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1 GENERAL 2003 2 MATERIAL 3 SEPARATING, BENDING 4 WELDING 5 MACHINING 6 ASSEMBLING 7 PRESERVING MANUFACTURING INSTRUCTIONS SN 200 8 LABELING 9 PACKAGING 10 INSPECTION This copy will not be updated in case of changes!

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  • 1 GENERAL 20

    03

    2 MATERIAL

    3 SEPARATING, BENDING

    4 WELDING

    5 MACHINING

    6 ASSEMBLING

    7 PRESERVING

    MA

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    8 LABELING

    9 PACKAGING

    10 INSPECTION

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  • 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 of SMS Demag AG is prohibited. Holder has to protect this document against unauthorized withdrawal of third parties. Offenders will be held liable for the payment of damages. All rights reserved in case of patent/utility model/trademark protection.

    SMS Demag Aktiengesellschaft Konstruktionsberatung/Normung

    Telefon: (0 27 33) 29-10 93 Fax: (0 27 33) 29-10 73

    E-mail: [email protected]

    1st edition (September 2003)

  • September 2003

    Manufacturing instructions

    GENERAL

    SN 200 Part 1

    These SN 200 manufacturing instructions specify the requirements made on the products 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 and its subsidiaries. The applicability of SN 200 is indicated in drawings and/or contracts 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 which are contained in 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 quality, price, faithfulness to deadlines as well as completeness of the documents, test records and certificates associated with the supplies and services ordered. We recommend all suppliers introducing a quality assurance system on the basis of ISO 9001. Referenced standards are indicated in the individual chapters. Rules and directives are German and European sets of rules, codes and regulations

    DIN standards are national standards of the Federal Republic of Germany

    EN standards are standards of the European Union

    ISO standards are standards of the International Organization for Standardization

    DIN EN standards are European standards incorporated in German language in the national set of standards DIN ISO standards are international standards incorporated in German language in the national set of standards DIN EN ISO 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 EN 10083 DIN EN ISO 9001 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 must be within the specified general or ISO tolerances.

    Continued on page 2

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  • Page 2 SN 200 Part 1 : 2003-09 Hazardous materials / environmental protection If safety data sheets drawn up on the basis of 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 consignment with indication of our purchase order number. If such sheets do not exist, you undertake to supply with the consignment, in due time and well visible, 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, on the basis of the European directives and standards, the fundamental requirements made on load carrying attachments with regard to design, manufacture and the respective scope of testing. It aims at standardising the design, manufacture and testing of load carrying attachments and at enforcing the requirements made in the directives of the European Union. Pipe classification SMS Demag has drawn up a standardisation of all components of pipe conduits. This standardisation is given in our company standards in Group 18 and must be observed. Material data The material data given in drawings and bills of material are based on stipulations taken from materials and product standards. These properties are shown in SN 359 on "Materials" and must be observed. Radioactivity All components and products must be free of any ionising radiation exceeding the natural characteristic radiation of the material. Ionising radiation exceeding the characteristic radiation of components and products is considered to exist when a radiation value above the ambient background radiation is found at the time of an examination. SMS Demag reserve the right of refusing the acceptance of any parts found to possess such ionising radiation. Residual magnetism The residual magnetism must not exceed 800 A/m at the time of delivery of the parts. Parts transported with lifting magnets and / or checked for surface defects with full-wave direct-current testers must be demagnetised if necessary. Checks for residual magnetism must always be performed with an appropriate field intensity meter. If requested by SMS Demag, the check has to be proven and/or certified.

  • September 2003

    Manufacturing instructions

    MATERIAL

    SN 200 Part 2

    Dimensions in mm Field of application The manufacturing instructions laid down in this part of SN 200 apply to all parts produced by casting, forging and rolling and to semi-finished products of ferrous and non-ferrous metals unless otherwise specified in drawings or other manufacturing documentation. Table of contents Page 1 Casting ....................................................................................................................................................................... 2 1.1 Surface qualities................................................................................................................................................ 2 1.2 General tolerances ............................................................................................................................................ 2 1.3 Degrees of accuracy.......................................................................................................................................... 2 1.3.1 Tolerance limits................................................................................................................................................. 2 1.4 General tolerances for cast steel products ......................................................................................................... 2 1.4.1 Outer and inner curvatures ................................................................................................................................ 3 1.5 General tolerances for cast iron products ........................................................................................................... 3 1.6 Mould tapers .................................................................................................................................................... 3 1.7 Offset................................................................................................................................................................ 4 1.8 Wall thicknesses ............................................................................................................................................... 4 1.9 Machining allowances ....................................................................................................................................... 4 1.9.1 Machining allowances for cast steel and cast iron products ................................................................................ 5 1.10 Inspections........................................................................................................................................................ 5 1.10.1 Cast steel products............................................................................................................................................ 5 1.10.1.1 Internal condition .............................................................................................................................................. 5 1.10.1.2 External condition.............................................................................................................................................. 6 1.10.2 Spheroidal graphite cast iron ............................................................................................................................. 6 1.10.2.1 Internal condition............................................................................................................................................... 6 1.10.2.2 External condition.............................................................................................................................................. 6 Referenced standards ..................................................................................................................................................... 6 Further standards............................................................................................................................................................ 6 2 Forging....................................................................................................................................................................... 7

    2.1 Forgings................................................................................................................................................................. 7

    2.2 External condition ................................................................................................................................................... 7

    2.3 Internal condition .................................................................................................................................................... 7 2.3.1 Surface condition.................................................................................................................................................... 7 2.3.2 Surface finish related to quality class....................................................................................................................... 7 2.3.3 Performance of the examination.............................................................................................................................. 7 2.3.4 Recording levels and acceptance criteria................................................................................................................. 8

    2.4 Inspections........................................................................................................................................................... 10

    Referenced standards ................................................................................................................................................... 10 3 Semi-finished products............................................................................................................................................ 11

    3.1 General tolerances ............................................................................................................................................... 11

    3.2 Technical delivery conditions................................................................................................................................. 11

    3.3 Plate .................................................................................................................................................................... 11

    3.4 Inspection............................................................................................................................................................. 11

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

    Continued on pages 2 to 12

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  • Page 2 SN 200 Part 2 : 2003-09 1 Casting Casting is a process for transforming, through filling of a mould, liquid steel, ferrous and non-ferrous metals into geometrically defined parts with defined properties to obtain 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 for blasted surfaces 3S1 for blasted surfaces 4S2 for ground 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 are applicable 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 grades of tolerance CT shown against a shaded background in the 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 blank dimensions of this casting blank have the same grade of tolerance, this means that only one grade of tolerance can be assigned to a workpiece. If smaller admissible casting tolerances are required, they are indicated in the drawing at the respective nominal dimension. 1.3.1 Tolerance limits 1 nom. dimension of the unfinished casting 2 dimensions after finish-machining 3 minimum limit of size 4 maximum limit of size 1.4 General tolerances for cast steel products

