Dieffenbacher Standards

Dieffenbacher Project Standards

Appendix 1

Table of contents
1 COMMUNICATION .................................................................................................................................... 3
2 STANDARDS AND REGULATIONS ......................................................................................................... 3
2.1 Languages .................................................................................................................................................. 3
2.2 Measuring system ...................................................................................................................................... 3
2.3 Numbering system ..................................................................................................................................... 3
2.4 Standards ................................................................................................................................................... 3
2.5 Quality assurance ....................................................................................................................................... 3
3 MECHANICAL DESIGN CRITERIA .......................................................................................................... 4
3.1 General ....................................................................................................................................................... 4
3.2 Pre-assembly.............................................................................................................................................. 4
3.3 Maintainability ............................................................................................................................................. 5
3.4 Flange connections .................................................................................................................................... 5
3.5 Drive systems ............................................................................................................................................. 5
3.6 Gear motors and reducers ......................................................................................................................... 5
3.7 Bearings ..................................................................................................................................................... 5
3.8 Pressurized systems and pressure vessels ............................................................................................... 5
3.9 Compressed air systems ............................................................................................................................ 5
3.10 Hydraulic systems ...................................................................................................................................... 6
3.11 Steel structures, platforms, catwalks, stairs ............................................................................................... 6
3.12 Support bases and anchor bolts................................................................................................................. 6
3.13 Special tools ............................................................................................................................................... 6
4 ELECTRICAL DESIGN CRITERIA ............................................................................................................ 7
4.1 Power supply .............................................................................................................................................. 7
4.2 Motors, motor starters and brakes ............................................................................................................. 7
4.3 Frequency drive controllers ........................................................................................................................ 7
4.4 Motor winding protection ............................................................................................................................ 7
4.5 Instrumentation ........................................................................................................................................... 8
4.6 Protection types for instrumentation, motors .............................................................................................. 8
4.7 Cabling ....................................................................................................................................................... 8
4.8 Grounding system ...................................................................................................................................... 8
4.9 Field devices............................................................................................................................................... 9
4.10 Markings and nameplates .......................................................................................................................... 9
4.11 Local disconnect switches .......................................................................................................................... 9
4.12 Shop assembly and pre-wiring ................................................................................................................... 9
4.13 Cable infeed fittings .................................................................................................................................. 10
4.14 Numbering system ................................................................................................................................... 10
4.15 Responsibility ........................................................................................................................................... 10
5 SAFETY PROVISIONS ............................................................................................................................ 11
5.1 Failsafe principle....................................................................................................................................... 11
5.2 System safety design ............................................................................................................................... 11
6 PAINTING AND PRESERVING ............................................................................................................... 12
6.1 Requirements for coating quality (DIN EN ISO 12944) ............................................................................ 12
6.2 Coating system ......................................................................................................................................... 12
6.3 Appearance / gloss level .......................................................................................................................... 12

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 Dieffenbacher Standards
7 DOCUMENTATION ................................................................................................................................. 13
7.1 Basic design data and engineering documents ....................................................................................... 13
7.2 Machine layouts........................................................................................................................................ 13
7.3 Foundation plans ...................................................................................................................................... 14
7.4 Exhaust / compressed air / water / heating / ventilation / insulation ........................................................ 14
7.4.1 Exhaust installation plans ............................................................................................................... 14
7.4.2 Extraction air list ............................................................................................................................. 14
7.4.3 Compressed air and water installation plans ................................................................................. 15
7.4.4 Consumer list compressed air, water, etc. ..................................................................................... 15
7.5 Plant security ............................................................................................................................................ 15
7.5.1 Safety plan / safety layout .............................................................................................................. 15
7.5.2 Assembly instruction ...................................................................................................................... 16
7.6 Steel structure principle drawings ............................................................................................................ 16
7.7 Engineering & manufacture drawings ...................................................................................................... 17
7.7.1 Engineering documents ................................................................................................................. 17
7.7.2 Layout plan for insulation (arrangement/survey) ........................................................................... 17
7.7.3 Manufacture drawings .................................................................................................................... 17
7.7.4 Manufacture drawings for sheet metal works, piping and ducts .................................................... 17
7.7.5 Workshop drawings for equipment ................................................................................................ 17
7.7.6 Workshop drawings for steel structure ........................................................................................... 18
7.8 Data and documents, electrical ................................................................................................................ 18
7.8.1 Data / documents for electrical engineering & design ................................................................... 18
7.8.2 Electrical documentation for field installation and commissioning ................................................. 19
7.9 Spare / wear parts list and drawings ........................................................................................................ 20
7.9.1 Spare / wear parts list .................................................................................................................... 20
7.9.2 Spare / wear parts drawings .......................................................................................................... 20
7.10 Erection and start-up instructions ............................................................................................................. 20
7.10.1 Erection and start-up data .............................................................................................................. 20
7.10.2 Erection drawings ........................................................................................................................... 21
7.10.3 Instructions for erection and start-up ............................................................................................. 21
7.10.4 Installation and start-up sequence as Gantt-chart (MS-Project) .................................................... 21
7.11 Operation manuals ................................................................................................................................... 21

