Manufacturing Instructions

Transcription

1 May 2016 Manufacturing Instructions Assembly and disassembly SN ICS Dimensions in mm Supersedes SN 200-6: Table of contents Page 1 Scope Normative references Terms and definitions Safety instructions Assembly Preparation Mechanical units Basic specifications Screwed/bolted joints Shrink fitting Lubrication Hydraulic systems Corrosion protection Fluid-carrying units Basic specifications Couplings and flanges Sealing of couplings and threaded fittings Connecting holes Arrangement of fastening elements Disassembly Basic specifications Mechanical units Fluid-carrying units Inspection of assembled units Basic specifications Shape and position lerances for assembled equipment components General lerances for pipe lines... 5 Referenced technical standards, codes and regulations... 6 Revision of May Scope This company standard specifies for SMS group the requirements be met for pre-assembly in manufacturing shops, disassembly for shipment and final assembly of products. 2 Normative references The documents listed below are required for the application of this standard. Dated references refer only the edition of the date indicated. Undated references refer the latest edition of the respective document inclusive of all revisions. SN SN Manufactuirng Instructions - Requirements and principles Manufacturing Instructions - Inspection Number of pages: 6 Edited by: SMS group Standards Office SMS group GmbH 2016 "The present document is protected by copyright. Reproduction, distribution and utilization of this document as well as communication of its contents others are prohibited unless expressly authorized by us. Any violations will be prosecuted under criminal law and will result in an obligation pay damages. All rights reserved."

2 Page 2 3 Terms and definitions For the application of this document, the following terms and definitions shall be used. Assembly Assembly is the permanent joining or other way of fitting gether of two or more workpieces of defined geometrical shape; it includes all handling and auxiliary procedures and measuring and inspection. Disassembly Taking apart of pre-assembled, partly assembled or finish-assembled units in components and/or assemblies. Disassembling [for the purpose of DIN 8591: ] Cutting (separating) of previously joined workpieces of geometrically defined shape or of workpieces of geometrically defined shape and filled in amorphous material without causing damage the workpieces. NOTE: Disassembling (as in DIN 8591) is the reverse of the process of joining specified in DIN Here the restriction applies that joined parts cannot always be separated by disassembling because some joining methods allow the cutting/separating of the joined parts only by destructing or damaging of the parts (refer DIN ). Irrespective of this, the number of disassembling methods is smaller than that of the joining methods because the disassembling methods are in many cases not distinguished the same extent as the joining methods. 4 Safety instructions The safety instructions and specifications concerning hazardous materials and environmental protection given in SN shall always be followed. 5 Assembly 5.1 Preparation All parts shall be deburred (free of burrs according DIN ISO 13715: ) and cleaned, all surfaces shall be properly dressed before assembling. Holes used for feeding fluids shall be illuminated, residues removed (e.g. with compressed air), and the holes then checked for correct passage of the fluid. The parts shall be assembled on a base surface which corresponds the future supporting surface and complies with the accuracy required for the inspections be made. The static and dynamic loads shall be taken in account. Assembling of the components shall be made only after the inspection of the individual parts, complete inspection records of all individual parts shall be made available, see SN Mechanical units Basic specifications For assembling (e.g. of wear plates, couplings, bushings etc.), the bonding, lubricating and sealing instructions of the makers shall be followed. On assembled parts and machined surfaces, the maximum surface contact percentages shall be achieved. The specified fitting clearances and contact patterns shall be taken in account, applied and documented. The geometrical lerances for the assembling of machine components shall be complied with according item Screwed/bolted joints For screwed/bolted joints which are not marked on drawings, the usual tightening procedures for assembling shall be applied. The specifications are given in SN 403. Tightening rques indicated on the drawings shall also be applied for partial assembling for the purpose of finish machining. When no rques or pretensioning values are indicated on the drawing and no other details on securing are given, the screwed/ bolted joints shall be secured e.g. with Loctite 243 or Delo 5249 according SN 507: Shrink fitting For the shrink fitting or removal by shrinking of bearings, couplings and other parts, the makers' installation instructions and the maximum permissible heating and undercooling temperatures shall be observed. This applies in particular quenched and tempered and hardened components Lubrication Grease bearing points and grease lines shall be delivered with initial fill. All components in need of lubrication shall be properly provided with sufficient quantities of one of the lubricants recommended in SN 180-1:

3 Page Hydraulic systems When hydraulic power packages are used effect movements, the necessary purity of the hydraulic fluid shall be ensured, at least degree of purity 15/14/11 acc. ISO 4406: As a minimum requirement, the hydraulic fluid shall fulfil the properties of an HLPD according DIN : (e.g. Renolin MRX 46) Corrosion protection Areas which are not accessible after assembly shall be provided with permanent corrosion protection in accordance with the specification in the manufacturing documents before assembly. Unless otherwise specified in the manufacturing documents, permanent corrosion protection shall be carried out according SN Unless otherwise specified in the manufacturing documents, all exposed worked contact and functional surfaces, except those intended for shrink joints, shall be provided with temporary corrosion protection according SN prior assembly. 5.3 Fluid-carrying units Basic specifications The locations of the pipelines, line components and line supports (SN 696) are shown on drawings. Deviations are allowed only upon agreement with the design department. For pipework which is not fully dimensioned and has be fitted during assembly, the following shall be taken in account: - Installation of the pipework as appropriate for the function according the general arrangement drawing, pipework or P&l diagram (pipework and instrument flow diagram); - Function-adapted installation of valves/fittings with due regard accessibility; - Appropriate pipework arrangement and routing for easy assembling and disassembling; - Installation of the pipe lines free of stresses according DIN EN : ; - The space required for the use of hydraulic pretensioning units (e.g. for anchor bolts, gear bearing bolts) shall be taken in account. The general lerances for the installation of pipe lines are specified in section 7.3. Prior final installation, pipework and fluid-carrying components shall be cleaned remove all impurities (dirt, chips, welding spatter, paint, etc.) from the inside surface Couplings and flanges In the assembling of pipe couplings, cleanliness and lubrication of the thread shall be ensured and the suppliers' assembling instructions shall be followed. When pipe couplings in stainless steel are assembled, the thread and the surface of the union nut which is in contact with the welding cone shall be provided with a sufficient quantity of lubricant (e.g. "Fett-Micro-Gleit GP 350" by Micro Gleit Company or any other lubricant approved by SMS group) avoid seizing of the couplings. When flanges made of two different materials are used, the parts remaining at 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 (split SAE flanges/split flanges etc.), the use of surface-treated (galvanized, chromalised or nickel-plated) steel is allowed. As shown in figure 1, the screw holes in pipe lines and valves/fittings shall be arranged in such a way that they are symmetrical the two main axes and that no holes are located on the axes themselves, refer DIN : Every flange shall be provided with a number of bolt holes that can be divided by four. Fig. 1 Flange Sealing of couplings and threaded fittings When male stud couplings with front-side elastic seal are used, no sealing agents shall be applied in addition. For the sealing of male stud couplings, no copper seals shall be used. In exceptional cases, couplings and threaded fittings without front-side elastic seals shall be sealed in the low-pressure range 1,6 MPa with Omnifit 50H (by Henkel), in the high-pressure range > 1,6 MPa with AVX No. 586 (by Loctite) or equivalent sealing compounds. Couplings sealed with AVX can be disconnected only by the introduction of heat (flame); for this reason AVX shall not be used for pipe lines which carry flammable fluids. Couplings in grease pipe lines shall not be provided with additional sealing.

4 Page Connecting holes To avoid contamination of the control elements, all connecting holes (of valves, measuring instruments, cylinder ports, valve block connections etc.) shall be kept closed with appropriate means like disks, caps, adhesive tape etc. until final assembly. Connecting holes opened for reasons of installation or inspection shall be closed again immediately after installation/inspection Arrangement of fastening elements Pipework shall be installed in such a way that the distance between two fasteners does not exceed the values in table 1. Fastenings shall always be used immediately near detachable connections and pipe bends. When pipe clamps are welded on, they shall be provided with a fillet weld of a = 0,3 x smallest plate thickness. Grease pipe lines of outside diameters up and including 10 mm shall be fastened the machine without clearance using appropriate pipe clamps. Table 1 Distances Pipe outside Max. distance in m 10 0,6 > ,5 > 38 88,9 2,5 > 88,9 3,0 6 Disassembly 6.1 Basic specifications The transportability of the units is decisively influenced by the degree of disassembly. It shall be borne in mind that disassembly must finally lead obtaining transportable units. 6.2 Mechanical units Disassembly shall be made only the necessary extent. Screws/bolts and shims shall be left on the components provided that this does not cause problems for shipment. Prior disassembling, parts likely be mixed up (e.g. pipe supports, split covers, split housings etc.) shall be provided with permanent and well visible marking using steel stamping letters or figures. 6.3 Fluid-carrying units Disassembling shall be made only the necessary extent. For pipework operated with oxygen, it shall be ensured that it is absolutely clean from any oil and grease. After cleaning, the pipe lines and fluid-carrying components shall be closed in such a way (e.g. using a steel plate plus soft seal for flanges) that new contamination is safely avoided. On ends without flanges, plastic caps are allowed for closing. Steel tubes for precision applications shall be closed with closing elements with 24 inside cone or with sealing plugs. 7 Inspection of assembled units 7.1 Basic specifications The scope of inspection for assembled units shall be agreed with the SMS group department of quality inspection, see SN The manufacturer shall draw up records of all checks/inspections carried out; As far as applicable and feasible, the minimum requirement is the examination of: - the lerances on shape and position for assembled units; - the general lerances for pipe lines; - the supporting and seating surfaces, connecting and takeover points; - clearances and contact patterns be adjusted; - surface contact percentages (with 0,05 mm feeler gauge); - movements and travelling distances (with auxiliary drives if necessary); - cylinder strokes (using suitable hydraulic power units); - corrosion protection, see SN