    Table 1 Overall casting tolerance 1)

    mm Nom. dimension of unfinished casting

    mm Tolerance grade for casting CT

    Casting tolerance CT for linear dimensions 2),

    drawing indication Associated casting tolerance CT for wall thicknesses 3)

    above up to and including 8 9 10 11 12 13 14 15 9 10 11 12 13 14 15 16

    - 25 1,2 1,7 2,4 3,2 4,6 6 8 10 1,7 2,4 3,2 4,6 6 8 10 12 25 40 63

    40 63 100

    1,3 1,4 1,6

    1,8 2 2,2

    2,6 2,8 3,2

    3,6 4 4,4

    5 5,6 6

    7 8 9

    9 10 11

    11 12 14

    1,8 2 2,2

    2,6 2,8 3,2

    3,6 4 4,4

    5 5,6 6

    7 8 9

    9 10 11

    11 12 14

    14 16 18

    100 160 250

    160 250 400

    1,8 2 2,2

    2,5 2,8

    3,2

    3,6 4 4,4

    5 5,6 6,2

    7 8 9

    10 11 12

    12 14 16

    16 18 20

    2,5 2,8 3,2

    3,6 4 4,4

    5 5,6 6,2

    7 8 9

    10 11 12

    12 14 16

    16 18 20

    20 22 25

    400 630 1000

    630 1000 1600

    2,6 2,8 3,2

    3,6 4

    4,6

    5 6 7

    7 8 9

    10 11

    13

    14 16 18

    18 20 23

    22 25 29

    3,6 4 4,6

    5 6 7

    7 8 9

    10 11 13

    14 16 18

    18 20 23

    22 25 29

    28 32 37

    1600 2500 4000 6300

    2500 4000 6300 10000

    3,8 4,4

    - -

    5,4 6,2 7

    -

    8 9

    10 11

    10 12 14 16

    15 17 20

    23

    21 24 28

    32

    - 30 35 40

    33 38 44 50

    5,4 6,2 7

    -

    8 9 10 11

    10 12 14 16

    15 17 20 23

    21 24 28 32

    - 30 35 40

    33 38 44 50

    42 49 56 64

    1) The tolerance zone must be arranged symmetrically to the nominal dimension. 2) Lengths, widths, heights, center distances, diameters and curvatures. 3) For wall thicknesses the next higher grade is applicable

    necessary machining allowance

    necessary machining allowance see table 6 see table 6

    Fig. 1

  • Page 3 SN 200 Part 2 : 2003-08

    1.4.1 Outer and inner curvatures In the case of 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: Nominal dimension of the curvature is 20 mm, cast grade of tolerance CT 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 for inner curvatures given in Table 2 must be used as required for the respective wall thickness. 1.5 General tolerances for cast iron products (EN-GJL and EN-GJS)

    Table 3 Nom. dimension of unfinished casting

    mm

    Overall casting tolerance 1) mm

    Tolerance grade for casting CT Casting tolerance CT for linear dimensions 2),

    drawing indication Associated casting tolerance CT for wall thicknesses 3)

    above up to and including 8 9 10 11 12 13 14 15 9 10 11 12 13 14 15 16

    - 25 1,2 1,7 2,4 3,2 4,6 6 8 10 1,7 2,4 3,2 4,6 6 8 10 12 25 40 63

    40 63 100

    1,3 1,4 1,6

    1,8 2 2,2

    2,6 2,8 3,2

    3,6 4 4,4

    5 5,6 6

    7 8 9

    9 10 11

    11 12 14

    1,8 2 2,2

    2,6 2,8 3,2

    3,6 4 4,4

    5 5,6 6

    7 8 9

    9 10 11

    11 12 14

    14 16 18

    100 160 250

    160 250 400

    1,8 2 2,2

    2,5 2,8

    3,2

    3,6 4 4,4

    5 5,6 6,2

    7 8 9

    10 11 12

    12 14 16

    16 18 20

    2,5 2,8 3,2

    3,6 4 4,4

    5 5,6 6,2

    7 8 9

    10 11 12

    12 14 16

    16 18 20

    20 22 25

    14 16

    18 20

    14 16

    18 20

    22 25

    400 630 1000

    630 1000 1600

    2,6 2,8

    3,2

    3,6 4

    4,6

    5 6 7

    7 8 9

    10 11

    13 18 23

    22 25 29

    3,6 4 4,6

    5 6 7

    7 8 9

    10 11 13 18 23 29

    28 32 37

    1600 2500 4000 6300

    2500 4000 6300 10000

    3,8 4,4

    - -

    5,4 6,2 7

    -

    8 9 10 11

    10 12 14

    16

    15 17 20

    23

    21 24 28

    32

    - 30 35 40

    33 38 44 50

    5,4 6,2 7

    -

    8 9 10 11

    10 12 14 16

    15 17 20 23

    21 24 28 32

    - 30 35 40

    33 38 44 50

    42 49 56 64

    1) The tolerance zone must be arranged symmetrically to the nominal dimension. 2) Lengths, widths, heights, center distances, diameters and curvatures. 3) For wall thicknesses the next higher grade is applicable.

    1.6 Mould tapers Additional tapers on shaped elements which is required to enable the separation of a casting or a pattern from a mould. The deviations from the nominal shape and dimensions of the casting blank resulting from the mould tapers are not considered as exceeding of the tolerance. The mould taper must be averaged in relation to the nominal dimension, mould taper . Mould tapers on surfaces that have to be machined must be arranged on the casting blank in such a way that the finished dimensions are kept. Table 4 Mould tapers for inner and outer surfaces

    Height

    up to 18

    > 18 to 30

    > 30 to 50

    > 50 to 80

    > 80 to

    180

    > 180 to

    250

    > 250 to

    315

    > 315 to

    400

    > 400 to

    500

    > 500 to

    630

    > 630 to

    800

    > 800 to

    1000

    > 1000

    to 1250

    > 1250

    to 1600

    > 1600

    to 2000

    > 2000

    to 2500

    > 2500

    to 3150

    > 3150

    to 4000

    in degrees () in mm Taper 2 1,5 1 0,75 0,5 1,5 2,0 2,5 3,0 3,5 4,5 5,5 7,0 9,0 11,0 13,5 17,0 21,0

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

    Table 2 Inner curvatures

    Wall thickness Inner curvature min.

    up to 10 6

    > 10 up to 30 10

    > 30 0,33 x wall thickness

  • Page 4 SN 200 Part 2 : 2003-09 1.7 Offset Unless otherwise specified, the offset shown in Fig. 2 must be within the tolerances stated in tables 1 and 3. If further restriction of the offset is required, the maximum value is indicated in the drawing. 1 maximum permissible offset 2 minimum limit of size 3 maximum limit of size 1.8 Wall thicknesses

    For wall thicknesses in the grades CT, the next higher grade is applicable (see tables 1 and 3). 1.9 Machining allowances Machining allowances on casting blanks is excess material which makes it possible to remove casting defects from the surface by 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 casting blank. These actual dimensions may show differences within the range of the specified and permissible general tolerances or the tolerance indicated with a dimension. Allowance is to be understood as allowance for every surface to be machined, this means on bodies of rotation or for machining on two sides the allowance is required two times.

    The specifications stated in table 4 are based on experience gathered by SMS Demag; the values deviate from the machining allowances given in DIN ISO 8062.

    Unless otherwise specified, the necessary machining allowance as in table 4 applies to the entire unfinished casting. The machining allowance depends on the biggest outside dimension of the casting blank and not on the casting tolerance grade CT. For the supply of parts in rough-machined condition, the responsibility for providing the necessary machining allowance for attaining the rough-machined and dross-free condition rests with the foundry, irrespectively of table 4.

