Professional Documents
Culture Documents
GENERAL
2007
2
MATERIAL
WELDING
MACHINING
ASSEMBLING
PRESERVING
LABELING
PACKING
10
INSPECTION
Weitergabe sowie Vervielfltigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind nur nach vorheriger ausdrcklicher schriftlicher Zustimmung von SMS Demag AG gestattet. Das Dokument ist vor unberechtigtem Zugriff Dritter zu schtzen. Zuwiderhandlungen verpflichten zu Schadensersatz. Alle Rechte aus Patent-/Gebrauchsmuster-/Markenschutz vorbehalten.
The reproduction, distribution and utilization of this document as well as the disclosure of its content to others without prior explicit written consent by SMS Demag AG are prohibited. This document must be protected against unauthorized access by third parties. Contravention obligates to payment of damages. All rights arising under patent/utility model/trademark protection reserved.
SMS Demag Aktiengesellschaft Normung Telephone: (0 27 33) 29-10 93 Telefax: (0 27 33) 29-10 73 E-mail: hueb@sms-demag.de 1st edition (February 2007)
February 2007
Manufacturing Instructions
GENERAL
SN 200
Part 1
The Manufacturing Instructions SN 200 specify the requirements made on products, materials and manufacturing methods. The instructions are classified by manufacturing methods irrespective of the product. They describe minimum requirements that have to be complied with unless otherwise indicated in orders, drawings or other manufacturing documents. The Manufacturing Instructions SN 200 apply to the manufacture of components of SMS Demag AG and of its subsidiaries. The applicability of SN 200 is indicated in drawings and/or contracts and/or purchase orders. Every manufacturer has the obligation to comply with the overriding requirements specified in parts 7 to 10 in addition to the manufacturing methods for the products of his scope of supply and services. The correct and complete delivery/performance of the supplies and services are recorded by SMS Demag in a supplier evaluation system. This evaluation covers the quality, price, faithfulness to deadlines and completeness of the documents, test records and certificates associated with the scope of supply and services. We recommend that all suppliers introduce a quality assurance system on the basis of ISO 9001.
Example:
DIN ISO
286
ISO
286
There is, however, not a German-language version (DIN-ISO) for every international standard (ISO)!
Tolerancing principle
Contrary to the stipulations made in ISO or DIN, the tolerancing principle of "envelope requirements" applies to tolerances of shape and parallelism in all manufacturing methods.
All dimensions are subject to the envelope requirements as specified in DIN 7167.
This means that all tolerances of shape and parallelism shall be within the specified general or ISO tolerances.
Continued on page 2
Load-carrying attachments
SN 195 specifies the basic requirements to be met by load-carrying attachments in case of own design and own manufacture. We recommend having load-carrying attachments, for which basic data are specified by SMS Demag, designed, manufactured and inspected by specialised companies that possess the appropriate qualifications for load-carrying attachments.
Pipe classification
SMS Demag has drawn up a standardisation of all components of pipe conduits. This standardisation is given in Group 18 of our company standards and shall be observed.
Material data
The material data given in drawings and bills of materials are based on specifications taken from material and product standards. These properties are shown in SN 359 on "Materials" and shall be observed.
Radioactivity
All components and products shall be free of any ionising radiation that exceeds the natural characteristic radiation of the respective material. Ionising radiation exceeding the characteristic radiation of components and products is considered to exist when at the point of time of an examination a radiation value is found that is higher than the value of ambient background radiation. SMS Demag reserve the right of refusing the acceptance of any parts found to possess such ionising radiation.
Residual magnetism
The residual magnetism of all parts shall not exceed 800 A/m at the time of their delivery. Parts transported with lifting magnets and/or checked for surface defects with full-wave direct-current testers shall be demagnetised if necessary. Checks for residual magnetism shall always be performed with an appropriate field intensity meter. If requested by SMS Demag, the check shall be proven and/or certified.
February 2007
Manufacturing Instructions
MATERIAL
Dimensions in mm
SN 200
Part 2
Field of application
The manufacturing instructions in this part of SN 200 apply to all parts produced by casting, forging and rolling and to semifinished products of ferrous and non-ferrous metals unless otherwise specified in drawings or other manufacturing documentation.
Content
Page
1 Casting ...............................................................................................................................................................................2 1.1 Surface qualities.......................................................................................................................................................2 1.2 General tolerances ...................................................................................................................................................2 1.3 Degrees of accuracy.................................................................................................................................................2 1.3.1 Tolerance limits ........................................................................................................................................................2 1.4 General tolerances for cast steel products ...............................................................................................................2 1.4.1 Outer and inner curvatures.......................................................................................................................................3 1.5 General tolerances for cast iron products.................................................................................................................3 1.6 Mould tapers ............................................................................................................................................................3 1.7 Offset........................................................................................................................................................................4 1.8 Wall thicknesses.......................................................................................................................................................4 1.9 Machining allowances ..............................................................................................................................................4 1.9.1 Machining allowances for cast steel and cast iron products ....................................................................................5 1.10 Inspections ...............................................................................................................................................................5 1.10.1 Cast steel .................................................................................................................................................................5 1.10.1.1 Internal condition .....................................................................................................................................................5 1.10.1.2 External condition .....................................................................................................................................................6 1.10.2 Cast iron ...................................................................................................................................................................6 1.10.2.1 Internal condition ......................................................................................................................................................6 1.10.2.2 External condition .....................................................................................................................................................6 Referenced standards.............................................................................................................................................................6 Further standards....................................................................................................................................................................6 2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.4 Forging ...............................................................................................................................................................................7 Forgings, general ...........................................................................................................................................................7 External condition...........................................................................................................................................................7 Internal condition............................................................................................................................................................7 Surface condition ...........................................................................................................................................................7 Surface finish and quality classes ..................................................................................................................................7 Performance of the examination ....................................................................................................................................7 Recording levels and acceptance criteria.......................................................................................................................8 Inspections ...................................................................................................................................................................10
Referenced standards...........................................................................................................................................................10
Semi-finished products General tolerances.......................................................................................................................................................11 Technical delivery conditions .......................................................................................................................................11 Plate.............................................................................................................................................................................11 Inspection.....................................................................................................................................................................11
Referenced standards...........................................................................................................................................................12
Continued on pages 2 to 12
1 Casting
Casting is a process in which liquid steel, ferrous and non-ferrous metals are filled in a mould to produce parts of defined geometry and properties and of a shape which is close to the finished dimensions.
1 2 3 4
nom. dimension of the raw casting dimensions after finish-machining minimum limit of size maximum limit of size
Fig. 1
Up to and including 25 40 63 100 160 250 400 630 1000 1600 2500 4000 6300 10000
Overall casting tolerance 1) mm Casting tolerance grade CT for linear dimensions 2) drawing indication 8 1,2 1,3 1,4 1,6 1,8 2 2,2 2,6 2,8 3,2 3,8 4,4 9 1,7 1,8 2 2,2 2,5 2,8 3,2 3,6 4 4,6 5,4 6,2 7 10 2,4 2,6 2,8 3,2 3,6 4 4,4 5 6 7 8 9 10 11 11 3,2 3,6 4 4,4 5 5,6 6,2 7 8 9 10 12 14 16 12 4,6 5 5,6 6 7 8 9 10 11 13 15 17 20 23 13 6 7 8 9 10 11 12 14 16 18 21 24 28 32 14 8 9 10 11 12 14 16 18 20 23 26 30 35 40 15 10 11 12 14 16 18 20 22 25 29 33 38 44 50 9 1,7 1,8 2 2,2 2,5 2,8 3,2 3,6 4 4,6 5,4 6,2 7 10 2,4 2,6 2,8 3,2 3,6 4 4,4 5 6 7 8 9 10 11 11 3,2 3,6 4 4,4 5 5,6 6,2 7 8 9 10 12 14 16
The tolerance zone shall be arranged symmetrically to the nominal dimension. Lengths, widths, heights, center distances, diameters and curvatures. Wall thicknesses use the next higher casting tolerance grade CT.
1.5 General tolerances for cast iron products (EN-GJL and EN-GJS)
Table 3 Nom. dimension of raw casting mm Up to and including 25 40 63 100 160 250 400 630 1000 1600 Casting tolerance 1) mm for wall thicknesses 3) 12 13 14 4,6 6 8 5 7 9 8 10 5,6 6 9 11 7 10 12 14 8 11 16 9 12 10 14 18 11 16 20 13 18 23 21 15 30 24 17 35 28 20 40 32 23
Casting tolerance grade CT for linear dimensions 2) drawing indication Above 8 9 10 11 12 13 14 15 9 10 1,2 1,7 2,4 3,2 4,6 6 8 10 1,7 2,4 25 1,3 1,8 2,6 3,6 5 7 9 11 1,8 2,6 40 1,4 2 2,8 5,6 8 10 12 2 2,8 4 63 1,6 2,2 3,2 4,4 6 9 11 14 2,2 3,2 100 1,8 2,5 3,6 5 7 10 12 16 2,5 3,6 160 2 2,8 4 5,6 11 14 18 2,8 4 8 250 2,2 3,2 4,4 6,2 12 16 20 3,2 4,4 9 10 7 5 3,6 2,6 5 3,6 400 14 18 22 11 8 6 4 2,8 6 4 630 16 20 25 13 9 7 4,6 3,2 7 4,6 1000 29 18 23 10 8 5,4 3,8 2500 1600 21 33 8 15 5,4 12 9 6,2 4,4 4000 30 2500 24 9 17 38 6,2 14 10 7 6300 35 4000 28 10 20 7 44 11 10000 40 6300 32 11 23 16 50 1) The tolerance zone shall be arranged symmetrically to the nominal dimension. 2) Lengths, widths, heights, center distances, diameters and curvatures. 3) Wall thicknesses use the next higher casting tolerance grade CT.
15 10 11 12 14 16 18 20 22 25 29 33 38 44 50
16 12 14 16 18 20 22 25 28 32 37 42 49 56 64
Taper
Fig. 2
> > > > > > > > > > > > > > > > > > >
30 50 80 120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 6300
1.10 Inspections
1.10.1 Cast steel products 1.10.1.1 Internal condition The table below states SMS Demag specific requirements on the basis of DIN EN 12680-1. If required, the specifications are indicated in the drawing or in product-specific SN standards. Severity level 5 as in DIN EN 12680-1 is not applicable to products of SMS Demag. Table 7 Requirements for ultrasonic testability Smallest flat-bottomed hole diameter Wall thickness detectable according to DIN EN 12680-1, item 5.2 300 3 > 300 to 400 4 > 400 to 600 6 > 600 8 Table 8 Recording levels of reflectors
1)
Wall thickness mm
300 > 300 to 400 > 400 to 600 > 600 1) 2)
Area tested
Based on a 2 MHz ultrasonic probe The equation for converting the flat-bottomed hole diameter into side-drilled hole diameter is given in item 5.2 of DIN EN 12680-1
1)
Severity level 2 3 > 50 >100 > 50 > 100 50 50 100 600 100 600 Reflectors without measurable extent 1 3 8
50
4 > 50 100
Biggest diameter of equivalent flat-bottomed hole Number of reflectors to be recorded within a frame of 100 mm x 100 mm
mm
Rim zone Core zone Rim zone Core zone Rim zone Core zone Rim zone Core zone Rim zone Core zone Rim Core Rim Core
3 3)
mm
Maximum length without measurable width Largest individual area 4) Largest total area per reference area 4) Reference area
1)
mm
Not permitted
mm mm mm
Rim zone = t/3, max. 100 mm, t = wall thickness in test area Severity level 5 is not applicable to products of SMS Demag Total of core zone and rim zone 4) Reflectors which are less than 25 mm apart shall be regarded as one indication.
2) 3)
Indications which exceed the acceptance limits shall be reported in writing to the Quality Inspection Dept. of SMS Demag.
1.10.1.2
External condition
The external condition is examined in the areas marked in the drawing using the magnetic particle method as in DIN EN 1369 or the liquid penetrant method as in DIN EN 1371-1. The specifications are given in the drawing or in product-specific SN standards. Severity level 5 is not applicable to products of SMS Demag. 1.10.2 Spheroidal graphite cast iron 1.10.2.1 Internal condition The procedure used for determining the internal condition shall be in accordance with DIN EN 12680-3. The requirements made on the internal condition of castings in spheroidal graphite cast iron are shown in the drawing as SMS Demag specific indications or are stated in product-specific SN standards. Severity level 5 as in DIN EN 12680-3 is not applicable to products of SMS Demag. 1.10.2.2 External condition The external condition is examined in the areas marked in the drawing using the magnetic particle method as in DIN EN 1369 or the liquid penetrant method as in DIN EN 1371-1. The specifications are given in the drawing or in product-specific SN standards. Severity level 5 is not applicable to products of SMS Demag.
Referenced standards
DIN EN ISO 8062-3 DIN EN 1369 DIN EN 1370 DIN EN 1371-1 DIN EN 12680-1 DIN EN 12680-3 Castings; System of dimensional tolerances and machining allowances Founding; Magnetic particle inspection Founding; Surface roughness inspection by visualtactile comparators Founding; Liquid penetrant inspection Ultrasonic examination; Part 1: Steel castings for general purposes Ultrasonic examination; Part 3: Spheroidal graphite cast iron castings
Further standards
DIN EN 1559-1 DIN EN 1559-2 DIN EN 1559-3 Founding; Technical conditions of delivery; General Founding; Technical conditions of delivery; Additional requirements for steel castings Founding; Technical conditions of delivery; Additional requirements for iron castings
2 Forging
Forging is hot shaping by die forging or open-die forging to obtain a shape which is close to the finished dimensions of the component. The shaping process creates a largely uniform structure over the entire cross-section.
2.3
Internal condition
The internal condition shall be examined using ultrasonic testing as in DIN EN 10228-3 and 4. 2.3.1 Surface condition General The surfaces to be examined shall be free of scale, oil, grease, machining marks, paint coats and any other foreign matter that may adversely affect the detection sensitivity or the interpretation of the indications found. Forgings supplied in the as-forged condition are considered acceptable when the specified quality class can be attained. 2.3.2 Surface finish The surface finish shall be compatible with the required quality class, see Table 1. Table 1 Quality class and roughness Ra Surface finish 1 25 m Machined x 2 12,5 m x 3 12,5 m x 4 6,3 m x
"x marks the quality class that can be attained for the specified surface roughness.
2.3.3 Performance of the examination Scanning shall be performed using the manual-contact pulse-echo technique. The necessary minimum scanning coverage depends on the type of the forging and on whether grid scanning coverage or 100% scanning coverage is specified in the order or drawing. Table 2 specifies the requirements for scanning coverage at perpendicular sound incidence of the forging types 1, 2 and 3. Table 3 specifies the requirements for scanning coverage at angular sound incidence for the forging types 3a and 3b which have an outside diameter to inside diameter ratio of less than 1,6. The depth covered in circumferential scanning is limited by the angle of incidence and the diameter of the forging.
Shape
Scan paths 2) 2 at 90 3 at 60 4 at 45 6 at 30
100% scanning 100% scan around at least 180 of cylindrical surface 100% scan on two surfaces at right angles to each other
1a 1 1b
Scanning along the lines of a square-link grid on two surfaces perpendicular to each other 3) 4)
100% scan around at least 180 on the cyScanning along the lines of a square-link grid around 360 on the cylinlindrical surface and drical surface and on one lateral surface. 100% of one lateral surface 3a Scanning along the lines of a square-link grid around 360 on the outer cylindrical surface 4) 100% scan around 360 on the outer cylindrical surface 100% scan around 360 on the outer cylindrical surface and on one lateral surface
3 3b and 3c 4
1) 2)
Scan along the lines of a square-link grid around 360 on the outer cylindrical surface and on one lateral surface 4)
Additional scanning (for example on both axial directions for type 3a) may be carried out if specified in the enquiry or order. 100% means at least 10% overlap of the consecutive scan paths. 3) If the presence of a hole makes it impossible to reach the opposite surface, the number of scan lines shall be doubled for the types 1a and 1b by including the opposite test surfaces. 4) The grid spacing shall be equal to the thickness of the part up to a maximum of 200 mm.
Table 3 Scanning coverage at angular sound incidence Type Grid scanning 1) 100% scanning
1) 2)
3a 3 3b Scanning in both directions along 360 circumferential grid lines the spacing of which, up to a maximum of 200 mm, is equal to the radial thickness 100% scan of the outer cylindrical surface in both circumferential directions
4
1) 2)
Additional scanning coverage may be made if specified in the enquiry or order. 100% means at least 10% overlap of the consecutive scan paths.
2.3.4
The tables 4, 5 and 6 state the recording levels and acceptance criteria of four quality classes to be applied. The sensitivity of the testing system (test unit, probe, cable) must be sufficient to ensure the detection of the smallest discontinuities specified for the respective quality class according to the demanded recording and interpretation limits.
>8 0,1
>5 0,3
>3 0,5
>2 0,6
1)
R=
2)
with n = 1 for t 60 mm and n = 2 for t < 60 mm Fo, n th Fn amplitude (height on screen) of the n reduced backwall echo th Fo,n amplitude (height on screen) of the n backwall echo in the nearest discontinuity-free section of the range of Fn . If the backwall echo reduction is so heavy that the recording level is not attained, further examinations shall be made. Ratio R applies only if heavy backwall echo reduction is caused by the presence of a discontinuity.
Fn
Table 5
Quality classes, recording levels and acceptance criteria in the use of angle-beam probes and DGS technique with flat-bottomed holes Quality class 1
3)
Recording level Recording level of flat-bottomed holes FBH deg in mm Acceptance limits FBH for isolated discontinuities deg in mm of diameter 8 5 5 3 3 2 >5 >3 >2
Table 6
Quality classes, recording levels and acceptance criteria in the use of angle-beam probes with reference line method and reference line based on a cross hole of 3 mm in diameter Recording level % of reference line
3)
Quality class
Acceptance limit Extended or grouped Isolated discontinuities 4) 4) discontinuities % % of reference line of reference line 100 200 100 200 60 100 50 100 50 100 30 50
1 2
3) 4)
1 50 2 100 2 50 3 4 100 2 30 4 4 50 Quality class 1 cannot be attained when angle-beam probes are used. The indication amplitude in dB, related to the reference line, is given in table 7.
2.4 Inspections
The data and results of the tests set out below shall be reported by the forging or manufacturing shop in an inspection certificate 3.1 as in DIN EN 10204. - Chemical analysis of each heat contained in the supply - Result of the hardness test and the mechanical properties of every heat and heat-treatment unit.
- Result of the elevated-temperature tensile test at maximum working temperature of the material for heat-resistant steels for
every heat and heat-treatment unit
Referenced standards
DIN EN 10204 DIN EN 10228-1 DIN EN 10228-2 DIN EN 10228-3 DIN EN 10228-4 Types of inspection documents Non-destructive testing of steel forgings; Magnetic particle inspection Non-destructive testing of steel forgings; Penetrant testing Non-destructive testing of steel forgings; Ultrasonic testing of ferritic or martensitic steel forgings Non-destructive testing of steel forgings; Ultrasonic testing of austenitic or austenitic-ferritic stainless steel forgings
3 Semi-finished products
Semi-finished products is the collective term for products of definite shape, but with at least one indefinite dimension. Such products are sections, bars, rods, tubes, sheets and plates, boards, panels, strips and similar products made by rolling, drawing, pressing or any other method and having constant cross-section along the length. The designation "St" is allowed for steel components without particular strength requirements. The manufacture from different semi-finished products is then left to the discretion of the manufacturer. Suitability for welding shall be taken into account. The same applies by analogy if tensile strength requirements are made, but the types of smelting and treatment left open. In this case the indication is "St with Rm min. .
