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Contents
1 Validity........................................................................................................................................................6
1.1 EU laws/directives................................................................................................................................7
Legend .............................................................................................................................................................47
List of illustrations
FIGURE 1............................................................................................................................................................13
FIGURE 2: PLANE-PARALLELISM OF FLANGES ........................................................................................................24
FIGURE 3: DISTANCE BETWEEN FLANGES .............................................................................................................25
FIGURE 4: LATERAL OFFSET OF THE FLANGES.......................................................................................................25
FIGURE 5: ARRANGEMENT OF THREADED HOLES...................................................................................................26
FIGURE 6: CLAMP SCREWS FOR DN25 – 150.......................................................................................................29
FIGURE 7: U BOLTS FOR DN200 – 300................................................................................................................30
FIGURE 8: PIPE SUPPORT INSTALLATION PROPOSAL ..............................................................................................31
FIGURE 9: U BOLTS, CROSS-SECTIONS, VARIOUS DN ...........................................................................................32
FIGURE 10: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................32
FIGURE 11: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................32
FIGURE 12: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................33
FIGURE 13: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................33
FIGURE 14: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................34
FIGURE 15: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................35
FIGURE 16: U BOLTS, CROSS-SECTIONS, VARIOUS DN .........................................................................................36
FIGURE 17: GUIDE VALUES FOR THE MAXIMUM PERMISSIBLE PIPE SPAN L AS A FUNCTION OF THE PIPE DESIGN AND
INTERNAL STEEL PIPE DIAMETER D(I) ...................................................................................................37
FIGURE 18: THERMAL EXPANSION OF A STEEL PIPE ...............................................................................................39
FIGURE 19: FIXING OF TRACING PIPES .................................................................................................................44
FIGURE 20: INSTALLATION EXAMPLE FOR TRACING TYPE HEATING ..........................................................................46
FIGURE 21: DESIGNATION OF A STIFFING SLEEVE MADE OF CUZN35NI FOR CU PIPE 12X1......................................49
FIGURE 22: WELD NIPPLE FOR BORE FORM IN ACCORDANCE WITH DIN 3861 – FORM K. DIMENSIONS IN MM ..........50
FIGURE 23: ADAPTATION TO DIFFERENT WALL THICKNESSES ON THE THICKER COMPONENT. ...................................54
FIGURE 24: EXAMPLE, EXTRACT FROM OVERVIEW TABLE 1, FOR AD2000, HP0, MATERIAL GROUP .......................55
1 Validity
These assembly instructions apply to the mechanical part of the pipes and equipment for stationary diesel
power plants from MAN B&W Diesel AG.
If MBD and the Client are identical, the assembly procedures shall normally correspond to the definitions
stipulated here. If the Client is not MBD, e.g. this function is performed by the customer and the latter
assumes manufacturer responsibility within the scope of the order, then his work scope shall be performed
subject to his own responsibility. In this case, the assembly instructions shall be considered as a guideline.
Deviations from the assembly instructions are then possible subject to his own responsibility, but shall
require written agreement with MBD. Violations of regulations shall be excluded from this.
The work specifications and acceptance conditions for pipes and equipment are described in the assembly
instructions.
The requirements stipulated in the instructions are designed to permit safe assembly and guarantee the
quality of work execution.
The work specifications and characteristics described here are minimum requirements.
These assembly instructions for pipes and equipment do not release the company performing assembly work
from its obligation to install the pipe systems and equipment parts in accordance with the respectively
applicable regulations and the current state of the art.
End customer specifications, national regulations or regulations at the place of plant construction as well as
the regulations of the World Bank (also refer to the section "Regulations and directives") apply in addition to
these assembly instructions. The higher requirements shall apply in all cases if there should be differences in
the requirements between these specifications, instructions, regulations, etc.
These assembly instructions shall apply to the company performing assembly work for pipes and equipment
(Contractor) irrespectively of whether this company has been assigned the work by MBD as the Client or
directly by the end customer/operator as the Client. These instructions shall not release the Client from his
manufacturer's obligation or parts of this with respect to the overall work or with respect to supervision of the
work and services performed by his contractor. Repeated consultation between all parties involved
(Client/Contractor/MBD) is essential during the course of plant construction and this shall be documented
correspondingly.
General information
o All components, and particularly the diesel generator set, shall be properly grounded. It
shall be guaranteed that transmission of current through the shaft to the bearings or via
the clutch to the diesel engine crankshaft as a result of a ripple voltage is not possible.
• Proper and expert cabling of all accessories and of the diesel generator set shall be ensured.
• The tightening torques for screws shall be applied corresponding to the screw material used
unless otherwise specified
The following abbreviations are used, among others, in the following document:
1.1 EU laws/directives
The basic standard of MBD for construction of diesel power plants is compliance with EU laws and
directives. For this reason, the Contractor shall meet the requirements of all EU laws and directives relevant
for the scope of the assigned work and services. He shall perform a conformity assessment for the scope of
his work and services and/or parts thereof and verify conformity with EU directives towards the ordering party
by way of a suitable document. At the same time, he shall produce internal documentation and keep this for
13 years as from the ordering date for the order. The orderer shall be entitled to inspect or request a copy of
this manufacturer documentation and of the risk analysis at any time. The Contractor shall hand over to the
Client the technical documentation required for the ordering party.
A different procedure may be agreed between the parties for individual points of these instructions in
individual cases outside the territorial validity of EU legislation. This shall be agreed on an order-specific
basis before order award in all cases.
Health and safety protection of workers in accordance with the requirements of the German Association
of Employers’ Liability Insurers for the Metal Industry (VMBG) or the order-specific or locally applicable
regulations. If the Client and MBD are identical, the accident prevention regulations from Germany shall
apply.
If DIN standards cited by MBD should have been partially or completely replaced by DIN-EN standards,
DIN-ISO standards or DIN-EN-ISO standards, then the Contractor shall notify MBD of this immediately.
The superseding standard shall apply in principle.
- DIN EN 288-1
- DIN EN 288-2
- DIN EN 288-3
- DIN EN 288-4
- DIN EN 288-5
- DIN EN 288-6
- DIN EN 288-7
- DIN EN 288-8
Welding personnel
- DIN EN 287-1
- DIN EN 719
- DIN EN 1418
- Welding quality requirements
- DIN EN 729-3
Welding fillers
- DIN EN 439
- DIN EN 440
- DIN EN 499
Personnel requirements for non-destructive material testing (test supervision and testers)
- DIN EN 473
3 Preconditions/Manufacturer qualifications
The Contractor shall apply the AD 2000 Code and prove conformity with the existing directives.
If MBD and the Client are identical, the Contractor requires supplier approval by MBD. This is issued subject
to the quality regulation Q10.09028-2161 - Internal working instruction for the supplier approval procedure.
Welding preconditions
In so far as the documents applicable to the order do not demand stricter preconditions, the following shall
apply:
Qualified welders/operators with valid welder/operator certificates in accordance with DIN EN 287-1/DIN EN
1418 shall be used. The validity of the welder/operator qualifications must fully cover the scope of work. An
additional certificate in accordance with DIN 18808 or comparable is required for multiple pipe joints (circular
pipe to circular pipe).
For the purpose of welding supervision, the welding company must have a welding supervisor who is
a permanent member of staff and who has comprehensive knowledge in accordance with the regulation
DVS-EWF 1173 or equivalent training.
Assessment group for imperfections in the weld seam in accordance with DIN EN ISO 5817, assessment
group C, in so far as a higher assessment group is not required in the applicable order documentation and
if the seam is not on a pipe or pressure vessel. In this case, it is necessary to observe Chap. 4.26, Welding.
In addition to the quality requirements from Directive 97/23/EC (where appropriate also in conjunction with
AD2000), the standard quality requirements for welding operations in accordance with DIN-EN 729-3 shall
also be observed. The traceability of material, welder and inspector shall be ensured.
Weld seams shall be stamped with the personal welder stamp of the welder performing the work which is
assignable to the welder's certificate.
The replacement standards shall apply automatically if the cited standards are updated or replaced.
Additional tests are necessary if the materials, dimensions and welding procedures are changed so that they
extend beyond the scope of the procedure qualification test.
The responsible independent body or an expert nominated by MBD shall produce a report on performance of
the procedure qualification test and the test results in the form of a Welding Procedure Acceptance Report
(WPAR). These reports must be available before the start of production or assembly.
The procedure assessments to be performed cover comparable steels within the material group for plain
carbon steels (1.5415, 1.0305, 1.0254), i.e. one assessment is sufficient for each material group.
Procedure assessments within the material group for stainless steels (e.g. 1.4541, 1.4550) cover comparable
steels, i.e. one assessment is sufficient for each material group.
Procedure assessments are required for each material in the case of all other materials.
The bending tools must have an unambiguous identification number. Only these bending tools shall be used
for production after a positive bending procedure assessment.
