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

ERECTION MANUAL (D)
for
4-stand Tandem Cold Mill
Saudi Arabia
Dsseldorf and Hilchenbach, Germany
Customer / User:
Maaden - Alcoa
Ras Az Zawr
Kingdom of Saudi Arabia
Contract:
A6RM-4-1002-00 / A6RM100009
Plant:
4-stand Tandem Cold Mill
Year of Supply:
2012
Types of Manuals
A - Operating Manual
Volume
B - Equipment Manual
Volume
C - Sub suppliers` Components Manual
Volume
D - Erection Manual
Volume
Auft.-Nr. / Order No.
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Instruction for Erection
Volume
1. General Information for Erection
2. Erection Measuring Reports
3. Single Function Test
4. Erection Time Schedule
The erection manual is a guideline only and has to be adapted to

actual conditions in the field.
In case of changes this manual will not be considered.
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Table of contents
Table of contents
1.
1.1.
General Information for Erection
General Safety Requirements
1.1.1.
1.1.2.
1.1.3.
1.1.4.
Safety Instructions for Erection, Commissioning, Operation and Maintenance

2
Safety Signs
6
Safety at Site
14
Transfer of risk for fire protection systems
22
1.2.
Preconditions for Erection to Start
23
1.3.
Plant Surveys
24
1.4.
Foundation Surveys
30
1.4.1.
Report on foundation acceptance
35
1.5.
Preparation of Foundations for Machine Erection
37
1.6.
Levelling/Alignment and Anchoring of Machines and Equipment Units
43
1.7.
Placing Under grouts
47
1.8.
Storage, Slinging, Load Table and Unpacking of Supplied Equipment
50
1.9.
Consumables Needed During Erection
60
1.10. Fitting, bending and welding of piping
63
1.10.1.
1.10.2.
1.10.3.
Execution of fitting work

Bending
Welding
63
80
81
1.11. Chemical Cleaning of Steel Pipes
84
1.12. Stainless Steel Pipes
88
1.13. Chemical cleaning of steel pipes by the immersion process
92
1.14. Flushing of pipelines for oil circulation and hydraulic systems
96
1.15. Preassembly of Machines and Components

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1.16. Pipeline Identification Letters Used for Various Utilities in the Drawings
111
1.17. Mounting Instructions in Drawings
112
1.18. Aligning and Tightening torque for couplings (Information given by Company
FLENDER)
113
1.19. Release for Machine Grouting / Open Package Inspection
115
1.20. Heavy-Duty Cranes and Transport Facilities
118
1.21. Tools, Appliances and Auxiliaries
119
1.22. Appendix
165
1.22.1.
1.22.2.
1.22.3.
1.22.4.
1.22.5.
1.22.6.
3.
3.1.
Single Function Tests
Precondition for Tests

3.1.1.
3.1.2.
3.1.3.
3.1.4.
3.1.5.
3.1.6.
3.1.7.
3.2.
Example of Pickling Scheme in Recirculation Process (ZS)

166
Example of Pickling Scheme in Recirculation Process (Hydraulic power
system)
167
Simplified representation in drawings
168
Drawings and bill of material for flushing plates conformable SMS SIEMAG
drawings
169
Off-loading of Mill Housing from flat bottomed vehicle and Positioning
181
Off-Loading of a Mill Housing from well wagon and positioning
183
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
Procedure of Tests
3.2.1.
3.2.2.
3.2.3.
3.2.4.
3.2.5.
10
Sense of Rotation of Electric Motors

Electrical Devices such as Proximity Switches, Limit Switches, Brakes,
Photocells etc.
Lubrication to Lube Instructions
Nozzles, Roll Cooling, Descaling
Shear Knife Gap
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12
13
14
15
Table of contents
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.
3.2.23.
3.2.24.
3.2.25.
3.2.26.
3.2.27.
3.2.28.
3.2.29.
3.2.30.
3.2.31.
3.2.32.
3.2.33.
3.2.34.
Pass Line and Roll Gap

16
Vertical Adjustment
17
CVC Shifting Device
18
Adjustment of Mechanical Equipment such as Rest Bar, Mill Guides etc. 19
Stand Clamping
20
Grease Systems, Control and Function
21
Strokes of Hydraulic Cylinders, Lifting Speed and Cushioning
22
Maintenance Unit for Compressed Air
23
Strokes of Compressed Air Cylinders, Stroke Speed and Cushioning
24
Check of Pressure Limiting Valves for Compliance with Preset Pressure 25
Pressure Setting of Pumps
26
Switch Elements at Oil Tank, Fill Level Indicator, Temperature
27
Filter: Differential Pressure
28
Oil Cooler: Water Flow
29
Accumulator: Pre-Fill Pressure
30
Controls and Functions of the Hydraulic Systems
31
Electrical Switching Elements, Pressure Transducers, Pressure Switches etc.
32
Lubricating-Oil Compact Unit: Filter, Pressure, Temperature
34
Pressure Tank: Pressure
35
Separator: Cup Assembly, Run-off Diameter, Temperature, Safety Device 36
Oil Pressure at the Consumers
37
Water-Inlet Alarm Device
38
Pneumatic Compact Unit: Filter, Pressure, Temperature
39
Hydraulic Lines as to Up tightness
40
Compressed-Air Lines as to Up tightness
41
Water Lines as to Up tightness
42
Grease Lines as to Up tightness
43
Oil-Lubricating Lines as to Up tightness
44
Process Section
45
3.3.
Certificate and Report of Completion of Erection
47
3.4.
Check List for Functional Tests
51
3.5.
Certificate for Preliminary Acceptance Test
62
4.
Erection Time Schedule
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1. General Information for Erection
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1.1.
General Safety Requirements
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.
1.1.1.
Safety Instructions for Erection, Commissioning, Operation

and Maintenance
In addition to the safety regulations in force in the user country and any in-plant
safety regulations concerning operation, maintenance and erection, the following
general instructions must be observed.
Accident prevention rules should be conspicuously displayed in a position which is
accessible to everyone working in the plant. Additional instruction should be provided by the safety officer in charge.
Each person having to do with erection, commissioning, operation, maintenance or
repair of plant equipment must have read and understood all corresponding Manuals A, B, C and D. The provisions furnished by the electrical equipment supplier(s) shall apply in regard to all electrical equipment.
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.
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.
Function checks, maintenance work:
User is obliged to have the plant inspected, at least once per shift, for
externally recognizable damages and deficiencies. Changes discovered that may affect equipment dependability and safety shall be reported and made good without delay.
User to take care that the plant will be operated while in unobjectionable state and condition only.
Maintenance, repair and cleaning work is prohibited on machines and
equipment in operation.
Inspections and/or checks of individual plant components may only be
carried out in strict compliance with applicable safety regulations and
while the respective machine or equipment unit is operating.
Emergency stop - emergency OFF switch
Emergency stop switch: Movement is stopped by electrically controlled blocking
of drive.
Emergency OFF switch: Movement is stopped by cutting out power supply.
Caution!
Emergency switches should be inspected for functional ability at
regular intervals.
Protective devices:
Existing protective devices may only be removed for repair and maintenance purposes and should be duly refitted after work has been finished.
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Job area safety:

Measures should be taken to ensure the safety of the job area the way
existing conditions may dictate.
Electric power should be switched off and steps should be taken to
prevent accidental enclosures.
All responsible executives should be notified in advance.
The name of the responsible executive, date and time should be stated on signs.
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.
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.
Fire Endangered Areas
Do not use any open flame in highly inflammable areas and prohibit all smoking.
Oil Leaks
No saw dust or cotton waste shall be used to remove leak oil due to the fire hazard
this would entail. Use commercial type hazardous neutralizing agents only.
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Utilities
Never have pumps started against closed suction-side shutoff valves.

It is a basic rule that the sense of rotation of all drives shall be checked
in inching mode prior to initial start-up of pump units and after each
motor change.
The instructions furnished by supplier/manufacturer companies shall
basically be observed for all maintenance/assembly of plant components.
Hydraulic / Pneumatic Systems:
The following procedure is generally to be adopted for all valves,
pumps, cylinders etc.:
Un-pressurize systems complete, for instance via measuring hose on
measuring couplings.
Note:
Certain accumulators such as those of the balancing system will
have to be kept under pressure in spite of pressure system relief.
Lock mechanical equipment, for example by Safety pins.
Close shutoff valves in pressure and control oil lines.

Cut out electrical equipment and protect against unforeseen switch-on.
The position and condition of seals and packing is to be particularly

checked during and after any work on equipment units.
Retightening of pipe screw joints and flange connections as well as
any other sealing measure shall be allowed to be carried out only
with the pipeline system in un-pressurized state.
Mechanical, - welding or soldering work is not allowed to be carried
out on hydraulic accumulators.
Safety Equipment for Operating Personnel
All persons assigned to any job within the plant will have to wear suitable protective garments. Instruction by the safety officer in each case.
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1.1.2.
Safety Signs
Safety signs are intended to ensure safety of people working in the plant. These
signs comprise:
Prohibitive signs
Warning signs
Mandatory signs
Rescue signs
Informative signs
Signs identifying permanent hazard areas
Signs for protection of specific work areas
It is necessary to post these signs during and after assembly in job and hazard areas throughout the plant.
All persons employed will be informed on the significance of all safety signs prior
to commencement of their activities, and in subsequent periods at adequate intervals, but at least once a year.
The responsibility for posting such signs shall rest with the plant user.
Caution:
Machine manufacturer shall not be liable in case of non-compliance
with above safety instructions.
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Prohibitive signs
No smoking
Fire, open flame

and smoking
prohibited
No pedestrians
Unauthorized persons keep off
No access for persons with pacemaker
Extinguishing with
water prohibited
No drinking water
Prohibited for floor

vehicles
Do not deposit or
store
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Warning signs
Warning:
inflammable substances
Warning:
substances
explosive
Warning:
poisonous
substances
Warning:
corrosive
substances
Warning:
radioactive
substances
Warning:
loads passing
substances
Warning:
transport vehicles
passing
Warning:
high voltage
Warning:
dangerous area
Warning:
danger of
crushing
Warning:
danger of
laser beam
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Mandatory signs
Wear goggles
Wear protective helmet
Wear ear muffle
Wear respirator
Wear safety shoes
Wear protective gloves
For pedestrians
Use crossover
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Rescue signs
Indication of first aid
Side stretcher
Arrow of direction *
for first-aid-kits
Escape route
Escape route
Emergency exit
* This arrow of direction shall be used only in connection

with another rescue sign for first-aid-kits
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Information signs
Indication of
fire extinguisher DIN 4066
Signs identifying permanent hazard areas
Identification of permanent hazard areas for instance

such places which involve the risk of hitting, crushing
and tumbling, stumbling of persons or dropping of loads.
Steps, floor hatches etc.
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Board indicating cut-out and reconnection requirements for drives during repair or
no production shifts
Cutout and Reconnection of drives

Date:
Date:
Time:
Time:
Demand - Cutout
of following drives
Demand - Reconnection
of following drives
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Request by
Signature
Function
Signature
Function
Request by
Type:
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Function
Signature
Function
Effected by
Effected by
Material:
Signature
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:
Barrier Chain
Fixed by 3 chain links on every barrier chain,

additionally screwed or hooked on walls and equipment.
270
Attention!
Hazardous Area
150
12
15
15
300
Admittance after Operator's

Permission!
3 thick
10
10
60
18
45
M 10
Stretched Length 164
10
36
10
R 16
Stretched Length 172
36
Weld on railing or equipment
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Fixed to foundation with dowel
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1.1.3.
Safety at Site
Purpose and Range of Application
These guidelines are applicable to our field staff.
They serve to promote the safety awareness and hence to safeguard the health
and efficiency of our field staff. After having done a good and successful job, they
shall complete each day or shift in good health and in the absence of any injury.
These guidelines are to be understood as supplement to the ruling safety regulations and will be distributed to all the SMS SIEMAG field staff.
Responsibility for Safety
Our board of management is conscious of its duty to care for and protect the safety and health of all the staff. It has incorporated in these responsibility supervisors
who are authorized to issue directives.
The prevention of dangers of accidents is a legal obligation to which, besides the
contractor, all the staff, too, is subjected without any exception. The responsibility
to implement safe working practices and the proper attitude in regard to safety
hence concerns all of us.
On the basis of our staffs readiness to assume responsibility and their comprehensive cooperation, we aim at creating and maintaining as safe and healthy
working conditions as possible.
Responsibility of Contractors Management
The ultimate responsibility for safety at the working place and health of our staff
rests with our board of management who is responsible that the ruling safety instructions and/or accident prevention rules are observed and enforced at our work.
For our sites the leader of the organization unit (OE) field assembly/commissioning
is the authorized person for job safety. For the individual site, our respective senior
site manager and/or site manager is in charge of job safety matters. They are authorized to order measures for job safety.
The supervisors at the site are directly responsible for the employees subordinated
to them. They supervise the work and control that the measures ordered are carried out. They take care that the work is done with due observance of the regulations for safety and health of all persons within the site/assembly area.
The executives carry out regular inspections of their sites in regard to job safety.
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Responsibility of Employees
The employees are obliged to take care of their own safety and health as well as
of those of other persons and to cooperate with the supervisors of the contractor to
prevent dangers of accidents. They are also obliged to use the prescribed safety
outfit.
The employees shall use safe working practices and processes, notify practices
and events which endanger the safety and cooperate in the case of investigations
into accidents.
General Safety Instructions:
Make full use of your personal protection outfit!
Make yourself familiar with the first-aid equipment!
Work can be better performed in a tidy and well-arranged area. Keep
your working place always in good order, especially the working platforms!
Safe access to and exit from the working area as well as keeping the
working area in a safe state are legal demands for the observance of
which you are also responsible. Abide by this in your own interest!
Keep away from the areas of suspended loads!
Observe warning signs and block off!
Keep traffic routes free!
Do not improvise! Use proper tools and facilities!
Help new fellow workers, especially young workers, by warning them
against dangers and risks known to you! Let other persons benefit
from your knowledge and experience!
Do not improperly use social equipment, site containers, staff containers, sanitary facilities and canteens!
The conditions at site change almost daily. Protect yourself and others
by constant vigilance!
Personal Safety Outfit
It is not always possible to eliminate dangers by technical or organizational
measures. The contractor then has to provide personal safety outfits which have to
be used by each worker.
Protection of Head
Whenever there is a danger of head injuries by dropping, toppling over or thrown
away objects or by hitting against edges and obstacles, hard hats are to be worn
which are examined and identified to the valid standard.
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Protection of Eyes
The eyes are our most sensitive and valuable sensory organs.
Everyone should have at least one pair of protective goggles with him
at site to protect his eyes at any time against dust or metal particles
flying about.
In the case of danger by infrared, ultraviolet or laser beams appropriate personal safety outfits have to be made available and have to be
worn.
Protection of Hands
The hands are our mostly used tool. They get damaged by cracks, pricks, cuts,
dislocations, bruises, crush injuries, burns and acid burns.
Therefore, always wear suitable hand protection!
Protection of Feet
The feet are endangered at site especially by falling objects or by stepping into
sharp or pointed objects.
Therefore, always wear appropriate safety shoes!
Cranes
Observe the applicable safety instructions and accident prevention rules
for cranes.
Possible causes of accidents in conjunction with cranes and hoisting appliances
are as follows:
Human failure of crane operator, attached or other persons involved in
the hoisting procedure; inattentiveness, boredom, readiness for risks,
inobservance of applicable guidelines or faults may be the cause of a
failure.
Insufficient attachments - in regard to bad weather conditions such as
strong wind.
Inappropriate load receiving means, unsuitable or damaged sling
means.
Improper use and maloperation of hoisting appliances.
Tools or devices dropping from the crane due to detachment by crane
movement.
Possible contact with current-conducting collector wires or obstruction
by restricted space.
These sources of dangers are to be recognized and secured. Moreover, other sources of danger have to be considered which may arise
in the respective working area.
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Hand-guided Electrical Tools

The following guidelines have to be observed irrespective of whether the tools
have been made available by SMS SIEMAG or others.
Most accidents are caused by incorrect handling:
The nearest electric connection is to be used to avoid long cable
routes.
It has to be ensured that cables are not routed in travelled areas etc.
or through water.
The tools are to be checked carefully prior to being used.
Tools being live are not allowed to be deposited and left unattended.
For certain work the protection of eyes is prescribed and sometimes
also the protection of ears necessary. This protection outfit must absolutely be worn!
Whenever an electrical defect comes up the tools are to be put out of
operation. Repairs are allowed to be done by qualified persons only.
Normally tools for AC with 240 V rated voltage are used. For work to
be done in co fined conductive rooms (for example tanks) only low
voltage (12 V) or machines actuated by compressed air under protective measures are to be used.
Grinding Machines
The use of grinding machines calls for observation of the instructions concerning
grinding bodies and grinding machines. You are also requested to observe the following items applicable for all grinding machines inclusive of portable electrical
and pneumatic grinding devices.
Grinding tools and disks are allowed to be used only after the protective devices have been fitted.
Grinding bodies are allowed to be clamped only on grinding or abrasive cutting machines, never on circular saw shafts.
Grinding bodies are permitted to be clamped on by experienced staff
only. Defective grinding bodies are not allowed to be used.
The highest permissible circumferential speed of the grinding bodies
must not be exceeded. The data given on the sticker to the grinding
body of the max. Permissible rotational speed must conform to that
of the machine as per identification plate. Those grinding bodies not
identified by stickers are not allowed to be used.
It is a must to wear eye protection in the case of grinding work.
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Work in free Heights

A precondition for work to be done in higher elevation is the physical aptitude.
Workers suffering from fainting spells, dizziness or similar weaknesses must not
be charged with such work. Since such ailments are not obvious in most cases,
workers have to inform their superior thereof, even if such ailments are only temporary.
Ladders:
Examine ladders regularly.
Remove defective ladders from their use immediately and reliably.
Have defective ladders repaired properly.
Secure ladders against:
Sliding
overturning, for instance by lashing the ladder head
excessive deflection
Ladders at traffic routes are to be particularly protected by blocking
offs or warning signs.
Lean-on ladders must extend at least 1,0 m beyond the exit point if
there is no other equivalent holding possibility.
Stepladders are not allowed for climbing over.
Ladders are usually used as accesses to working places only if stairs
or other installed footsteps are missing.
Work of minor extent only is allowed to be done from lean-on ladders.
Scaffolds
Scaffolds are to be installed and maintained by a specialist company.
Besides the legally prescribed acceptances by a competent 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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Work on Structural Components

