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1

GENERAL

2007
2

MATERIAL

MANUFACTURING INSTRUCTIONS SN 200

THERMAL CUTTING AND BENDING

WELDING

This copy will not be updated in case of changes!

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.

No guarantee can be given in respect of this translation.


In all cases the latest German version of this standard shall be taken as autoritative.

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.

This copy will not be updated in case of changes!

Referenced standards are indicated in the individual chapters.


Rules and directives DIN standards EN standards ISO standards DIN EN standards DIN ISO standards DIN EN ISO standards are German and European sets of rules, codes and regulations are national standards of the Federal Republic of Germany are standards of the European Union are standards of the International Organization for Standardization are European standards incorporated in German language in the national set of standards are international standards incorporated in German language in the national set of standards are international standards that were made part of the European standards and incorporated in German language in the national set of standards.

Example:

DIN ISO

286

ISO

286

DIN EN 10083 DIN EN ISO 9001

EN 10083 ISO 9001

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

Page 2 SN 200 Part 1 : 2007- 02

Hazardous materials / environmental protection


If safety data sheets according to the hazardous materials rules exist for substances and preparations to be supplied by you or for substances which are used as constituents of products to be supplied by you, these sheets have to be joined to the supply with indication of our purchase order number. If such sheets do not exist, you undertake to supply with the consignment, in due time and in a well visible way, other product information relevant for environmental protection and safety so as to allow proper transport and handling, storage and disposal of the substances/preparations by SMS Demag or by our customer in accordance with the regulations.

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

This copy will not be updated in case of changes!

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

3 3.1 3.2 3.3 3.4

Semi-finished products General tolerances.......................................................................................................................................................11 Technical delivery conditions .......................................................................................................................................11 Plate.............................................................................................................................................................................11 Inspection.....................................................................................................................................................................11

Referenced standards...........................................................................................................................................................12

Continued on pages 2 to 12

Page 2 SN 200 Part 2 : 2007-02

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.

1.1 Surface qualities


If no drawing indications are made, the following applies according to DIN EN 1370: for cast steel and non-ferrous metals for cast iron 4S1 4S2 for blasted surfaces for ground surfaces 3S1 for blasted surfaces 3S2 for ground surfaces

1.2 General tolerances


The authoritative standard for the definition of the general tolerances is DIN ISO 8062. These general tolerances apply to unmachined faces of metal casting blanks. Half the respective general casting tolerance is applicable to a dimension between a machined and an unmachined surface for which no individual tolerance is indicated. The values of the general tolerances are indicated in the tables 1 to 3 under the selected grade of tolerance CT.

1.3 Degrees of accuracy


The casting tolerances (CT) shown against a shaded background in tables 1 and 3 are SMS Demag standard for the respective nominal dimension range. The grade of tolerance to be selected depends upon the biggest nominal dimension of the workpiece. All dimensions of this casting blank have the same grade of tolerance, this means that only one grade of tolerance can be assigned to a casting. If smaller admissible casting tolerances are required, they shall be indicated in the drawing at the respective nominal dimension. 1.3.1 Tolerance limits

necessary machinig allowance see Table 6

necessary machining allowance see Table 6

1 2 3 4

nom. dimension of the raw casting dimensions after finish-machining minimum limit of size maximum limit of size

Fig. 1

1.4 General tolerances for cast steel products


Table 1 Nom. dimension of raw casting mm Above 25 40 63 100 160 250 400 630 1000 1600 2500 4000 6300
1) 2) 3)

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

for wall thicknesses 3) 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 16 12 14 16 18 20 22 25 28 32 37 42 49 56 64

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.

Page 3 SN 200 Part 2 : 2007-02


1.4.1 Outer and inner curvatures For outer and inner curvatures the tolerance zone according to Table 1 is arranged in such a way that the lower tolerance limit is always zero. Example: The nominal dimension of the curvature is 20 mm, the casting tolerance grade CT is 13; the relevant tolerance given in Table 1 is 6 mm; thus the lower tolerance limit applicable to the curvatures is 0, the upper limit is 6 mm. To reduce the risk of cracking, the minimum values given in Table 2 shall be used for inner curvatures as required for the respective wall thickness. Table 2 Inner curvatures Inner curvature Wall thickness min. Up to 10 > 10 to 30 > 30 6 10 0,33 x wall thickness

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.

11 3,2 3,6 4 4,4 5 5,6 6,2 7 8 9 10 12 14 16

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

1.6 Mould tapers


Additional tapers on shaped elements required to allow the separating of a casting or pattern from a mould. The deviations from the nominal shape and dimensions of the raw casting that are due to mould tapers are not considered as failures to meet the tolerances. The mould taper shall be averaged in relation to the nominal dimension, mould taper . Mould tapers on surfaces to be machined shall be arranged on the raw casting in such a way that the finished dimensions are kept. Table 4 Mould tapers for inner and outer surfaces
Height Up to 18 2 > > > 18 30 50 to to to 30 50 80 in degrees () 1,5 1 0,75 > 80 to 180 0,5 > 180 to 250 1,5 > 250 to 315 2,0 > 315 to 400 2,5 > 400 to 500 3,0 > 500 to 630 3,5 > 630 to 800 4,5 > > 800 1000 to to 1000 1250 in mm 5,5 7,0 > 1250 to 1600 9,0 > 1600 to 2000 11,0 > 2000 to 2500 13,5 > 2500 to 3150 17,0 > 3150 to 4000 21,0

Taper

Table 5 Mould tapers for core prints Height Up to 70 > 70 Taper 5 3

Page 4 SN 200 Part 2 : 2007-02 1.7 Offset


Unless otherwise specified, the offset shown in Fig. 2 shall be within the tolerances stated in Tables 1 and 3. If further restriction of the offset is required, the maximum value shall be indicated in the drawing.

Fig. 2

1 maximum permissible offset 2 minimum limit of size 3 maximum limit of size

1.8 Wall thicknesses


Wall thicknesses in CT grades use the next higher grade (see Tables 1 and 3).

1.9 Machining allowances


Machining allowances on raw castings are excess material which makes it possible to remove shortcomings due to casting from the surface by subsequent machining and to attain the desired surface condition and the necessary dimensional accuracy. The amount of material to be removed by machining also depends upon the actual dimensions of the raw casting. These actual dimensions may vary within the range of the specified and permissible general tolerances or the tolerance indicated for a dimension. Allowance is to be understood as allowance for every surface to be machined, this means on rotational bodies or for machining on two sides the allowance is required two times. The specifications stated in Table 6 are based on experience gathered by SMS Demag; the values deviate from the machining allowances given in DIN EN ISO 8062-3. Unless otherwise specified, the necessary machining allowance as in Table 6 applies to the entire raw casting. The machining allowance depends on the biggest outside dimension of the raw casting and not on the casting tolerance grade CT. When parts are supplied in rough-machined condition, the foundry is, irrespective of Table 6, responsible for providing the necessary machining allowance for attaining the rough-machined and dross-free condition.

Page 5 SN 200 Part 2 : 2007-02


1.9.1 Machining allowances for cast steel and cast iron products Table 6
Nominal dimension range (biggest length, width, height or diameter of the casting) Up to To To To To To To To To To To To To To To To To To To To 30 50 80 120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 6300 10000 GS EN-GJS (GGG) EN-GJL (GGL) (cast steel) (nodular graphite cast iron) for upper faces or faces in verfor upper faces or faces in verfor faces in vertical for upper faces Per Per Per tical position in the mould (tatical position in the mould (taposition (taper) additionally surface surface surface per) additionally per) additionally additionally (dross layer) 4 5 4 4 6 2 5 - 45 7 5 8 10 3 12 14 16 18 20 25 30 4 8 10 12 15 5 7 Up to 100 mm 17 20 4 5 3 8 10 12 15 17 20 Up to 80 mm 4 5 110 - 500 3 50 - 240 6 6 20 - 110 2 5 2

> > > > > > > > > > > > > > > > > > >

30 50 80 120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 6300

Hole not cored by foundry

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

Reflectors without measurable extent Diameter of equivalent flat-bottomed hole 2) min. mm


4 6 6 8 3

Reflectors with measurable extent Diameter of equivalent flat-bottomed hole 2) min. mm


3 4 6 8 3

Special rim zone

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)

Table 9 Recording levels and acceptance limits of backwall echo reduction


Wall thickness Area tested mm 300 > 300 to 400 > 400 to 600 > 600 1)

Recording level min. dB 12 -

Acceptance limit max. dB 12 -

Special rim zone

Based on a 2 MHz ultrasonic probe

Page 6 SN 200 Part 2 : 2007-02


Table 10 Acceptance limits of volumetric reflectors
Feature Casting wall thickness in the area tested Unit mm Zone
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

5 2) > 100 600

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)

Not used as criterion Not used as criterion

Not used as criterion Reflectors with measurable extent

Biggest diameter of equivalent flat-bottomed hole

mm

Max. extent of the reflector in wall-thickness direction

15% of zone thickness 15% of wall thickness


75 75 75 1000 10000 10000 15000 75 100 1000 15000 10000 15000 75 75 600 15000 10000 15000 75 75 2000 15000 10000 20000 75 120 2000 20000 10000 20000 75 100 2000 15000 10000 15000 75 100 2000 15000 15000 20000 75 150 2000 20000 15000 20000

Maximum length without measurable width Largest individual area 4) Largest total area per reference area 4) Reference area
1)

mm

Not permitted

75 600 10000 10000 10000

mm mm mm

150 000 (390 mm x 390 mm)

100 000 (320 mm x 320 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

Page 7 SN 200 Part 2 : 2007-02

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.

2.1 Forgings, general


The following requirements shall be fulfilled: - If no particular requirements are made, the technical conditions of delivery and quality specifications can be taken from the relevant DIN, EN, ISO or SEW material standards. When particular requirements are made, the quality specifications for these forgings are given in the drawing on drawing sticker F1001. - If heat treatment is required for reasons of manufacture, this treatment shall be arranged for by the forging shop and/or the machining shop.

2.2 External condition


The external condition shall be examined in the areas marked on the workpiece using the magnetic particle method as in DIN EN 10228-1 or the liquid penetrant method as in DIN EN 10228-2. The surfaces to be examined shall be free of scale, oil, grease, machining marks, paint and any other foreign matter that may adversely affect the detection sensitivity or the interpretation of the indications found. The quality classes specified in the DIN EN standards are not applied. The entire workpiece shall be absolutely free of cracks.

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.

Page 8 SN 200 Part 2 : 2007-02


Table 2 Scanning coverage at perpendicular sound incidence Type Grid scanning 1) Diameter D in mm D 200 200 < D 500 500 < D 1000 D > 1000
1) 2)

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)

Scanning coverage shall be specified in the enquiry or order.

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)

Scanning coverage shall be specified in the enquiry or order.

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

Recording levels and acceptance criteria

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.

Page 9 SN 200 Part 2 : 2007-02


Table 4 Quality classes, recording levels and acceptance criteria in the use of straight-beam probes Quality class Recording levels Flat bottomed holes (FBH) deg in mm of diameter R ratio for abrupt attenuation of the backwall echo
1) 2)

>8 0,1

>5 0,3

>3 0,5

>2 0,6

Acceptance limits FBH in isolated point discontinuities deg in mm of diameter in mm of diameter 12 8 8 5 5 3 3 2

FBH in extended or grouped discontinuities deg

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

FBH in extended or grouped discontinuities deg in mm of diameter


3)

angular sound incidence is not applicable to quality class 1.

