MAN Assembly Instructions Pipes and Equipment

Assembly instructions for stationary diesel power plants – Pipes and equipment
Assembly instructions for stationary diesel power plants
Pipes and equipment
Revision: 02.02.2005 Page 1 of 123 MAN assembly instructions pipes and

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Contents
1 Validity........................................................................................................................................................6
1.1 EU laws/directives................................................................................................................................7
2 Regulations and directives.......................................................................................................................8

2.1 Deviating regulation .............................................................................................................................9
2.2 Proof of conformity .............................................................................................................................10
3 Preconditions/Manufacturer qualifications ..........................................................................................11

3.1 Manufacturer preconditions ...............................................................................................................11
3.2 Preconditions for procurement by the Contractor ..............................................................................11
3.3 Approvals for joining procedures (welding procedures).....................................................................12
3.4 Work inspection of the pipe bending procedure ................................................................................12
3.5 Preconditions for non-destructive material testing (test supervisor and testers) ...............................15
4 Turnkey assembly ...................................................................................................................................16

4.1 Construction site equipment ..............................................................................................................16
4.2 Unloading and transport on the construction site ..............................................................................17
4.3 Incoming goods inspection ................................................................................................................18
4.4 Storage...............................................................................................................................................18
4.5 Work preparation................................................................................................................................18
4.6 Material issue, preservation of identification ......................................................................................19
4.7 Assembly date planning, tracking and progress reports....................................................................20
4.8 Personnel deployment and qualifications ..........................................................................................20
4.9 Tools and equipment..........................................................................................................................20
4.10 Auxiliary materials, consumables and operating media for assembly ...............................................21
4.11 Measuring and test equipment...........................................................................................................21
4.12 Scaffolding and working platforms .....................................................................................................21
4.13 Care during assembly ........................................................................................................................22
4.14 Component and module assembly ....................................................................................................22
4.15 Component connections ....................................................................................................................22
4.16 Pipe and pipe support assembly........................................................................................................26
4.17 Spans .................................................................................................................................................37
4.18 Bellows expansion joints and expansion compensators....................................................................38
4.19 Hoses .................................................................................................................................................41
4.20 Tracing type heating...........................................................................................................................44

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4.21 Screw-connected pipelines ................................................................................................................47
Legend .............................................................................................................................................................47
Work sequence ...............................................................................................................................................47

4.22 Screw-connected copper pipes, tracing type heating ........................................................................49
4.22.1 Stiffing sleeves............................................................................................................................49
4.22.2 Weld nipples ...............................................................................................................................50
4.23 Approved welding procedures ...........................................................................................................51
4.24 Approved weld seam preparation ......................................................................................................52
4.25 Welding ..............................................................................................................................................53
4.26 Marking of weld seams ......................................................................................................................54
4.27 Inspection and test scope on weld seams and pipe bends ...............................................................55
4.28 Cleanliness of components before and during assembly ..................................................................56
4.29 Cleaning by flushing, pickling, acid treatment, etc.............................................................................56
4.30 Cleaning .............................................................................................................................................57
4.31 Mechanical cleaning (general) ...........................................................................................................58
4.32 Chemical cleaning..............................................................................................................................59
4.33 Dowel work.........................................................................................................................................64
4.34 Insulation............................................................................................................................................64
4.35 Touch protection ................................................................................................................................64
4.36 Cleanliness of the construction site/waste disposal...........................................................................65
4.37 Marking of fittings and pipes etc. .......................................................................................................65
4.38 Compliance with safety regulations/First Aid ...................................................................................109
4.39 As-built record ..................................................................................................................................109
4.40 Pressure test ....................................................................................................................................109
4.41 Paint finish........................................................................................................................................113
4.42 Assignment of colours to transported media ...................................................................................113
4.43 Inspection at the end of assembly ...................................................................................................115
5 Quality assurance and documentation ...............................................................................................116

5.1 Procedure and work inspections and tests ......................................................................................116
5.2 Welding procedure specifications/test instructions ..........................................................................116
5.3 Welder test certificates.....................................................................................................................116
5.4 Welder list ........................................................................................................................................117
5.5 Welding supervisor...........................................................................................................................117
5.6 Welding monitoring ..........................................................................................................................117

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5.7 Proof of qualifications for test and inspection personnel .................................................................117

5.8 List of test and inspection personnel................................................................................................119
5.9 Weld seam testing............................................................................................................................119
5.10 Pipe bend tests ................................................................................................................................119
5.11 Inspection of chemical cleaning .......................................................................................................119
5.12 Inspection of mechanical installation ...............................................................................................119
5.13 Documentation of the pipe weld seams, pipe bends and corresponding tests................................120
5.14 Pressure test records .......................................................................................................................120
5.15 Client’s quality plan ..........................................................................................................................120
5.16 MBD quality management, quality assurance and quality plan .......................................................120
5.17 Constructional deviations if the Client is identical with MBD ...........................................................121
5.18 Fault reporting ..................................................................................................................................121
5.19 Content of the document folder:.......................................................................................................121
6 Environment, legality ............................................................................................................................123

6.1 Materials, substances ......................................................................................................................123
6.2 Emissions.........................................................................................................................................123
6.3 Recycling..........................................................................................................................................123

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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 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

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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
• The possibility of removing pipes or sections to permit disassembly of components for

maintenance/overhaul, for example, shall be guaranteed
• The possibility of installing/removing components and modules shall be guaranteed
• Installation of measuring instruments shall be performed in such a way as to guarantee proper
operation
• Cabling shall not impede access (maintenance/installation/removal) to components/modules.
• Proper air circulation for air supply and ventilation shall not be impeded by cables/pipes.
• Fittings for problem-free system filling/draining shall be provided at the lowest point.
• Pipe/cable wall ducts shall be sealed to prevent transmission of structure-borne noise and for the
purpose of fire protection.
• Grounding

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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:
AG Client (may be identical with MBD–MAN B&W Diesel AG)

MBD-QP MAN B&W Diesel AG – Quality Department of Power Plant Division
AN Contractor (company performing assembly of pipes and equipment)
MT Magnetic Particle Testing
PT Penetrant Testing
RT Radiographic Testing
UT Ultrasonic Testing
VT Visual Testing
WPAR Welding Procedure Acceptance Report
WPS Welding Procedure Specification
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.

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2 Regulations and directives

The following regulations and specifications shall apply to construction (assembly) and the quality
requirements for pipe systems and equipment:
• National laws, regulations, directives, decrees, specifications of the World Bank

• In so far as agreed between Contractor and MBD, the Quality Agreement Q 61.62000-1100 shall
apply additionally
• All relevant EU directives and laws
• The specifications of the Client,
• German Construction Site Regulations (BaustellV) dated 10th June 1998 (German Federal Gazette I
P. 1283), German Regulations on Hazardous Substances (GefStoffV § 7(8)) for construction sites in
the Federal Republic of Germany or local construction site regulations
• The Client’s specifications on quality assurance, e.g. based on the quality or inspection plan
• AD 2000 Code; this must be applied in all cases as standard
• Paint finish of engines, turbochargers and plant components – MBD Specification AN 410 Design
and realisation
• Corrosion protection in accordance with MBD Specification AN 400
• ISO standards, EN standards, DIN standards, harmonised standards corresponding to EU directives
shall be given priority
• VDMA standard VDMA 24277
• MBD pipe classes
• Design specifications of MBD as well as safety and assembly instructions
• Safety and assembly instructions of the component suppliers
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.
List of important reference standards:

Dimension standards/Technical delivery specifications
In accordance with applicable standards and MAN pipe class overviews
Welding and inspection standards/Recognition of welding procedures
- 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

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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
Non-destructive material testing

- DIN EN 970
- DIN EN 1289
- DIN EN 1290
- DIN EN 1291
- DIN EN 1435
- DIN EN 1711
- DIN EN 1712
- DIN EN 1713
- DIN EN 1714
- DIN EN 12062
- DIN EN 12517
Personnel requirements for non-destructive material testing (test supervision and testers)
- DIN EN 473
Terms, definitions, imperfections /weld seam

- DIN EN 1792
- DIN EN 12345
- DIN EN 12585
- DIN EN 22553
- DIN EN 29692
- DIN EN ISO 4063
- DIN EN ISO 6520
- DIN EN ISO 6947
- DIN EN ISO 6992
2.1 Deviating regulation

If the Contractor cannot meet ISO standards, EN standards, DIN standards and regulations, then he shall
prove the conformity of his standards towards MBD before applying them by way of verification by an
independent national body at his own cost.

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2.2 Proof of conformity

The Contractor shall perform a conformity assessment and verify conformity with EU directives towards the
Client by way of suitable documents. This shall apply to orders in the EU or countries where EU legislation
is valid. In other countries, the Contractor shall prove conformity with national regulations in a suitable way.
The applicable legal regulations shall apply to production of the technical documentation and the quality
documents and to their storage.

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3 Preconditions/Manufacturer qualifications
3.1 Manufacturer preconditions

The Contractor must have a valid, certified quality management system in accordance with DIN EN ISO
9000 ff. Alternatively, a successful audit performed by the Client on the Contractor may replace this
requirement if the Contractor does not have certification to DIN EN ISO 9000.
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.
3.2 Preconditions for procurement by the Contractor

If the supplier carries out procurement of components/materials for construction of the ordered scope, then
this shall take place on the basis of the specifications defined by the Client or MBD. The Contractor shall
perform an incoming goods inspection. In the event of deviations, he shall take the necessary measures
against his supplier.
In so far as the Client or MBD has not stipulated otherwise with respect to quality assurance/quality
documentation and/or technical documentation for procurement of components/materials for construction
of the ordered scope by the Contractor, the Contractor shall ensure that he receives adequate quality
documentation to prove the supplier quality of his subcontractors. If technical documentation is required for
components, the Contractor shall request this (user or assembly instructions, terminal diagrams, etc.) and
forward it to the Client.
The following shall apply as standard to procurement:

Components in compliance with EU laws (CE). Particular attention shall be paid to the regulations relating
to safety components and equipment components with a safety function.
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.

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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.
3.3 Approvals for joining procedures (welding procedures)

The contractor shall prove in a procedure qualification test (WPAR) that he masters the applied welding
procedures.
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.
3.4 Work inspection of the pipe bending procedure

Suitable bending equipment shall be used for production of pipe bends (cold-bent pipes). Proof shall be
supplied before the start of production by means of a procedure assessment (work inspection) that the
following required conditions are met.
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 scope of validity for the dimensions is determined as follows:
Wall thickness range 0.75tB ≤ tT ≥ 1.25 tB

tB – Component wall thickness
tT - Test piece wall thickness
Bending radius/diameter ratio Rm/da ≥ 3.0

Rm – Mean bending radius
da – Outside diameter
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.

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The responsible independent body or an expert nominated by MBD shall check the bend ovality measured
by the manufacturer on a random sample basis.
Ovality is defined as follows:
The following requirements shall be met:
da ≤ 60.3
Rm/da ≥ 3.0 (smaller bending radii shall be agreed with the Client)
The maximum permissible ovality for cold bending is ≤ 4%.
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 %.
The measured values (dimensions in mm) are as follows:

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• Wall thickness (a – h) in the planes 1 to 15

• Diameter (a-e / c-g) in the planes 1 to 15
• Circumference in the planes 1 to 15
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
Figure 1. Measurement of wrinkles
At the same time, the wrinkle spacing (a) must be
Cold forming with a degree of deformation of ≤ 5 % is permitted to correct form deviations. Back forming
of cold bends is not permitted.
Welding in the bending zone of pipe bends is not permitted.

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3.5 Preconditions for non-destructive material testing (test

supervisor and testers)
The non-destructive tests defined in these assembly instructions shall be performed by the Contractor. The
test supervisor and testers are generally employed by the Contractor or assigned with this task by him. The
test supervisor and testers must possess a certificate in accordance with DIN EN 473 or equivalent and be
approved by a recognised independent test authority.
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.

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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.
• Lube oil system

• Fresh water system
• Raw water system
• Fuel system
• Combustion air and exhaust gas system
• Pressure air system
• Heat recovery and heating system
• as well as sub-systems
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.
4.1 Construction site equipment

The following points shall be observed with respect to equipment of the construction site. Details and
additions shall be clarified on a project-specific basis between the Client and the Contractor, where
appropriate involving MBD.
- 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.