Structural components must be sufficiently strong and stable if work
has to be carried out from them.
It must be possible to enter and leave a working place safely and
quickly at any time. A fall of persons or the dropping of objects must
be prevented during work.
At the outer edges of a building and at larger openings on a structural
component area at least a 3-part side protection has to be provided if
the fall height exceeds 2.0 m and the distance to strong structural
components is more than 0.3 m. Unless a side protection can be fitted, the fall of persons or the dropping down of subjects must be prevented by providing safety (catcher) stands, protective walls or
catcher nets which substantially extend up to immediately underneath the fall-down edge.
For construction work occurring at short notice and suddenly, scaffold
construction work or similar technical measures will not be possible
for various reasons. In that case, the safety belts are to be used for
personal protection.
A further preventive measure is the installation of danger signs to increase the safety of persons working in that area or passing underneath.
Mobile Gear
Only authorized drivers are permitted to operate the mobile gear. This also relates
to the staff of the subcontractors.
Dangers by Electric Current
Defective electrical equipment and materials mean a high risk for life and health.
Defective electrical devices are to be removed from further use immediately and
reliably and to be repaired by an electrical specialist.
Danger by electric current is impending in the case of:
damaged insulation of mobile or firmly installed connection and extension lines
kinks in the lines
exposed single wires at cable entries or in the cable routing
defective plugs
not regular and improper examination of electrical equipment and materials
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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
Attention is directed to the safety instructions Handling of Carcinogenic Materials.
First Aid
A sufficient first-aid outfit must be available at site at any time. It is to be provided
either by the contractor or by the customer. To render first aid, a completely
equipped First-Aid Kit must be available which will be checked either by the 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.
For all accidents first aid is to be rendered immediately and the superior to be informed without delay who will possibly initiate rescue measures.
Notification of Accident
All accidents however slight must be notified to the superior immediately since
each documented injury may be important for future determination of a work accident. The senior site manager/site manager is responsible for documentation of
the notification of accident.
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D1
Fire Protection
Suitable fire extinguishers are made available at site for fire protection.
Pay special attention to the fire protection regulations when welding and abrasive
cutting work is done.
Gas bottles and inflammable materials are to be stored appropriately and checked
regularly to prevent fires.
Observe No Smoking signs and do not use any matches or other open flame
near inflammable materials.
Special requirements of the customer for fire protection are to be adhered to strictly.
Behaviour at Customers Site
It is the objective of our company to fulfill the expectations of our customers within
the framework of the agreements reached. We shall not only render our services
promised, but our staff at sites shall also adapt themselves into our customers
works order and organization.
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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21
D1
1.1.4.
Transfer of risk for fire protection systems

(To be carried out prior to the hot commissioning of "First Coil")
1. Confirmation
Of the readiness for operation of all envisaged and installed fire alarm systems and fire extinguishing systems.
The Customer
Represented by
Ms./Mr.
hereby confirms
that the
fire alarm systems and fire extinguishing systems

envisaged and installed
for safe hot commissioning of the plant (plant section)
Designation:
Are ready for operation.

Date
Signature of Customer
Signature of SMS SIEMAG AG
2. Transfer of risk to the Customer

It is hereby confirmed,
that the responsibility for the fire alarm systems and fire extinguishing systems as from
Date:
for the following plants / plant sections
Time:
Designation:
shall be transferred to the Customer and assumed by him

Date:
Signature of Customer
A00226.580 / MAADEN
Signature of SMS SIEMAG AG
Stand / Revision
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D1
1.2.
Preconditions for Erection to Start

Buildings, Foundations:
Roofing of bays completed.
Sidewall panelling closed as far as practicable.
Foundations complete and in broom-clean state.
Anchor and other holes clean, i.e. free from dirt or other impurities.
Embedded parts fitted in accordance with applicable drawings.
Electric rooms complete and fitted with doors and windows.
Floor finishes in electric rooms and cellars will be provided on completed erection and after placing the grouts for main equipment.
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.
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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D1
1.3.
Plant Surveys
Marking of Longitudinal and Transversal Axes as well as Elevations:
The longitudinal and transversal axes of the plant will be fixed by embedded steel
plates (without protection box) to mark respective axis points (Figure 1).
Figure 2 - Figure 4 may also apply.
Elevation benchmarks will be fitted on operator and drive side to fix all elevation
points (referred to plant floor).
Drawing symbols used and their meaning:
Figure 1:
Axis Mark A - A for Longitudinal axes

Axis Mark B - B for Transversal axes
Figure 2:
Elevation benchmarks
Figure 3:
Levelling screws
Figure 4:
Foundation Recess for Protection Box
Required points are shown on sketches of axis plan and erection measuring 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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24
D1
Figure 5:
Axis Mark (without Protection Box)
100
A00226.580 / MAADEN
82
16
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2011
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25
D1
Figure 6:
Elevation Benchmarks and Axis Marks with

Protection Box and Levelling Spindle
260
50
100
Legend:
1) Grout
2) Epoxy Resin with Quartz Sand
3) Concrete
Figure 7:
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26
150
120
D1
Figure 8:
Protection Box
140
120
115
150
200
Figure 9:
Elevation Benchmark and Axis Mark
55 min
85 max
55
80
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D1
Figure 10: Setting of Centrelines by means of Theodolit
E
C
B
D
Figure 11: Setting of Centrelines using Piano Wire and Plumb Bob
E
C
B
D
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D1
Figure 12: Setting of auxiliary Axis by means of Theodolit
A
90
Figure 13: Setting of auxiliary Axis using Piano Wire and Plumb Bob
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29
D1
1.4.
Foundation Surveys
Surveys for individual machine foundations will be made with reference to the
foundation drawings to fix:
their position by main longitudinal and transversal axis
the spacing between anchor holes
the elevations of the foundation top surfaces as poured.
It should be observed in this conjunction that the machine grout thicknesses as
given in the foundation drawings will be complied with. This check will be effected
by means of a levelling instrument (Figure 14) and Report on foundation acceptance page 35.
Checking of Anchor Holes:
For stone bolts by simple depth measuring with the aid of a measuring
rod (Figure 15).
For anchor bolts with embedded anchor plates by insertion of corresponding bolts, making sure that the correct position of the anchor
plates fitted to the bolt T-head will be ensured. Also checked will be
the bolt length with due consideration to under grout thickness.
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.
Construction of Batter boards
Batter boards will be constructed from steel angles or channels in the form of vertical columns with crossbeams welded on top and diagonal braces (Figure 17).
Longitudinal or transversal axis points are to be fixed by transposition to the batter
board transoms, using an adjustable device on the transoms and/or crossbeams
or notches in the latter (Figure 18 and Figure 19).
Longitudinal and transversal axes will be identified by a steel wire of abt. 0.5 mm
dia which is loaded on both ends and which is taken from the above defined fixed
points.
Precision bobs to shall be used for all plumb bob measuring operations.
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D1
Figure 14: Foundation Check

A
1
2
Legend:
1) Measuring Rod
2) Dumpy level / Transit
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D1
Figure 15: Measuring of Anchor Hole Depth

1
Legend:
1) Measuring Rod
Figure 16: Surveys to determine the Position of Anchor Bolts
Legend:
1) Reference Point
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D1
2000
Figure 17: Piano Wire fitting Rig
10
00
800
Figure 18: Batter board

1
2
Legend:
1) Lock up Band
2) Piano Wire
3) Adjustable Device for taking up of Piano Wire
4) Plumb Bob
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D1
Figure 19: Device to receive Piano Wire
100
Legend:
1) Piano Wire
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D1
1.4.1.
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D1
Area according to SMS SIEMAG foundation drawings
Foundation meets requirements
Foundation does not meet requirements
Description of defects / Comments:
Elimination of defects by (date)
Date
A00226.580 / MAADEN
SMS SIEMAG site management
Customer / Buyer
Stand / Revision
2011
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Executed by
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36
D1
1.5.
Preparation of Foundations for Machine Erection

Smooth foundation surfaces are to be roughened up in order to improve bonding
between concrete and under grouting (Figure 20).
The foundation surface is to be cleaned from loose particles as well as from oil,
grease and other bond affecting residues.
Before the machine elements are mounted on top of the foundation, shim plates
are fitted on either side of the anchor bolts (Figure 21 and Figure 22).
Arrangement and positioning of the shim plates is to be performed in the way that
no projections beyond machine elements are exist.
After the machines have been levelled and aligned, all shim plates are to be spot
welded with each other to prevent any displacements.
All shim plates have to be supplied by the erection company are not part of SMS
SIEMAG scope of supply.
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D1
Figure 20: Chipping of Foundation Surfaces
Legend:
1) Bush Hammer
Figure 21: Arrangement of Shim Plates

2
600
Legend:
1) Anchor Hole
2) Shim Plates
Figure 22: Shim Plates
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D1
Figure 23: Formwork for Level Compensation
20 min
60 max
120
140
Figure 24:
Legend:
1) Handle
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D1
Figure 25:
1
3
5
Legend:
1) Machine/Plant section
2) Shim plates
3) Base plate
4) Existing foundation
5) Grouting mortar
Secure shim plates by weld spot after finish-alignment!
Figure 26:
1
Legend:
2) Shim plates
3) Base plate
5) 2 - component plastic material
Secure shim plates by weld spot after finish-alignment!
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D1
Figure 27:
1
Legend:
2) Inclination 1:100
3) Base plate
4) Grouting mortar
6) Pair of wedges
min.50mm longer Tolerance e. g. Bed plate / Base plate
Secure pair of wedges by weld spot after finish-alignment!
Alignment work in mill stands

Prepare foundation
Shim plates
There are different possibilities of aligning the shim plates on the foundation:
The base plate is laid in a mortar bed into the level surface (Figure 25).
The foundation surface is chiselled out by about 25 mm longer and wider than
the base plate, and around 10 mm deep. Following this, the recess is grouted
with a 2-component plastic material (epoxies resin). After hardening, the material is absolutely plane and ready for receiving the shim plates (Figure 26).
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D1
Wedges.
Here, the procedure can be similar to that described Shim
plates(Figure 27).
Insert anchor bolts.
Insert anchor bolts

before inserting the anchor bolts, a sketch showing the anchor plate
position should be prepared because it is not sure that the tee-head
slots are always oriented towards the same direction.
Alignment of bed plates.
Level height of shim plates.
Deposit bed plates.
Pre-align first bed plate towards axis and height.
Finishing-align bed plate after placing the mill stand housings.
Alignment of housings.
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D1
1.6.
Levelling/Alignment and Anchoring of Machines and Equipment Units

Where T-head bolts are used, check to see that these have been fitted into the
foundation anchor holes prior to setting up any of the machine or equipment units.
Install machines on prepared bases or levelling screws and adjust to specified elevation while simultaneously taking surveys by means of level.
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.)
Machines or equipment units anchored by means of stone bolts will be pre-levelled
/ pre-aligned to their defined level and axes. Stone bolt holes will be filled with initial grouts to three quarters of their height. The machine or equipment unit concerned will be finish levelled / finish-aligned after the grout has cured.
Example
Levelling/alignment of bedplates, bases, roller tables etc. (Figure 28)
Measurement of couplings (Figure 29,29b and Figure 30).
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D1
Figure 28: Levelling/Alignment of Bedplates, Bases, and Roller Tables etc.
B
B
7
10
8
B
0
3
4
1
2
A
Legend:
1 10
1+6
2
3+4
7
8
9
10
A00226.580 / MAADEN
=
=
=
=
=
=
=
=
=
=
Measuring Points
Parallelism
Position
Coordinate Measurement
Distance Dimension
Levelling
Horizontal Plane
Flatness
Benchmarks
Axis Marks
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2011
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D1
Figure 29: Measurement of Couplings

1
Legend:
1) Misalignment
Figure 30:
Legend:
1) Feeler Gauges
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D1
Figure 29 b: Adjustment of couplings with laser units

Adjustment of coupled and uncoupled shafts
Adjustment of horizontal, vertical and flange-mounted machines
Adjustment of cardan and intermediate shafts
Adjustment of machine lines
Figure 29 b
Copyright by Prftechnik Dieter Busch AG
( Is not in SMS SIEMAG scope of supply )
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D1
1.7.
Placing Under grouts

Before placing under grouts for individual machine or equipment units or before
bringing in initial grouts for stone bolts, a written request will be sent to the 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.
Foundation areas mark
in the construction drawings will not be
grouted until after installation and/or erection of the corresponding equipment units
when these have been aligned / levelled and their foundation bolts have been firmly tightened down. The quality of the under grout material used must at least be
equal to that of the foundation concrete. It is recommended instead of concrete or
mortar to use a special under grout mass which is both shrink-free and also faster
curing.
Where under grout areas are not distinctly identified, the basic rule applies that all
horizontal faces under machine frames will be grouted.
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.
Release for Machine Grouting see: Chapter 1.17.
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D1
Examples of Application for Machine grouting:

Figure 31:
6
Legend for Figure 31 and Figure 32:
1) Machine part
2) Shims
3) Formwork
4) Foundation
5) Grout
6) Funnel
Figure 32:
1
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D1
Figure 33:
2
1
5
3
Legend:
1) Machine part
2) Shims
3) Formwork
4) Foundation
5) Grout
Preparation of placing grout:

Surface
thoroughly clean, and remove excess cement debris as well as oil
and grease. The surface should be made approx. 6 hours in advance.
Formwork
Tightly secure and seal.
Mixing
Is ready for use, requiring only the addition of water. 7 9 l of water
are required for 50 kg of grout.
Grouting
Pour from one side or corner only without interruption.
Note
Open areas are to be protected against premature water evaporation.
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D1
1.8.
Storage, Slinging, Load Table and Unpacking of Supplied Equipment

Materials and/or equipment can be protected against climatic influences by means
of suitable packaging measures only when the climatic conditions (for instance
temperatures, atmospheric humidity, and precipitations) to be expected during
storage, interim storage, transfer and transport operations are sufficiently known.
The standard signs shown on all packages are to be observed for storage and
slinging of cases.
Figure 34: Fragile
Figure 35: Use no hand hooks
Figure 36: This way up
Figure 37: Keep away from

sunlight
Figure 38: Keep away from rain
Figure 39: Centre of gravity
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D1
Figure 41: Do not use hand truck

here
Figure 40: Do not roll
....kg max
Figure 42: Use no forks
Figure 43: Stacking limit by mass
Figure 44: Clamp as indicate
Figure 45: Do not clamp as

indicated
Figure 46: Sling here
Figure 47: Temperature limits
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D1
Irrespective of the packing medium used, distinction will made between two basic
types of packing for shipment:
Self - supporting type of packing
Figure 48:
Figure 49:
Depending type of packing
Figure 50:
Figure 51:
After unpacking, the contents of each package will be checked for completeness
and potential damage with reference to applicable shipping documents.
The conditions and contents of the cases to be confirmed by an appropriate certificate (see Chapter 1.17.).
Storage after unpacking:
Mechanical equipment
Electrical equipment
Structural
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Indoor, dry
Indoor, dry, air conditioned
Outdoor
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D1
Load Table for Slinging Means of Steel Wire Ropes N

This table is only applicable to steel wire slinging ropes N (normal) to DIN 3088
(issue May 1989) featuring a rated strength of the individual wires of 1770 N/mm2.
Load Capacity in kg
Rope
Rated
Diameter
Single Strand
Double Strand
with inclination angle
from 0 to 45
from 45 to 60
60
45
mm
8
10
12
14
16
18
20
22
24
26
28
32
36
40
44
48
52
56
60
A00226.580 / MAADEN
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
Stand / Revision
2011
560
850
1250
1700
2240
2800
3550
4250
5000
6000
6700
9000
11200
14000
17000
20000
23600
26500
31500
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D1
Load Table for Slinging Means of Steel Wire Ropes K

This table is only applicable to steel wire slinging ropes K (cable slinging rope) to
DIN 3088 (issue May 1989) featuring a rated strength of the individual wires of
1770 N/mm2.
Load Capacity in kg
Rope
Rated
Diameter
Single Strand
directly
from 0 to 45
from 45 to 60
60
45
mm
24
27
30
33
36
39
42
48
54
60
3150
4000
4750
6000
7100
8000
9500
12500
16000
19000
4500
5600
6700
8500
10000
11200
13200
18000
22400
26500
3150
4000
4750
6000
7100
8000
9500
12500
16000
19000
Due for laying aside; rope types N and K

Slinging ropes are to be taken out of use upon discovery of the following types of
damage or defects:
Fracture of a strand.
Buckles and kinks (cramps).
Slackening of the outer layer in the free length.
Corrosion pits.
Crushing in the free length.
Wire fractures in a large number.
Crushing in the eye depositing area, exhibiting more than 4 wire fractures in strand ropes or more than 10 wire fractures in cable slinging
ropes.
Damage or heavy wear of the ropes or rope-end joints.
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D1
Load Table for Slinging Means of Chemical Fibre Ropes

The load capacities apply to slinging fibre ropes according to DIN 83 302 (issue
May 1990). The table is applicable to twisted heavy drag ropes from polyester as
per DIN 83 331 and polypropylene type 2 as per DIN 83 332. In case of ropes from
polypropylene type 1 as per DIN 83 329, the load capacity is to be reduced to
about 50 %.
Load Capacity in kg
Rope
Rated
Diameter
directly
Double Strand
braided
from 0 to
45
from 45 to
60
45
mm
Polyester
60
16
20
24
28
32
36
40
48
560
850
1250
1700
2150
2650
3350
4500
450
670
1000
1320
1700
2120
2650
3550
800
1180
1800
2360
3000
3750
4750
6300
560
850
1250
1700
2120
2650
3350
4500
Polypropylene
Fibre material
Single Strand
16
20
24
28
32
36
40
48
475
710
1000
1320
1700
2120
2500
3550
375
560
800
1060
1320
1700
2000
2800
670
1000
1400
1900
2360
3000
3550
5000
475
710
1000
1320
1700
2120
2500
3550
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D1
Load Table for Slinging Means of Natural Fibre Ropes

The load capacities apply to slinging fibre ropes according to DIN 83 302 (issue
May 1990). The table is applicable to twisted heavy drag ropes from Manila as per
DIN 83 322 and hemp as per DIN 83 325.
Single Strand
Rope
Rated
Diameter
directly
Double Strand
braided
from 0
to 45
60
45
Manila
mm
from 45
to 60
16
20
24
28
32
36
40
48
250
400
560
750
1000
1250
1500
2120
200
315
450
600
800
1000
1180
1700
355
560
800
1060
1400
1800
2120
3000
250
400
560
750
1000
1250
1500
2120
Hemp
Fibre material
Load Capacity in kg
16
20
24
28
32
36
40
48
212
315
450
630
800
1060
1250
1800
170
250
355
500
630
850
1000
1400
300
450
630
900
1120
1500
1800
2500
212
315
450
630
800
1060
1250
1800
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Due for laying aside; chemical fibre ropes and natural fibre ropes
Fibre ropes (in general) are to be taken out of use upon discovery of the following
types of damage or defects:
Fracture of a strand.
Mechanical damage, heavy wear or slackening.
Damage caused by aggressive matter.
Slackening of splices.
Additionally to be applied to natural fibre ropes:
Dropping-out of fibre flour during untwisting of the rope.
Damage caused by moist storage.
Additionally to be applied to chemical fibre ropes:
Heavy warp age caused by heat, e. g. due to internal and external friction, heat radiation.
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D1
Load Tables of Round Steel Chains Grade Class 8