3.3 Plate
The applicable standard for deviations in thickness and flatness of plates is DIN EN 10029, Table 1, class A, and Table 4, class N. The permissible deviations given in DIN EN 10029 for the nominal thickness range of 150 to 250 mm are also applicable to plate thicknesses over 250 mm. Use shall be made of plates having class A surface condition as in DIN EN 10163.
3.4 Inspection
The results of all inspections on the semi-finished product (primary material) set out below shall be certified in an inspection certificate 3.1 as specified in DIN EN 10204. If the inspections/tests stated have been made on the semi-finished product, component parts need not be tested and certified again. It shall be ensured, however, that the components are made from the tested semi-finished products.
- Plate 1) 2 Plate of thickness 100 mm and yield point 250 N/mm shall be ultrasonically tested as specified in DIN EN 10160, quality class S2/E2, and tested for tensile strength or hardness. - Unalloyed steel Round bar of dia. 150 mm Square steel of lateral length 150 mm Flat bar of width 150 mm and thickness 100 mm
... shall be ultrasonically tested as in DIN EN 10228-3 (type 1 grid scanning, quality class 2) and tested for tensile strength or hardness. - Alloy steel Round bar of dia. 80 mm Square steel of lateral length 80 mm Flat bar of width 80 mm and thickness 80 mm
shall be chemically analysed, ultrasonically tested as in DIN EN 10228-3 (type 1 grid scanning, quality class 2) and tested for tensile strength or hardness. - Heat-resistant steel If specified in the order or drawing, semi-finished products made of heat-resistant steel shall, in addition to the chemical analysis, be tensile-tested at elevated temperature for each heat and heat-treatment unit at the maximum allowable working temperature of the steel. - Pipe For pipe of outside diameter 38 mm and wall thickness 5 mm, testing as required in the technical delivery conditions for pipe shall be certified.
1)
Referenced standards
DIN EN 1370 DIN EN 10021 DIN EN 10029 DIN EN 10140 DIN EN 10160 DIN EN 10163-1 DIN EN 10163-2 DIN EN 10163-3 DIN EN 10204 DIN EN 10228-3 Founding; Surface roughness inspection by visualtactile comparators General technical delivery requirements for steel and iron products Hot rolled steel plate 3 mm thick or above; tolerances on dimension, shape and mass Cold rolled narrow steel strip; tolerances on dimensions and shape Ultrasonic testing of steel flat product Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections; general requirements Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections; plate and wide flats Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections; sections Types of inspection documents Non-destructive testing of steel forgings; Ultrasonic testing of ferritic or martensitic steel forgings
February 2007
Manufacturing Instructions
THERMAL CUTTING AND BENDING
Dimensions in mm
SN 200
Part 3
Field of application
The manufacturing instructions specified in chapter 1 are extracts from DIN EN ISO 9013 and apply to materials which are suitable for oxyfuel flame cutting, plasma arc cutting and laser beam cutting. Chapter 2 deals with the cold bending of workpieces and pipes. All instructions/data given apply if no specifications to the contrary are made in drawings or other manufacturing documents.
Content
Page
1 Thermal cutting ..................................................................................................................................................................... 1 1.1 Oxyfuel flame cutting........................................................................................................................................................... 1 1.2 Plasma arc cutting............................................................................................................................................................... 1 1.3 Laser beam cutting.............................................................................................................................................................. 1 1.4 Cut surface quality............................................................................................................................................................... 2 1.4.1 Perpendicularity or angularity tolerance ............................................................................................................................ 2 1.4.2 Mean height of the profile, RZ5........................................................................................................................................... 2 1.4.3 Measuring points ............................................................................................................................................................... 3 1.4.3.1 Locations of the measuring points.................................................................................................................................. 3 1.4.4 Perpendicularity or angularity tolerance, u ........................................................................................................................ 3 1.4.5 Mean height of the profile, RZ5........................................................................................................................................... 3 1.5 Form and location tolerances ............................................................................................................................................... 4 1.6 Dimensional tolerances ........................................................................................................................................................ 5 2 Bending ................................................................................................................................................................................. 5 2.1 Bending ................................................................................................................................................................................ 5 2.1.1 Bending of flat products..................................................................................................................................................... 5 2.1.2 Bending of pipes................................................................................................................................................................ 6 2.1.3 General tolerances ............................................................................................................................................................ 6 3 Inspection ............................................................................................................................................................................. 7 Referenced standards ................................................................................................................................................................. 7
1 Thermal cutting
1.1 Oxyfuel flame cutting
Oxyfuel flame cutting is a process of thermal cutting which uses a fuel gas-oxygen flame and cutting oxygen. The heat of the heating flame and produced during combustion allows continuous combustion through the cutting oxygen. The oxides produced, mixed with some molten metal, are driven out by the kinetic energy of the cutting oxygen jet. The kerf is produced in the process. The instructions/data apply to flame cuts of 3 mm to 300 mm.
Continued on pages 2 to 7
Fig. 1
a) Vertical cut
1.4.2 Mean height of the profile, RZ5 Arithmetic mean of the single profile elements of five adjacent single measurements
Fig. 2
Key ln Zt1 to Zt5 lr evaluation length single profile elements single sampling length (1/5 of ln)
1.4.3 Measuring points 1.4.3.1 Locations of the measuring points The characteristic of perpendicularity or angularity tolerance u is determined only in a limited area of the cut surface. The area shall be reduced by the dimension a according to Table 1 from the upper and the lower cut surface edges (see Figure 1). The reason for the reduced cut face profile is to allow for the melting at the top edge of the cut. Table 1 - Dimensions for a Cut thickness a mm 3 > 3 6 > 6 10 > 10 20 > 20 40 > 40 100 > 100 150 > 150 200 > 200 250 > 250 400 a mm 0,1a 0,3 0,6 1 1,5 2 3 5 8 10
Table 2 - Perpendicularity or angularity tolerance, u Cut >20 >40 >60 >80 >100 thickness Up to to to to to to a 20 40 60 80 100 120 u for ranges 1,3 1,6 1,9 2,2 2,5 2,8 3 and 4
1.4.5 Mean height of the profile, RZ5 Table 3 Mean height of the profile, RZ5 Cut >20 >40 >60 >80 >100 >120 >140 >160 >180 >200 >220 >240 >260 >280 thickness Up to to to to to to to to to to to to to to to a 20 40 60 80 100 120 140 160 180 200 220 240 260 280 400 RZ5 0,146 0,182 0,218 0,254 0,290 0,326 0,362 0,398 0,434 0,470 0,506 0,542 0,578 0,614 0,650 for range 4 For SMS Demag purposes, the cut thicknesses range up to a = 400.
Page 4 SN 200 Part 3 : 2007-02 1.5 Form and location tolerances (extract from DIN EN ISO 9013)
Figure 3 shows the maximum effective deviations within the tolerance zone.
Fig. 3
a) Through thickness
b) Flat
straightness tolerance (see 14.1 of DIN ISO 1101: 1983) for cut length; straightness tolerance (see 14.1 of DIN ISO 1101: 1983) for cut width; perpendicularity tolerance (see 14.8 of DIN ISO 1101: 1983) for cut width referred to A; parallelism tolerance (see 14.7 of DIN ISO 1101: 1983) for cut width referred to A on sheet level; perpendicularity tolerance (see 14.8 of DIN ISO 1101: 1983) in cutting direction.
Table 4 Limit deviations for nominal dimensions of tolerance class 1 Nominal dimensions 35 125 < 125 < 315 Limit deviations 0,2 0,3 0,4 0,6 0,7 1,3 2 2,7 0,2 0,3 0,5 0,7 0,8 1,4 2,1 2,7 -
Workpiece thickness
315 < 1000 0,3 0,4 0,5 0,7 1 1,7 2,3 3 3,7 4,4
1000 < 2000 0,3 0,4 0,5 0,7 1,6 2,2 2,9 3,6 4,2 4,9
2000 < 4000 0,3 0,4 0,6 0,8 2,5 3,1 3,8 4,5 5,2 5,9
0 1
1 3,15 6,3 10 50
3,15 6,3
> 10 > 50 > 100 > 150 > 200 > 250
For SMS Demag purposes, the tolerances range up to a workpiece thickness of 400 mm.
2 Bending
2.1 Bending
2.1.1 Bending of flat products In the cold bending of flat steel products the admissible bending radii as in Table 5 shall be observed. Further specifications are given in DIN 6935. Fig. 4
Table 5 Bending radii for a bending angle of 90 along the direction of rolling for steel grades of a min. tensile strength Rm of 390 N/mm Plate thickness Bending radius Leg length min. s r l 1 1,5 2,5 10 2 2,5 3 3 16 4 6 24 5 8 32 6 10 40 8 16 64 10 20 80 12 24 15 30 20 40 25 50 30 60 35 40
70 100
min.
2.1.2 Bending of pipes Cold bending of pipes shall be preferred to the welding-in of elbows. If drawings show welding elbows that can be replaced by a cold-bent pipes taking into account the bigger bending radius, the manufacturing shop is free to use bent pipes instead of elbows. When pipes are shown in isometric drawings, compliance with the drawing indications shall be ensured. Bending radii for cold-bent pipes are specified in Table 6 and in SN 740-1 and 2.
Table 6 Bending radii of pipes Pipe outside diameter 6 > 12 > 48,3 to 12 to 48,3 to 114,3 Bending radius 2 x outside pipe diameter for wall thicknesses > 1,0 2 x outside pipe diameter for all wall thicknesses 2,5 x outside pipe diameter for all wall thicknesses
2.1.3 General tolerances The general tolerances are specified in tables 7 and 8 according to DIN EN ISO 13920. These general tolerances correspond to the welding tolerances and shall be applied to bent parts by analogy.
The following applies: Tolerance category B for completely dimensioned pipe lines (for example pipe detail, isometric drawing) and for workpieces produced by bending of flat products. Tolerance category C for not completely dimensioned and freely laid pipe lines.
Table 7 Linear dimensions (outside, inside, stepped dimensions, bending diameters and bending radii) Nominal dimension range Tolerance category 2 to 30 1 1 > 30 to 120 2 3 > 120 to 400 2 4 > 400 to 1000 3 6 > 1000 to 2000 4 8 > 2000 to 4000 6 11 > 4000 to 8000 8 14 > 8000 to 12000 10 18 > 12000 to 16000 12 21 > 16000 to 20000 14 24 > 20000
B C
16 27
Table 8 Angular dimensions Nominal dimension range (length of the shorter leg) Admissible deviations in degrees and minutes Admissible deviations in terms of tangent values > 400 > 1000 > 400 > 1000 Up to 400 to 1000 Up to 400 to 1000 0,013 0,009 0,006 45' 30' 20' 0,018 0,013 0,009 1 45' 30'
Tolerance category B C
The shorter leg of the angle is taken as reference leg for the limit dimensions of the angles. Its length can also be counted from a particular reference point which then is shown in the drawing (examples are given in Figs. 5 to 9). The figures were taken from DIN EN ISO 13920 for welded components.
ref. point
Fig. 5
3 Inspection
Flame-cut and bent parts shall be checked by the manufacturer for compliance with the dimensions and angles indicated. The manufacturer shall also inspect the surface quality (height of the profile Rz5) of flame-cut faces. Documenting of the inspections is not required.
Referenced standards
DIN 6935 DIN EN ISO 1302 Cold bending of flat rolled steel products Geometrical Product Specifications (GPS); Indication of surface texture in technical product documentation Classification of thermal cuts General tolerances for welded constructions Technical drawings; Geometrical tolerancing Bending Radii for Piping and Tubing; Minimum dimensions associated with quarter bends and offset bends Bending radii for piping and tubing; determination of pipe lengths considering various bending angles and radii
DIN EN ISO 9013 DIN EN ISO 13920 DIN ISO 1101 SN 740-1 SN 740-2
February 2007
Manufacturing Instructions
WELDING
Dimensions in mm
SN 200
Part 4
Field of application
The manufacturing instructions in this part of SN 200 apply to all welded components unless otherwise specified in drawings and other manufacturing documents. The welding standards applicable to the respective materials (DIN, DVS, SEW etc.) shall be observed. Welding is a special process whose result (quality) cannot be fully assessed by subsequent examination of the product. The quality requirements for welding as in DIN EN 729 shall be fulfilled. We recommend establishing a quality assurance system on the basis of DIN EN ISO 9001.
Content
Page
1 Drawings and other manufacturing documents ................................................................................................................. 2 1.1 Representation in drawings.............................................................................................................................................. 2 1.1.1 Fillet welds ....................................................................................................................................................................... 2 1.1.2 Butt welds, partly and fully bevelled welds ....................................................................................................................... 2 1.1.3 Welds for subsequent machining ..................................................................................................................................... 2 1.1.4 Welds on pipe lines .......................................................................................................................................................... 2 1.1.5 Deposit welding................................................................................................................................................................ 2 1.2 Representation as in DIN EN 22553 (ISO 2553).............................................................................................................. 2 1.2.1 Basic symbols for weld types ........................................................................................................................................... 2 1.2.2 Combinations of basic symbols........................................................................................................................................ 2 1.2.3 Supplementary symbols................................................................................................................................................... 3 1.3 Positions of the symbols in drawings ............................................................................................................................... 3 1.3.1 Elements of the reference symbol and indications at the symbol..................................................................................... 3 1.3.2 Relation between arrow line and joint .............................................................................................................................. 3 1.3.3 Direction of the arrow line ................................................................................................................................................ 4 1.3.4 Position of the symbol with regard to the reference line................................................................................................... 4 1.3.5 Examples of application ................................................................................................................................................... 5 2 General tolerances ................................................................................................................................................................ 5 2.1 Linear dimensions ............................................................................................................................................................ 5 2.2 Straightness, flatness and parallelism.............................................................................................................................. 5 2.3 Angular dimensions.......................................................................................................................................................... 5 3 Execution of welding work .................................................................................................................................................. 6 3.1 Demands made on manufacturers of welded components .............................................................................................. 6 3.1.1 Equipment subject to construction-supervision regulations.............................................................................................. 6 3.1.2 Equipment not subject to construction supervision regulations ........................................................................................ 6 3.2 Weld preparation, general ............................................................................................................................................... 7 3.3 Filler metals...................................................................................................................................................................... 7 3.4 Preheating........................................................................................................................................................................ 7 3.5 Weld execution................................................................................................................................................................. 7 3.5.1 Weld execution, general................................................................................................................................................... 7 3.5.2 Weld execution for ferritic-austenitic weld joints............................................................................................................. 11 3.6 Notches.......................................................................................................................................................................... 12 3.7 Weld preparation on fluid-carrying components like pipelines, vessels, etc. ................................................................ 12 3.8 Weld execution on fluid-carrying components like pipelines, vessels, etc..................................................................... 13 3.8.1 Fluid-carrying steel components .................................................................................................................................... 13 3.8.2 Fluid-carrying components in stainless and acid-resistant steels................................................................................... 13 3.9 Quality of weld, quality level on fluid-carrying components like pipelines, vessels, etc. ............................................... 13 4 Postweld heat treatment .................................................................................................................................................... 13 4.1 Postweld heat treatment, general................................................................................................................................... 13 4.2 Postweld heat treatment of stainless steel ..................................................................................................................... 14 4.2.1 Heat treatment of non-stabilised austenitic steels .......................................................................................................... 14 4.2.2 Heat treatment of stabilised austenitic steels ................................................................................................................. 14 4.2.3 Heat treatment of low carbon steels............................................................................................................................... 14 4.2.4 Heat treatment of ferritic-austenitic weld joints............................................................................................................... 14 5 Filler metal ........................................................................................................................................................................... 14 6 Inspection ........................................................................................................................................................................... 14 6.1 Inspection of load-bearing welds with partial or full material penetration ....................................................................... 15 6.1.1 Inspection directions for the quality levels of welds, general.......................................................................................... 16 6.2 Inspection directions for the quality levels of welds on fluid-carrying components......................................................... 16 7 Guideline for the quality levels of imperfections ............................................................................................................. 17
Single-V butt weld Singlebevel butt weld Single-V butt weld with broad root face
14
15
17
1.2.2 Combinations of elementary symbols Where necessary, combinations of elementary symbols are used for representation. Typical examples are given in table 2. Table 2 Combinations of elementary symbols Designation Double-V butt weld (X-weld) Doublebevel butt weld (K-shape) Double-V butt weld with broad root face Illustration Symbol Designation Doublebevel butt weld with broad root face Double-U butt weld Double-J butt weld Illustration Symbol Designation Single-V and single-U butt weld Single-V butt weld and backing run Fillet weld and fillet weld Illustration Symbol
Table 5 Examples of application of supplementary symbols Designation Flat (flush) single-V butt weld Convex double-V weld Illustration Symbol Designation Single-V butt weld with broad root face and backing run Flush finished single-V butt weld Fillet weld with smooth blended face Illustration Symbol
Concave fillet weld Flat (flush) single-V butt weld with flat (flush) backing run
1.3.2 Relation between arrow line and joint The side of the joint to which the arrow line points is called the arrow side. The other side of the joint is called the opposite side. The arrow line points preferably to the upper workpiece face. The examples in figures 3 and 4 explain the terms - arrow side of the joint - opposite side of the joint opposite side arrow side arrow side opposite side Joint A Arrow line Joint B opposite side of joint A" arrow side of joint A" Arrow line opposite side arrow side of joint A" of joint B" Arrow line Joint A Joint B
Arrrow line
arrow side a) opposite side arrow side b) opposite side of joint B" of joint B" of joint A" of joint B" Fig. 4 Cruciform joint with two fillet welds
Fig. 5
b)
Fig. 6a
Fig. 6b
Butt welds
Illustration
Symbolic representation
Fig. 7a
Fig. 7b
General tolerances
SMS Demag standard general-tolerance classes are specified in tables 6 to 8 on the basis of DIN EN ISO 13920. Drawing indication is not required.
16
16
Reference point
Reference point
Reference point
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
For conversion of angular dimensions into linear dimensions for measuring purposes, the limit deviations of the angles are additionally indicated in terms of tangent values. Table 8 Angular dimensions Nominal dimension range (length of the shorter leg) Tolerance class Admissible deviations in degrees and minutes Up to 400 B 45' > 400 to 1000 30' > 1000 Up to 400 20' 0,013 Admissible deviations in terms of tangent values > 400 to 1000 0,009 > 1000 0,006
The maximum admissible deviation in mm is calculated by multiplying the tangent value x by the length of the shorter leg.