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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.
4.2 Unloading and transport on the construction site

Unloading of deliveries, also of products supplied by MBD, shall be part of the scope of work to be provided
by the Contractor, unless otherwise agreed.
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.

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4.3 Incoming goods inspection

The incoming goods inspection shall be performed by the Contractor, also for deliveries from MBD.
The following inspection items are compulsory:
- 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.
The Contractor shall dispose of any packaging.
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.
4.5 Work preparation

The scope of work and services to be provided by the contractor shall include careful preparation of the
assembly activities. All activities for prefabrication and assembly shall be prepared as follows:
- 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

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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.
4.6 Material issue, preservation of identification

Material shall be issued corresponding to the parts list of the respective work folder.
- 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,
Marking of the separated components includes:
• Material
• Batch No. (possibly including material as short designation). Assignment to the material certificate
must be guaranteed by means of a marking transfer certificate.

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• Stamp of the person authorised to perform marking transfer (personal stamp of the authorised
person).
4.7 Assembly date planning, tracking and progress reports

The Contractor will receive a general schedule from the Client for the overall construction project in
MS-Project. The Contractor shall produce an assembly schedule for the individual assembly steps in
MS-Project on the basis of this general schedule.
The Contractor shall maintain this schedule (target/actual) and shall provide the Client and MBD with
assembly progress reports and updated schedules 2 x weekly. The deviations between the target dates and
actual dates shall be indicated in the assembly progress reports. The Contractor shall describe here how he
plans to catch up with any delays (increased deployment of assembly personnel, weekend work, shift work,
etc.).
These measures shall be agreed with the Client and MBD.
4.8 Personnel deployment and qualifications

The Contractor shall name a Project Manager who is responsible for coordination of the awarded order
on behalf of the Contractor until the order has been completed. The Project Manager is responsible for
all issues in relation to the order which affect the Contractor both from the orderer and also from external
parties, and in particular from sub-contractors.
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.
4.9 Tools and equipment

The Contractor shall provide all the tools and equipment required for his scope of delivery and performance
in a sufficient quantity. These must comply with the legal regulations and customer specifications. They must
not pose any risk to persons, parts of the plant or the environment.
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.

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Tools for processing ferritic and austenitic materials shall be clearly identified and shall be used only for the
intended material.
4.10 Auxiliary materials, consumables and operating media

for assembly
The Contractor shall provide all auxiliary materials, consumables and operating media required for his scope
of delivery and performance. These must comply with the legal regulations. They must not pose any risk to
persons, parts of the plant or the environment.
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.
4.11 Measuring and test equipment

The Contractor shall provide all the measuring and test equipment required for his scope of delivery and
performance both for own monitoring purposes and for the QP department of MBD.
The test equipment shall be monitored in accordance with the applicable regulations.
4.12 Scaffolding and working platforms

The Contractor shall provide all the scaffolding and working platforms required for his scope of delivery and
performance. These must comply with the legal regulations. The Contractor shall ensure that they are fit for
purpose and monitor their operational safety. The scaffolding erector shall attach weather-proof, easily
visible, written scaffold approvals to the scaffold ladders as proof.
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.

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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.
4.13 Care during assembly

Assembly work shall be performed in such a way that there is no risk to persons, parts of the plant or the
environment. If necessary, special measures shall be taken as protection for the above, e.g. by sheeting,
guards or lining with boards. Particular attention shall be paid to the safety regulations for hot work.
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.).
4.14 Component and module assembly

The assembly instructions of the respective module and component manufacturers shall generally be
observed. In addition, the specifications of the present assembly instructions and all documents produced
or made available by MAN B&W shall be taken into account.
If there are contradictions in the content of the available documents, the Contractor shall be responsible for
technical clarification with MBD or the Client.
4.15 Component connections

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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:
- Dead weight of the pipe, with insulation where applicable,

- Dead weight of the fluid,
- Stationary internal pressure,
- Pressure surges,
- Pressure pulsing,
- Thermal expansion,
- Assembly-related constraining forces and moments
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)
Pump deformations cause:
- 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
Permissible connecting piece loads must be observed.
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.

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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.
The following tolerances are permitted:
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:
- 0.3 mm for DN < 150

- 0.4 mm for DN 200 to 300
- 0.5 mm for DN > 300
Figure 2: Plane-parallelism of flanges

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Gape distance (distance between flanges)
The distance S 3 (see Figure 3) between the flanges shall correspond to the seal thickness +1.0 mm.
Figure 3: Distance between flanges
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.
Figure 4: Lateral offset of the flanges
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.

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Figure 5: Arrangement of threaded holes
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.
Final inspection for pumps
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.
4.16 Pipe and pipe support assembly

The pipes and pipe support structures shall be assembled in accordance with the planning documents and
specifications. The site management shall be consulted immediately if there are collisions with other trades
during assembly, construction deviations or similar. These specifications are defined by the following
planning documents, among other things:

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• 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:

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• Realisation in accordance with flow diagram and pipe class

• Any insulation and the insulation thickness shall be taken into account corresponding to Chapter
4.29 with respect to distances from other pipes.
• The support specifications (function and spans) are defined in the planning documents (Pipe Support
Plan, Support Construction Typical Plan, etc.).
Proposals for pipe mounting:
The following support types are possible:
• FP: Fixed point

• SP: Sliding point
and
• Free support (complete without bracket)

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Figure 6: Clamp screws for DN25 – 150

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Figure 7: U bolts for DN200 – 300

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Figure 8: Pipe support installation proposal

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Figure 9: U bolts, cross-sections, various DN

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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
empty pipe without

insulation
filled pipe without insulation
10
L
filled pipe with insulation
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

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4.18 Bellows expansion joints and expansion compensators

General information on installation of bellows expansion joints
When installing bellows expansion joints (elastic pipe connections), the following must be observed in
addition to the manufacturer's specifications:
• 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.
EB = Steel expansion bellow
EB = Rubber expansion bellow
EH = Elastic pipe connection (hose pipe)
EP = Expansion compensator with L pipe bend
EP = Expansion compensator with U pipe bend
Table 1: Bellows expansion joints and expansion compensators
x = Distance between fixed bearings
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.

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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
Figure 18: Thermal expansion of a steel pipe

Installation of steel and rubber expansion bellows
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.

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Prestress
Operating state
X = Distance between fixed bearings
Installation of expansion compensators with L pipe bend
Linear expansion
Prestress
Operating state
Installation of expansion compensators with U bend
Linear expansion
Prestress
Operating state

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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.
The following information is based on DIN 20066, Part 4.
Wrong Correct Comments

Hoses must be installed in
such a way that there is no
tensile loading (except for
dead weight) or compressive
loading in any operating
state. For this reason, hoses
should always be installed
with slack in order to
compensate for any
shortening of the hose. (Also
refer to the sections on
length changes and increase
in volume of hoses).
Twisting of the hose must be

avoided, because torsional
loads result in reduction of
the cross-section and in the
most unfavourable case also
cause damage to the plies
(pressure absorbers). In
addition, no torsion forces
must be produced in the
hose when the fittings are
installed.

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Wrong Correct Comments

Hoses must not be bent
beyond the permitted
bending radius or even
kinked, as this will increase
the flow resistance. In such
cases, angle pieces or
elbows must be used. The
minimum bending radii
specified in the catalogue
refer to rigid installation of
the hoses. If hose movement
has to be repeated very
frequently in a small bending
radius (continuous
operation), it is
recommended to choose the
largest possible hose. The
hose bend must start only
after a length of >1.5 d.
Any deviation from the
bending radii defined in the
relevant standard may
influence the service of life
of the hose, depending on
the load in question.
Although hoses are

designed with a certain level
of resistance to abrasion,
they must be protected
against external damage
which may lead to scraping
off or tearing of the hose
material and therefore to
premature failure of this
material.
Hoses must be protected
against external temperature
influences which exceed the
limits applicable to the
respective hose.
Particular care must be
taken when routing hoses in
the area of hot manifolds. In
some applications, it may
therefore be necessary to
protect the hose or to route it
so that it is not exposed to
the above influences.

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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:
• Hoses should follow the contour of the machine or equipment if possible.

• Route hoses together and in parallel.
• Use supports and clamps to hold the hose in position.
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.

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4.20 Tracing type heating

Heating medium
MBD usually uses saturated steam with a pressure of 8 bar (174 °C temperature) in stationary diesel plants.
The steam system is protected by safety valves (set to 10 bar).
Fuel line Tracing type heating Insulation thickness

DN (mm) DN (mm) (mm)
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
Table 2: Number of tracing pipes as a function of pipe diameter (guide values)

Tracing pipe material: Seamless copper pipe in accordance with DIN 1754
Fixing of tracing pipes
Figure 19: Fixing of tracing pipes

The tracing pipes must be attached to the pipes to be heated using suitable fixing material (e.g. binding wire)
at intervals of approximately one metre. If several tracing pipes are required for a product line, then each
auxiliary pipe must be fixed individually in order to prevent the pipes from slipping. Fixed points are produced

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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.
Heating of control and pump station

It must generally be ensured that no short circuits are produced and that forced flow-through is guaranteed in
all heating pipes. The risk of incorrect installation is particularly high at control stations. In the case of pump
stations, the branch to the reserve pump is provided with its own steam trap.
Heating dead pipe ends

So-called dead pipe ends are heated even if the pipe itself does not require heating due to continuous
medium flow.
Arrangement of expansion bends

The elongation of a tracing pipe is absorbed by U-shaped expansion bends. The distance between two
expansion bends may be around 20 m with a U-leg projection of around 300 mm. It must be taken into
account that pipe bends required for other reasons in feed and discharge lines, around flanges and for
heating fittings are also involved in absorbing elongation. The number of expansion bends still required
is then reduced correspondingly. The fixed points required between the expansion bends of the tracing
pipes are realised by means of two tightened clamps. Refer to 5 for details on fixing tracing pipes.
Permissible length of tracing type heating sections

The permissible length of tracing type heating sections depends on the number of gradients and water
pockets and on the number of pipe bends. Relatively straight heating sections including supply pipes from
the steam distributor and the discharge pipes to the condensate trap may be up to 80 m long.
Draining of tracing type heating

Tracing type heating systems should be drained every 10-20 m by a steam trap. Thermodynamic or thermal
enclosed steam traps are used primarily for this purpose. Bimetallic steam traps are used if the condensate
should be backed up slightly in the tracing type heating system. Also refer to the technical documentation of
the steam trap manufacturer.
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.

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Figure 20: Installation example for tracing type heating
Paint finish of pipes with tracing type heating and insulation
No top coat is applied to pipes with tracing type heating. The pipes are only primed.

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4.21 Screw-connected pipelines
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
1. Cut off pipe at right angles and deburr.

Pipe cutters (see Figure) are very suitable for this purpose.
The pipe is cut with a cutting wheel. The inside edge of the pipe can
then be deburred by means of 3 cutting edges inside the handle or
Pipe cutter by means of a spot facer. Remove swarf carefully by blowing out!
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.
3. Screw on the union nut by hand until it perceptibly contacts the

cutting and taper ring. Then press the pipe against the stop in the
internal taper and tighten the union nut by approximately ½ to ¾
turn. The cutting and taper ring then bites into the pipe, which means
that it is not necessary to press the pipe on any further. Final
tightening is performed by tightening the union nut by approximately
Before tightening one turn. The ring cuts into the pipe as a result and throws up a
visible collar in front of its cutting edge.
A marking line on the union nut makes it easier to keep to the

specified number of turns.
4. Pipes with a smaller outside diameter can be secured without pre-

assembly in threaded connections if they are screwed tight onto the
engine.
It is expedient to pre-assemble pipes with a larger outside diameter

and all connections in free pipes in a vice. The open-jaw wrench
should have a length which is approximately 15 times the width
across flats (possibly extend with a pipe). Otherwise proceed as
above. Final tightening is made easier if the union nut is loosened
several times so that oil penetrates between the friction surfaces
After tightening again.