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

Nominal test frequency

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.

Page 10 SN 200 Part 2 : 2007-02


Table 7 Indication amplitude in dB related to the reference line in % Reference line % 30 50 60 100 200 Indication amplitude related to the reference line dB - 10 - 6 - 4 0 + 6

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

- Results of other tests/inspections specified in the drawing

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

Page 11 SN 200 Part 2 : 2007-02

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. .

3.1 General tolerances


The relevant documents for the general tolerances of steel products are the respective DIN and DIN EN standards for semifinished products.

3.2 Technical delivery conditions


The technical delivery conditions are specified in DIN EN 10021 and in the corresponding standards for semi-finished products.

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

made of unalloyed steels, 1) 2 yield point 250 N/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

made of alloy steels, 1) 2 yield point 350 N/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)

The yield point refers to the smallest standardised material thickness.

Page 12 SN 200 Part 2 : 2007-02

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

This copy will not be updated in case of changes!

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.

1.2 Plasma arc cutting


Plasma arc cutting is a process of thermal cutting in which a constricted arc is used. In the arc polyatomic gases are dissociated and partially ionized; monoatomic gases are partially ionized. The plasma arc thus generated has a high temperature and high kinetic energy and melts or partially vaporizes the material and drives it off. The kerf is produced in the process. The instructions/data apply to plasma cuts of 1 mm to 150 mm.

1.3 Laser beam cutting


Laser beam cutting is a process of thermal cutting in which the focused laser beam supplies the energy required for cutting which is then converted into heat in the material. The cutting process is supported by a gas jet. In laser beam cutting a distinction is made between laser-beam oxygen cutting, fusion cutting and sublimation cutting. The instructions/data apply to laser cuts of 0,5 mm to 40 mm.

Continued on pages 2 to 7

Page 2 SN 200 Part 3 : 2007-02 1.4 Cut surface quality


1.4.1 Perpendicularity or angularity tolerance Distance between two parallel straight lines between which the cut surface profile lies within the theoretical angle (for example 90 in the case of vertical cutting). NOTE: The perpendicularity or angularity tolerance includes both the straightness and the flatness deviations. Figures 1 and 2 show the maximum effective deviations within the tolerance class.

Fig. 1

a) Vertical cut

b) Bevel cut a = area for determining the perpendicularity-angularity tolerance

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)

Page 3 SN 200 Part 3 : 2007-02

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

For SMS Demag purposes, the cut thicknesses range up to a = 400.

1.4.4 Perpendicularity or angularity tolerance, u

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

>120 to 140 3,1

>140 to 160 3,4

>160 to 180 3,7

>180 to 200 4,0

>200 to 220 4,3

>220 to 240 4,6

>240 to 260 4,9

>260 to 280 5,2

>280 to 400 5,5

For SMS Demag purposes, the cut thicknesses range up to a = 400.

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

Key tG1 tG2 tw tp u

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.

Page 5 SN 200 Part 3 : 2007-02

1.6 Dimensional tolerances


The drawing dimension shall be taken as nominal dimension. The actual dimensions shall be measured on the cleaned cut surfaces. The limit deviations as in Table 4 shall apply to dimensions without tolerance indications.

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

>0 <3 0,04 0,1 0,3 -

3 < 10 0,1 0,2 0,3 0,5 0,6 -

10 < 35 0,1 0,2 0,4 0,6 0,7 1,3 1,9 2,6 -

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

100 150 200 250 400

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.

96 120 160 200 240 280 320

Page 6 SN 200 Part 3 : 2007-02

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

Page 7 SN 200 Part 3 : 2007-02

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 ref. point

ref. point

ref. point Fig. 6 Fig. 7 Fig. 8

ref. point Fig. 9

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

Referenced standards .......................................................................................................................................... 32


Continued on pages 2 to 33

Page 2 SN 200 Part 4 : 2007-02

1 Drawings and other manufacturing documents


1.1 Representation in drawings
1.1.1 Fillet welds Fillet welds are represented by a blackened triangle or welding symbols according to ISO 2553 (see 1.3) at the weld joints of the parts to be welded either in sectional view or in the view of the part to be welded. 1.1.2 Butt welds, partly and fully bevelled welds Butt welds, partially and fully bevelled welds are represented in drawings in section or in the view with symbols according to ISO 2553 (see 1.3) and with indication of the weld depth s. 1.1.3 Welds for subsequent machining Welds intended for subsequent machining are shown with dimensioning of the weld depth as shown in Fig 1. Fig. 1 1.1.4 Welds on pipe lines The operating pressure of the pipe line shall be indicated. Welding symbols as in ISO 2553 (see 1.3) or data as in Table 13 are shown only in exceptional cases. 1.1.5 Deposit welding For deposit welding see SN 402.

1.2 Representation as in DIN EN 22553 (ISO 2553)


1.2.1 Elementary symbols for the categories of joints The various categories of joints are each characterised by a symbol which, in general, is similar to the shape of the weld to be made. The symbols characterise the shape, preparation and execution of the welds. The symbols do not determine the welding process to be applied. Table 1 Elementary symbols for the categories of joints No. 2 Designation Square butt weld Illustration Symbol No. 6 Designation Single-bevel butt weld with broad root face Single-Ubutt weld Single-J butt weld (J-groove weld) Backing run (sealing run) Illustration Symbol No . 10 Designation Fillet weld Steepflanked singleV butt weld Steepflanked single-bevel butt weld Surfacing Illustration Symbol

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

Page 3 SN 200 Part 4 : 2007-02


1.2.3 Supplementary symbols Elementary symbols may be completed by a symbol which characterises the shape of the surface or the shape of the weld. The absence of a supplementary symbol means that the shape of the surface shall comply with the weld quality indicated. A combination of more than two supplementary symbols is not allowed. Table 3 Supplementary symbols Shape of weld surface a) Flat b) Convex c) Concave Symbol Execution of weld d) Toes blended smoothly g) Permanent backing strip used h) Removable backing strip used Symbol Table 4 Complementary symbols Meaning Circumferential weld Site weld SMS Demag indication workshop assembly weld 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 Positions of the symbols on drawings


1.3.1 Elements of the reference symbol and indications at the symbol - Elements of the reference symbol - Indications at the reference symbol 1 2 = Weld joint = Arrow line 1 2 3 4 = Main dimensions of weld thickness = Weld symbol = Weld length dimensions = Indications for welding process Quality level, welding position, filler metal Fig. 2

3a = Reference line (solid line) 3b = Reference line (dashed line) 4

= Forked line for supplementary indications (shown only when required)

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

Arrow line a) weld on arrow side b) weld on opposite side

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. 3 T-joint with one fillet weld

Page 4 SN 200 Part 4 : 2007-02


1.3.3 Position of the arrow line When the butt welds are asymmetrical, the arrow line shall always point to the non-vertical flank of the joint, this means to the workpiece which requires groove preparation. Example see Fig. 7b. 1.3.4 Position of the symbol with regard to the reference line The symbol is placed either above or below the reference line. - When the symbol is placed on the side of the solid reference line, the weld is on the arrow side of the joint (Fig. 5a). - When the symbol is placed on the side of the dashed reference line, the weld is on the opposite side of the joint (Fig. 5b). - When the welds are symmetrical, the dashed line is not used (Fig. 5c).

Fig. 5

a) weld, made from arrow side

b)

weld, made from opposite side

c) only for symmetrical welds

1.3.5 Examples of application Fillet welds

Fig. 6a

Fig. 6b

Butt welds

Illustration

Symbolic representation

Fig. 7a

Fig. 7b

For further application examples, see DIN EN 22553 (ISO 2553).

Page 5 SN 200 Part 4 : 2007-02

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.

2.1 Linear dimensions


The tolerances stated in the table apply to linear dimensions (external dimensions, inside dimensions, stepped dimensions, widths and central lengths). Table 6 Linear dimensions Nominal dimension range Tolerance class 2 to 30 1 > 30 to 120 2 > 120 to 400 2 > 400 to 1000 3 > 1000 to 2000 4 > 2000 to 4000 6 > 4000 to 8000 8 > 8000 to 12000 10 > 12000 to 16000 12 > 16000 to 20000 14 > 20000

16

2.2 Straightness, flatness and parallelism


The tolerances stated in the table apply to the overall dimensions of a welded part, a welded assembly and to partial lengths. Table 7 Straightness, flatness and parallelism tolerances Nominal dimension range (length of longer side of the surface) Tolerance class > 30 to 120 1 > 120 to 400 1,5 > 400 to 1000 3 > 1000 to 2000 4,5 > 2000 to 4000 6 > 4000 to 8000 8 > 8000 to 12000 10 > 12000 to 16000 12 > 16000 to 20000 14 > 20000

16

2.3 Angular dimensions


For the tolerances of the angles, the shorter leg of the angle is taken as reference leg. Its length can also be counted from a particular reference point which then shall be shown in the drawing (examples are given in Figs. 8 to 12).
Reference point Reference point Reference point

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.

Page 6 SN 200 Part 4 : 2007-02

Execution of welding work

3.1 Demands made on manufacturers of welded components


The demands made on the manufacturers are classified as shown below, on the basis of the legal regulations and the demands concerning the components: 3.1.1 Equipment subject to construction supervision Table 9 Components Buildings subject to construction supervision (halls, chimneys etc.) Machinery and equipment intended for permanent presence of persons (control pulpits, casting platforms, stair towers etc.) Place of manufacture Worldwide Germany Outside Germany Worldwide Cranes, lifting equipment and load-carrying equipment (C-hooks, dismantling beams etc., see also SN 195) Germany Outside Germany Worldwide Germany Pressure vessels Germany Outside Germany Place of use Germany Outside Germany Outside Germany Germany Outside Germany Outside Germany Europe Europe Outside Europe Outside Europe DIN 18800 Demands on the manufacturer

National regulations of user country

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.

Page 7 SN 200 Part 4 : 2007-02 3.2 Weld preparation, general


The type of weld preparation must be selected by the contracting workshop as required for the welding procedure applied. Deviations from the drawing indications are allowed only if the specified weld-depth and weld-quality requirements are fulfilled. The type of weld preparation is selected according to DIN EN ISO 9692 (ISO 9692), tables 11 and 12. Deviations from DIN EN ISO 9692-1:

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).

3.3 Filler metals


All filler metals shall be stored and handled with care and in compliance with DIN EN 1011-1, item 8.2, and DIN EN 1011-2, item 7.

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

Minimum values of preheat temperature Tp as a function of carbon equivalent CET.

Measuring of the preheat, interpass and preheat maintenance temperatures shall be on the basis of DIN EN ISO 13916.