    Fig. 2

  • Page 5 SN 200 Part 2 : 2003-09

    1.9.1 Machining allowances for cast steel and cast iron products Table 6

    GS EN-GJL (GGL) EN-GJS (GGG) Nominal dimension range (biggest length, width, height or

    diameter of the casting)

    per surface

    for upper faces or faces in vertical position in the mould

    (taper) additionally

    per surface

    for upper faces or faces in vertical position in the mould

    (taper) additionally

    per surface

    for faces in vertical position (taper)

    additionally

    for upper faces additionally

    (dross layer) up to 30 4

    > 30 to 50 5 > 50 to 80 > 80 to 120 > 120 to 180

    6 4 4

    > 180 to 250 > 250 to 315

    7

    > 315 to 400 > 400 to 500

    8

    2

    5 5

    5 - 45

    > 500 to 630 > 630 to 800

    10 6 6

    > 800 to 1000 > 1000 to 1250

    12 3

    8 8 20 - 110

    > 1250 to 1600 14 10

    2

    10

    2

    > 1600 to 2000 > 2000 to 2500

    16 4

    12 3 12 3 50 - 240

    > 2500 to 3150 18 15 15 > 3150 to 4000 20 > 4000 to 6300 25

    5 17

    4 17

    4

    > 6300 to 10000 30 7 20 5 20 5

    110 - 500

    Hole not cored by foundry up to 100 mm up to 80 mm

    1.10 Inspections

    1.10.1 Cast steel products 1.10.1.1 Internal condition The table below specifies 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 Ultrasonic testability requirements

    Wall thickness Smallest flat-bottomed hole diameter

    detectable according to item 5.2 of DIN EN 12680-1

    300 3 > 300 to 400 4 > 400 to 600 6

    > 600 8 Table 8 Recording levels for discontinuities 1)

    Wall thickness

    mm

    Tested area

    Reflectors without measurable dimension

    Diameter of the equivalent

    flat-bottomed hole 2) min. mm

    Reflectors with measurable dimension

    Diameter of the equivalent

    flat-bottomed hole 2) min. mm

    300 - 4 3 > 300 to 400 - 6 4 > 400 to 600 - 6 6

    > 600 - 8 8 - Special rim zone 3 3

    1) related to a 2 MHz ultrasonic probe 2) formula for converting the flat-bottomed hole diameter into side-drilled hole diameter see item 5.2 of DIN EN 12680-1 Table 9 Recording levels and acceptance limits for back echo reduction 1)

    Wall thickness

    mm Tested area

    Recording level min. dB

    Acceptance limit min. dB

    300 - > 300 to 400 - > 400 to 600 -

    > 600 -

    12 12

    - Special rim zone - - 1) related to a 2 MHz ultrasonic probe

  • Page 6 SN 200 Part 2 : 2003-09

    Table 10 Acceptance limits for volumetric discontinuities

    Severity level Feature Unit Zone 1) 1 2 3 4 5 2) Casting wall thickness at the examined area mm - 50

    > 50 100

    >100 600 50

    > 50 100

    > 100 600 50

    > 50 100

    > 100 600

    Reflectors without measurable dimension

    rim zone Largest diameter of equivalent

    flat-bottomed hole mm core zone

    3 8

    rim z. 3 5 6 6 not used as criterion Number of discontinuities to be recorded in a frame of 100 mm x 100 mm

    - core

    3 3) not used as criterion not used as criterion

    Reflectors with measurable dimension

    rim z. Largest diameter of equivalent flat-bottomed hole mm core

    3 8

    rim z. 15% of zone thickness Maximum values of dimension in through-wall direction of discontinuities

    - core 15% of wall thickness

    rim z. 75 75 75 75 75 75 75 75 75 Maximum length without measurable width mm core 75 75 100 75 75 120 100 100 150

    rim z. 600 1000 1000 600 2000 2000 2000 2000 2000 Largest individual area 4) mm core 10000 10000 15000 15000 15000 20000 15000 15000 20000 rim z. 10000 10000 10000 10000 10000 10000 10000 15000 15000 Largest total area for

    a reference area 4) mm

    core 10000 15000 15000 15000 20000 20000 15000 20000 20000

    Reference area mm

    not permitt

    ed

    150 000 (390 mm x 390 mm)

    100 000 (320 mm x 320 mm)

    1) rim zone = t/3, max. 100 mm, t = wall thickness in testing zone 2) severity level 5 is not applicable to products of SMS Demag. 3) accumulated in core zone and rim zone. 4) indications less than 25 mm apart shall be considered as one discontinuity. Indications which are not within the acceptance limits must be reported in writing to the SMS Demag Dept. of Quality Inspection.

    1.10.1.2 External condition

    The external condition is examined on the spots marked in the drawing with magnetic particle testing as in DIN EN 1369 or liquid penetrant inspection as in DIN EN 1371-1. The specifications are indicated 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 must be in accordance with DIN EN 12680-3. The requirements made on the internal condition of castings made of spheroidal graphite cast iron are shown in the drawing as SMS Demag specific indications or are specified in the 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 on the spots marked in the drawing with magnetic particle testing as in DIN EN 1369 or dye penetrant inspection as in DIN EN 1371-1. The specifications are indicated in the drawing or in product-specific SN standards. Severity level 5 is not applicable to products of SMS Demag. Referenced standards DIN ISO 8062 Castings; System of dimensional tolerances and machining allowances DIN EN 1369 Founding; Magnetic particle inspection DIN EN 1370 Founding; Surface roughness inspection by visualtactile comparators DIN EN 1371-1 Founding; Liquid penetrant inspection DIN EN 12680-1 Ultrasonic examination; Part 1: Steel castings for general purposes DIN EN 12680-3 Ultrasonic examination; Part 3: Spheroidal graphite cast iron castings Further standards DIN EN 1559-1 Founding; Technical conditions of delivery; General DIN EN 1559-2 Founding; Technical conditions of delivery; Additional requirements for steel castings DIN EN 1559-3 Founding; Technical conditions of delivery; Additional requirements for iron castings

  • Page 7 SN 200 Part 2 : 2003-09

    2 Forging Forging is a method of hot shaping in the form of 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 must 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 on the forgings, the respective quality specifications are indicated in the drawings in the form of drawing stickers.

    - If heat treatment is required for reasons of manufacture, this treatment has to be arranged for by the forging shop and/or by the manufacturing company.

    2.2 External condition The external condition must be examined in the areas marked on the workpiece using magnetic particle inspection as in DIN EN 10228-1 or liquid penetrant inspection as in DIN EN 10228-2.Surfaces to be examined must be free of scale, oil, grease, machining marks, paint coats and any other foreign matter that could adversely affect detection sensitivity or the interpretation of indications. The quality classes specified in the DIN EN standards are not applied. Absence of cracks must be always be guaranteed throughout the entire workpiece.

    2.3 Internal condition

    The internal condition is examined by ultrasonic testing as in DIN EN 10228-3 and 4.

    2.3.1 Surface condition

    General Surfaces to be examined must be free of paint, non-adhering scale, dry coupling medium and any other foreign matter and free of surface irregularities that could adversely affect coupling conditions, hinder free movement of the probe or cause errors in interpretation.