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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.
After completion of the connection and each time it is loosened, the

union nut must be tightened without wrench extension and without
increased force.
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
Minimum distance and bending radii
Pipe bending fixture

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4.22 Screw-connected copper pipes, tracing type heating

Copper pipes are used for installation of tracing type heating systems. In the case of copper pipes, it is
necessary to observe the instructions relating to use of stiffing sleeves and weld nipples in addition to the
information in the chapter “Screw-connected pipelines”
4.22.1 Stiffing sleeves
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-
6x1 3.8 2.6 14.0 VH04MSX 6x1-CuZn35Ni2
8x1 5.8 4.6 14.0 VH06MSX 8x1-CuZn35Ni2
10x1 7.8 6.6 15.5 VH08MSX 10x1-CuZn35Ni2
12x1 9.8 8.6 15.5 VH10MSX 12x1-CuZn35Ni2
14x1
11.8 10.2 17.0 VH12MSX 14x1-CuZn35Ni2
15x1.5
16x1 13.8 12.2 17.0 VH14MSX 16x1-CuZn35Ni2
18x1.5 14.8 13.8 20.0 VH15MSX 18x1,5-CuZn35Ni2
20x1 17.8 16.2 20.0 VH18MSX 20x1-CuZn35Ni2
22x1.5 18.8 17.2 16.0 VH19MSX 22x1,5-CuZn35Ni2
28x2 23.8 22.2 23.5 VH28MSX 28x2-CuZn35Ni2

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Table 3: Material: CuZn35Ni2

Use: Only for copper pipe connections which have to be frequently undone, e.g. the cooling water
connections for fuel needle valves.
The stiffing sleeves are knocked or pressed into the pipe end without any special preparation of the Cu pipe.
4.22.2 Weld nipples
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-
10 7 1.5 33.5 32.5 8 x 1.5 10 x 1.5 K 10 x 1.5
12 9 1.5 33.5 32.5 10 x 1.5 12 x 1.5 K 12 x 1.5
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 15 2.5 47 45 16.3 x 2.4 20 x 2.5 K 20 x 2.5
20 14 3 47 45 16.3 x 2.4 20 x 3 K 20 x 3
25 17 4 53 49.5 20.3 x 2.4 25 x 4 K 25 x 4
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

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4.23 Approved welding procedures

The following welding procedures are approved for welding pipes:
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):
- Metal active gas welding – MAG welding (only in production)

- Manual arc welding
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.

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4.24 Approved weld seam preparation

The following weld seam preparation procedures are approved for welding pipes (DIN EN 29692):
Code number Workpiece thickness* Designation
1.2 t ≤ 4.0 mm I-seam

1.3 t ≤ 10.0 mm V-seam
1.5 t ≤ 15.0 mm Y-seam
1.7 t > 15.0 mm U-seam
2.3.3 t > 10.0 mm X-seam
X-seam
2.3.3 t > 10.0 mm asymmetrical
(e.g. ⅓-⅔)
1.4 t ≤ 10.0 mm HV-seam

K-seam
2.4.4 t > 10.0 mm
Double HV-seam
3.10 B t1t2 > 2.00 mm Fillet weld (lap joint)
*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):
Code number Workpiece thickness Designation
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

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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).

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Figure 23: Adaptation to different wall thicknesses on the thicker component.
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
4.26 Marking of weld seams

The marking methods shall be chosen dependent on product, 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,
Marking of the weld seam includes:

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• 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
Ultraschall- oder Durchstrahlungsprüfung Oberflächenprüfung

Werk- Stahlsorten
Wanddicke des Behältermantels oder Dicke des
stoff- Prüfumfang Prüfverfahren und SIN und KN 8) Prüfungsum-

grupp Prüfklasse in fang in
Berechnungsspannung in der Schweißnaht 3)
LN 7) St 7) RN 7) Abhängigkeit von Abhängigkeit von Prüf-

e
Wärmebehandlungszustand 2) nach dem
Wanddicke für Spalten der Wanddecke für verfahren

1)
Anschluss-querschnittes
17, 18, 19 LN, St und RN für

Spalte 23
Wanddicke Prüfungs- Prüfver-
umfang fahren
Ausnutzung der zulässigen
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.
Visual testing (VT)

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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.
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.
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.
4.28 Cleanliness of components before and during assembly

Pipes and pipe parts shall be stored so that they cannot become soiled internally. Pipes should generally
be sealed with plastic caps during storage. This shall also apply to other pipe parts which are not stored in
a hall.
After production, the spools must be sealed again with caps. These must be removed only immediately
before assembly. The interior cleanliness of the pipe spools must be checked before assembly. If the visual
inspection gives arise to doubts with respect to the interior cleanliness, then the required cleanliness shall be
produced before assembly by suitable means such as flushing with water or blowing out with compressed
air.
4.29 Cleaning by flushing, pickling, acid treatment, etc.

Caution: It must be ensured that no combustible or ignitable residue of the cleaning agents or
vapours from them remain in the pipes or other components, particularly in the engine pipes,
exhaust pipes and hot pipes. There is a risk of explosion!
The same applies to anti-corrosion agents!

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4.30 Cleaning
Cleaning of the plant pipes depends on the transported medium and on the installation location of the
respective pipe.
Pipes on the engine

If not otherwise agreed, pipes of cooling water, heating, exhaust and intake air systems shall be cleaned
mechanically. Pipes of lube oil, fuel, compressed air, gas, steam and condensate systems shall be cleaned
mechanically and chemically. Shut-off and control elements and other devices in the individual systems shall
be installed only after cleaning.
The pipes which are installed on the engine (generator set) shall be cleaned mechanically and/or chemically
after manufacture and before final assembly of the individual pipe. 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 suited for this task as they cannot be overseen.
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. These pipes must be
mechanically cleaned in order to remove the sand residue.
The complete fuel and lube oil system shall be flushed thoroughly with the operating medium before the
engine plant is put into operation.
Pipes without filter in the circuit
- 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
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:

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- Pipes are bright inside and show no signs of corrosion.

- No tools intended for black steel must be used on the stainless steel pipes.
- Weld seams must be produced using the TIG procedure. No longer accessible interior seams must
be protected with forming gas during welding.
- Non-formed weld seams must be treated with approved pickling/passivating procedures or existing
oxide layers must be removed with stainless steel brushes.
Starting air pipes
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:
c) Acid cleaning after welding

d) The weld seams must be mechanically cleaned inside. The flanges must be positioned in
the pipes so that it is possible to see into the complete pipe and so that each weld can be
mechanically cleaned.
The filling lines to the starting air bottles are
a) connected with Ermeto coupling – without strainer before the starting air bottle
b) welded – with strainer before the starting air bottle
4.31 Mechanical cleaning (general)

Scale and welding beads at the welding locations must be carefully removed. Individual pipe pieces must be
knocked with a hammer and blown through with compressed air at the same time if possible, so that even
the smallest residue (e.g. sand filled in the pipes for warm bending) is removed.
All pipe connections must be sealed until assembly.
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.

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4.32 Chemical cleaning

An acid bath is required for pipes which are to be cleaned chemically.
Acid bath preparation
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.
Minimum safety measures
• 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.
Hydrochloric acid bath
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.
Mixture ratio for bath: HCI : H2O = 1:3 a 1:4.
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).
• Do not place any hot sections in the acid bath.

• Do not place any copper pipes in the hydrochloric bath if it is intended to treat steel
pipes again subsequently. As a result of the reaction of the copper (Cu) with the
diluted hydrochloric acid (HCI), the dissociated salt copper chloride (CuCl2) is
formed in the aqueous solution. If an iron pipe is then placed in the acid, the base
iron oxidises by releasing its positive unit charges, so that the iron ions dissolve
while the metallic copper is deposited. The iron or steel pipe is then coated with
a copper layer which does not adhere intensively.

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Sulphuric acid bath (copper pipes)
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.
Mixture ratio for bath: H2SO4 : Ro = R1_ + R2 + R3 + R4
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.
Mixture ratio for bath: Na3Po4 : Ro = R1_ + R2 + R3 + R4
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 following accessories will be provided by MAN B&W:
• Lube oil system: Running-in filter with insert, installed on engine

• Fuel oil system: Flushing filter, loose
• Water systems: Strainer inserts, mesh spacing, 1.0 mm; loose
The following order must be observed for the flushing operations:
1. Engine cooling water system

2. Lube oil system
3. all other systems

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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.
Flushing the systems
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.
First flushing phase
The following work steps are required for the first flushing phase:
• Blank off the lube oil entry at the engine.

• The automatic filter elements must be removed for flushing. Flushing takes place via the indicator
filter
• Route a provisional pipe from the pressure pipe upstream of the engine to the oil drain pipe (base
plate). If a rubber hose is used, fix this securely inside the oil pan. Route the pipe so that it cannot
be damaged or torn off when the engine turns.
• Heat the cooling water and flushing oil to approx. 40 °C (oil viscosity < 70mm²/s, or 70 cSt or <9E).
If the cooling water cannot be heated, the flushing oil must also not be heated, since otherwise
condensation will form on the colder components.
• Force the flushing oil through the system, making sure that it also flows through all reserve
assemblies such as standby pump, cooler, etc. through which oil also flows at times.
• Tap oil-carrying pipes during flushing, particularly in the area of weld seams.
• Allow the lube oil separator to run as well if possible.
• Observe the differential pressure of the indicator filter continuously and carefully. The filter elements
must be cleaned if the differential pressure reaches the maximum value.
• Flushing must be continued until there is no longer any recognisable filter soiling, but for at least
24 hours.
Second flushing phase
The following work steps are required for the second flushing phase:
• Remove provisional pipes and restore original engine installation

• Insert filter element rods in the automatic filters
• Make sure that the filter elements are installed in the running-in filter

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• 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.
Third flushing phase
The following work steps are required for the third flushing phase:
• The blank plates on the turbocharger must be removed.

• Flush the system and engine with bearings, turning the engine at intervals of approx.
30 minutes with the electrical turning gear.
• The 3rd flushing phase can normally be ended after 3-4 hours. A precondition for this is that
there is no longer any large increase in differential pressure (i.e. no significant contamination)
in the filters within a short period.
• The flushing operation must take place in the presence of a MAN fitter/engineer, the Client
and, if wished by the Client, an acceptance officer. The three parties must agree on
termination of flushing at the last filter inspection.
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.
First flushing operation
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 engine must be excluded from the flushing circuit.
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”.

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Second flushing operation
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.
Emptying and cleaning of system parts
The end preheater, filter chamber and mixing tank must be de-sludged through their drain pipes.
Cooling water system
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.
Manufacturer Product Concentration Duration of cleaning/Temperature

Drew HDE-777 2 – 5% 4 h at 50 – 60 °C
Unitor Seaclean 0.5% 4 h at 50 – 60 °C 1)
Vecom Ultrasonic Multi Cleaner 4% 12 h at 50 – 60 °C
Table 5 Cleaning agents for removal of oily residue
1)
Also suitable for short-time engine operation
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.

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Pressure air system
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.
4.33 Dowel work

Dowels are permitted only for fixing components and do not serve the purpose of absorbing loads. The
dowels in accordance with the component supplier specifications or deliveries must be used. Refer to the
planning documents for the location of the dowel holes.
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.
4.35 Touch protection

Before the end of the assembly, a plant inspection tour must be performed together with the Client. During
this inspection, it must be defined at which easily accessible locations touch guards must be fitted. 60 °C is
usually recognised as the maximum permissible surface temperature.
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.

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4.36 Cleanliness of the construction site/waste disposal

The Contractor is obliged to keep his assembly areas, stores and accommodation in an orderly and clean
condition. The construction site shall be tidied up at least weekly.
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!
4.37 Marking of fittings and pipes etc.