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Dieffenbacher Standards
1 COMMUNICATION

In all correspondence the project name, contract no. as well as a precise designation of the object dealt with
shall be mentioned. In e-mail correspondence the subject heading should be as follows:

Nomenclature: [YYMMDD] [Project name] – [topic]

Example: “181030 Sample project – final layout drawings”

The relevant project e-mail address (given by the Client) must always be in carbon copy [cc.].

Technical matters shall be handled directly between the Contractor and the Client’s technical departments. The
Client will forward the corresponding information to the concerned parties.
Commercial matters shall be handled between the Contractor and the Client’s purchasing department.

2 STANDARDS AND REGULATIONS

2.1 Languages
According to Dieffenbacher Project Specification (DPS).

2.2 Measuring system

For all design work, drawings and instrumentation the metric system shall be used. The Client will inform the
Contractor expressly, if in an exceptional case the imperial system is required.

2.3 Numbering system

In all documents to be prepared by the Contractor, only the item numbers as determined in Appendix 2 - Tech-
nical specification shall be used.

2.4 Standards

According to Dieffenbacher Project Specification (DPS).

2.5 Quality assurance

The Contractor shall only use long life quality components. The Contractor undertakes to deliver spare parts for
the equipment/components supplied at the usual market conditions for duration of 10 years following End Cus-
tomer’s commissioning.

Contractor’s scope of delivery and services shall comprise all deliveries and all services which are required for
the intended purpose and which enable appropriate operation as well as all special features of the equipment or
which typically belong to the delivery, irrespective of whether or not these deliveries and services are listed in
detail in these Standards or the contract documents, respectively. The Contractor shall inspect and test all
equipment prior to the shipment, independent from inspections by the Client or the End Customer. This inspec-
tion/test will not release the Contractor from any warranty or guaranty responsibilities.

The Contractor shall perform the services employing its own personnel hired by it and directly depending on it or
hiring one or more subcontractors, having the experience, technical capacity and proper professional prepara-
tion to execute the tasks contemplated under this contract. The Contractor agrees that it will completely and
thoroughly comply with all applicable laws, regulations and industry norms currently in force that are applicable to
or associated with the delivery of the equipment and the performance of the services, especially those regarding

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labor, social security, security and sanitation, environmental, hazardous substance or material, natural resources,
safety and occupational health matters.

The Contractor expressly certifies that it has obtained all the authorizations or permits requested by current regu-
lations for the delivery of the equipment and performance of the services and commits itself to maintaining those
authorizations and permits, at its exclusive cost.

The Contractor shall verify without any delay, if the Client’s requirements and specifications are unclear, incom-
plete or incorrect, and if the offered or supplied/performed equipment or services deviate therefrom. In the event
the Contractor becomes aware of any such circumstances, it shall notify the Client immediately in writing.

After placing of the order the Contractor shall not be allowed to make any changes of the ordered equipment or
services, including changes regarding the design, engineering, materials or (if relevant) production processes,
without the Client’s prior written consent. If the specific design, engineering, materials or production process is
determined only after order placing, or if changes are made with the Client’s consent, the Contractor shall exam-
ine the potential consequences regarding the equipments’ or services’ quality or fitness for the intended purpose.
In this case, the Contractor will immediately inform the Client of any such potential consequences or any neces-
sary or useful consequential changes. In the event that during five (5) years preceding the order placing the Cli-
ent has procured identical or similar equipment or services for an identical or similar purpose from the Contractor,
the Contractor shall explicitly notice the Client of any and all potentially quality related or functionally relevant
changes of materials and production processes or services since the previous order, even though such changes
not affect the specification of the ordered equipment or services.