3.5 Execution of the weld 3.5.1 Execution of the weld, general


The surfaces in the weld area shall be cleared of scale, slag, rust, paint, oil, grease and moisture prior to assembling. To avoid stray currents and their effects (destruction of electric protective conductors etc.), the welding current return line shall be connected direct to the workpiece to be welded or the workpiece support (welding table, welding grid, assembly plate etc.). Steel structures, rails, pipe lines, bars and similar objects shall not be used as current conductors unless they are the workpiece to be welded. Tack-welds shall be at least 40 mm long. All cracks, lack-of-fusion spots and clusters of pores in tack welds shall be removed before welding. If accessible, the roots of two-sided welds having full material penetration shall be gouged, checked for absence of cracks and counterwelded. Unless otherwise specified in the drawing, weld seams shall be closed around all corners. This applies with the only exception of ribs and webs as in Figure 18. Shrinkage stresses due to one-side welding-on of parts shall be compensated by counterheating. When postweld heat treatment is made, the welding shop shall open all hermetically closed hollows prior to annealing by drilling a 10 mm round hole in a suitable place on the neutral axis, even if such measure is not expressly indicated in the drawing. Upon heat treatment, these round holes shall be closed again. When plates are welded on, a short section shall be left without weld and closed by welding after heat treatment.

Page 8 SN 200 Part 4 : 2007-02

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

Symbol (as in ISO 2553)

Illustration

Cross-section

Angle ,

1)

Gap b bt

1.2.1

4 3<t8 15 Square butt weld -

Thickness of root face c --

Groove face height h

1.2.2

6b8 t 1 0

3 111 141 13 141 52

With backing strip

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

Single-V butt weld

40 60 6 8

4 -

With backup strip where applicable

1.5

5 t 40

Single-V butt weld with broad root face

60

1b4

2c4

1.8

> 12

Single-U butt weld

8 12

111 13 141

1)

10 t 25

Single-bevel butt weld

35 60

2b4

1c2

1)

SMS Demag stipulation

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

Steepflanked single bevel butt weld

6 b 12 15 60 12 -

111 With backing strip 13 141 -

1.11

> 16

Single-J butt weld (J-groove weld)

10 20

2b4

1c2

111 13 141

8 2. 1 15 Square butt weld -

t 2

111 141 -

Page 9 SN 200 Part 4 : 2007-02

0 60

t 2

13 52 111 141 13

2.5.1

> 10

Double-V butt weld

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

Page 10 SN 200 Part 4 : 2007-02

Ref. No.

Gap b

Thickness of root face c

Groove face height h

Recommended welding process3) (as in ISO 4063)

Remarks

2.5.2

> 10

Asymmetric double-V butt weld

111 141

13

2.7

30

Double-U butt weld

8 12

tc 2

111 13 141

2.9.1 > 10 2.9.2

Doublebevel butt weld (K-weld)

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

2 2.11 > 30 Double-J butt weld 10 20 3 <2

tc 2 t 2

111 13 141

Page 11 SN 200 Part 4 : 2007-02


3.5.1.1 Slot welding up to t1 = 10 above t1 = 10

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

Page 12 SN 200 Part 4 : 2007-02


3.6 Notches

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

The types of notches are shown in the drawings without dimensioning.

3.7 Weld preparation on fluid-carrying components like pipelines, vessels


Weld preparation for butt welds and corner welds is made as shown in table 13. This is an SMS Demag-specific stipulation. For edge misalignments on joints between pipes of different wall thicknesses, the values of the required quality level shall apply as in DIN EN ISO 5817, imperfection No. 3.1, related to the smaller wall thickness. If edge misalignment exceeds the admissible values, a tapered transition 10 is required, see DIN 2559, parts 2 to 4. Table 13 SMS Demag-specific Wall thickness Designation Symbol
1)

Weld groove designs Cross-section

Degrees -

Dimensions Root opening 2) b 0 to 3

Root height c

Groove face height h -

Up to 2

Square butt weld

Above 2 to 25

Single-V butt weld

60

2 to 4

to 2

Above 25

U-butt weld on V-root

60

15

2 to 3

All thicknesses

Single-bevel butt weld

All thicknesses (admissible only up to max. PN 25)


1) 2)

Fillet weld

Additional symbols see DIN EN 22553. Dimensions apply to tack-welded condition.

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.

Postweld heat treatment

4.1 Postweld heat treatment, general


When postweld heat treatment is made, the welding shop shall open all hermetically closed hollows prior to annealing by drilling a 10 mm round hole in a suitable place on the neutral axis, even if such measure is not expressly indicated in the drawing. After heat treatment the round holes shall be closed again. Shrinkage stresses due to one-side welding-on of parts shall be compensated by counterheating. Any postweld heat treatment (for example stress relief annealing) required for functional reasons shall be indicated in the drawing by the designer. Heat treatment required for reasons of manufacturing sequence (remachining etc.) shall be arranged for by the contracting workshop. Heat treatment required from a welding viewpoint shall be carried out in the responsibility of the manufacturing shop. The use of relieving methods other than stress relief annealing (vibratory stress relief etc.) shall be previously agreed with SMS Demag. Heat treatment on quenched and tempered steels shall be made at a temperature which is 20 to 30 K below the tempering temperature. The contracting workshop shall obtain information on the tempering temperature used for the material. All heat treatments must be proved by annealing diagrams and inspection certificate 3.1 as in DIN EN 10204.

Page 14 SN 200 Part 4 : 2007-02

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 Postweld heat treatment of stainless steel


4.2.1 Non-stabilised austenitic steels for ex.: 1.4301 1.4401 1.4436 X5CrNi 18 - 10 X5CrNiMo 17 12 - 2 X3CrNiMo 17 13 - 3

shall never be heat treated after welding.

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

Page 15 SN 200 Part 4: 2007-02

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.

6.1 Inspection of load-bearing welds with partial or full material penetration


These instructions apply to load-bearing welds for which partial material penetration is specified in the drawing. The inspection serves in particular the purpose of proving the admissible imperfections as in DIN EN ISO 5817. 5 % of all load-bearing welds with partial material penetration shall be inspected. If no reasons for complaints are found, the scope of inspection may be reduced upon previous agreement with our department of quality inspection. The welds shall be inspected at the front side at a depth corresponding to weld depth + 5 mm (s + 5 mm) using the magneticparticle method. Inspection is by partial grinding of the seam prior to closing at the front side, if necessary, closed welds shall be opened for inspection at the front side. The instructions given are applicable by analogy to full-penetration welds if non-destructive testing is impossible or possible only to a limited extent because of the degree of accessibility.

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.

Page 16 SN 200 Part 4 : 2007-02


6.1.1 Inspection directions for the quality levels of welds, general Table 14 Quality level as in DIN EN ISO 5817 Cons. No. as in DIN EN ISO 5817
Without full material penetration

Stringent B All Yes Yes Yes 25 %


4)

Intermediate C All Yes Yes Yes - 10 %


4) 3

Moderate D SMS Demag standard All No No (see 6.1) Yes ---

Drawing indication required Proof of quality required Visual inspection Ultrasonic testing Required inspec2 Crack detection tions and testing Pressure testing Leakage testing

Only in exceptional cases All Yes Yes Yes 50 % 25 %


4)

Cons. No. as in DIN EN ISO 5817 Drawing indication required


With full material penetration 1

All, but 9 acc. to B Yes Yes Yes 25 % 10 %


4) 3

All, but 8 and 9 acc. to B Yes Yes Yes 25 % --

Proof of quality required Visual inspection Ultrasonic testing Required inspec2 Crack detection tions and testing Pressure testing Leakage testing

Only in exceptional cases

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

Moderate D SMS Demag standard All, but 9 acc. to C 25 bar No No Yes --

Yes Yes Yes 25 %

Required inspec2 tions and testing

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)

7 Quality levels for imperfections

extract from DIN EN ISO 5817

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

- 72 - 111 - 135 - 136

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

End crater pipe

Not permitted Not permitted Not permitted Not permitted Not permitted

Page 17 SN 200 Part 4 : 2007-02

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

Page 18 SN 200 Part 4 : 2007-02

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

Smooth transition is required.

0,5 to 3 >3

h 0,2 mm + 0,1 t Short imperfection: h 0,2 t, but max. 2 mm

Short imperfection: h 0,1 t Short imperfection: h 0,1 t, but max. 1 mm

Not permitted

Short imperfection: h 0,05 t, but max. 0,5 mm

1.9

502

Excess weld metal (butt weld)

Smooth transition is required.

0,5

h 1 mm + 0,25 b, but max. 10 mm

h 1 mm + 0,15 b, but max. 7 mm

h 1 mm + 0,1 b, but max. 5 mm

1.10

503

Excessive convexity (fillet weld)

0,5

h 1 mm + 0,25 b, but max. 5 mm

h 1 mm + 0,15 b, but max. 4 mm

h 1 mm + 0,1 b, but max. 3 mm

Table 16 No. 1.11

(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

Reference No. acc. to ISO 6520-1 504

1.12

505

Incorrect weld toe

- butt welds

0,5

90

110

150

- fillet welds

0,5

90

100

110

Page 19 SN 200 Part 4 : 2007-02

a1 a2 1.13 506 Overlap 0,5 h 0,2 b Not permitted Not permitted

Table 16 (continued)

Page 20 SN 200 Part 4 : 2007-02

No. 1.14

Reference No. acc. to ISO 6520-1 509

Imperfection Remarks Designation Sagging Smooth transition is required.

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

Smooth transition is required.

0,5 to 3 >3

h 0,2 mm + 0,1 t Short imperfection: h 0,2 t, but max. 2 mm

Short imperfection: h 0,1 t Short imperfection: h 0,1 t, but max. 1 mm

Not permitted

Short imperfection: h 0,05 t, but max. 0,5 mm

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

Excessive throat thickness

The actual throat thickness of the fillet weld is too large.

0,5

Permitted

h 1 mm + 0,2 a, but max. 4 mm

h 1 mm + 0,15 a, but max. 3 mm

1.22

601

Stray arc

0,5 0,5 0,5 0,5

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

2 Internal imperfections 2.1 100 Crack 2.2 1001 Microcrack

Acceptance depends on the type of parent metal with particular reference to crack sensitivity.

Page 21 SN 200 Part 4 : 2007-02

Table 16 (continued)

Page 22 SN 200 Part 4 : 2007-02

No.

Reference No. acc. to ISO 6520-1 2011 2012

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

Limits for imperfections in the quality levels C B

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

For single layer: 2,5 % For multi-layer: 5 %

For single layer: 1,5 % For multi-layer: 3 %

For single layer: 1 % For multi-layer: 2 %

2,5 %

1,5 %

1%

d 0,4 s, but max. 5 mm d 0,4 a, but max. 5 mm

d 0,3 s, but max. 4 mm d 0,3 a, but max. 4 mm

d 0,2 s, but max. 3 mm d 0,2 a, but max. 3 mm

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

case 2 (D < dA2)

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

Clustered (localized) porosity

Page 23 SN 200 Part 4 : 2007-02

0,5

d 0,4 s, but max. 4 mm d 0,4 a, but max. 4 mm

d 0,3 s, but max. 3 mm d 0,3 a, but max. 3 mm

d 0,2 s, but max. 2 mm d 0,2 a, but max. 2 mm

Page 24 SN 200 Part 4 : 2007-02

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

case 2 (D < d2)

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).