Fittings, pipes and measuring points shall be marked in accordance with the specifications of the planning
documents:
- 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.
German designation Designation Abschnitt Blatt

Section Sheet
Allgemein General
Kennzeichnungsvorschrift Marking Instruction 1 1-4
Kurzzeichen für Zubehör Code for Accessories 2 1 - 10
Symbolliste I List of Symbols I 3 1-8
Symbolliste II List of Symbols II 4 1-8
Mediumab- und unabhängige Medium and Medium-Related 5 1-5

Schlüsselnummern Code Numbers
Table 6: Marking of fittings and pipes

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Kurzzeichen für Zubehör / P&ID

Codes for Accessories / P&ID
Kennzeichn.
Benennung Designation
Eqp. Code
A Angetriebene Hauptmaschinen Driven Machines
A-001 Generator Alternator
AIR Belüftungssysteme Ventilation Systems
Ansaugschalldämpfer, Intake Silencer, genset room ventilating

AIR-001 Maschinenhausbelüftung system
Zuluftjalousie, Maschinenhausbelüftung Air-in louver, genset room ventilating

AIR-002 system
Abluftschalldämpfer, Outlet-air silencer, genset room

AIR-003 Maschinenhausbelüftung ventilating system
Dachlüfter, Maschinenhausbelüftung Roof vent, genset room ventilating

AIR-004 system
Zuluftschalldämpfer, Inlet-air silencer, sludge container room

AIR-005 Maschinenhausbelüftung
Abluftschalldämpfer mit Lüfter, Outlet-air silencer, sludge container

AIR-006 Schlammbehälterraum room
AIR-007 Zuluftschalldämpfer, Separatorraum Inlet-air silencer, separator room
Abluftschalldämpfer mit Lüfter, Outlet-air silencer, separator room

AIR-008 Separatorraum
Zuluftschalldämpfer, Inlet-air silencer, consumables

AIR-009 Betriebsbehälterraum container room
Abluftschalldämpfer mit Lüfter, Outlet-air silencer, separator room

AIR-010 Betriebsbehälterraum

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AIR-011 Feststehende Wetterjalousie Louvre fixed
AIR-012 Sandrückhalteeinrichtung Sand retaining device
AIR-013 Jalousie für Umlauffilter Louvre for circulation-filter
AIR-014 Absauganlage Exhaust assembly
AIR-015 Fundamentbelüftung Foundation ventilation
AIR-016 Lufttrockner Air dryer
AIR-017 Maschinenhausbelüftungsanlage Genset room ventilation system
AIR-018 Schalldaempfer Absauganlage Suction unit silencer
Abluftjalousie, Maschinenhausbelüftung Outlet air louvre, genset room

AIR-019 ventilating system
B Verbrennung Incineration
B-001 Schlammverbrennung Sludge-incineration device
BL Turbolader, Geblaese, Ventilator Turbocharger, blower, fan
BL-001 Abgasturbolader Exhaust-gas turbocharger
Ventilator zur Kugelregen- Fan for shot-blast cleaning system

BL-002 Reinigungsanlage
BL-003 Abgaskessel-Reinigungsanlage Exhaust-gas boiler cleaning system
Abgasgebläse- und Exhaust-gas boiler incinerator unit

BL-004 Verbrennungseinheit
BL-005 Hilfsluftgebläse für Ladeluft Auxiliary blower for charge air
BL-006 Abgassystem Spuelgeblaese Exhaust gas system venting fan
BL-020 Power Turbine Power turbine unit
C Kompressoren Compressors
C-001 Kompressor mit Elektromotor Compressor with electric motor
C-002 Kompressor mit Dieselmotor Compressor with diesel engine
C-003 Kompressor / Arbeitsluft Compressor / working air
C-004 Gaskompressor Gas compressor
C-005 Kompressor / Steuerluft Compressor / control air

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CK Dreiwegehahn, manuell betätigt Three-way-cock, manually operated
Dreiwegehahn, Umschaltung MDO- Three-way-cock, switching of the MDO

CK-001 Rücklauf vom Motor zwischen den return pipes between the service tanks
Tagestanks
Dreiwegehahn, Umschaltung von MDO Three-way-cock, switching between

CK-002 auf HFO MDO and HFO
Dreiwegehahn, Umschaltung zum Three-way-cock, switching to MDO-

CK-003 MDO- Kühler cooler
Umschaltvorrichtung, Rücklaufleitung Change over device, return line

CK-004
Umschaltvorrichtung, Hilfsdiesel Change over device, Aux. Engine

CK-005
CF Zentrifugen Centrifuges
CF-001 Schmieröl-Separator Lube-oil separator
CF-002 Schweröl-Separator Heavy fuel-oil separator
CF-003 Dieselöl-Separator Diesel fuel-oil separator
CF-004 Schlamm-Separator Sludge centrifuge unit
CF-005 Fahrbarer Separator Module separator unit
CF-006 Öl / Wasser separator Oily water separating unit
CF-007 Freistrahlzentrifuge Free jet centrifugal pump
CP Überwachung Control panel
Steuer- und Switchgear and monitoring system,

CP-001 Überwachungsschrank,Motor engine
Steuer- und Überwachungsschrank für Switchgear and monitoring system

CP-002 allgemeine Hilfsgeräte auxiliary equipment
Steuer- und Überwachungsschrank, Switchgear and monitoring system,

CP-003 Schmierölseparator lube-oil separator
Steuer- und Überwachungsschrank, Switchgear and monitoring system,

CP-004 Schwerölseparator heavy-oil separator
CP-005 Fahrstand Motor Engine control panel

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Steuer- und Ueberwachungsschrank, Switchgear and monitoring system,

CP-006 Generator alternator
Steuer- und Ueberwachungsschrank, Switchgear and monitoring system,

CP-007 Radiator radiator
CP-008 Mittelspannungsanlage Mean voltage system
CP-009 Hochspannungsanlage High voltage system
MCC fuer Hilfsbetriebe / Low voltage system

CP-010 Niederspannungsanlage
Steuer- und Überwachungsschrank für Switchgear and monitoring

CP-011 Power Turbine systempower turbine
Schaltschrank, Hilfseinrichtungen Switch gear cabinet, auxiliary

CP-012 equipment
CU Strom Current
CU-001 Erdung Earthing
CU-002 Batterieladegeraet Battery charger
CU-003 24 VDC Batterieanlage 24 VDC battery rack
CU-004 125 VDC Batterieanlage 125 VDC battery rack
CU-005 Eigenbedarfstrafo Auxiliary transformer
CU-006 Hochspannungstrafo Step up transformer
D Diesel-Aggregate Diesel generator sets
D-001 Dieselmotor Diesel-engine
D-002 Diesel Notstromaggregat Black start unit
D-003 Hilfsdiesel Auxiliary engine
F Fundamentierung Foundation
F-001 Fundamentleiste Foundation girders
F-002 Federisolatoren Resilent insulators
F-003 Viskosedaempfer Viscose dampers

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FBV Strangregulierventil Flow balancing valve
Strangregulierventil fuer Flow balancing valve for multi engine

FBV-010 Mehrmotorenkraftstoffsysteme, fuel systems, installation at engine
Installation an Motoraustritt outlet
Strangregulierventil fuer Flow balancing valve for multi engine

FBV-011 Mehrmotorenkraftstoffsysteme, fuel systems, installation in
Installation im Wartungsbypass maintenance bypass
Strangregulierventil fuer Flow balancing valve for cooling water

FBV-020 Kuehlwassersysteme systems
FIL Filter Filters
FIL-001 Schmieröl-Automatikfilter / Hauptfilter Lube-oil automatic filter
FIL-002 Schmieröl-Doppelfilter Lube-oil duplex filter
FIL-003 Kraftstoff Automatikfilter Fuel oil automatic filter
FIL-004 Schmierölvorfilter Lube-oil prefilter
FIL-005 Dieselöldoppelfilter (supply) Diesel-oil duplex filter
FIL-006 Schweröldoppelfilter (supply) HFO duplex-filter
FIL-007 Ansaugluftfilter Intake-air filter
FIL-008 Rohwasserfilter Raw-water filter
FIL-009 Zylinder-Schmieroelfilter Cylinder lube oil filter
Zuluftfilter, Maschinenhaus Air-filter, genset room ventilating

FIL-010
system
FIL-011 Dieselölfilter Diesel-fuel filter
FIL-012 Leckölfilter Leakage-oil filter
FIL-013 Kraftstoffindikatorfilter Fuel duplex filter
FIL-014 Schweröl-Doppelfilter (Lagerung) HFO duplex-filter
FIL-015 Schlammseparator Doppelfilter Sludge-separator duplex-filter
FIL-016 Doppelfilter Duplex-filter
FIL-017 Wasserfilter Water filter
FIL-018 Schwefelwaschanlage De-sulphurisation plant

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FIL-019 Seewasserfilter Sea water filter
FIL-020 Frischwasserfilter KWE Fresh water filter FWE
Schmutzfänger, Kühlwassersystem, für Strainer, cooling water system, for com-

FIL-021 Inbetriebnahme missioning
FIL-022 Schmieröleinfahrfilter Lube oil run in filter
FIL-023 SCR Katalysator SCR catalytic converter
FIL-024 ESP Partikelabscheider ESP particle precipator
FIL-025 Oxidationskatalysator Oxidation catalytic converter
FIL-026 Gas-Filter Gas filter
FIL-027 Feinfilter Schmierölreinigung Fine filter lube oil cleaning
FM Homogenisator Fuel mill
FM-001 Homogenisator KWE Fuel mill FWE
FSH Kontrollbehälter für Leckage Leakage monitoring tank
FSH-001 Leckkraftstoff Kontrollbehälter Leakage fuel oil monitoring tank
FSH-002 Kondenswasser Kontrollbehälter Condensate water monitoring tank
FQ Durchflussmengen-Messgeräte Flow quantity measuring instruments
FQ-001 Ovalradzähler für Schmierölnachfüllung Flowmeter lube oil filling
FQ-002 Ovalradzähler für Zylinderschmierung Flowmeter cylinder-lube-oil
FQ-003 Ovalradzähler für Kraftstoff Flowmeter fuel oil
FQ-004 Ovalradzähler für Schwerölnachfüllung Flowmeter HFO-filling
FQ-005 Ovalradzähler für Dieseloelnachfüllung Flowmeter diesel-oil-filling
FQ-006 Wärmezähler Heatmeter
FQ-007 Gaszähler Gasmeter
Durchflussmesser Flowmeter lube-oil storage tank

FQ-008 Schmierölvorratsbehälter
Durchflussmesser Flowmeter HFO-storage tank

FQ-009 Schwerölvorratsbehälter

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FQ-010 Durchflussmesser fuer Wasser Flowmeter for water
Messwertaufnehmer
FQE Sensor flow quantity
Durchflussmenge
FQE-001 Messung Wassergehalt KWE Measuring water content FWE
FV Spülventil Flushing valve
FV-001 KWE-Spülventil FWE flushing valve
FV-002 Gas-Entlueftungsventil mit Antrieb Gas venting valve with actuator
FV-003 Gas Entlueftungsventil, manuell Gas venting valve, manual
GR Antriebe Prime mover
GR-001 Schwungrad Flywheel
GR-002 Törngetriebe Turning gear
GR-003 Kupplung Coupling
H Heizgeräte Heater
H-001 Motorkühlwasservorwärmer Engine cooling water-preheater
H-002 Schmierölvorwärmung Separierung Lube-oil preheater separator
Einsteckheizregister für Insert heater HFO day-tank

H-003 Schwerölbetriebsbehälter
H-004 Endvorwärmer für Schweröl Final heater HFO
Einsteckheizregister für Insert heater nozzle cooling water

H-005 Düsenkühlwasser
H-006 Kraftstoffvorwärmer Fuel-oil preheater
Einsteckheizregister Insert heater HFO storage-tank

H-007 Schwerölvorratsbehälter
H-008 Schwerölvorwärmer, Separierung HFO preheater, separator
H-009 Einsteckheizregister, Schlammbehälter Insert heater, sludge tank
Bodenheizschlange HFO- Heating coil HFO storage tank

H-010 Vorratsbehälter
H-011 Ansaugluftvorwärmer Intake-air preheater

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Heizschlange für Leckölbehälter Heating coil for leakage-oil tank (fuel)

H-012 (Kraftstoffteil)
Bodenheizschlange fuer Heating-coil fuel-oil day-tank

H-013 Kraftstoffbetriebsbehälter
Bodenheizschlange für Heating-coil HFO sludge-tank

H-014 Schwerölschlammtank
Einsteckheizregister für Leckölbehälter Insert heater leak oil tank (fuel)