5 Page Shape and position lerances for assembled equipment components The lerances in table 2 are related the indicated reference length or relevant overall length of the components. Tolerance class medium (m) is the SMS group standard lerance class. The SMS group-specific indication of the level condition is shown in table 3. The lerances for assembled components which are subject the Construction Products Regulation 305/2011 EU are indicated in DIN EN : , Annex D. Property Axial alignment Angularity Parallelism Perpendicularity Straightness Flatness Level condition Vertical Table 2 - Shape and position lerances Tolerance class Very fine (sf) Fine (f) Medium (m) 0,03 0,05 Coarse (g) 0,1 0,2 0,5 Table 3 Level condition Symbol Tolerance zone definition Drawing indication Explanation The leranced horizontal line shall lie between two horizontal lines which are t = 0,2 mm apart. When no reference length is indicated, reference is always made the relevant overall length. 7.3 General lerances for pipe lines For pipework which is not fully dimensioned and freely installed, the priority is on the guaranteeing of its function. All unleranced dimensions are subject accuracy classes C and F according tables 4 6; extract from DIN EN ISO 13920: For fully dimensioned pipework (e.g. pipe detail drawings, isometric drawings), accuracy classes B and F according tables 6 8 apply all unleranced dimensions; extract from DIN EN ISO 13920: Tolerance class Table 4 Tolerances on linear dimensions (external, internal and stepped dimensions) 2 30 > > > > Nominal dimension range > > > > > > B C Tolerance class Table 5 Tolerances on angular dimensions Nominal dimension range (length of the shorter leg, see SN 200-4, section 8.3) > 400 > 1000 > 400 > 1000 Up Up Permissible deviations in degrees and minutes Permissible deviations in tangent values B + 45' + 30' + 20' 0,013 0,009 0,006 C ' + 30' 0,018 0,013 0,009 Tolerance class > Table 6 - Tolerances on straightness, flatness and parallelism > Nominal dimension range (longer lateral length of the surface) > > > > > ,000 > 12,000 16,000 > 16,000 20,000 > 20,000 F 1 1,5 3 4,

6 Page 6 Referenced technical standards, codes and regulations DIN : DIN 8591: DIN DIN EN : DIN EN : Pressure fluids Hydraulic oils Part 2: HLP hydraulic oils; Minimum requirements Manufacturing processes disassembling - Classification, subdivision, definitions Manufacturing processes joining - Part 0: General - Classification, subdivision, terms and definitions Flanges and their joints; Circular flanges for pipes, valves, fittings and accessories, PN designated; Part 1: Steel flanges Metallic industrial piping - Part 4: Fabrication and installation DIN EN ISO 13920: Welding - General lerances for welded constructions - Dimensions for lengths and angles, shape and position DIN ISO 13715: ISO 4406: SN 180-1: SN SN SN SN 403 SN 507: SN 696 Technical drawings - Edges of undefined shape - Vocabulary and indications Hydraulic fluid power - Fluids - Method for coding the level of contamination by solid particles Operating materials - Lubricant, grease - Selection Manufacturing Instructions - Principles Manufacturing Instructions - Coating and preserving Manufacturing Instructions - Inspection Pretensioning and operating forces for bolted joints - Design guideline Glueing Piping support Revision of May 2016 Edirial revision. Titel Section 1 Section 2 Section 3 Section 5.2 Section Section Section Section 5.3 Section Section 6.1 Section 6.3 Section 7 Section 7.2 Changed from Assembling Assembly and disassembly Change of Scope Normative references added Terms and definitions added Changed from Machines Mechanical units Calculation facrs for rques of the bolts removed and reference SN 403 added Information added (e.g. Renolin) Coats changed Corrosion protection Changed from Fluid-carrying components Fluid-carrying units Note on cleaning of the pipelines and fluid-carrying components added Section newly added Note concerning necessity of cleaning from oil and grease of oxygen lines; closing of pipe ends with caps and plugs added Inspection changed Inspection of assembled units Reference lerances of the Construction Products Regulation 305/2011 EU added