Table 16 No. 2.5

(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

Reference No. acc. to ISO 6520-1 2014

8%

4%

2%

2.6

2015 2016

Elongated cavity Wormholes

- butt welds - fillet welds

2.7

202

Shrinkage cavity

2.8

2024

Crater pipe

0,5 to 3 >3 The larger value of h or l shall be measured.

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

Page 25 SN 200 Part 4 : 2007-02

Not permitted

Not permitted

h or l 0,2 t, but max. 2 mm

Page 26 SN 200 Part 4 : 2007-02

Table 16 No. 2.9

(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

Reference No. acc. to ISO 6520-1 300 301 302 303

- 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

- butt welds - fillet welds

2.11 2.12

3042 401

4011 4012 4013

Table 16 No. 2.13

(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

Reference No. acc. to ISO 6520-1 402

T-joint (fillet weld)

T-joint (partial penetration)

0,5

Butt joint (partial penetration) 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

Page 27 SN 200 Part 4 : 2007-02

Butt joint (full penetration)

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

Page 28 SN 200 Part 4 : 2007-02

Reference No. acc. to ISO 6520-1

3 Imperfections in joint geometry 3.1 507 Linear misalignment

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

Incorrect root gap for fillet welds

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

h 0,5 mm + 0,1 a h 1 mm + 0,3 a, but max. 4 mm

h 0,3 mm + 0,1 a h 0,5 mm + 0,2 a, but max. 3mm

h 0,2 mm + 0,1 a h 0,5 mm + 0,1 a, but max. 2mm

Table 16 No.

(continued) Imperfection Remarks Designation mm D C B t Limits for imperfections in the quality levels

Reference No. acc. to ISO 6520-1

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

Maximum total height of the imperfections h 0,4 t or 0,25 a

Maximum total height of the imperfections h 0,3 t or 0,2 a

Maximum total height of the imperfections h 0,2 t or 0,15 a

h1 + h2 + h3 + h4 + h5 = h

see Annex A

Page 29 SN 200 Part 4 : 2007-02

Table 16 No. 4.2

(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

Page 30 SN 200 Part 4 : 2007-02

Reference No. acc. to ISO 6520-1 None

h1 x l1 + h2 x l2 + h3 x l3 = h x l case 2 (D < l3)

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.

Page 31 SN 200 Part 4 : 2007-02 Annex A Explanations on Table 16:

Terms and definitions


For the purposes of this international standard, the following terms and definitions apply:

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.

Page 32 SN 200 Part 4: 2007-02 Symbols


The following symbols are used in Table 16: a A b d dA h l lp s t wp z nominal throat thickness of the fillet weld (see also ISO 2553) pore surrounding area width of weld reinforcement diameter of pore diameter of pore surrounding area height or width of imperfection length of imperfection in longitudinal direction of the weld length of the projected or cross-section area nominal butt weld thickness (see also ISO 2553) pipe-wall or plate thickness (nominal size) width of the weld or width or height in case of fracture area leg length of a fillet weld (see also ISO 2553) angle of weld toe angle of angular misalignment

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 1011-1 DIN EN 1011-2 DIN EN 1289 DIN EN 1290

Page 33 SN 200 Part 4 : 2007-02

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

This copy will not be updated in case of changes!

Referenced standards ...................................................................................................................................... 17


Continued on pages 2 to 17

Page 2 SN 200 Part 5 : 2007-02

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.

1.2 Selection of measured variables of surface roughness comparative table


Table 1 Selection of measured variables of surface roughness comparative table

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

The values in shaded boxes are SMS Demag standard.

1.3 Symbols for indication of surface condition


Table 2 Symbol Meaning Basic symbol. Additional information is required for definition. Surface produced by any process within the center line average value of Ra 3,2 m The surface shall be produced by metal-cutting process (machining), no specification of center line average roughness. Surface shall be produced by metal-cutting process (machining) within the center line average roughness of Ra 3,2 m No working, surface remains in the as-delivered condition.

1.4 Positions of surface indications at the symbol


Table 3 a = roughness value Ra in m b = manufacturing process, surface treatment c = reference length d = groove direction e = machining allowance f = other measured roughness variables, such as Rz, Rmax Indications are given only if indispensable for functional reasons. SMS Demag standard indication, contrary to DIN EN ISO 1302

Page 3 SN 200 Part 5 : 2007-02 1.5 Indication of surface lay


Table 4 Symbol Meaning Illustration

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.

1.6 SMS Demag stipulations


Table 5 Symbol Meaning Machining after welding-in or welding-on. (Machining allowance required.) Note: Use only for detailed torch-cut parts. Example of drawing indication

Machining before welding-in or welding-on. (Machining allowance required.)

a = roughness value Ra in m

Free choice of tool (see item 3.1).

___

Page 4 SN 200 Part 5 : 2007-02

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.

2.1 Lengths, angles, radii of curvature and chamfer heights


2.1.1 Field of application General tolerances as in DIN ISO 2768-1 and DIN 7168 for lengths, angles, radii of curvature and chamfer heights shall be applied to machined parts. They apply to dimensions without tolerance indication between two machined surfaces of a part made of any metallic material, provided that no material-specific general tolerances are defined in other specifications or standards. For dimensions between an unmachined surface and a machined surface of a part for which no individual tolerance is indicated, half the general tolerances specified in the corresponding standard for cast, torch-cut and forged parts shall be applied. Dimensions shown in brackets are not required for the geometrical definition (manufacture) of the part. General tolerances apply to the following: - linear dimensions such as outside, inside, stepped dimensions, diameters, distances (see table 6), - radii of curvature and chamfer heights (bevels) (see table 7); - angles, whether indicated or not normally indicated, such as angles of equal-sided polygons (see table 8); - linear and angle dimensions resulting from the machining of joined parts. General tolerances do not apply to the following: - auxiliary dimensions shown in brackets as in DIN 406-11; - theoretical dimensions shown in rectangles according to DIN ISO 1101; - hole-center distances, hole-circle diameters (see table 13); - non-indicated right angles between lines which form axes of coordinates; - linear and angle dimensions resulting from joining/assembling. 2.1.2 Degree of accuracy General tolerances are subject to degree of accuracy

DIN ISO 2768 - m


2.1.3 Linear dimensions Upper and lower deviations for linear dimensions. The values indicated for sawing are SMS Demag specific stipulations. Table 6 Degree of accuracy 0,5 to 6 m (medium) Sawing
1)

>6 to 30 0,2 1

> 30 to 120 0,3

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

> 12000 > 16000 to to 16000 20000 5 6

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)

Values shown in shaded boxes correspond to DIN 7168.

1)

Permissible deviations for nominal dimensions smaller than 0,5 mm are shown at the nominal dimension itself.

Page 5 SN 200 Part 5 : 2007-02


2.1.5 Angle dimensions (inclination) Table 8 Degree of accuracy Up to 10 m (medium) Tangent values For lubrication holes c (coarse) Tangent values 1 0,0175 1 30' 0,0262 Limit deviations in angle units for nominal dimension ranges of the shorter leg > to 10 50 > 50 to 120 0 20' 0,0058 0 30' 0,0087 > 120 to 400 0 10' 0,0029 0 15' 0,0044 > 400 0 5' 0,0015 0 10' 0,0029

0 30' 0,0087 1 0,0175

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.

2.2 Form and location tolerances


2.2.1 Field of application General tolerances of form and location as in DIN ISO 2768-2 are applicable to machined parts. They are also applied to dimensions toleranced individually or in accordance with the ISO tolerance system provided that they are not superseded by a drawing indication according to DIN EN ISO 1101. 2.2.2 Degree of accuracy Tolerances of form and location are subject to degree of accuracy

DIN ISO 2768 - H


2.2.3 Tolerances of form 2.2.3.1 Flatness and straightness General tolerances of flatness and straightness are given in Table 9. 2.3.3.2 Roundness, cylinder, line and surface forms The tolerances of form are limited by the dimensional tolerance areas defined by the dimensional tolerances including the general tolerances of the respective workpiece form elements. 2.2.4 Tolerances of location 2.2.4.1 Parallelism The permissible position tolerances for parallelism are limited by the tolerance assigned to the distance between the parallel lines or surfaces. 2.2.4.2 Perpendicularity The general tolerances for perpendicularity are stated in Table 10. 2.2.4.3 Inclination (angularity) The general tolerances for inclination (angularity) are stated in Table 8. 2.2.4.4 Symmetry The general tolerance for form elements without rotational symmetry are defined in Table 11. The general tolerance also applies if one of the symmetrical form elements possesses rotational symmetry and the other does not (for example universal joint-shaft heads and sockets). 2.2.4.5 Coaxiality General tolerances for coaxiality have not been specified. In the extreme case they are allowed to be as high as the runout tolerance given in Table 12. 2.2.4.6 Run The general tolerances for radial and axial runouts are limited by the permissible tolerance specified in Table 12. Table 12 Tolerance class H Runout tolerance 0,1 Table 9 Tolera nce class H General tolerances for straightness and flatness for nominal dimension ranges Up to 10 0,02 > 10 to 30 0,05 > 30 to 100 0,1 > 100 to 300 0,2 > 300 to 1000 0,3 > 1000 to 3000 0,4

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

Page 6 SN 200 Part 5: 2007-02


2.2.4.7 Tolerances for hole-center distances and hole-circle diameters The tolerances shown in Table 13 are to be understood as position tolerances according to DIN EN ISO 1101 and apply to non-toleranced hole-center distances and hole-circle diameters. The indication of the position tolerances prohibits the summation of the tolerances. This means that the distances between the holes are theoretically exact coordinate dimensions without deviations the intersections of which define tolerance cylinders corresponding to the tolerances shown in Table 13. Table 13 Thread size Through-hole for mechanical engineering Through-hole for structural steel engineering M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48 M56 M64 M72 M80 M90 M100

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

For tap hole

and through-hole

2.2.4.8 Hole centerline tolerance in deep drilling

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.

Page 7 SN 200 Part 5: 2007-02

3 General manufacturing instructions


3.1 Free choice of tool
Curvatures and chamfers, keyways, bore mouths and end faces of recesses can be produced as required for the tool contour. The necessary drawing indication shall be made as shown in the following examples. Table 14 Situation Curvatures and chamfers on turned and milled parts Possible tool contours: Necessary drawing indications

or

Fig. 1

Fig. 2

Fig. 3 Fig. 4 (with indication of functional dimensions)

or

or Fig. 5 Fig. 6 Fig. 7 Fig. 8 .

Drilling tool runout Possible drilling tool runouts:

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

Page 8 SN 200 Part 5 : 2007-02 3.2 Surface finish


Drawing indication is not necessary for the SMS Demag standard surface finish. The indications shown in Table 15 are also valid when the summarising symbol is shown. Table 15 Linear dimensions referring to surfaces without indication of roughness variables (e.g. surfaces produced by sawing) Holes up to dia 40, oblong holes, keeper plate slots Premachined parts, weld-in parts Screw contact faces - on rolled plate - on other surfaces of blanks

- on countersinks for screws


Undercuts, chamfers, threads, thread undercuts, keyseats, keyways and lubrication grooves, end faces of stationary sealing surfaces, grooves for retaining rings Radii or curvatures and chamfers on: inner curvatures of the finer adjoining surface, outer curvatures of the coarser adjoining surface, chamfers of the coarser adjoining surface.