    2.3.2 Surface finish related to quality class

    The surface finish shall be compatible with the required quality class, see table 1. Table 1

    Quality class and roughness Ra

    1 2 3 4 Surface finish

    25 mm 12,5 mm 12,5 mm 6,3 mm

    Machined x x x x

    Machined and heat-treated x x x -

    "x marks the quality class that can be achieved for the specified surface roughness.

    2.3.3 Performance of the examination

    Scanning shall be performed using the manual contact pulse-echo technique. The minimum scanning coverage required is dictated by the type of forging and whether grid scanning coverage or 100% scanning coverage has been specified in the order or the specification in the drawing. Table 2 specifies the requirements for scanning coverage of the forging types 1, 2 and 3 with perpendicular incidence. Table 3 specifies the requirements for scanning coverage with angular sound incidence for forging types 3a and 3b which have outside diameter to inside diameter ratio of less than 1,6. The effective depth of circumferentially oriented scans is limited by the angle of incidence and the diameter of the forging.

  • Page 8 SN 200 Part 2 : 2003-09 Table 2 Scanning coverage with normal probes

    Grid scanning 1) Type

    Shape Diameter D in mm Scan lines 2)

    100% scanning 1)

    1a 200 < 500 <

    D 200 D 500 D 1000 D > 1000

    2 at 90 3 at 60 4 at 45 6 at 30

    Scan 100% around at least 180 of cylindrical surface

    1

    1b Scan along the lines of a square-link grid on two perpendicular surfaces 3) 4)

    Scan 100% on two perpendicular surfaces

    2 Scan along the lines of a square-link grid around 360 on the cylindrical surface and one lateral surface.

    Scan 100% around at least 180 on the cylindrical surface and 100% of one lateral surface

    3a Scan along the lines of a square-link grid around 360 on the outer cylindrical surface 4) Scan 100% around 360 on the outer cylindrical surface

    3

    3b & 3c Scan along the lines of a square-link grid around 360 on the outer cylindrical surface and one lateral surface 4)

    Scan 100% around 360 on the outer cylindrical surface and one lateral surface

    4 Scanning coverage shall be specified in the enquiry or order. 1) Additional scanning (for example in both axial directions for type 3a) may be carried out if specified in the enquiry or order. 2) 100% means at least 10% probe overlap between consecutive probe traverses. 3) For types 1a or 1b, if the presence of a bore prevents the opposite surface being reached, the number of scan lines shall be doubled symmetrically. 4) The grid line separation shall be equal to the thickness of the part up to a maximum of 200 mm.

    Table 3 Scanning coverage with shear wave probes

    Type Grid scanning 100% scanning 1) 2)

    3a

    3

    3b

    Scan in both directions along 360 circumferential grid lines the separation of which is equal to the radial thickness up to a maximum of 200 mm

    Scan 100% of outer cylindrical surface in both circumferential directions

    4 Scanning coverage shall be specified in the enquiry or order.

    1) Additional scanning coverage may be carried out if specified in the enquiry or order. 2) 100% means at least 10% probe overlap between consecutive probe traverses.

    2.3.4 Recording levels and acceptance criteria

    Tables 4, 5 and 6 detail recording levels and acceptance criteria which shall be applied to four quality classes. The sensitivity of the testing system (test unit, probe, cable) must be sufficient to ensure detection of the smallest discontinuities that are specified for the demanded recording and interpretation limits for the respective quality class.

  • Page 9 SN 200 Part 2 : 2003-09

    Table 4 Quality classes, recording levels and acceptance criteria for normal probes

    Quality class 1 2 3 4

    Recording levels

    Flat-bottomed holes FBB deg in mm of diameter > 8 > 5 > 3 > 2

    R ratio for abrupt attenuation of the backwall echo 1) 2) 0,1 0,3 0,5 0,6

    Acceptance limits

    Flat-bottomed holes in isolated point discontinuities deg in mm of diameter 12 8 5 3

    Flat-bottomed holes in extended or grouped discontinuities deg in mm of diameter 8 5 3 2

    1) R = nFo

    Fn

    , with n = 1 for t 60 mm and n = 2 for t < 60 mm

    Fn amplitude (screen height) of the nth reduced backwall echo Fo,n amplitude (screen height) of the nth backwall echo in the nearest discontinuity-free area at the same range as Fn 2) If the reduction in backwall echo is so heavy that the recording level is not attained, this shall be further investigated. Ratio R applies only to heavy reduction of backwall echo caused by the presence of a discontinuity.

    Table 5 Quality classes, recording levels and acceptance criteria for shear wave probes using DGS techniques with

    flat-bottomed holes

    Quality class 1 3) 2 3 4

    Recording level

    Recording level with flat-bottomed holes FBB deg in mm - > 5 > 3 > 2

    Acceptance limits

    Flat-bottomed holes in isolated point discontinuities deg in mm of diameter - 8 5 3

    Flat-bottomed holes in extended or grouped discontinuities deg in mm of diameter - 5 3 2

    3) shear wave scanning does not apply to quality class 1.

    Table 6 Quality classes, recording levels and acceptance criteria for shear wave probes using the reference line method, reference line based on a side-drilled hole of 3 mm in diameter

    Acceptance limit

    Quality class Nominal test frequency Recording level

    % of reference line

    Isolated discontinuities 4)

    % of reference line

    Extended or grouped discontinuities 4)

    % of reference line

    1 3)

    1 50 100 50 2

    2 100 200 100 2 50 100 50

    3 4 100 200 100 2 30 60 30

    4 4 50 100 50

    3) Quality class 1 does not apply to scanning with shear wave probes. 4) The indication amplitude in dB, relative to the reference line, is given in table 7.

  • Page 10 SN 200 Part 2 : 2003-09

    Table 7 Indication amplitude in dB relative to the reference line in %

    Reference line

    %

    Amplitude of indication relative to reference line

    dB

    30 - 10

    50 - 6

    60 - 4

    100 0

    200 + 6

    2.4 Inspections The data and results of the tests set out below shall be reported by the forging shop or the manufacturing shop in an inspection certificate as in DIN EN 10204 3.1B.

    - Chemical analysis of each heat contained in the supply. - Result of the hardness test and the mechanical properties determined per heat and heat-treatment unit. - Result of the elevated-temperature tensile test at maximum working temperature of the material for heat-resistant

    steels per heat and heat-treatment unit. - Results of other tests/inspections specified in the drawing

    Referenced standards DIN EN 10204 Types of inspection documents DIN EN 10228-1 Non-destructive testing of steel forgings; Magnetic particle inspection DIN EN 10228-2 Non-destructive testing of steel forgings; Penetrant testing DIN EN 10228-3 Non-destructive testing of steel forgings; Ultrasonic testing of ferritic or martensitic steel forgings DIN EN 10228-4 Non-destructive testing of steel forgings; Ultrasonic testing of austenitic or austenitic-ferritic stainless

    steel forgings

  • Page 11 SN 200 Part 2 : 2003-09

    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 types of products made by rolling, drawing, pressing or any other method and having constant cross-section along the length. The designation "St" is permitted 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 must be ensured. The same applies analogously if tensile strength requirements are made, but the type of smelting and treatment is left to the discretion of the maker. 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 semi-finished 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. The plates used must have class A surface condition as in DIN EN 10163. 3.4 Inspection The results of all below inspections/tests made on the semi-finished product (primary material) must be certified in a document as specified in DIN EN 10204 3.1.B. Components need not be tested again individually and certified provided the above testing has been made on the semi-finished products. It must be ensured, however, that the components are made from the tested semi-finished products. - Plate

    Plate of thickness 100 mm and yield point 1) 250 N/mm2 must be ultrasonically tested as specified in SEL 072, table 1, quality class 3 and tested for tensile strength and hardness.