The Contractor shall in its sole responsibility establish a quality assurance system and an internal inspection
concept in order to meet the requirements of the Client. The Contractor is committed to the “zero-defect objec-
tive”. The Contractor shall be obliged to examine all functional relevant characteristics of the ordered equipment
or services by means of appropriate testing procedures on a regular basis during the production process and
prove the examination results by providing the testing protocols, if so requested by the Client.

Upon Contractor’s receipt of any notice for complaint, it shall immediately ensure the necessary repair, replace-
ment or other remedy measures and dispatch the required qualified service personnel to the End Customer’s
site. The Contractor shall to initiate and carry out all required measures in order to avoid or limit any further dam-
age, in particular resulting from delays on the site, to the Client and the End-Customer. Upon Contractor’s receipt
of Client’s notice for complaint, the warranty period shall be suspended for as long as the complaint is not reme-
died in full or the negotiations between the Contractor and the Client are not concluded; in any case the warranty
claims shall become time-barred at the earliest three (3) months after the end of the suspension.

3 MECHANICAL DESIGN CRITERIA

3.1 General
All elements, components and machineries shall be designed to function in the environment of a plant for derived
timber products. This type of operation demands specifically rugged and impact resistant hardware. The func-
tions and controls shall be foolproof and failsafe according to the expected level of untrained staff. Prototype
design of equipment or its components are subject to the Client’s written approval. The equipment must be de-
signed in a way that no ignition sources can occur. The Contractor is responsible for the equipment calculations
in extreme weather conditions (temperature, wind, snow, etc.).

3.2 Pre-assembly

For shipment, all supplied equipment must be pre-assembled in the Contractor‘s workshop as far as technically
possible. Junction points of disassembled parts must be marked and identified in assembly drawings.

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3.3 Maintainability

The design of the equipment shall provide direct, easy and safe access (for people and tools) to all parts requir-
ing frequent inspection, replacement, lubrication and/or adjustment. Lubrication points for example shall be ac-
cessible from walkways. Ease of maintenance shall take priority over ease of fabrication. For all access and in-
spection doors off center, quick clamps with safety interlocks must be used.

3.4 Flange connections

For all flange connections, such as machine in- and outlets, rotary air locks, ducts and pipes, the Contractor has
to deliver drilled flat bar mating counter flanges including bolts, nuts and gaskets if required. Connecting chutes
will be field made at erection.

3.5 Drive systems

Drives must be designed and supplied complete, including motor pulleys resp. sprockets, belts resp. chains and
couplings, even when the motor is provided by the End Customer. Use taper lock type hubs for all drive sprock-
ets, sheaves, couplings, pulleys etc., where the design is applicable.

3.6 Gear motors and reducers

Wherever technically possible, gear motors must be used. Gear boxes with separate motor are only accepted if
technically inevitable. Bases for gear motors and reducers must be designed for adjustment.

3.7 Bearings

Except other types are dictated by design, all bearings shall be made of pillow block type, ball or roller element
type and heavy duty design. Bearings with permanent lubrication are preferred. For motors >100 kW with varia-
ble frequency drive (VFD), isolated bearings must be used in order to prevent the system from electrical fluting.

3.8 Pressurized systems and pressure vessels

For each pressurized system and pressure vessels, the following documentation has to be provided to the Client
in addition to the technical documentation:
 General plans
 Stability calculations
 Certificates for the materials used for manufacturing
 Check protocols of the welding connections indicating the points subject to checking
 Radiograms of the welds
 Protocols of hydraulic and other checks
 Official acceptance certificate of the technical authorities in charge

All piping systems must be provided with stop valves for maintenance purposes.

3.9 Compressed air systems

For all compressed air connections, solenoid valves and filter/regulator sets have to be delivered with the equip-
ment. The Contractor’s scope of supply shall include the complete piping inside the machine up to filter / regula-
tor set. If there are several connections at one machine, one common set has to be provided. Only modular type
filter / regulator sets should be used.

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3.10 Hydraulic systems

The scope of supply shall include the complete piping inside the machine and between the various units. All hy-
draulic units have to be provided with filters and if required with cooling system. Oil heating if required. Designed
must be in accordance to the regulations mentioned in the Dieffenbacher Project Specification.

