Fo
r
inf
Figure 158:
Figure 159:
A00226 / MAADEN
Hydrotechnik
Stand / Revision
2010
Index
--
Blatt / Sheet
144
D1
on
ly
or
m
at
ion
Figure 161:
Fo
r
inf
Figure 162:
Note:
A00226 / MAADEN
Figure 163:
Stand / Revision
2010
Index
--
Blatt / Sheet
145
D1
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
on
158. Eyebolt
Figure 164:
DIN 6453
200- 250 mm long
at
ion
Figure 165:
DIN 6451
200- 250 mm long
or
m
inf
Figure 166:
DIN 6455
200 mm long x 6,
200 mm long x 8
200 mm long x 10
Figure 167:
Fo
r
Figure 168:
300 mm long
Figure 169:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
146
D1
165. Pincers
Figure 170:
166. Rubber Mallet
on
DIN 5128
ly
250 mm long
at
ion
Figure 171:
Figure 172:
2 - 12"
or
m
inf
Fo
r
Figure 173:
Lockable, empty
Figure 174:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
147
D1
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
inf
comprising:
Pliers
Pliers
Pliers
Pliers
Pliers
Fo
r
A00226 / MAADEN
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
ly
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
on
ly
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
or
m
Figure 179:
inf
comprising:
Screwdriver
Screwdriver
Screwdriver
Screwdriver
Screwdriver
Screwdriver
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:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
149
D1
ly
Figure 182:
comprising:
Hand File
Hand File
Hand File
Hand File
Hand File
Hand File
Hand File
on
at
ion
Figure 183:
or
m
comprising:
Square File
Square File
Square File
Square File
Square File
Square File
inf
comprising:
Three-Square File
Three-Square File
Three-Square File
Three-Square File
Three-Square File
Three-Square File
A00226 / MAADEN
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.
Stand / Revision
2010
Index
--
Blatt / Sheet
150
D1
ly
comprising:
Bastard File
Bastard File
Bastard File
Bastard File
Bastard File
Bastard File
on
at
ion
or
m
comprising:
Round File
Round File
Round File
Round File
Round File
Round File
inf
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
Figure 189:
DIN 395
100-, 140- and 160 mm long
Figure 190:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
151
D1
on
Figure 191:
ly
at
ion
Figure 192:
Figure 193:
inf
or
m
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Fo
r
A00226 / MAADEN
14/17 mm
16/18 mm
19/22 mm
24/27 mm
30/32 mm
36/41 mm
Figure 194:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
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
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
or
m
DIN 7444
Fo
r
inf
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
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
A00226 / MAADEN
SW 170
SW 180
Stand / Revision
2010
Index
--
Blatt / Sheet
153
D1
DIN 896
at
ion
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
on
Figure 198:
ly
DIN 3112
or
m
Figure 199:
inf
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
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
A00226 / MAADEN
2010
Index
--
Blatt / Sheet
154
D1
ly
on
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
198. Set of Hex. Socket Screw
Keys
Figure 201:
inf
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
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
Figure 203:
on
inf
comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
A00226 / MAADEN
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
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
inf
or
m
comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
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
ly
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
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
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
or
m
inf
comprising:
Hand Reamer
208. Set of Taps, 3-part
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:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
158
D1
DIN 5157
for Pipe
Figure 208:
on
comprising:
Threads
ly
at
ion
Figure 209:
comprising:
Standard Threads
or
m
inf
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
dia. 20, dia. 25, dia. 30, dia. 38, dia. 45,
dia. 55
DIN EN 22568
Figure 211:
comprising:
Die Holder
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
159
D1
DIN 1814
Jaws Size 5, 6 and 7
ly