DIN 18800 DIN 15018 National regulations of user country Directive 97/23/EC on pressure equipment National regulations of user country National regulations of user country
The assignment to the equipment subject to construction supervision or to Directive 97/23/EC on Pressure Equipment and to the Water Resources Management Law is indicated on the drawings. 3.1.2 Equipment not subject to construction supervision Table 10 Quality of weld DIN EN ISO 5817 Demands on the manufacturer Requirements to be fulfilled by the welding shop on the basis of DIN EN 729: Basic requirements - suitable welding equipment - proof of welders qualification acc. to DIN EN 287, in case of doubt, proof of qualification by trial welds - proof of filler-metal storage and handling in accordance with supplier recommendation Extended requirements - fulfilment of the above basic requirements - welding supervision by supervisory personnel as in DIN EN 719 - appropriate storage of base materials to maintain the marking - prior to manufacture, proof of application/mastering of welding procedures acknowledged in DIN EN ISO 15610 - keeping available of welding and working instructions - use of personnel qualified acc. to DIN EN 473 for quality inspections
Components
Machinery and related equipment not subject to construction supervision (strand guide segments, shears, millstands, millstand platforms, converters, pipe lines) B and C
Note:
If a manufacturing shop does not fulfil the above requirements, other national or international regulations/permits (for example ASME) can be accepted. Their equivalence shall be proved by the contracting workshop before the beginning of manufacture.
When full material penetration required, the indication shown below shall be made in the drawing at the weld full penetration concerned. In case of demand joints full material penetration shall always be made,
even if this is not indicated on the drawing (see item 3.5.1.5).
3.4 Preheating
The welding areas shall be preheated as required for the respective material composition. The minimum preheat temperature Tp is determined according to SEW 086 and SEW 088 on the basis of carbon equivalent CET. In the case of multi-pass welds, the terms minimum preheat temperature and minimum interpass temperature shall have the same meaning. These instructions apply to steels of CET 0,5.
CET = C +
Mn + Mo
+
Cr + Cu 20
Ni 40
in (%)
10
Tp = 750 x CET 150 (C) Fig. 13
Measuring of the preheat, interpass and preheat maintenance temperatures shall be on the basis of DIN EN ISO 13916.
Table 11
Groove forms for butt welds (extract from DIN EN ISO 9692-1)
Weld Material thickness t Weld groove design Dimensions Recommended welding process 3) (as in ISO 4063) Remarks
Ref. No.
Designation
Illustration
Cross-section
Angle ,
1)
Gap b bt
1.2.1
1.2.2
6b8 t 1 0
1.2.3 100
Square butt weld with backing strip Square butt weld with centering lip 3 111 13 141 52 111 13 141 30 1) 51 72 1) -
1.2.4
1.3
3 t 10 8 < t 12
40 60 6 8
4 -
1.5
5 t 40
60
1b4
2c4
1.8
> 12
8 12
111 13 141
1)
10 t 25
35 60
2b4
1c2
1)
Table 11 (continued)
Weld Material thickness t Weld groove design Dimensions Designation Symbol (as in ISO 2553) Illustration Cross-section Angle 1) , Gap b Thickness of root face c Groove face height h Recommended welding process3) (as in ISO 4063) Remarks
Ref. No.
1.9.1 3 < t 10 Single bevel butt weld 35 60 2b4 1c2 111 13 141 -
1.9.2
1.10
> 16
6 b 12 15 60 12 -
1.11
> 16
10 20
2b4
1c2
111 13 141
t 2
111 141 -
0 60
t 2
13 52 111 141 13
2.5.1
> 10
1b3 40 60
t 2
Table 11 (continued)
Weld Material thickness t Weld groove design Dimensions Designation Symbol (as in ISO 2553) Illustration Cross-section Angle 1) , 1 60 2 60 1b3 40 1 60 40 1 60 2
t 3
Ref. No.
Gap b
Remarks
2.5.2
> 10
111 141
13
2.7
30
8 12
tc 2
111 13 141
h= 35 60 1b4 2 or h=
t 2 t 3
111 13 141
This groove can also be asymmetric, similar to the asymmetric double-V butt weld
tc 2 t 2
111 13 141
half fill
Fig. 13
Fig. 14
The slot width b depends on the plate thicknesses t1 and t2 and the necessary weld junction; for t1 15 mm, b is min. 0,5 x t1, but at least 4 mm, for t1 > 15 mm, b is min. 15 mm. 3.5.1.2 Plug weld Plug welds are allowed only for plate thicknesses t1 40 mm. Hole diameter d = t1, but at least 20 mm, with preparation as in Fig. 14. 3.5.1.3 Weld thickness on butt welds, partly and fully bevelled welds The weld thickness of these welds shall correspond to the indicated weld depth. For butt and fillet welds the max. weld reinforcement () is determined by the weld quality. For partly and fully bevelled welds the weld reinforcement () for single-bevel and double-bevel welds has been determined to be 0 to 0,3 x weld depth (s) and for single-J, double-J and square-edge butt welds, to be 0 to 0.2 x weld depth (s). (Fig. 15) Fig. 15 3.5.1.4 Weld thickness on fillet welds In general, the weld shall be made as shown in Fig. 16. If the leg thickness (z) is decisive for the execution of the weld, the letter z and this thickness are indicated in the drawing as shown in Fig. 17. for example z = 5
Fig. 16
Fig. 17
Contrary to DIN EN 22553 (ISO 2553), the indication (a) for fillet weld thicknesses is not made in SMS Demag drawings. Fillet welds shall be executed as follows: Fillet welds on both sides: a = 0,3 x smallest plate thickness; fillet welds on one side: a = 0,6 x smallest plate thickness, but max. 12 mm. Dimension (a) depends on the thinner of the parts to be joined and shall not exceed 12 mm; above 12 mm shall be made as partly or fully bevelled welds. If the inner joint of a two-sided seam is not accessible and cannot be welded, the design department shall be consulted. 3.5.1.5 Quality of weld; quality level for welding, general In table 16 the quality of weld is defined in quality levels according to DIN EN ISO 5817. Unless otherwise specified in the drawing, quality level D is the SMS Demag standard. The restrictions given in table 14 shall be observed. Demand joints on plates and sections shall be full penetration welds of quality level B, the quality of weld shall be proved by ultrasonic or radiographic testing. 3.5.1.6 Deposit welding Quality level D is SMS Demag standard with restriction to the imperfections Nos. 1.1 and 1.2, 2.3 to 2.6 and 2.12, see table 16. The stipulations of SN 402 shall be observed. 3.5.2 Weld execution for ferritic-austenitic weld joints Ferritic-austenitic weld joints are mixed joints between unalloyed/alloyed structural steels and austenitic chromium-nickel steels established by welding with CrNi (Mn, Mo) filler metals. Mixed joints between steels and nickel or nickel alloys also count among the ferritic-austenitic weld joints because of the use of nickel-based filler metals. Welding of ferritic-austenitic joints shall be made in accordance with the specific regulations and only with filler metals approved for use on such joints.
10
Notches shall be made as shown in figures 18 to 20. The dimensions of I (= R) in table 12 are big enough to allow welding through underneath the bracing. Weld seams shall be closed around Table 12 the corners even without express drawing indication: - as shown in Fig. 18 for ribs and webs of 12 mm max. thickness; Plate thickness l=R - as shown in Fig. 19 for ribs and webs above 12 mm; of rib - as shown in Figs. 19 and 20 for ribs and webs without notches, Up to 12 25 when b 100/200 mm. Above 12 to 30 40 50 For reasons of strength and in seal welding, ribs and webs of this type Above 30 shall be avoided.
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Degrees -
Root height c
Up to 2
Above 2 to 25
60
2 to 4
to 2
Above 25
60
15
2 to 3
All thicknesses
Fillet weld
Page 13 SN 200 Part 4 : 2007-02 3.8 Weld execution on fluid-carrying components like pipe lines, vessels, etc.
The surfaces in the weld area shall be clear of scale, slag, rust, paint, oil, grease and moisture prior to the assembling of parts to be welded. Cracks, lack-of-fusion areas and clusters of pores in tack welds shall be removed before welding over. Welding spatter is not allowed on the inner surfaces of pipelines; it is recommended using TIG welding for the root pass. The reduction of the pipe cross-section due to root reinforcement shall not exceed 20 % on pipes 25 mm outside diameter and shall not exceed 15 % on pipes > 25 mm outside diameter, related to the cross-section of flow of the pipe (observe table 16, No. 16). Compliance with the above shall be ensured by visual inspection and, if necessary, excess reinforcement shall be removed by grinding etc.. All welds in the interiors of vessels and chambers shall be continuous welds without interruption. The pipes of conduits in stainless and acid-resistant steels according to DIN EN 10297-2, DIN EN 10217-7, DIN EN 10216-5 shall be flooded with forming gas (for ex. N = 90%, H = 10%) both during tack-welding and root-pass welding (observe DVSMerkblatt (DVS Reference Sheet) 0937). Forming gases are used to remove the oxygen from the heated weld areas and thus prevent oxidation. They also have a favourable effect on the forming of the root geometry and on the surface quality and prevent the formation of pores.
3.8.1 Fluid-carrying steel components Unless otherwise specified in the drawing, butt welds shall be full penetration welds. All corner joints up to PN 25 bar shall be made at least in the form of fillet welds, over PN 25 bar, as single-bevel butt welds.
3.8.2 Fluid-carrying components in stainless and acid-resistant steels Unless otherwise specified in the drawing, all weld joints shall be full penetration welds. Gaps shall be avoided to reduce the corrosion probability of stainless and acid-resistant steels in areas exposed to water. A gap width over 0,5 mm and a gap depth of less than half the gap width can generally be regarded as uncritical (DIN EN 12502-4).
3.9 Quality of weld, quality level on fluid-carrying components like pipe lines, vessels, etc.
The quality of weld is specified in quality levels as in DIN EN ISO 25817, see table 16. Unless otherwise specified in the drawing, quality level D is SMS Demag standard. The restrictions shown in table 15 shall be observed.
General remarks on stress relief annealing for material groups S 235 and S 355 The annealing temperature shall be between 550 C and 600 C, for S355 max. 580 C. The heating rate shall not exceed 50 C per hour. The holding time shall be at least 1 minute for each millimeter of material thickness (120 minutes for 120 mm thickness). The cooling rate shall not exceed 50 C per hour.
4.2.2 Stabilised austenitic steels for ex.: 1.4541 1.4550 1.4571 1.4580 X6CrNiTi 18 - 10 X6CrNiNb 18 - 10 X6CrNiMoTi 17 12 - 2 X6CrNiMoNb 17 12 - 2
shall remain without postweld heat treatment whenever possible. If heat treatment cannot be avoided, it shall take place only after previous agreement with our specialist department (for example 750 C / holding time 1 hour / quick cooling down).
4.2.3 Low carbon steels for ex.: 1.4306 1.4404 1.4435 X2CrNi 19 - 11 X2CrNiMo 1712-2 X2CrNiMo 1814-3
shall remain without postweld heat treatment whenever possible. If heat treatment cannot be avoided, it shall take place only after previous agreement with our specialist department (for example 750 C / holding time 1 hour / quick cooling down).
4.2.4 Postweld heat treatment of ferritic-austenitic joints shall be made only in exceptional cases. If a component which requires stress relief annealing is to be provided with non-detachable stainless-steel parts, these parts shall be welded on or in only after annealing.
Filler metal
The alloy-element contents of the filler metal shall be generally the same as, or higher than, those of the parent material and shall be approved through suitability testing. Detailed information on the properties of suitable filler metals can be found in: DIN EN 440 DIN EN ISO 2560 DIN EN 1600 DIN EN 12536 DIN EN 14700 Wire electrodes and deposits for gas-shielded arc welding of non-alloy and fine-grain steels Covered electrodes for manual metal arc welding of non-alloy and fine grain steels Covered electrodes for manual metal arc welding of stainless and heat-resisting steels Welding consumables; Rods for gas welding of non alloy and creep-resisting steels; Classification Welding consumables; Welding consumables for hard-facing
Inspection
Type and extent of inspection of welded parts are specified by this Part 4 of SN 200 or by drawing indications. The inspections shall be made by the welding shop. If intermediate inspection is specified, the contracting welding shop shall make a report to the SMS Demag department of quality inspection for the purpose of such inspection. Dimensions having closer tolerances than the general tolerances stated in section 2 require documentation of the inspection indicating the desired and the actual dimensions. Pressure or leak tests shall be documented stating the kind of test, test pressure, testing time and pressure fluid. When there is no suitable method of non-destructive testing to prove the quality of the weld and the flow cross-section, our department of quality inspection (acceptance inspector) reserves the right to sever the pipelines at suitable points for inspection of those welds which are not visible from outside. Visual inspections shall be made as specified in DIN EN 970. Ultrasonic testing shall be made as in DIN EN 1712, 1713 and 1714. Radiographic examinations shall be made as in DIN EN 12517 and 1435. Magnetic-particle inspections shall be made as in DIN EN 1290 and 1291. Liquid penetrant inspections shall be made as specified in DIN EN 1289. All inspections shall be certified in an inspection document 3.1 as in DIN EN 10204.
Lifting devices welded to the workpiece shall be checked for cracks at the weld and in the heat-affected zone. Extent of inspection 100%, evaluation according to quality level C.
Drawing indication required Proof of quality required Visual inspection Ultrasonic testing Required inspec2 Crack detection tions and testing Pressure testing Leakage testing
Proof of quality required Visual inspection Ultrasonic testing Required inspec2 Crack detection tions and testing Pressure testing Leakage testing
6.2 Inspection directions for the quality levels of welds on fluid-carrying components
Table 15 Quality level as in DIN EN ISO 5817 Cons. No. as in DIN EN ISO 5817 Execution for PN of Drawing indication required Proof of quality required Visual inspection Nondestructive testing 5) (radiographing etc. ) Pressure testing Leakage testing Stringent B All
5) 6)
Intermediate C All > 25 bar Yes Yes Yes 10 % Only in exceptional cases
3
1)
When full material penetration is required, this shall be indicated in the drawing at the respective weld seam. (See item 3.2) The evaluation criteria for visual inspection and crack detection are applicable according to DIN EN ISO 5817. Testing methods shall be as specified in the respective DIN and AD reference sheets (DIN- and AD-Merkbltter). In case of doubt, testability shall be clarified with our department of quality inspection. The percentage indication of the extent of testing refers to the length of each individual weld. 3) Pressure or leakage testing is compulsory when: - components consist of several separate chambers or hollows. In this case testing is made on every individual chamber or hollow. - the weld seams have been treated by machining. Upon previous consultation with our department of quality inspection, crack detection can be used instead of leakage testing. For all other welds on components, pressure or leakage testing is not required provided the welds have been properly executed in the demanded quality. 4) On lifting devices welded to the workpiece, 100% crack detection shall be made on the weld and in the heat-affected zone. 5) Radiographing can be replaced by equivalent methods of testing of the internal condition. These tests are required only if the contracting workshop has not proved and documented the qualification of its personnel by suitable statistical methods and procedures. Approval by SMS Demag shall be obtained before beginning of manufacture. 6) In case of special requirements irrespective of the pressure stage.
2)
The instructions given herein apply to - alloyed and unalloyed steels; - nickel and nickel alloys; - titanium and titanium alloys; - manual, mechanized, partly mechanized and automatic welding; - all welding positions; - all weld joints such as butt welds, fillet welds and pipe branches; - the following welding processes and the associated individual processes as in ISO 4063: - 11 metal arc welding without gas protection; - 12 submerged arc welding; - 13 gas-shielded metal arc welding; - 14 gas-shielded welding with non-consumable electrode; - 15 plasma arc welding; - 31 oxy-fuel gas welding (only for steel). Metallurgical aspects like grain size, hardness etc. are not covered by DIN EN ISO 5817.
electroslag welding (RES) E manual metal arc welding metal active gas (MAG) welding tubular cored metal arc welding with active gas shield - 141 tungsten inert gas (TIG) welding
Table 16 Limits for imperfections No. Reference No. acc. to ISO 6520-1 Imperfection Remarks Designation mm D C B t Limits for imperfections in the quality levels
1 Surface imperfections 1.1 1.2 1.3 100 104 2017 Crack Crater crack Surface pore Maximum dimension of a single pore for - butt welds - fillet welds Maximum dimension of a single pore for - butt welds - fillet welds 0,5 0,5 0,5 to 3 >3 0,5 to 3 >3 0,5 Not permitted Not permitted d 0,3 s d 0,3 a d 0,3 s, but max. 3 mm d 0,3 a, but max. 3 mm h 0,2 t h 0,2 t, but max. 2 mm Not permitted Permitted Short imperfection: h 0,2 t, but max. 2 mm Not permitted Not permitted Not permitted Not permitted Not permitted Not permitted
d 0,2 s, but max. 2 mm d 0,2 a, but max. 2 mm Not permitted h 0,1 t, but max. 1 mm Not permitted Permitted Not permitted
Not permitted
1.4
2025
Not permitted Not permitted Not permitted Not permitted Not permitted
1.5
401
1.6
4021
Lack of fusion (incomplete fusion) Micro lack of fusion Only detectable by micro examination Incomplete root Only for single-side butt welds penetration
0,5
Table 16 (continued) Reference Imperfection No. acc. to No. ISO 6520-1 Designation 1.7 5011 5012 Continuous undercut Intermittent undercut
T Remarks mm Smooth transition is required. 0,5 This is not regarded as systematic imperfection. to 3 >3 D Short imperfection: h 0,2 t h 0,2 t, but max. 1 mm
Limits for imperfections in the quality levels C Short imperfection: h 0,1 t h 0,1 t, but max. 0,5 mm B Not permitted h 0,05 t, but max. 0,5 mm
1.8
5013
Shrinkage groove
0,5 to 3 >3
Not permitted
1.9
502
0,5
1.10
503
0,5
(continued) Imperfection Remarks Designation Excess penetration mm 0,5 to 3 >3 D h 1 mm + 0,6 b h 1 mm + 1,0 b, but max. 5 mm C h 1 mm + 0,3 b h 1 mm + 0,6 b, but max. 4 mm B h 1 mm + 0,1 b h 1 mm + 0,2 b, but max. 3 mm t Limits for imperfections in the quality levels
1.12
505
- butt welds
0,5
90
110
150
- fillet welds
0,5
90
100
110
Table 16 (continued)
No. 1.14
t mm 0,5 to 3 >3 D Short imperfection: h 0,25 t Short imperfection: h 0,25 t but max. 2 mm Not permitted h 2 mm + 0,2 a
Limits for imperfections in the quality levels C Short imperfection: h 0,1 t Short imperfection: h 0,1 t but max. 1 mm Not permitted h 2 mm + 0,15 a B Not permitted
511
Incompletely filled groove Burn through Excessive asymIn cases where a symmetric fillet weld has not metry of fillet weld been prescribed. (excessive unequal leg length)
1.15 1.16
510 512
0,5 0,5
Short imperfection: h 0,05 t but max. 0,5 mm Not permitted h 1,5 mm + 0,15 a
1.17
515
Root concavity
0,5 to 3 >3
Not permitted
1.18
516
Root porosity
1.19
517
Poor restart
Spongy formation at the root of a weld due to 0,5 bubbling of the weld metal at the moment of solidification. (e.g. lack of gas backing) 0,5
Locally permitted
Not permitted
Not permitted
Permitted. The limit depends on the type of imperfection occurred due to restart.