These tables are applicable to slinging chains to DIN 5688 Part 3 Slinging Chains,
Hook Chains, Ring Chains, Grade Class 8.
Load Capacity in kg in Straight strand

Chain
Nominal
Thickness
Single
Strand
Double Strand
With inclination angle
from 0
to 45
Three- and Four Strand

With inclination angle
from 45
to 60
from 0
to 45
from 45
to 60
45
mm
4
6
8
10
13
16
18
20
22
26
28
32
36
40
45
45
60
500
1000
2000
3200
5000
8000
10000
12500
15000
20000
25000
32000
40000
50000
63000
700
1400
2800
4500
7100
11200
14000
18000
21200
28000
35500
45000
56000
71000
90000
500
1000
2000
3200
5000
8000
10000
12500
15000
20000
25000
32000
40000
50000
63000
1050
2100
4250
6700
10000
17000
21200
26500
32000
40000
50000
63000
80000
-----
60
750
1500
3000
4750
7500
11800
15000
18000
22400
30000
37500
47500
60000
-----
If several strands are used for slinging, only two of them are allowed to be taken
as carrying means. This does not apply in case it is sure that the load is uniformly
distributed also onto additional strands. Should the load distribution not be uniform, the admissible load of the individual strands must not be exceeded.
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Load Tables for Round Steel Chains in Grade Class 8
Load Capacity in kg in Lasso position

Chain
Nominal
thickness
Double Strand
with inclination
Single Strand
from 0 to 45
45
from 45 to 60
60
mm
4
6
8
10
13
16
18
20
22
26
28
32
36
40
45
400
800
1600
2500
4000
6300
8000
10000
12000
16000
20000
25000
32000
40000
50000
560
1120
2240
3550
5600
9000
11200
14000
17000
22400
28000
35500
45000
56000
71000
400
800
1600
2500
4000
6300
8000
10000
12000
16000
20000
25000
32000
40000
50000
Due for laying aside

Slinging chains are not allowed to be used any longer when the complete chain or
a single link has become elongated by 5 % or more, or when the link thickness
(nominal thickness) has reduced at any point or other by more than 10 %. (see
DIN 685 Tested round steel chains).
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1.9.
Consumables Needed During Erection

Power for Electric Tools, Welding Machines etc.
Distribution boxes with fuses should be available in adequate number.
Current intensity and frequency to National Standards.
Power consumption to be estimated by erection contractor.
KVA
Water for Erection Purposes.

Water quality with: pH value 7.
Temperature abt. 20C.
Extraction points in various areas throughout the site as indicated.
Consumption each extraction point to be estimated by erection contractor.
m3/day
Note:
Water consumption may increase to three to four times the above figure during
chemical cleaning of pipelines.
Compressed Air from Works System for Erection Purposes.
Pressure abt. 5 bar in various Tops throughout the bay above and below mill floor.
Compressed air should be free from oil and water.
Consumption to be estimated by erection contractor.
m3/day
Gas Welding
Gas welding rods, diameter:
2.0 mm
2.5 mm
3.0 mm
4.0 mm
compatible with the parent material to be welded.
Gas welding rods to DIN 8554 (low alloy type).
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Arc Welding
Stick electrodes, diameter:
2.50 mm
3.25 mm
4.00 mm
5.00 mm
compatible with the parent material to be welded.
Stick electrodes to DIN EN 499 (low alloy type).
Stick electrodes to DIN 8556/8555/ISO 3581 (corrosion resistant).
Shielded Arc Welding
Welding rods, diameter:
1.6 mm
2.0 mm
2.4 mm
3.0 mm
or coiled welding rods, diameter:
1.0 mm
1.2 mm
1.6 mm
Welding rods to DIN 8575 (low alloy type)
Welding rods to DIN 8556 (corrosion resistant).
Cored Wire Welding
Cored wire electrodes, diameter
1.6 - 2.8 mm
Cored wire electrodes to DIN EN 440
Chemicals for Pipeline Cleaning
See Chapter Chemical Cleaning of Steel Pipes on page 83.
All consumables and supplies mentioned here shall be made available by the customer in sufficient quantities in close vicinity to the point of consumption.
They are not included in the scope of supply of SMS SIEMAG.
The amount of consumables has to be estimated by the erection sub-contractor.
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Sundries
Oils and greases (for assembly of machinery and equipment)
Acetylene
Oxygen
Argon or helium
Sealing tape
Loctite
Liquid surface sealing compound
Filter elements for flushing according to SMS SIEMAG circuit diagrams
Shim Plates
Material: St 37 or similar.
Shims must be plane-parallel and deburred on all sides.
All shim plates have to be supplied by the erection company and are not part of
SMS SIEMAG scope of supply.
Dimensions (mm)
200 x 100 x 40
200 x 100 x 30
200 x 100 x 25
200 x 100 x 20
200 x 100 x 15
200 x 100 x 10
200 x 100 x 5
200 x 100 x 2
200 x 100 x 1,5
200 x 100 x 1
200 x 100 x 0,5
200 x 100 x 0,2
200 x 100 x 0,1
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1.10.
1.10.1.
Fitting, bending and welding of piping

Execution of fitting work
Steel piping is normally obtainable on the market in lengths of ca. 6 meters and
must follow the contour of walls and machines during erection work. Pipe connections are therefore inevitable.
A distinction is made between:
welded and thus fixed connections and
pipe couplings that can be separated.
A piping network has to be manufactured and installed diligently since the 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.
The following must be observed in particular:
split-up into prefabrication and fabrication on the site,
installation of straight, direct, clearly arranged and flow-favourable
lines,
cleanness during work,
proper fastening of the piping system,
tension-free installation.
Split-up into prefabrication and fabrication on site
The fabrication of piping systems is performed in accordance with 2 methods that
deviate from each other:
prefabrication in workshop and
fabrication on site.
A mixture of the two types is often chosen out of technical and practical considerations.
Prefabrication
In the case of prefabrication the piping is manufactured in a workshop, separately
in time and place from the activities on the site, and delivered to the site for installation.
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Fabrication on site
In the case of manufacture on the site the piping is manufactured in accordance with the progress
of erection.
Figure 52: Saw off pipe at right angles and debur it but do not use a pipe cutter.
Use a sawing machine if possible. Slightly debur pipe ends on inside
and outside. Clean.
Cleanness in work
During the installation work it must be ensured without fail that dirt does not penetrate into the piping system. Piping and components must be delivered to the place
of installation in a properly closed state.
During the progress of the installation work the connections of the pipes and 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.
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.
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Fitting of welded connections

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

In the case of separable connections the pipes are connected with a coupling or
with a flange. This may be done with various systems.
Depending on the connection we distinguish at SMS SIEMAG between:
screw connections,
compression-ferrule pipe couplings,
welding-nipple pipe couplings and
flanged connections.
A distinction must be made between the pipe/pipe coupling and the pipe coupling/component connection (valves, base plates, control blocks, pumps).
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Fitting of connection pipe/pipe coupling

Screw connection (Figure 53)
The fitting of screw connections is characterized by the fact that the
connection pipe/pipe coupling is executed with the aid of a thread
cut onto the pipe. The sealing here is metal-metal. These threads are
normally screwed in with sealing tape. The holding function is in the
thread. Connections of this kind are used for example with water
lines.
Figure 53: Screw connection, metal-metal sealing, holding function using thread,
use in low-pressure range (e.g. on water lines)
Compression-ferrule pipe coupling (Figure 54)
In the fitting of ferrule pipe couplings a ferrule (bite ring) is pulled onto the pipe. It
cuts into the pipe surface and fulfills at this point the holding and sealing functions. The function sealing to pipe-coupling body is also metal-metal. The holding
function of a ferrule toward the pipe coupling is ensured with the aid of the union
(cap) nut.
Ferrule couplings have to be serviced as they would otherwise tend to leak due to
their metal-metal sealing and to the settling that results there from. Due to the
surface brittleness it is however only possible to tighten within certain limits.
The ferrule should be pulled onto the pipe with particular care, as the ferrule would
slip from the pipe under load if it did not cut sufficiently far into the pipe.
During fitting it should also be ensured that the pipe ends are cut off at right angles
and cleanly deburred.
The fitting instructions of the coupling maker must be observed.
Figure 54: Ferrule pipe-coupling, metal-metal sealing, holding function by a

cutting edge
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Welding-nipple pipe coupling (Figure 55)

In the fitting of welding-nipple pipe couplings a welding cone is welded on to the
pipe (butt welding).
The sealing between the welding cone and the coupling is elastic. The holding
function between the cone and the coupling is fulfilled by the union nut.
The fitting instructions of the coupling maker must be observed.
Figure 55: Welding-nipple coupling with cone, elastic sealing, holding function by
weld seam
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Fitting of connection pipe coupling/component

In these pipe couplings the holding function between the coupling and the component is fulfilled with the aid of the thread. Coupling bodies are distinguished by the
kind of sealing of the body toward the components.
Coupling body with sealing edge (Figure 56)
With sealing-edge coupling bodies a sealing edge that seals metalmetal on the components is machined onto the screwed plug. The
precondition is that the screw-on surface is at right angles to the
thread and does not display any cross scoring. The pulsation usual in
the hydraulic equipment may lead to material hardening occurring
that necessitates the retightening of the couplings.
Normally the threads are however glued in with sealing material, e.g.
with Loctite. The sealing function is then in the thread.
The fitting instructions of the coupling makers and of the sealingmaterial maker must be observed.
Figure 56: Coupling body with sealing edge,

Metal-metal sealing,
Countersink at right angles to thread,
Countersink is damaged by cutting edge
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Coupling body with U-ring (Figure 57)

With the coupling body with a U-ring the sealing function is fulfilled by
the latter. The precondition for this is also that the securing surface is
at right angles to the thread and that it does not display any cross
scoring. The surface roughness of the contact face and of the U-ring
compartment should not exceed
RZ 16.
The fitting instructions of the coupling makers must be observed.
Figure 57: U-ring, elastic sealing

Pipe coupling body with NPT thread (Figure 58)
The NPT threads are tapered. They are inserted in a tapered screwin thread. The sealing is metal-metal. Normally speaking these
threads are glued in with sealing material, e.g. with Loctite.
As a result of the slanted thread of the screwed plug there is the
danger that components made of castings or aluminium are burst as
the coupling is screwed in.
The fitting instructions of the sealing-material maker (Loctite) must be
observed.
Figure 58: NPT thread,

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

Pipe couplings larger than DN 40 are no longer usual.
From DN 40 flanges upwards are used to connect pipelines with each other and
with components.
With the flange connections the connection flange/pipe is welded in almost all
cases. A butt weld is almost always used.
The type of the flanges used depends essentially on the components used and on
the pressure.
Flanges according to DIN (Figure 59)
Ball valves, butterfly valves and other valves have in some cases the
connection pattern for a DIN flange, so that the latter is used for this
reason also.
(1) Gasket to DIN 2690

Figure 59: Flange with sealing, holding function by bolts
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SAE flanges
Many components in hydraulics have screw-on surfaces for so-called
SAE flanges from DN 40. A distinction is made between
one-part SAE flanges and
multi-part SAE flanges.
SAE flange one-part (Figure 60)

The one-part SAE flange is made in one piece. Different weld-on plugs for varying pipe dimensions may be equipped with the same SAE connection pattern.
The one-part SAE flange can no longer be adjusted after it has been welded
on.
The fitting instructions of the flange maker must be observed.
Figure 60: SAE flange, one-part with O-ring, holding function by bolts
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SAE flange, multi-part (Figure 61)

The multi-part SAE flange consists of the so-called welding collar, of a turning
part or shaped component in weld able material and of the two flange shoulders
that perform the holding function.
The sealing between the base surface and the SAE flange or between one SAE
flange and another is done elastically with the aid of O-rings.
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.
Figure 62: Flange connection with square flange,

Elastic sealing by O-ring,
Holding function by bolts
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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.
The compensators used in hydro systems are made of steel or rubber/artificial
rubber in various qualities that is affixed to a rugged carcass of synthetic fibre or
steel wire, depending upon the pressure.
For attachment to the piping system pipe couplings are used from DN 40 upwards
steel flanges in St 37.2 or, if necessary, in other materials
(Figure 63 and Figure 64).
Figure 63: Compensator for flange connection
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Outer layer
(2) Inner layer
(3) Flange with profile collar
(4) Flange with full profile
Figure 64: Compensator for flange connection
Compensators as elastic pipe connections must be installed in such a way that
visual monitoring is possible. The rubber parts must not be coated (painting). No
insulation material may be applied.
Compensators should be installed in such a way that if possible they are loaded
when pressed together. Stretching in the operating state must be avoided. Torsion
is inadmissible.
Between two fixed points a max. of only one elastic pipe connection must be used.
Rubber compensators should be protected against radiation and heat and if 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.
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.
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Fitting of hose lines

Hose lines are elements for energy transfer in media systems. They are intended
to compensate movements or serve as a length compensation in long piping systems.
Hose lines consist of the actual hose itself and the matching fittings. The fittings
have been adapted to the connecting system within the pipeline.
Fitting of hose lines
The lifetime of hose lines is lengthened if they are correctly laid.
Twisting of the hose during fitting should be avoided!
Hose lines should be fitted in such a way that there is no tension load, except by
natural weight!
The smallest admissible bending radii must not be gone below!
If a houseline is fitted bent, its length must be selected in such a way that the
bend-free zone is retained!
Fittings should be selected in such a way that the additional loading of the hose is
avoided!
Hose lines should be protected against external influences. Sharp-edged components should be covered. When necessary, hoses should be protected by suitable
sleeves!
The fitting instructions of the hose line makers must be observed.
Figure 65: Examples for correct laying of hose lines
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Fitting of pipe supports

Supports are used to secure piping efficiently. Pipe clamps are made of steel, aluminium, plastic or plastic with a rubber lining.
The clamp base plates are made in weld able steel so that they can be properly
secured to the substructure.
Figure 66: Pipe clamp, heavy-duty series
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Figure 67: Clamp stack, e.g. for two pipes arranged one above the other
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The piping system is usually secured to the machine structure or to the foundation
walls. A separate substructure must often be created for the piping (Figure 68).
The distance between two clamps depends upon the pipe outer diameter.
See SN 573 for fitting of pipe holders.
The fitting instructions of the pipe support makers must be observed.
Figure 68: Substructure to receive piping system

Identification of valves, measuring devices etc.
Valves, measuring devices etc. are identified in the flow diagrams (process schematics, P + I) and in the installation and piping drawings as well as in the layouts
of electrical devices with special identification numbers.
These components must, insofar as they are not already delivered with the identnumber, be labelled provisionally during the fitting of the piping (immediately after
fitting) by means of adhesive tape for example.
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1.10.2.
Bending
For pipe bending radii, minimum dimensions for angled pipes and determination of
pipe lengths with consideration to various bending angles and bending radii also
see SN 740 Part 1 and 2 or DIN 2916.
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1.10.3.
Welding
Weld preparation of pipelines with reference to DIN 2559/1.
Table 1 ( SN 200 Part 4):
Illustration
Wall
thickness Designation
t
to 2
over 2
Section
Weld joint preparation

View
s=t
Single V
butt weld
s=t
Single U
butt weld
over 20
over 20
Depth of
weld seam
s
Square butt
weld
to 20
Butt-type joint
Shape of
groove
Comer joint
2-3
25
To 2
60
25
To 2
10
6 10
10
25
To 2
30 - 40
s=t
all
s=t
Steepflanked
single V
butt weld
Dimensions
Approximates
Single J
butt weld
s=t
Fillet weld
all
s=t
t
Note:
All hydraulic pipelines are to be butt-welded.

Pipelines and welding - neck flanges provided with a 40 m prime coat
must be machined at the welding ends such that a prime coat of
max 20 m is left.
20 m dry coat thickness for the prime coat will permit proper welding.
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Welding Processes
Gas welding (oxyacetylene welding)
Gases: Oxygen O2 + acetylene C2H2
Filler metal: compatible with pipe material.
Application: All pipes to DIN 2391 and DIN 2448 having wall thicknesses 3 mm.
No weld preparation, however with gap corresponding to filler rod diameter. 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).
Application: All pipes to DIN 2391, DIN 2448, DIN 2462 and DIN 2463 having wall
thicknesses > 3 mm.
Electrodes to be compatible with the material of the parts to be joined by welding.
Electric arc welding always require mechanical inside post treatment by manual
methods.
Inert Gas Welding
Tungsten inert gas welding, in brief TIG.
Welding gas argon/helium (purity 99 %).
Filler rod selected under the aspect of compatibility with the pipe material.
Application: Universal for all pipelines for reasons of costs to be used for root
passes only. Between-beads and final passes can be provided by
electric arc welding. Weld preparation same as for electric arc welding
(see Table 1).
Pipeline must be purged with antis lag gas to the following criteria to protect pipe
inner walls and root passes.
Required in all cases for pipelines of stainless steels.