3.3 Workpiece edge


All workpiece edges produced by machining shall be deburred according to DIN ISO 13715. for outer edges: for inner edges:

free of burrs up to 0.3

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.

3.5 Roller burnishing and deep-rolling


The difference between the two processes consists mainly in their purposes. The purpose of roller burnishing is the producing of the prescribed surface roughness. Deep-rolling is a proven process for surface hardening by mechanical treatment. It makes use of the combination of three physical effects taking place at the same time. Residual compressive stress Strength increase by shaping Smoothing through removal of roughness Premachining: - preferably by turning, boring, inside turning or reaming with angular reamer, - less suitable procedures are: grinding, honing, reaming with multiple-edged reamers, and milling. Deep-rolling requires permanent control of the working parameters during the process. (rolling force, feed rate, speed and geometry). Table 16 Roller burnishing and deep-rolling Roller burnishing (surface smoothing) Deep rolling (surface smoothing) Hardening of the surface layer (increase of local surface hardness by approx. 30%) Drawing indication required roller burnish deep-roll It is recommended performing roller burnishing or deep-rolling at the end of machining forming in one setup on the machine.

Page 9 SN 200 Part 5: 2007-02

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

4.1 Inspection of surface condition, measuring conditions


To avoid measuring errors, the dependence shown in the table below exists, according to DIN EN ISO 4288 / DIN EN ISO 3274, between the roughness-trace length or sampling length, and the cutoff wavelength. Table 17 Regularly repeating profiles (geometrically defined cutting edge) Groove spacing Sm mm > > > > > 0,01 0,04 0,13 0,4 1,3 to to to to to 0,04 0,13 0,4 1,3 4 > > > 0,1 to 0,5 to 0 to Non-repeating profiles (geometrically undefined cutting edge) Average peak-tovalley height Rz m 0,1 0,5 10 50 > > > 0,02 to 0,1 2 to to Center line average roughness Ra m 0,02 0,1 2 10 80 Cutoff wavelength c mm 0,08 0,25 0,8 2,5 8 Single sampling length lr mm 0,08 0,25 0,8 2,5 8 Sampling length ln mm 0,4 1,25 4 12,5 40

> 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.

4.2 Inspection of dimensions, requirements on measuring tools/instruments


Every manufacturer shall make available sufficient measuring tools/instruments for verification of the features produced. Measuring and inspection equipment shall be selected and used as appropriate for the respective measuring requirements; the measuring inaccuracies of the equipment used shall be known. When necessary, proof shall be furnished of fulfilment of the requirements concerning the control of measuring and test equipment as in ISO 9001, item 7.6: "Control of monitoring and measuring devices" and in DIN ISO 10012. Tolerances of form and location shall be examined on calibrated 3-coordinate measuring machines. If the manufacturer possesses neither a three-coordinate measuring machine nor any other measuring and testing equipment, SMS Demag reserve the right to demand inspection of the workpiece by scanning on a machine tool in unclamped condition. This inspection shall be performed on a machine whose accuracy is known and which was not involved in the production of the workpiece. The accuracy of the machine shall be proved when required. Machine errors shall be eliminated; if this is not possible, they shall be taken into account. Deviations from these requirements require previous approval by the SMS Demag department of quality inspection.

Page 10 SN 200 Part 5 : 2007-02

5 Tolerancing of form and location (abridged version)


5.1 General
DIN ISO 1101 shall be applied in case of deviations from the permitted form and location tolerances as specified in Tables 9 to 12. Contrary to the stipulations of DIN ISO 8015, the principle of independency does not apply and the principle of envelope requirements continues to apply at SMS Demag. All dimensions are subject to the envelope requirements as specified in DIN 7167. This means that all tolerances of form and parallelism shall always be within the specified general or ISO tolerances. Tolerances of form and location can be stated in addition to dimensional tolerances to ensure function and replaceability. Form tolerances limit the extent to which an individual element is allowed to deviate from its geometrically ideal shape. Location tolerances limit the extent of deviation of the relative locations of two or more elements one of which is, for functional reasons or for the purpose of clear definition, usually used as reference element for the tolerance indications. When necessary, it is allowed to specify more than one reference element. The reference element shall be of sufficient accuracy (if necessary, a form tolerance shall be specified).

5.2 Drawing indication

indication arrow toleranced element

reference letter (if necessary) tolerance value (t) symbol of tolerance type

reference letter reference triangle reference element

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.

SMS Demag stipulation

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.

Page 11 SN 200 Part 5 : 2007-02


When the indication refers to the axis of the workpiece, the indication arrow or reference triangle is placed against the arrow of the dimension line. If the indication arrow is placed on the centerline, the tolerance zone applies to all axes represented by this centerline. An indication referring to the surface line is made by placing the indication arrow or reference triangle at a distance of at least 4 mm to one side of the dimension line.

Reference to the axis

Reference to all axes represented by centerline

Reference to surface line

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.

Page 12 SN 200 Part 5 : 2007-02 5.3 Symbols with detailed definitions


Table 18 Form and location tolerances Detailed definitions of the tolerances Tolerance area Drawing indication according to DIN ISO 1101 Explanation The axis of the cylindrical body to which the tolerance indication refers shall lie within a cylindrical tolerance zone of dia. 0,08

Symbol and toleranced feature


Straightness

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

SMS Demag stipulation Roundness

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.

Line shape Single or related elements

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 (related elements)

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.

Continued on following page

Page 13 SN 200 Part 5 : 2007-02


Table 18 (continued) Symbol and toleranced feature Location The axis of the hole shall lie within a cylinder of 0,08 dia. whose axis is located in the theoretically exact place. Tolerance area Detailed definitions of the tolerances Drawing indication Explanation according to DIN ISO 1101

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

Overall axial runout

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)

Overall radial runout

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)

Page 14 SN 200 Part 5: 2007-02

6 Tolerances and limit deviations for linear dimensions from 1 to 10000 mm


6.1 Field of application and purpose
This standard is used to determine the tolerances for all linear dimensions such as lengths, widths, heights, depths, diameters etc. It defines, for linear dimensions over 1 up to 10,000 mm, tolerances in 12 different tolerance classes, which shall be selected and agreed upon as required for the respective application. Note 1: For nominal dimensions up to 3150 mm, the tolerances are identical to ISO standard tolerances of DIN ISO 286. Fundamental tolerances for nominal dimensions over 3150 mm are, however, not stated in DIN ISO 286. Note 2: For ISO standard tolerances for nominal dimensions over 3150 mm, see DIN 7172. Note 3: It is pointed out that for dimensions over 500 mm special care is required in manufacture to ensure fulfilment of tolerances of the tolerance classes finer than 8, in particular with respect to temperature variations and temperature gradients in the workpiece.

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.

6.3 Designation of tolerance series


Tolerance series Tolerance series Designation Main DIN number IT symbol and tolerance class (IT = international tolerance grade) DIN ISO 286DIN 7172IT ... IT ... (up to 3150 mm) (above 3150 mm)

6.4 Standard tolerances


Table 19 Standard tolerances Nom. dimension range mm From 1 > 3 > 6 > 10 > 18 > 30 > 50 > 80 > 120 > 180 > 250 > 315 > 400 > 500 > 630 > 800 > 1000 > 1250 > 1600 > 2000 > 2500 > 3150 > 4000 > 5000 > 6300 > 8000 to to to to to to to to to to to to to to to to to to to to to to to to to to 3 6 10 18 30 50 80 120 180 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 IT m 5 4 5 6 8 9 11 13 15 18 20 23 25 27 32 36 40 47 55 65 78 96 105 130 160 195 240 6 6 8 9 11 13 16 19 22 25 29 32 36 40 44 50 56 66 78 92 110 135 165 200 250 310 380 7 10 12 15 18 21 25 30 35 40 46 52 57 63 70 80 90 105 125 150 175 210 260 320 400 490 600 8 14 18 22 27 33 39 46 54 63 72 81 89 97 110 125 140 165 195 230 280 330 410 500 620 760 940 9 25 30 36 43 52 62 74 87 100 115 130 140 155 175 200 230 260 310 370 440 540 660 800 980 1200 1500 10 40 48 58 70 84 100 120 140 160 185 210 230 250 280 320 360 420 500 600 700 860 1050 1300 1600 1950 2400 11 60 75 90 110 130 160 190 220 250 290 320 360 400 440 500 560 660 780 920 1100 1350 1650 2000 2500 3100 3800 12 100 120 150 180 210 250 300 350 400 460 520 570 630 700 800 900 1050 1250 1500 1750 2100 2600 3200 4000 4900 6000 13 140 180 220 270 330 390 460 540 630 720 810 890 970 1100 1250 1400 1650 1950 2300 2800 3300 4100 5000 6200 7600 9400 14 250 300 360 430 520 620 740 870 1000 1150 1300 1400 1550 1750 2000 2300 2600 3100 3700 4400 5400 6600 8000 9800 12000 15000 15 400 480 580 700 840 1000 1200 1400 1600 1850 2100 2300 2500 2800 3200 3600 4200 5000 6000 7000 8600 10500 13000 16000 19500 24000 16 600 750 900 1100 1300 1600 1900 2200 2500 2900 3200 3600 4000 4400 5000 5600 6600 7800 9200 11000 13500 16500 20000 25000 31000 38000

Page 15 SN 200 Part 5: 2007-02 6.5 Limit deviations for shafts


Nominal dimension range mm > > > > > > > > > 1 to 3 to 6 to 10 to 18 to 30 to 50 to 65 to 80 to

(nominal dimension range up to 3150 mm)

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

3 - 14 - 24 6 - 20 - 32 10 - 25 - 40 18 - 32 - 50 30 - 40 - 61 50 - 50 - 75 65 80 100 120 140

- 60 - 60 - 60 - 30 - 10 0 - 90 - 106 - 134 - 60 - 29 - 19 - 72 - 72 - 72 - 36 - 12 0 - 107 - 126 - 159 - 71 - 34 - 22

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

+ 52 + 20 + 57 + 21 + 63 + 23 + 70 + 26 + 80 + 30 + 90 + 34 + 106 + 40 + 126 + 48 + 150 + 58 + 178 + 68 + 211 + 76

+ 66 + 34 + 73 + 37 + 80 + 40 + 88 + 44 + 100 + 50 + 112 + 56 + 132 + 66 + 156 + 78 + 184 + 92 + 220 + 110 + 270 + 135

+ 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)

Above nominal dimension range 500: js6 or JS7

Page 16 SN 200 Part 5: 2007-02 6.6 Limit deviations for holes


Nominal dimension range mm

(nominal dimension range up to 3150 mm)


Deviations in m

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

+ 60 + 39 + 16 + + 20 + 14 + 6 + + 78 + 50 + 22 + + 30 + 20 + 10 + + 98 + 61 + 28 + + 40 + 25 + 13 + + 120 + 75 + 34 + + 50 + 32 + 16 + + 149 + 92 + 41 + + 65 + 40 + 20 + + 180 + 112 + 50 + + 80 + 50 + 25 +