Figure 212:
on
DIN 377
Figure 213:
comprising:
Tap Extension
or
m
at
ion
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
Figure 214:
Figure 216:
Figure 217:
220. Wire Rope
A00226 / MAADEN
DIN 3088
with loops, dia. 8 x 1.5 m
Stand / Revision
2010
Index
--
Blatt / Sheet
160
D1
DIN 3088
with loops, dia. 10 x 1.5 m
DIN 3088
with loops, dia. 12 x 1.5 m
DIN 3088
with loops, dia. 14 x 1.5 m
DIN 3088
with loops, dia. 16 x 1.5 m
DIN 3088
with loops, dia. 12 x 4.0 m
DIN 3088
with loops, dia. 12 x 6.0 m
on
DIN 3088
with loops, dia. 12 x 8.0 m
DIN 3088
with loops, dia. 16 x 4.0 m
or
m
at
ion
ly
DIN 3088
with loops, dia. 16 x 6.0 m
DIN 3088
with loops, dia. 16 x 8.0 m
DIN 3088
with loops, dia. 20 x 8.0 m
DIN 3088
with loops, dia. 20 x 10.0 m
DIN 3088
with loops, dia. 36 x 8.0 m
DIN 3088
with loops, dia. 36 x 10.0 m
Fo
r
inf
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
161
D1
DIN 3088
with loops, dia. 36 x 12.0 m
DIN 3088
with loops, dia. 42 x 8.0 m
DIN 3088
with loops, dia. 42 x 10.0 m
DIN 3088
with loops, dia. 24 x 6.0 m
DIN 3088
with loops, dia. 24 x 8.0 m
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
at
ion
ly
DIN EN 1261
endless, dia. 30
DIN EN 1261
endless, dia. 40
25.0 t
50.0 t
inf
DIN 82101
1.0 t
248. Shackles
DIN 82101
2.0 t
Fo
r
247. Shackles
249. Shackles
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
163
D1
Appendix
Fo
r
inf
or
m
at
ion
on
ly
1.20.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
164
D1
1.20.1.
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
165
D1
1.20.2.
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
Dismantling of pipes
and tank pickling
Figure 219
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
166
D1
1.20.3.
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
Fo
r
15
0
0
0
6
30
0
50
12
18
12
60
23
100
80
80
38
140
Figure 221
A00226 / MAADEN
Stand / Revision
Index
2010
--
Blatt / Sheet
167
D1
1.20.4.
Drawings and bill of material for flushing plates conformable SMS SIEMAG drawings
ly
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:
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
168
D1
Material
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
ly
Amount
129
Fo
r
inf
or
m
at
ion
on
Viton / 70
A00226 / MAADEN
Stand / Revision
Index
2010
--
Blatt / Sheet
169
D1
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:
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
170
D1
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
Fo
r
A00226 / MAADEN
Stand / Revision
Index
2010
--
Blatt / Sheet
171
D1
Fo
r
inf
or
m
at
ion
on
ly
Figure 224:
Auft.-Nr. / Order No.
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
172
D1
Material
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
ly
Amount
129
Fo
r
inf
or
m
at
ion
on
Viton / 70
A00226 / MAADEN
Stand / Revision
Index
2010
--
Blatt / Sheet
173
D1
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
2x A - A
4x B - B
Figure 225
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
174
D1
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
Fo
r
inf
Material
ly
Amount
A00226 / MAADEN
Stand / Revision
Index
2010
--
Blatt / Sheet
175
D1
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:
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
176
D1
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
Fo
r
inf
Material
ly
Amount
A00226 / MAADEN
Stand / Revision
Index
2010
--
Blatt / Sheet
177
D1
on
44,9
73,5
ly
102,1
53
147
132,2
106,6
73,5
40,4
14,8
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:
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
178
D1
Description
Material
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
ly
Amount
129
Fo
r
inf
or
m
at
ion
on
Viton / 70
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
179
D1
1.20.5.
Fig. 1
Fig. 2
Flat-bottomed vehicle
Mill housing
or
m
Wooden plank
at
ion
on
ly
Fig. 3
Lifting device
Bed plate
Fo
r
inf
Fig.4
Fig. 6
Fig. 5
Figure 230:
Auft.-Nr. / Order No.
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
180
D1
on
ly
Fig. 2
at
ion
Fig. 1
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
Figure 231
Auft.-Nr. / Order No.
A00226 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2010
--
181
D1
on
Fo
r
inf
or
m
at
ion
Lifting device
ly
Mill housing
1.20.6.