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

Butt welding:
Figure 69:
One weld seam required for each welded joint

Weld seam up to standard, transferring the same force factor as the actual
pipe
No internal dirt deposits between the pipe ends, resulting in unobjectionable inside purification by way of rinsing in the case of pickling pipes
No additional stress formation in longitudinal direction
Precise alignment of pipe axles necessary
TIG root welding prevents spatters on inner surface
Socket welding
Figure 70:
Two weld seams required for each welded joint

Due to fillet weld, weld seam transfers at best 60 % of the pipe force factor
Due to thermal expansion, axial gap necessary; otherwise additionally
stress formation in longitudinal direction
Undercut in pipe, resulting in reduced wall thickness
Axial gap prevents inside purification during rinsing
Settling of dirt particles in axial gap which detach after start-up and lead to
malfunctions in the valves
Note!
SMS SIEMAG does not apply to socket welding!
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1.11.
Chemical Cleaning of Steel Pipes

(Degreasing, pickling, passivating)
One of the major preconditions to be satisfied for trouble-free operation is that the
inside surfaces of the supply pipes are clean. To ensure this, all pipe systems are
degreased, pickled and passivated to defined rules and criteria prior to commissioning.
The following pipelines are to undergo chemical cleaning:
Pipelines for Morgoil lubrication systems

Pipelines for oil circulation lubricating systems
Pipelines for hydrostatic systems
Pipelines for hydraulic systems
Pipelines for emulsion systems
Pipelines for grease systems
Pipelines for oxygen systems
Pipelines for water systems
Pipelines for gas systems
Chemical cleaning can be done by two different methods:

Chemical cleaning by the recirculation process
Chemical cleaning by the immersion process
Fluids to be used:
- Degreasing agent Lutensol

ON70 (BASF)
0.02 %
- Inhibitor Rodine 31 A:
0.15 %
- Citric acid (GRAN) C6 H8 O7:
7%
- *Ammonium bifluoride (NH4) HF2:
1%
- Citric acid (GRAN) C6 H8 O7:
0.3 %
- Ammonia NH3OH:
0.9 %
- Sodium nitrite NaNO2:
0.3 %
or
- Hydrogen peroxide approx. 35% H2O2:
0.5%
- Sodium hydroxide NaOH:
or
- Calcium hydroxide
200 g/m
1.5 kg/m
70 kg/m
10 kg/m
3 kg/m
9 kg/m
3 kg/m
5 kg/m
50 kg/m
50 kg/m
*In case ammonium bifluoride is not available, the minimum pickling temperature
must be 45C, but maximum 80C.
Make sure pickling equipment, hoses, etc. are temperature resistant.
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Description of the recirculation process

Caution!
Basically, chemical cleaning should be carried out by specialized
companies in due compliance with the safety rules applicable to the
handling of substances that are detrimental to water. Disposal of
neutralised pickling solutions must be effected in conformity with official national rules and requirements.
After assembly of the pipelines the specialized company will define

which interconnecting pipelines are combined to form a circuit.
All valves, fittings and equipment units fitted in a circuit which are not
pickling liquor-resistant are removed and replaced by connecting
pieces made from accessory pipe work made from the same material
. Seals made from rubber, or plastics (Viton, Perbunan) are pickling
liquor-resistant and are not removed.
The circuit that has been prepared to specific instructions starts from
and terminates in a tank (chemicals dosing tank) from which the fluid
is fed into the circuit and into which it also finally returns. The length
of the pipes combined into a circuit depends on the inside diameter
of the pipe.
The pickling process commences with filling the pipe system with water. As soon as the water starts flowing inside the circuit, all of the
pipe connections are leakage-tested. If the circuit is found to be tight,
the degreasing agent is added to the water.
The complete chemical process can be carried out without heating,
provided the fluid temperature is not less than + 20C.
Next, the inhibitor and then nitric acid and ammonium bifluoride are
added by metering and recirculated for 6 to 10 hours. During recirculation, the chemical reaction is tested by measurements of the returning acid. The termination of the pickling process depends on the results of these measurements. During pickling, a piece of pipe with
weld seam is hung into the pickling fluid in the chemicals dosing tank.
This test piece should exhibit a similar degree of contamination as
the pipe system to be pickled. This may be used to visually observe
the pickling progress and also the end of pickling.
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The pickling liquor in the pipes is flushed with clear water in a separate
neutralisation tank and neutralised there to a pH value of approx. 7
by adding sodium hydroxide or calcium hydroxide.
The pickled pipes are passivated to preserve their inside faces for a
period of 2 to 6 weeks (depending on the ambient humidity). Another
recirculation treatment is made with the following steps : Circuit with
0.3% nitric acid for 2 to 4 hours, depending on the temperature and
system size. Then slow metered dosing of ammonia solution (25%)
to the citric acid until pH > 9.5 and recirculation for 1 hour. Then slow
metered dosing of 0.3% sodium nitrite and recirculation for 1 to 3
hours, depending on the temperature and system size. (to improve
metered dosing, the sodium nitrite may be pre-dissolved in water.)
The passivating solution is then drained. Pipes up to 50 DN max. are
then purged with dry compressed air or nitrogen (no oxygen). The
passivating treatment protects the pipe inside faces against rust film
formation for the period mentioned.
It is recommended that the pipe systems be filled or flushed with suitable fluids, preferably directly after the chemical cleaning process. If
possible, the passivating solution may be pumped through bag filters.
This process allows particles to be flushed out of the pipes more efficiently than with hydraulic oil later on. In addition, pull-through elements (pigs) may be "shot" through pipes of unchanging cross section with compressed air or nitrogen several times, if necessary.
Then the pipes / systems are blown dry with clean compressed air or
nitrogen. Preferably up to a dew point of -20C, but least until such
time as no humidity comes out of the pipes anymore. Check with the
back of the hand or a white cloth.
Note:
Absolutely dry pipes are a prerequisite for good results during later oil flushing,
because:
Residual humidity / water droplets from the oil particle counter are detected as dirt particles.
Residual humidity affects the oil quality and is difficult to remove from
the oil.
Residual humidity in the tank and in pipes not permanently filled will
lead to corrosion / rust.
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86
D1
Process equipment and facilities

Recirculation process for carbon steel pipes
1 tank of about 1 000 x 1 000 x 800 mm high, made from rubbercoated steel plate of about 6 - 8 mm thickness
1 neutralising tank with a capacity of 3 - 15 m, made from rubbercoated steel plate of about 10 - 12 mm thickness
Various rubber-coated shut-off valves (diaphragm valves) DN 32 - DN
80
1 acid-resistant pump, about 25 - 80 m/hour at 25 - 60 m delivery
head.
Various connecting hoses with hose clips about DN20 DN80
Various flange sockets for connecting hoses, sizes as required.
Various transition screw joints and flange-type reducers, sizes as required. The number of connections and bypass connections actually
required depends on the size of system to be pickled.
Comparison of immersion and recirculation process

See 1.13. page 95.

See 1.22.1.
Example of Pickling Scheme in Recirculation Process (Hydraulic power system)

See 1.22.2.
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87
D1
1.12.
Stainless Steel Pipes



Fluids to be used:
- Degreasing agent ON70 (BASF)

- Hydrofluoric acid HF, 40 %:
- Nitric acid HNO3, 53-56%
- Calcium hydroxide
0.02 %
3%
12 %
200 g/m
75 kg/m
240 kg/m
110 kg/m
Caution!
The concentration may vary as a function of the state and condition
of the inside surface.
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88
D1
Description of the recirculation process

Caution!
Basically, chemical cleaning should be carried out by specialised
After assembly of the pipelines the specialised company will define
whichinterconnecting pipelines are combined to form a circuit.
All valves, fittings and equipment units fitted in a circuit which are not
pickling liquor-resistant are removed and replaced by connecting
pieces made from accessory pipework made from the same material
. Seals made from rubber, or plastics (Viton, Perbunan) are pickling
liquor-resistant and are not removed.
The circuit that has been prepared to specific instructions starts from
and terminates in a tank (chemicals dosing tank) from which the fluid
is fed into the circuit and into which it also finally returns. The length
of the pipes combined into a circuit depends on the inside diameter
of the pipe.
The pickling process commences with filling the pipe system with water. As soon as the water starts flowing inside the circuit, all of the
pipe connections are leakage-tested. If the circuit is found to be tight,
the degreasing agent is added to the water.
The complete chemical process can be carried out without heating,
provided the fluid temperature is not less than + 20C.
The next step is to add metered nitric acid and hydrofluoric acid one
after the other and to recirculate this mixture for approx. 4 to 6 hours.
During recirculation, the chemical reaction is tested by measurements of the returning acid. During pickling, a piece of pipe with weld
seam is hung into the pickling fluid in the chemicals dosing tank.
This test piece should exhibit a similar degree of contamination as
the pipe system to be pickled. This may be used to visually observe
the pickling progress and also the end of pickling.
The acid prevailing in the piping system is flushed with demineralised
water (water of at least drinking water quality) and neutralised to
pH7. The remaining clear flushing water is drained and the pipes are
purged with dry compressed air or nitrogen (no oxygen). Passivating
is not required. If passivating is required for certain fluids, this is done
by using a 10% nitric acid and by recirculating it in the same way as
for pickling for 2 to 3 hours, depending on the system size and temperature.
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D1
The acid prevailing in the piping system is flushed with demineralised

water (water of at least drinking water quality) and neutralised to
pH7. The remaining clear flushing water is drained and the pipes are
purged with dry compressed air or nitrogen (no oxygen!).
It is recommended that the pipe systems be filled or flushed with suitable fluids immediately after chemical cleaning has been completed.
If possible, the last neutral flushing water may be pumped through bag
filters. This process allows particles to be flushed out of the pipes
more efficiently than with hydraulic oil later on. In addition, pullthrough elements (pigs) may be "shot" through pipes of unchanging
cross section with compressed air or nitrogen several times, if necessary. Then the pipes / systems are blown dry with clean compressed air or nitrogen. Preferably up to a dew point of -20C, but
least until such time as no humidity comes out of the pipes anymore.
Check with the back of the hand or a white cloth.
Note:
Absolutely dry pipes are a prerequisite for good results during later oil flushing,
because:
Residual humidity / water droplets from the oil particle counter are detected as dirt particles.
Residual humidity affects the oil quality and is difficult to remove from
the oil.
A00226.580 / MAADEN
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2011
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90
D1
Equipment needed for the recirculation process:

Recirculation process for stainless steel :
1 tank of about 1 000 x 1 000 x 800 mm high, made from rubber-coated

steel plate of about 6 - 8 mm thickness.
1 neutralising tank with a capacity of 3 - 15 m, made from rubber-coated
steel plate of about 10 - 12 mm thickness.
Various rubber-coated shut-off valves (diaphragm valves) DN 32 - DN 80
1 acid-resistant pump, about 25 - 80 m/hour at 25 - 60 m delivery head.
Various connecting hoses with hose clips about DN20 DN80
Various flange sockets for connecting hoses, sizes as required.
Various transition screw joints and flange-type reducers, sizes as required.
The number of connections and reconnections actually required depends
on the size of system to be pickled.

See 1.13. page 95.

See 1.22.1.

See 1.22.2.
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D1
1.13.
Chemical cleaning of steel pipes by the immersion process



Fluids to be used:
Ready-made pickling / phosphating solution
This must be used according to the manufacturer's instructions.
Phosphating at a temperature of 40 to 50C is to be preferred because it works more quickly
makes drying after phosphating easier.
A00226.580 / MAADEN
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92
D1
Description of immersion process

Caution!
Basically, chemical cleaning should be carried out by specialised
The treatment is performed in two steps:
Degreasing by high water pressure / high-pressure cleaner with the addition of a degreasing agent (e.g., Lutensol diluted with water at a rate of
1:10) via the chemicals tank.
Putting the pipes into the phosphating trough. While immersing the piping
elements care must be taken to ensure that they are completely ventilated
and completely immersed.
After 2 to 4 hours (depending on the temperature and degree of contamination), take out the pipes and spray-clean at high water pressure/with a highpressure cleaner. Use a suitable hose with rotating pipe cleaning nozzle for
the pipe inside surfaces. Following a visual inspection, re-immerse pipes into the phosphating trough.
After 1 to 2 hours (depending on the temperature), take out pipes and blow
off and out with clean, dry compressed air. Use a fan heater for drying, if
necessary.
Pickling and phosphating times are determined on the basis of the degree of cleanliness required and may be longer than the times required for the recirculation pickling process. All sealing faces,
threads, etc. have to be protected against damage caused by external influences.
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D1
Note:
After phosphating, complete drying and hardening usually takes approx. 24 hours.
Only thereafter may the pipes be coated / prime-coated or preserved with oil on
the inside.
After these treatments the pipe elements must be protected by suitable packing
material (ends closed with caps, etc.) to prevent them from becoming contaminated again and from damage.
The exact treatment times must be agreed with the manufacturer / supplier of the
phosphating solution. If necessary, tests must first be carried out on test pieces.
Process equipment and facilities

Immersion process for carbon and stainless steel pipes:
1 tank, approx. 8000 x 2000 x 1000 mm high made from 10 to 12 mm steel

plate with stiffener ribs, rubber or plastic-coated on the inside with chemicals recirculation pump and filter unit
1 high-pressure cleaner.
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D1

Conventional immersion process
Recirculation process
Assembly/ installation:
Pipes must be flanged in lengths of 6 m.
Disadvantage:
Maximum use of flanges, screws
Seals and welding metals as well as corresponding installation times.
Assembly/ installation:
Pipes are welded endlessly to maximum extent.
Advantage:
Reduced use of flanges, screws, seals and
welding material as well as correspondingly
shorter installation times.
Dismantling:
Not applicable
Advantage:
Saves time and money
Transport to the pickling line:
not applicable
Advantage:
Saves time and money.
Dismantling:
The pipelines must be dismantled for pickling.
Disadvantage:
Large labour and time effort.
Transport to the pickling line:
Means of transport required.
Disadvantage:
Large expenditure in terms of means of
transport, labour and time.
Pickling:
The pipes are pickled in tanks.
Disadvantage:
The size of the tanks is limited for technical reasons. The continuous shifting from tank to tank
results in large expenditure of labour and time, a
crane is required. The pickling liquid is circulated
only in the tank; contaminants dissolve relatively
slowly.
Transport to the place of installation:
Means of transport required.
Disadvantage:
Large expenditure in terms of transport, labour
and time. Pipes can become contaminated
again.
Maintenance of pipeline:
Many flange connections
Disadvantage:
Many flanged connections = many sources of
error, continuous expenditure of time and material as well as storage of many spare parts required
Pickling:
The pipes are pickled in the recirculation process.
Advantage: Less work space required, decreased pickling time since pickling takes place
in large circuits and with adapted circulation.
Contaminants dissolve faster. The pipelines
can be put into operation immediately after
pickling.
Transport to the place of installation: not applicable.
Advantage:
Saves time and money, no danger of contamination.
Maintenance of pipeline:
Minimum number of flanged connections.
Advantage:
Fewer flanged connections = fewer sources of
error, less expenditure of time and material,
minimised storage required for spare parts.
The decision as to which process is the more favourable one must be made with
due consideration for the location of the site, for the type of pipe installation and for
the possibilities of disposing of the chemicals.
A00226.580 / MAADEN
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2011
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95
D1
1.14.
Flushing of pipelines for oil circulation and hydraulic systems

Degree of cleanliness of pipelines
Prior to flushing the pipelines, all inside faces have to be cleaned to the level of
cleanliness BE or Sa 3 according to DIN 55928 Part 4 by means of suitable
measures (pickling).
These cleanliness levels apply to pipelines in:
Morgoil lubrication systems
Oil circulation lubricating systems
Hydraulic systems
Caution!
For pressure, temperature etc. please observe manufacturer's guidelines on fire-resistant fluids.
Work to be performed for the flushing of the oil circulation lubricating systems with
flushing oil
Carefully clean all tanks and pressure vessels in conformity with DIN 55928
Part 4
Fill one tank per system with flushing oil to about 80 % via the filling line
and heat the oil to a temperature of 70 C.
All oil feed lines are short-circuited to the return flow lines upstream of the
consumption point, thereby bypassing bearings and gear units.
The entire system is rinsed with hot flushing oil.
All pumps are in operation (incl. the standby pump) to deliver the flushing
oil in recirculation, with the duplex filters set for full passage.
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96
D1
In case of filter clogging, the system is switched back to 1 delivery pump

and 1 filter half, and the deactivated half of the filter unit is cleaned.
Flushing must be performed continuously, preferably at different temperatures between 30C and 70C. The differential pressure at the filter, which
provided with clean filter elements, must not exceed the admissible working
range of the filter flow curve in case of an 8-hour flushing time.
Pump off flushing oil, making sure that lower-level pipe sections are
drained.
Detach flange connections and remove the dirt between flange sealing strip
and sealing bore.
Replace defective seals.
Clean oil tank and pipe connections and make the measuring and control
instruments ready for operation.
Fill in operating oil and start up the system (see Maintenance Manual B)
For flushing-oil specification see SN 180

Viscosity ISO VG 46
e.g., HLP 46 (hydraulic oil to DIN 51524/2) or
CL 46 (flushing oil to DIN 51502)
Compatibility of flushing oil with operating oil must be ensured.
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97
D1
The following cleanliness levels must be ensured:

for systems with directional control valves
NAS 1638 group 6 8
for systems with proportional valves
NAS 1638 group 5 6
for systems with servo valves
NAS 1638 group 4 5
(after ISO 4406 (c) (1999)):

for systems with directional control valves and proportional valves
17 / 15 / 12
for systems with regulating valve and servo valves
15 / 13 / 10
The cleanliness levels are to be demonstrated and taken from the attached tables.
After flushing, the hydraulic fluid must be tested to ensure that it is operationally efficient.
For flushing-oil specification see SN 180
Operating oil is to be used as a flushing medium for the hydraulic system.
Operation on water glycol HFC
Conditions: Flushing with water glycol only
Max. temperature 40C
Make up evaporation losses by fully demineralised water.
For the use of flushing plates see "Simplified representation in drawings for flushing plates" (1.22.3.).
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98
D1
Work to be performed for the flushing of hydraulic systems
Preparatory work:
Disconnect the hoses from the cylinders and short-circuit them.
Remove all filter elements and install envisaged operational flushing elements.Setting of:
Pressure switches
Thermostats on the oil tank
Cooling water regulating valves
Pressure reducers
Safety relief valves
Work to be performed:
Fill in oil via filling filter, the degree of cleanliness of the oil filled in should
be NAS 1638, class 10 or (ISO 4406 (1999) 20/19/16).
Before flushing commences, the filled-in oil needs to be prefiltered to at least the
cleanliness level of the operating oil by means of recirculation (recirculation
pumps).
None of the servo and proportional valves are to be fitted, make provision
for valve flushing plates instead.
Preflushing should be carried out by a separate flushing unit (pumps and

tank).
Final flushing is to be carried out via the filters using the existing main
pumps. Replace the elements if the filters get clogged.
To flush out particles from a pipe, the flow of the fluid must be turbulent.
(Turbulences Reynold's number min. 3000 ) The following factors have
an essential impact on the above: Cross section of pipe, Viscosity of oil which in turn is significantly influenced by the temperature during oil flushing. (Temperature during oil flushing 50C). From these factors results the
necessary flow speed for the respective pipe cross section: see table.
A00226.580 / MAADEN
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2011
Index
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Blatt / Sheet
99
D1
Pipe diame- Wall thickter

ness
mm
mm
16
20
25
30
38
60.3
76.1
88.9
114.3
Intake
pressure
bar
2
2.5
3
4
4
8
10
12
14
Discharge Pump delivery

pressure
flowrate
bar
liters/minute
40
35
20
15
9
6.3
5.7
5.5
5.2
5
5
5
5
5
5
5
5
5
Reynold's
number
approx.
Flowrate
m/s
Pipe length
m
3000
3000
3000
3000
3000
3000
3000
3000
3000
11.8
9.1
7.2
6.3
4.6
3.1
2.5
2.3
1.6
20
20
20
20
20
20
20
20
20
80
97
124
145
197
290
378
455
574
Oil: HLP 46 at 50 C
For this it may be necessary to operate several pumps simultaneously.
For systems with directional control valves, filter elements with 8 m mesh width
have to be used, for systems with proportional valves filter elements with 3 m
mesh width.
Oil temperature:
50C
Preflushing ranging between 5 and 20 bar
Final flushing up to 100 bar
Where hydraulic accumulators are existing, the pipelines will have to be intermittently pressurised through these accumulators after the continuous flushing process.
Samples are to be taken in the following areas:
In the suction line
upstream the servo-valves
upstream the inlet of the return line into the tank
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
100
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
50 100
25 50
Over 100
22
10 25
44
250
125
Over 100
16
50 100
28
93
25 50
210
670
10 25
Particle
Size
m
-5
4600
2700
16
89
500
56
380
2680
9700
Class
to NAS 1638
11
110
780
5360
24000
Class
21
225
1510
10700
32000
41
430
3130
10
21400
87000
11
92
1000
6500
42000
12
128000
32
178
11
63
356
22
126
712
45
253
16
90
506
1425 2850
32
180
1012
5700
64
360
2025
128
720
4050
256
1440
8100
11400 22800 45600
512
2880
16200
91200
1024
5760
32400
182400
1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000
1340
Particle
Size
m
-5
to SAE 749
D1
Purities Required for Hydraulic Systems