+ 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

+ 185 + 305 + 185 + 83 + 106 + 54 + 77 + 40 + 63 + 100 + 400 + 630 + 145 + 145 + 85 + 43 + 43 + 14 + 14 0 0 0 0 0

+ 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

+ 16 - 36 + 17 - 40 + 18 - 45 0 - 70 0 - 80 0 - 90 0 - 105 0 - 125 0 - 150 0 - 175 0 - 210

0 - 52 0 - 57 0 - 63 - 26 - 96 - 30 - 110 - 34 - 124 - 40 - 145 - 48 - 173 - 58 - 208 - 68 - 243 - 76 - 286

- 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)

Above nominal dimension range 500: js6 or JS7

Page 17 SN 200 Part 5: 2007-02 6.7 Limit deviations for shafts


Nominal dimension range mm > 3150 to 4000 > 4000 to 5000 > 5000 to 6300 > 6300 to 8000 > 8000 to 10000 (nominal dimension range from 3150 mm to 10000 mm) Deviations in m m6 + 263 + 98 + 320 + 120 + 395 + 145 + 495 + 185 + 610 + 230 n6 + 330 + 165 + 400 + 200 + 500 + 250 + 610 + 300 + 760 + 380 p6 + 455 + 290 + 560 + 360 + 690 + 440 + 850 + 540 +1060 + 680

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

6.8 Limit deviations for holes


Nominal dimension range mm > 3150 to > 4000 to > 5000 to > 6300 to 4000 5000 6300 8000

(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

> 8000 to 10000

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

Safety instruction ............................................................................................................................................................ 1 Preparation........................................................................................................................................................................ 1 Execution ........................................................................................................................................................................... 2


Assembling of machines.................................................................................................................................................. 2 Tolerances of form and location for assembled machine components............................................................................ 2 Permissible loads on screws of strength category 8.8..................................................................................................... 3 Assembling of pipe lines .................................................................................................................................................. 3 Locations of pipe lines and line components ................................................................................................................... 3 General tolerances for pipe lines ..................................................................................................................................... 3 Assembling of pipe couplings and flanges....................................................................................................................... 4 Sealing of pipe couplings and threaded fittings ............................................................................................................... 4 Arrangement of fastening elements ................................................................................................................................. 4 Cleanness of pipe lines and fluid-carrying components .................................................................................................. 4 Positions of screw holes.................................................................................................................................................. 4 Connection holes ............................................................................................................................................................. 5

This copy will not be updated in case of changes!

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

Page 2 SN 200 Part 6: 2007-02

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 Assembling of machines

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.

Page 3 SN 200 Part 6: 2007-02


3.1.2 Permissible loads on screws of strength category 8.8

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.

3.2 Assembling of pipe lines


3.2.1 Locations of pipe lines and line components The locations of pipe lines, line components and pipe supports are shown in drawings. Deviations are allowed only upon agreement with the design department. For pipework which is not fully dimensioned and which has to be fitted during assembling, the manufacturing shop shall take into account the following: - functional laying of pipework according to the general arrangement drawing, the pipework or P&l diagram; - functional installation of fittings with due regard to accessibility; - appropriate pipework arrangement and routing for easy assembling and disassembling. - laying of the pipe lines without stresses (DIN EN 13480-4). - The space required for the use of hydraulic screw pretensioning units (anchor bolts, gear bearing screws etc.) shall be taken into account.. 3.2.2 General tolerances for pipe lines For pipework which is not fully dimensioned and freely laid, the priority is on the guaranteeing of its function. All untoleranced dimensions are subject to accuracy classes C and F according to Tables 3 to 5 in DIN EN ISO 13920. For fully dimensioned pipework (pipe detail drawings, isometric drawings etc.), accuracy classes B and F according to Tables 3 to 5 in DIN EN ISO 13920 apply to all untoleranced dimensions. Table 3 Linear dimensions (outside, inside and stepped dimensions) Nominal dimension range Tolerance class 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

Page 4 SN 200 Part 6: 2007-02


Table 4 Angular dimensions Nominal dimension range (length of the shorter leg) Admissible deviations in degrees and minutes Admissible deviations in terms of tangent values Up to and including 400 + 45' + 1 > 400 to 1000 + 30' + 45' > 1000 + 20' + 30' Up to and including 400 0,013 0,018 > 400 to 1000 0,009 0,013 > 1000 0,006 0,009

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.

Table 6 Pipe outside diameter 10 > 10 38 > 38 88,9 > 88,9

Max. distance in m 0,6 1,5 2,5 3,0

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.

Page 5 SN 200 Part 6: 2007-02

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

This copy will not be updated in case of changes!

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

Referenced standards .............................................................................................................................................9

Continued on pages 2 to 9

Page 2 SN 200 Part 7: 2007-02

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.

1.2 Indication in drawings and other manufacturing documents


Apart from the basic exceptions described under item 1.1, indications in drawings and other manufacturing documents shall be made when deviations from the standard specifications given in Tables 1 to 3, items 3.1, 3.2 or 3.3, are required for functional reasons. Only the top coat is indicated, for example - oil-resistant coat: - heat-resistant coat: - no coating, only preservation: SN 200 Part 7 - 3.3.4.1 SN 200 Part 7 - 3.3.2 SN 200 Part 7 - 4.

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.

2.2 Standard preparation grades of steel surfaces prepared by blasting


Preparation grade Sa 2 is required for parts which are subject to normal corrosion attack, in case of very heavy corrosion attack, when the functioning of the equipment (gear unit, vessel etc.) can be affected by corrosion, preparation grade Sa 3 is required. The following conditions shall be fulfilled according to DIN EN ISO 12944-4: Sa 2 = scale, rust and coats have been removed to such an extent that remainders on the steel surface are visible only as spots of slight shading due to discolouring of pores. Sa 3 = scale, rust and coats have been completely removed (when viewed without magnification).

2.3 Standard preparation grade of steel surfaces prepared by manual derusting


Preparation grade St 3 is required for machine components which cannot be blasted due to their sizes or weights, for example mill housings. The following conditions shall be fulfilled according to DIN EN ISO 12944-4: St 3 = loose coats or scale have been removed; rust has been removed to such an extent that, after subsequent cleaning, the steel surface shows a clear lustre given by the metal itself.

2.4 Standard preparation grade of steel surfaces prepared by pickling


Instead of blasting, pickling can be used for derusting and preparing the surfaces of small parts when a pickling tank is available, for example in a hydrochloric acid bath, with subsequent passivation. In this case, preparation grade Be is required. Requirement according to DIN EN ISO 12944-4: Be = coat residues, scale and rust shall have been completely removed, preparation grade Be corresponds to preparation grade Sa 3.

2.5 Derusting by blasting


To achieve preparation grade Sa 2 or Sa 3, the following metallic chilled-cast blast-cleaning abrasive with sharp-edged grain is used: blast-cleaning abrasive ISO 11124 M/CI/G70

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.

Page 3 SN 200 Part 7: 2007-02

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)

Standard preparation grade Sa 2 or Be Sa 2 or Be Sa 2 or Be Sa 2 or Be Sa 3 or Be

Layer thickness (m)

Temp. max. (C)

Max. durability 2) (in months) Indoor Outdoor storage storage

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

For footnotes, see page 6

Page 4 SN 200 Part 7: 2007-02 3.2 Delivery and intermediate coats


Basic specifications The delivery coat is required only if the cover coat is to be applied after site installation. The intermediate coat is required only for machines or machine components in areas of acid fumes or splashes. Drawing indication is necessary. The intermediate coat shall be applied after completion of workshop assembly or functional or acceptance testing, immediately before the application of the cover coat. Delivery and intermediate coats and their properties The following delivery and intermediate coats shall be applied: Table 2 Delivery coat and intermediate coat 3.2.1 Delivery coat Like 3.1.1 SMS Demag standard, but olive grey, similar to RAL 7002 3.2.3 Intermediate coat Two-component epoxy-resin primer with zinc phosphate and iron mica, reddish brown, similar to RAL 3009 Layer thickness (m) 40-50 Temp. max. (C) 120 Max. durability 2) (in months) Indoor Outside storage storage 36 18 Note Cover coat after site installation. Specification required through shop order or interoffice letter. Machines or machine parts exposed to acid fumes and splashes. Drawing indication

No

40-50

150

36

18

Yes

3.3 Cover coat


Basic specifications As a rule, the cover coat is applied only after proper application of the coats stated in Tables 1 and 2 and after completion of assembling or functional or acceptance testing of the machine. It shall be ensured that the surfaces to be coated are free of grease, oil, dirt and dust. Areas which are not accessible after assembling shall be provided with prime and top coats prior to the final assembling. Cover coats and their properties The following cover coats shall be applied: Table 3 Type of cover coat 3.3.1 SMS Demag standard All-purpose cover coat on alkyd-resin basis (lead and chromate-free), green, similar to RAL 60113) 3.3.2 Heat-resistant Silicone bronze paint, white aluminium, similar to RAL 9006 3.3.3 Acid-resistant Two-component epoxy-resin coating compound, green, similar to RAL 6011 3.3.4 3.3.4.1 Oil-resistant External coat like 3.3.1 SMS Demag standard 3.3.4.2 Internal coat Two-component epoxy-resin cover coat, ivory, RAL 1014 Layer thickness (m) 40-50 Temp. max. (C) 120 Max. durability 2) (in months) Indoor Outdoor storage storage 36 18 Note All machines and structural steel components, pipe lines and vessels in steel. Machines or machine parts exposed to elevated temperatures. Machines or machine parts exposed to acid fumes or splashes Drawing indication

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

For footnotes, see page 6

Page 5 SN 200 Part 7: 2007-02

3.4 Standard colours for special cover coats


Table 4 Application Rotating parts in danger zone Cover plates (bulb or checker plate) Cover plates Anti-slip coat for smooth plates, for example 3M Safety Walk Extra Stark (extra strong), Anti-slip coat for bulb plates, for example 3M Safety Walk Verformbar (deformable) Slip blocking grade: R 13, Standard preparation grade Sa 2 SMS Demag logo Bar in the logo Hand railing Purchased parts Hydraulic cabinets, servo boxes or other hydraulic units with internal coat Colour DIN 4844 yellow/black marking RAL 1004 / RAL 9005 Jet black RAL 9005 Drawing indication Yes No

Jet black RAL 9005

Yes

Jet black RAL 9005 Traffic red RAL 3020 Yellow RAL 1004 Makers standard Cream RAL 9001

No No No

3.5 Coating of follow-up and Morgoil spare parts


Follow-up spare parts are spare parts which are not part of the original equipment delivery. Unless otherwise specified in the shop order or drawing, follow-up and Morgoil spare parts shall only be provided with the standard primer as under 3.1.1. Machined functional surfaces shall be provided with preservation as under item 1.1. If customers request deviations from the above, our specialist painting department shall be consulted.

3.6 Emulsion-resistant coat


Data on prime and cover coats and their properties with regard to emulsion resistance depend on the respective emulsion. Generally valid specifications cannot be given here, the situation shall be examined and specifications given from case to case. A drawing indication is required.

For footnotes, see page 6

Page 6 SN 200 Part 7: 2007-02

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.