Figure 232:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
182
Fo
r
A00226 / MAADEN
Stand / Revision
2010
Bed plate
or
m
inf
on
Wooden plank
Mill housing
at
ion
ly
Lifting device
D1
General Information for Erection
Figure 233:
Index
--
Blatt / Sheet
183
D2
Fo
r
inf
or
m
at
ion
on
ly
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
D2
ly
on
*2
at
ion
0,2/1000
1,0
Shape
*1
Horizontal
Plane
SN200
Flatness
1,0 A
or
m
Parallelism
inf
2,0
50
50
Position
100
100
Fo
r
Position
1,0
1,0 A
A
Symmetry
Perpendicularity
A00226 / MAADEN
Stand / Revision
2010
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
Fo
r
inf
or
m
at
ion
on
ly
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
D3
3.1.
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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
D3
3.1.1.
Mechanical Equipment
on
ly
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.
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D3
3.1.2.
at
ion
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Fo
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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
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on
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3.1.3.
at
ion
Fo
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inf
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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
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D3
3.1.4.
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D3
3.1.5.
Grease Systems
at
ion
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Fo
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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
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D3
3.1.6.
on
ly
at
ion
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D3
3.1.7.
on
ly
at
ion
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Procedure of Tests
Fo
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at
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3.2.
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D3
3.2.1.
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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.
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D3
3.2.2.
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Checks to be made:
on
Fo
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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.
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12
D3
3.2.3.
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Checks to be made:
Lubrication as per lube instructions in conjunction with the lube chart - relubricate if so required.
Fo
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at
ion
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D3
3.2.4.
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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
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at
ion
The reference values are contained in the technical data or rather equipment arrangement drawing.
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14
D3
3.2.5.
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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
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inf
or
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The reference value is indicated in the technical data or rather equipment arrangement drawing.
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15
D3
3.2.6.
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Checks to be made:
Horizontal and vertical alignment of the machines and devices involved in the
rolling process.
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.
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D3
3.2.7.
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
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17
D3
3.2.8.
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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.
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18
D3
3.2.9.
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at
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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.
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D3
3.2.10.
Stand Clamping
Both the mechanical and the hydraulic systems of the stand clamping device will
be visually checked.
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Checks to be made:
Opening and closing of the stand clamping mechanism.
Fo
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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.
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D3
3.2.11.
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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.
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D3
3.2.12.
at
ion
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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
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The reference values are indicated in the technical data or rather equipment arrangement drawing.
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D3
3.2.13.
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at
ion
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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.
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D3
3.2.14.
at
ion
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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
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inf
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The reference values are indicated in the technical data or rather product arrangement drawing.
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D3
3.2.15.
at
ion
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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
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D3
3.2.16.
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.
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26
D3
3.2.17.
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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.
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D3
3.2.18.
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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
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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.
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3.2.19.
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.
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D3
3.2.20.
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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.
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D3
3.2.21.
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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
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.
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3.2.22.
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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.
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D3
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.
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D3
3.2.23.
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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
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.
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D3
3.2.24.
on
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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
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D3
3.2.25.
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.
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36
D3
3.2.26.
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
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or
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2010
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37
D3
3.2.27.
on
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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.
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2010
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38
D3
3.2.28.
on
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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
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
39
D3
3.2.29.
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.
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2010
Index
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40
D3
3.2.30.
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.
A00226 / MAADEN
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2010
Index
--
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41
D3
3.2.31.
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.
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Stand / Revision
2010
Index
--
Blatt / Sheet
42
D3
3.2.32.
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
43
D3
3.2.33.
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.
A00226 / MAADEN
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2010
Index
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Blatt / Sheet
44
D3
3.2.34.
Process Section
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.
B...
E...
Q... Agitators
Agitator vanes to be checked for freedom of movement
F...
H...
H...
at
ion
or
m
inf
Fo
r
I...
on
A...
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D3
K...
K...
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...
A00226 / MAADEN
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2010
Index
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46
D3
Fo
r
inf
or
m
at
ion
on
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3.3.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
47
D3
Drawing-No.