(Number of foreign particles per 100 cm3 oil for system classification)
Blatt / Sheet
101
D1
A00226.580 / MAADEN
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2011
Index
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Blatt / Sheet
102
D1
Material for flushing of pipe lines
Note!
All material for flushing is not in SMS SIEMAG scope of supply.
Material of loops at machines should be determined at site.
Figure 71
Figure 72
Figure 73
Figure 74
Table 1
Table 2
A00226.580 / MAADEN
Flushing header
Header connection to and from cylinder lines
Header connection to pressure line P
Header connection to tank T
Code of parts in flushing diagrams
Flushing volume and velocity
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2011
Index
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Blatt / Sheet
103
14
14
A00226.580 / MAADEN
15
15
15
04
04
15
03
03
01 = 1 1/2" SAE butt weld flange (2 off)

02 = 2" SAE butt weld flange (2 off)
03 = 1 1/2" SAE butt weld flange + blind flange tapped 1/2" BSP
04 = 1 1/2" SAE butt weld flange + blind flange tapped 3/4" BSP
05 = 1 1/2" SAE butt weld flange + blind flange tapped 1" BSP
06 = 1 1/2" SAE butt weld flange + blind flange tapped 1 1/4" BSP
07 = 1 1/2" SAE butt weld flange + blind flange
08 = 3" SAE butt weld flange + blind flange tapped 1/2" BSP
09 = 3" SAE butt weld flange + blind flange tapped 3/4" BSP
10 = 3" SAE butt weld flange + blind flange tapped 1" BSP
11 = 3" SAE butt weld flange + blind flange tapped 1 1/2" BSP
12 = 3" SAE butt weld flange + blind flange tapped 2" BSP
13 = 3" SAE butt weld flange + blind flange tapped 2 1/2" BSP
14 = 3" SAE butt weld flange + blind flange
15 = TEE 3" x 1 1/2" ANSI B 16.5 ( 3000 psi )
16 = TEE 3" x 2" ANSI B 16.5 ( 3000 psi )
15
02
05
06
01
15
02
05
06
01
15
07
07
08
12
09
13
10
11
ATTENTION:
All components should be
suitable for working pressure
PN 210 bar (3000 psi)
08
D1
2011
Material for Flushing Header (Hydraulic only)

Figure 71:
Stand / Revision
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Blatt / Sheet
104
D1
2
G
B
Flow Direction
Connection to cylinder line 1 or 2
Header Connection to and from Cylinder Lines

Figure 72:
A00226.580 / MAADEN
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2011
Index
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Blatt / Sheet
105
D1
F
D
Flow direction
Connection to pressure line 1 or 2
Pump station
supply
Header Connection to Pressure Line

Figure 73
A00226.580 / MAADEN
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2011
Index
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Blatt / Sheet
106
D1
F
D
Flow direction
Connection to tank line 1 or 2
Tank
Header Connection to Tank Line

Figure 74:
A00226.580 / MAADEN
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2011
Index
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Blatt / Sheet
107
A00226.580 / MAADEN
Stand / Revision
2011
AFP 4 - 3
RI ED x 1 1/2
Index
--
FKB 80
FKB 32
AFB 4 - 6
AFB 1 - 3
AFB 1 - 6
FKB 100
FKB 80
108
Blatt / Sheet
AFB - 6
AFB - 6
AFB - 3
5 150 psi
4 2500 psi
AFB 3 - 6
FKB 65
AFB - 3
GAV 38 x 3/GAV 38 x 3
GEV 30 (UNF)
GEV 25 (UNF)
GEV 20 (UNF)
GEV 16 (UNF)
GAV 38 x 6/GAV 20 x 3
GAV 26 x 2,5/GAV 12 x 2
2 2500 psi GAV 20 x 2,5/GAV 20 x 2,5
AFB 2 - 6 3 2500 psi
AFB 2 - 6
AFB 1 - 6 2 2500 psi
AFB 1 - 6 1 2500 psi GAV 16 x 2,5/GAV 16 x 2,5
1 2500 psi GAV 30 x 5/GAV 25 x 3
FKB 50
FKB 40
GAV 30 x 3/GAV 30 x 3
4 150 psi
AFP 3 - 3
RI ED x 1 1/2
ST2 P DN 40 X...AS/AS GUV 50 x 7 G A
GAV 16 x 3/GAV 12 x 1,5
AFP 2 - 3 3 150 psi
TV 38 x 6
RI ED x 1 1/2
GAV 16 x 2/GAV 25 x 3
2 150 psi GAV 25 x 3/GAV 25 x 3
AFP 1 - 3 2 150 psi
AFP 1 - 3 1 150 psi GAV 20 x 3/GAV 25 x 3
AFP 2 - 3
ST2 P DN 32 X...AS/AS GUV 38 x 5 G A
H
Special part
2 x GAV AVIT part1
or
1 x GEV part 1
AFP 1 - 3 1 150 psi GAV 25 x 3/GAV 38 x 5
AVIT
ANSI B 16.5
AFKB=
or
3000 / 6000
FKB-AVIT
psi
PN 320, Ser. 4
G
Blind flange
TV 30 x 4
RI 1 ED x 1 1/2
ST2 P DN 25 X...AS/AS GUV 30 x 4 G A RI 1 ED x 1
TV 25 x 3
RI 1 ED x 1 1/2
ST2 P DN 20 X...AS/AS GUV 25 x 3 G1A
RI ED x 1 3/4
TV 16 x 2
RI 1 ED x 1 1/2
AVIT
Part 1 only
E
F
Equal TEE Blind flange
ST2 P DN 16 X...AS/AS GUV 20 x 2,5-G A RI 1 ED x 1
SN 591
D
Socket type
Reducer pipe
TV 20 x 3
SN 759
AVIT
C
Socket type
Reducer pipe
SN 455
or
FKB-AVIT
PN 250, Ser. 3
ST2 P DN 13 X...AS/AS GUV 16 x 2 G A RI 1 ED x 1 1/4 RI 1 ED x 1 1/2
B
Socket
A
High pressure hose
G 1 A
G A
G 1 A
DIN 2990
(SN 718)
K
Doublenipple
KHB G 2
G 2 A
KHB G 1 G 1 A
KHB G 1 G 1 A
KHB G 1
KHB G
KHB G
HYDAC
J
Straight flow
valve
D1
Code of Parts in Flushing Diagrams (Table 1)
D1
Flushing volume and velocity

Table 2
Pipe inside
l/min
(4 m/sec)
l/min
(6 m/sec)
l/min
(8 m/sec)
DN 8
12
18
24
DN 10
18
28
38
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
DN 32
190
295
390
DN 40
300
450
600
DN 50
480
700
950
DN 60
690
1000
1350
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109
D1
1.15.
Preassembly of Machines and Components

It is due to specific erection sequences that some of the machines and components have to be assembled before being placed on top of their foundations.
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.
After preassembly, all machined faces are to be protected against corrosion by
applying a film of oil or grease thereto.
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
110
D1
1.16.
Pipeline Identification Letters Used for Various Utilities in the Drawings

Abbreviation
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
A00226.580 / MAADEN
MC
IC
DC
SW
HW
PW
EW
HP
DI
SO
IW
WW
FF
MW
SL
CA
PN
NI
AR
NG
OX
HA
CG
LP
MG
IA
GR
LO
EM
RO
SE
WO
HY
HM
HE
HS
ST
CO
AC
AL
Stand / Revision
2011
Index
--
Blatt / Sheet
111
D1
1.17.
Mounting Instructions in Drawings

Particular attention is invited to the notes and instructions given in various drawings for field erection.
These activities are the responsibility of the erection contractor in charge of erecting corresponding plant components.
Required tools, appliances and consumables are not included in the SMS
SIEMAG extent of supplies.
Example:
Field-welded
Field - Welds
Figure 75:
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.
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
112
D1
1.18.
Aligning and Tightening torque for couplings

(Information given by Company FLENDER)
Aligning
The couplings compensate for positional variations of the shaft ends to be connected up to the data refer to page 113.
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.
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.
Ruler
Feeler gauge
Figure 76:
Caution!
Check the tightening torque of the screws after re-establishing the
connection (refer to page 113)
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
113
D1
Possible misalignments for couplings
S2 max
S2 max
S2 min
Kw
Kw
Ka
S2 min
Figure 77:
Coupling Type
Axial misalignment
Ka
Angular misalignment
Kw
Radial misalignment
Kr
Tightening torques
TA
H 140 - 180
+ 1 mm
0,24 mm
0,24 mm
29 Nm
H 110 - 140
+ 1 mm
0.18 mm
0.18 mm
14 Nm
H 160 - 140
+ 1 mm
0.27 mm
0.27 mm
35 Nm
H 95 - 100
+ 1 mm
0.15 mm
0.15 mm
10 Nm
H 110 - 140
+ 1 mm
0.18 mm
0.18 mm
14 Nm
B 125
+ 1 mm
0.21 mm
0.21 mm
17.5 Nm
H 95 - 100
+ 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
H 110 - 100
+ 1 mm
0.18 mm
0.18 mm
14 Nm
H 225 - 180
+ 1 mm
0.38 mm
0.38 mm
89 Nm
H 200 - 180
+ 1 mm
0.34 mm
0.34 mm
67 Nm
H 180 - 180
+ 1 mm
0.30 mm
0.30 mm
44 Nm
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
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
114
D1
1.19.
Release for Machine Grouting /

Open Package Inspection
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
115
D1
Release for Machine Grouting
Area acc. to Foundation Drawing
Grouting of Stone Bolts Machine Under grouting
Grouting Material:
Remarks:
Date:
A00226.580 / MAADEN
SMS SIEMAG Site Management: Contractor:
Stand / Revision
2011
Index
--
Blatt / Sheet
116
D1
Open Package Inspection

Package:
Delivery Note No.:
_________________________
Part-Consignment No. / Package
_________________________
Completeness /
Delivery complete
Description of State and Condition:
Equipment in proper State
Part missing
Part damaged
Quantity SMS SIEMAG Complaints Report

No.
Instructions:
Type of Storage
Package No.
Additional Requirements
Outdoors
Repackaging
Outdoors plus covered up
Repeat Preservation Treatment
Under roof shelter

Dry room
Temperature controlled room
Remarks:
Date:
A00226.580 / MAADEN
SMS SIEMAG Site Management: Contractor:
Stand / Revision
2011
Index
--
Blatt / Sheet
117
D1
1.20.
Heavy-Duty Cranes and Transport Facilities

For intermediate transport if necessary. To be defined by erection contractor according to mobilization.
Designation
Number Provided
Load Capacity ( t )
Mobile Crane
Tractor-Flatbed
Trailer Units
Trucks
Fork Lift Trucks
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
118
D1
1.21.
Tools, Appliances and Auxiliaries

(Is not part of SMS SIEMAG scope of supply).
Site Shop
Item Designation
1.
Specification / Type
Upright Drilling Machine
Morse taper 3, 100 - 1000 RPM with motor

for direct-on-line starting and
5 m long connecting cable complete with
plug
Figure 78:
2.
Bench Drilling Machine
Morse taper 2, 430 - 4500 RPM with motor

for direct-on-line starting and 5 m long
connecting cable complete with plug
Figure 79:
3.
Dual Tool Grinding
A00226.580 / MAADEN
Wheel size 300 x 40 x 76 mm with standard

Machine, Upright Design tip, tool rests,
spark protector as well as 5 m long connecting cable complete with plug (refer to
Figure 80)
Stand / Revision
2011
Index
--
Blatt / Sheet
119
D1
4.
Dual Tool Grinding
Wheel size 150 x 20 x 32 mm with standard

Machine, Bench Design tip, tool rests,
spark protector as well as 5 m long connecting cable complete with plug
Figure 80:
5.
Power Hacksaw
AC motor (variable cutting speeds), complete with 5 m long connecting cable and
plug
Figure 81:
6.
Mobile screw type compressor 4.00 m3/min

referred to 7 bar, max. operating pressure
8 bar
Compressor
Figure 82:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
120
D1
Test- and Checking devices for Hydraulic Equipment

Item Designation
7.
Test kit for proportional
Type G040-123-001 with Accessories
8.
Kit for checking, maintenance and adjustment for

Moog-servo valves
Valve tester for Moog
valves
Tools kit
Model F087-127
9.
10.
11.
12.
13.
14.
15.
Model G040-119
Model B61042005
Valve tester for energizing

of servo- and proportional
valves
Servo valve tester II
Test kit for checking and
adjustment of proportional
pressure valves and directional valves
O-Ring kit
R-Ring kit
VT-VETSY-1-1X/1-2-1-1-1
(Rexroth)
Testing Equipment for

proportional valves, Servo-valves + Solenoid
valves
Type 4
Service for following valves
D661 MOOG
WRZ Rexroth
DER Rexroth
A00226.580 / MAADEN
Type 828293
Type 828294
Stand / Revision
2011
Index
--
Blatt / Sheet
121
D1
16.
Pressure testing set
Complete (HGM 2020)
Figure 83:
17.
18.
19.
20.
Portable nitrogen preloading devices with oil aggregate

Filling and testing device
Hydac.
Digital measuring instrument for voltage, current

and resistor
Oil-contamination control
device
Siemens-Multizet
0 - 250 bar, 0 - 400 bar
ARTI / PODS
Figure 84:
21.
Leak detector
Complete (SPM instrument)
22.
Digital thermometer
D 700 (Impact Tastotherm)

with Sensor OT 1301
23.
Digital manual speed indicator
HT 4100 (Dr. Horn)
Figure 85:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
122
D1
Electric Welding Machines

Item Designation
24.
Welding Generator
up to 200 A welding power
25.
Welding Generator
26.
Welding Generator
Figure 86:
27.
TIG Welder

(shielded arc welding)
Figure 87:
Note:
All welding machines complete with connecting cable and plug as well
as welding and earthling cable (VDE tested)
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
123
D1
Oxy/Acetylene Welding and Cutting Torches

Item Designation
28.
Cutting Torch Kit
Complete with handle, cutting tips size

3 - 8, torch guide, radius rod, torch wrench
and tip cleaner. Preheat orifices / tips of all
sizes (cutting torch DIN EN ISO 5172)
Figure 88:
29.
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
32.
Pressure Reducer
DIN EN 385
with pressure gauge for oxygen bottles
1 200 bar
Figure 89:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
124
D1
Accessories to Oxy/Acetylene Welding and Cutting Torches

Item Designation
33.
Hand Shield
DIN 58214
Complete with light and dark panes,
DIN EN 169, protection class 13
Figure 90:
34.
Fixed Shield
DIN 58214
Complete with light and dark panes,
Figure 91:
35.
Protective Gloves
DIN EN 374
Leather, with long cuffs
Figure 92:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
125
D1
36.
Welders Apron
Leather
Figure 93:
37.
Slag Hammer
DIN 5133
Figure 94:
38.
Wire Brush
for steel
Figure 95:
39.
Wire Brush
for stainless steel

(refer to Figure 95)
40.
Protective Gloves for Argon gas welders
DIN EN 379
Soft leather, with long cuffs
41.
Protective Goggles
DIN EN 1836
Welders goggles with dark glasses,
Figure 96:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
126
D1
42.
Protective Goggles
DIN EN 1836,with light glasses,

43.
Lighters
for welding and cutting torch
44.
Bottle Cart for 2 bottles
load capacity 500 kg, sturdy tubular structure, high stability, bottle shovel angle ironframed on 3 sides, wheels arranged on ball
bearings, dia. 400, solid rubber-tired
Figure 97:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
127
D1
Tackles and Appliances (incl. Spare Parts)

Item Designation
45.
Hydraulic Jacks
HP 100/250 (t / stroke in mm)
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
Figure 98:
53.
Hand Pumps for Hydraulic

Presses, incl. Hydr. Fluid
4.5 l
54.
Hand Pumps for Hydraulic

Presses, incl. Hydr. Fluid
1.3 l
Figure 99:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
128
D1
55.
Steel Winch
DIN 7355
5 tons with safety crank
56.
Steel Winch
DIN 7355
10 tons, with safety crank
57.
Chain fall with Articulated

Chain
Chain fall with Articulated
Chain
1.5 tons
58.
3.0 tons
Figure 100:
59.
Draw Winch
3.2 tons, complete with 25 m rope

Figure 101:
60.
Deflector Pulley
A00226.580 / MAADEN
for draw winch, refer to item 59
Stand / Revision
2011
Index
--
Blatt / Sheet
129
D1
Mechanics and Pipe Fitters Tools

Item Designation
61.
Mechanics Work-Pipe
Bench, incl. Sub cabinets
Vice up to 3" and parallel vice 150 mm jaw

width
Figure 102:
62.
Pipe Bending Machine
Hydraulic pipe bending unit with bending

bocks for pipes 1/2" - 3" and standardwalled boiler tubes up to max. 60,3x8.
63.
Electro hydraulic Universal Pipe Bending Machine
Complete with accessories Pipe Bending