H-016 Einsteckheizregister, Schlammtank Insert heater, HFO sludge tank
H-017 Vorwärmer Preheater
H-018 Vorwärmer Schlammseparator Sludge separator preheater
H-019 Vorwärmer Dieseloelseparator Diesel oil separator preheater
H-020 Wasservorwärmer Water preheater
H-021 Raumluftvorwärmer Room air preheater
Bodenheizschlange Schmieröl- Heating-coil LO storage tank

H-022 Vorratstank
H-023 Bodenheizschlange Altölbehälter Heating-coil used oil tank
Bodenheizschlange Schmieröl- Heating-coil LO maitenance tank

H-024 Ablassbehälter
H-025 Schmieröl-Vorwärmer LO preheater
H-026 Dieselöl-Vorwärmer DO preheater
H-027 Vorwärmer für Hilfsdiesel Preheater for aux. engine
H-028 Vorwärmer Wasserdosiereinheit KWE Preheater water dosing unit FWE
H-029 Hilfsdampfkessel Aux. boiler
Heizschlange für Leckölbehälter Heating-coil for leakage oil tank (fuel)

HE Kühlung Cooling
HE-001 Ladeluftkühler Charge air cooler
HE-002 Schmierölkühler Lube oil cooler
HE-003 Motorkühlwasserkühler Engine cooling water cooler
HE-004 Kühlturm Cooling tower

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HE-005 Düsenkühlwasserkühler Nozzle cooling water cooler
HE-006 Abgaskessel Exhaust gas boiler
HE-007 Gasöl- / Dieselölkühler Gas oil / diesel oil cooler
HE-008 Ladeluftkühler (Stufe 2) Charge air cooler (Stage 2)
HE-009 Überproduktionskühler Dump cooler
HE-010 Ladeluftkühler (Stufe 1) Charge air cooler (Stage 1)
HE-011 Probeentnahmekühler Sample cooler
HE-012 Generatorlager-Kühler Alternator bearing cooler
HE-013 Notkühler für Wärmenutzung Emergency cooler
Wärmetauscher für Wärmenutzung Heat-exchanger for heat recovery (lube

HE-014 (Schmieröl) oil)
HE-015 Speisewasservorwärmung Feed water preheater
HE-016 Schmierölkühlwasserkühler Lube oil cooling water cooler
HE-017 Ablaufwasserkühler Run down water cooler
HE-018 Kondensatkühler Dampfturbine Steam turbine condensate cooler
HE-019 Zentralkühler Central cooler
HE-020 Seewasserkühler Sea water cooler
HE-021 Verstellpropeller Kühler CPP cooler
HE-022 Kühler für Drehzahlregleröl Cooler for governoroil
HE-023 Getriebe Schmierölkühler Gearbox lube oil cooler
HE-024 Kühler für NT-Kühlwasser Cooler for LT-cooling water
Kühler für Zirkulation im Cooler for circulation fuel oil feeding

HE-025 Kraftstoffzubringerteil part
HE-026 Frischwassererzeuger Fresh water generator
HE-027 Schmierölkühler Hilfsdiesel Lube oil cooler aux. Engine
HE-028 Wrasendampfkühler Vapor cooler
HE-029 Generatorkuehlwasserkuehler Alternator cooling water cooler
HE-030 Ladeluftkuehlwasserkuehler Charge air cooling water cooler
HE-031 Kraftstoffkuehlwasserkuehler Fuel oil cooling water cooler

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Wärmetauscher für Wärmenutzung Heat-exchanger for heat recovery

HE-032 (Motorkühlwasser) (engine cooling water)
HI Isolierungen Insulatings
HI-001 Isolierung, Schwerölleitung Insulating, HFO-pipes
HI-002 Isolierung, Schwerölleitung Insulating, HFO-pipes
HI-003 Isolierung, Ansaugluftleitungen Insulating, intake-air-pipes
HI-004 Isolierung, Abgasleitungen Insulating, exhaust-pipes
ICV Dosierventil Dosingvalve
ICV-001 Wasserdosierventil KWE Water dosing valve FWE
LC Schmieroelueberwachung Lube-oil control
LC-001 Schmierölstandsregler Lube-oil controller
LC-002 Überwachungsbehälter Control-tank
LOV Schwimmerbetätigtes Ventil Float operated valve
Füllventil im Schmieröl Overflow in the lub oil run down tank

LOV-001
Nachlaufbehälter
M Ventil Valve
M-019 Ventil für Motorstartverblockung Valve for engine interlocking device
MOD Module Modules
MOD-001 Aggregat DG set
MOD-002 Motorkühlwassermodul Engine cooling water module
MOD-003 Hilfsbetriebe-Modul Auxiliary module
MOD-004 Vorwärmaggregat Preheating unit
MOD-005 Düsenkühlwassermodul Nozzle cooling water module
MOD-006 Schmierölmodul Lube-oil module
MOD-007 Schmierölseparatormodul Lube-oil separation module

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MOD-008 Kraftstoffmodul Fuel oil module
MOD-009 Kraftstofffiltermodul Fuel oil filter module
MOD-010 Schwerölseparatormodul HFO-separation module
MOD-011 Lecköl- / Schlammodul Leak-oil / sludge module
MOD-012 Arbeitsluft-Kompressormodul Working air compressor module
MOD-013 Speisewassermodul Feed water module
MOD-014 Kondensatsammelmodul Condensate collecting module
MOD-015 Dieselölentlademodul Diesel oil unloading module
MOD-016 Schwerölentlademodul HFO unloading module
MOD-017 Schmierölentlademodul Lube-oil unloading module
MOD-018 Schwerölfüllpumpenmodul HFO-Filling pump module
MOD-019 Wassermodul Water module
MOD-020 Ladeluftkühlwassermodul Charge air cooling water module
MOD-021 Druckluftreduzierstation Pressure air reducting module
MOD-022 Kompressormodul Compressor module
MOD-023 Verteilerpumpenmodul (Wärmeträger) Discharge pump module (heating)
MOD-024 Dieselöl-Ringleitungsmodul DO ring-pipe module
MOD-025 Schweröl-Ringleitungsmodul HFO ring-pipe module
MOD-026 Wärmeträger-Pumpenmodul Heating pump module
MOD-027 Entschwefelungsanlage Scrubber module
MOD-028 Vorwärmmodul Preheater module
MOD-029 Schlammseparatormodul Sludge separation module
MOD-030 Schmierölpumpenmodul L.O. pump module
MOD-031 Service-Schmierölpumpenmodul L.O. maintenance pump module
MOD-032 Wasser-Pumpenmodul (Versorgung) Water pump module
MOD-033 Dieselöl-Separier-Modul Diesel oil separator-module
MOD-034 HFO-Modul für KWE HFO module for FWE
MOD-035 Wasser Dosiermodul KWE Water injection module FWE
MOD-036 Chemikaliendosiermodul Chemical dosing unit

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MOD-037 Speisepumpenmodul Feeder pump module
MOD-038 Schlammmodul (Dampf) Blow down module (steam)
MOD-039 Abgaskesselmodul Exhaust gas boiler module
MOD-040 Ausdampftrommelmodul Steam down module
MOD-041 Heißwasserpumpenmodul Hot water pump module
MOD-042 Schlammpumpenmodul Sludge pump module
MOD-043 Hilfskesselmodul Auxiliary boiler module
MOD-044 Pumpenmodul Schlammseparator Pump module sludge separator
MOD-045 Vorwärmmodul Schlammseparator Preheating module sludge separator
MOD-046 Überschussdampfkühlermodul Dump condenser module
MOD-047 Schlammentwässerungsmodul Sludge press filter module
MOD-048 Radiatorkühler Modul Radiator cooler module
MOD-049 Ansaugluftmodul Suction air module
Schweröl und HFO and MDO pressure control unit

MOD-050 Dieselöldruckreguliereinheit
MOD-051 Komponenten Traegermodul Frame auxiliary box (FAB)
MOD-052 Gas-Regelstreckenunit Gas pressure regulating unit
MON Ueberwachung Monitoring
MON-001 SCADA SCADA
MOV Motorgetriebener Temp. Regler Temp. control valves, motor driven
MOV-001 Schmieröl Temperaturregelventil Lube-oil temperature control valve
Motorkühlwasser Temperaturregelventil Engine-cooling water temperature

MOV-002 control valve
Chatco, Ladeluft Temperaturregelventil Chatco, charge air temperature control

MOV-003 valve
Ladeluftkühlwasser Charge air cooling water temperature

MOV-004 Temperaturregelventil control valve
MOV-005 Umschaltventil, Diesel-/Schwerölbetrieb Switch-over valve, diesel fuel / HFO

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Motorgesteuerte Abgasklappe vor Motor-driven exhaust-gas flap before

MOV-006 Kessel boiler
Motorgesteuerte Abgasklappe nach Motor-driven exhaust-gas flap after

MOV-007 Kessel boiler
Motorgesteuerte Abgasklappe im Motor-driven exhaust-gas flap in

MOV-008 Bypass bypass
MOV-009 Kondensattemperaturregler Condensate temperature controller
Temperaturregelventil für Temperature control valve for HFO-

MOV-010 Schwerölendvorwärmer preheater
MOV-011 Rezirkulationsventil HFO-Modul Recirculation valve HFO-module
Motorbetriebenes Umschaltventil zum Motordriven switch-over valve to diesel

MOV-012 Dieselölkühler oil cooler
Temperaturregelventil Temperature regulating valve hot water

MOV-013 Heißwasserkreislauf (>100°C) (>100°C)
Temperaturregelventil für Notkreislauf Temperature control valve for

MOV-014 emergency cooler
Temperaturregelventil für Heizkreislauf Temperature control valve for heating

MOV-015 circuit
NT-Motorkühlwasser L.T. engine-cooling water temperature

MOV-016 Temperaturregelventil control valve
MSV Anlassventil Starting valve
MSV-001 Hauptanlassventil Main starting valve
NRF Rückschlagklappe Non return flap
Rückschlagklappe nach der Non return flap after attached lube oil
NRF-001 angebauten Schmierölpumpe pump
NRV Rückschlagventil Non return valve
Rückschlagventil nach Schmierölnach- Non return valve after lube oil run down
NRV-002 laufbehälter tank
Sicherheitsventil im Druckluftsystem, Safety valve in pressure air system,

NRV-004 Trennung der Steuerluft bei Mehrmoto- separation of control air at multi engine
renanlagen plants

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O Drosselblende Throttling orifice
Drosselblende im Kühlwassersystem Throttling orifice in cooling water

O-001 nach Motor system after engine
P Pumpen Pumps
P-001 Schmierölpumpe Lube-oil pump
P-002 Motor-Kühlwasser-Pumpe Engine cooling-water pump
P-003 Druckerhöhungspumpe Booster pump
Rohwasser-Kreiselpumpe (NT- Raw water pump (LT cooling water)

P-004 Kühlwasser)
P-005 Düsenkühlwasserpumpe Nozzle cooling water pump
P-006 Dieselöl-Handfüllpumpe Diesel fuel hand-pump
P-007 Vorschmierpumpe (elektrisch) Pre-lubrication pump (electrical)
P-008 Dieselölförderpumpe Diesel-oil supply pump
P-009 Vorschmierpumpe (Hand) Pre-lubrication pump (hand)
P-010 Entleerpumpe Rückspülbehälter Drain pump back flushing tank
P-011 Schmierölseparator-Zubringerpumpe Lube-oil feed pump separator
P-012 Schmieröl-Füllpumpe Lube-oil filling pump
Schmieröl-Entleerpumpe für Drain-pump, used lube-oil

P-013 Altölbehälter
P-014 Schlammpumpe, Schmierölseparator Sludge-pump, lube-oil-separator
P-015 Zubringerpumpe, Schwerölseparator Feed pump, heavy oil separator
P-016 Handpumpe für Viskosimeter Hand pump, viscosimeter
P-017 Schlammpumpe, Schwerölseparator Sludge pump, HFO separator
P-018 Schweröl Förderpumpe HFO supply pump
P-019 Speisewasserpumpe Feed water pump
P-020 Heisswasser-Umlaufpumpe Boiler circulating pump
P-021 Schmieroelförderpumpe, Vorwärmung Lube oil supply pump, Preheating
P-022 Wärmeträgeröl-Umwälzpumpe Thermal-oil circulating pump