Not permitted
Not permitted
Table 16 (continued) No. 1.20 Reference No. acc. to ISO 6520-1 5213 Imperfection Remarks Designation Insufficient throat thickness Not applicable to processes with proof of greater depth of penetration. mm 0,5 to 3 >3 D Short imperfection: h 0,2 mm + 0,1 a Short imperfection: h 0,3 mm + 0,1 a, but max. 2 mm C Short imperfection: h 0,2 mm Short imperfection: h 0,3 mm + 0,1 a, but max. 1 mm B Not permitted t Limits for imperfections in the quality levels
Not permitted
1.21
5214
0,5
Permitted
1.22
601
Stray arc
1.23
602
Welding spatter
All types of cracks except microcracks and crater cracks. A crack usually only visible under the microscope. (50x)
Permitted if the parentNot permitted Not permitted metal properties are not affected. Acceptance depends on application, for example material, corrosion protection Not permitted Permitted Not permitted Not permitted
Acceptance depends on the type of parent metal with particular reference to crack sensitivity.
Table 16 (continued)
No.
Imperfection Remarks Designation Gas pore Porosity (uniformly distributed) The following conditions and limits for imperfections shall be fulfilled; see also Annex B for information:
t mm D
2.3
a1) Maximum dimension of the area of the im- 0,5 perfection (including systematic imperfection) related to the projected area NOTE: The porosity in the projected area depends on the number of layers (volume of the weld) a2) Maximum dimension of the cross-section 0,5 area of the imperfection (incl. systematic imperfection) related to the fracture area (only applicable to production, to welder or procedure tests) b) Maximum dimension of a single pore for - butt welds - fillet welds 0,5
2,5 %
1,5 %
1%
Table 16 (continued) No. 2.4 Reference No. acc. to ISO 6520-1 2013 Imperfection Remarks Designation Clustered (localized) porosity case 1 (D > dA2) mm D C B t Limits for imperfections in the quality levels
Sum of the different pore areas (A1 + A2 + ) related to the evaluation area lp x wp (case 1). The reference length for lp is 100 mm. If D is less than dA1 or dA2 , whichever is smaller, the envelope surrounding the porosity areas A1 + A2 shall be considered as one area of imperfection (case 2). The following conditions and limits for imperfections shall be fulfilled; see also Annex A for information: a) Maximum dimension of the summation of the projected area of the imperfection (incl. systematic imperfection) b) Maximum dimension of a single pore for - butt welds - fillet welds 0,5 16 % 8% 4%
2.4
2013
0,5
Table 16 (continued) No. Reference No. acc. to ISO 6520-1 2014 Imperfection Remarks Designation Linear porosity case 1 (D > d2) mm D C B t Limits for imperfections in the quality levels
2.5
The sum of the different pore areas related to the evaluation area lp x wp (case 1). If D is smaller than the smaller diameter of one of the neighbouring pores, the full connected area of the two pores shall be applied to the sum of the imperfection (case 2).
(continued) Imperfection Remarks Designation Linear porosity The following conditions and limits for imperfections shall be fulfilled; see also Annex A for information: a1) Maximum dimension of the area of the im- 0,5 perfection (incl. systematic imperfection) related to the projected area NOTE: The porosity in the projected area depends on the number of layers (volume of the weld) a2) Maximum dimension of the cross-section area of the imperfection (incl. systematic imperfection) related to the fracture area 0,5 (only applicable to production, to welder or procedure tests) b) Maximum dimension of a single pore for - butt welds - fillet welds 0,5 0,5 0,5 0,5 For single layer: 8 % For multi-layer: 16 % For single layer: 4 % For multi-layer: 8 % For single layer: 2 % For multi-layer: 4 % mm D C B t Limits for imperfections in the quality levels
8%
4%
2%
2.6
2015 2016
2.7
202
Shrinkage cavity
2.8
2024
Crater pipe
d 0,4 s, but max. 4 mm d 0,4 a, but max. 4 mm h 0,4 s, but max. 4 mm l s, but max. 75 mm h 0,4 a, but max. 4 mm l a, but max. 75 mm Short imperfection permitted, but not breaking of the surface - butt welds: h 0,4 s, but max. 4 mm - fillet welds h 0,4 a, but max. 4 mm h or l 0,2 t
d 0,3 s, but max. 3 mm d 0,3 a, but max. 3 mm h 0,3 s, but max. 3 mm l s, but max. 50 mm h 0,3 a, but max. 3 mm l a, but max. 50 mm Not permitted
d 0,2 s, but max. 2 mm d 0,2 a, but max. 2 mm h 0,2 s, but max. 2 mm l s, but max. 25 mm h 0,2 a, but max. 2 mm l a, but max. 25 mm Not permitted
Not permitted
Not permitted
(continued) Imperfection Remarks Designation Solid inclusion Slag inclusion Flux inclusion Oxide inclusion - butt welds mm 0,5 0,5 0,5 0,5 0,5 0,5 D h 0,4 s, but max. 4 mm l s, but max. 75 mm h 0,4 a, but max. 4 mm l a, but max. 75 mm h 0,4 s, but max. 4 mm h 0,4 a, but max. 4 mm Not permitted Short imperfection permitted. - butt welds: h 0,4 s, but max. 4 mm - fillet welds: h 0,4 a, but max. 4 mm C h 0,3 s, but max. 3 mm l s, but max. 50 mm h 0,3 a, but max. 3 mm l a, but max. 50 mm h 0,3 s, but max. 3 mm h 0,3 a, but max. 3 mm Not permitted Not permitted B h 0,2 s, but max. 2 mm l s, but max. 25 mm h 0,2 a, but max. 2 mm l a, but max. 25 mm h 0,2 s, but max. 2 mm h 0,2 a, but max. 2 mm Not permitted Not permitted t Limits for imperfections in the quality levels
- fillet welds
2.10
304
Metallic inclusion other than copper Copper inclusion Lack of fusion (incomplete fusion) Lack of side wall fusion Lack of inter-run fusion Lack of root fusion
2.11 2.12
3042 401
(continued) Imperfection Remarks Designation Lack of penetration mm > 0,5 D Short imperfection: h 0,2 a, but max. 2 mm C Not permitted B Not permitted t Limits for imperfections in the quality levels
0,5
Short imperfection: - butt joint: h 0,2 s, but max. 2 mm - T-joint: h 0,2 a, but max. 2 mm Short imperfection: h 0,2 t, but max. 2 mm
Short imperfection: - butt joint: h 0,1 s, but max. 1,5 mm - fillet joint: h 0,1 a, but max. 1,5 mm Not permitted
Not permitted
Not permitted
Table 16 No.
(continued) Imperfection Remarks Designation mm D h 0,2 mm + 0,25 t h 0,25 t, but max. 5 mm C h 0,2 mm + 0,15 t h 0,15 t, but max. 4 mm B h 0,2 mm + 0,1 t h 0,1 t, but max. 3 mm t Limits for imperfections in the quality levels
The limits relate to deviations from the correct position. Unless otherwise specified, the position is correct when the centerlines coincide (see also Section 1). t refers to the smaller thickness.
0,5 to 3 >3
Fig. A: Plates with longitudinal welds 0,5 h 0,5 t, but max. 4 mm h 0,5 t, but max. 3 mm h 0,5 t, but max. 2 mm
3.2
617
Fig. B: Circumferential welds A gap between the parts that are joined. Gaps exceeding the permitted limit may in special cases be compensated by appropriate additional fillet weld thickness.
0,5 to 3 >3
Table 16 No.
(continued) Imperfection Remarks Designation mm D C B t Limits for imperfections in the quality levels
4 Multiple imperfections 4.1 None Multiple imperfections in any crossa section 0,5 to 3 Not permitted Not permitted Not permitted
>3 h1 + h2 + h3 + h4 + h5 = h
h1 + h2 + h3 + h4 + h5 = h
see Annex A
(continued) Imperfection Remarks Designation Projected or cross- case 1 (D > l3) section area in longitudinal direction mm D C B t Limits for imperfections in the quality levels
h1 x l1 + h2 x l2 +
x D + h3 x l3 = h x l h x l 16 % hxl8% hxl4%
The sum of the areas h x l shall be calculated 0,5 as a percentage related to the evaluation area lp x wp (case 1). If D is smaller than the shorter length of one of the neighbouring imperfections, the full connection of the two imperfections shall be applied to the sum of imperfections (case 2). NOTE: See also Annex A for information.
Quality level
Description of the quality of a weld on the basis of type and size of selected imperfections.
Fitness-for-purpose
Ability of a product, process or service to serve a defined purpose under specific conditions.
Short imperfection
In welds of 100 mm length or more, imperfections are considered to be short imperfections when their total length is not greater than 25 mm in any 100 mm weld length in which the most imperfections occur. In welds of less than 100 mm length, imperfections are considered to be short imperfections when the length of the imperfection does not exceed 25% of the weld length.
Systematic imperfections
Imperfections that are distributed at regular distances in the weld over the weld lengths to be examined with the sizes of the single imperfections being within the limits of acceptance.
Projected area
Area in which the imperfections distributed throughout the volume of the weld under consideration are imaged twodimensionally.
Note
In contrast to the cross-section area the occurrence of imperfections in radiographic exposures depends on the thickness of the weld (see Fig. 22),
Key
1 Direction of X-ray 2 4 pores per volume unit 3 6-fold thickness 4 3-fold thickness 5 2-fold thickness 6 1-fold thickness
Figure 22 Radiographic films of specimens with identical occurrence of pores per volume unit.
Assessment of imperfections
Limits for imperfections are given in Table 16. If microscopic examination is used for the detection of imperfections, only those imperfections shall be considered which can be detected using a magnification equal to or less than tenfold. Excluded herefrom are micro lacks of fusion (see Table 16, 1.5) and microcracks (see Table 16, 2.2). Systematic imperfections are only permitted in quality level D provided that other requirements of Table 16 are fulfilled. A welded joint shall normally be assessed separately for each individual type of imperfection (see Table 16, 1.1 to 3.2). Different types of imperfections occurring at any cross section of the joint may need special consideration (see multiple imperfections in Table 16, 4.1). The limits for multiple imperfections (see Table 16) are only applicable in cases where the requirements for a single imperfection are not exceeded. Any two adjacent imperfections separated by a distance smaller than the major dimension of the smaller imperfection shall be considered as a single imperfection.
Referenced standards
DIN 2559-2 to 4 DIN 15018 DIN 18800-1 DIN 18800-7 DIN EN DIN EN DIN EN DIN EN DIN EN 287-1 440 473 719 970 Edge preparation for welding Cranes; principles relating to steel structures; verification and analyses Structural steelwork, design and construction Steel structures, fabrication, verification of qualification for welding Approval testing of welders, fusion welding, steel Wire electrodes and deposits for gas-shielded metal arc welding of non-alloy and fine-grain steels Qualification and certification of NDT personnel; general principles Welding coordination - tasks and responsibilities Non-destructive examination of fusion welds Visual examination Welding; Recommendations for welding of metallic materials General guidance for arc welding Welding; Recommendations for welding of metallic materials Arc welding of ferritic steels Non-destructive examination of welds, penetrant testing of welds Non-destructive examination of welds, magnetic particle examination of welds
DIN EN 1291 DIN EN 1435 DIN EN 1600 DIN EN 1712 DIN EN 1713 DIN EN 1714 DIN EN 10204 DIN EN 12062 DIN EN 10216-5 DIN EN 10217-7 DIN EN 10297-2 DIN EN 12502-4 DIN EN 12517-1 DIN EN 12536 DIN EN 22553 DIN EN ISO 2560 DIN EN ISO 3834 DIN EN ISO 4063 DIN EN ISO 5817 DIN EN ISO 6520-1 DIN EN ISO 9001 DIN EN ISO 9692-1 DIN EN ISO 9692-2 DIN EN ISO 9692-3 DIN EN ISO 13916 DIN EN ISO 13920 DIN EN ISO 15610 DVS-Merkblatt 0937 SN 195 SN 200 SN 402 SEW 086 SEW 088 Richtlinie 97/23/EG
Non-destructive examination of welds - Magnetic particle examination of welds Acceptance levels Non-destructive testing of welds - Radiographic testing of welded joints Welding consumables, covered electrodes for manual metal arc welding of stainless and heat-resisting steels Non-destructive examination of welds - Ultrasonic examination of welded joints Acceptance levels Non-destructive examination of welds - Ultrasonic examination Characterization of indications in welds Non-destructive examination of welds - Ultrasonic examination of welded joints Metallic products; types of inspection documents Non-destructive examination of welds General rules for metallic materials Seamless steel tubes for pressure purposes - Technical delivery conditions Part 5: Stainless steel tubes Welded steel tubes for pressure purposes - Technical delivery conditions Part 7: Stainless steel tubes Seamless steel tubes for mechanical and general engineering purposes Technical delivery conditions Part 2: Stainless steel Protection of metallic materials against corrosion Guidance on the assessment of corrosion likelihood in water distribution and storage systems Part 4: Influencing factors for stainless steels Non-destructive testing of welds Part 1: Evaluation of welded joints in steel, nickel, titanium and their alloys by radiography Acceptance levels Welding consumables; Rods for gas welding of non alloy and creep-resisting steels; Classification (ISO 2553) Welded, brazed and soldered joints; symbolic representation on drawings Welding consumables - Covered electrodes for manual metal arc welding of non-alloy and fine grain steels - Classification Quality requirements for fusion welding of metallic materials Welding and allied processes; Nomenclature of processes and reference numbers Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded); Quality levels for imperfections Welding and allied processes, classification of geometric imperfections in metallic materials Quality management systems; Requirements Metal-arc welding with covered electrode, gas-shielded metal-arc welding and gas welding; joint preparations for steel Welding and allied processes; Joint preparation; Submerged arc welding of steel Welding and allied processes; Recommendations for joint preparation; Metal inert gas welding and tungsten inert gas welding of aluminium and its alloys Welding Guidance on the measurement of the preheat, interpass and preheat-maintenance temperatures Welding, general tolerances for welded constructions Dimensions for lengths angles, shape and position Specification and qualification of welding procedures for metallic materials DVS Reference Sheet 0937 on root protection in gas-shielded welding Load carrying attachments; Guidelines on design and manufacture, Inspection instruction Manufacturing Instructions Deposit welding on non-alloy and alloy high-temperature ferritic steels, preheating for welding on weldable fine-grained structural steels, guidelines for processing, in particular for fusion welding Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment
February 2007
Manufacturing Instructions
MACHINING
Dimensions in mm
SN 200
Part 5
Field of application
The manufacturing instructions laid down in this part apply to all workpieces produced by machining on the basis of SMS Demag drawings unless other instructions are given in drawings or other manufacturing documentation.
Table of contents
Page
1 Surface condition ........................................................................................................................................................... 2 1.1 General .................................................................................................................................................................... 2 1.2 Selection of measured variables of surface roughness comparative table............................................................ 2 1.3 Symbols for indication of surface condition .............................................................................................................. 2 1.4 Positions of surface indications at the symbol .......................................................................................................... 3 1.5 SMS Demag stipulations .......................................................................................................................................... 3 1.6 Indication of surface lay............................................................................................................................................ 3 2 General tolerances as in DIN ISO 2768 Parts 1 and 2.................................................................................................. 4 2.1 Lengths, angles, radii of curvature and chamfer heights ......................................................................................... 4 2.1.1 Field of application ................................................................................................................................................... 4 2.1.2 Degree of accuracy .................................................................................................................................................. 4 2.1.3 Linear dimensions .................................................................................................................................................... 4 2.1.4 Radii of curvature and chamfer heights (bevels) ...................................................................................................... 4 2.1.5 Angle dimensions (inclination).................................................................................................................................. 5 2.2 Form and location tolerances .................................................................................................................................. 5 2.2.1 Field of application ................................................................................................................................................... 5 2.2.2 Degree of accuracy .................................................................................................................................................. 5 2.2.3 Tolerances of form ................................................................................................................................................... 5 2.2.3.1 Flatness and straightness ........................................................................................................................................ 5 2.2.3.2 Roundness, cylindricity, line and surface tolerances ................................................................................................ 5 2.2.4 Tolerances of location .............................................................................................................................................. 5 2.2.4.1 Parallelism................................................................................................................................................................ 5 2.2.4.2 Rectangularity .......................................................................................................................................................... 5 2.2.4.3 Inclination (angularity) .............................................................................................................................................. 5 2.2.4.4 Symmetry ................................................................................................................................................................. 5 2.2.4.5 Coaxiality.................................................................................................................................................................. 5 2.2.4.6 Run........................................................................................................................................................................... 5 2.2.4.7 Tolerances for hole-center distances and hole-circle diameters .............................................................................. 6 2.2.4.8 Hole centerline tolerance in deep drilling.................................................................................................................. 6 3 General manufacturing instructions ............................................................................................................................. 7 3.1 Free choice of tool.................................................................................................................................................... 7 3.2 Surface finish............................................................................................................................................................ 8 3.3 Workpiece edge ....................................................................................................................................................... 8 3.4 Thread...................................................................................................................................................................... 8 3.4.1 Thread tolerance for metric ISO thread (selection series SN 152) .......................................................................... 8 3.4.2 Thread runout/thread undercut................................................................................................................................. 8 3.5 Roller burnishing and deep-rolling............................................................................................................................ 8 4 Inspection........................................................................................................................................................................ 9 4.1 Inspection of surface condition, measuring conditions ............................................................................................. 9 4.2 Inspection of dimensions, requirements on measuring tools/instruments ................................................................ 9 5 Tolerancing of form and location (abridged version) .................................................................................................. 10 5.1 General .................................................................................................................................................................. 10 5.2 Entries in drawings ................................................................................................................................................. 10 5.3 Symbols with detailed definitions............................................................................................................................ 12 6 Tolerances and limit deviations for linear dimensions from 1 to 10,000 mm.......................................................... 14 6.1 Field of application and purpose ............................................................................................................................ 14 6.2 General .................................................................................................................................................................. 14 6.3 Designation of tolerance series .............................................................................................................................. 14 6.4 Standard tolerances ............................................................................................................................................... 14 6.5 Limit deviations for shafts (nominal dimension range up to 3150 mm)....................................................... 15 6.6 Limit deviations for holes (nominal dimension range up to 3150 mm)....................................................... 16 6.7 Limit deviations for shafts (nominal dimension range over 3150 mm to 10,000 mm)................................. 17 6.8 Limit deviations for holes (nominal dimension range over 3150 mm to 10,000 mm)................................. 17
1 Surface condition
1.1 General
For the indication of the surface condition in drawings, DIN EN ISO 1302 (see item 1.4) is applicable with restriction. The preferred measured variable indicated in the drawing is the center line average roughness Ra, but only the roughness value itself (see tables 1 and 2). All other measured roughness variables are indicated in the drawing.
DIN EN ISO 1302 Ra m 50 25 12,5 6,3 3,2 2,5 1,6 0,8 0,4 0,2 0,1 Ra inch 2000 1000 500 250 125 100 63 32 16 8 4 Rz m 160 100 63 40 25 16 12,5 6,3 2,5 1,6 1 Roughness class N 12 N 11 N 10 N 9 N 8 -N 7 N 6 N 5 N 4 N 3
Grooves parallel to the plane of projection of the view in which the symbol is used. direction of lay
Grooves perpendicular to the plane of projection of the view in which the symbol is used. direction of lay
Grooves crossed in two oblique directions relative to the plane of projection of the view in which the symbol is used. direction of lay
Multidirectional grooves.