    - Unalloyed steel

    Round bar of 150 mm Square steel of lateral length 150 mm Flat bar of width 150 mm and thickness 100 mm

    ... must be ultrasonically tested as in DIN EN 10228-3, type 1, quality class 2, and tested for tensile strength/hardness.

    - Alloy steel

    Round bar of 80 mm Square steel of lateral length 80 mm Flat bar of width 80 mm and thickness 80 mm

    ... must be subjected to chemical analysis and tested for tensile strength/hardness. - Heat-resistant steel

    If specified in the order or the drawing, heat-resistant steel must, in addition to the chemical analysis, be subjected to an elevated-temperature tensile test at the maximum permissible working temperature of the steel for each heat and heat-treatment unit.

    - Pipe

    For pipe having outside diameter 38 mm and wall thickness 5 mm, testing as required in the technical delivery conditions for pipes must be certified.

    1) The yield point refers to the smallest standardised material thickness.

    made of unalloyed steels and yield point 1) 250 N/mm2

    made of alloy steels and yield point 1) 350 N/mm2

  • Page 12 SN 200 Part 2 : 2003-09

    Referenced standards DIN EN 1370 Founding; Surface roughness inspection by visualtactile comparators DIN EN 10021 General technical delivery requirements for steel and iron products DIN EN 10029 Hot rolled steel plate 3 mm thick or above; tolerances on dimension, shape and mass DIN EN 10140 Cold rolled narrow steel strip; tolerances on dimensions and shape DIN EN 10163-1 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections;

    general requirements DIN EN 10163-2 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections;

    plate and wide flats DIN EN 10163-3 Technical delivery conditions for the surface condition of hot rolled steel plate, wide flats and sections;

    sections DIN EN 10204 Types of inspection documents DIN EN 10228-3 Non-destrucive testing of steel forgings; Ultrasonic testing of ferritic or martensitic steel forgings

    SEL 072 Ultrasonically tested heavy plate; technical delivery specifications

  • September 2003

    Manufacturing instructions THERMAL CUTTING AND FORMING BY BENDING

    SN 200 Part 3

    Dimensions in mm

    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 applies to workpieces and pipe conduits produced by cold bending. All instructions given apply if no different instructions are shown in drawings or other manufacturing documents. Table of contents Page 1 Thermal cutting............................................................................................................................................................. 1 1.1 Oxyfuel flame cutting.................................................................................................................................................... 1 1.2 Plasma cutting............................................................................................................................................................. 1 1.3 Laser cutting................................................................................................................................................................ 1 1.4 Quality of the cut surface.............................................................................................................................................. 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 Location 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 Forming by 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 is performed with a fuel gas/oxygen flame and cutting oxygen. The heat released by the heating flame and the heat produced during combustion permit continuous combustion by the cutting oxygen. The oxides produced, mixed with some molten metal, are driven out by the kinetic energy of the cutting oxygen jet. By this action, the kerf is produced. The instructions apply to flame cuts of 3 mm to 300 mm. 1.2 Plasma cutting Plasma cutting is a process of thermal cutting in which a constricted arc is used. Polyatomic gases dissociate in the arc and partially ionize; monoatomic gases partially ionize. The plasma beam thus generated has a high temperature and kinetic energy; it melts or partially vaporizes the material and blows it away. Thereby the kerf is produced. The instructions apply to plasma cuts of 1 mm to 150 mm. 1.3 Laser cutting Laser cutting is a process of thermal cutting in which the focused laser beam supplies the energy required for cutting, this energy then being converted into heat in the material. Cutting is supported by a gas jet. With laser beam cutting a difference is made between laser oxyfuel flame cutting, laser fusion cutting and laser sublimation cutting. The instructions apply to laser cuts of 0,5 mm to 40 mm. Continued on pages 2 to 7

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  • Page 2 SN 200 Part 3 : 2003-09 1.4 Quality of the cut surface

    1.4.1 Perpendicularity or angularity tolerance

    Distance between two parallel straight lines between which the cut surface profile is inscribed, and within the set angle (for example 90 in the case of vertical cuts). NOTE: The perpendicularity or angularity tolerance includes not only the straightness, but also the flatness deviations. Figures 1 and 2 show the maximum effective deviations within the tolerance class. a = area for determining the pependicularity-angularity tolerance 1.4.2 Mean height of the profile, RZ5 Arithmetic mean of the single profile elements of five bordering single measured distances Key ln evaluation length Zt1 to Zt5 single profile elements lr single sampling length (1/5 of ln)

    a) Vertical cut

    b) Bevel cut

    Fig. 1

    Fig. 2

  • Page 3 SN 200 Part 3 : 2003-09

    1.4.3 Measuring points

    1.4.3.1 Location of the measuring points

    The characteristic value 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 Da 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 of the top edge. Table 1 - Dimensions for Da

    Cut thickness a mm

    Da mm

    3 0,1a > 3 6 0,3 > 6 10 0,6 > 10 20 1 > 20 40 1,5 > 40 100 2 > 100 150 3 > 150 200 5 > 200 250 8 > 250 300 10

    1.4.4 Perpendicularity or angularity tolerance, u Table 2 - Perpendicularity or angularity tolerance, u

    Cut thickness

    a

    up to 20

    >20 to 40

    >40 to 60

    >60 to 80

    >80 to

    100

    >100 to

    120

    >120 to

    140

    >140 to

    160

    >160 to

    180

    >180 to

    200

    >200 to

    220

    >220 to

    240

    >240 to

    260

    >260 to

    280

    >280 to

    300 u

    for ranges 3 & 4

    1,3 1,6 1,9 2,2 2,5 2,8 3,1 3,4 3,7 4,0 4,3 4,6 4,9 5,2 5,5

    1.4.5 Mean height of the profile, RZ5 Table 3 Mean height of the profile, RZ5

    Cut thickness

    a

    up to 20

    >20 to 40

    >40 to 60

    >60 to 80

    >80 to

    100

    >100 to

    120

    >120 to

    140

    >140 to

    160

    >160 to

    180

    >180 to

    200

    >200 to

    220

    >220 to

    240

    >240 to

    260

    >260 to

    280

    >280 to

    300 RZ5

    for range 4 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

  • Page 4 SN 200 Part 3 : 2003-09 1.5 Form and location tolerances Figure 3 shows the maximum deviations within the tolerance zone. Fig. 3

    a) Through thickness b) Flat Key tG1 straightness tolerance (see 14.1 of DIN ISO 1101: 1983) for cut length; tG2 straightness tolerance (see 14.1 of DIN ISO 1101: 1983) for cut width; tw perpendicularity tolerance (see 14.8 of DIN ISO 1101: 1983) for cut width referred to A; tp parallelism tolerance (see 14.7 of DIN ISO 1101: 1983) for cut width referred to A on sheet level; U perpendicularity tolerance (see 14.8 of DIN ISO 1101: 1983) in cutting direction;