3.11 Steel structures, platforms, catwalks, stairs

The design has to be in accordance with the local valid standards. Junctions should be in bolted design; welds at
site are only permitted in exceptional cases. The static calculation is required for the design and has to be pro-
vided to the Client. Where platforms, catwalks and stairs are supplied with the equipment, a minimum live load of
2,0 kN/m² must be considered. Where ever technically possible, ladders should be avoided and access by stairs
provided. Platforms, catwalks and stairs shall be adequately equipped with handrails and foot protection accord-
ing to local standards and covered by galvanized grating, if not explicitly specified otherwise.

3.12 Support bases and anchor bolts

All equipment, structures and machines shall be designed with support bases/ footplates to enable anchoring to
the facility floor or to the building steel.

All concrete-inserts for the Contractor’s scope of supply (anchor bolts, stone screws, fitting sheets, fixing dowels,
etc.) are included in the Contractor’s scope of supply and must fit to the slab thickness. This does not include
steel reinforcement of concrete. Wherever technically possible, the Contractor's design has to provide for ex-
panding, chemical or similar anchors which can be drilled through footplates after placement of equipment (with-
out removal). All anchoring material and anchors shall be provided by the Contractor. All provided anchors and
grouted anchor bolts must be shown in the foundation plans.

3.13 Special tools

Special tools for installation, operation and maintenance must be supplied by the Contractor.

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4 ELECTRICAL DESIGN CRITERIA

The control power system shall enable an Uninterruptible Power Supply (UPS) connection for PCs and CPU-
units at the site.

4.1 Power supply

Power infeed is AC line voltage only; the Contractor has to generate control voltages in his control system.

The power supply system shall either be:

 a TN-S-NET (L1,L2,L3, N, PE) with protective and neutral conductors completely separated
in then whole system, or
 a TN-C-NET (L1,L2,L3, PEN).

The Contractor’s incoming feeding section must be able to connect both variants. However, no load shall be
connected against the Neutral by several reasons.

4.2 Motors, motor starters and brakes

For projects in China, the following special requirements apply:
 All motors with a capacity from 0,55 - 315 kW must be delivered according the “China
Energy Label” regulations. The motors must be labelled with the “China Energy Label”. This
label indicates the efficiency class of the motor. The efficiency of the motor must be indicated
on the type label as well.

Should, for technical reasons, starting of the motors need to deviate from the stipulated standards, this must be
indicated in the engineering documents (questionnaire, motor list). This includes frequency control and soft start-
er requirements. Soft start shall be provided especially for heavy starting mechanical conveyors.

 Motor speed (preferred) 4-polar, 1500 rpm or

6-polar, 1000 rpm

Brake rectifiers have to be supplied mounted on the motor, resp. inside the terminal board, in the case of motors
with brakes. Break voltage see chapter “Control voltage” in the attachment to this document.
Brakes of variable or multi speed motors will be controlled by separate contactor.
All motors need to be in accordance to to IEC/DIN/EN 60034-30-01. According to this standard, all three-phase-
motors which are directly connected to the power net with rated power of 0,75 - 375 kW must be supplied in effi-
ciency class IE3 (premium efficiency).

4.3 Frequency drive controllers

If not specified differently in Appendix 2 (scope of supply) variable speed drives (VFD) are part of the Contrac-
tor’s scope. In order to guarantee a larger frequency setting range, frequency controlled drives have to be de-
signed preferably with a motor frequency at max. speed approx. up to 90 Hz. In case the Contractor does not
supply the control system, layout data has to be agreed upon with the Client. Frequency controlled motors may
be started / stopped via the drive controller’s “save stop” function, if available with a manufacturers certificate,
waving extra contactors, if applicable codes and standards permit. The use of DC motors is not allowed.

4.4 Motor winding protection

All frequency or soft-starter controlled motors, as well as motors of 45 kW and larger, in case of higher ambient
temperature and if in specific cases required by ATEX, must be fitted with thermal motor winding protection. The
Design should be based on thermistor protection (cold conductor).

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4.5 Instrumentation

All limit switches, sensors, speed monitoring devices incl. amplifiers / signal processing units, actuators and other
instrumentation including mounting brackets have to be included in the Contractor´s supply.