It is recommended to place the zone of the straight pipe with the greatest wall thickness in the bending
tension zone. This applies particularly to bends with a small bending radius (Rm/da<3).
In the case of longitudinally welded pipes, the longitudinal seam should be positioned in the neutral zone.
The responsible independent body or an expert nominated by MBD shall check the bend ovality measured
by the manufacturer on a random sample basis.
da ≤ 60.3
Rm/da ≥ 3.0 (smaller bending radii shall be agreed with the Client)
The agreement of the ordering party shall be obtained in each individual case if the permissible ovality
is exceeded.
Measurements are performed in the measuring planes of the wall thickness measurement. The
circumference must also be measured at these points.
The measurements shall be performed by the Contractor and recorded in a component-specific manner, and
shall also be checked by the responsible independent body or an expert nominated by MBD on a random
sample basis.
View y
Flow direction
Figure 1
The measured values shall be specified in a report. The inspection scope shall be 100 %.
Individual flat wrinkles in the inner bend side are permissible subject to the following restriction:
• The mean wrinkle height (hm) must not exceed 3 % of the mean diameter (dm) up to max. 5 mm.
• The permissible wrinkle height hm is determined as follows:
where
or
Mean diameter
of straight end
Cold forming with a degree of deformation of ≤ 5 % is permitted to correct form deviations. Back forming
of cold bends is not permitted.
Test supervisor
The test supervisor must possess the know-how required for his tasks and basic knowledge of welding
engineering, and must have training, qualification and certification in accordance with DIN EN 473 (at least
level 2) or equivalent for the industrial sector “weld seams”. The test supervisor must master the tests in
accordance with the requirements defined in these assembly instructions. In addition, he must ensure that
the testers have the necessary level of qualifications and that the test equipment is in perfect order.
The test supervisor must be independent of production and shall be appointed by the Contractor.
The test supervisor shall determine the test procedure to be applied, define the details of test execution in
a test plan taking into account these assembly instructions, and shall assign the testers. The test plan shall
be agreed with the Client and/or MBD, depending on order case.
The test supervisor shall sign the test reports which must be produced in accordance with these assembly
instructions.
Testers
The testers shall possess training, qualifications and certification in accordance with DIN EN 473 or
equivalent in the industrial sector “Weld seams” for all the test procedures to be implemented, and shall have
sufficient basic technical knowledge in order to master the tests to be performed by them in accordance with
the requirements stipulated in these assembly instructions.
Note: If no documentation in accordance with DIN EN 473 is available with respect to tester approval, then
the Contractor shall provide evidence of the suitability of the personnel to the Client/MBD in individual cases
by way of suitable proof. The Contractor shall remain liable/responsible for test execution in accordance with
the applicable regulations, even if MBD agrees to or tolerates use of such personnel.
4 Turnkey assembly
This refers to assembly (turnkey construction) of the following primary systems taking into account all
planning documents, including all pipe supports, fittings, components and modules, as well as insulation,
in some cases with tracing-type heating, the corresponding test scopes and complete recording of testing.
Pipe assembly shall take place subject to observance of the valid safety regulations. Pipe assembly shall
always take place on a system basis in the order large pipes – small pipes – cables. Assembly of the
supports shall always take place before assembly of the pipes. Assembly of pipes in provisional supports
is permitted only in exceptional cases and subject to the full responsibility of the Contractor.
Attachment of gripping and lifting equipment to the building structure or other components shall always
require the approval of the site management. The permitted load forces on the building structure or other
components must not be exceeded.
The site management must be continuously consulted with respect to the assembly work, also in respect of
other trades. Transport and pulling operations shall be notified in good time. Subject to previous agreement
with the site management, existing transport facilities such as cranes may be used at their own risk by
correspondingly appointed personnel of the Contractor.
- Space for the day accommodation with connections for drinking water, waste water and site
electricity.
- The connections for electricity, service water and drinking water for the day accommodation and
for all facilities (e.g. field works) not located directly at the assembly site shall be realised by the
Contractor.
The quantity, size and space requirement as well as type of containers (sanitary or recreation) shall
be notified to the site management in good time (at the latest within 3 weeks after order award).
- Space for pre-assembly and storage purposes
- Provision of site electricity for direct construction and assembly work.
The Contractor shall also permit other assembly companies (small consumers) to use the electricity
supply from his site power distribution units.
For safety reasons, it is not permitted to heat construction site equipment of any kind in a manner
other than expressly prescribed by the site management.
The Contractor shall also be responsible for the following, among other things:
- Provision of the complete construction site equipment (including workshop, site huts, storage halls,
including facilities for proper storage of fittings in accordance with the supplied parts lists, sanitary
facilities, distribution units for site power supply, connections, etc.) with verified statics and a building
license application for the whole duration. This shall require the approval of the ordering party and of
the responsible authorities. One-off relocation of the construction site equipment shall be cost-
neutral.
- Provision of the necessary tools, gripping equipment, scaffolding and lifting devices
- Provision of welding, annealing and turning equipment, welding tents or, where appropriate, heat
accumulation chambers, provision of the required welding and inert gases as well as of the welding
fillers
- Provision of suitable pumps and acid baths for chemical cleaning
- Required tools and devices for insulating work
- Provision of power sub-distribution units and supply and routing of the power cables from the main
distributor to the sub-distribution units
- Provision of functioning fire extinguishers and first aid equipment in an adequate quantity and with
identification in accordance with applicable regulations
- Provision of air-conditioned office containers with phone, fax and internet connection, as well as
refrigerators, desks, a DIN A0 plotter, tables and chairs for the consultants of MBD and the site
management of the Client.
Routing of supply and discharge lines for water, waste water and compressed air from the site distribution
unit or the client-provided connection to the place of use or discharge.
The construction site equipment shall be erected only on the areas assigned for this purpose by the Client
(where appropriate after consultation with MBD). After the end of construction, the Contractor shall clear the
construction site and restore the original condition.
Provision of suitable means of transport (a teleloader is ideally suited for internal transport) shall form part of
the scope of work to be provided by the Contractor.
Large and bulky transport operations shall be agreed with the site manager and all necessary safety
precautions taken. In particular, load-carrying capability, bottlenecks, clearance heights of access routes
and safety distances from overhead power lines must be observed. Transport damage shall be reported
immediately and in writing to the site management by the party responsible for causing the damage.
It may be necessary to perform such transport operations outside normal working hours in order to make
sure that the rest of construction site operation is not disturbed. The Contractor shall be responsible for
closing off areas and organising diversions as well as ensuring protection of the other trades. Delivery of
materials and equipment shall take place during the working hours of the Contractor and shall be notified
to the site management.
The transfer of risk is defined in the contracts between the Client, Contractor and MBD, unless otherwise
agreed.
- Identity
- Quantity
- Dimensions
- Labelling
- Damage
- Material certificates
Deviations which are established in the incoming goods inspection, also in the case of deliveries from MBD,
must be notified immediately to the site manager of the Client and the responsible person at MBD in writing.
The incoming goods inspection shall take place on the basis of delivery notes, package lists and parts lists.
The incoming goods inspection must be documented at least on the package lists by ticking off and by the
signature of the inspecting person.
4.4 Storage
The Contractor shall store all materials properly and appropriately. Fittings, components and austenitic semi-
finished products must not be stored outside, but must be stored in a warehouse, for example. This must be
heatable if appropriate.
In the case of parts which are stored outside, suitable measures shall be taken to ensure that these parts do
not become contaminated and are sufficiently preserved.
Ferritic and austenitic semi-finished products shall be stored separately.
The storage facility must be lockable or guarded so that theft of material is not possible.
- Production of work folders containing all the necessary documentation for the individual assembly
sections. This includes drawings, isometric drawings, support drawings and support standards,
welding procedure specifications, assembly instructions for fittings, components, etc.
- Check of material availability,
- Check that construction area is free,
- Check that components are ready for connection,
- On-the-spot dimensional check. Deviations shall be entered visibly in the work folder drawings and
shall be taken into account in prefabrication and assembly. After definition of the order of assembly,
the persons responsible for work preparation shall define fitting lengths for the pipeline in the event
of pipe prefabrication (suitable separation of the pipes on the isometric production drawings). These
subsequently allow the prefabricated pipes to be adapted to the construction conditions. This may
include: position of the modules, pipe bridges, pipe supports, different trades (fire extinguishing
lines). The fitting lengths must be entered in the isometric production drawings.
- Availability of personnel and equipment
Assembly shall be started only after completion of the work folders and the necessary checks. Additional
costs which are caused during assembly by inadequate work preparation shall be borne by the Contractor.
Assembly may be started only after agreement of the assembly dates with the site manager.
However, the Contractor may start prefabrication of pipes and supports at his own risk. However, he shall
guarantee proper and appropriate intermediate storage himself.