Preserving compounds and their properties


Preserving compounds shall be used as specified in Table 5. Table 5 Type of preservation 4.1 Preservation of external surfaces Tectyl 846 Preservation of 4.2 internal surfaces 4.2.1 Tectyl 502C 4.2.2 4.2.3 Tectyl 511M Renolin MRX 46 Standard Layer preparatio thickness 4) (m) n grade Sa 3 50 Max. durability (in months) Indoor Outdoor storage storage 36 12
2)

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

4.3 Preservation of Morgoil bearings Tectyl 502-C 95 % Tectyl 511-M 5 %

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)

Page 7 SN 200 Part 7: 2007-02

5 Coating and preservation of pipe lines, pipes and vessels


Pipe lines Pipe lines are prefabricated lines laid on machinery and consisting of pipes and pipe line components. This includes pipe lines delivered to the site in prefabricated condition. They are used to convey fluid (cooling water, air, oil, etc.) from the point of provision (tank etc.) to the point of consumption (cylinder etc.). Pipes Pipes means any pipe which has not undergone machining and is delivered to the site by the meter in the as-produced condition for further treatment and use for interconnecting conduits. Vessels Vessels means any vessel which holds fluid ready for use and in which, due to operation, a pressure exists or may be generated which is 0,1 bar or -0,2 bar (pressureless vessel), or > 0,1 bar or < -0,2 bar (pressure vessel).

5.1 Pipe lines


5.1.1 Pipe lines in steel - Pipe lines consisting of pipes according to DIN EN 10220 shall be pickled, flushed and then passivated. Pickling residues shall be removed by blowing off with compressed air. The required preparation grade is Be. - Pipe lines consisting of pipes according to DIN EN 10305-1 with cutting-ring or similar couplings, for example WALFORM, which are not welded and not heat treated, shall neither be pickled nor passivated if they are supplied with corrosion protection. - Pipe lines shall be clean inside. - External coating shall be made as specified in 3.1.1, an internal coat is not applied. - The max. durability period is 18 months in case of indoor storage. - Internal preservation, if required, shall be made with Tectyl 511-M or equivalent products. Drawing indication or specification through a shop order is required. With internal preservation the max. durability period is 36 months in case of indoor storage.

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.

Page 8 SN 200 Part 7: 2007-02

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

Prime-coated Inside Outside

Closed with caps

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.

5.3 Pipe fasteners


5.3.1 Pipe fasteners in steel Depending on quantity and condition, prefabricated fasteners shall be pickled or sand-shot blasted to preparation grade Sa 2 and subsequently provided with a 40 m prime coat as in 3.1.1. The max. durability period is 21 months in case of indoor storage. 5.3.2 Pipe fasteners in stainless and acid-resistant steels Prefabricated fasteners which have been welded or heat treated are pickled, blast-cleaned or brushed to remove the scale layers and annealing colours and to ensure 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, annex A, annealing colours 1 and 2). Coating or preservation is not required.

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.

Page 9 SN 200 Part 7: 2007-02 5.4 Vessels


5.4.1 Vessels in steel - Vessels shall be steel-shot blasted, the required preparation grades are Sa 3 for hydraulic vessels and Sa 2 for centralised and Morgoil lubrication systems, water and compressed-air systems. - Vessels without manholes (small inspection opening) shall be pickled inside, flushed and passivated; the required preparation grade is Be. External coating shall be made as in 3.1.1 SMS Demag standard (all-purpose coat on Pu alkyd basis with zinc phosphate (lead and chromate-free, grey, similar to RAL 7005). - Internal coating shall be made with Tectyl 502-C or equivalent products according to Table 7. Table 7 Type of internal coat Tarponal (zinc-rich paint) Copaphen Aluminium Inertol Poxitar Tectyl 502-C Layer thickness (m) 40 50 2 approx. 250 g/m 2 x 30 2 approx. 350 g/m 3 x 80 2 approx. 1000 g/m 40 Note To be used for hydraulic systems To be used for centralised and Morgoil lubrication systems To be used for water and compressed-air systems To be used for vessels Drawing indication Yes Yes Yes Yes

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

This copy will not be updated in case of changes!

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

Page 2 SN 200 Part 8: 2007-02 1.2 Identification No.


Number which is used to identify parts (for example drawing No., material No.).

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.

1.5 Shipping unit (VE)


Consecutive number of a unit of the SMS Demag scope of supply, for example unassembled parts of an item or assembled unit, cardbox with several identical parts.

1.6 Shipment label


Stick-on label which states the specific data of the shipping unit. The shipment label gives the following information: Example:

SMS Demag Aktiengesellschaft


PROJEKT NR.: PROJECT NO.: IDENT NR.: IDENT. NO.: BENENNUNG: DESIGNATION: MENGE: QUANTITY: VERSANDEINHEIT NR.: SHIPPING UNIT NO.:

1.7 Preliminary package (VP)


Transport unit ready for shipment to the packaging company. The preliminary package contains one or more shipping units and shall be labelled with an additional VP label.

1.8 VP label
Label which is used to identify a preliminary package (VP) for shipment to the packaging company.

Example:

Codeword: Order No.: VP No.: Package No.: Type of package: Storage:

Lysteel 72023858 BSME-SMS(2)-041 (88945) 88945 Case Hall

Explanations on how to complete the VP label are given in our shipping instructions.

1.9 Final package


Package for shipment direct to the customer.

Page 3 SN 200 Part 8: 2007-02

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.

2.2 Reporting of the shipping units


The report of the shipping units documents the assignment of the project items to the shipping units. An example is shown on page 5.

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.

2.4 Labeling of shipping units


The shipment labels provided by SMS Demag shall be attached to the respective shipping units; they contain the following information: The first eight digits of the project No. are indicated when the assembled parts belong to the same equipment unit, but to different assemblies. The first ten digits of the project No. are indicated when the assembled parts belong to the same assembly, but to different sub-assemblies. The first twelve digits of the project No. are indicated when the assembled parts belong to the same assembly and the same sub-assembly. The first fourteen digits of the project No. are indicated when the parts belong to the same sub-assembly and the same item (component part identification). All seventeen digits of the project No. are indicated when the parts belong to the same item and the same sub-item (component identification). Identification No. Indication of the identification No. which belongs to the project No. Designation Indication of the designation which belongs to the project No. and which is taken over from the shipment handling system (VAB). Quantity Refer to item 1.4 Shipping unit (VE) Consecutive Nos. of the SMS Demag shipping units

3 Reporting of shipping units and packages containing items of foreign design


The suppliers shall report the shipping units and packages containing assemblies and equipment units of other than SMS Demag make only in the Excel table provided by SMS Demag as this form can be processed by our data systems. Further proceeding is according to the description given under item 2. Contrary to the information given there, only blank forms will be made available as the supplier is responsible for drawing up the bill of materials. For this reason the supplier shall only report the contents of his packages; component parts supplied by him shall be designated in detail.

Page 4 SN 200 Part 8: 2007-02

4 Fixing of the shipment labels


The shipment label is sticked on a punched plastic support. The labels are fixed on the shipping units with non-rotting pack threads, zinc-coated or stainless-steel tying wire or with cable fasteners. The labels shall not be sticked on the shipping units.

Referenced standards
None

For Annexes, see pages 5 and 6.

Example on

2.2 Reporting of the shipping units


Reporting of the shipping units
7 Qty. 7a Unit of quantity 8 Weight in kg 9 Designation 11 12 13 14 15 16 17 18

Annexes

Purchase order No. 1928888.001 K


1 Project No. 2 3 4 5 6 Identification No.

AB AU AP AUP

Unassembled shipping units

Assembled shipping units

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

These columns are already completed in our form

Page 5 SN 200 Part 8: 2007-02

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.

Page 6 SN 200 Part 8: 2007-02

Example on

2.3 Reporting of the package data


Reporting of the package data
7 8 9 9a Unit of quantity Meter Piece Piece Piece 10 13 Package No. 1 2 2 3 14 Pack. type U KA U 15 Size (L x W x H) in cm 5x220x600 20x20x2 913x71x68 16 NET weight in kg 27 4 208 17 GROSS weight in kg 27 6 208

Purchase order No. 1928888.001 K


1 2 3 4 5 6

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

M9030026 20405337 M9030025 20405338

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

This copy will not be updated in case of changes!

Referenced standards, guidelines and ordinances ....................................................................................... 8 Annexes ............................................................................................................................................................................. 9


Admissible stresses ............................................................................................................................................................. 9 Construction of bottom ......................................................................................................................................................... 9 Construction of side part, end part and top ........................................................................................................................ 10 Dimensioning of mushroom head bolts.............................................................................................................................. 10 Construction examples....................................................................................................................................................... 11 Continued on pages 2 to 13

Page 2 SN 200 Part 9: 2007-02

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

Page 3 SN 200 Part 9: 2007-02

2 Quality and strength of the materials


2.1 General
Specific requirements of a buyers country concerning type and nature of materials are defined in the relevant Consular and Standard Regulations of the Hamburg Chamber of Commerce.

2.2 Instructions applying to packings of categories 1 to 8 and 11 to 13:


- For load-bearing structural parts only the use of coniferous timber as in DIN 4074 -1 - S 10 TA/FI (pine/fir) dry is allowed. - For non-load-bearing structural elements inside the barrier sheathing of cases the use of timber as in DIN 4074 1 - S 7 TA/FI (pine/fir) - dry is allowed. Supplements to DIN 4074-1 shall be observed: Sorting class S 10 Max. rosin galls Min. specific gravity l = 5,0 cm b = 0,5 cm 0,45 to 0,50 kg/dm3

Sorting class S7 l = 10 cm b = 1 cm 0,45 to 0,50 kg/dm3

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.

2.3 Instructions applicable to packings of category 9:


- Only type-tested cases and containers as in RM 001 shall be used.

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)

- nailing as in DIN 1052: nailing of wooden cleats (Fig. 5),


- wood quality categories according to item 2.2, - nailing of end-grained wood shall be applied only for fixing the components of a case, - cleats are arranged inside the cases.

Page 4 SN 200 Part 9 : 2007-02 3.2 Cases of packing categories 1 to 4 and 13


Cases are assigned to type classes according to the weights to be packed (Table 3). Details resulting from this classification are shown in the tables 4 to 10. The case shall be designed in such a way that: - it has at least two entries for the forklift, 2 - the cases and crates can be stacked in conventional loading up to a stacking impact pressure of 10 kN/m , - cases of 5 t and more are provided with heavy-lift corners at the rope sling points and with edge guards at the tops (min. plate thickness: 3 mm), - the packages withstand the tying-up forces occurring in transhipment, - handling with hoisting gears and/or industrial trucks is possible, All end headers shall be bolted up with the longitudinal skids. Bolt details are shown in table 10. Double-bolting is required for cases of type 5. When vertical side cleats are used, proof of twofold safety against buckling is required for these cleats. The vertical elements shall be fixed in their positions. The side and end faces shall be provided with vertical wooden sheathing. Case tops shall be sealed against ingress of moisture with appropriate sealing elements at the bottom side of the top. The sealing element shall be placed between wooden sheathing and cleat frame. Vertical openings of the package having diameters of 500 mm and more shall be covered with 5 or 6 mm thick plywood panels. The plywood panels shall be fixed in their positions.