If technically possible, proximity switches of the inductive type have to be used. 24 V DC, 3-wire, PNP-type shall
be the standard for all electronic binary sensors. For light sensors (photo eyes) only laser beam reflection types
or light beams with separate transmitter and receiver should be used. Whenever technically possible, the use of
photoelectric proximity switches (German: Lichttaster) shall be avoided.

All instrumentation must be compatible with the planned PLC System with connection via remote I/O- bus mod-
ules or the respective direct fieldbus interface. Types and brands see chapter “Selection of Electrical Equipment
and Systems”. All instruments for measuring values need to have an output currency of 4 - 20 mA (0 - 10 V DC
voltage only after Client’s confirmation) or fieldbus interface (preferred).

Equipment with remote adjustments must be provided with motorized positioners and encoder-feedback or
equivalent equal.

4.6 Protection types for instrumentation, motors

Each system element shall operate satisfactorily at its final location indoor or outdoor in the respective environ-
ment of the plant. They shall in addition satisfy the defined fire and explosion protection category according to
the actual ATEX standard.

4.7 Cabling

The End Customer will supply all standard cable according to the Contractor´s specification for installation on
site, unless the scope of supply stipulates differently. The End Customer’s or Client’s supply normally includes
standard control- and power cables for indoor and outdoor use, as well as standard shielded cables, if not speci-
fied differently in scope of supply.

All necessary special cables such as:

 heat-resistant cables
 flexible connections including cable carrier systems with junction boxes
 data cables
 cables for measuring and pluggable connections
 cables with current collector
 fiber optic cables etc.
are included in the Contractor’s scope of supply, if not explicitly excluded.

Separate cable ways have to be provided and considered in the engineering for:
 Power cable
 Control cable
 Data and measuring value cable

4.8 Grounding system

Grounding connection point’s at all electrical equipment shall be provided as part of the Contractor’s supply as
well as ground connections at machinery.

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4.9 Field devices

For all field-mounted indoor equipment dust-tight enclosures and for outdoor equipment water tight enclosures as
specified in the attachment to this document must be provided by the Contractor. Only equipment specially de-
signed for field mounting under the specified conditions shall be used.

Suitable industrial type junction boxes with screw-type cable infeed fittings have to be provided, mounted on the
machine, for field instrumentation, which has no terminal or plug connection (e.g. proximity switches fixed con-
nected cable, etc.) in order to connect the field wiring. Screwed connecting counter-plugs have to be provided for
pluggable units or counter plugs with shop made cable, with length lasting until the next junction box. All valve
plugs must have illuminated indicators to show the switching condition.

For all field sensors, min. 5 % reserve (min. 1 piece) shall be supplied in order to support fast start up and small-
er modifications during initial production. In case of high value units (encoder, flow meter, etc.) this shall be
agreed upon with the Client, especially if the Client will provide the control system.

4.10 Markings and nameplates

Each electrical device and piece of electrical equipment shall be labelled with a durable, text printed or engraved,
nameplate, letter height minimum 5 mm. It should be installed as close as possible to related device, however
not at the device itself. Cables have to be marked on both ends with complete cable name on durable attached
cable tags. Nameplate identification shall be consistent with all control documentation and control software iden-
tification of each particular device. This applies to panels, field devices and cables.

All internal single wires inside terminal boxes, cabinets and local panels have to be labeled on both ends. At
minimum labeling includes device ID and connection point. Example: -K05:13; -X123:14

4.11 Local disconnect switches

For machines on which during normal operation regular inspections, maintenance or tool-change etc. have to be
carried out with the need to switch off the motor (blender, saws, airlocks etc.), locally lockable disconnect switch-
es have to be provided by the Contractor of electric control. For pre-wired complete machines, these disconnect
switches are delivered by the machine supplier and to be mounted in a housing and, as far as technically possi-
ble, pre-wired to the relevant motor and adequately labeled.
The disconnect switches must be designed for 3-phase power switching (also for Y/D-starter) and have minimum
one dry aux. contact for acknowledgement to control system. If shielded cables are provided for frequency con-
trolled motors, metallic enclosures should be used for the local disconnect switches.

4.12 Shop assembly and pre-wiring

Motors and disconnect switches, as well as limit switches, sensors, valves and other field units have to be sup-
plied for each machine unit shop mounted and pre-wired to junction boxes. The pre-wiring has to follow the Cli-
ent’s electrical drawings. The Client will supply this documents right in time, if the Contractor will start the pre-
wiring sooner, so he has to request this information from the Client. If pre-wiring cannot be carried out because it
is either technically not possible or feasible, the Client must be informed immediately.