- Identity
- Dimensions
- Materials
- Quantities
- Material certificates
The identification of the materials shall be preserved during processing. The identification shall normally be
transferred before processing if original material identification disappears during processing or if parts
without identification may be produced by separation. Transfer shall be performed so that assignment of the
material certificates to the components is possible in the same way as with the original identification, where
appropriate by means of a certificate produced for this purpose. Appropriate measures shall be taken to
ensure that mix-ups are not possible during transfer.
In the case of weld-on parts which are not pressurised, the identification shall be transferred only if the
material assignment is not clear from the drawing or parts list.
In the case of materials which are supplied with acceptance test certificate 3.1. in accordance with DIN EN
10204, transfer of the identification may be performed by the Contractor or supplier subject to a prior written
agreement with the responsible authority (marking transfer certificate). In this agreement, the works
employee responsible for transfer of the material identification is named and the personal mark used by him
defined. Exceptions are permitted in individual cases in non-EU countries subject to agreement between the
Contractor and Client/MBD.
The material identification shall be transferred and certified with the personal mark in the case of materials
which are supplied with acceptance test certificate 3.1 and which do not need providing with batch
identification in accordance with the technical delivery specifications (e.g. St 37.0).
The marking methods shall be chosen dependent on material and wall thickness so that product damage is
avoided and so that no pronounced notching or inadmissible deformation is caused.
Marking methods include, for example:
• Hard stamping, stamping with steel stamps (separate stamps for C-steel and stainless steel),
• Vibrograph,
• chloride-free grease pencils,
• electrical etching devices,
• Material
• Batch No. (possibly including material as short designation). Assignment to the material certificate
must be guaranteed by means of a marking transfer certificate.
• Stamp of the person authorised to perform marking transfer (personal stamp of the authorised
person).
The Project Manager and the principal staff must possess relevant experience and qualifications. The
Contractor reserves the right to reject the nomination of the Project Manager or individual principal members
of staff if there are important reasons for this.
An organisation chart for execution of the order which names all responsible employees shall be handed
over to the Client within 15 days of the order coming into force . All persons named here must possess
relevant experience and qualifications. If other companies are involved in order execution, the cooperation
between all parties involved, including tasks and interfaces, shall be defined. Use of sub-contractors by the
Contractor shall be listed by the Contractor corresponding to the specific trades, and this list shall be
submitted to the Client and approved by the latter.
If MBD is not identical with the Client, MBD shall receive all the necessary organisational information from
the Client.
This shall also include ventilation and extraction systems for working in confined spaces and lighting systems
for assembly work.
Equipment and tools which are subject to mandatory inspection shall be inspected and marked in
accordance with the relevant regulations. These inspections must be recorded, and the records must be
available for viewing on the construction site. Equipment which has not been inspected or which is not
clearly marked shall not be used. Use of tools and equipment which have not been inspected, which are
faulty, or for which the inspection periods have expired is prohibited.
The Contractor shall be liable for any damage or losses caused by violation of this prohibition of use.
Tools for processing ferritic and austenitic materials shall be clearly identified and shall be used only for the
intended material.
Lifting slings, wire ropes and other load suspension devices are also subject to recurring inspections. They
must be marked correspondingly. Use of lifting slings, wire ropes and other load suspension devices which
are damaged, for which the inspection period has expired or which have not been inspected is prohibited.
The Contractor shall be liable for any damage or losses caused by violation of the above prohibition of use.
Forming gases and welding gases which are not clearly identified must not be used and must be removed
immediately from the construction site.
Transport of forming and welding gases shall be performed only using the means of transport intended for
this purpose.
In particular, gas cylinders shall be protected against strong heat irradation (also sunlight), and standing gas
cylinders shall be secured to prevent them from falling over. Storage or leaving of compressed gas cylinders
after the end of work or transport of propane gas cylinders into working areas under ground level is
prohibited. Use without the corresponding safety equipment for oxy-fuel and propane apparatus is prohibited;
this safety equipment is subject to legal inspection periods.
The use of porous hoses is generally prohibited.
The valves on the gas cylinders shall be closed during working breaks and at the end of work and use by
third parties shall be prevented; the hoses shall be removed from confined spaces in the case of working
breaks.
Cutting wheels for C-steels and carbon steels shall be stored separately and may be used only for the
intended steels. Cutting wheels for stainless steels must not contain chlorides.
Erected scaffolds may be used by other suppliers after consultation with the Contractor’s site manager,
whereby all personnel must convince themselves that the scaffolding is in a proper state before
commencing work.
Unauthorised modifications to scaffolds by the user are prohibited, and use of scaffolds must be prevented
if they are defective.
The period and place of installation shall be agreed with the site manager before scaffolding is erected.
Assembly openings and provisional openings in platforms and scaffolds which are produced for assembly
operations shall be secured. Bar grates shall be secured again properly after the openings are closed.
No load suspension devices shall be attached to hand wheels, spindles, drives, shafts or similar sensitive
elements on fittings, pumps or similar components being assembled.
Attachment of load suspension devices to existing components or equipment for assembly purposes or
transport of heavy single loads via platforms is prohibited.
When performing welding work, care shall be taken to ensure that dashpots, resilient supports, fitting
components, pumps or other components with narrow clearances are not in the current flow, otherwise they
may be destroyed. The ground connection shall be connected at a distance of max. 1 m from the welding
location. The Client shall provide works grounding.
Connection of pipes to vessels, storage tanks and sensitive components such as pumps, heat exchangers,
recoolers, etc. shall take place in compliance with the specifications of the component suppliers. In
compliance with these specifications, pipes shall be connected load-free in the case of free-lying, balanced
pipe ends. A joint record of connection shall be produced by the Contractor and Client. In the case of vessel
and storage tank connections, it is recommended to perform connection only after their pressure test. The
cleanliness of pipes shall be checked in accordance with the specifications of MBD before assembly or
connection to components.
The Contractor shall make sure that the areas and equipment used by him are cleared up and that escape
routes are kept free during assembly work and before leaving the assembly locations or construction site.
Any rubble and scrap which is produced shall be removed and the plant must be kept in a condition which
excludes the risk of accidents.
The applicable safety regulations shall be observed when accessing closed systems or tanks
(ventilation/forced ventilation, provisional lighting, etc.).
If there are contradictions in the content of the available documents, the Contractor shall be responsible for
technical clarification with MBD or the Client.
The specifications of VDMA standard VDMA 24277, currently draft 2001-01, shall apply generally to
component connections.
Entry and exit pipes can transfer considerable forces and moments to components. The most important
causes of such loads are as follows:
Pipes can also cause considerable stress loads if provisional pipe supports are used at locations other than
the final positions during assembly. As a consequence of this, changed weight distributions and changed
bending lines of the pipe occur when the final pipe supports are installed, and this may cause “tilting” of the
flange at the component. Provisional holders and supports must therefore be avoided.
Inadmissible loading at the component connections leads to loading of the component parts where force
transfer takes place and this in turn causes deformation. Component parts which are particularly subjected
to loading include, for example:
- Connecting flanges
- Casing parts
- Casing feet and their screw connections
- Support feet and their screw connections
- Bearing casings
- Shaft ends and bearings (as a result of restoring forces of coupling)
- Radial shaft (coupling) displacement; this results in an increase in the vibration amplitude and
possibly damage to bearings, shaft seal and shaft.
- Radial impeller displacement; this causes a risk of scraping
- Misalignment of the elastic coupling, thus causing coupling wear and reducing its service life
When assembling pipes, assembly should take place towards the connection socket of the respective
component. Pipes shall be assembled stress-relieved towards the component; this shall also apply to flange
connection of blank disks.
Connections at the engine are made by means of bellows expansion joints, which must not be used to
compensate for assembly tolerances. Connections to all other components are rigid.
Stress-relieved connection of the pipes shall take place after cleaning the pipes and performing a pressure
test of the pipe line.
The following work and checks shall be performed before stress relieving the pipe line:
- All pipe supports shall be checked to make sure that they are present and are realised properly in
accordance with their intended function.
- An alignment check shall be performed before the pipes are undone at the component. The
alignment values must be recorded.
- In the case of pumps, all entry and exit lines which have not already been assembled by the pump
manufacturer (such as auxiliary pipes) shall be undone at the pump and a check made to ensure
that any blanks in these pipes have been removed. When removing the blank disks, it must be
ensured that no dirt or foreign matter can enter the pump or the pipes.
- All protecting covers on the pipe connections of the components or the corresponding plant parts
shall be removed carefully. It must be ensured that no contamination or foreign matter can fall into
the component. After removing the protecting cover, a check must be made to ensure that all foreign
matter has been removed.
- A check must be made to ensure that the prescribed seals have been installed in the pipes and, in
the case of pumps, to make sure that the prescribed strainer has been correctly installed in the entry
line.
The pipes are stress relieved by straightening the pipe (e.g. heating) until plane-parallelism is achieved
between the pipe flange and component flange and, in the case of pumps, until the coupling alignment is
in the permitted range. It shall be ensured that the flange sealing surface is not made uneven as a result
of heating the pipe close to the flange.