Remarks
Fo
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or
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at
ion
on
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Confirmation:
Date:
A00226 / MAADEN
Stand / Revision
2010
Seller:
Index
--
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48
D3
ly
Customer:
57271 Hilchenbach
Contractor:
on
Wiesenstrasse 30
...................................................
at
ion
...................................................
...................................................
Agreement item:
Plant designation:
......................................
or
m
......................................
......................................
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
Adherence to deadlines
The erection was completed on ...............
The contractually stipulated date was ..............
This results in an erection delay of ............... days.
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49
D3
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
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
Warranty
Fo
r
inf
............................., ................................
_______________________
_______________________
On behalf of SMS Siemag
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50
D3
3.4.
m3/h
measurement:
m3/h
Pressure:
design:
at
ion
on
Item No.:___________
ly
bar ()
measurement:
m3/h
or
m
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
51
D3
ly
m3/h
measurement:
m3/h
Pressure:
design:
bar ()
measurement:
at
ion
bar ()
m3/h
measurement:
m3/h
or
m
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
52
D3
ly
m3/h
measurement:
m3/h
Pressure:
design:
at
ion
bar ()
measurement:
bar ()
m3/h
measurement:
m3/h
or
m
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
53
D3
ly
m3/h
measurement:
m3/h
Pressure:
design:
bar ()
measurement:
at
ion
bar ()
m3/h
measurement:
m3/h
or
m
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
54
D3
ly
m3/h
measurement:
m3/h
Pressure:
design:
at
ion
bar ()
measurement:
bar ()
m3/h
measurement:
m3/h
or
m
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.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
55
D3
Fo
r
inf
or
m
at
ion
on
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3.5.
A00226 / MAADEN
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2010
Index
--
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56
D3
Equipment:
CHECK
yes
on
Item No.:
ly
Mechanical Equipment
not appl.
Remarks
at
ion
or
m
inf
Fo
r
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
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57
D3
Equipment:
CHECK
yes
on
Item No.:
ly
Mill Stand
not appl.
Remarks
at
ion
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
Fo
r
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
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58
D3
Equipment:
CHECK
yes
not appl.
Remarks
or
m
at
ion
on
Item No.:
ly
Hydraulic Equipment
Fo
r
inf
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
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59
D3
Equipment:
CHECK
yes
not appl.
Remarks
at
ion
on
Item No.:
ly
inf
or
m
Fo
r
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
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60
D3
Equipment:
not appl.
Remarks
inf
or
m
yes
at
ion
CHECK
on
Item No.:
ly
Pneumatic System
Fo
r
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
Blatt / Sheet
61
D3
Equipment:
CHECK
yes
not appl.
Remarks
or
m
at
ion
on
Item No.:
ly
Grease Equipment
inf
Fo
r
Date:
A00226 / MAADEN
Seller:
Stand / Revision
2010
Index
--
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62
D3
Equipment:
CHECK
yes
on
Item No.:
ly
Piping
not appl.
Remarks
inf
or
m
at
ion
Seller:
Fo
r
Date:
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
63
D3
Equipment:
CHECK
yes
on
Item No.:
ly
Water Pumps
not appl.
Remarks
at
ion
or
m
inf
Fo
r
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
Blatt / Sheet
64
D3
Equipment:
yes
not appl.
Remarks
Fo
r
inf
or
m
at
ion
CHECK
on
Item No.:
ly
A00226 / MAADEN
Buyer:
Seller:
Stand / Revision
2010
Index
--
Blatt / Sheet
65
D3
Fo
r
inf
or
m
at
ion
on
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3.6.
A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet
66
D3
Drawing-No.
Remarks
Fo
r
inf
or
m
at
ion
on
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Enclosures:
Confirmation:
Date:
A00226 / MAADEN
Stand / Revision
2010
Seller:
Index
--
Blatt / Sheet
67
D4
Fo
r
inf
or
m
at
ion
on
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A00226 / MAADEN
Stand / Revision
2010
Index
--
Blatt / Sheet