3.3 Crates of packing category 5


The above instructions given for the cases (3.2) also apply to crates. The bottom of the crate is the load-carrying element and shall always remain closed. Two thirds of the end, side and top faces shall be provided with wooden sheathing.

3.4 Bundles of packing category 6


A bundle shall be made up in such a way that: - it has at least two entries for the forklift, - it withstands the tying-up forces occurring in transhipment, - handling with hoisting gears and/or industrial trucks is possible, Bundling shall be carried out as follows: - with square-timber clamps and clamping screws (threaded rods), - with intermediate layers in wood, plywood or plastic material, dimensioned as required for the weight of the goods and secured with clamping screws to avoid slipping, - with suitable screws/bolts whose projecting lengths shall be covered with strips provided with appropriate recesses. The cover strips shall be fastened with nails. - The screw connection shall be properly secured. The clamps are also allowed in the form of channel sections.

3.5 Sledges of packing category 7


The sledge shall be designed in such a way that: - it has at least two entries for the forklift, - the rope sling points are provided with heavy-lift corners when the weight exceeds 5 t, - it withstands the tying-up forces occurring in transhipment, - handling with hoisting gear and/or industrial trucks is possible. The sledge structure is allowed in timber or in steel. If direct bolting is not possible, the goods shall be fastened on the sledge with appropriate bands. Length and width of the sledge structure shall not be smaller than the respective dimensions of the goods. The ends of longitudinal bottom ledges shall be bevelled at 45 leaving at least 30 % of the ledge thickness. If necessary, appropriate padding shall be provided between the goods and the supporting structure and between the goods and the fastening elements.

3.6 Plankings of packing category 8


The planking shall be designed in such a way that: - it has at least two entries for the forklift, - the rope sling points are provided with heavy-lift corners when the weight exceeds 5 t, - it withstands the tying-up forces occurring in transhipment, - handling with hoisting gear and/or industrial trucks is possible, Preservation is made by applying contact preservative and adhesive aluminium foil. Wood planking of the machined faces shall cover the entire surface. Fittings and projecting parts shall be fully wood-planked and padded if necessary.

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.

3.8 Transport packing of packing category 11


The transport packing shall be designed in such a way that: - it has at least two entries for the forklift, - it withstands the tying-up forces occurring in transhipment, - handling with hoisting gear and/or industrial trucks is possible, - the parts are protected against climatic influences and mechanical influences during transport.

3.9 Container packing of packing category 12


When goods are packed in containers, the inside dimensions of the containers shall be observed.

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

(according to HPE Guidelines 2003/06)

(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.

4.2 Fixing of goods


- The merchandise shall be bolted to the case bottom structure through load-distributing transverse wooden members. The num-

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).

Page 6 SN 200 Part 9: 2007-02

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.

6.2 Execution of the marking


If there are no regulations to the contrary, all inscriptions shall be in Arabic numerals and Latin capital letters. The letter size shall be chosen as appropriate for sizes of the inscription surface. Letter sizes of less than 2 cm shall not be used. Handling marking shall be made according to DIN EN ISO 780 in the usual letter sizes specified in the standard.

Page 7 SN 200 Part 9: 2007-02 6.3 Application of the marking


The packages shall be marked either with labeling template using seawater-resistant, light-proof contrasting paint (preferably black, RAL 9005) or with labeling plates approved by SMS Demag with regard to plate material, inscription, letter and plate sizes. When sledge structures are used or when the parts are not packed, the marking may be applied on the merchandise itself. The handling marking shall be applied as specified in DIN EN ISO 780.

6.4 Arrangement of the marking


The marking shall be applied on at least two faces of the package. Packages of cylindrical shape shall be provided with marking on two opposite faces. Handling marking shall be applied as specified in DIN EN ISO 780.

6.5 Permitted storage classes

Pictorial marking as in DIN EN ISO 780

- Open-air storage under tarpaulin or roofing (outdoor storage)

- Closed building without temperature control (indoor storage)

50 C - Building protected from frost Temperature range from 5 C to 50 C

5 C

25 C - Air-conditioned building Temperature between 15 C and 25 C Relative humidity between 40 % and 60 %

15 C

-Special storage area for dangerous goods

Marking according to 6.6

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).

6.6 Marking of dangerous goods


Dangerous goods within the meaning of the Dangerous Goods Ordinance for the respective type of transport (GGVSee = Dangerous Goods Ordinance for sea transport, GGVSE = DGO for road and rail transport, IATA-DGR = DGO for air transport) shall be provided at least with the following additional marking: - Inscription: UN number and technical designation of merchandise, - marking with danger class symbol and figure; additional danger class symbols shall be applied in case of more than one dangerous property of the merchandise. The size of the marking shall be at least 100 x 100 mm, on containers, 250 x 250 mm. When packages are combined to form loading units, markings and symbols of the individual packages must be fully and clearly visible, otherwise the loading unit shall be provided with new markings.

Page 8 SN 200 Part 9: 2007-02

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.

Referenced standards, guidelines and ordinances


DIN 603 DIN 1052, Sheet 1 DIN 4074-1 DIN 53122-1 DIN 55402-2 DIN 55474 DIN EN 300 DIN EN ISO 780 DIN EN ISO 15106-3 Mushroom head square neck bolts Timber structures, design and construction Strength grading of wood, coniferous sawn timber Determination of water vapour transmission Marking for shipping of packages; directive for export packaging Desiccants in bag Oriented strand boards (OSB) Pictorial marking for handling of goods (ISO 780) Plastics; Film and sheeting Determination of water vapour transmission rate Part 3: Electrolytic detection sensor method

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

Page 9 SN 200 Part 9 : 2007-02

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

250 300 120

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

Angle a or between connecting load and direction of grain 0 10 20 30 40 50 60 70 80 90

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

Page10 SN 200 Part 9: 2007-02


Table 4 Number of squared timbers (longitudinal skids) Bottom width (cm) Number of squared timbers 120 2 121 - 180 3 181 - 240 4 241 300 5 301 350 6

Construction of side part, end part and top


Table 5 Construction of side part, end part and top 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 Cleat frame, diagonal, horizontal in cm 10 x 2,4 10 x 2,4 12 x 3 12 x 3 12 x 5

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

Width of top (cm) Squared timber W x H (cm)

Dimensioning of mushroom head bolts


Table 10 Dimensioning of mushroom head bolts, fixing of goods

Type of case
1 2 3 4 5

Net weight
in kg

Diameter of mushroom head bolt in mm


12 12 16 16 20

Max. hole dia. in mm


13 13 17 17 21

< 1 000 > 1 000 - 5 000 > 5 000 - 10 000 > 10 000 - 25 000 > 25 000

Use shall be made of mushroom head bolts according to DIN 603.

Page 11 SN 200 Part 9: 2007-02


Table 11 Admissible loads on mushroom-head bolt joints for application of force in direction of grain, in N Coniferous wood including larch 550 N/mm x a1 x d, but not more than 2 2,400 N/mm x d Oak and beech wood 700 N/mm x a1 x d, but not more than 2 2,800 N/mm x d

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.

Page 12 SN 200 Part 9 : 2007-02


Fig. 2: Joint bottom side wall
side sheathing boards diagonal cleat

vertical support for cross-timber (top joist)

vertical cleat

longitudinal bottom cleat

bottom boards

end header longitudinal skid stop cleat for rope (sliding cleat)

Fig. 3: Joint top - bottom side wall


side wall end wall vertical cleats

transverse top cleat

longitudinal top cleat

transverse bottom cleat

end header

longitudinal bottom cleat

bottom boards

rope stop cleats (sliding cleats) longitudinal skids

Page 13 SN 200 Part 9: 2007-02


Fig. 4: Piercing of barrier films

nut washer machine base

rubber pad sealing compound barrier film sealing compound

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

Fig. 5: Nailing of wooden cleats

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.

diagonal bracing 120

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

This copy will not be updated in case of changes!

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

Referenced standards ............................................................................................................................................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.

2 General inspection instructions


All features produced by the manufacturer shall be inspected by the manufacturer himself. Recording of the inspection results shall be made in accordance with the instructions in the drawings and purchase orders and with the criteria stated in the preceding parts of this SN. Inspection records and certificates shall be drawn up in German or English language. To allow clear identification, all documents shall state our project number, drawing number and, where applicable, our purchase order number and the designation of the part. Every manufacturer shall ensure that all residues from processing or machining (welding slag, loose burrs, chips, drilling emulsion etc.) are removed from the product after completion. The clean condition shall be checked by visual inspection as in DIN EN 13018 and guaranteed. Independently of the maker's obligation to draw up records, SMS Demag quality inspectors have the right to check the fulfilment of all features or to demand proof that all features have been fulfilled. If inevitable, destructive testing is permitted and the maker shall carry out such testing if so requested by the SMS Demag quality inspector. All features tested/examined within the scope of intermediate or final inspection are recorded by the SMS Demag quality inspector or put down in writing on the report drawn up by the manufacturer.

3 Inspection instructions for component parts


Component parts are parts which cannot be further disassembled and are identified by at least 14 digits of the project number. Inspection instructions for component parts are given in the relevant drawings, purchase orders and in the parts of this standard; the extent of inspection depends on the respective scope of supplies and services of the manufacturer. The inspection instructions for high-quality components are stated in component-specific SN standards; the applicable standards are indicated in the drawing of the respective component. In exceptional cases additional inspection schedules for component parts are drawn up by the Quality Inspection Department of SMS Demag and made available to the manufacturer together with the drawings and ordering documents.

Continued on pages 2 and 3

Page 2 SN 200 Part 10: 2007-02

4 Inspection instructions for assembled units (assemblies and equipment units)


Given the wide range of products of SMS Demag, it is not possible to define standard inspection instructions for assembled units within the scope of this SN 200. Manufacturers of assembled units are therefore bound to contact our Department of Quality Inspection to agree on the relevant inspection procedures. For the most part, the scopes of assembly and inspection are shown in specific schedules, which will be made available to the manufacturer and are considered to be constituent parts of this SN. Within the scope of these inspections, functional and movement tests are the minimum requirements for the inspection of oscillating and rotating parts.

5 Particular inspection instructions


Equipment such as hoists, pressure vessels etc. shall be acceptance-tested/inspected according to the statutory regulations or other regulations having legal force (for example Accident Prevention Instructions, AD codes of practice).

6 Inspections made by the end buyer (acceptance by customer)


Inspections/testing which has been contractually agreed between SMS Demag and the customer will be notified to the manufacturer in the respective documents (internally: shop order, externally: ordering document).

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.

Page 3 SN 200 Part 10: 2007-02

9 Types of inspection documents (extract from DIN EN 10204)


Summary of inspection documents

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

Inspection certificate 3.1

Certificat de rception 3.1

3.2

Abnahmeprfzeugnis 3.2

Inspection certificate 3.2

Certificat de rception 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

Page 1 Revisions of February 2007

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 3 Thermal cutting and bending


- Increase of SMS Demag-specific cut thickness value to a = 400 - Reference to DIN EN ISO 9013 for tolerances of form and location - Table 6: Pipe diameter changed from >10 to > 6

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

Page 2 Revisions of February 2007

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 8 Labeling - Addition of information concerning the introduction of SAP.

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.