Heat treatments such as stress relief annealing, for example, shall be performed only on a material-specific
basis in accordance with process instructions approved by the Client. Distortion and impairment of
mechanically required bright surfaces shall be avoided.
Plane-parallelism
The gap between the sealing surfaces of flanges shall be checked with respect to plane-parallelism using
a feeler gauge with the flange undone.
The maximum permitted tolerance (S 2 – S 1) measured over the whole flange diameter (see Figure 2) is:
The distance S 3 (see Figure 3) between the flanges shall correspond to the seal thickness +1.0 mm.
Lateral offset
The lateral offset of the flanges must be so small (see Figure 4) that the threaded pins can be installed
without force in the holes which are defined in accordance with the standard for nominal pressure and
nominal diameter. The lateral offset S 4 shall be a maximum of 0.5 mm.
Threaded holes
The threaded holes shall be arranged in accordance with DIN 2501, Sheet 1 with a permissible rotational
misalignment measured at the hole circle of < 0.5 mm.
Other work
After completing the work described above, the next steps are as follows:
- In the case of pumps, the first pipe must then be connected securely and the change in coupling
alignment checked.
- If necessary, the pipe must be straightened until the permissible values for coupling alignment and
plane-parallelism of the flanges are achieved.
- This stress-relieved pipe must now be undone again.
- As described above, all pipes must be stress-relieved at the components one after the other.
- In the case of pumps, it is recommended to check their alignment once more at the defined
maximum working temperature.
- After completion of the work and checking, an alignment record shall be produced by the Contractor,
signed together with the site manager of the Client and handed over to the latter.
When all pipes have been stress-relieved (also large auxiliary pipes), the following final inspection must
be performed:
- Check the alignment of the pump with the pipe undone and the pump securely bolted onto the
foundation or base plate.
- Check the alignment of the pump with connected pipes and undone pump foot screw.
- Determine the alignment difference and observe the permissible alignment tolerances for the
type and size of the pump and coupling.
- The alignment is correct if the pump can be moved easily into the "required" position without
resistance.
- Realignment by correcting the pipe must be performed if the pump cannot be moved into the
"required" position without resistance.
• Layout/foundation plan
• Equipment location plan
• Pipeline installation plan
• Additional steel structure plan
• Pipe isometric drawing
• System isometric drawing
• Pipe support plan
• Support location plan
• P+I Diagrams
• Material take off (MTO)
Unavoidable deviations occur between the planning documents and the real measurements as a result of
existing building tolerances as well as tolerances in assembly of equipment or components or in the
equipment itself. Experience shows that these tolerances can frequently amount to up to +/-100 mm in
different directions in spite of careful planning.
It is therefore the task and part of the scope of performance of the Contractor to plan fitting lengths in the
planning documents and to take these into account in production. The resultant costs are not additional costs
which must be borne by the Client or MBD.
Pipe support assembly normally precedes pipe assembly. Provisional support of pipes is permitted only in
exceptional cases and subject to the full responsibility of the Contractor. Otherwise, the following points shall
be observed under all circumstances in accordance with the specifications.
• Location (coordinates x, y, z)
• Dimensions
• Support functions
• Check of spans
Static dimensioning of the pipe support structures, delivery, production and assembly shall be performed by
the Contractor. MBD shall specify the support function and the pipe loads on the support in the planning
documents.
If deviations (structural tolerances, dimensional tolerances of components and modules, etc.) are established
during work preparation, then these deviations shall be transferred as “red” entries to the specification
documents and taken into account in production and assembly after consultation with the Client and
approval. MBD shall be notified in writing about deviations by means of the attached Deficiency Report.
The manufacturer’s assembly instructions shall be observed with respect to screw connection systems. Also
refer to the section “Screw-connected pipes”
Pipe supports on the engine shall be produced on the spot corresponding to the local conditions, as planning
of these would be too complex and not adequately possible.
Pipes with sizes down to DN 10 are largely planned; small pipes < DN25 shall be considered only as an aid
to planning, however. Execution of these pipes and their supports shall therefore be performed by the
Contractor on the basis of the P+IDs.
Small pipes (< DN25) and tracing type heating which is to be planned and assembled by the Contractor on
site shall take into account the following:
and
• Free support (complete without bracket)
4.17 Spans
The permitted spans for support structures for pipes which are not included in the plans shall be realised in
accordance with AD2000. The following diagram provides reference values:
100
1
10 100 1000
d(i)
Figure 17: Guide values for the maximum permissible pipe span L as a function of the pipe design
and internal steel pipe diameter d(i)
Source: Vogel Fachbuch – Kamprath Reihe, Walter Wagner Rohrleitungstechnik, 8th edition, 2000
• No stressing of the component/diesel generator set must be caused (stress-free expansion joint
installation!)
• Test points must be chosen before and after the elastic pipe connection!
• The elastic pipe connections must be installed in the horizontal plane in the case of pipes from
and to the elastically mounted diesel generator set.
Steel expansion bellows are primarily installed in exhaust gas and charge air pipes. Hoses are used only
for small pipe diameters. The thermal expansion of a steel pipe as a function of material and temperature
is shown in the diagram Thermal Expansion (Figure 18).
If not otherwise specified, bellows expansion joints or expansion compensators must be installed with
50% prestress.
Thermal Expansion
14
12
10
Thermal expansion
[mm/m]
0
0 100 200 300 400 500 600
Temperature [°C]
AlMg3 X10CrNiMoTi1810(1.4571)
X10CrNiTi189 (1.4541) X8CrNiMoVNb1613 (1.4988)
St35.8 St45.8 15Mo3 13 CrMo44
If steel or rubber expansion bellows are installed in pressure systems, fixed bearings on both sides of the
expansion bellows must absorb the thrust forces resulting from the internal pressure.
Prestress
Operating state
Linear expansion
Prestress
Operating state
Linear expansion
Prestress
Operating state
4.19 Hoses
General guidelines for routing hoses
A number of basic rules must be observed when routing hoses in order to guarantee or maintain proper
functioning of the hoses, i.e. attention should be paid to easy installation and removal, optimum route
selection and the possibility of continuous monitoring in order to minimise related problems.
It is naturally not possible to show all the possible cases of wrong or correct installation by way of examples.
Special tests may be necessary before hose selection in the case of exceptional applications.
Practical information
The outer sheath of the hose offers the best protection against abrasion. However, the corresponding limits
must be observed here as well. Continuous abrasion at one point can gradually cause wear of the sheath
and lead to premature destruction of the hose.
If abrasion of the hose is unavoidable, suitable protection must be provided (abrasion protection coil).
Various designs can be found in our catalogue.
The manufacturing tolerances permitted in hose production may occasionally lead to the length of hoses
changing slightly under pressure. Such length changes are compensated by the required hose slack or bent
installation.
A hose should never be supported in such a way that it is squeezed through the fixing clamps as a result of
length changes under load. If a support is necessary for a long hose, the support points should only guide
the hose and a tension spring at the end of the hose (or at the hose bend in the case of a change in
direction) should always return the hose to its initial position.
A hose should never be fixed at the hose bend, because this is the best place to compensate for any change
in length.
Vibrations
If the hose is exposed to vibrations, it is best to route the hose so that the connections are not exactly in the
direction of the vibrations but at an angle to them.
Appearance
Good functioning and proper routing of hoses go hand-in-hand. Observing the following criteria will result in
hose installation which is both tidy and beneficial for hose operation:
Temperature
High outside temperatures can considerably reduce the service life of hoses. For this reason, it is expedient
to route hoses so that they are sufficiently far away from components which radiate heat (exhaust, etc.).
A protective shield can be installed if this is not possible.
Storage
Hose reels and hoses must be stored in a cool, dry place away from sunlight. Electrical devices which
produce ozone as a result of spark formation should not be used in the storage room if possible.
15 1x8
20 1x8
25 1 x 10
32 1 x 10 30
40 1 x 15
50 1 x 15
65 1 x 15 40
80 1 x 15
100 2 x 15 50
125 2 x 15 60
150 3 x 15 70
200 3 x 15
with two wires pulled tight in each case. It must be possible to slide the tracing pipes under the wires at all
other fixing points (sliding bearings).
In theory, the tracing pipe has line contact, but in practice it lifts off the pipe to be heated between the fixing
points so that heat transfer is unfavourable. For this reason, several tracing pipes must be installed for large
pipe diameters.
Heating of fittings
Fittings are heated by appropriately shaped pipe coils which differ corresponding to the housing shape of the
fittings and installation position.
The tracing type heating pipe should be routed at the side and not underneath when installed close to a main
line with flanges, otherwise pockets form which have to be drained. See Figure 20.
No top coat is applied to pipes with tracing type heating. The pipes are only primed.
Legend
4 Cutting and taper ring
5 Internal taper
1 Union nut 6 Visible collar
2 Stop 7 Marking
3 Pipe
Deburring H = Height of union nut (1)
2H = Minimum distance of a pipe bend
R = Bending radius
D = Outside diameter
Work sequence
2. Oil the thread and the cutting and taper ring (4) well (do not grease).
Then push the nut and ring over the pipe end as shown.