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P-023 Entleerpumpe für Kraftstoffüberlauftank Discharge pump for overflow tank
Kühlwasserpumpe für Cooling-water pump for dump cooler

P-024 Überschussdampferhitzer
P-025 Ladeluftkühlwasserpumpe Charge air cooling water pump
P-026 Kondensat-Förderpumpe Condensate pump
P-027 Schweröl-Rezirkulationspumpe HFO-recirculating pump
P-028 Dieselölförderpumpe Diesel-fuel supply pump
P-029 Schlammpumpe Sludge pump
P-030 Transport-Entleerpumpe Mobile transfer pump
P-031 Füllpumpe, Wasser, elektr. Filling pump, water, electr.
P-032 Füllpumpe, Wasser, manuell Filling pump, water, manual
P-033 Heisswasserumwälzpumpe Hot water circulating pump
P-034 Druckerhöhungspumpe, Speisewasser Booster pump feedwater
P-035 Dosierpumpe Proportioning pump
Wasserversorgungspumpe Water-supply pump cooling tower basin

P-036 Kühlturmbecken
P-037 Vakuum-Pumpe Vacuum pump
P-038 Schweröl-Füllpumpe HFO filling pump
Druckerhöhungspumpe, Booster pump, water supply

P-039 Wasserversorgung
P-040 Kühlwasserpumpe (Dampf) Cooling-water pump (Steam)
P-041 Schlammumwälzpumpe Sludge circulating pump
Zubringerpumpe (Schlamm) Incinerator feed pump

P-042 Schlammverbrennung
Zubringerpumpe (Diesel) Incinerator diesel-oil feed pump

P-043 Schlammverbrennung
P-044 Zubringerpumpe Schlammseparator Sludge separator feed pump
P-045 Schlammpumpe Schlammseparator Sludge pump, sludge separator
P-046 Entleerungspumpe, Schlammtank Discharge pump sludge collecting tank
P-047 Umwälzpumpe, Vorwärmung Circulating pump, preheating
P-048 Schmutzwasserpumpe Dirty water pump

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P-049 Hydraulikpumpe Hydraulic pump
P-050 Schlammpumpe Dieselöl Separator Sludge pump diesel-oil separator
P-051 Schmierölkühlwasserpumpe Lube oil cooling water pump
P-052 Schwerölwärmeverwertungspumpe HFO heat recovery pump
P-053 Dosierpumpe Proportioning pump
P-054 Entleerungspumpe Neutralisationstank Discharge pump neutralization tank
P-055 Feuerlöschpumpe Fire fighting pump
P-056 Altölentleerpumpe Used oil drainage pump
P-057 Dieselölfüllpumpe Diesel-oil filling pump
P-058 Schlammentleerungspumpe Sludge drainage pump
P-059 Schmierölfüllpumpe Lube-oil filling pump
P-060 Sumpfpumpe Sump pump
P-061 MKW Vorwärmpumpe ECW preheating pump
P-062 Seewasserpumpe Sea water pump
P-063 Wärmeträgeröl-Verteilerpumpe Thermal oil discharge pump
P-064 Zubringerpumpe Feed pump
P-065 Wasserdosierpumpe KWE Water dosing pump FWE
P-066 Entleerpumpe Schmierölwartungstank Drain pump lube oil maintenance tank
P-067 Entleerpumpe Entwaesserungstank Drain tank discharge pump
P-068 Entleerpumpe Schlammtrocknung Sludge dryer discharge pump
P-069 Generatorkuehlwasserpumpe Alternator cooling water pump
P-070 Nachkuehlpumpe (Motorkuehlwasser) After cooling water pump
P-071 Entleerpumpe Kraftstoffleckölbehälter Drain pump fuel oil tank
P-072 Entleerpumpe Schmierölschlammtank Drain pump lube oil sludge tank
P-073 Zubringerpumpe MDO Separator Supply pump MDO separator
P-074 Schmierölpumpe freistend Lube-oil pump electrical
P-075 Zylinder-Schmieroelpumpe Cylinder lube oil pump
P-076 Pumpe für NT-Kühlwasser Pump for L.T. cooling water
P-077 Schwerölzubringerpumpe KWE Heavy fuel oil supply pump FWE

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P-078 Kraftstoffkuehlwasserpumpe Fuel oil cooling water pump
Rohwasser-Kreiselpumpe (HT- Raw water pump (HT-cooling water)

P-079 Kühlwasser)
P-080 Füll-/Entleerpumpe Wärmeträgeröl Filling / discharge pump thermal oil
P-081 HFO-Entladepumpe HFO unloading pump
P-082 DO-Entladepumpe DO unloading pump
P-083 LO-Entladepumpe LO unloading pump
PCV Druckregelgeräte Pressure control valves
PCV-001 Druckminderstation für Steuerluft Pressure reduction station control air
Druckminderstation für Arbeitsluft 10/6 Pressure reduction station working air

PCV-002 bar 10/6 bar
PCV-003 Druckminderstation fuer Zubehör Pressure reduction valve equipment
PCV-005 Dampfdruckregler Steam pressure regulator
PCV-006 Automatische Nachfülleinrichtung Automatic refill device
PCV-007 Absteuerventil, Schmierölsystem Spill valve, lube oil system
Druckhalteventil nach Motor, MDO- Pressure retaining valve, MDO

PCV-008 Betrieb, offenes System operation, open system
Druckbegrenzungsventil, HFO Zubrin- Pressure limiting valve, HFO feeder

PCV-009 gersystem, nicht vorgesteuert system, not precontrolled
Druckbegrenzungsventil, HFO Zubrin- Pressure limiting valve, HFO feeder

PCV-010 gersystem, vorgesteuert system, precontrolled
Absteuerung im Einmotorenbetrieb bei Spill in single engine operation at multi

PCV-011 Mehrmotorenanlagen im Kraftstoff- engine plants in fuel oil system
System
Druckhalteventil nach Motor, HFO- Pressure retaining valve, HFO

PCV-012 Betrieb, Mehrmotorenanlage operation, multi engine plant
Druckregelventil für KWE Pressure regulating valve for FWE

PCV-013 Zubringersystem feeding system
Gasdruck-Regelventil mit externer Gas pressure-control valve with

PCV-014 Sollwertvorgabe und SAV-Funktion external set-point presetting and
integrated safety shut off function

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PLC Programmierbare Steuerung Programmable logical control
PLC-001 SACOS (Motorsteuerung) SACOS (engine control)
PLC-002 SCPLC (Hilfsbetriebesteuerung) SCPLC (auxiliary control)
POF Druckluftbetaetigte Absperrklappe Pressure air operated flap
Absperrklappe der Verbindungsleitung Shut off flap of connection line charge

POF-001 LLK-Stufe 1 mit LLK-Stufe 2 air, cooler stage 1 to charge air cooler-
stage 2
Absperrklappe Zulauf LLK Stufe 2 Shut off flap inlet charge air cooler
POF-002 stage 2
PR Sicherheitseinrichtungen Safety equipment
Gitterrostabdeckung auf Grate covering on free engine side

PR-001
Kupplungsseite
PR-002 Generator Schutzgeländer Alternator guard rail
Motor-Galerie mit Treppe und Motor gallery with stairs and girder
PR-003 Galerieträger
PR-004 Gitterrostabdeckung im Maschinenhaus Grate cover, power house
PR-010 Kühlergestell Cooler frame
Kessel-Tragkonstruktion mit Boiler supporting frame with

PR-011 Wartungsbühne maintenance gallery
PSV Druckbegrenzungsventil Pressure safety valve
Sicherheitsventil an der Saugseite der Safety valve on suction side of attached

PSV-004 angebauten Pumpe, Schmierölsystem pump, lube oil system
Q Detektoren Detectors
Q-001 Ölnebeldetektor Oil-mist detector
Q-002 Öleinbruchsmelder Oily water detector
Q-003 Gas-Detektor Gas detector
Q-004 Methanzahlsensor Methane number sensor

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QSV Schnellschlussventile Quick action stop valve
QSV-001 Gas-Schnellschlussventil Gas quick action stop valve
SOV Magnetventile Solenoid valves
SOV-001 Schmierölnachfülleinrichtung Lube oil replenishing system
Not Kraftstoff Druckhaltung (Mischtank) Emergency fuel control EFC (mixing

SOV-002 tank)
ST Strukturen Structures
ST-001 Schornstein Exhaust stack
STR Schmutzfänger Strainer
Schmutzfänger im Y-type strainer

STR-010
Kraftstoffzubringerteil
SL Schalldämpfer Silencer
SL-001 Ansaugschalldämpfer Intake air silencer
SL-002 Abgasschalldämpfer Exhaust gas silencer
SL-003 Regenhaube Rain cover
T Behälter Vessels and tanks
T-001 Schmieröl-Betriebsbehälter Lube-oil service tank
T-002 Motorkühlwasser-Ausgleichsbehaelter Engine cooling water expansion tank
T-003 Dieselöltagestank Diesel-oil day tank
Ladeluftkühlwasser- Charge air cooling water expansion

T-004
Ausgleichsbehaelter tank
T-005 Düsenkühlwasser-Ausgleichsbehälter Nozzle cooling water expansion tank
T-006 Leckölbehälter Leakage oil tank
T-007 Anlassluftgefäß Starting air vessel
T-008 Kraftstoff-Pufferbehälter Fuel-oil dumper tank

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T-009 Schlammbehälter, Schmierölseparator Separator sludge tank
T-010 Schweröl-Betriebsbehälter HFO day tank
T-011 Kraftstoff-Mischbehälter Fuel-oil mixing tank
T-012 Reinöl-Vorratsbehälter Clean-oil tank
T-013 Schmutzöl-Vorratsbehälter Used-oil tank
T-014 Standrohr Stand pipe
T-015 Dieselöl-Vorratsbehälter Diesel-oil storage tank
T-016 Schweröl-Vorratsbehälter HFO-storage tank
T-017 Wasservorratsbehälter, Frischwasser Water storage tank, fresh water
T-018 Druckluftbehälter für Jet-Assist Air vessel for jet assist
T-019 Schlammbehälter Sludge tank
T-020 Entgasungstopf Degassing tank
T-021 Schlammbehälter, Schwerölseparator Sludge tank for HFO-separator
T-022 Schweröl Tagestank HFO day tank
T-023 Kraftstoffüberlaufbehälter Overflow tank
T-024 Kondensat- und Speisewasserbehälter Feed water tank
T-025 Ausdampftrommel Evaporating drum
T-026 Steuerluftflasche Control air bottle
T-027 Schmierölwartungstank Lube oil maintenance tank
T-028 Sammelbehälter Wärmeträgeröl Collecting tank, thermal oil
T-029 Ausgleichsbehälter, Wärmeträgeröl Expansion tank, thermal oil
T-030 Ausgleichsbehälter, Zwischenkreislauf Expansion tank, intermediate circuit
T-031 Kondensatsammeltank Condensate collecting tank
T-032 Dampfverteiler Steam distributor
T-034 Dampfverteiler Tanklager Steam distributor
T-035 Wasservorratsbehaelter Water storage tank
T-036 Arbeitsluftflasche Working air bottle
T-037 Separatorschlammtank Separator sludge collecting tank

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T-038 Dosierbehälter Proportioning tank
Wasservorratsbehaelter, aufbereitetes Water storage tank, treated water

T-039 Wasser
T-040 Weichwassererzeuger Water softening plant
T-041 Speisewasserhochbehaelter Feed-water head tank
T-042 Schlammtank, Schlammseparator Separator sludge tank
T-043 Grundwasser Zwischentank Bilge water intermediate tank
T-044 Vorratstank für Schlammverbrennung Incinerator storage tank
T-045 Wasseraufbereitung für Separator Water softening plant for separator
T-046 Dieselöltank, Schlammverbrennung Diesel-oil tank incinerator
T-047 Weichwassertank Softened water tank
T-048 Abschlammtank Blow down tank
T-049 Neutralisationstank Neutralisation tank
T-050 Nachschmierbehaelter Lube-oil tank
T-051 Chemikalienbehälter Chemical tank
T-052 Schlammtank Sludge tank
T-054 Anfahrbehälter Hilfskessel Start up tank auxiliary boiler
T-055 Ablassbehälter für Schmieröl Maintenance tank for lube-oil
Druckausgleichsbehälter Dampf- / Expansion tank steam / thermal oil