A space of min. 25 % has to be reserved in the junction and switch boxes. Some spare terminals have to be
installed. If specified in the scope of supply, fieldbus modules and field bus connector in the control type terminal
boxes have to be included.

All necessary mounting plates, brackets and fixing material for the electrical equipment such as motors, sensors,
instruments, junction boxes and field control boxes must be supplied by the Contractor and, as far as is techni-
cally possible, pre-mounted by the manufacturer. Field units, which cannot be mounted for mechanical reasons,
have to be supplied separately including all fixing material, clearly described for easy identification. Descriptions
such as „one box small materials, limit switches, etc.“ are not permitted.
Hinged doors shall be provided at all field enclosures and with a ground connection inside.

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4.13 Cable infeed fittings

For all motors, brakes, limit switches, junction and switch boxes, as well as for all field instrumentation, suitable
metric screw type cable fittings (bushings) have to be supplied, completely mounted, by the Contractor. For mo-
tors metal types have to be used. In all cases extended motor connection boxes have to be used.

For bigger motors, the following cable size termination must apply (at 400 V up to approx. 100 m and under nor-
mal temperature conditions). The Contractor has to take care, that motor termination box and cable glands will fit
to connect NYY-cables as per listed sizes.

 90 kW - 2 cable 3 x 50+ 25 mm²

 110 kW - 2 cable 3 x 70+ 35 mm²
 132 kW - 2 cable 3 x 70+ 35 mm²
 160 kW - 2 cable 3 x 95+ 50 mm²
 200 kW - 2 cable 3 x 120+ 70 mm² (3x 150/70mm² at 380V)
 250 kW - 2 cable 3 x 185+ 95 mm²
 315 kW - 4 cable 3 x 95+ 50 mm²
 350 kW - 4 cable 3 x 95+ 50 mm² (3x 120/70mm² at 380V)
 400 kW - 4 cable 3 x 120+ 70 mm²
 450 kW - 4 cable 3 x 150+ 70 mm²

Notes:
 Usually cable infeed for 315 / 350 kW motors are obtainable for two main cable in-feeds only.
The Contractor has to make sure, that the above listed cable sizes are connectable.
 Variations have to be clarified with the Client (e.g. the use of 240 mm² cable)
 For frequency controlled motors which are wired up with shielded cables, screw fittings with
integrated shield connection such as Lapp “Skin top MS-SC-M” must be used.

4.14 Numbering system

The Client’s standard system (DIN EN 81346) must be used. In case of a written approval for deviation (see Ap-
pendix 2) at least the Client’s area descriptions and code letters have to be applied as leading ID code charac-
ters.

4.15 Responsibility

The Contractor is completely responsible for the engineering and design, resp. for the sufficient specification in
case the control system is supplied by the Client or by Others, of the complete electrical and automation system,
including the parts supplied by the Contractor or from the End Customer, such as control units, controllers for
variable speed drives.

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5 SAFETY PROVISIONS

5.1 Failsafe principle

In the event of an equipment failure or external influence, such as improper operation, high temperature, power
failure or other adverse conditions affecting the proper function of a system or element involved with safety of life
or health, the system or element shall automatically revert to a state known to be safe to all personnel interfacing
with the equipment. This includes constructional provisions by the Contractor or relevant instructions to the con-
trol.

5.2 System safety design

All control methods, circuitry, mechanical and operating equipment shall be designed to provide maximum safety
for operating and maintenance personnel and to minimize potential damage to equipment and to the product as
a result of equipment failure.

All applicable safety regulations have to be taken into consideration during construction. All protective systems
and safety nameplates on the machines have to be supplied with the machines by the Contractor. If protective
systems cannot be mounted on the machines directly, this has to be indicated in the engineering documentation.
Recommendations for mounting relevant protective fences have to be supplied by the Contractor.