If the cutting and taper ring cannot be pushed over the pipe end or if
this is possible only with difficulty, file the pipe end so that it is
thinner.
Note: It must be ensured that each pipe end enters the same internal
taper again in which pre-assembly took place.
5. After final tightening, loosen the union nut and check whether a
thrown-up, visible collar (6) fills the space in front of the cutting edge;
if this is not the case tighten again briefly. It does not matter if the
cutting and taper ring can be turned on the pipe end.
Note: The straight pipe end projecting into the bolted joint must have
Pre-assembly in vice a minimum length of 2 times the height (H) of the union nut.
It is necessary to fit pipe supports in the case of long pipes or pipes
subject to high loads. A bending fixture with interchangeable rollers
is recommended for bending steel and copper pipes (see Figure).
The bending radius R must not be less than twice the outside pipe
diameter
(R ≧ 2 D).
Check
Figure 21: Designation of a stiffing sleeve made of CuZn35Ni for Cu pipe 12x1
Stiffing sleeve R512 – 12x1 – CuZn35Ni2
Standard short
Ermeto order
Connecting pipe D4 D3 L1 code
code
R512-
14x1
11.8 10.2 17.0 VH12MSX 14x1-CuZn35Ni2
15x1.5
Figure 22: Weld nipple for bore form in accordance with DIN 3861 – Form K. Dimensions in mm
Designation of a weld nipple Form K with D = 10 and pipe wall thickness s = 1.5
Weld nipple R 502 – K 10 x 1,5, Material: St35.4 NBK
Standard
Pipe outside Pipe
D1 s L L1 O ring desig.
diameter [D] diameter
R 502-
16 12 2 40.5 39 13 x 2 16 x 2 K 16 x 2
20 16 2 47 45 16.3 x 2.4 20 x 2 K 20 x 2
20 14 3 47 45 16.3 x 2.4 20 x 3 K 20 x 3
30 24 3 57 52 25.3 x 2.4 30 x 3 K 30 x 3
30 20 5 57 52 25.3 x 2.4 30 x 5 K 30 x 5
Table 4: Dimensions in mm
C-steel
- Tungsten inert gas welding (TIG welding) as manual welding or orbital welding
- Manual arc welding, only in combination with TIG welding (root run)
- Submerged arc welding (in production), only in combination with TIG welding (root run)
Stainless steel
- Tungsten inert gas welding (TIG welding) as hand welding or orbital welding
- Manual arc welding, only in combination with TIG welding (root run)
- Submerged arc welding with strip electrode (in production), only in combination with TIG welding
(root run)
The following welding procedures are approved for welding pipe supports (steel construction):
Valid reports on acceptance of the welding procedure (WPAR) in accordance with DIN EN 288 and AD 2000
Code must be available for all welding procedures.
The welding fillers or the combination of welding fillers must be tested and certified by an independent test
body. They must be ordered with works certificate “3.1 in accordance with DIN EN 10204” or equivalent.
X-seam
2.3.3 t > 10.0 mm asymmetrical
(e.g. ⅓-⅔)
*recommended workpiece thickness, which may vary in accordance with DIN EN 29692 upon recognition of
the welding procedure of the Contractor.
The following weld seam preparation procedures are approved for welding pipe supports (steel construction)
(DIN EN 26692):
Fillet weld
3.10A t1, t2 > 2.0 mm
(T-joint)
Fillet weld
3.10B t1, t2 > 2.0 mm
(lap joint)
4.10.10 C t1, t2 > 2.00 mm Double fillet weld
4.25 Welding
Basic information
Before the start of assembly, corresponding agreements shall be reached between the Client and Contractor
as to which work approval procedures are necessary for performing hot work.
It is prohibited in all cases to perform welding work in the direct proximity of objects with a fire risk. If hot work
cannot be avoided, the fire risk shall be eliminated, suitable protective measures organised and suitable fire
extinguishing agents provided in a sufficient quantity.
In the case of bad weather such as wind and rain, the welding area must be protected against these
influences by protective measures such as tarpaulins or tents. In the case of temperatures below + 5°C,
conditions with high air humidity and rain, the weld seam areas must be preheated to approx. 50 °C.
(min. 20 x wall thickness on both seam sides).
Valid welding procedure specifications (WPS) which individually specify the required variables (current,
polarity, inert and forming gases, welding fillers, base materials, etc.) shall be available to the welding
personnel and shall be observed by them when carrying out welding work.
Tacks outside the weld seam are not permitted. This also applies to ignition points. If ignition points should
be found outside the weld seam, these shall be removed completely and without cracks by surface grinding.
After welding, any welding splashes shall be removed from the pipes and pipe supports.
The minimum distance between circular seams shall be at least 50 mm for wall thicknesses below 5 mm,
and shall otherwise be 10 x wall thickness. Welding in the bending zone of pipe bends is not permitted.
No cross joints of the weld seams are permitted on welded pipes and form pieces (welded segment bends).
The minimum distance between longitudinal seams shall be 10 x wall thickness.
Load-absorbing weld-on parts must be a minimum distance away from longitudinal and circular seams of at
least 5 t (t= component thickness of weld-on part).
If load-absorbing weld-on parts are to be attached to pipes with large nominal diameters and small wall
thicknesses, these must not be welded directly on to the pipe. Large-area load distribution plates shall be
welded on in this case in order to achieve better load distribution and to minimise stressing. The required
distance from longitudinal and circular seams shall be observed for these load distribution plates as well.
The form of the load distribution plates must be adapted to the pipe (saddle) and the plates must be welded
all round. Sufficient ventilation holes must be produced in the load distribution plate so that the air between
the pipe and load distribution plate can escape during welding.
Adaptation to different wall thicknesses shall take place on the thicker component. The thicker component
shall be adapted to the dimension of the thinner component by grinding or another suitable mechanical
process at an angle of ≤ 10° (see Figure 23).
Welding work
Welding shall take place in accordance with the approved welding procedure and in observance of the
parameters of the welding procedure specification. The specifications from the sections “Qualifications of
welding personnel (welding supervisor and welders)" to "Welding quality requirements” shall be observed.
All root runs of all pipes in a system shall be realised as TIG roots.
Weld seams on pressure-carrying parts shall be realised so that they correspond to Assessment group B in
accordance with DIN EN ISO 5817 with respect to their external characteristics.
In deviation from this, Assessment group C in accordance with DIN EN ISO 5817 shall be sufficient for the
following imperfections:
• Undercut, Classification No. in accordance with ISO 6520-1: 5011/5012 (continuous not
permitted; this also applies to fillet welds)
• Excessive weld convexity (fillet welds)
Classification No. in accordance with ISO 6520-1: 502
• Excessive root convexity (fillet welds)
Classification No. in accordance with ISO 6520-1: 504/504f
• Edge offset h for circular seams welded on both sides, Classification No. in accordance
with ISO 6520-1: 507/5072
• Underfill (in the case of TIG orbital welding without welding filler, underfill/root reinforcement
are permitted to the following extent in the 12 o’clock position and root concavity/overfill in the
6 o’clock position of welding position PF, PG: h<= 0.2t+0.12b, max 0.6 mm (t= wall thickness,
b= seam width, h= underfill/overfill); Classification No. in accordance with ISO 6520-1: 511
• Excessive unequality of fillet welds, Classification No. in accordance with ISO 6520-1: 512
• Root concavity, Classification No. in accordance with ISO 6520-1: 515
• The weld seam number must be entered by hand on the pipe isometric drawing as a “BLUE
ENTRY” (as-built entries are made in RED)
• Welder number (personal identification of welder)
• Zero point and counting direction for non-destructive material testing.
4.27 Inspection and test scope on weld seams and pipe bends
The scope of inspection and testing on weld seams and pipe bends shall comply with the stipulations of
AD2000 Code HP5.3. Reduction of inspection and testing as described here is possible. The Contractor
shall notify this to the Client. The latter shall have a right of objection.
Figure 24: Example, Extract from Overview Table 1, for AD2000, HP0, material group
Art und Umfang der zerstörungsfreien Prüfung
und Prüf-
klasse
Schweißen
% mm % % % mm % mm %
1 2 6 7 8 17 18 19 20 21 22 23 24
Stähle innerhalb ≤ 30 100 12) 100 25 13) ≤ 30 D(A) oder US(A) 17)
1 der folgenden U 100 > 30 ≤ 38 10) 100 100 25 10 18)
Analysengruppen >38 ≤ 50 10)
100 100 25 > 30 ≤ 60 D(B) oder 10 18)
(Schmelzenanalyse) US(B)
mit einer Mindest-
streckgrenze ≤ 30 100 12) 100 25 12) >60 ≤ 90 US(B) 17)
<370N/mm29), W 100 > 30 ≤ 50 100 12) 100 25 12 ) 10 18)
ausgenommen kalt- > 50 100 100 25 > 90 US(C) 19)
zähe Stähle, wenn sie 10 19)
nach AD 2000-
Merkblatt W 10 im
Beanspruchungsfall I 13)
U, W 85 ≤ 15 2 14) 2 13) 17) Stutzen- und
unter –10 °C ver- 17)
>15 ≤ 30 10 16) 100 16) 2 13) Kehlnähte
wendet werden
sind einer
Oberflächen-
C ≤ 0,22 ≤ 0,20 prüfung (MP,
Si ≤ 0,50 ≤ 0,50 FE) zu
Mn ≤ 1,6 ≤ 0,8 unterziehen.