T-056 Thermalöl
T-057 Wasseraufbereitungsanlage Water treatment plant
T-058 Druckspeicher Pressure accumulator
T-059 HFO-Zwischentank HFO buffer tank
T-060 KWE Betriebsbehälter FWE service tank
Ausgleichsbehälter Expansion tank water dosing unit

T-061 Wasserdosiereinheit (KWE) (FWE)
T-071 Kraftstoffleckölbehälter Leakage fuel tank
T-072 Schmierölschlammbehälter Sludge tank (lube oil)

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Behälter für Turbolader Run down tank for turbocharger

T-073 Nachlaufschmierung lubrication
T-074 Frischwassersammeltank Fresh water collecting tank
NT-Motorkühlwasser L.T. engine cooling water expansion

T-075 Ausgleichsbehälter tank
T-076 Düsenkühlwasser Betriebsbehälter Nozzle cooling water service tank
T-077 Ladeluftkühler Reinigungsbehälter Charge air cooler cleaning tank
T-078 Schmutzwassertank Waste water tank
T-079 Entwässerungstank Drain tank
T-080 Feuerloeschwasser Vorratstank Fire water storage tank
T-081 Chemikaliendosiereinrichtung (HT) Chemical dosing device (HT)
T-082 Chemikaliendosiereinrichtung (NT) Chemical dosing device (NT)
T-083 Chemikaliendosiereinrichtung (DKW) Chemical dosing device (NCW)
Chemikaliendosiereinrichtung Chemical dosing device (Preheating)

T-084 (Vorwärmung)
T-085 Heisswasser Ausgleichsbehälter Hot water expansion tank
TCV Temperatur-Regelventile Temperature control valves
TCV-001 Temperaturregelventil für Schmieröl Lube-oil temperature control valve
Temperaturregelventil für Engine cooling water temp. control

TCV-002 Motorkühlwasser valve
Temperaturregelventil für Charging air cooling water temp.

TCV-003 Ladeluftkühlwasser control valve
TCV-004 Temperaturregelventil für Rohwasser Raw-water temp. control valve
Düsenkühlwasser- Nozzle cooling water temp. control

TCV-005
Temperaturregelventil valve
TCV-006 Kraftstoff-Temperaturregelventil Fuel-oil temperature control valve
TCV-007 Heisswasser-Temperaturregelventil Hot water temperature control valve
Temperaturregler Temperature control intake air

TCV-008 Ansaugluftvorwaermung preheating
Temperaturregelventil für die Temperature control valve for heating

TCV-009 Beheizung des of the nozzle cooling water expansion
Düsenkühlwasserausgleichsbehälters tank

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Temperaturregler für Temperature control valve HFO service

TCV-010 Schwerölbetriebsbehälter tank
Temperaturregler-Dampf für Temperature control valve for heating

TCV-011 Einsteckheizregister coil HFO-tank
Schwerölvorratstank
Temperaturregelventil für Temperature control valve for HFO-

TCV-012 Bodenheizschlange Schweröltank tank
Temperaturregelventil für Lecköltank Temperature control valve for leak oil

TCV-013 Schweröl HFO
Temperaturregelventil für Schlammtank Temperature control valve for sludge

TCV-014 Schweröl tank HFO
Temperaturregelventil für Schlammtank Temperature control valve for sludge

TCV-015 Schmieröl tank lube-oil
Temperaturregelventil Altölbehälter Temperature control valve for used oil

TCV-017 tank
Temperaturregelventil Schmieröl- Temperature control LO-preheating

TCV-018 Vorwärmung
Temperaturregelventil, Temperature controlvalve, engine

TCV-019 Motorkühlwasservorwärmung cooling water preheating
Temperaturregelventil Schmieröl- Temperature control valve for LO st.

TCV-020 Vorratsbehaelter tank
Dampf-Regelventil für Steam control valve for lube oil service

TCV-021 Schmierölbetriebsbehälter tank
TR Abscheider Trap
Kondensatableiter im Schmierölsystem Condensate trap in lube oil system /

TR-001 / Entlüftungsleitung vent pipes
TR-002 Ölabscheider im Druckluftsystem De-oiler in compressed air system
TR-003 Lufttrockner Air dryer
TR-004 Entgaser Deaerator
Wasserabscheider im Druckluftsystem, Water trap in pressure air system,

TR-005 Steuerluft vor Motor working air before engine
TR-006 Automatischer Wasserabscheider Automatic condensate trap in starting

Anlassluftgefäß air vessel
TR-007 Öldunst-Entlüftungsventil Oil mist venting

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TY Warnanlage Typhon
TY-001 Allgemeine Warnanlage General typhon
V Absperrhahn Shut-off cock
Plombiertes Durchgangsventil, Umge- Lead sealed globe valve, bypass to

V-001 hung zum Schmieröl Hauptfilter lube oil main filter
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.
V-003 Gas-Hand-Absperrventil Gas hand stop valve
VI Viskosemessgeraete Viscosimeter
VI-001 Viskosemessgeraet Viscosimeter
W Werkzeuge Tools
W-001 Maschinenhauskran Engine building crane
W-002 Hebezeug Lifting device
W-003 Waschtisch für Separator Washing stand for separator
W-004 Fahrbares Siebreinigungsgerät Movable sieve cleaner
W-005 Hochdruckreiniger High pressure cleaner

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4.38 Compliance with safety regulations/First Aid

The Contractor shall keep the relevant safety regulations on the construction site and instruct his personnel
to the required extent and in good time in accordance with the legal requirements.
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 local safety regulations must always be observed.
4.39 As-built record

After assembly, the as-built status must be transferred to the corresponding planning documents by the
Contractor as “red” entries. The as-built record includes the pipes, pipe supports and module installation.
The original “as-built” documents shall be handed over by the Contractor to MBD for further use.
If necessary, the “As-built record” shall already be started during assembly (e.g. in the case of high pipes
which cannot subsequently be checked without a scaffold).
4.40 Pressure test

General
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:
Number range Pipe class Description Design

TC (°C) PC (bar)
21 10 LO 03 lube oil main 100 10

22 10 LO 03 lube oil separation 100 10
23 10 LO 03 lube oil supply 100 10
24 10 LO 03 cylinder lubrication 100 10
25 10 LO 03 turbocharger lubrication 100 10
26 10 LS 03 lube oil main (stainless steel) 100 10
28 10 LO 03 oil mist 100 10
31 10 W 03 engine cooling water 100 10

32 10 W 03 charge air cooling water 100 10
34 10 W 03 nozzle cooling water 100 10
35 10 W 03 water supply (treated) 100 10
36 10 WN 03 water supply (galvanized) 50 10
37 10 WD 03 water supply (stainless steel) 50 10
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
50 300 FG 03 gas (high pressure) 50 300
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51 10 FL 03 light fuel oil (HFO operation) 80 10

52 10 FL 03 light fuel oil (DO operation) 80 10
53 10 FL 03 light fuel supply 80 10
54 10 FH 03 heavy fuel separation 160 10
55 10 FH 03 heavy fuel supply 160 10
56 10 FH 03 heavy fuel (treated) 160 10
57 10 FH 03 heavy fuel supply (treated) 160 10
58 16 FG 03 gas 50 16
59 10 FH 03 sludge 160 10
61 01 IA 03 intake air 50 01
62 06 CA 03 charge air 250 06
65 06 EG 03 exhaust gas 450 06
71 40 AS 03 starting air (30 bar) 50 40

72 10 AI 03 control air 50 10
73 10 AW 03 working air 50 10
74 40 ASS 03 starting air (30 bar, stainless steel) 50 40
81 10 S 03 steam (inside power house) 190 10

82 10 S 03 steam (outside power house) 190 10
83 10 SH 03 steam heating (tracing) 184 10
84 25 HW 03 hot water 200°C 200 20
85 10 S 03 feed water 190 10
86 10 C 03 condensate (inside power house) 180 10
87 10 C 03 condensate (outside power house) 180 10
88 40 HW 03 hot water 250°C 250 40
89 16 TO 03 thermal oil 250 16
Table 7
Pressure testing of pipe components in the system with test medium.
Test pressure PT = 1.25 x PS x temperature factor acc. to AD2000 HP 30, 4.17, but at least 1.43 + PS
MBD recommends the following procedure:
• Acid-clean pre-fabricated pipe sections

• Neutralise pre-fabricated pipe sections
• Pressure-test, empty and dry pre-fabricated pipe sections
• After installation, fill the system, test for leaks with the operating pressure and fill the systems
with operating medium.
• Caution: If blank disks or sealing caps were fitted, these must be removed for flushing or
subsequent operation!
• Use test, venting and draining connections for filling (draining) the systems.
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.
The first pressure test takes place
• after the last heat treatment,

• before application of paint finishes, insulation, rubber coatings or similar,
• after non-destructive testing,
• or special leak tests.
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.
Preparation for fluid pressure test
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
Proceed as follows when performing the pressure test:
• Slowly and continuously increase the pressure up to the test pressure.

In the case of pressure vessels, the hydrostatic test pressure must correspond to the higher of the
following values in accordance with AD 2000:
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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.
Note on pressure test
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.
Pressure tests with air or gas are not permitted.
4.41 Paint finish

Uninsulated plant pipes shall be realised in RA9002 – gray white. Identification of the medium and direction
of flow in the pipe shall take place by means of stickers, usually in English. The sticker colours for media
identification shall be based on DIN 2403.
4.42 Assignment of colours to transported media

The media transported in the pipes are divided into 10 groups according to their general properties, and the
corresponding colours are defined in Table 12.
Closest colour
Colour code
sample in RAL
Medium Group Colour name acc. to DIN 6164
colour register
Part 1
RAL 840 HR
Water 1 Green 23 : 7 : 3 RAL 6018
Steam 2 Red 7:8:3 RAL 3000
Air 3 Gray 18 :1 : 3 RAL 7001
Combustible gases Yellow 2:6:1 RAL 1021
or 2:6:1 RAL 1021

4
Yellow with additional 7:8:3 RAL 3000
colour red
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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
Non-combustible Yellow 2:6:1 RAL 1021

gases With additional colour
Black N : 0 : 9.5 RAL 9005
5
or
Black N : 0 : 9,5 RAL 9005
Acids 6 Orange 5:5:1 RAL 2003
Lyes 7 Violet 11 : 2 : 4 RAL 4001
Combustible fluids Brown 3:5:4 RAL 8001
or
8
Brown 3:5:4 RAL 8001
With additional colour
Red 7:8:3 RAL 3000
Non-combustible fluids Brown 3:5:4 RAL 8001

With additional colour
Black N : 0 : 9.5 RAL 9005
9
or
Black N : 0 : 9.5 RAL 9005
Oxygen 0 Blue 17 : 5 : 2 RAL 5015
Table 8: Assignment of colours to transported media
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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4.43 Inspection at the end of assembly

A joint inspection shall be performed by the Client and MBD after the end of assembly. This shall be done
by checking the documents, test and inspection plan and test records to be presented by the Contractor for
completeness and correctness of execution. This shall be followed by a joint inspection tour of the plant to
verify its readiness for operation. Particular attention shall be paid to the following:
• Agreement with the specifications of the Client and MBD

• Agreement with the test items of the Client; if MBD is identical with the client, agreement with the
quality plan as well as complete and correct test documentation
• Execution in accordance with drawings
• Completeness
• Turnkey execution:
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
• Agreement with P+ID

• Freedom of movement
• Accessibility
• Removal of assembly aids
• External appearance
• Observance of escape routes
• Installation of touch protection
• Cleanliness of the plant
• Electrical installation has been completed
Turnkey completion shall be documented in a joint record.
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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5 Quality assurance and documentation