  • Page 5 SN 200 Part 3 : 2003-09

    1.6 Dimensional tolerances The dimension in the drawing shall be taken to be the nominal dimension. The actual dimensions will be determined on the clean surfaces of the cut. The limit deviation specified in Table 4 shall apply to dimensions without tolerance indications. Table 4 Limit deviations for nominal dimensions of tolerance class 1

    Nominal dimensions > 0 < 3

    3 < 10

    10 < 35

    35 < 125

    125 < 315

    315 < 1000

    1000 < 2000

    2000 < 4000

    Workpiece thickness

    Limit deviations

    > 0 1 0,04 0,1 0,1 0,2 0,2 0,3 0,3 0,3

    > 1 3,15 0,1 0,2 0,2 0,3 0,3 0,4 0,4 0,4

    > 3,15 6,3 0,3 0,3 0,4 0,4 0,5 0,5 0,5 0,6

    > 6,3 10 - 0,5 0,6 0,6 0,7 0,7 0,7 0,8

    > 10 50 - 0,6 0,7 0,7 0,8 1 1,6 2,5

    > 50 100 - - 1,3 1,3 1,4 1,7 2,2 3,1

    > 100 150 - - 1,9 2 2,1 2,3 2,9 3,8

    > 150 200 - - 2,6 2,7 2,7 3 3,6 4,5

    > 200 250 - - - - - 3,7 4,2 5,2

    > 250 300 - - - - - 4,4 4,9 5,9

    2 Forming by bending

    2.1 Bending

    2.1.1 Bending of flat products For the cold bending of flat steel products the permissible bending radii as in Table 5 must be observed. Further specifications are given in DIN 6935. Fig. 4 Table 5 Bending radii for bending angles of 90 (along the direction of rolling for steel grades of a min. tensile strength Rm of 390 N/mm)

    Plate thickness s 1 1,5 2 2,5 3 4 5 6 8 10 12 15 20 25 30 35 40

    Bending radius min r 2,5 3 6 8 10 16 20 24 30 40 50 60 70 100

    Leg length min. l 10 16 24 32 40 64 80 96 120 160 200 240 280 320

  • Page 6 SN 200 Part 3 : 2003-09 2.1.2 Bending of pipes Cold bending of pipes is preferable to welding-in of elbows. If drawings show welding elbows which can be replaced by a cold-bent pipe taking into account the bigger bending radius, the replacement can be carried out by the manufacturing workshop. When pipes are shown in isometric drawings, compliance with the drawing indications must 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 Bending radius

    10 to 12 2 x outside pipe diameter for wall thicknesses >1,0

    > 12 to 48,3 2 x outside pipe diameter for all wall thicknesses

    > 48,3 to 114,3 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 analogously for bent components. The following applies: Tolerance category B for completely dimensioned pipe conduits (e.g. pipe detail, isometric drawing) and for workpieces produced by bending of flat products. Tolerance category C for not completely dimensioned and freely laid pipe conduits. Table 7 Lengths (outside, inside and stepped dimensions, diameters and radii)

    Nominal dimension range

    Tolerance category

    2 to 30

    > 30 to

    120

    > 120

    to 400

    > 400

    to 1000

    > 1000

    to 2000

    > 2000

    to 4000

    > 4000

    to 8000

    > 8000

    to 12000

    > 12000

    to 16000

    > 16000

    to 20000

    > 20000

    B 1 2 2 3 4 6 8 10 12 14 16

    C 1 3 4 6 8 11 14 18 21 24 27

  • Page 7 SN 200 Part 3 : 2003-09

    Table 8 Angular dimensions

    Nominal dimension range (length of shorter leg)

    Permissible deviations in degrees and minutes Permissible deviations as tangent values Tolerance category

    up to 400 > 400

    to 1000 > 1000

    up to 400 > 400

    to 1000 > 1000

    B 45' 30' 20' 0,013 0,009 0,006 C 1 45' 30' 0,018 0,013 0,009

    The shorter leg of the angle is taken as reference for the limit dimensions of the angles. Its length can also be applied from a particular reference point shown in the drawing. (examples see Figs. 5 to 9) The figures were taken from DIN EN ISO 13920 for welded components. Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9

    3 Inspection Flame-cut and bent parts are inspected by the manufacturer with regard to the observance of 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 Cold bending of flat rolled steel products

    DIN EN ISO 1302 Geometrical Product Specifications (GPS); Indication of surface texture in technical product documentation

    DIN EN ISO 9013 Classification of thermal cuts

    DIN EN ISO 13920 General tolerances for welded constructions

    DIN ISO 1101 Technical drawings; Geometrical tolerancing

    SN 740-1 Bending radii for piping and tubing; minimum dimensions with bent pipes

    SN 740-2 Bending radii for piping and tubing; determination of pipe lengths considering various bending angles and radii

    Ref. point Ref. point

    Ref. point

    Ref. point

    Ref point

  • September 2003

    Manufacturing instructions

    WELDING

    SN 200 Part 4

    Dimensions in mm

    Field of application The manufacturing instructions specified in this part of SN 200 are applicable to all welded components unless otherwise specified in drawings or other manufacturing documents. The welding standards (e.g. DIN, DVS, SEW etc.) applicable to the respective materials must be observed. Welding is a special process whose result (quality) cannot be fully assessed by subsequent testing on the product. The quality requirements for welding as in DIN EN 729 must be fulfilled. We recommend establishing a quality assurance system on the basis of DIN EN ISO 9001. Table of contents Page

    1 Drawings and other manufacturing documents .......................................................................................................... 2 1.1 Indication 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 1.2 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 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 relative 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 the manufacturer of welded components...................................................................................... 6 3.1.1 Equipment subject to construction-supervision regulations......................................................................................... 6 3.1.2 Equipment not subject to regulations of construction supervision................................................................................ 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, e.g.: pipelines, vessels .................................................................. 12 3.8 Weld execution on fluid-carrying components, e.g.: pipelines, vessels...................................................................... 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, e.g.: pipelines, vessels .................................................. 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 Wrmebehandlung an sogenannten Low-Carbon-Sthlen........................................................................................ 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 without full material penetration ............................................................................. 15 6.1.1 Inspection directions for the quality levels of welds, general ..................................................................................... 16 6.2 Testing directions for the quality levels of welds on fluid-carrying components .......................................................... 16

    7 Guideline for the quality levels of imperfections ...................................................................................................... 17

    Referenced standards..................................................................................................................................... 21

    Continued on pages 2 to 22

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  • Page 2 SN 200 Part 4 : 2003-09 1 Drawings and other manufacturing documents

    1.1 Indication in drawings

    1.1.1 Fillet welds Fillet welds are indicated by a blacked-in triangle or welding symbols according to ISO 2553 (see 1.3) at the weld joints of the parts to be welded, shown in sectional view or in the view of the parts to be welded.

    1.1.2 Butt welds, partly and fully bevelled welds Butt welds, partly and fully bevelled welds are shown in drawings in sectional view or in the view with symbols according to ISO 2553 (see 1.3) with 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.