Mo - ≤ 0,65 Bei Stutzen
P,S je ≤ 0,05 je ≤ 0,05 mit Innen- >50 10
sonst durchmesser
MP
insges. ≤ 0,8 ≤ 0,5 ≥ 120 mm
sonst und einer
einzeln ≤ 0,3 ≤ 0,3 Dicke des
Anschluß-
querschnittes
über 15 mm
ist zusätzlich
eine
Ultraschall-
oder
Durchstrahl-
ungs-
prüfung
durch-
zuführen.
All weld seams shall be subjected to a 100 % visual inspection in accordance with DIN EN 970 by the
Contractor’s welding supervisor.
Recognisable and tolerable surface flaws shall be removed by surface grinding. Larger surface flaws and
surface flaws which cannot be tolerated shall require repair or rewelding of the seam. Before the repair or
rewelding of the seam is initiated, one of the following non-destructive tests should be performed additionally,
depending on suitability: PT, MT, RT, UT
Penetrant testing (PT)
Penetrant testing shall take place in accordance with DIN EN 571-1 and DIN EN 1289 in conjunction with
DIN EN 12062. Assessment of imperfections shall take place in accordance with the above-mentioned
assessment groups. The test personnel must be qualified and certified in accordance with DIN EN 473.
A record of the test result shall be produced and included in the documentation.
Magnetic particle testing (MT)
Magnetic particle testing shall take place in accordance with DIN EN 1290 and DIN EN 1291 in conjunction
with DIN EN 12062. Assessment of imperfections shall take place in accordance with the above-mentioned
assessment groups.The test personnel must be qualified and certified in accordance with DIN EN 473.
A record of the test result shall be produced and included in the documentation.
Radiographic testing (RT)
Radiographic testing shall take place in accordance with DIN EN 444 and DIN EN 1435 in conjunction with
DIN EN 12517. Assessment of imperfections shall take place in accordance with the above-mentioned
assessment groups.The test personnel must be qualified and certified in accordance with DIN EN 473.
A record of the test result shall be produced and included in the documentation.
Ultrasonic testing (UT)
Ultrasonic testing shall take place in accordance with DIN EN 1714 and DIN EN 1712. Assessment of
imperfections shall take place in accordance with the above-mentioned assessment groups. The test
personnel must be qualified and certified in accordance with DIN EN 473. A record of the test result shall
be produced and included in the documentation.
4.30 Cleaning
Cleaning of the plant pipes depends on the transported medium and on the installation location of the
respective pipe.
- Pipes without filter in the circuit are the pipes in the following systems:
- Water
- Steam/condensate and thermal oil
- Working air
- Control air
- Tank ventilation and sludge
- Lube oil (upstream of filter and downstream of engine)
- Fuel (upstream of filter and downstream of engine)
a) A precondition for omitting chemical cleaning of pipes without filter in the circuit is that the
pipe is clean inside and not rusted when it is visually inspected; standard parts (T-pieces)
must have been used for outlets. In the case of outlets with threaded sockets, sleeves, etc.,
the required holes must have been drilled, then deburred (not burnt out) and the root run
produced using the TIG procedure. Random checks of the condition of the inner pipe walls
(particularly the weld seams) shall be made before final sealing and filling of the pipes.
b) If the preconditions of a.) are not met, the pipes shall be cleaned chemically before final
assembly (except water, tank ventilation and sludge)
Pipes downstream of the filter and upstream of the engine in the lube oil and fuel system must be chemically
cleaned. These pipes must be divided so that the respective individual sections can be viewed completely
and can be mechanically cleaned. The condition of the inside pipes must be checked visually immediately
before they are sealed and filled to ensure that they are in perfect condition. Otherwise they must not be
assembled.
If stainless steel pipes are used in this area, it is possible to dispense with complete chemical cleaning
subject to observance of the following boundary conditions:
The starting air pipe does not have a filter. Since scale cannot be completely avoided during welding (also
TIG welding), there are two methods which can be used for cleaning the starting air pipes and their
connecting pipes:
a) connected with Ermeto coupling – without strainer before the starting air bottle
b) welded – with strainer before the starting air bottle
If there is a long period between cleaning and installation (replacement pipe), the pipes shall be preserved
and sealed at the ends. Sealing plugs or caps made of plastic in conspicuous colours are best used for this
task as they cannot be overseen. An exception to this applies in the case of the starting air pipes (30 bar), as
these must not be preserved with anti-corrosion oils due to the risk of explosion. Other suitable preservation
measures must be taken. A further possibility is to clean the pipes only shortly before engine commissioning.
All other pipes shall be subjected to a visual inspection before use and all signs of rust removed.
Shut-off and control elements and other devices in the individual systems shall be installed only after
cleaning.
Only completely dry, fine-grain sand may be used for pipes which are filled with sand for warm bending.
There is a risk of accident as a result of steam formation in the case of damp sand.
If possible, the pickling tank should be set up outside, since the acid is aggressive and attacks objects. If the
acid treatment is performed in a closed room, then there must be sufficient air ventilation with an extraction
system.
It must be ensured that the pickling tank has sufficient resistance to the pickling bath.
The applicable work safety regulations and environmental regulations shall be observed.
• Use acid-proof suits, rubber boots, rubber gloves and protective goggles.
• Have a connected water hose ready.
• Avoid naked flames and lights.
• Observe environmental safety regulations for working with acid.
Steel pipes must be treated in a hydrochloric acid or sulphuric acid bath. Hydrochloric acid (HCI) is available
commercially with a concentration of approx. 30 % and less than 0.1 % arsenic.
Caution! Pour acid into water and not the other way round!
The bath temperature should not be below 20°C and also not considerably above this temperature. The
treatment duration is 1-1.5 hours depending on the concentration and condition of the bath. A longer duration
is necessary as the bath ages.
The pipe sections must be laid down in the bath or stood in the bath vertically and filled with acid. After the
acid treatment, the pipes must be rinsed well with water, hosed out and placed in the neutralisation bath or
filled with neutralisation solution.
Note: In the case of pipes with taper-cut threads, make sure that the thread points are not
attacked (reduce treatment duration correspondingly).
Copper pipes must be treated in a sulphuric acid bath. Sulphuric acid (H2SO4) is commercially available with
a concentration of 60 % and can be transported in closed iron containers. Sulphuric acid attacks iron and
copper only in conjunction with water, and practically not at all in concentrated form.
Caution! Pour acid into water and not the other way round!
The prepared acid bath should be left for 24 hours before use. The treatment duration is ¼ hour at the start
for copper pipes and correspondingly longer as the acid bath ages. After removing the pipes from the bath,
they must be rinsed well with water and dried with a mild flame. The copper pipes can be scoured with sand
in order to obtain a bright surface. The cleaning speed can be increased in exceptional cases by heating the
acid bath or the pipes.
Neutralisation bath
Steel pipes must be placed in a neutralisation bath after acid treatment and after rinsing thoroughly with
water. This neutralises all acid residue from the fine pores of the surface as well and makes the surface less
susceptible to corrosion. However, the effect of the phosphate coating is not unlimited. Normally, a trisodium
phosphate bath is used.
The bath temperature should be between 60 and 80 °C, whereby steam is normally used for heating. The
vapours produced must be able to escape safely.
Tongs must be used for placing pipes in the bath and removing them because gloves will be destroyed by
the heat. After treatment, the pipes must be dried and the lye in the pipes must be evaporated quickly,
possibly by warming with a burner.
A neutralisation bath (phosphating) is not absolutely essential for copper pipes, but is recommended to
prevent formation of verdigris if the pipes are to be stored for a long time.
Flushing
Before flushing, all systems must be checked for foreign objects (tools, cleaning rags, caps, blank disks,..)
and any objects found removed.
The installed service pumps are used for the flushing operation. The pumps must be commissioned properly
before they are started up (check direction of rotation!). The manufacturer's instructions and the MAN
document D36 5688 must be observed for this purpose.
Lube oil
Experience shows that it is not possible to remove all assembly dirt without flushing, even in the case of
careful handling.
The lube oil system must therefore be flushed thoroughly before a new engine is put into operation.
The lube oil service tank must be checked before flushing to ensure that it is clean, and the tank must be
cleaned manually if necessary.