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6 PAINTING AND PRESERVING

6.1 Requirements for coating quality (DIN EN ISO 12944)

All machines and equipment must be supplied with a satin finishing coat according to DIN 53778 / EN 13300.
Machined surfaces must be coated with protective paint (e.g., EPE zinc primer similar to RAL 7001 grey). Sur-
faces which are not paintable, such as shafts, chains, inner surfaces of pipes, etc., must be treated with anticor-
rosion protection, ensuring an outdoor storage of at least 6 months.
Prior to priming (zinc phosphate base), all relevant parts must be carefully cleaned or scintillated (according to
SA 2.5 ISO 8501-1).
Reserve colors must be supplied in order to correct transport and assembly damage (notification to shipping
department required- dangerous goods).
If parts of the equipment supplied must be specially stored, an explicit information must be given to the Client.
Alternative coating systems are possible, provided the requirements described below are met with regard to cor-
rosivity categories, durability and gloss level.

6.2 Coating system

According to DIN EN ISO 12944-5, Annex A, Table A.1.

Machine location outside:

Corrosivity categories: C3 (moderate) ISO 12944-2
Shelf life: M (5-15 years) ISO 12944-1

Example: ISO 12944-5 Annex A Table A.1 System No.: A01.04  C3 – M

 2 x basic coat dry film thickness per coat 40 to 60 μm
 2 x top coat dry film thickness per coat 30 to 50 μm

Machine location outside: OPTIONAL at locations near the sea

Corrosivity categories: C4 (high) ISO 12944-2
Shelf life: M (5-15 years) ISO 12944-1

Example: ISO 12944-5 Annex A Table A.1 System No.: A01.12  C4 - M

 2 x basic coat dry film thickness per coat 50 to 70 μm
 2 x top coat dry film thickness per coat 40 to 60 μm

Machine location in indoor rooms:

Corrosivity categories: C2 (low) ISO 12944-2
Shelf life: M (5-15 years) ISO 12944-1

Example: ISO 12944-5 Annex A Table A.1 System No.: A01.01  C2 - M

 1 x basic coat dry film thickness per coat 40 to 60 μm
 1 x top coat dry film thickness per coat 40 to 60 μm

6.3 Appearance / gloss level

Gloss level: satin gloss according to DIN 53778

Medium gloss according to DIN EN 13300

Gloss level (measurement to DIN EN ISO 2813)

DIN 53778 DIN EN 13300
Measuring angle/ Measuring angle/
Designation Designation
Reflectometer value Reflectometer value
satin gloss 60° 31 ± 5 Medium gloss 60° < 60 - 25

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7 DOCUMENTATION

All technical documentation has to be sent to the Client. The required quantities can be taken from the attach-
ment to this Document (Dieffenbacher Project Specification). The dates and address for delivery of the documen-
tation will be stipulated in Appendix 2 - Technical Specification.

On the request of the Client, documentation must be made available to the Client’s “Managed File Transfer Sys-
tem” (MFT) in the following formats:

Drawings ACAD, PDMS, E3D DWG, DXF, TXT, STP, PDF, IFC, IFCZIP
Descriptions MS-Word or Acrobat DOC, PDF
Tables, calculations MS-Excel XLS, PDF

All documentation (drawings, listings, specification, manuals, etc.) must show the reference to the project name.
The documentation includes all required information needed by the End Customer to reach the approval of oper-
ation.

3D models need to be reduced to the outer contour in order to reduce the data volume. Internal elements as well
as standard parts like bolts, screws, washers etc. must not be shown. Most important details are the outer con-
tour, including motors and drives, as well as interface points and connection points for exhaust air, water supply
and compressed air with their exact dimensions and position.
2D drawings must not show any Z coordinate > 0 or < 0, only 0 is allowed for Z coordinates.

7.1 Basic design data and engineering documents

For small scope of supply, the following information can be summarized in fewer documents, if accepted by the
Client.

7.2 Machine layouts

Planning scale ≤ 1 : 100

The machine layout plan includes all machine arrangements and their interfaces combined in one function unit.

Main characteristics:
 Main machine dimensions, main machine axis
 Material inlet and outlet dimensions and location in relation to main axis
 Levels indication above sea level or determined level
 Indication of special connections e.g. flexible to avoid vibrations
 Necessary possibilities of access
 Necessary operating-, maintenance-, installation- and dismantling space
 Necessary interface information (flange size, level, …)
 Clear definition of Contractor’s scope of supply and Client’s scope of supply
 Indication of plant coordination system according to Client’s definition as well as indication of
main machine coordinate in the plant.
 Top view and all required side views.
 3D model as .txt file or .stp file.
 Building requirements (e.g. doors/gates, installation/maintenance openings)
 Indication of customer equipment at the interfaces (e.g. feeding and discharge conveyors of
a machine)
 Labeling of the machines according machine numbers in Appendix 2.