Grooves approximately circular relative to the center of the surface to which the symbol applies.
Grooves approximately radial relative to the center of the surface to which the symbol applies.
a = roughness value Ra in m
___
General tolerances
The general tolerances specified in DIN ISO 2768, Parts 1 and 2, are based on international stipulations. It does not fully cover the national regulations in force so far; for this reason, all differing data have been taken from DIN 7168 and are shown against shaded background.
>6 to 30 0,2 1
Limit deviations for nominal dimension ranges > 120 > 400 > 1000 > 2000 > 4000 > 8000 to to to to to to 400 1000 2000 4000 8000 12000 0,5 0,8 1,2 2 2 3 3 4
0,1
2.1.4 Radii of curvature and chamfer heights (bevels) Upper and lower limits for radii of curvature and chamfer heights (bevels) Table 7 Limit deviations for nominal dimension ranges Degree of accuracy 0,5 1) to 3 0,2 > 3 to 6 0,5 > 6 to 30 1 > 30 to 120 2 > 120 to 400 4
m (medium)
1)
Permissible deviations for nominal dimensions smaller than 0,5 mm are shown at the nominal dimension itself.
The maximum permissible deviation in mm is calculated by multiplying the tangent value by the length of the shorter leg. Any smaller angular tolerance required shall be indicated in the drawing.
Table 10 Toleranc e class H Perpendicularity tolerance for nominal dimension ranges for the shorter angle leg Up to 100 0,2 Table 11 Tolerance class H Symmetry tolerance 0,5 > 100 to 300 0,3 > 300 to 1000 0,4 > 1000 to 3000 0,5
4,5 5,5
6,6
11 13,5 17,5 22
26
33
39
45
52
62
70
78
86
96
107
10
12 14,5 18,5 24
28
35
42
48
56
0,25
0,3
0,5
0,75
1,0
1,5
2,0
3,0
3,5
Location tolerance
and through-hole
In drilling with single-lip drill or ejector drill and rotating workpiece, a hole centerline tolerance of 0.5 mm for 1000 mm of drilling depth shall not be exceeded. When the workpiece does not rotate, twice this hole centerline tolerance is permitted.
or
Fig. 1
Fig. 2
or
Fig. 9
Fig. 10
Fig. 11
End faces of countersinks Milling of a joint countersink area for several individual countersinks is allowed. Possible end faces are shown below:
or Fig. 12
Choice of drilling tool for stepped holes Unless otherwise detailed in drawings, it is left to the manufacturer's discretion to produce stepped (or smooth) holes depending on the available drilling tool.
G x 16 / 11-22x1200
or G x 16/ 11-22x1200
transition up to 0.3
3.4 Threads
3.4.1 Thread tolerance for metric ISO thread (selection series SN 152) Thread tolerance class as in DIN ISO 965-1: medium (m) Tolerance zone as in DIN ISO 965-1: 6g for the bolt Tolerance zone as in DIN ISO 965-1: 6H for the nut For thread sizes of M64 and above, a drawing indication is required. 3.4.2 Thread runout/thread undercut The normal case according to DIN 76- 1 and 2 is applicable to all thread runouts and undercuts.
4 Inspection
All features created during the manufacturing processes (dimensions, surface roughness etc.) shall be inspected by the manufacturer. When surface crack detection is specified in the drawings, this inspection shall be carried out by the manufacturer of the surface after finish-machining. The manufacturer shall record the results of the inspections using the criteria set out below indicating the associated desired and actual values in an inspection certificate 3.1 as in DIN EN 10204. - Dimensional tolerances with IT tolerance class IT9 - Dimensional tolerances without IT tolerance class as shown in the following: Dimensions below 180 mm with tolerance ranges 0,1 mm Dimensions > 180 to 800 mm with tolerance ranges 0,2 mm Dimensions > 800 to 2000 mm with tolerance ranges 0,4 mm Dimensions > 2000 to 5000 mm with tolerance ranges 0,8 mm Dimensions > 5000 mm with tolerance ranges 1,0 mm - tolerances of form and location of small tolerance class H according to DIN ISO 2768-2. - for angles, curves and radii, small degree of accuracy m according to DIN ISO 2768-1. - surface roughness values Ra 0,8 m as in DIN EN ISO 1302. - pressure tests for operating pressures exceeding 25 bar stating the type of test, test pressure, test time and pressure fluids. - threads, except for metrical (normal) vee threads and pipe threads, with indication of testing method/means. - toothings, stating base tangent lengths, tooth form, tooth alignment, pitch. - surface treatments and coats with indication of hardness and of coat thickness. - external condition, e.g. surface crack detection using dye penetrant and magnetic particle testing, with indication of recording and acceptability limits and with sketches where necessary
> 50
to 200
> 10
Regularly repeating profile: turned, milled, planed Non-repeating profile: ground, honed, lapped.
Cutoff wavelength: wave filters as in DIN EN ISO 11562 are named according to their cutoff wavelengths. They are profile filters which, depending on the filter characteristics, have the effect that the long-wave portions of the actual profile are incorporated in the roughness profile/measuring result only in part or not at all.
reference letter (if necessary) tolerance value (t) symbol of tolerance type
theoretically exact 1) dimension (in a box) , valid only in conjunction with location tolerance
reference triangles with reference letter R shown in a circle are reference surfaces which mark the point of departure for dimensioning and shall be taken into account for the defining of the manufacturing sequence.
The tolerance refers to the overall dimension of the element concerned. When the tolerance applies only to part lengths in any position, a linear dimension must be indicated in addition to the tolerance value and separated from it by a stroke; for example:
If the tolerance indication is to apply only to a prescribed area, this area shall be dimensioned and marked with a wide dash-dot line; for example:
1)
Theoretically exact dimensions are the bases for the locations of the form and location tolerance zones. The general tolerances do not apply to these dimensions.
The tolerance zone is cylindrical when the symbol precedes the tolerance value. When this symbol is not indicated, the tolerance zone is delimited by two lines or surfaces whose distance in the direction of the indication arrow is equal to the tolerance value.
When a common tolerance zone is intended to apply to several individual elements, this requirement is shown by adding the letters CZ (for common zone). These stipulations can be applied by analogy to other types of tolerances. In the example shown all three surfaces are required to be parallel to the reference surface. As a result, they are also symmetrical to each other within the tolerance of 0,1 mm.
Flatness
The surface shall lie between two parallel planes which are 0,08 apart.
Single elements
Level condition
The toleranced horizontal line shall lie between two horizontal lines which are t = 0,2 mm apart. When a reference length is not indicated, reference is always made to the respective overall length.
Tolerances of form
The circumferential line of every cross-section shall lie between two concentric circles which are in the same plane and 0,1 apart.
Cylindrical shape
The toleranced outside cylinder surface shall lie between two coaxial cylinders which are 0,1 apart.
In every section parallel to the drawing plane, the toleranced profile shall lie between two lines which envelope circles of 0,04 dia. whose centers lie on a line of geometrically ideal shape.
Surface shape
The toleranced surface shall lie between two surfaces which envelope spheres of 0,02 dia. whose centers lie on a surface of geometrically ideal shape.
Parallelism
Ball
The toleranced axis shall lie within a cylinder of 0,03 dia. which is parallel to reference axis A.
Tolerances of orientation
On a partial length of 100 in any position and any direction on the toleranced surface, all points shall lie between two planes parallel to reference surface A and 0,01 apart.
Perpendicularity
The toleranced axis of the cylinder shall lie between two parallel planes which are perpendicular to the reference surface and 0,1 apart.
Inclination (angularity)
The toleranced surface shall lie between two parallel planes which are 0,08 apart and at an angle of 40 to reference surface A.
Symmetry The central plane of the groove shall lie between two parallel planes which are 0,08 apart and which are symmetrical to the central plane of reference element A.
Location tolerances
Coaxiality The axis of the cylinder to which the tolerance indication refers shall lie within a cylinder which is coaxial to reference axis AB and has a dia. of 0,08. 2)
Concentricity
Tolerances (related elements)
The center of the toleranced circle shall lie within a circle of dia. 0,01 and concentric to the center of reference circle A.
Axial runout In one rotation around reference axis D the axial runout in any measuring position shall not exceed 0,1.
Radial runout In one rotation around reference axis AB, the radial runout shall not exceed 0,1 in any measuring plane.
Runout tolerances
In repeated rotation around reference axis D and radial shifting between workpiece and measuring unit, all surface points of the toleranced element shall lie within the overall axial runout of t = 0,1. 3)
In repeated rotation around reference axis A-B and axial shifting between workpiece and measuring unit, all surface points of the toleranced element shall lie within the overall radial runout of t = 0,1. 3)
The symbols shown against a shaded background are subject to the envelope requirements with due regard to Table 9 (general tolerances).
1)
Theoretically exact dimensions are the bases for the locations of the form and location tolerance zones. The general tolerances do not apply to these dimensions. As axes are difficult to determine by measuring, runout should be preferred to coaxiality. During shifting either the measuring unit or the workpiece shall be moved along a line which has the theoretically exact form and is in the correct position relative to the reference axis.
2) 3)
6.2 General
The standard tolerances stated in Table 19 are assigned to the respective tolerance series and classes. All values are based on the reference temperature of 20 C as in DIN EN ISO 1.
Table 20 Tolerance zones for outside dimensions of shafts as in DIN ISO 286-2 (SMS Demag selection). Deviations in m
e7 e8 14 28 20 38 25 47 32 59 40 73 50 89 e9 - 14 - 39 - 20 - 50 - 25 - 61 - 32 - 75 - 40 - 92 - 50 - 112 f7 6 16 10 22 13 28 16 34 20 41 25 50 g6 2 8 4 12 5 14 6 17 7 20 9 25 h6 0 6 0 8 0 9 0 11 0 13 0 16 h9 0 - 25 0 - 30 0 - 36 0 - 43 0 - 52 0 - 62 h11 0 60 0 75 0 90 0 110 0 130 0 160 j6 / js6 + 4 - 2 + 6 - 2 + 7 - 2 + 8 - 3 + 9 - 4 + 11 - 5 + 12 - 7 + 13 - 9
1)
k6 + + + + + + + + + + + 6 0 9 1 10 1 12 1 15 2 18 2
m6 + + + + + + + + + + + + 8 2 12 4 15 6 18 7 21 8 25 9 + + + + + + + + + + + +
n6 10 4 16 8 19 10 23 12 28 15 33 17 + + + + + + + + + + + +
p6 12 6 20 12 24 15 29 18 35 22 42 26
r6 + 16 + 10 + 23 + 15 + 28 + 19 + 34 + 23 + 41 + 28 + 50 + 34 + 60 + 41 + 62 + 43 + 73 + 51 + 76 + 54 + 88 + 63 + 90 + 65 + 93 + 68 + 106 + 77 + 109 + 80 + 113 + 84 + 126 + 94 + 130 + 98 + 144 + 108 + 150 + 114 + 166 + 126 + 172 + 132 + 194 + 150 + 199 + 155 + 225 + 175 + 235 + 185 + 266 + 210 + 276 + 220 + 316 + 250 + 326 + 260 + 378 + 300 + 408 + 330 + 462 + 370 + 492 + 400 + 550 + 440 + 570 + 460 + 685 + 550 + 715 + 580
s6 + 20 + 14 + 27 + 19 + 32 + 23 + 39 + 28 + 48 + 35 + 59 + 43 + 72 + 53 + 78 + 59 + 93 + 71 + 101 + 79 + 117 + 92 + 125 + 100 + 133 + 108 + 151 + 122 + 159 + 130 + 169 + 140 + 190 + 158 + 202 + 170 + 226 + 190 + 244 + 208 + 272 + 232 + 292 + 252 + 324 + 280 + 354 + 310 + 390 + 340 + 430 + 380 + 486 + 430 + 526 + 470 + 586 + 520 + 646 + 580 + 718 + 640 + 798 + 720 + 912 + 820 +1012 + 920 +1110 +1000 +1210 +1100 +1385 +1250 +1535 +1400
0 0 - 74 - 190 0 0 - 87 - 220
+ 21 + 2 + 25 + 3
+ 30 + 11 + 35 + 13
+ 39 + 20 + 45 + 23
+ 51 + 32 + 59 + 37
> 100 to > 120 to > 140 to > 160 to > 180 to > 200 to > 225 to > 250 to > 280 to > 315 to > 355 to > 400 to > 450 to > 500 to > 560 to > 630 to > 710 to > 800 to > 900 to > 1000 to > 1120 to > 1250 to > 1400 to > 1600 to > 1800 to > 2000 to > 2240 to > 2500 to > 2800 To
- 85 - 85 - 85 - 43 - 14 0 160 - 125 - 148 - 185 - 83 - 39 - 25 180 200 - 100 - 100 - 100 - 50 - 15 0 225 - 146 - 172 - 215 - 96 - 44 - 29 250 280 315 355 400 450 500 560 630 710 800 900 1000 1120 1250 1400 1600 1800 2000 2240 2500 2800 3150 - 110 - 110 - 110 - 56 - 17 0 - 162 - 191 - 240 - 108 - 49 - 32 - 125 - 125 - 125 - 62 - 18 0 - 182 - 214 - 265 - 119 - 54 - 36 - 135 - 135 - 135 - 68 - 20 0 - 198 - 232 - 290 - 131 - 60 - 40 - 145 - 145 - 145 - 76 - 22 0 - 215 - 255 - 320 - 146 - 66 - 44 - 160 - 160 - 160 - 80 - 24 0 - 240 - 285 - 360 - 160 - 74 - 50 - 170 - 170 - 170 - 86 - 26 0 - 260 - 310 - 400 - 176 - 82 - 56 - 195 - 195 - 195 - 98 - 28 0 - 300 - 360 - 455 - 203 - 94 - 66 - 220 - 220 - 220 - 110 - 30 0 - 345 - 415 - 530 - 235 - 108 - 78 - 240 - 240 - 240 - 120 - 32 0 - 390 - 470 - 610 - 270 - 124 - 92 - 260 - 260 - 260 - 130 - 34 0 - 435 - 540 - 700 - 305 - 144 - 110 - 290 - 290 - 290 - 145 - 38 0 - 500 - 620 - 830 - 355 - 173 - 135
0 0 - 100 - 250
+ 14 - 11
+ 28 + 3
+ 40 + 15
+ 52 + 27
+ 68 + 43
0 0 - 115 - 290
+ 16 - 13
+ 33 + 4
+ 46 + 17
+ 60 + 31
+ 79 + 50
0 0 - 130 - 320 0 0 - 140 - 360 0 0 - 155 - 400 0 0 - 175 - 440 0 0 - 200 - 500 0 0 - 230 - 560 0 0 - 260 - 660 0 0 - 310 - 780 0 0 - 370 - 920 0 0 - 440 -1100 0 0 - 540 -1350
+ 16 - 16 + 18 - 18 + 20 - 20 + 22 - 22 + 25 - 25 + 28 - 28 + 33 - 33 + 39 - 39 + 46 - 46 + 55 - 55 + 67 - 67
+ 36 + 4 + 40 + 4 + 45 + 5 + 44 0 + 50 0 + 56 0 + 66 0 + 78 0 + 92 0 + 110 0 + 135 0
+ 88 + 56 + 98 + 62 + 108 + 68 + 122 + 78 + 138 + 88 + 156 + 100 + 186 + 120 + 218 + 140 + 262 + 170 + 305 + 195 + 375 + 240
Tolerance zones for nominal dimension range above 3150 mm are subject to DIN 7172 (see page 17).
1)
Table 21 Tolerance zones for inside dimensions of holes as in DIN ISO 286-2 (SMS Demag selection). D7
+ 30 + 20 + 42 + 30 + 55 + 40 + 68 + 50 + 86 + 65 + 105 + 80
D10
E9
F7
F8
20 6 28 10 35 13 43 16 53 20 64 25
G7
+ + + + + + + + + + + + 12 2 16 4 20 5 24 6 28 7 34 9
G8
+ + + + + + + + + + + + 16 2 22 4 27 5 33 6 40 7 48 9
H7
+ 10 0 + 12 0 + 15 0 + 18 0 + 21 0 + 25 0
H8
+ 14 0 + 18 0 + 22 0 + 27 0 + 33 0 + 39 0
H9
+ 25 0 + 30 0 + 36 0 + 43 0 + 52 0 + 62 0
H12
+ 100 0 + 120 0 + 150 0 + 180 0 + 210 0 + 250 0
H13 J7/JS7
+ 140 0 + 180 0 + 220 0 + 270 0 + 330 0 + 390 0 + + + + + + 4 6 6 6 8 7 10 8 12 9 14 11
1)
K7
+ + + + + 0 10 3 9 5 10 6 12 6 15 7 18 -
M7
2 12 0 - 12 0 - 15 0 - 18 0 - 21 0 - 25 0 - 30 0 - 35
P9
6 31 12 42 15 51 18 61 22 74 26 88
1 to 3 to 6 to 10 to 18 to 30 to 50 to 65 to 80 to
3 6 10 18 30 50 65 80 100 120 140 160 180 200 225 250 280 315 355 400 450 500 560 630 710 800 900
+ 130 + 220 + 134 + 60 + 76 + 40 + 56 + 30 + 46 + 74 + 300 + 460 + 100 + 100 + 60 + 30 + 30 + 10 + 10 0 0 0 0 0 + 155 + 260 + 159 + 71 + 90 + 47 + 66 + 35 + 54 + 87 + 350 + 540 + 120 + 120 + 72 + 36 + 36 + 12 + 12 0 0 0 0 0
+ 18 - 12 + 22 - 13
+ 9 - 21 + 10 - 25
- 32 - 106 - 37 - 124
> 100 to > 120 to > 140 to > 160 to > 180 to > 200 to > 225 to > 250 to > 280 to > 315 to > 355 to > 400 to > 450 to > 500 to > 560 to > 630 to > 710 to > 800 to
+ 26 - 14
+ 12 - 28
0 - 40
- 43 - 143
+ 216 + 355 + 215 + 96 + 122 + 61 + 87 + 46 + 72 + 115 + 460 + 720 + 170 + 170 + 100 + 50 + 50 + 15 + 15 0 0 0 0 0
+ 30 - 16
+ 13 - 33
0 - 46
- 50 - 165
+ 242 + 400 + 240 + 108 + 137 + 69 + 98 + 52 + 81 + 130 + 520 + 810 + 190 + 190 + 110 + 56 + 56 + 17 + 17 0 0 0 0 0 + 267 + 440 + 265 + 119 + 151 + 75 + 107 + 57 + 89 + 140 + 570 + 890 + 210 + 210 + 125 + 62 + 62 + 18 + 18 0 0 0 0 0 + 293 + 480 + 290 + 131 + 165 + 83 + 117 + 63 + 97 + 155 + 630 + 970 + 230 + 230 + 135 + 68 + 68 + 20 + 20 0 0 0 0 0 + 330 + 540 + 320 + 146 + 186 + 92 + 132 + 70 + 110 + 175 + 700 +1100 + 260 + 260 + 145 + 76 + 76 + 22 + 22 0 0 0 0 0 + 370 + 610 + 360 + 160 + 205 + 104 + 149 + 80 + 125 + 200 + 800 +1250 + 290 + 290 + 160 + 80 + 80 + 24 + 24 0 0 0 0 0 + 410 + 680 + 400 + 176 + 226 + 116 + 166 + 90 + 140 + 230 + 900 +1400 + 320 + 320 + 170 + 86 + 86 + 26 + 26 0 0 0 0 0 + 455 + 770 + 455 + 203 + 263 + 133 + 193 + 105 + 165 + 260 +1050 +1650 + 350 + 350 + 195 + 98 + 98 + 28 + 28 0 0 0 0 0 + 515 + 890 + 530 + 235 + 305 + 155 + 225 + 125 + 195 + 310 +1250 +1950 + 390 + 390 + 220 + 110 + 110 + 30 + 30 0 0 0 0 0 + 580 + 1030 + 610 + 270 + 350 + 182 + 262 + 150 + 230 + 370 +1500 +2300 + 430 + 430 + 240 + 120 + 120 + 32 + 32 0 0 0 0 0 + 655 + 1180 + 700 + 305 + 410 + 209 + 314 + 175 + 280 + 440 +1750 +2800 + 480 + 480 + 260 + 130 + 130 + 34 + 34 0 0 0 0 0 + 730 + 1380 + 830 + 355 + 475 + 248 + 368 + 210 + 330 + 540 +2100 +3300 + 520 + 520 + 290 + 145 + 145 + 38 + 38 0 0 0 0 0
+ 36 - 16 + 39 - 18 + 43 - 20 + 35 - 35 + 40 - 40 + 45 - 45 + 52 - 52 + 62 - 62 + 75 - 75 + 87 - 87 + 105 - 105
- 56 - 186 - 62 - 202 - 68 - 223 - 78 - 253 - 88 - 288 - 100 - 330 - 120 - 380 - 140 - 450 - 170 - 540 - 195 - 635 - 240 - 780
> 900 to 1000 >1000 to 1120 >1120 to 1250 >1250 to 1400 >1400 to 1600 >1600 to 1800 >1800 to 2000 >2000 to 2240 >2240 to 2500 >2500 to 2800 >2800 to 3150
Tolerance zones for nominal dimension range above 3150 mm are subject to DIN 7172 (see page 17).