Machine
Figure 103:
64.
Metal Saw Frame
DIN 6473
300 mm long, complete with saw blades
Figure 104:
65.
Electric Hand Sawing Machine
Complete with saw blade for stainless steel
Figure 105:
66.
Water Pump Pliers
DIN ISO 8976
Figure 106:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
130
D1
67.
Pipe Pliers
1/2" - 4"
Figure 107:
68.
Elbow Pipe Pliers
1/2" - 4"
Figure 108:
69.
Pipe Cutter
1/8" - 2" (refer to Figure 109)
70.
Pipe Cutter
1 1/4" - 4"
Figure 109:
71.
Pipe Die Stock for

Threads to
DIN ISO 228

1/8", 1/4", 3/8", 1/2", 3/4"
incl. ratchet and dies
72.
Pipe Die Stock for

Threads to
DIN ISO 228

1", 1 1/4", 1 1/2", 1 3/4", 2"
73.
Pipe Die Stock for

Threads to
DIN ISO 228

2 1/4", 2 1/2", 2 3/4", 3", 3 1/2", 4"
Figure 110:
74.
Steel Tape Rule
DIN 6403
2 m long
Figure 111:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
131
D1
75.
Folding Rule
DIN 2268 (graduation)

2 m long, wood
Figure 112:
76.
Wood Spirit Level
400 mm long
Figure 113:
77.
Pipe Welder - Grip Pliers
Figure 114:
78.
Engineers Square
250 x 165 mm
Figure 115:
79.
Back square
DIN 875
300 x 175 mm
Figure 116:
80.
Centre Square
300 x 180 mm
Figure 117:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
132
D1
81.
Bevel Steel Square
Universal type bevel steel square, 300 mm
Figure 118:
82.
Vernier Callipers
DIN 862
Measuring range 250 mm, with nibs, stainless
Figure 119:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
133
D1
Measuring and Testing Equipment

Item Designation
83.
Dumpy Level / Transit
Precision 0.1 mm, incl. stand

Type NA2 with micrometer GPM3
Wild Leica
Figure 120:
84.
Levelling Rod
DIN 18703
3 m long, graduation to match level
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
Figure 121:
87.
Collimator marks kit
A00226.580 / MAADEN
1 Stand GDF 21
1 Collimator plate GZT 1
1 Beam GZR 1
Wild Leica
Stand / Revision
2011
Index
--
Blatt / Sheet
134
D1
88.
External Micrometer
DIN 863
Range 0 - 300 mm, 25 mm increments
Figure 122:
89.
Internal Micrometer
DIN 863
Range 0 - 300 mm, 25 mm increments
Figure 123:
90.
Extensions for Inside
DIN 863 Range up to 500 mm Micrometer
Figure 124:
91.
Straightedge
DIN 874 Part 1

5.0 m long (refer to Figure 125)
92.
Straightedge
DIN 874 Part 1

93.
Straightedge
DIN 874 Part1

94.
Straightedge
DIN 874 Part 1

95.
Straightedge
DIN 874 Part 1

96.
Straightedge
DIN 874 Part 1

97.
Straightedge
DIN 874 Part 1

0.5 m long
Figure 125:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
135
D1
98.
Gauge Blocks
DIN 861
150 x 130 x 75 mm, size 2, class 1
Figure 126:
99.
Surface Plate
DIN 876, Part 2

200 x 300 mm, size 4, class 1
Figure 127:
100. Electric Alignment Checker, complete
101. Phosphor Bronze Wire
(Piano Wire) or Steel Wire
102. Gradient Indicator
dia. 0.3 mm, 0.5 mm, 1.0 mm

DIN 877
200 mm, accuracy 0.10 mm/m
(Frame Spirit Level)
Figure 128:
103. Gradient Indicator (Frame
Spirit Level)
DIN 877
104. Gradient Indicator (Shaft

Spirit Level)
DIN 877
Figure 129:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
136
D1
105. Vernier Callipers
DIN 862
Range 250 mm, with nibs, stainless
Figure 130:
106. Sliding Depth
DIN 862
Range 250 mm, stainless Gauge
Figure 131:
107. Dial Gauge
DIN 878
Accuracy 1/100 mm, range 0 - 10 mm
Figure 132:
108. Magnetic Stand
for dial gauge (refer to 107)
Figure 133:
109. Measuring Tape
DIN 6403
50 m, stainless
110. Measuring Tape
DIN 6403
30 m, stainless
111. Measuring Tape
DIN 6403
20 m, stainless
Figure 134:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
137
D1
112. Plumb Bob with
Complete with cord

Removable Tip
Figure 135:
113. Steel Tape Rule
DIN 6403
2 m long
Figure 136:
114. Folding Rule
DIN 2268 (graduation)

2 m long, wood
115. Feeler Gauge
DIN 2275
100 mm long, 0.05 - 1.0 mm
116. Feeler Gauge
DIN 2275
600 mm long, 0.05 - 1.0 mm
Figure 137:
117. Screw Pitch Gauge
for Metric and With worth threads
Figure 138:
118. Graduated Steel Straightedge
however s = 1
DIN 866
however s = 1 500 x 30 x 1 mm, graduations 0.5 mm and 1 mm

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

however s = 1
DIN 866
however s = 1 2000 x 30 x 1 mm, graduations 0.5 mm and 1mm
Figure 139:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
138
D1
121. Bevel Steel Straightedge
DIN 874 Part 2

100 mm long, with case (Figure 140)
122. Bevel Steel Straightedge
DIN 874 Part 2

200 mm long, with case
Figure 140:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
139
D1
Pneumatic Machine Tools

Item Designation
123. Hand Drilling Machines
Morse taper 1 - 3
Figure 141:
124. Angle Type Drilling Machines
Morse taper 1 - 3
Figure 142:
125. Magnetic Standard Drilling
Machines
126. Taper Sleeves
Morse taper 1 - 3
127. Drill Chuck
DIN 6349
Opening 1 mm - 13 mm
128. Drift Pins
DIN 317
for the drilling machines
129. Grinding Machine
with roughing and abrasive cutter wheel

attachment
DIN 1808
Morse taper 2/1, 3/2, 4/3
Figure 143:
130. Rubber Grinding Disk elements
for above grinding machine, with fixing
Figure 144:
Note:
All pneumatic machine tools with suitable hoses and hose connectors.
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
140
D1
Electric Hand-Operated Machine Tools

Item Designation
131. Electric Multi-speed Handoperated, Drilling Machine
with drill chuck to DIN 6349, drilling capacity for steel up to 32 mm
Figure 145:
132. Electric Two-speed Drilling Machine
capacity for steel up to 16 mm
Figure 146:
133. Electric Angle Type Grinding Machine
Grinding wheel dia. 178 / 125 mm and rubber disk
Figure 147:
134. Electric Grinding Machine
(High-Speed Type)
for abrasive pencils, rotating milling cutters

etc. shank, dia. 6 mm
Figure 148:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
141
D1
135. Magnetic Standard
for electric hand drilling machines
Figure 149:
Note:
All electric units with connecting cable and plug, VDE-tested.
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
142
D1
Sundries
Item Designation
136. Aluminium Assembly Ladder
DIN 14711 Part 2

4 m and 6 m long
Figure 150:
137. No stationary Work-site
Distribution Board
with connection for 3 x 220 V, 3 x 380 V,

incl. fusing and feeder cable
Figure 151:
138. Cable Drum
with 50 m cable, 3 receptacles, 220 V
Figure 152:
139. Hand lamp 100 Watt
with 50 m cable complete with plug
Figure 153:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
143
D1
140. Flashlights
Complete with cells and bulbs (spare bulbs

and cells must be available)
Figure 154:
141. Safety Belt
with safety ropes to DIN EN 354, holding

belts to DIN 7470, catch belts to DIN 7478
Figure 155:
142. Scaffold Planks
abt. 4 m long
143. Assembly Timber Assembly Pedestals

144. Pails
Plastics, abt. 10 l
145. Pails
Galvanized, abt. 11 l
146. Sundry Brushes

147. Bottle
Graduated polyethylene collecting bottle

200 ml capacity (refer to Figure 156)
148. Bottle
Graduated polyethylene collecting bottle

850 ml capacity
Figure 156:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
144
D1
149. Hydr. pre-stressing Device

with pump and pressure
gauge, refer to SN 403
(turning)
M 24, M 30, M 36, M 42, M 48, M 56, M 64,

M 72 x 6, M 80 x 6, M 90 x 6, M 100 x 6,
M 110 x 6, M 120 x 6 M 125 x 6, M 140 x 6,
M 160 x 6
Figure 157:
150. Hydr. pre-stressing Device
with pump and pressure
gauge, refer to SN 403
(drawing)
M 24, M 30, M 36, M 42, M 48, M 56, M 64,

M 72 x 6, M 80 x 6, M 90 x 6, M 100 x 6,
M 110 x 6, M 120 x 6 M 125 x 6, M 140 x 6,
M 160 x 6
151. Power Screwdriver
for Sizes SW 17 - SW 42
(SW = width across flats)
Figure 158:
152. Pressure Gauges
0 - 10 bar, (DIN EN 837)

0 - 160 bar, (DIN EN 837)
0 - 600 bar, (DIN EN 837)
Figure 159:
153. Minimess Box
A00226.580 / MAADEN
Hydrotechnik
Stand / Revision
2011
Index
--
Blatt / Sheet
145
D1
154. Torque Wrench
DIN ISO 6789

0 - 500 Nm with various torques
Type RAHSOL
GEDORE
Figure 160:
155. SKF HP Oil Pump
abt. 1000 bar with accessories such as

hoses and fittings
Figure 161:
156. Drill Hammer
Type Hilti with drill holder and drills

dia. 10, 12, 14, 18, 20, 25, 28
Figure 162:
157. Mobile Grease Pump
Compressed-air driven, incl. accessories for

various grease nipples
Figure 163:
Note:
Spares and wearing parts in adequate number must be available at site

for all machines and devices. (Electric parts corresponding to VDE
0100, Part 704)
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
146
D1
General Tools
Item Designation
158. Eyebolt
DIN 580
M 10, M 12, M 16, M 20, M 24, M 30, M 36
159. Crowbar
dia. 20 mm, 1000- and 2000mm long

Figure 164:
160. Flat Chisel
DIN 6453
200- 250 mm long
Figure 165:
161. Cape Chisel
DIN 6451
200- 250 mm long
Figure 166:
162. Groove Chisel
DIN 6455
200 mm long x 6,
200 mm long x 8
200 mm long x 10
Figure 167:
163. Check Plug
Shank dia. 15 mm, 150 mm long

Figure 168:
164. Hand-Operated Plate

Shear
300 mm long
Figure 169:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
147
D1
165. Pincers
250 mm long
Figure 170:
166. Rubber Mallet
DIN 5128
Figure 171:
167. Plastic Mallet
Figure 172:
168. Chain Pipe Tong
2 - 12"
169. Wheel Puller
Two-armed 250- and 700 mm
Figure 173:
170. Tool Case
Lockable, empty
Figure 174:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
148
D1
171. Set of Pliers for Shaft Retaining Rings
DIN 5254, Form A
Figure 175:
comprising:
Pliers
Pliers
Pliers
Pliers
Pliers
dia. 10 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm
172. Set of Pliers for Shaft Retaining Rings
DIN 5254, Form B
Figure 176:
comprising:
Pliers
Pliers
Pliers
Pliers
Pliers
dia. 10 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm
173. Set of Pliers for Bore Retaining Rings
DIN 5256, Form C
Figure 177:
comprising:
Pliers
Pliers
Pliers
Pliers
Pliers
A00226.580 / MAADEN
dia. 8 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm
Stand / Revision
2011
Index
--
Blatt / Sheet
149
D1
174. Set of Pliers for Borex Retaining Rings
DIN 5256, Form C
Figure 178:
comprising:
Pliers
Pliers
Pliers
Pliers
Pliers
dia. 8 - 25 mm
dia. 19 - 60 mm
dia. 40 - 100 mm
dia. 85 - 165 mm
dia. 125 - 300 mm
175. Set of Screwdrivers
Cross point Screw DIN 5262 and

Slotted Head / Grub Screw DIN 5265
Figure 179:
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
176. Square Scraper
DIN 8350, Form A

with handle, 250 mm long
Figure 180:
177. Three-Square Flat Ground

Scraper
DIN 8350, Form B

178. Three-Square Hollow

Ground Scraper
DIN 8350, Form C

Figure 181:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
150
D1
179. Set of Hand Files
DIN 7261, Form A
Figure 182:
comprising:
Hand File
Hand File
Hand File
Hand File
Hand File
Hand File
Hand File
Cut 1, 350 mm long

Cut 2, 350 mm long
Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long
180. Set of Square Files
DIN 7261, Form D
Figure 183:
comprising:
Square File
Square File
Square File
Square File
Square File
Square File
Cut 2, 350 mm long

Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long
181. Set of Three-Square Files
DIN 7261, Form C
Figure 184:
comprising:
Three-Square File
Three-Square File
Three-Square File
Three-Square File
Three-Square File
Three-Square File
A00226.580 / MAADEN
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
Stand / Revision
2011
Index
--
Blatt / Sheet
151
D1
182. Set of Bastard Files
DIN 7261, Form E

Figure 185:
comprising:
Bastard File
Bastard File
Bastard File
Bastard File
Bastard File
Bastard File
Cut 1, 350 mm long

Cut 3, 350 mm long
Cut 1, 250 mm long
Cut 3, 250 mm long
Cut 1, 150 mm long
Cut 3, 150 mm long
183. Set of Round Files
DIN 7261, Form F

Figure 186:
comprising:
Round File
Round File
Round File
Round File
Round File
Round File
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
184. Flat Rasp
DIN 7263, Form A

Cut 1, 300 mm long
Figure 187:
185. Half-Round Rasp
DIN 7263, Form C

Cut 1, 300 mm long
Figure 188:
186. Milled File
DIN 7264, Form A

A 300 - 3, A 400 - 1
Figure 189:
187. File Hand
DIN 395
100-, 140- and 160 mm long
Figure 190:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
152
D1
188. Oil Can
0.25 l and 0,5 l
Figure 191:
189. Grease Gun
with hand lever and accessories
Figure 192:
190. Set of Double Head Box
Wrenches
with flat offset DIN 897 and

with deep offset DIN 838
Figure 193:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
SW
SW
SW
SW
SW
SW
191. Set of Double Head OpenEnded Wrenches
14/17 mm
16/18 mm
19/22 mm
24/27 mm
30/32 mm
36/41 mm
DIN 3110, Series C
Figure 194:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
A00226.580 / MAADEN
SW
SW
SW
SW
SW
SW
Stand / Revision
2011
14/17 mm
16/18 mm
19/22 mm
24/27 mm
30/32 mm
36/41 mm
Index
--
Blatt / Sheet
153
D1
192. Set of Single-Ended Open

Jaw Wrenches
DIN 3114, Series C
Figure 195:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
193. Set of Slugging Ring

Wrenches
30 mm
34 mm
36 mm
41 mm
46 mm
55 mm
65 mm
75 mm
85 mm
90 mm
DIN 7444
Figure 196:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
194. Open Jaw Slugging

Wrenches
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
A00226.580 / MAADEN
SW 170
SW 180
Stand / Revision
2011
Index
--
Blatt / Sheet
154
D1
195. Set of Tee-Handled Double-Ended Socket

Wrenches
DIN 896
Figure 198:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
Wrench
with bin handle, dia. 6, SW 8/ 9 mm

with bin handle, dia. 6, SW 10/11 mm
196. Set of Tee-Handled Socket Wrenches
DIN 3112
Figure 199:
comprising:
Wrench
Wrench
Wrench
Wrench
Wrench
without bin handle, dia. 26, SW 55 mm

197. Set of Hook Wrenches
DIN 1810, Form A
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
A00226.580 / MAADEN
for nut outer dia. 16 - 20 mm

Stand / Revision
2011
Index
--
Blatt / Sheet
155
D1
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
Hook Wrench
198. Set of Hex. Socket Screw
Keys

DIN ISO 2936
Figure 201:
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
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
199. Set of Allan Keys with

Spigot
3 mm
4 mm
5 mm
6 mm
8 mm
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm
24 mm
DIN 6911
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
A00226.580 / MAADEN
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
SW
Stand / Revision
2011
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
156
D1
200. Set of Straight Shank

Twist Drills
Short DIN 338 and Long DIN 340
Figure 203:
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
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
201. Set of Twist Drills with

Morse Taper 1
Standard DIN 345 and Long DIN 341

comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
A00226.580 / MAADEN
dia. 10.5 mm
dia. 11.0 mm
dia. 11.5 mm
dia. 11.8 mm
dia. 12.0 mm
dia. 12.5 mm
dia. 13.0 mm
dia. 13.5 mm
dia. 14.0 mm
Stand / Revision
2011
Index
--
Blatt / Sheet
157
D1

Morse Taper 2

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
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

Morse Taper 3

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

Morse Taper 4
Figure 204:
comprising:
Twist Drill
Twist Drill
Twist Drill
Twist Drill
Twist Drill
A00226.580 / MAADEN
dia. 32.0 mm
dia. 33.0 mm
dia. 37.5 mm
dia. 39.0 mm
dia. 45.0 mm
Stand / Revision
2011
Index
--
Blatt / Sheet
158
D1
205. Set of Taper Pin Twist

Drills
DIN 1898
Figure 205:
comprising:
Taper Pin Twist Drill
with cyl. shaft, dia. 4 mm, Form A

with Morse taper, dia. 5 mm, Form B
206. Set of Taper Pin Twist

Drills
DIN 1898 ,Form B

comprising:
with Morse taper 2, dia. 12 mm

207. Set of Hand Reamers

each
DIN 206, Form A/B,

dia. 5, dia. 8, dia. 10, dia. 16, dia. 20,
dia. 25, dia. 30,dia. 40, dia. 50
Figure 206:
comprising:
Hand Reamer
208. Set of Taps, 3-part
DIN 352
for Metric ISO Standard
comprising:
Threads
M 4, M 5, M 6, M 8, M 10, M 12, M 16,

M 20, M 24, M 30, M 36, M 42
Figure 207:
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
159
D1
209. Set of Taps, 2-part
DIN 5157
for Pipe
Figure 208:
comprising:
Threads
1/8", 1/4", 3/8", 1/2", 3/8", 1", 1 1/4", 1 1/2",

1 3/4" , 2", 2 1/2", 3"
210. Set of Round Threading

Dies,
DIN EN 22568
for Metric ISO
Figure 209:
comprising:
Standard Threads
M 5, M 6, M 8, M10, M 12, M 16,