Flushing oil
The original fresh oil is used for flushing; this must then be carefully cleaned by means of filters during and
after flushing. The system must be heated so that a viscosity of <70mm²/s = cSt (<9E) is reached.
Flushing operation
The flushing operation is divided into individual phases which are designed so that first only the pipe system
outside the engine is flushed and only then the overall system with all engine bearings.
The following work steps are required for the first flushing phase:
The following work steps are required for the second flushing phase:
• Close off the oil supply to the turbocharger with a blank disk
• After the first flushing phase, flush the engine as well, but blank off the oil supply bores to the
engine bearings.
• Heat the cooling water to approx. 40 °C (see first flushing phase).
• Observe the increase in differential pressure and flushing interval of the automatic filter and
monitor the differential pressure at the running-in filter. In the event of an increase in pressure,
shut down the system and clean the filters.
• The second flushing phase must also be continued until there is no longer any recognisable
filter soiling but for a minimum of 24 hours.
The following work steps are required for the third flushing phase:
Note: Make sure that no cleaning rags or tools are left in the oil chambers.
Fuel system
The pipes between the flushing filter to be installed directly upstream of the engine and the engine intake are
subject to the same regulations as the above-described lube oil pipes.
The ring pipe systems for diesel and heavy fuel oil and the main fuel system must also be flushed in two
steps in order to be able to remove all assembly dirt from the pipes.
Gas oil or diesel oil must be used for this purpose.
The whole pipe system is flushed via the corresponding filters in this operation.
The automatic filter and the viscosity control system must be bypassed by means of their bypass pipes.
The oil flow is returned to the service tank for heavy fuel oil via the flushing pipe by switching the 3-way cock
upstream of the mixing tank. The tank must not yet contain any heavy fuel oil for this purpose. In this case,
the three-way cock for fuel selection can be switched to supply from this tank after filling the system with
diesel oil and gas oil and return of a sufficient oil quantity to the service tank. Diesel or gas oil is then
pumped round the whole system.
The flushing operation must be performed as described in the section on “Lube oil”.
This flushing operation must be performed under the supervision of MBD personnel.
The overall system is flushed here, including the automatic filter and viscosity control system.
The flushing operation must be continued until only small differential pressures build up in the filters.
After completion of flushing, all filter elements must be cleaned and checked for any damage. The engine
must then be connected to the fuel circuit.
The end preheater, filter chamber and mixing tank must be de-sludged through their drain pipes.
Before the engine and injection valve cooling system is put into operation, it must be ensured that the
surfaces which come into contact with the cooling water are free of rust and other deposits.
If signs of rust are found, the system must be cleaned in accordance with work cards D36 5600/000.08-1
and D36 5600/000.16-1.
Before the engine is put into operation, the cooling water system must be flushed with fresh water after
installation of the supplied flushing strainers. A cleaning agent must be added to the water so that all residue
of the preserving agent can be removed. The table below lists some of the suitable agents in alphabetical
order. Cleaning agents from other manufacturers can be used if they have similar properties. The system
must be flushed again with untreated fresh water after cleaning.
Provisional installation of dirt traps is essential to filter out coarse dirt particles. The mesh size must be
≤ 1 mm for the high and low temperature systems.
The smallest gap in the injection valve is 0.5 mm. Provisional installation of a dirt trap with a mesh size of
≤ 0.4 mm is necessary for flushing the cooling water system of the injection valves in order to prevent dirt
deposits here and thus avoid reduced heat dissipation.
Water is prevented from escaping by installing two gate valves in each case when cleaning and removing
the dirt traps.
After flushing, the fresh water must be prepared in accordance with the quality requirements for cooling
water D36 5600 / 1.41-1.
The whole system must be cleaned carefully before the engine is put into operation. All pressure and control
pipes must be free from slag, scale and rust on the inside. For this purpose, the pipe must be disconnected
from the main starting valve and the exposed engine intake closed off. The control air pipe upstream of the
engine must also be removed.
The air pipes are cleaned by blowing through 3 to 4 times with the air of the starting tanks compressed to
30 bar.
Ear protection must be worn when cleaning the pressure air system, and the area to be cleaned must be
cordoned off to prevent access by other persons. All national regulations and standards, particularly those
relating to work safety, shall be observed (e.g. accident prevention regulations, etc.).
All dismantled pipes must be connected again after cleaning.
The dowel holes must be produced only with hammer drills and normal drills. It is not permitted to cut
through the reinforcement.
The following conditions must be observed correspondingly in the case of dowel anchors:
- Axis spacing
- Edge spacing
- Component thickness
- Minimum spacing
- Drill hole diameter
- Drill hole depth
4.34 Insulation
If the insulating material should be supplied by MBD, refer to the manufacturer’s specifications and the
instructions provided for the supplied material.
Guidelines in accordance with the insulating instructions can be used as reference for general realisation
of the insulation.
A simple perforated plate or insulating material or similar can be used for touch protection. The realisation
and type of protection shall be agreed between the Contractor and Client corresponding to the local
circumstances or in accordance with the contractual conditions.
The Contractor shall dispose of the waste produced from his scope of performance properly, in accordance
with the legal regulations and at his own cost. Suitable receptacles such as containers, barrels, skips etc.
shall be provided by the Contractor at his own cost.
After completion of individual rooms of building sections, these must be cleaned and swept.
MBD reserves the right to use cleaning companies and charge the costs to the Contractor if the construction
site is not kept clean.
Burning of waste on the construction site is prohibited!
- Pipes shall be marked with self-adhesive, coloured tapes with direction arrows.
- Fitting number
- Module number.
The signs will be supplied by MBD. The signs shall be attached by the Contractor in agreement with
the Client.
Allgemein General
Kennzeichn.
Benennung Designation
Eqp. Code
B Verbrennung Incineration
C Kompressoren Compressors
CF Zentrifugen Centrifuges
CU Strom Current
F Fundamentierung Foundation
Messwertaufnehmer
FQE Sensor flow quantity
Durchflussmenge
H Heizgeräte Heater
HE Kühlung Cooling
HI Isolierungen Insulatings
M Ventil Valve
Rückschlagklappe nach der Non return flap after attached lube oil
NRF-001 angebauten Schmierölpumpe pump
Rückschlagventil nach Schmierölnach- Non return valve after lube oil run down
NRV-002 laufbehälter tank
P Pumpen Pumps
Absperrklappe Zulauf LLK Stufe 2 Shut off flap inlet charge air cooler
POF-002 stage 2
Motor-Galerie mit Treppe und Motor gallery with stairs and girder
PR-003 Galerieträger
Q Detektoren Detectors
ST Strukturen Structures
SL Schalldämpfer Silencer
TR Abscheider Trap
TY Warnanlage Typhon
Absperrung der Absteuerung des HFO Shut-off of the HFO spill for single
V-002 bei Einmotorenbetrieb in einer Mehrmo- engine operation of a multi engine
torenanlage plant.
VI Viskosemessgeraete Viscosimeter
W Werkzeuge Tools
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The site management reserves the right to intervene in the event of violation of these safety regulations
and/or other applicable regulations. Such intervention may extend to stopping work. The costs incurred as
a result of such an interruption shall be borne by the Contractor. The site management has the right to ban
personnel from the construction site.
Permits (e.g. work approval certificate, hot work approval, access permit) are prescribed for dangerous work
or work on or in the area of certain installations.
The Contractor’s personnel shall be obliged to ensure that the necessary approvals have been granted in
consultation with the appointed representative of the site management before the start of any work.
These approvals are coordinated by the site management or its appointed representatives.
The Contractor shall provide especially trained personnel in First Aid and corresponding materials and
equipment in accordance with the legal regulations so that adequate First Aid treatment is guaranteed. Every
Site Manager shall have the right and obligation to order First Aid equipment in the necessary quantity. The
First Aid personnel shall be named in writing to the site management of the Client together with information
on their First Aid training and the period of validity of this training. An accident location must be left
unchanged if possible until all investigations have been completed. All those not involved in coordinating
assistance or securing the accident location must stay away from the site of an accident. The traffic routes
must be kept clear until the rescue services arrive.
The pressure test tests whether pressure-bearing walls are tight under test pressure and whether any
deformations occur which may be a safety concern.
The pressure tests shall be performed in accordance with the stipulations of the AD2000 Code. The tests
shall be performed by the Contractor and approved by the Client and, where appropriate, by a designated
body.
The following special instructions must be observed for the pipe pressure tests:
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• The lube oil and fuel systems must not be tested with water in order to avoid the risk of corrosion in
these systems.
• MBD recommends using lube oil as the test medium in the lube oil circuit. Handling must take place
as described in the chapter “Flushing”.
• The fuel system (DO + HFO) must be tested with diesel oil.
• Since these are combustible media, fire safety measures must be observed in all cases!
• Observe the safety data sheet in all cases!
• Do not smoke and do not use naked flames!
• Danger of fire!
• Compressed air is to be pressure-tested with water. In the case of large volumes, it may be
necessary to provide additional support for the pipe or tank.