1)
Table 22 Tolerance zones for outside dimensions of shafts as in DIN 7172 (SMS Demag selection). e7 - 320 - 580 - 350 - 670 - 380 - 780 - 420 - 910 - 460 -1060 e8 - 320 - 730 - 350 - 850 - 380 -1000 - 420 -1180 - 460 -1400 e9 - 320 - 980 - 350 -1150 - 380 -1360 - 420 -1620 - 460 -1960 f7 - 160 - 420 - 175 - 495 - 190 - 590 - 210 - 700 - 230 - 830 g6 - 40 - 205 - 43 - 243 - 47 - 297 - 51 - 361 - 55 - 435 h6 0 - 165 0 - 200 0 - 250 0 - 310 0 - 380 h9 0 - 660 0 - 800 0 - 980 0 -1200 0 -1500 h11 0 -1650 0 -2000 0 -2500 0 -3100 0 -3800 js6 + 83 - 83 + 100 - 100 + 125 - 125 + 155 - 155 + 190 - 190 k6 + 165 0 + 200 0 + 250 0 + 310 0 + 380 0
(nominal dimension range from 3150 mm to 10000 mm) Deviations in m JS7 + 130 - 130 + 160 - 160 + 200 - 200 + 245 - 245 + 300 - 300 K7 0 - 260 0 - 320 0 - 400 0 - 490 0 - 600 M7 - 98 - 358 - 120 - 440 - 145 - 545 - 185 - 675 - 230 - 830
Table 23 Tolerance zones for inside dimensions of holes as in DIN 7172 (SMS Demag selection). D7 + 840 + 580 + 960 + 640 +1120 + 720 +1290 + 800 +1480 + 880 D10 +1630 + 580 +1940 + 640 +2320 + 720 +2750 + 800 +3280 + 880 E9 + 980 + 320 +1150 + 350 +1360 + 380 +1620 + 420 +1960 + 460 F7 + 420 + 160 + 495 + 175 + 590 + 190 + 700 + 210 + 830 + 230 F8 + 570 + 160 + 675 + 175 + 810 + 190 + 970 + 210 +1170 + 230 G7 + 300 + 40 + 363 + 43 + 447 + 47 + 541 + 51 + 655 + 55 H7 + 260 0 + 320 0 + 400 0 + 490 0 + 600 0 H8 + 410 0 + 500 0 + 620 0 + 760 0 + 940 0 H9 + 660 0 + 800 0 + 980 0 +1200 0 +1500 0 H12 +2600 0 +3200 0 +4000 0 +4900 0 +6000 0 H13 +4100 0 +5000 0 +6200 0 +7600 0 +9400 0
Referenced standards
DIN 76 DIN 7167 DIN 7168 DIN 7172 DIN EN 10204 DIN EN ISO 1302 DIN EN ISO 11562 DIN ISO 286-1 DIN ISO 286-2 DIN ISO 1101 DIN ISO 2768-1 DIN ISO 2768-2 DIN ISO 8015 DIN ISO 10012-1 DIN ISO 13715 DIN EN ISO 9001 Run out and undercut for metric ISO threads according to DIN 13 Relationship between dimensional tolerances and form and parallelism tolerances; Envelope principle without drawing indication General tolerances of linear and angular dimensions and general geometrical tolerances Tolerances and limit deviations for sizes above 3150 up to 10,000 mm; principles, standard tolerances, limit deviations Types of inspection documents Geometrical Product Specifications (GPS); Indication of surface texture in technical product documentation Surface texture: Profile method, metrological characteristics of phase correct filters ISO system of limits and fits; Bases of tolerances, deviations and fits ISO system of limits and fits; Tables of standard tolerance grades and limit deviations for holes and shafts Technical drawings; Geometrical tolerancing; tolerances of form, orientation, location and runout General tolerances; Tolerances for linear and angular dimensions without individual tolerance indications General tolerances; Geometrical tolerances for features without individual tolerance indications Technical drawings; Fundamental tolerancing principle Quality assurance requirements for measuring equipment; Metrological confirmation system for measuring equipment Edges of undefined shape; Vocabulary and indications Quality management systems; Requirements
February 2007
Manufacturing Instructions
ASSEMBLING
Dimensions in mm
SN 200 Part 6
Field of application
The manufacturing instructions laid down in this part of SN 200 apply to all components to be assembled and assembled units, unless otherwise specified in drawings or other manufacturing documentation. Assembling is the permanent linking or other way of joining two or more workpieces of defined geometrical shape; it also includes all handling and auxiliary procedures including measuring and inspection.
Table of contents
1 2 3
Page
3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8
Inspection .......................................................................................................................................................................... 5
Referenced standards........................................................................................................................................................... 5
Safety instruction
- The data and safety sheets of all chemical substances used (glues, lubricants, sealants etc) shall be available and the instructions given shall be followed. The data and safety sheets shall be included in the supply to SMS Demag. - The use of asbestos and substances containing asbestos is always prohibited. - Pipe couplings and flanged elements for oxygen pipe lines shall be absolutely free of grease. - Couplings requiring introduction of heat (flame) for disconnecting shall not be used on pipe lines which carry inflammable fluids.
Preparation
- All parts shall be deburred (free of burrs acc. to DIN ISO 13715) and cleaned, all surfaces shall be properly dressed before assembling.
- Holes used for feeding fluids shall be illuminated and checked for correct passage (for example with compressed air). - The parts shall be assembled on a base surface which corresponds to the future supporting surface and complies with the
accuracy required for the inspections to be made. The static and dynamic loads shall be taken into account. - Assembling of the components shall be made only after inspection of the individual parts, complete inspection records of all individual parts shall be submitted.
Continued on pages 2 to 5
3
-
Execution
For assembling (of wear plates, couplings, bushings etc.) the bonding, lubricating and sealing instructions of the maker shall be observed. When shrink fitting or removing bearings, couplings and other parts, the installation instructions given by the makers and the maximum allowable heating and undercooling temperatures shall be observed (in particular for quenched and tempered and for hardened gear wheels). Areas that are not accessible after assembling shall be provided with priming and top coats before assembling. (see Part 7) Grease bearing points and grease lines shall be delivered with initial fill. The specified fitting clearances and contact patterns shall be observed, set and documented. On assembled parts and machined surfaces, the maximum surface contact percentage shall be achieved. Prior to assembling, all exposed worked contact faces, with the exception of shrink joints, shall be provided with anticorrosion compound Tectyl 511-M or equivalent products. All components which need lubrication shall be properly provided with sufficient quantities of one of the standardised lubricants according to SN 180. Tightening torques indicated in the drawings shall also be observed in case of partial assembling for the purpose of finish machining. Screwed joints which are not marked in the drawings shall be established at the usual tightening torques for assembling. Here the tightening torques of Table 2 shall be achieved taking into account the respective screw materials. When no torques or pretensioning values are indicated on the drawing and no notes on securing are given, the screwed connections are secured with Loctite 243 according to SN 507. Dismantling shall be only to the necessary extent; screws and shims shall be left on the equipment provided this does not cause problems for shipment. Prior to disassembling, parts likely to be mixed up (pipe supports, split covers and housings etc.) shall additionally be provided with permanent and well visible marking using steel stamping letters or figures. If movements are effected by means of a hydraulic power package, the necessary purity of the hydraulic fluid shall be ensured, but at least degree of purity 17/13 acc. to ISO 4406.
3.1.1 Tolerances of form and location for assembled machine components These tolerances are referred to the respective overall lengths of the parts.
Table 1 Tolerances of form and location Feature Straightness Flatness Parallelism Perpendicularity Inclination Level condition Vertical Axial alignment Very fine (sf) 0,05 0,05 0,03 0,05 0,03 0,05 0,05 0,03 Tolerance class Medium Fine (f) (m) 0,1 0,2 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,2 0,2 0,2 0,2 0,2 0,2 0,2 Coarse (g) 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5
SMS Demag standard use is tolerance class medium. Deviations are indicated in the associated drawings or testing schedules.
They do not apply to screws with fine threads, necked-down bolts and T-head bolts as in SN 425. Extract from SN 403 Table 2 Permissible screw loads Screw size d1 M 6 M 8 M 10 M 12 M 16 M 20 M 24 M 30 M 36 M 42 M 48 M 56 M 64 M 72x6 M 80x6 M 90x6 M 100 x 6 M 110 x 6 M 125 x 6 M 140 x 6 M 160 x 6 P 1 1,25 1,5 1,75 2 2,5 3 3,5 4 4,5 5 5,5 6 Stressed cross-section As 2 [mm] 20,1 36,6 58 84,3 157 245 353 561 817 1121 1473 2030 2676 3463 4344 5590 7000 8560 11800 14200 18700 Tightening method Turning Pretensioning force Tightening torque FV [kN] [Nm] 7 7 13 18 20 35 29 61 55 149 86 290 124 500 199 1004 291 1749 401 2806 529 4236 732 6791 969 10147 1265 14689 1597 20368 2069 29492 2605 41122 3198 54799 4205 80284 5352 113326 7073 171027 Stretching Pretensioning force FV [kN] 158 251 366 502 660 909 1199 1551 1946 2504 3136 3835 5018 6362 8378
The pretensioning forces and tightening torques for screw materials of other strength categories can be calculated with the following factors: Screw material strength: 5.6 = 0,47; 10.9 = 1,41; 12.9 = 1,69; A 2-70 = 0,71; A 2-80 = 0,94.
B C
+ 16 + 27
Tolerance class
B C
Table 5 Straightness, flatness and parallelism tolerances Tolerance class F > 30 to 120 1 > 120 to 400 1,5 > 400 to 1000 3 Nominal dimension range (length of longer side of the surface) > 12000 > 8000 > 4000 > 2000 > 1000 to to to to to 16000 12000 8000 4000 2000 4,5 6 8 10 12 > 16000 to 20000 14 > 20000
16
3.2.3 Assembling of pipe couplings and flanges In the assembling of pipe couplings, cleanliness and lubrication of the thread shall be ensured and the assembling instructions given by the suppliers shall be followed. In the case of pipe couplings in stainless steel the threads and contact surfaces of the union nuts on the welding cones shall be provided with sufficient quantities of lubricant (for example with "Fett-Micro-Gleit GP 350" of Micro Gleit Company or any other lubricant approved by SMS Demag) to avoid seizing of the couplings. When flanges made of two different materials are used, the parts remaining on the pipe (flanges and welding collar) shall always be made of equivalent pipe material for reasons of pickling. For all piping components which can be removed before pickling (like split flanges etc.), the use of surface-treated (galvanized, chromalised or nickel-plated) steel is allowed. 3.2.4 Sealing of pipe couplings and threaded fittings When use is made of male stud couplings with front-side elastic seal, no additional sealing agents shall be applied. In exceptional cases couplings and threaded fittings without front-side elastic seals shall be sealed in the low-pressure range <16 bar with Omnifit 50H (by Messrs. Henkel), in the high-pressure range >16 bar with AVX No. 586 (by Loctite Company) or equivalent sealing compounds. Couplings in grease pipe lines shall not be provided with additional sealing compound. As couplings sealed with AVX can be disconnected only by the introduction of heat (flame), this sealing compound shall not be used for pipe lines which carry inflammable fluids.
3.2.5 Arrangement of fastening elements Unless otherwise specified in drawings, pipework shall be installed in such a way that the distance between two fastenings does not exceed the values in Table 6. Fastenings shall be used immediately near detachable connections and bends. Weld-on pipe fasteners are welded on using a fillet weld of a = 0,3 x smallest plate thickness. Grease pipe lines of outside diameters up to and including 10 mm are fastened on the machine without clearance using appropriate pipe clamps.
3.2.6 Cleanness of pipe lines and fluid-carrying components Prior to final assembling, pipework and fluid-carrying components shall be cleaned so that all impurities (dirt, chips, welding spatter, paint, etc.) on the inside surface are removed. Then the pipe lines and fluid-carrying components shall be closed so that ingress of dirt etc. is safely avoided.
3.2.7 Positions of screw holes Screw holes in pipe lines and fittings shall be arranged in such a way that they are symmetrical to the two main axes and that no holes are located on the axes themselves (refer to DIN 2501-1). Every flange is provided with a number of bolt holes that can be divided by four.
3.2.8 Connection holes To avoid contamination of the control elements, all connection holes (fittings, measuring instruments, cylinder ports, valve block connections etc.) shall be kept appropriately closed (with disks, caps, adhesive tape etc.) until final assembling. Connecting holes opened for reasons of installation shall be closed again immediately after installation.
4 Inspection
The scope of inspection of assembled units shall be agreed upon with the SMS Demag department of quality inspection. (refer to Part 10, Section 2) As far as applicable and feasible, the minimum requirement is the check of - tolerances of form and location of assembled units, - supporting and seating surfaces, connecting and takeover points, - clearances and contact patterns to be adjusted, - surface contact percentages (with 0,05 mm feeler gauge), - movements and travelling distances (with auxiliary drives if necessary), - cylinder strokes (with suitable hydraulic packages), - corrosion protection and coat of paint. The manufacturer shall draw up reports of all checks/inspections that have been made.
Referenced standards
DIN 2501-1 Flanges, mating dimensions DIN EN 13480-4 Metallic industrial piping, Fabrication and installation DIN EN ISO 13920 General tolerances for welded constructions DIN ISO 13715 ISO 4406 SN 180 SN 403 SN 507 Technical drawings; edges of undefined shape; vocabulary and indications Hydraulic fluids, method for coding the level of contamination by solid particles Operating materials/supplies (grease, oil) Permissible bolt loads Metal bonding
February 2007
Manufacturing Instructions
PRESERVING
Dimensions in mm
SN 200
Part 7
Field of application
The manufacturing instructions in this part of SN 200 define our standard for corrosion protection of machinery, pipes and pipelines, vessels and structural steel components unless otherwise specified in drawings or other manufacturing documents. It is recommended making the coating instructions available to the contracting workshop at the beginning of the project. The change-over to coating agents of low solvent contents is under preparation and will be incorporated in the next edition of SN 200.
Table of contents
1
1.1 1.2
Page
Principles........................................................................................................................................................................... 2 Basic instructions ............................................................................................................................................................. 2 Indication in drawings and other manufacturing documents ............................................................................................ 2
2 Surface condition.............................................................................................................................................................. 2 2.1 Surface preparation.......................................................................................................................................................... 2 2.2 Standard preparation grade of steel surfaces prepared by blasting ................................................................................. 2 2.3 Standard preparation grade of steel surfaces prepared by manual derusting.................................................................. 2 2.4 Standard preparation grade of steel surfaces prepared by pickling ................................................................................. 2 2.5 Derusting by blasting........................................................................................................................................................ 2 3 Coating .............................................................................................................................................................................. 3 3.1 Prime coat ........................................................................................................................................................................ 3 3.1.1 Basic specifications.......................................................................................................................................................... 3 3.1.2 Prime coats and their properties ...................................................................................................................................... 3 3.2 Delivery and intermediate coats ....................................................................................................................................... 4 3.2.1 Basic specifications.......................................................................................................................................................... 4 3.2.2 Delivery and intermediate coats and their properties ....................................................................................................... 4 3.3 Cover coat........................................................................................................................................................................ 4 3.3.1 Basic specifications.......................................................................................................................................................... 4 3.3.2 Cover coats and their properties ...................................................................................................................................... 5 3.4 Standard colours for special cover coats ......................................................................................................................... 5 3.5 Coating of follow-up and Morgoil spare parts................................................................................................................... 5 3.6 Emulsion-resistant coat.................................................................................................................................................... 5 4 Preservation ...................................................................................................................................................................... 6 4.1 Basic specifications.......................................................................................................................................................... 6 4.2 Preserving compounds and their properties..................................................................................................................... 6 5 Coating and preservation of pipe lines, pipes and vessels .......................................................................................... 7 5.1 Pipe lines ......................................................................................................................................................................... 7 5.1.1 Pipe lines in steel ............................................................................................................................................................. 7 5.1.2 Pipe lines in stainless and acid-resistant steels ............................................................................................................... 7 5.2 Pipes ................................................................................................................................................................................ 8 5.2.1 Steel pipes ....................................................................................................................................................................... 8 5.2.2 Pipes in stainless and acid-resistant steels...................................................................................................................... 8 5.3 Pipe fasteners .................................................................................................................................................................. 8 5.3.1 Pipe fasteners in steel...................................................................................................................................................... 8 5.3.2 Pipe fasteners in stainless and acid-resistant steels ........................................................................................................ 8 5.4 Vessels ............................................................................................................................................................................ 9 5.4.1 Vessels in steel ................................................................................................................................................................ 9 5.4.2 Vessels in stainless and acid-resistant steels .................................................................................................................. 9 6 Inspection.......................................................................................................................................................................... 9
Continued on pages 2 to 9
1 Principles
1.1 Basic instructions
All surfaces in steel (except stainless steel) of machine or structural steel elements shall be provided with a coat of
paint. This does not apply to contact surfaces and functional surfaces, they shall be preserved. All colours shall be the glossy type. All parts which have to remain uncoated shall be preserved with Tectyl 502-C or equivalent products after shotblasting/pickling; drawing indication is required.