M 20, M 24
211. Set of Round Threading

Dies
DIN EN 24231
for Pipe G-DIN/ISO 228
Figure 210:
comprising:
Threads
G 1/8", G 1/4", G 3/8", G 1/2", G 3/4"
212. Set of Die Holders
DIN EN 22568
comprising:
Die Holder
dia. 20, dia. 25, dia. 30, dia. 38, dia. 45,
dia. 55
213. Set of Die Holders
DIN EN 22568
Figure 211:
comprising:
Die Holder
A00226.580 / MAADEN
G 1/8", G 1/4", G 3/8", G 1/2", G 1/2"
Stand / Revision
2011
Index
--
Blatt / Sheet
160
D1
214. Tap Wrenches, with Movable
DIN 1814
Jaws Size 5, 6 and 7
Figure 212:
215. Set of Tap Extensions
DIN 377
Figure 213:
comprising:
Tap Extension
4.5 mm, 5.6 mm, 7.1 mm, 9.0 mm,

11.2 mm,12.5 mm, 14.0 mm, 16.0 mm,
18.0 mm, 20.0 mm, 22.4 mm, 25.0 mm
216. Hand Hammer Round Set

Hammer
DIN 1041
DIN 1042
300 g, 500 g, 1000 g, 2000 g, 4000 g,
8000 g, 12000 g
Figure 214:
217. Screwdrivers for
Slotted Head / Grub
Screw
DIN 5265
Figure 215:
Screws
3, 5, 8, 11 mm
218. Combination Wrenches
DIN 3113
SW 6, 7, 8, 9, 10, 11, 12, 13, 14, 16, 17, 18,
19, 21, 22, 24, 27, 34 mm
Figure 216:
219. Hex. Socket Screw
Wrenches
DIN ISO 2936

SW 3, 4, 5, 8, 9, 10, 12, 14 ,17, 18,
20, 24 mm
Figure 217:
220. Wire Rope
A00226.580 / MAADEN
DIN 3088
with loops, dia. 8 x 1.5 m
Stand / Revision
2011
Index
--
Blatt / Sheet
161
D1
221. Wire Rope
DIN 3088
222. Wire Rope
DIN 3088
223. Wire Rope
DIN 3088
224. Wire Rope
DIN 3088
225. Wire Rope
DIN 3088
226. Wire Rope
DIN 3088
227. Wire Rope
DIN 3088
228. Wire Rope
DIN 3088
229. Wire Rope
DIN 3088
230. Wire Rope
DIN 3088
231. Wire Rope
DIN 3088
232. Wire Rope
DIN 3088
233. Wire Rope
DIN 3088
234. Wire Rope
DIN 3088
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
162
D1
235. Wire Rope
DIN 3088
236. Wire Rope
DIN 3088
237. Wire Rope
DIN 3088
238. Wire Rope
DIN 3088
239. Wire Rope
DIN 3088
240. Wire Rope
DIN 3088
241. Wire Rope
DIN 3088
242. Hemp Rope
DIN EN 1261
endless, dia. 20
243. Hemp Rope
DIN EN 1261
endless, dia. 30
244. Hemp Rope
DIN EN 1261
endless, dia. 40
245. Rope Protectors
25.0 t
246. Rope Protectors
50.0 t
247. Shackles
DIN 82101
1.0 t
248. Shackles
DIN 82101
2.0 t
249. Shackles
DIN 82101
4.0 t
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
163
D1
250. Shackles
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
256. S-Hooks
1.0 t
257. S-Hooks
2.0 t
258. S-Hooks
5.0 t
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
164
D1
1.22.
Appendix
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
165
D1
1.22.1.

Legend:
1 Oil tank
2 Lubrication oil pump
3 Double screen filter
4 Oil cooler
5 Air vessel
6 Consumer
6
7 Pickling tank
8 Pickling pump
6
6
6
Provisional connection
with hoses
6
6
7
5
8
2
2
4
1
3
Figure 218
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
166
D1
1.22.2.
LP
4
LP
Legend:
5
1 Oil tank
2 High pressure pump
3 Circulation pump
4 Filter
5 Cooler
6 Accumulator
7 Valve stand
8 Hydraulic cylinder
2
1
9 Pickling pump
10 Pickling tank
3
T
7
P
Y
10
6
Y
6
Provisional connections with hoses:

Pickling circuit 1
Pickling circuit 2
Pickling circuit 3
Dismantling of pipes
and tank pickling
Figure 219
A00226.580 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2011
--
167
D1
1.22.3.
Simplified representation in drawings
120 x 30
38 x 140
50 x 60
7 x80
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
7 x 100
0
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
Bores commencing)
non centrically in
a centering point
Bores and countersinks

situated at a centre
Thread and core

hole depths
0
0
0
30
0
15
0
6
50
12
6
18
12
60
23
100
80
80
38
140
Core hole bores

also serving
as hydr. bore
Figure 221
A00226.580 / MAADEN
Stand / Revision
Index
2011
--
Blatt / Sheet
168
D1
1.22.4.
Drawings and bill of material for flushing plates conformable SMS SIEMAG drawings
Flushing Plate for D 760 (SMS Drwg. 2/5929970)
For fastening of flushing plate screws of valve can be used Material of flushing plate St
0
G 1/8 x 8/13
8 x 81
20
30
56
40,5
G 1/4 x 12/36
G 3/8 x 12/30
G 1/8 x 8/18
94
G 1/8 x 8/13
8 x 61
5,3 x 14
4x 8 x 30
81,6
81,6
C2
69,2
67,1
G 1/4 x 12/30
T
C2
4x G 3/8 x 12 / 18
11 x 33
A
47
47
47
58,1
47
4x 15 x 22 / 9
35,9
G 1/4 x 12/30
C1
C1
24,8
20
0
0
16,3
29,4
40,5
51,6
30
45
81
73
59,6
37,5
40,5
15,4
7,9
0
0
30
G 1/8 x 8/13
8 x 39
14- 0,2
1,5 0,05
55
0,
2
45
G 1/4 x 12/36
30
G 3/8
G 3/8
G 3/8
G 3/8
C1
C2
D 760
0,
2
G 1/8
1,6
39
20,3
5x A - A
Figure 222:
A00226.580 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2011
--
169
D1
Additional Parts for Flushing Plate of Valve Block D 760

as per SMS SIEMAG Draw. 2/5929970
Amount
Description
Material
Socket head screw

ISO 4762 M8 x 50
129
O-Ring
SN 430 10 x 2 - N
similar to DIN 3771
Viton / 70
Plug screw
SN 870 VSTI G 1/8 A-ED
ST / Viton
Plug screw
ST / Viton
Plug screw
ST / Viton
Plug screw
SN 869 G 1/8 A
ST
Socket
SN 759 GUV 12 / G 3/8
ST
High pressure hose

DN 8 x 800 - 2 x M 20 x 1,5 - 490 bar
Supplier: Aeroquip
Type: 2755 - 6 - 00800
2 x GC 3471 - 6
2 x 41.721 - 12 - 6
A00226.580 / MAADEN
Stand / Revision
Index
2011
--
Blatt / Sheet
170
D1
Flushing Plate for NG 16XY (SMS Drwg. 2/5929990)

108
0
0
G 3/4
G 3/4
G 3/4
G 3/4
N G 16 X Y
G 1/8
G 1/8 x 8/13
6,8 x 50
M 8 x 42
4x G 3/4 x 16/25
M8
4x 18 x 33
4x 18 x 12/ 11
2x 11 x 12/ 6,6
95
2x 7 x15
84,1
G 3/8 x 12/52
G 1/8 x 8/13
7 x 55
82,5
P
T
73
68,2
64
66,6
50
B
A
26,9
26
25,3
23
12,6
11
39,3
55,1
71
86,9
109,1
97,6
122,6
93
71
80
55,1
48
142
39
21
40
55
28- 0,2
2
0,
0,
1,5 0,05
14- 0,2
G 1/8 x 8/13
7 x 45
G 1/8 x 8/13
7 x 45
2,3 + 0,05
40
0,
0,
98
39
1.6
2x A - A
4x B - B
Figure 223:
A00226.580 / MAADEN
Stand / Revision
Index
Blatt / Sheet
2011
--
171
D1
Additional Parts for Flushing Plate of Valve Block NG 16 XY

Amount
Description
Material
Socket head screw

ISO 4762 M6 x 60
129
Socket head screw

ISO 4762 M10 x 60
129
O-Ring
SN 430 10 x 2 - N
similar to DIN 3771
Viton 70
O-Ring
SN 430 22 x 3 - N
similar to DIN 3771
Viton 70
Plug screw
ST / Viton
Plug screw
ST / Viton
Plug screw
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
High pressure hose

DN 16 x 800 - 2 x M 30 x 2 - 400 bar
Supplier: Aeroquip
Type: 2755 - 10 - 00800
2 x GC 3471 - 10
2 x 41.721 - 20 - 10
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172
D1
Flushing Plate for NG 10XY (SMS Drwg. 2/5929980)

Figure 224:
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173
D1

Amount
Description
Material
Socket head screw

ISO 4762 M6 x 60
129
O-Ring
SN 430 12 x 2 - N
similar to DIN 3771
Viton / 70
Plug screw
ST / Viton
Plug screw
ST / Viton
Plug screw
ST / Viton
Grub screw
ISO 7434 M8 x 12
14 H
Socket
SN 759 GUV 16 / G 1/2
ST
High pressure hose

DN 12 x 800 - 2 x M 24 x 1,5 - 420 bar
Supplier: Aeroquip
Type: 2755 - 8 - 00800
2 x GC 3471 - 8
2 x 41.721 - 16 - 8
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174
D1
40,3
Flushing Plate for NG 25 XY (SMS Drwg. 2/5193810)

For fastening of flushing plate use screws M12 x 60 Material of flushing plate St
G1/8 x 8/13
6,8 x 79
M8 x 72
31
120
G1/8 x 8/13
6,8 x 135
92,5
86,5
T
88,5
4x G1 x 18/35
A
6x 20 x 16
13,5
B
4x 22 x 33
2x 10 x 30
58
33,5
33
31,5
27,5
87
38,3
50,2
74
98
133,5
31
195
151
124,5
104
98
74
68
47,2
21
121,6
14
G1/8 x 8/13
6,8 x 63
M8 x 50
58
31
22 - 0,2
2
M8
Y
1,6
M8
0,
G1
0,
0,
G1
0,
38 - 0,2
G1
NG 25 XY
2,3 0,05
131,5
1,5 0,05
G1
2x A - A
4x B - B
Figure 225
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175
D1

Amount
Description
Material
Socket head screw

ISO 4762 M12 x 55
129
O-Ring
SN 430 18 x 2 - N
similar to DIN 3771
Viton / 70
O-Ring
SN 430 32 x 3 - N
similar to DIN 3771
Viton 70
Plug screw
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
High pressure hose

DN 20 x 800 - 2 x M 36 x 2 - 420 bar
Supplier: Aeroquip
Type: GH 506 - 12 - 00800
2 x GH 10243 - 12
2 x GH 10235 - 12
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176
D1
Flushing Plate for D079 1 (SMS Drwg. 2/5193730)

For fastening of flushing plate use screws M10 x 70 Material of flushing plate St
140
4 x 18 x 13,5
11
4 x G3/4 x 16/24
19 x 55
4 x 16 x 15
C1
110,4
106,5
2 x 4,5 x 38
95,4
C1
70
X
A
70
50
33,5
29,6
44,6
C2
G1/8 x 8/13
6,8 x 100
C2
9,6
55
69
80,4
100,4
1,6
29,6
34
110
97,8
80,4
55
29,6
12,2
G1/2 x 14/49
54
25 - 0,2
12 - 0,2
R
2
0,
2
0,
G 3/4
G 3/4
G 3/4
G 3/4
C1
C2
D079 -1
1,5 0,05
1,9 0,05
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
0,
0,
3
34
Figure 226:
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177
D1
Additional Parts for Flushing Plate of Valve Block D 079 - 1

Amount
Description
Material
Socket head screw

ISO 4762 M10 x 70
129
O-Ring
SN 430 8 x 2 - N
similar to DIN 3771
Viton / 70
O-Ring
SN 430 20 x 2,5 - N
similar to DIN 3771
Viton 70
Plug screw
ST / Viton
Plug screw
ST / Viton
Plug screw
ST / Viton
Socket
SN 759 GUV 20 / G 3/4
ST
High pressure hose

DN 16 x 800 - 2 x M 30 x 2 - 400 bar
Supplier: Aeroquip
Type: 2755 - 10 - 00800
2 x GC 3471 - 10
2 x 41.721 - 20 - 10
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178
D1
44,9
73,5
102,1
53
147
132,2
106,6
73,5
40,4
14,8
Flushing Plate for D079 2 (SMS Drwg. 2/5193740)

0
4 x G1 x 18/35
34,6
45,9
C2
C2
50,4
66,1
90
T
113,9
129,6
C1
134,1
C1
145,4
4 x 28 x 25
8 x 26 x 17,5
17,5
0,
2
38- 0,2
2,3 0,05
180
G1
G1
G1
C1
G1
D079 - 2
0,
1,6
C2
4x A - A
Figure 227:
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2011
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179
D1
Additional Parts for Flushing Plate of Valve Block D 079 - 2

Amount
Description
Material
Socket head screw

ISO 4762 M16 x 65
129
O-Ring
SN 430 32 x 3 - N
similar to DIN 3771
Viton / 70
Plug screw
SN 870 VSTI G 1 A-ED
ST / Viton
Socket
SN 759 GUV 25 / G1
ST
High pressure hose

DN 20 x 800 - 2 x M 36 x 2 - 420 bar
Supplier: Aeroquip
Type: GH 506 - 12 - 00800
2 x GH 10243 - 12
2 x GH 10235 - 12
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180
D1
1.22.5.
Off-loading of Mill Housing from flat bottomed vehicle and Positioning

Overhead travelling crane 2

Drive side (outside)
Minimum load - carrying

capacity of cranes:
weight of mill housing
plus
weight of lifting device
Fig. 1
Fig. 2
Flat-bottomed vehicle
Fig. 3
Mill housing
Wooden plank
Lifting device
Fig. 6
Bed plate
Fig.4
Drive side (outside)
Fig. 5
Center line of mill
Center line of mill
Figure 230:
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D1
Operating side (inside)
Minimum load - carrying

capacity of cranes:
plus
Fig. 1
Fig. 2
Flat-bottomed vehicle
Fig. 3
Mill housing
Wooden plank
Lifting device
Bed plate
Fig. 6
Fig. 7
Fig.4
Operating side (inside)
Fig. 5
Center line of mill
Center line of mill
Center line of mill
Figure 231
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D1
Off-Loading of a Mill Housing from well wagon and positioning
Minimum load - carrying capacity

of overhead travellingcrane:
plus
Lifting device
Mill housing
1.22.6.
Figure 232:
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183
A00226.580 / MAADEN
2011
Stand / Revision
Bed plate
Wooden plank
Mill housing
Minimum load - carrying capacity

of overhead travelling crane:
plus
Lifting device
D1
Figure 233:
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D3
3. Single Function Tests
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3.1.
Precondition for Tests
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
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3.1.1.
The following energy carriers and utilities are available:

current
hydraulic medium
compressed air
lube oil and grease
cooling water
high-pressure water
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.
Hydraulic Systems (Cylinders, Hydraulic Motors)

Check to see whether:
tanks and pipelines are free from inadmissible contaminations
filter inserts are free from inadmissible contaminations
tank is filled with hydraulic oil, level indicators and monitors are in a
functional state
pipelines have been:
pickled
pressure-tested
connections established in accordance with control circuits
vented
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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3.1.3.
Pneumatic Systems (Cylinders, Pneumatic Motors)

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

connections have been established as per circuit diagram
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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3.1.4.
Oil Lube Systems

cooling water is present for oil cooler
compressed air is present for pressure tank and controller
oil tank and pipeline system are free from inadmissible contaminations
controllers are preset to their service data
tank is filled with lube oil, the level indicator and monitor are in a functional state
all pressure switches, level switches etc. are set to special instructions
and their functions have been tested
motors and heaters
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3.1.5.
Grease Systems
grease tank on pump is filled with grease and is free from inadmissible
contaminations
filter insert at pump is free from inadmissible contaminations
pipeline system:
pressure-tested
connections have been established to circuit diagram
filled with grease
vented
all pressure switches, level switches etc. are set to special instructions
and their functions have been tested
motors
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D3
3.1.6.
Cooling Water Systems

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

signal transducers preset to their service data.
motors
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D3
3.1.7.
High-Pressure Water System

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

signal transducers preset to their service data.
release is present for the electrical control inclusive of voltage supply
to motors
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D3
3.2.
Procedure of Tests
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10
D3
3.2.1.
Sense of Rotation of Electric Motors

Visual check of sense of rotation of the electric motors.
Checks to be made:
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.
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.
Electrical Devices such as Proximity Switches, Limit Switches, Brakes,

Photocells etc.
Visual check of electrical switch elements.
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.
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 lightemitting 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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D3
3.2.3.
Lubrication to Lube Instructions

Visual check of lube points at the machine.
Checks to be made:
Lubrication as per lube instructions in conjunction with the lube chart re-lubricate if so required.
See also Manual B, Chapter .1
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13
D3
3.2.4.
Nozzles, Roll Cooling, Descaling

Visual check of nozzles.
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.
The reference values are contained in the technical data or rather equipment arrangement drawing.
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14
D3
3.2.5.
Shear Knife Gap

Visual check of shear knife gap
Checks to be made:
Spacing between the closed shear knives.
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.
The reference value is indicated in the technical data or rather equipment arrangement drawing.
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15
D3
3.2.6.
Pass Line and Roll Gap

Visual check of pass line
Checks to be made:
Horizontal and vertical alignment of the machines and devices involved in the rolling process.
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.
Visual check of roll gap
Checks to be made:
Distance between top and bottom roll.
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.
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.
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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16
D3
3.2.7.
Vertical Adjustment
Visual check of the adjusting system
Checks to be made:
Traversing stroke of top or rather bottom roll
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.
In case of hydraulic vertical adjusting systems, the vertical shifting stroke is
checked by means of an electro-hydraulic position control, i.e. through position
measurements by position transducers at the mill stand.
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D3
3.2.8.
CVC Shifting Device

Visual check of the CVC shifting device
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.
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.
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.
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.
Adjustment of Mechanical Equipment such as Rest Bar, Mill Guides etc.