• After pressure testing, empty, blow out and dry the pipes!
• Do not use oil for compressed air pipes!
• The systems on the diesel engine must not be included in pressure testing under any circumstances.
• Equally, the components and modules supplies by MBD must also not be pressure-tested. If
necessary, blank disks must be fitted. The service pressure gauges and measuring and control
devices supplied by MBD must also not be included in testing under any circumstances.
MBD therefore recommends pressure testing prefabricated pipe sections with 1.43 times the nominal
pressure and recording this – also see list below.
Pipe class:
41 10 WS 03 sea water 50 10
43 10 W 03 raw water (cooling tower) 100 10
46 10 W 03 charge air cooling water (radiator) 100 10
48 10 W 03 hot water (cooling water) < 100°C 100 10
49 10 W 03 sewage water 100 10
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61 01 IA 03 intake air 50 01
62 06 CA 03 charge air 250 06
65 06 EG 03 exhaust gas 450 06
Test pressure PT = 1.25 x PS x temperature factor acc. to AD2000 HP 30, 4.17, but at least 1.43 + PS
When the pre-fabricated pipe sections have been treated as described above, the systems must be flushed
and filled ready for operation with the prescribed operating media. The pipes and connections must then be
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checked for leaks in installed condition under operating conditions with running service pump and the results
documented.
Time of testing
Pressure tests must be timed so that the person performing the test is able to adequately inspect all
pressure-bearing parts. If this is not possible in the final state, the first pressure test must be performed
as a part test in testable condition.
General preparation
The Contractor shall define and number the pressure circuits (pressure circuit = system section with the
same operating parameters) and define the corresponding test pressure in the P+ID.
If components (e.g. tanks, pumps, heat exchangers, etc.) are not to be integrated in a pressure test, these
components must be isolated from the pipe by means of suitable measures, e.g. by installing blank disks.
Calibrated pressure gauges shall be used for pressure testing. In addition, adequately dimensioned devices
(blank flanges, blank disks, caps, pressured devices, etc.) must be provided to seal off the pressure space.
A responsible person shall be nominated for coordination and permanent monitoring.
The following preconditions must be checked or established as preparation for the fluid pressure test:
• Check whether there are sufficient venting and drainage possibilities in the test area,
• Make sure that sufficient quantities of water or other media are available,
• The ambient temperature must be above 0°C when the system is filled with water and during the
pressure test. In the case of lower ambient temperatures, a pressure test must be performed only
if it is ensured that the test area, pressure gauge and feeder pipes cannot freeze.
• Make sure that the surfaces of the test section are dry and clean,
• Check all closures of the test section,
• Check the loading capacity of supports, foundation supports and floors by water weight,
• Check locking of spring-mounted supports,
• Safety devices such as safety valves and bursting disks must be fitted
• Remove or disconnect sensitive measuring devices,
• Fill the test section and vent at the highest point so that the system is completely filled with test fluid,
• The test section must be pre-pressurised only up to the maximum operating pressure until the
person responsible for testing arrives.
Test procedure
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o 1.25x the value of the maximum loading of the pressure device in operation taking into
account the maximum permitted pressure and maximum permitted temperature, or
o 1.43x the value of the maximum permitted pressure
• Establish the indicated test pressure from a safe distance and from a protected location,
• Keep the test section at the test pressure for a sufficiently long time,
• The test area must be accessed to inspect the walls only after the test pressure has been reduced
to the maximum permitted operating pressure,
• Reduce the pressure further after inspecting the walls. Open the vents before draining, otherwise
there is a risk of denting as a result of a vacuum forming,
• Completely drain the test fluid, and sufficiently ventilate the test section, otherwise there is a risk
of corrosion.
• Each pressure test must be documented correspondingly.
In individual cases and in countries where EU laws do not apply, the Contractor and Client / MBD can agree
not to apply AD2000 and to substitute it by equivalent regulations (e.g. ASME etc.). However, national
regulations or specifications of the World Bank shall always be observed. The procedure for performing the
pressure test shall then be based on the regulations applied.
Closest colour
Colour code
sample in RAL
Medium Group Colour name acc. to DIN 6164
colour register
Part 1
RAL 840 HR
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Closest colour
Colour code
sample in RAL
Medium Group Colour name acc. to DIN 6164
colour register
Part 1
RAL 840 HR
or
8
Brown 3:5:4 RAL 8001
With additional colour
Red 7:8:3 RAL 3000
The paint finish must always be realised in accordance with MBD works standard AN410. Coating thickness
tests shall be performed, recorded and enclosed with the quality documentation.
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o Systems are cleaned, flushed, tested and assembled ready for operation
o After the successful pressure tests, the seals fitted for the tests have been replaced by
the original seals
o Insulation and paint finish are completed
Any outstanding work which is established shall be listed and rectified immediately. Completion of this work
shall be notified to the site management of the Client and to MBD and shall be confirmed as completed in the
list after inspection.
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If the Client and MBD are not identical, it is recommended that the Client produce a quality or test and
inspection plan for his Contractor. If the Client wishes support from MBD for this, he can order this service
from MBD.
If the Client and MBD are not identical and if assembly takes place within territory covered by EU Directives,
the Client shall be responsible for ensuring that the Contractor complies with the valid regulations and is able
to prove conformance to him. If MBD must prove the overall conformance of a trade and this includes parts
of the assembly order of the Client, MBD shall receive the required documentation in compliance with the
relevant directives from the respective Client (on the basis of the Contractor documentation). A written
confirmation from the Client is normally sufficient for MBD in which the Client confirms that all the necessary
documents for verification of the conformity of the work and services of his Contractor are available to him in
checked and archived form and that the specifications of the EU Directives for the scope of performance of
his Contractor are therefore met.
The same also applies analogously in countries where EU Directives do not apply. The proof required shall
then be restricted to the standards defined for a specific order.
If a quality plan was or is produced for the order, the Client shall receive a test and inspection plan from the
Contractor for his scope of performance before the start of work. Agreement between the two parties shall
take place at the initiative of the Client before the start of work.
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• Serial No.
• Last name, first name of welder
• Personal stamp No. of welder
• Welder qualification in accordance with DIN EN 287
• Date of issue of welder qualification
• Validity ∅ from / to (mm) and t from / to (max.)
• First deployment (date), last deployment (dates)
The corresponding welder certificates (certified copy) must be filed corresponding to the Serial No.
The European Association for Welding Technology (EWF) (?) has worked out the following
recommendations for the minimum requirements for training, testing and certification of welding supervisors,
on a voluntary basis.
The recommendations are contained in the following documents:
In case welding supervisors which meet the requirements laid down in these documents or have approved
national qualifications are employed, it can be assumed that the corresponding requirements according to
5.2.2, 5.2.3 and 5.2.4 are met.
In case the welding supervisors notice deviations from the required execution, they are to initiate measures
immediately which will ensure that all requirements are met. These deviations and the measures initiated
are to be documented and to be coordinated with the Contractor in writing.
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The Contractor is authorised to carry out checks and examinations at any time in order to see if all
requirements and guidelines have been observed. He is to be provided free access to the manufacturing
and assembly departments at any time. Furthermore, he is guaranteed access to the current documentation.
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• Serial No.
• Last name, first name of tester
• Test procedure
• Qualification level
• Date of certificate
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The mechanical installation of equipment shall be checked and the results documented. Agreement on the
inspection scope and inspection documentation shall be reached between the Contractor/Client and MBD at
the initiative of the Contractor. The Client shall receive the inspection documentation.
• Pipe No.
• Material, batch number, certificate number
• Weld seam No.
• Welder No.
• VT (visual test)
• RT (radiographic test)
• PT/MT (penetrant/magnetic particle test)
• UT (ultrasonic test)
The welder No. and the respective tests (test report No.) shall be assigned to the individual weld seams.
The overall quality assurance procedure for stationary installations referred to the scope of order
performance is defined internally at MBD by the organisation guideline A1844.
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The reports shall be made to MBD project management through the Site Manager.
The reports shall be submitted to MBD project management through the Site Manager.
If the Client is identical with MBD, the scope of quality documentation to be supplied by the Contractor to
MBD is as follows:
If the scope is not otherwise defined on an order-specific basis, the Contractor shall supply the quality
documentation to MBD in a suitable document folder and on a CD (PDF format with bookmark structure) with
the content as outlined below.
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6 Environment, legality
It is the objective of the Client to minimise the negative effects of his products on humans and the
environment taking into account technical and economic criteria. For this reason, the Client has
established an environmental management system ( ISO 14001). The specifications from this
therefore also apply to the Contractor’s scope of performance.
6.2 Emissions
The supplier shall minimise exhaust, noise, substance and radiation emissions in accordance with the
latest state of the art and shall observe the corresponding valid regulations.
6.3 Recycling
The use of materials which cannot be recycled must be reduced as far as possible. Materials which
are capable of recycling must be marked where possible. Design measures must be taken to ensure
that these materials can be dismantled.
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