Exceptions:
Anchor plates as in SN 227 for casting in concrete shall be only blasted to remove rolling skin and annealing scale from
the surface. These parts shall be neither coated nor preserved to achieve better adhesion to the foundation. Indoor storage of the parts is required to avoid new formation of rust. All parts in stainless and acid-resistant steels shall be neither coated nor preserved.
2 Surface condition
2.1 Surface preparation
All surfaces to be provided with a coat or with preserving compound shall be cleared of annealing colours, rust, slag, rolling skin, mill scale, dirt, dust, oil, grease, old paint, cooling lubricants etc. before the prime coat is applied.
When this type of blast-cleaning abrasive is used taking into account the impact energy and the blasting angle, the actual average roughness shall not be markedly higher than the specified average roughness of Ra = 12,5 m.
3 Coating
3.1 Prime coat
Basic specifications Upon preparation of the steel surface, the prime coat shall be applied within 6 hours to prevent new formation of rust. When surface preparation is made by pickling in phosphoric acid bath, the prime coat shall be applied not earlier than after 48 hours to avoid chemical change of the prime coat. This prime coat prevents penetration of cooling lubricants during machining. Depending on the degree of damage to the prime coat by finish-machining or welding, the prime coat is either repaired or newly applied. The weld seam area shall be cleaned with particular care to remove the alkaline or acid filler metal constituents and to avoid their destructive effects. Areas which are not accessible after assembling shall be provided with prime and top coats prior to the final assembling. Prime coats and their properties The following prime coats shall be applied: Table 1 Type of prime coat
1)
Note All machine and structural steel components, pipe lines and vessels in steel. Follow-up and Morgoil spare parts. Machines or machine parts exposed to elevated temperatures.
Drawing indication
3.1.1 SMS Demag standard All-purpose primer on Pu-alkyd basis with zinc phosphate (lead and chromate-free), grey, similar to RAL 7005 3.1.2 Heat-resistant Silicate zinc dust primer, moisture-hardening, grey, similar to RAL 7037 3.1.3 Acid-resistant Two-component epoxy-resin primer with zinc phosphate, reddish brown, similar to RAL 3009 3.1.4 Oil-resistant 3.1.4.1 External coat Like 3.1.1 SMS Demag standard 3.1.4.2 Internal coat Two-component epoxy-resin primer, reddish brown, similar to RAL 3011
40-50
120
21
No
70-75
400
24
12
Yes
Machines or machine parts exposed to acid fumes or splashes It is recommended making vessels in stainless and acid-resistant steel 40-50 150 21 9 40-50 120 21 9 All machines
Yes
No
40-50
150
21
Gear housings and gear internals like welded gear wheels, etc.
Yes
No
40-50
150
36
18
Yes
No
15-20
400
36
18
Yes
40-50
150
39
24
Yes
40-50
120
36
18
All machines
No
40-50
150
36
18
Gear housings and gear internals like welded gear wheels, etc.
Yes
Yes
Jet black RAL 9005 Traffic red RAL 3020 Yellow RAL 1004 Makers standard Cream RAL 9001
No No No
4 Preservation
Basic specifications
Surfaces without prime, delivery or cover coats are provided with preservative compound only after application of the final coat when assembling or functional/acceptance testing of the machine has been completed. It shall be ensured that the surfaces to be covered with preserving compound are free of grease, oil, dust and film rust. To avoid formation of rust under the coat, preservative compounds shall be applied only on absolutely dry surfaces.
Note
Drawing indication
Metallically bright surfaces; agent can be removed with solvent. Metallically bright surfaces, gear internals. Agent dissolves during the test run. For intermediate storage and transports of short duration For hydraulic units. Oil/preserving oil for functional test.
No
Sa 3
40
24
No
Sa 3 Sa 3
15 -
18 24
No
Sa 3
Dipping 70
36
Morgoil bearings
No
1)
When other prime coats are used, they shall be environmentally compatible, i.e. no use of PVC coats or primers containing zinc chromate. Indoor storage = closed building without temperature control Outdoor storage = storage under tarpaulin or roof see SN 200 Part 9
2)
3)
There are other colours to choose from, such as grey: RAL 7000, 7031, 7032, green: RAL 6010, 6021, blue: RAL 5010 or colours for different fluids (fluids conveyed according to DIN 2403), but these shall be specified in drawings and/or other manufacturing documents. Indication of Sa 3 with regard to preservation refers to the features of the preparation grades as in DIN EN ISO 12944-4 and not to the rust removal method Sa = blast cleaning.
4)
5.1.2 Pipe lines in stainless and acid-resistant steels - Pipe lines consisting of pipes according to DIN EN ISO 1127 are pickled, blast-cleaned or brushed to remove scale layers or annealing colours. Scale and slag shall be completely removed, annealing colours are acceptable up to colour scale brown (refer to DIN 25410, page 9, Annex A, annealing colours 1 and 2). Pipe lines consisting of pipes according to DIN EN ISO 1127 with cutting-ring or similar couplings (WALFORM) which are not welded and not heat treated shall remain without post-treatment. Pipe lines shall be clean inside. Coating or preservation is not required.
5.2 Pipes
5.2.1 Steel pipes Treatment and delivery condition of steel pipes as stated in Table 6. Table 6 Pipes Treatment/delivery condition Fluids Blast-cleaned inside Water Steam Condensate Gases/compressed air Oil/emulsion Hydr. fluid Instrument air Oxygen Grease outside
Pickled, flushed, passivated
No
Yes
1)
No
No
Yes
1)
Yes
No
No
Yes
1)
No
Yes
1)
Yes
No No
No No
Yes Yes
1)
No No
Yes Yes
1)
Yes Yes
5.2.2 Pipes in stainless and acid-resistant steels Pipes shall be supplied in pickled or descaled (metallically bright) condition and delivered to the place of use without further treatment. All pipes shall be closed with caps.
1)
Not applicable to pipes as in DIN EN 10305-1; these pipes remain in the treatment/delivery condition (bright annealed and oiled) in which they are supplied by the manufacturer.
All parts installed in vessels shall not be coated, but preserved with Tectyl 502-C or equivalent products. Vessels without manholes shall be rinsed with Inertol. The Vessels shall be clean inside. After surface treatment, all openings shall be safely closed for transport. The max. durability period is 24 months in case of indoor storage.
5.4.2 Vessels in stainless and acid-resistant steels Vessels shall be pickled, blast-cleaned (with quartz sand, glass beads) or brushed to remove scale layers and annealing colours resulting from welding and to ensure the formation of the passivation layer. Scale and slag shall be completely removed, annealing colours are acceptable up to colour scale brown; refer to DIN 25410 (page 9, Annex A, annealing colours 1 and 2). The Vessels shall be clean inside. After surface treatment, all openings shall be safely closed for transport. Coating or preservation is not required.
6 Inspection
All suppliers are bound to present the prime coats on machines or machine components to SMS Demag before the cover coat is applied. We reserve the right to check the compliance with the specified number of paint coats and layer thicknesses as well as their proper application. The paints and related products, preservative compounds, adhesives and sealing materials used shall be certified by safety data sheets and technical specifications.
Referenced standards
DIN 2403 DIN 4844-1 DIN 25410 DIN EN 10220 DIN EN 10255 DIN EN 10305-1 Identification of pipelines according to the fluid conveyed Safety marking; concepts, principles and safety signs Nuclear facilities, surface cleanliness of components
Seamless and welded steel tubes; Dimensions and masses per unit length Non-alloy steel tubes suitable for welding and threading Technical delivery conditions Steel tubes for precision applications Technical delivery conditions Part 1: Seamless cold drawn tubes DIN EN ISO 1127 Stainless steel tubes; dimensions, tolerances and conventional masses per unit length DIN EN ISO 11124-2 Specifications for metallic blast-cleaning abrasives; Part 2: Chilled-iron grit DIN EN ISO 12944-4 Corrosion protection of steel structures by protective paint systems; Types of surface and surface preparation SN 200-9 Manufacturing Instructions; Packaging SN 227-1 Anchor plates for tee-head bolts, single anchor plates SN 227-2 Anchor plates for tee-head bolts, double anchor plates SN 903 Delivery condition of pipes, fittings and pipe supporting material
February 2007
Manufacturing Instructions
LABELING
SN 200
Part 8
Field of application
The manufacturing instructions given in this part of SN 200 apply to all parts which are processed in the STOR system and intended for shipment, unless otherwise specified in drawings or other manufacturing documents. Labeling is with stick-on labels which shall be attached by supplier. During the term of validity of this edition of SN 200 a different procedure will have to be followed after the introduction of the SAP software, sub-project (TP) 3. The Department of Standardization will give notice of this change when the occasion arises.
Table of contents
Page
1 Definitions of terms .......................................................................................................................................................... 1 1.1 Project No. ....................................................................................................................................................................... 1 1.2 Identification No. ............................................................................................................................................................. 2 1.3 Designation ..................................................................................................................................................................... 2 1.4 Quantity .......................................................................................................................................................................... 2 1.5 Shipping unit (VE)............................................................................................................................................................ 2 1.6 Shipment label ................................................................................................................................................................ 2 1.7 Preliminary package (VP) ................................................................................................................................................ 2 1.8 VP label ........................................................................................................................................................................... 2 1.9 Final package .................................................................................................................................................................. 2 2 Reporting of shipping units and packages containing items of SMS Demag design ................................................ 3 2.1 General ............................................................................................................................................................................ 3 2.2 Reporting of the shipping units ....................................................................................................................................... 3 2.3 Reporting of the package data......................................................................................................................................... 3 2.4 Labeling of shipping units ............................................................................................................................................... 3 3 4 Reporting of shipping units and packages containing items of foreign design ......................................................... 3 Fixing of the shipment labels .......................................................................................................................................... 4 Examples on item 2.2 ...................................................................................................................................................... 5 Examples on item 2.3 ....................................................................................................................................................... 6
1 Definitions of terms
1.1 Project No.
This number is used to subdivide the equipment on the basis of functional aspects from the equipment unit level (machine) to the sub-item level. Project structure For example Equipment Equipment unit Assembly Sub-assembly Item Sub-item Project No. Equipment 54014 AE 100 AB 01 AU 01 AP 01 AUP 001
Continued on pages 2 to 6
1.3 Designation
Designation of the shipping unit.
1.4 Quantity
Numerical indication of the number of parts contained in the shipping unit. Piece(s) as unit of quantity is not indicated, other units of quantity (set, meter, kg etc.) shall be expressly indicated.
1.8 VP label
Label which is used to identify a preliminary package (VP) for shipment to the packaging company.
Example:
Explanations on how to complete the VP label are given in our shipping instructions.
2 Reporting of shipping units and packages containing items of SMS Demag design
2.1 General
The suppliers shall report the shipping units and packages only in the table made available by SMS Demag as only this form can be processed by our data systems. The shipment labels provided shall be attached to the respective shipping units.
2.3 Reporting of the package data The report of the package data documents the assignment of the shipping units to the packages. These data serve
as basis for the SMS Demag delivery note. An example is shown on page 6.
Referenced standards
None
Example on
Annexes
AB AU AP AUP
No.
46015239 46015239 46015239 46015239 46015239 46015239 46015239 46015239 46015239 71 71 71 71 71 71 71 71 71 9 9 9 9 9 9 9 9 9 4 4 4 4 4 4 5 6 7 1 2 3 4 5 20405338 M9052547 M9722894 M9021028 M9021028 M9040109 M9030026 20405337 46015239710907 1 2 31 5 7 2 10 2 4 Piece Meter Meter Meter Meter m Meter Piece Stck 208 Ladder with safety cage 72 Tube DIN 2448 48,3x3,6 mm 38 Square DIN 1014 20 50 x 5 50 x 5 5 50 x 50 x 5 1 2 3 17 Flat steel bar DIN 1017 79 Flat steel bar DIN 1017 0 Plate EN 10029 27 Angle bar 3 Ladder base 0 Upat-UKA3 anchor bolt M16
Quantity
4
1 2 31 5 7 2
10 2 4
Column: 1 2 3 4 5 6 7 7a 8 9 11 12 13 14 15 16 17 18
In this column the unassembled parts are indicated with consecutive numbers; assembled units are indicated in columns 13 to 19. This column shows the parts which are shipped unassembled.
The numbers of the assembled shipping units (VE) are entered as column headings; below the headings, the quantity of the parts assembled in the respective VE is filled in.
Example on
SMS Supplier Demag Project No. AB AU AP AUP VE No. VE No. 1 2 3 4 46015239 46015239 46015239 46015239 71 71 71 71 9 9 9 9 5 6 7 4
Ident. No.
Qty.
Designation
10 2 4 1
Angle bar Ladder base Upat-UKA3 anchor bolt M16 Ladder with safety cage
Column: 1 2 3 4 5 6 7 8 9 9a Please indicate here the shipping unit number you have assigned to the item in the Reporting of the shipping units. This column is not relevant for suppliers.
These columns need not be filled in, the data can be taken from the Reporting of the shipping units.
10 Please enter the designation of the shipping unit in this column. This is of particular importance for assembled units, as their designations may differ from those in our bill of materials.
13 Please indicate a consecutive package number in this column. KA = cardbox, KH = timber structure, KI = case, U = unpacked, VS = crate) 15 16 17 Please enter here the sizes (in cm) and weights (in kg) of your packages.
11 Please indicate packing type of package. (for example, B = bundle, CO = container, EP = Europallet, EW = disposable pallet, FA = barrel, GB = skeleton container
February 2007
Manufacturing Instructions
PACKING
Dimensions in mm
SN 200
Part 9
Field of application
The manufacturing instructions specified in this part of SN 200 apply to all components shipped on behalf of SMS Demag unless otherwise specified in drawings or other manufacturing documents. With special regard to the product structure of SMS Demag, the execution of the packages described herein shall be regarded as the applicable minimum requirement. In specific cases, it may be impossible to comply with these instructions due to the particular nature of the packages. In such cases checking back with our Department of Quality Inspection is required and the packing measures to be taken shall be of provable adequacy to the instructions given herein. The packing categories shall always be selected as required for the nature of the respective equipment, the type of transport and the duration of storage. The examples given apply to the packaging of goods for transport by sea. The shipping units shall be made up properly, this means as space-saving units and with due regard to a favourable ratio between size and weight. When necessary, the present instructions will be completed with special packing and labeling instructions for project-specific purposes of SMS Demag. The treatment of the package against vermin and germs, which is required in certain countries, shall be made as stipulated in the contract.
Table of contents
Page
1 Packing categories....................................................................................................................................................... 2 1.1 Category 1 ................................................................................................................................................................ 2 1.2 Category 2 ................................................................................................................................................................ 2 1.3 Category 3 ................................................................................................................................................................ 2 1.4 Category 4 ................................................................................................................................................................ 2 1.5 Category 5 ................................................................................................................................................................ 2 1.6 Category 6 ................................................................................................................................................................ 2 1.7 Category 7 ................................................................................................................................................................ 2 1.8 Category 8 ................................................................................................................................................................ 2 1.9 Category 9 ................................................................................................................................................................ 2 1.10 Category 10 .............................................................................................................................................................. 2 1.11 Category 11 .............................................................................................................................................................. 2 1.12 Category 12 .............................................................................................................................................................. 2 1.13 Category 13 .............................................................................................................................................................. 2 2 Quality and strength of the materials ......................................................................................................................... 3 2.1 General ..................................................................................................................................................................... 3 2.2 Packings of categories 1 to 8 and 11 to 13 .............................................................................................................. 3 2.3 Packings of category 9 ............................................................................................................................................. 3 3 Design of packages...................................................................................................................................................... 3 3.1 General ..................................................................................................................................................................... 3 3.2 Cases of packing categories 1 to 4 and 13............................................................................................................... 4 3.3 Crates of packing category 5 .................................................................................................................................... 4 3.4 Bundles of packing category 6.................................................................................................................................. 4 3.5 Sledges of packing category 7.................................................................................................................................. 4 3.6 Planking of packing category 8 ................................................................................................................................. 4 3.7 Dangerous goods packing of packing category 9 ..................................................................................................... 5 3.8 Transport packing of packing category 11 ................................................................................................................ 5 3.9 Container packing of packing category 12................................................................................................................ 5 4 Fixing of goods............................................................................................................................................................. 5 4.1 Assumed loads ......................................................................................................................................................... 5 4.2 Fixing of goods.......................................................................................................................................................... 5 5 Packing.......................................................................................................................................................................... 6 6 Marking.......................................................................................................................................................................... 6 6.1 Elements of the marking ........................................................................................................................................... 6 6.1.1 Inscription ................................................................................................................................................................. 6 6.1.2 Handling marking ...................................................................................................................................................... 6 6.2 Execution of the marking .......................................................................................................................................... 6 6.3 Application of the marking ........................................................................................................................................ 7 6.4 Arrangement of the marking ..................................................................................................................................... 7 6.5 Permitted storage classes ........................................................................................................................................ 7 6.6 Marking of dangerous goods .................................................................................................................................... 7 7 Inspection...................................................................................................................................................................... 8
1 Packing categories
1.1 Category 1
Packing in cases with protective jute paper, goods sealed in aluminium compound foil (BWB TL 8135-0003 or equivalent foil) with addition of appropriate desiccant; guaranteed durability of 24 months. Corrosion-sensitive mechanical-engineering and electric materials, prefabricated pipe lines
Goods
1.2
Category 2 Like 1.1., but double case with padding elements suitable for the sensitivity of the goods (g-values to be specified), case-in-case packing. Goods Highly sensitive electrical and control components. Category 3
Goods Like 1.1, but sealed in 0,2 mm PE-foil (BWB TL 8135-0019 or equivalent foil); guaranteed durability of 12 months. Like 1.1. Like 1.1, without sealing of goods in plastic foils, but with gilled plates in upper section of case. Shock and corrosion resistant units (simple machine components, pins, components for pipe lines such as welding fittings, threaded fittings) Crate Components insensitive to corrosion and to the usual mechanical effects occurring during transport; all types of vessels. Bundle Pipes sold by the meter, structures/racks not requiring protection against usual mechanical effects and combined only for the purpose of forming a loading unit Sledge Robust corrosion-resistant components whose dimensions exceed the usual loading gauges. Planking (including cable drums) Components whose unit weights exceed 30 tonnes and/or whose dimensions exceed the usual loading gauges. Components are insensitive to corrosion and mechanical effects of transport, only the machined surfaces are protected by planking. Dangerous goods packing Dangerous goods as in Dangerous Goods Ordinance Sea transport by sea Dangerous Goods Ordinance Road and Rail transport by road and rail IATA-DGR transport by air
1.3
1.4
Category 4
Goods
1.5
Category 5
Goods
1.6
Category 6
Goods
1.7
Category 7
Goods
1.8
Category 8
Goods
1.9
Category 9
Goods
1.10 Category 10
Goods
Unpacked goods Components not requiring specific protection for shipment. Transport packing (without durability guarantee for storage) Parts for intermediate shipment (to subsuppliers, machining workshops, central packers). These parts shall be protected against climatic and mechanical influences during transport. Container packing, packing on load-bearing transport bottoms, goods sealed in aluminium compound foil (BWB TL 8135-0003 or equivalent foil) with addition of appropriate desiccant; guaranteed durability of 6 months. Like 1.1. Tugged packing Components which are loaded with the loading gear attached to the goods themselves.