    1.1.4 Welds on pipe lines The operating pressure of the pipe line must be indicated. Welding symbols as in ISO 2553 (see 1.3) or information as in Table 13 are shown only in exceptional cases. 1.2 Representation as in DIN EN 22553 (ISO 2553)

    1.2.1 Basic symbols for weld types

    The various types of welds are characterised by symbols which are in general similar to the appearance of the welds. The symbols characterises the shape, preparation and execution of the welds. The symbol does not determine the welding process to be applied. Table 1 Basic symbols for weld types 1.2.2 Combinations of basic symbols When necessary, combinations of basic symbols are used for indication. Typical examples are given in table 2. Table 2 Combinations of basic symbols

    Fig. 1

  • Page 3 SN 200 Part 4 : 2003-09

    1.2.3 Supplementary symbols Basic symbols may be supplemented by a symbol characterising the shape of the surface or the execution of the weld. The absence of a supplementary symbol means that the surface shape must comply with the weld quality indicated. Combination of more than two supplementary symbols is not permitted. Table 3 Supplementary symbols Table 4 Complementary symbols

    Shape of weld surface Symbol Execution of weld Symbol Meaning Symbol

    a) flat d) toes blended smoothly circumferential weld

    b) convex g) use of permanent backing strip site weld

    c) concave h) use of removable backing strip

    Table 5 Examples of the application of supplementary symbols 1.3 Positions of symbols in 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 = Weld joint 1 = Main dimensions of weld thickness 2 = Arrow line 2 = Weld symbol 3a = Reference line (solid line) 3 = Weld length dimensions 3b = Reference line (dashed line) 4 = Indications for welding process 4 = Forked line for supplementary indications (line shown only when required) quality level for welding Fig. 2 position, filler metal 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 opposite side arrow side opposite side arrow side - arrow side of the joint of joint A of joint A of joint A of joint B - opposite side of the joint

    opposite side arrow side arrow side opposite side a) weld on arrow side b) weld on opposite side arrow side a) opposite side arrow side b)opposite side of joint B" of joint B" of joint A" of joint B"

    Fig. 3 T-joint with fillet weld Fig. 4 Cruciform joint with two fillet welds

    workshop assembly weld

    SMS Demag specification

    Join

    t A

    Join

    t B

    Joint A

    Joint B

    arrow line arrow line

    arrow line arrow line

    arrow line arrow line

  • Page 4 SN 200 Part 4 : 2003-09 1.3.3 Direction of the arrow line When the butt welds are asymmetrical, the arrow line always points to the non-vertical flank of the joint, i.e. to the workpiece which requires groove preparation. Example see Fig. 7b. 1.3.4 Position of the symbol relative to the reference line The symbol is placed either above or below the reference line. - When the symbol is shown on the side of the solid reference line, the weld is on the arrow side of the joint (Fig. 5a). - When the symbol is shown 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 b) weld, made c) only for symmetrical from arrow side from opposite side welds 1.3.5 Examples of application Fillet welds Fig. 6a Fig. 6b Butt welds Fig. 7a Fig. 7b For further application examples see DIN EN 22553 (ISO 2553).

    Illustration Symbolic representation

  • Page 5 SN 200 Part 4 : 2003-09

    2 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

    Range of nominal dimensions

    Tolerance class

    2 to 30

    > 30 to

    120

    > 120 to

    400

    > 400 to

    1000

    > 1000

    to 2000

    > 2000

    to 4000

    > 4000

    to 8000

    > 8000

    to 12000

    > 12000

    to 16000

    > 16000

    to 20000

    > 20000

    B 1 2 2 3 4 6 8 10 12 14 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

    Range of nominal dimensions (length of longer side of the surface)

    Tolerance class

    > 30 to

    120

    > 120 to

    400

    > 400 to

    1000

    > 1000

    to 2000

    > 2000

    to 4000

    > 4000

    to 8000

    > 8000

    to 12000

    > 12000

    to 16000

    > 16000

    to 20000

    > 20000

    F 1 1,5 3 4,5 6 8 10 12 14 16

    2.3 Angular dimensions The shorter leg of the angle is taken as reference leg for the tolerances of the angles. Its length can also be applied from a particular point of reference, which then has to be stated in the drawing (examples see figures 8 to 12). 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 as tangent values. Table 8 Angular dimensions

    Range of nominal dimensions (length of shorter leg)

    Permissible deviations in degrees and minutes Permissible deviations as tangent values Tolerance

    class

    up to 400 > 400

    to 1000 > 1000

    to 400 > 400

    to 1000 > 1000

    B 45' 30' 20' 0,013 0,009 0,006 The maximum permissible deviation in mm can be calculated from the tangent value x of the length of the shorter leg.

    Reference point

    Reference point

    Reference point

    Reference point Reference point

  • Page 6 SN 200 Part 4 : 2003-09 3 Execution of welding work

    3.1 Demands made on the manufacturer of welded components The demands made on the manufacturer are split up as follows, on the basis of the legal regulations and the demands made on the components: 3.1.1 Equipment subject to construction-supervision regulations

    Table 9

    Components Place of manufacture Place of use Demands on the maker

    worldwide Germany

    Germany outside Germany DIN 18800

    Buildings subject to construction supervision (eg bays, chimneys) Machinery and equipment intended for the permanent presence of persons (e.g. control stands, casting platforms, stair towers)

    outside Germany outside Germany national regulations of user

    country

    worldwide Germany

    Germany outside Germany

    DIN 18800 DIN 15018 Cranes, lifting equipment and load-carrying equipment

    (e.g. C-hooks, dismantling beams, see also SN 195)

    outside Germany outside Germany national regulations of user

    country

    worldwide Europe Germany Europe

    Directive 97/23/EC on pressure equipment

    Germany outside Europe national regulations

    of user country Pressure vessels

    outside Germany outside

    Europe

    national regulations of user country

    The assignment to the range of equipment or buildings subject to construction supervision or to the Directive 97/23/EC on Pressure Equipment and to the Water Resources Management Law is shown on the drawings.

    3.1.2 Equipment not subject to regulations of construction supervision

    Table 10

    Components Quality of weld DIN EN 25817

    (ISO 5817)

    Demands on the maker

    Requirements to be fulfilled by the welding shop on the basis of DIN EN 729:

    D

    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 suppliers recommendations Machinery and related equipment not

    subject to construction supervision (strand guide segments, shears, millstands, millstand platforms, converters, pipe lines)

    B and C

    Extended requirements - fulfillment of above-mentioned basic requirements - supervisory personnel for welding supervision 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 288 - keeping available of welding and working instructions - use of personnel qualified acc. to DIN EN 473 for

    quality inspections

    Note: If a manufacturing shop does not fulfill the above requirements, other national or international regulations or permits (e.g. ASME) can be accepted. Their equivalence must be proved by the contracting workshop before the beginning of manufacture.

  • Page 7 SN 200 Part 4 : 2003-09

    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 provided that the specified weld depth and the weld quality requirements are fulfilled. Selection of weld preparation in accordance with DIN EN 29692 (ISO 9692), Tables 11 and 12. Deviations from DIN EN 29692 (ISO 9692) specifications: 3.3 Filler metals All filler metals must 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 must be preheated as required for the respective material composition. The minimum preheating temperature TP is determined on the basis of carbon equivalent CET as specified in SEW 086 and SEW 088. In the case of multi-pass welds, the terms minimum preheating temperature and minimum interpass temperature have the same meaning. These specifications apply to steel with CET = 0,5.