In the mechanical equipment, adjustments and positions are visually checked.
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.
Checks to be made:
Opening and closing of the stand clamping mechanism.
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.
Grease Systems, Control and Function

Grease systems are subjected to a visual check.
No check of the pump pressure and control system is necessary in case of manually driven grease systems.
Checks to be made:
Overall function of the manual grease system.
When operating the grease pump, check some grease points for escape of
grease.
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.
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.
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.
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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21
D3
3.2.12.
Strokes of Hydraulic Cylinders, Lifting Speed and Cushioning

Check of technical data and set values of the hydraulic cylinders will be done visually.
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.
The reference values are indicated in the technical data or rather equipment arrangement drawing.
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D3
3.2.13.
Maintenance Unit for Compressed Air

Visual check of maintenance unit for compressed air.
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.
Strokes of Compressed Air Cylinders, Stroke Speed and Cushioning

Checking of technical data and set values of the pneumatic cylinders is visual.
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.
The reference values are indicated in the technical data or rather product arrangement drawing.
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D3
3.2.15.
Check of Pressure Limiting Valves for Compliance with Preset Pressure

Visual check of the opening pressure set on the pressure limiting valve
(safety valve).
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.
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.
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.
The opening of the pressure limiting valve is audibly distinguished by flowing noises since opening is accompanied by heavy noise emission. Moreover, valve opening is recognized by the fact that the pressure indicated by the pressure meter
does not increase any further despite rising of the operating pressure setting for
the pump.
Now, the pressure setting of the pressure limiting valve on the pressure meter can
be read and recorded.
Prior to disconnecting the hydraulic system or rather the lube-oil recirculation system, the system operating pressure has to be reset to the normal operating pressure assessed at the commencement of the measurements.
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3.2.16.
Pressure Setting of Pumps

Visual check of pressure setting at the pressure-controlled main pumps.
Checks to be made:
Operating pressure in hydraulic system
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.
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.
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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3.2.17.
Switch Elements at Oil Tank, Fill Level Indicator, Temperature

Visual check of electrical switch elements.
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.
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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3.2.18.
Filter: Differential Pressure

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

Check by sensor of the water flow in the oil cooler.
Checks to be made:
Water flow in oil cooler.
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.
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.
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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3.2.20.
Accumulator: Pre-Fill Pressure

Visual check of the nitrogen pre-fill pressure in the accumulator.
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.
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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3.2.21.
Controls and Functions of the Hydraulic Systems

Visual and/or electromechanical function checks of the solenoid valves and/or the
proportional valves and servo valves.
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.
It is convenient, however, to check the hydraulic valves on a suitable test stand. If
no such stand is available, the hydraulic valves can be checked in installed state,
too.
For checking the way valves, the hydraulic system is cut on with its pump via the
electrical control. Then the way valve to be checked is actuated manually under
special observance of the safety instructions via the electrical control and monitored to test the alternating stroke movement of the associated hydraulic cylinder.
If the function of a valve is not selectable separately, appropriate aids are to be
used for triggering, as a substitute even hand operation of the valve.
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.
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.
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.
Electrical Switching Elements, Pressure Transducers, Pressure

Switches etc.
Visual check of electrical switching elements.
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.
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.
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
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.
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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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.
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.
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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3.2.23.
Lubricating-Oil Compact Unit: Filter, Pressure, Temperature

Visual check of filter, pressure and temperature of the compact unit
(lube-oil recirculation system).
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.
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.
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.
If there is no such firmly integrated pressure measuring device available at the
lube-oil recirculation system, a pressure measuring device with a suitable measuring range is, for checking of the operating pressure in the lube-oil recirculation system, connected to the corresponding test-point connection by means of a hose
with test-point coupling and the operating pressure read thereon.
The operating temperature of the lube-oil recirculation system.
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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3.2.24.
Pressure Tank: Pressure

Visual check of the pressure in the pressure tank.
Checks to be made:
The oil pressure in the pressure tank of the lubricating-oil circulation
system when having been cut on.
the Plant Layout.
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.
through the electrical control system whereupon the operating pressure in the
pressure tank can be read on the pressure-measuring device, and recorded.
pressure tank, a pressure measuring device with a suitable measuring range is, for
checking of the operating pressure in the pressure tank, connected to the corresponding test-point connection by means of a hose with test-point coupling, and
the operating pressure in the pressure tank read thereon.
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3.2.25.
Separator: Cup Assembly, Run-off Diameter, Temperature, Safety Device

Visual check of the separator.
Checks to be made:
The faultless mounting of the cup assembly and its balancing.
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.
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.
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 contact-type 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.
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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3.2.26.
Oil Pressure at the Consumers

Visual check of the operating pressure at the machines (consumers).
Checks to be made:
The operating pressure of the lubricating-oil circulation system at the
machines
(consumers).
the Plant Layout.
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).
through the electrical control system whereupon the operating pressure at the machine (consumers) can be read on the pressure-measuring device, and recorded.
machine (consumers) , a pressure measuring device with a suitable measuring
range is, for checking of the operating pressure at the machine (consumers), connected to the corresponding test-point connection by means of a hose with testpoint coupling, and the operating pressure read thereon.
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3.2.27.
Water-Inlet Alarm Device

Visual check of the electrical switching elements of the water-inlet alarm device.
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.
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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3.2.28.
Pneumatic Compact Unit: Filter, Pressure, Temperature

Visual Check of filter, pressure and temperature of the compact unit.
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 Plant Layout.
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.
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.
A maximum temperature figure might be specified in the Technical
Data and/or in the Plant Layout. For checking the temperature of the
pneumatic unit, the system with its compressor is cut on via the electrical control and the temperature measured at the outside of the wall
of the compressed-air accumulator after lapse of several hours either
by use of a contact-type thermometer or by hand. Should the compressed-air accumulator avail of a firmly installed temperature measuring device, the temperature can also be read there.
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3.2.29.
Hydraulic Lines as to Up tightness

Visual check of the hydraulic pipelines.
Checks to be made:
As to any escape of hydraulic oil.
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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3.2.30.
Compressed-Air Lines as to Up tightness

Acoustical check of the compressed-air lines.
Checks to be made:
As to inadmissible escape of compressed air.
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.
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3.2.31.
Water Lines as to Up tightness

Visual check of the water pipelines.
Checks to be made:
As to inadmissible escape of water.
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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3.2.32.
Grease Lines as to Up tightness

Visual check of the grease pipelines.
Checks to be made:
As to inadmissible escape of grease.
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.
Also see the test features: Grease Systems, Control and Function.
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3.2.33.
Oil-Lubricating Lines as to Up tightness

Visual check of the oil-lubricating pipelines.
Checks to be made:
As to inadmissible escape of lubricating oil.
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.
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3.2.34.
Process Section
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.
The components listed are to be checked as under:
A...
Condensate discharge device

Direction of mounting to be checked
B...
Vessels and tanks

Vessels/tanks to be checked inside for cleanliness
E...
Q... Agitators
Agitator vanes to be checked for freedom of movement
F...
Filters and strainers

Filter inserts/strainers to be checked for cleanliness/damage
H...
Ball valve (manually operated)

Manual function (Open/Close) to be checked
Limit switch operation possibly to be checked
H...
Ball valve (pneumatically operated)

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

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

Manual function test (open/close)
Limit switch operation to be checked if required
K...
Butterfly valves (pneumatically operated)

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

Butterfly valves to be opened/closed via local remote control
Check to see if in Close direction the Butterfly Valve Closed limit
switch is operated before the torque switch
Manual function to be checked
Position indication to be checked
P...
Pumps
No pump test to be carried out without medium in the pump!
Check of rotational sense of motor with disconnected pump only!
R...
Check valves
Direction of mounting to be checked
Feeding screw
Sense of rotation to be checked
Freedom of movement to be checked
T...
V...
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
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3.3.
Certificate and Report of Completion of Erection
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Certificate of Completion of Erection
Contract Item / Equipment Designation /

Functional Unit
Confirmation:
Drawing-No.
Remarks
It is hereby confirmed that above-mentioned equipment / functional

units have been completely delivered and installed in line with
associated drawings, documents and contract-specification.
Date:
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Report on the end of erection
Customer:
SMS Siemag Aktiengesellschaft

Wiesenstrasse 30
57271 Hilchenbach
Contractor:
...................................................
...................................................
...................................................
Agreement item:
Plant designation:
SMS Siemag Code:
......................................
......................................
SMS Siemag Order No.

SMS Siemag Order
......................................
No.
......................................
dated ......................................
It is hereby certified that the overall erection has been carried out
with the exception of the cases listed below
in accordance with our Order No.
...................................... and
the pertaining drawings.
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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Acceptance reports
The acceptance reports for all machines for which a report had to be prepared
have been submitted and have been signed by the site manager of the erection
company and the site manager of SMS Siemag.
Functional tests
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.
Outstanding work
According to the list of outstanding items dated ................................
Warranty
The warranty period begins on................................
............................., ................................
_______________________
_______________________
On behalf of SMS Siemag
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3.4.
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Item No.:
Equipment:
CHECK
yes
not appl.
Remarks
Lubrication to lube instructions

Electrical motors sense of rotation
Strokes of hydraulic cylinders, stroke
rates and cushioning
Strokes of compressed air cylinders,
stroke rates and cushioning
Compressed air unit
Electrical facilities such as proximity
switches, limit switches, brakes, photocells, etc.
Hydraulic pipelines for leak test
Compressed air lines for leak test
Water lines for leak test
Grease lines for leak test
Lube oil lines for leak test
Nozzles, roll cooling, etc.
Note: Technical Data see Manual - B.

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Mill Stand
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks

Pass line and roll gap
Radial screw down
Vertical adjustment
Strokes of hydraulic cylinders, stroke
rates and cushioning
Strokes of compressed air cylinders,
stroke rates and cushioning
Compressed air unit
Hydraulic pipelines for leakage
Compressed air lines for leakage
Water lines for leakage
Grease lines for leakage
Lube oil lines for leakage
Nozzles for de-scaler box, roll cooling,
etc.
Adjustment of mechanical equipment
such as rest bars, mill guides, etc.
Basic adjustment of spindle chairs
Stand and roll clamping

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Hydraulic Equipment
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks

Pressure limiting valves for specified
pressure
Pump pressure setting
Switching elements on oil tank:
Level indication
Temperature
Filter:
Differential pressure
Oil cooler:
Water flow volume
Accumulator:
Pre-charge pressure
Controls and functions
Hydraulic lines for leakage
Electrical switching elements:
Pressure transducer
Pressure switch
Position transducer
Limit switch
Water alarm
Water ingress alarmed device

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Oil Lubrication System
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks

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

Date:
Buyer:
A00226.580 / MAADEN
Seller:
Stand / Revision
2011
Index
--
Blatt / Sheet
55
D3

Pneumatic System
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks
Compressed air unit:

Filter
Pressure
Lubricator

Date:
Buyer:
A00226.580 / MAADEN
Seller:
Stand / Revision
2011
Index
--
Blatt / Sheet
56
D3

Grease Equipment
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks

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


Date:
Buyer:
A00226.580 / MAADEN
Seller:
Stand / Revision
2011
Index
--
Blatt / Sheet
57
D3

Piping
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks
Hydraulic pipelines for leakage


Date:
Buyer:
A00226.580 / MAADEN
Seller:
Stand / Revision
2011
Index
--
Blatt / Sheet
58
D3

Water Pumps
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks



Date:
Buyer:
A00226.580 / MAADEN
Seller:
Stand / Revision
2011
Index
--
Blatt / Sheet
59
D3
Item No.:
Equipment:
CHECK
yes
not appl.
Remarks

Date:
Buyer:
A00226.580 / MAADEN
Seller:
Stand / Revision
2011
Index
--
Blatt / Sheet
60
D3
SMS Siemag Project No.:
Test Record
Fluid systems / pipelines / pressure tests
Codeword:
(Operating pressure in bar x 1,3 bar =

Test pressure)
Sheet
Customer contract No.:
Designation:
WBS element:
Material No. in BOM:
Material No.:
Document No.:
System / line number:
Operating pressure
in bar
Scope of
testing
Test pressure
in bar
OK
X
of
Not
OK
X
Remark:
Operating fluid:
Duration of test (min)
Leakage test (X)
Measuring points acc. to circuit diagram
Remark:
...
Inspection dept.
Name
A00226.580 / MAADEN
Date
SMS Siemag signature
Stand / Revision
2011
Index
--
Customer signature
Blatt / Sheet
61
D3
3.5.
Certificate for Preliminary Acceptance Test
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
62
D3
Preliminary Acceptance Certificate
Contract Item / Equipment Designation /

Functional Unit
Drawing-No.
Remarks
Enclosures:
Confirmation:
This is to confirm that above mentioned equipment / functional units

were completely supplied, installed and tested in accordance with the
Contract
Date:
A00226.580 / MAADEN
Purchaser / Inspector:
Stand / Revision
2011
Seller:
Index
--
Blatt / Sheet
63
D4
Erection Time Schedule
4. Erection Time Schedule
A00226.580 / MAADEN
Stand / Revision
2011
Index
--
Blatt / Sheet
General Time Schedule

Alcoa Ma'aden
(Saudi Arabian Mining Company), Ras Al Khair, Saudi Arabia, 1 & 4 Aluminium TCM Mill
No.
Activity EN
Start
Selected Preconditions for installation TCM Appendix 3 SMS Contract

Schedule
2012
End
15.12.11
31.01.13
09
10
11
12
01
02
03
04
05
06
07
08
09
10
11
12
01
02
03
04
05
06
07
08
09
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Main bay roof + side walls closed incl. Drainage
01.06.12
01.06.12
Over head cranes operational
01.04.12
01.04.12
01. Apr '12
Power supply for erection
01.04.12
01.04.12
01. Apr '12
Light in Main bay + cellars installed + operational
01.04.12
01.04.12
01. Apr '12
Equipment foundations Areawise ready for installation
01.04.12
01.04.12
01. Apr '12
01. Jun '12
TCM Area
01.04.12
01.04.12
01. Apr '12
Coiler Area
01.04.12
01.04.12
01. Apr '12
Media rooms
01.04.12
01.04.12
01. Apr '12
WTP - indirect cooling water available
15.12.12
15.12.12
11
Final power supply
15.11.12
15.11.12
12
Media supply ( Indirect Cooling water, Instrument air, compressed air,

RO Water, Fire fighting, waste water) required by SMS
01.11.12
01.11.12
13
Roll shop operational
31.01.13
31.01.13
14
Delivery FOB Main Equipment
15.12.11
31.12.12
10
15
Main Mechanical & Media Equipment
15.01.12
31.07.12
16
Main Electrical Equipment
15.12.11
31.07.12
17
Main drive motors
06.01.12
30.03.12
18
Delivery of spare parts
01.10.12
31.12.12
01.07.11
25.07.13
01.07.11
30.06.12
19
20
Overall Project Schedule of Construction & Cold Commissiong (SAMSUNG)

Civil
21
Equip. Foundation(1)
01.07.11
30.04.12
22
Availibility of TCM Switchhouse 1-2 incl HVAC working

(temporarily)
Floor Pavement
30.06.12
30.06.12
01.02.12
31.05.12
Col. Foundation
01.08.11
30.09.11
01.09.11
30.04.12
23
24
25
Arch.
26
Structure Erection
01.09.11
31.03.12 p '11
27
Cladding
01.11.11
30.04.12
28
Mech./Elec. & MC
01.05.12
25.07.13
29
Cold Rolling Mill; Erection
01.05.12
31.01.13
30
Cold Rolling Mill; Cold Commissioning
01.01.13
25.03.13
31
Cold Rolling Mill; Hot Commissioning
26.03.13
25.06.13
32
Cold Rolling Mill; Product Performance Test (1 month)
26.06.13
25.07.13
Projekt: A000226 Maaden TCM Overall Schedule 2011.10.14

Datum: 14.10.11
User: dale
All dates are preliminary
1 / 1
TASK
Milestone
2013
08
15. Dez '12

15. Nov '12
01. Nov '12
31. Jan '13

15. Jan '12
31. Jul '12
15. Dez '11

06. Jan '12
31. Jul '12

30. Mrz '12
01. Okt '12
31. Dez '12
30. Apr '12

30. Jun '12
01. Feb '12
SMS Recommend Ready by end of April
31. Mai '12
30. Sep '11

31. Mrz '12
01. Nov '11
30. Apr '12

01. Mai '12
31. Jan '13

Start Single Function Test 1 December
First Coil 25.03.13

26. Mrz '13
25. Jun '13

26. Jun '13
Summary
25. Jul '13

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

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

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ERECTION MANUAL (D)

Dsseldorf and Hilchenbach, Germany

4-stand Tandem Cold Mill

C - Sub suppliers` Components Manual

Auft.-Nr. / Order No.

Instruction for Erection

1. General Information for Erection

2. Erection Measuring Reports

3. Single Function Test

4. Erection Time Schedule

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

In case of changes this manual will not be considered.

Auft.-Nr. / Order No.

General Information for Erection

General Safety Requirements

Safety Instructions for Erection, Commissioning, Operation and Maintenance

Preconditions for Erection to Start

Report on foundation acceptance

Preparation of Foundations for Machine Erection

Levelling/Alignment and Anchoring of Machines and Equipment Units

Placing Under grouts

Storage, Slinging, Load Table and Unpacking of Supplied Equipment

Consumables Needed During Erection

1.10. Fitting, bending and welding of piping

Execution of fitting work

1.11. Chemical Cleaning of Steel Pipes

1.12. Stainless Steel Pipes

1.13. Chemical cleaning of steel pipes by the immersion process

1.14. Flushing of pipelines for oil circulation and hydraulic systems

1.15. Preassembly of Machines and Components

1.17. Mounting Instructions in Drawings

1.20. Heavy-Duty Cranes and Transport Facilities

1.21. Tools, Appliances and Auxiliaries

Single Function Tests

Precondition for Tests

Example of Pickling Scheme in Recirculation Process (ZS)

Sense of Rotation of Electric Motors

Auft.-Nr. / Order No.

Pass Line and Roll Gap

Certificate and Report of Completion of Erection

Check List for Functional Tests

Certificate for Preliminary Acceptance Test

Erection Time Schedule

Auft.-Nr. / Order No.

General Information for Erection

1. General Information for Erection

Auft.-Nr. / Order No.

General Information for Erection

General Safety Requirements

Safety Instructions for Erection, Commissioning, Operation

Auft.-Nr. / Order No.

General Information for Erection

Auft.-Nr. / Order No.

General Information for Erection

Job area safety:

Auft.-Nr. / Order No.

General Information for Erection

Never have pumps started against closed suction-side shutoff valves.

Lock mechanical equipment, for example by Safety pins.

Close shutoff valves in pressure and control oil lines.

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

Auft.-Nr. / Order No.

General Information for Erection

Auft.-Nr. / Order No.