1.11 Category 11
Goods
1.12 Category 12
Goods
1.13 Category 13
Goods
The following material is allowed for surface planking: - wood as in DIN 4074-S7-TA/FI - half-dry - plywood as in DIN 68705-BFU 100, min. thickness 12 mm - plywood of the types APA RATED SHEATHING and APA RATED STURD-I FLOOR, bonding method EXTERIOR, min. thickness 9 mm (to be used only for case types 1 to 3, see Table 3) - boards as in DIN EN 300 OSB3, min. thickness 12 mm (use only for case types 1 to 3, see Table 3) It shall be borne in mind that only vertical bordering joints are permitted.
3 Design of packages
3.1 General
For packages exceeding one of the following values: Length = 1190 cm Width = 240 cm 240 cm Height =
Weight = 20000 kg the packer shall, upon request, draw up transport/packing sketches and hand them over to SMS Demag before packing. The maximum package dimensions permitted for air freight shall be agreed upon with SMS Demag from case to case. The following conditions shall also be taken into account: - strength values and design features as in DIN 1052 (see Tables 1 and 2), - assumed loads, such as drop heights and acceleration during transport, as in strength calculations for wooden packings used in the shipping of heavy-goods (RGV), - diagonal bracing of cleat frames (pages 11 and 12): Joints: Top - side - bottom (Fig. 1) Bottom - side wall (Fig. 2) Top - bottom - side wall (Fig. 3)
Page 5 SN 200 Part 9: 2007-02 3.7 Dangerous goods packing of packing category 9
When packing units are prepared, special attention shall be paid to the regulations on the maximum quantities that are allowed for the packing together of dangerous goods.
4 Fixing of goods
4.1 Assumed loads
g values for the forces of gravity The forces of gravity which are relevant for the securing of the goods result from the actually occurring acceleration and deceleration values. The following table states acceleration factors for the different types of transport. g values associated with the acceleration rates (max. rates occurring in regular operation)
Acceleration forces Type of transport Railway Road Sea Air Horizontal forces Forward/backward Transverse 4,0 g 0,8 g 0,25 g 1,5 g 0,5 g 0,5 g 0,25 g 1,5 g Vertical forces 0,3 g 1,0 g 1,0 g 3g
(HPE: The Registered Federal Association for Wooden Packages, Pallets and Export Packaging)
When means of transport are combined, the highest value of each kind of acceleration force out of the types of transport shall be taken into account.
ber of bolts and their dimensioning shall be calculated according to Table 11. The minimum bolt spacing and the minimum bolt distance from the loaded edge in grain direction shall be 7 d, but at least 10 cm. - The securing in place of movable parts of the merchandise shall be in the same quality as the fixing of the merchandise on the case bottom structure. - If screw-fastening/bolting of the merchandise to the case bottom structure is impossible or possible only to a limited extent, use of appropriate intermediate layers, padding elements, supports or blocking elements shall be made to avoid slipping of the merchandise in the case. The following measures are appropriate: - jamming of the goods using wooden thrust blocks and threaded rods (min. bolt diameter see table 10), - lashing of the goods using prestretched wire and turnbuckle (proof of sufficient wire cross-section is required), - bracing with wooden members (direct wood-to-metal contact is not permitted).
5 Packing
Within the scope of the inspection of incoming and outgoing goods, the preservative applied to the parts by the supplier shall be checked by the packer for absence of damage on the outer surfaces and, if necessary, shall be properly repaired using an agent according to SN 200, Part 7. Depending on the durations of transport and storage, protection against corrosion is made according to the desiccant method by sealing of the goods in plastic film. The following materials are used for the barrier layer: - Polyethylene foil according to BWB TL 8135-0019 or equivalent foil, - Aluminium compound foil according to BWB TL 8135-0003 or equivalent foil. Preservation using the VCI method with appropriate carrier material (paper, film, foam pack, etc.) is an alternative possibility, but requires previous consultation with SMS Demag with regard to compatibility. Barrier sheathings shall be designed to allow the proper opening and reclosing of the sheathings for two times. The necessary desiccant quantity is calculated according to DIN 55474 for a maximum permissible ultimate humidity of 40%. The water vapour permeability is established using the procedures specified in DIN EN ISO 15106-3; the foils shall be checked both in as-delivered and in aged condition. The testing climates to be used shall be chosen as appropriate for the country of destination. If no climate data are available, climate B according to DIN 53122-1 shall be used. If no particular proof of water vapour permeability has been furnished, the max. permissible water vapour permeability factor (mean value of as-delivered and aged condition) stated in the relevant technical delivery condition shall be used. The test results shall be proven in an inspection certificate 3.1 or 3.2 according to DIN EN 10204. The desiccant bags of the lowdust type shall be attached in the upper section of the packing and properly secured against falling. The desiccant bags shall be fastened in such a way that they permanently withstand loads resulting from transport, handling, and weight increase due to the absorption of moisture. Direct contact between merchandise and desiccant is not allowed. Projecting parts and sharp edges shall be properly padded to prevent wearing through or piercing of the foil. The air inside the barrier layer shall be exhausted. Openings in the barrier sheathing such as areas pierced by fastening elements shall be sealed vapour-tight with seals and sealing compound applied on both sides of the barrier film (see Fig. 4).
6 Marking
6.1 Elements of the marking
The marking consists of the inscription and the handling marking. 6.1.1 Inscription The inscription is project-related and is part of our shipping instructions. The shipping instructions will be made available to the contractor in due time. 6.1.2 Handling marking In addition to the inscription, the packages shall be provided with the relevant internationally used handling symbols according to DIN EN ISO 780. All packages of more than 5 t in weight shall be provided with the marking of the center of gravity and of the attachment point. The storage class shall be marked using the symbols shown under item 6.5.
5 C
15 C
The storage class used shall be suitable for the most sensitive component. If no specifications are given by SMS Demag, the storage class shall be determined by the maker or supplier of the goods. The selected storage class shall also be documented in plain text in an appropriate place of the accompanying documents of the merchandise (for example advice of delivery, delivery note, packing list).
7 Inspection
SMS Demag shall be informed by the contractor in due time (at least two days) before the beginning of packaging and has the right of attendance during packaging. SMS Demag reserve the right to inspect the packing. The packer shall complete an inspection report (SMS Demag form No. 1325) for every package. In addition, the calculation documents and a list of the materials used stating quantities, cross sections etc. shall also be drawn up for each package. These documents shall be submitted to SMS Demag for countersigning (company-specific records giving identical information will be accepted by SMS Demag). If, on the basis of the records or during inspection of the packages, there is reasonable doubt concerning proper preservation, marking or packing, the authorized representative of SMS Demag will decide as to whether opening of the packages and possibly the barrier sheathings is required. If the opened packages are found to be unacceptable, the representative of SMS Demag will decide whether additional opening of twice the number of packages opened for previous inspection shall take place. Such additional inspection will be repeated till all packages of an additional inspection have been found fully acceptable. The contractor shall be liable to SMS Demag for correct packaging in compliance with these minimum requirements and for perfect quality of the packing material. Any deviation from these conditions requires the previous written approval by SMS Demag. The contractor shall be liable to SMS Demag for any damage resulting from improper or faulty packing. The inspection of the package does not relieve the packaging company from its warranty obligations and liability.
HPE Packaging Guidelines (HPE: The Registered Federal Association for Wooden Packages, Pallets and Export Packaging) Instruction Sheets covering Export Packing for Shipment to Overseas Countries (RGV) Provisions of the countries of destination Dangerous Goods Ordinance Road and Rail Dangerous Goods Ordinance Sea Dangerous Goods Ordinance Air Transport RM 001(Guidelines associated with the Dangerous Materials Handling Provisions/Refers to all Carriers of Goods) K and M, Consular and Standard Regulations of the Hamburg Chamber of Commerce BWB TL 8135-0003, Federal Office for Military Engineering and Procurement BWB TL 8135-0019, Federal Office for Military Engineering and Procurement
Annexes
Admissible stresses
Table 1 Strength data for wood used as packing material Admissible stresses admiss and admiss in N/cm2 for load case H Sorting category S7 Kind of stress Coniferous wood Hardwood Bending b admiss Bending of through beams without joints b admiss Tension in direction of grain s z admiss Pressure in direction of grain d admiss Pressure perpendicular to direction of grain s d admiss 900 950 0 750 950 1000 0 900 400 500 130 Sorting category S10 Coniferous wood Hardwood 1250 1250 1100 1100 250 300 120 1400 1500 1250 1250 400 500 130
Pressure perpendicular to direction of grain in components in which minor indentations are harmless d admiss Shearing off in direction of grain and glued joint admiss
Table 2
Admissible compressive stress in N/cm for angular application of force on wood of sorting category S10 for load case H (main forces) d admiss d admiss - (d admiss - d admiss ) sin Coniferous wood __ 1100 950 800 650 550 450 400 300 270 250 For components for which minor indentations are harmless 1100 1100 900 700 600 500 450 370 330 320 __ 1250 1100 950 820 700 600 500 430 400 390 Oak and beech wood For components for which minor indentations are harmless 1250 1130 1000 900 770 680 600 550 530 500
For load case HZ (main and additional forces) shunting impact, transport by crane or industrial truck the admissible stresses are multiplied by the factor 1.15.
Construction of bottom
Table 3 Construction of bottom Type of case 1 2 3 4 5 Net weight in kg < 1 000 > 1 000 - 5 000 > 5 000 - 10 000 > 10 000 - 25 000 > 25 000 Board thickness in mm 24 24 24 24 24 Longitudinal skid W x H in cm 8 x 10 10 x 12 12 x 14 14 x 16 > 16 x 18 Rubbing skid W x H in cm 10 x 10 10 x 10 10 x 10 12 x 12 > 12 x 12 End header W x H in cm 8x 8 8 x 10 10 x 12 12 x 14 > 16 x 18
Table 6 Number of side-part panels Length of case (cm) Number of panels 300 1 301 - 500 2 501 - 700 3 701 - 900 4 > 900 5
Table 7 Number of end-part panels Length of case (cm) Number of panels 200 1 > 200 2
Table 8 Number of longitudinal cleats of the top Width of top (cm) Number of cleats 100 3 101 - 200 4 201 - 250 5 251 - 350 7
Table 9
Dimensioning and quantities of top joists (center distance from square timber to square timber max. 70 cm) 100 6x8 101 - 150 8 x 10 151 - 200 10 x 12 201 - 250 12 x 14 251 - 300 14 x 16 301 -350 14 x 18
Type of case
1 2 3 4 5
Net weight
in kg
< 1 000 > 1 000 - 5 000 > 5 000 - 10 000 > 10 000 - 25 000 > 25 000
single-lap joint
d = bolt diameter in mm
Construction examples
Fig. 1: Joint top - side - bottom
end sheathing
top joists (3) vertical center cleat side sheathing diagonal end bracing
vertical corner cleat diagonal side wall bracing end header main skid rubbing skid
bottom board
To guarantee withstanding of the compressing stress on stack of 10 kN/m, it may be necessary to prop the top joists with vertical supports.
vertical cleat
bottom boards
end header longitudinal skid stop cleat for rope (sliding cleat)
end header
bottom boards
transverse timber
rubber pad padding film for protection of barrier film bottom board
longitudinal skid
washer bolt head Important: Hole-circle diameters in the rubber pads shall be smaller than the shank diameters of the fastening bolts
rubbing skid
cleat frame
Shortest applicable nail distances: 10 d from loaded edge 5 d from unloaded edge d = nail diameter sheathing 80-200 The cleats shall be fixed with at least 2 nails in every board.
February 2007
Manufacturing Instructions
INSPECTION
Dimensions in mm
SN 200
Part 10
Field of application
The valid inspection instructions for SMS Demag are compiled in this SN 200. They shall be applied to all components, assemblies and equipment units are manufactured on the basis of SMS Demag drawings. This includes all work and services which are performed by third parties on behalf of SMS Demag. If the requirements stated in the drawings and relevant technical documents differ from those specified in these inspection instructions, these requirements have priority over those specified in SN 200.
Table of contents
1 2 3 4 5 6 7 8 9
Page
Warranty ............................................................................................................................................................................ 1 General inspection instructions ...................................................................................................................................... 1 Inspection instructions for component parts................................................................................................................. 1 Inspection instructions for assembled units.................................................................................................................. 2 Particular inspection instructions ................................................................................................................................... 2 Inspections made by the end user .................................................................................................................................. 2 Inspection results ............................................................................................................................................................. 2 Inspection documents...................................................................................................................................................... 2 Types of inspection documents ...................................................................................................................................... 3
1 Warranty
The manufacturer shall warrant the proper execution of all his supplies and services. He is responsible for material quality, execution of welding, dimensional accuracy, surface condition, methods of processing and treatment etc. as required for his scope of supply. Inspections made by SMS Demag quality inspectors do not relieve him of his warranty obligation.
7 Inspection results
All inspections made on the basis of the inspection instructions given in the individual parts of this SN shall be documented showing the desired and the actual values. Appropriate forms and certificates for the reporting/documenting of inspection results are available at SMS Demag and will be made available when required. Company-specific reports showing the same contents and drawn up by the supplier within the scope of his own quality assurance system will be accepted by SMS Demag provided that they can be assigned to the SMS Demag project number and to the purchase order and drawing numbers. If the drawing stipulates identification marking of every single component part (for example by stamped figures or engraving), the actual values of every single component part shall be stated (one report for every part). If parts are manufactured in quantities greater than 1 and if identification marking is not made for these parts, it is sufficient to report the actual values of the respective upper and lower limits (i.e. one report per lot stating values ranging from ... to ...). Inspections of assembled units shall also be reported with indication of the desired and actual values. The original reports shall be handed over complete, in size A4, to the SMS Demag quality inspection representative during his visit to the manufacturer's works. If SMS Demag does not make an inspection at the manufacturer's works, the original reports shall be sent to the SMS Demag Department of Quality Inspection. All reports requested by SN 200 are constituent parts of the scope of order or supply. If inspection reports are missing or not complete, payments will be withheld by SMS Demag.
8 Inspection documents
In general, inspection documents shall be drawn up on the basis of DIN EN 10204 according to the requirements made in the drawings and ordering documents. If no special requirements are made in drawings or ordering documents, the inspection documents stated in the individual parts of this SN 200 are the minimum requirement for component parts. The minimum requirement for assembled units for which no particular specifications are made in the drawings and ordering documents is a declaration of compliance with the order drawn up on the basis of DIN EN 10204, type 2.1. For the further requirements according to item 3, an inspection certificate 3.1 according to DIN EN 10204 shall be issued; the test reports of the component parts and the test report of the assembled unit shall be annexed to the certificate. If payments by SMS Demag or its customers depend on the presentation of the inspection documents, an inspection certificate 3.2 according to DIN EN 10204 shall be drawn up by the manufacturer in mutual agreement with the SMS Demag quality inspector instead of the inspection certificate 3.1 according to DIN EN 10204.
Designations of the inspection documents of DIN EN 10204 in different languages Designations of the document types according to DIN EN 10204 Type 2.1 German Werksbescheinigung English Declaration of compliance with the order Test report French Attestation de conformit la commande Relev de contrle Statement of compliance with the order Statement of compliance with the order, with indication of results of nonspecific inspection Statement of compliance with the order, with indication of results of specific inspection The manufacturer Content of the document
Document validated by
2.2
Werkszeugnis
The manufacturer The manufacturers authorized inspection representative independent of the manufacturing department The manufacturers authorized inspection representative independent of the manufacturing department and either the purchasers authorized inspection representative or the inspector designated by the official regulations
3.1
Abnahmeprfzeugnis 3.1
3.2
Abnahmeprfzeugnis 3.2
Statement of compliance with the order, with indication of results of specific inspection
Referenced standards
DIN EN 10204 DIN EN 13018 Metallic products; types of inspection documents Visual testing; general principles
Part 1 General
Revision of passage concerning load-carrying attachments.
Part 2 Material
Section on casting - More precise definition of casting tolerance grade - Table 9: Acceptance limit changed from Min. to Max. Section of forging - Item 2.3.1, new definition of surface condition - Table 1: Cancelling of line on "Machined and heat-treated" - Change of inspection document type from 3.1B to 3.1. Section on semi-finished products - Item 3.4 Inspection: Ultrasonic inspection of plate changed from SEL 072 to DIN EN 10160. - Addition of grid scanning coverage for unalloyed steel - Addition of ultrasonic examination for alloy steel
Part 4 Welding
- Item 1.1.5; reference to SN 402 for deposit welding. - Item 1.3.5, revision of welding indication. - Table 10, change from DIN EN 288 to DIN EN ISO 15610. - Additional text in remark on full material penetration. - Item 3.4, addition of equation - Table 11, change to new standard. - Fig. 14, change from 10 to 10 - Item 3.5.1.6, numbers of imperfections adapted to new standard - Table 13, cancelling of key numbers; change to SMS Demag stipulation; change of root opening dimensions. - Item 3.8, change of material standards - Item 4, addition of postweld heat treatment, change of type of inspection certificate from 3.1B to 3.1 - Table 15, addition of footnote 6 - New structure of evaluation levels for imperfections due to change of standard New explanations on Table 16 Addition of symbols and evaluations of imperfections
Part 5 Machining
- DIN EN ISO 1101, new edition - Change of inspection document type from 3.1B to 3.1. - Change of tolerance zone indication for the nut from 6h to 6H - Change of thread size from M64 to M64 - Item 4.1, change of standard, Table 17, adaptation to new standard - Item 5, addition of information on envelope requirement, envelope requirement symbols shown against shaded background
Part 6 Assembling
- Item 3.1, addition of instruction and documented for specified fitting clearances and contact patterns, change of passage concerning the securing of screwed connections. - Item 3.1.2, addition of information on screws with fine threads and on necked-down bolts and T-head bolts. - Item 3.2.1, addition of passage on the laying of the pipe lines without stresses.. Addition of note concerning the space required for the use of hydraulic screw pretensioning units. - Item 3.2.3, addition of grease Micro-Gleit GP 350. - Item 3.2.7, addition of note concerning number of bolt holes that can be divided by four.
Part 7 Preserving
In Field of application, addition of the passage that the change-over to coating agents of low solvent contents is under preparation - Item 1.1, addition of passage on functional surfaces. - Item 3.4, change of anti-slip coat for cover plates, new colour definition for company logo and bar. - Item 3.5, addition of note concerning shop order or drawing. - Item 4.2.3, new wording of the note, footnote 3, addition of fluids conveyed according to DIN 2403. - Item 5.1.1, change of standard for pipes. - Table 7, addition of note on Tectyl 502-C to be used for vessels.
Part 9 Packing
- Addition of passage concerning treatment of the package against vermin and germs. - Change of weight of cases concerning the use of heavy-lift corners from 3 t to 5 t. - Item 5, change of standard concerning the water vapour transmission rate. - Item 6, change of weight of packages from 3 t to 5 t.
Part 10 Inspection
- Revision of the types of inspection documents.