All the quality documents specified in these assembly instructions (e.g. marking transfer certificates, test
records, etc.) and other applicable documents for the order (e.g. quality plans), as well as documents
required for verification of compliance with EU Directives (in countries where EU law is valid) shall be handed
over to the Client for inspection and archiving. In addition, MBD shall be provided with a copy of all
documents produced in the form of a CD (PDF format). There shall be order-specific consultation between
the Contractor and Client with respect to this in all cases. If the Client and MBD are identical, the Contractor
shall consult MBD Dept. QP. The Dept. QP will normally produce a quality plan in this case. In addition,
conclusion of a quality agreement Q 61.62000-1100 is then required in this case.
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.
5.1 Procedure and work inspections and tests

The Contractor shall provide the Client with all procedure and work inspections and tests (copy) which are
required for execution of this order for inspection by the Client.
5.2 Welding procedure specifications/test instructions

The Contractor shall produce welding procedure specifications and test instructions for all the required
joining operations of this order in accordance with the existing procedure and work inspections and tests and
the current state of the art. The Client shall have the right to inspect these instructions. The current welding
procedure specifications must be available in the work folder on the spot with the welder and must be
observed by the welder.
5.3 Welder test certificates

Copies of the original welder test certificates shall be handed over to the Client. The original shall be kept by
the welding supervisor of the Contractor on the construction site and is kept with the welder list, Section 5.4.
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5.4 Welder list

The welding supervisor of the Contractor shall keep a welder list for all welders on the construction site with
the following content:
• 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.
5.5 Welding supervisor

The welding supervisor of the Contractor shall ensure that only certified and qualified welders with a valid
technical qualification are used within the respective area of validity.
The welding supervisor shall keep the welder list in accordance with Section 5.4.
In addition, the welding supervisor of the Contractor shall coordinate the necessary inspections of the weld
seams and shall ensure compliance with the required scope of inspection. If required for the order, and if the
Client and MBD are identical, there shall be an extended scope of inspection and documentation as defined
by an MBD quality plan. The Contractor shall be responsible for taking the initiative towards the Client with
respect to consultation and agreement. The Contractor shall recognise this scope. The welding supervisor of
the Contractor shall be responsible for prompt documentation and shall ensure that all welders are covered
equally by the demanded weld seam inspection. The welding supervisor shall keep a statistical record of the
welded and inspected seams and of the proportion of repairs.
5.6 Welding monitoring

Welding supervision, monitoring, tasks and responsibilities are based on DIN EN 719.
Skills according to Section 5.2.2 are required.
In this connection, the following minimum requirements apply:
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:
- European welding engineer Doc EWF 02-409-93;

- European welding technician Doc. EWF 02-410-93;
- European welding specialist Doc. EWF 02-411-93.
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.
5.7 Proof of qualifications for test and inspection personnel

The test supervisor and test and inspection personnel of the Contractor shall be trained, qualified and
certified in accordance with DIN EN 473.
The test supervisor shall coordinate deployment of the test and inspection personnel and the test equipment,
and shall sign the necessary test reports after evaluation. In addition, the test supervisor shall keep the list of
test and inspection personnel in accordance with the assembly instructions.
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5.8 List of test and inspection personnel

The test supervisor of the Contractor shall keep a list of the deployed test and inspection personnel on the
construction site with the following content:
• Serial No.
• Last name, first name of tester
• Test procedure
• Qualification level
• Date of certificate
The Client shall be provided with copies of the test certificates.

The test certificates (certified copy) shall be filed corresponding to the Serial Nos. Certification of the test
certificates shall take place as described in Section 5.3 for welding products.
5.9 Weld seam testing

The weld seams shall be tested with the required test procedure and test scope as described above. The
tests shall be documented with test reports. It must be possible to unambiguously assign the test reports to
a specific pipe or to the component and weld seam. The reports shall be numbered consecutively for each
test procedure. The Client shall receive the test reports (copies where appropriate).
If weld imperfections are established during the tests which are not permitted, then the seam shall be
repaired or rewelded subject to agreement between the site management and the welding supervisor of the
Contractor.
The site management shall be informed before a repair/rewelding is performed.
Two additional welds of the affected welder shall be checked for every established inadmissible imperfection
(repair/rewelding). If inadmissible weld imperfections should be established again in these additional
inspections, the scope of testing and inspection of the affected welder shall be increased to 50% of all seams
welded up to this point. If additional inadmissible weld imperfections are established, the scope of testing
and inspection shall be increased to 100% and the welder shall be prohibited from carrying out any further
welding work.
The costs for additional tests resulting from repairs shall be borne by the Contractor.
5.10 Pipe bend tests

The pipe bends shall be tested with the required test procedure and test scope as described in Section 3.4.
The tests shall be documented with test reports.
The form and content of the test reports shall be agreed between Client and Contractor. It must be possible
to unambiguously assign the test reports to a specific pipe and the pipe bend. The reports shall be numbered
consecutively for each test procedure. The Client shall receive the test documentation
5.11 Inspection of chemical cleaning

Chemical cleaning shall be checked and the results documented.
5.12 Inspection of mechanical installation
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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.
5.13 Documentation of the pipe weld seams, pipe bends and

corresponding tests
Pipe weld seams and the corresponding tests etc. shall be documented clearly on a suitable form. The test
locations and results shall be clearly assigned on the form, where appropriate by means of diagrams.
The form shall be agreed between the Client and Contractor.
It shall at least include:
• 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.
5.14 Pressure test records

The pressure test records shall be produced for each pressure circuit.
The pressure circuits shall be defined on the spot depending on the possibilities available on site in
cooperation between the Contractor and Client and in agreement with MBD; these circuits shall then be
defined in the flow diagram and named. The Contractor shall provide the Client with the test records which
are assignable to the test location, test pressure and target/actual result, etc.
5.15 Client’s quality plan

If the Client has produced a quality plan which defines the scope of testing and documentation, the
Contractor shall bindingly recognise this. All work shall then be executed in accordance with these
specifications, where appropriate in addition to the Contractor’s quality assurance measures, and shall be
documented in the form specified by the Client.
5.16 MBD quality management, quality assurance and quality plan

The location Augsburg, Germany, has implemented a quality management system in accordance with
DIN EN ISO 9001 2000 and an environmental management system in accordance with DIN EN ISO 14001,
and is certified by Germanischer Lloyd Certification GmbH.
An Integrated Quality and Environmental Management Manual Q10.09006-5000 (I-Q-U) is available and is
implemented in the processes. These management systems are permanently maintained and further de-
veloped by comprehensive internal measures such as internal and external audits. The process descriptions
Quality Management for Plant Construction, No. A2705 and A1844 form part of the I-Q-U Manual.
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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5.17 Constructional deviations if the Client is identical with MBD

If constructional deviations from the specification occur which are caused by the Contractor with respect to
his scope of performance but where utilisation appears possible, then the Contractor shall produce a
deviation report with the form FK 0904. The Contractor shall apply for an approval from MBD as soon as a
deviation is established. The deviation report must contain detailed information on the respective deviation,
the planned corrective measures and the remaining deviation after correction. Components with approved
constructional deviations shall be identified in the quality documentation. No hand-over shall occur if the
Contractor does not have an approval of the constructional deviation from MBD. The Contractor shall keep
records of all deviations from the specification which show the cause of the fault, the fault location and the
corrective measures which are necessary to avoid the fault being repeated. These records shall be made
available to the ordering party on request.
The reports shall be made to MBD project management through the Site Manager.
5.18 Fault reporting

Faults which become evident during construction of the plant in supplied components or also systems shall
be reported to MBD using Form FK 0917.
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.
5.19 Content of the document folder:

• Legally binding and signed Quality Report FK 0920,
• Manufacturer approvals of the supplier
• The following quality documentation shall be supplied from the tests and inspections for each
individual item of the scope of performance for which a test plan has been defined:
o Final inspection / release report of the supplier for the individual item
o Test plan (copy of the ordering party’s specification)
o Record of the test results with assignment to the test items from the test plan (form provided
by the ordering party)
o Record of material traceability (where appropriate with welder assignment)
o Material certificates for starting materials (sheets, sections), analysis and strength, in so far
as procured by the supplier
o Material certificates for welding fillers
o Welding plan (WPS)
o Welding approvals
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o Welding procedure tests

o Welder qualifications (welding supervisor and welders)
o Non-destructive testing – qualifications of test supervisor and testers
o Non-destructive testing – Procedure / Method
o Surface treatment / paint finish, test in accordance with AN410
o Marking transfer certificate
o If applicable for the system, conformity declaration / manufacturer’s declaration in
accordance with EU laws / directives and, if applicable, conformity proof for national
specifications in the country of operation or for World Bank specifications.
• CD data medium with corresponding content.
If an acceptance record from MAN B&W Diesel AG is planned for the supplier’s scope of performance, the
Contractor shall receive this from MBD. The procedure for dealing with the list of outstanding items shall be
clarified immediately.
If not otherwise required in the order, the Contractor shall hand over the documentation (document folder) to
MBD in one delivery at short notice and within a maximum of 2 weeks after the last inspection.
Note:
The order shall be deemed as complete only when the agreed quality documentation has been supplied
completely and correctly.
Important:
User instructions for components which are subject to EU Directives and which must be supplied
unrequested as well as ordered technical documentation shall be handed over to MBD, Dept. GM, on an
order-specific basis.
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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.
6.1 Materials, substances

The use of certain materials and substances is regulated by corresponding legislation (e.g. prohibition
of heavy metals and asbestos, etc.). The Contractor is obliged to observe these regulations. He shall
produce material/safety data sheets for hazardous materials and enclose these with the
documentation for the ordering party.
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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MAN Assembly Instructions Pipes and Equipment

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Assembly instructions for stationary diesel power plants – Pipes and equipment

Assembly instructions for stationary diesel power plants

Pipes and equipment

Revision: 02.02.2005 Page 1 of 123 MAN assembly instructions pipes and

2 Regulations and directives.......................................................................................................................8

3 Preconditions/Manufacturer qualifications ..........................................................................................11

4 Turnkey assembly ...................................................................................................................................16

Revision: 02.02.2005 Page 2 of 123 MAN assembly instructions pipes and

4.21 Screw-connected pipelines ................................................................................................................47

Work sequence ...............................................................................................................................................47

5 Quality assurance and documentation ...............................................................................................116

Revision: 02.02.2005 Page 3 of 123 MAN assembly instructions pipes and

5.7 Proof of qualifications for test and inspection personnel .................................................................117

6 Environment, legality ............................................................................................................................123

Revision: 02.02.2005 Page 4 of 123 MAN assembly instructions pipes and

Revision: 02.02.2005 Page 5 of 123 MAN assembly instructions pipes and

• The possibility of removing pipes or sections to permit disassembly of components for

Revision: 02.02.2005 Page 6 of 123 MAN assembly instructions pipes and

AG Client (may be identical with MBD–MAN B&W Diesel AG)

Revision: 02.02.2005 Page 7 of 123 MAN assembly instructions pipes and

2 Regulations and directives

• National laws, regulations, directives, decrees, specifications of the World Bank

List of important reference standards:

Welding and inspection standards/Recognition of welding procedures

Revision: 02.02.2005 Page 8 of 123 MAN assembly instructions pipes and

Non-destructive material testing

Terms, definitions, imperfections /weld seam

2.1 Deviating regulation

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2.2 Proof of conformity

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3.1 Manufacturer preconditions

3.2 Preconditions for procurement by the Contractor

The following shall apply as standard to procurement:

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3.3 Approvals for joining procedures (welding procedures)

3.4 Work inspection of the pipe bending procedure

The scope of validity for the dimensions is determined as follows:

Wall thickness range 0.75tB ≤ tT ≥ 1.25 tB

Bending radius/diameter ratio Rm/da ≥ 3.0

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Ovality is defined as follows:

The following requirements shall be met:

The maximum permissible ovality for cold bending is ≤ 4%.

The measured values (dimensions in mm) are as follows:

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• Wall thickness (a – h) in the planes 1 to 15

Figure 1. Measurement of wrinkles

At the same time, the wrinkle spacing (a) must be

Welding in the bending zone of pipe bends is not permitted.

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3.5 Preconditions for non-destructive material testing (test

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• Lube oil system

4.1 Construction site equipment

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4.2 Unloading and transport on the construction site

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4.3 Incoming goods inspection

The Contractor shall dispose of any packaging.

4.5 Work preparation

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4.6 Material issue, preservation of identification