    10

    MoMnC

    ++ +

    20

    CuCr + +

    40

    Ni (%)

    TP = 750 x CET 150 (C) Fig. 13 Minimum values of preheating temperature TP as a function of carbon equivalent CET.

    Measuring of the preheat, interpass and preheat maintenance temperatures must be made in accordance with DIN EN ISO 13916. 3.5 Weld execution 3.5.1 Weld execution, general The surfaces in the weld area must be freed from scale, slag, rust, paint, oil, grease and humidity prior to assembling. To avoid stray currents and their effects (destruction of electric protective conductors etc.), the welding current return line must be connected direct to the workpiece to be welded or to the workpiece support (e.g. welding table, welding grid, assembly plates). Steel structures, rails, pipe lines, bars and similar objects must not be used as current conductors, unless they are the workpiece to be welded. Tack-welded areas must be at least 40 mm long. All cracks, lack-of-fusion spots and clusters of pores must be removed before welding over. If accessible, the roots of two-sided welds having full material penetration must be gouged, checked for absence of cracks and counterwelded. Unless otherwise specified in the drawing, weld seams must be closed around all corners. Exceptions to this are only ribs and webs as in Figure 18. Shrinkage stresses due to one-side welding-on of parts must be compensated by counterheating. In case of postweld heat treatment, the welding shop must open all hermetically closed hollows prior to annealing by applying 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 must closed again. When plates are welded on, a short section is left without weld and closed after heat treatment.

    If full material penetration is required, the indication shown below is made in the drawing at the weld concerned:

    full penetration

  • Table 11 Groove forms for butt welds

    Weld Weld groove design

    Dimensions Key No.

    Workpiece thickness

    t Designation Symbol (as in ISO 2553) Representation Section Angle

    1)

    a, b Gap 2)

    b Root height

    c

    Groove face height

    Recommended welding process 3) (as in ISO 4063)

    Remarks

    t 4 - b t -- - 3

    111 141

    -

    1.2

    3 < t 8

    Square butt weld

    - 6 h 8 - - 131 135 141

    With weld pool backup

    1.3 3 t 10 Single-V butt weld

    40 a 60 b 4 c 2 - 3 With backup strip if required

    1.5 5 t 40

    Single-V butt weld with broad root

    face

    a 60 1 b 4 2 c 4 -

    111 131 135 141

    -

    1.7 t > 12 Single-U-butt weld

    8 b 12 1 b 4 c 3 -

    111 131 135 141

    -

    1)

    -

    10 t 25 Single-bevel butt weld

    35 b 60 2 b 4 1 c 2 - - -

    1) SMS Demag stipulation

    Pag

    e 8 S

    N 200 P

    art 4 : 2003-09

  • Table 11 continued

    Weld Weld groove design

    Dimensions Key No.

    Workpiece thickness

    t Designation Symbol (as in ISO 2553) Representation Section Angle 1)

    a, b Gap 2)

    b Root height

    c

    Groove face height

    h

    Recommended welding process 3) (as in ISO 4063)

    Remarks

    1.4 3 < t 10 Single-bevel butt weld

    35 b 60 2 b 4 1 c 2 -

    111 131 135 141

    -

    6 b 12 111

    1.15 t > 16 Steep-flanked single-bevel

    butt weld

    15 b 30

    b 12

    - -

    131 135

    With weld pool backup

    1.8 t > 16

    Single-J butt weld

    (J-groove weld)

    10 b 20 2 b 4 1 c 2 -

    111 131 135 141

    -

    - b 2

    t - -

    111 141

    2.2 t 8 weld

    - b 2

    t - -

    131 135

    -

    a 60 111 141

    2.3.3 t > 10 Double-V butt

    weld

    40 a 60

    1 b 3 c 2

    131 135

    -

    Pag

    e 9 S

    N 200 P

    art 4: 2003-09

  • Weld Weld groove design

    Dimensions Key No.

    Workpiece thickness

    t Designation Symbol (as in ISO 2553) Representation Section Angle 1)

    a, b Gap 2)

    b Root height

    c

    Groove face height

    h

    Recommended welding process (as in ISO 4063)

    Remarks

    a1 60 a2 60

    111 141

    2.3.3 t > 10 Asymmetric

    double-V butt weld

    40 a1 60 40 a1 60

    1 b 3 c 2 h = 3

    t

    131 135

    2.7.7 t 30 Double-U butt weld

    8 b 12 b 3 c 3 h 2

    ct -

    111 131 135 141

    2.4.4 t > 10 Double-bevel

    butt weld (K weld)

    35 b 60 1 b 4 c 2

    h = 2

    t

    or

    h = 3

    t

    111 131 135 141

    2.8.8 t > 30 Double-J butt weld

    10 b 20 b 3 c 2 -

    111 131 135 141

    This groove can also be asymmetric,

    similar to the asymmetric double-

    V butt weld

    Table 11 continued P

    age 10

    SN

    200 Part 4 : 2003-09

  • Page 11 SN 200 Part 4 : 2003-09

    3.5.1.1 Slot welding Fig. 13 Fig. 14 The slot width b depends upon the plate thicknesses t1 and t2 and the necessary weld junction, for t1 15 mm, b min. is 0,5 x t1, but at least 4 mm for t1 > 15 mm, b min. is 15 mm

    3.5.1.2 Plug weld

    Plug weld is 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 thicknesses on butt welds, partly and fully bevelled welds The weld thickness of these weld types must correspond to the stated weld depth. For butt and fillet welds the max. weld reinforcement () is determined by the weld quality. With partly and fully bevelled welds the weld reinforcement () for single-bevel and double-bevel welds is 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 It is assumed that the weld is made as shown in Fig. 16. If the execution of the weld depends on the leg thickness (z), this thickness is indicated in the drawing with the letter z as shown in Fig. 17.

    e.g. 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 are executed as set out below:

    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 upon the thinner of the parts to be joined and must not exceed 12 mm, above 12 mm must 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 must be consulted.

    3.5.1.5 Quality of weld; quality level for welding, general The quality of weld is specified in Table 16 in quality levels according to DIN EN 25817 (ISO 5817). Unless otherwise specified in the drawing, quality level D is SMS Demag standard. The restrictions shown in Table 14 must be observed. Demand joints on plates and sections must be full penetration welds with quality level B, the quality of weld must 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 to 5 and 8, see Table 16. The specifications of SN 402 must be complied with.

    3.5.2 Weld execution for ferritic-austenitic weld joints Ferritic-austenitic weld joints are mixed joints established between structural unalloyed or structural alloy steels and austenitic chromium-nickel steels 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 filler metals on nickel basis. Ferritic-austenitic weld joints must be established by welding in accordance with the specific regulations and with filler metals whose use is permitted for this combination.

    up to t1 = 10

    min. 2 or 3 half fill

    above t1 = 10

  • Page 12 SN 200 Part 4 : 2003-09 3.6 Notches Notches must be made as shown in figures 18 to 21. Dimension I or R in Table 12 is selected such that welding through underneath the bracing rib is possible. Weld seams must be closed around all corners even without express mention in the drawing: - as shown in Fig. 18 for ribs and webs of 12 mm max. thickness; - as shown in Fig. 19 for ribs and webs above 12 mm; - as shown in F