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7.3 Foundation plans

Planning scale ≤ 1 : 100

The foundation plan is valid for the design of the foundations.

Main characteristics:
 Support surfaces
 Levels indication for foundations in reference to plant reference level given by the Client
 Anchoring details
 Referencing of the load points
 Unfactorized static/dynamic loads (without safety margins)
 Tabular indication of dynamic load, dead load and live load as well as extraordinary load
(e.g. extinguishing water, explosions), center of gravity incl. mass for seismic load calculation
and if applicable wind and snow loads. Effective direction of loads must be indicated with the
coordination system provided by the Client.
 If area loads are shown, the max. point load and machine load must be indicated.
 Clear definition for required foundation tolerances and admissible settings
 For foundation inserts the possible orientation and location tolerance must be shown.
 Definition for grounding/earthing points
 Type and dimension of fixing element
 Clear definition of Contractors scope of supply and Client’s scope of supply
 Positioning of the main machines and their facilities via a coordinate system (main axes)
referred to the stipulated reference point
 Indication of installation axis and/or installation marks
 Definition of required pits (incl. pump sump or drain) with access (stair or ladder), cover,
railing, safety fence, etc. Client’s scope must be shown in e.g. a special color.

7.4 Exhaust / compressed air / water / heating / ventilation / insulation

7.4.1 Exhaust installation plans

The positions of the individual exhaust points have to be presented in both top view and in side view. Each ex-
haust point is marked with a clear ident number. The installation plans shall also include the indication of the
reference point and the description of the valid coordinate- and axis picture of the connection points. Depending
on the scope of supply, the position of the suction points can be specified either by dimensioning on a machine
axis or by specifying coordinates with respect to a reference point.

7.4.2 Extraction air list

The template for this list is provided by the Client. For each exhaust point it shows the following information:

 Machine number according Appendix 2

 Ident number of the exhaust point
 Material description
 Material moisture
 Mass flow, as far as decisive
 Bulk weight, as far as decisive
 Volume flow, as far as decisive
 Air flow
 Connection diameter
 Connection type (flange, flexible, sliding pipe,…)
 Required static pressure at interface point
 Stroke for movable connections
 Remarks

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7.4.3 Compressed air and water installation plans

The position of the individual utility points has to be represented in both top view and sectional view. Each utility
point is marked with a clear ident number. Thereby, the following media are differentiated (according to Contrac-
tor´s scope of supply) e.g.:
 Compressed air
 Process water (cold)
 Process water (hot)
 Waste water
 Cooling water
 Extinguishing water
 Steam
 Sealing water

The installation plans also include the indication of the reference point and the description of the valid coordinate-
and axis picture of the connection points.

7.4.4 Consumer list compressed air, water, etc.

The consumer lists, templates given by the Client, are maintained for each medium in a table sheet. They show
for each connection point the following information:
 Machine number according Appendix 2
 Ident number of the connection point
 Description of the connection point
 Connection diameter
 Consumption
 Operating pressure
 Height above ground level for water consumers
 Remarks

For each medium a brief description of the required media quality is indicated.

7.5 Plant security

7.5.1 Safety plan / safety layout

The safety plan documents a protective concept for machines or lines as a result of a risk assessment. The safe-
ty plan describes the respective protective measures for the purpose of the risk minimization. According to the
design and volume of the machines or lines, the safety plan includes the following information:

 Definition and location of safety areas and dangerous spots

 Position and design of safety fences incl. required height at all dangerous spots (e.g.
machines, pits, etc.)
 Location and design of accesses to the safety zones (e.g. by safety doors with electrical
control system and lock)
 Separations from other safety zones (e.g. by light barriers or mechanical avoidance of
access)
 Position and design of equipment as access protection with dangerous areas (e.g. light
curtains, machine covers etc.)
 Position and type of mandatory signs
 Position and type of prohibition signs
 Position and type of warning signs and information signs
 Position and type of safety related equipment (e.g. emergency stop button, rope switch,
alarm horn, laser scanner etc.)
 Type and design of access hindrances (e.g. light grids, multiple light barriers etc.)
 Position of pressure relief systems including flame profile definition (length, width and height)
 Clear definition of Contractor’s and Client’s scope of supply
 Clear definition of requirements to adjacent equipment.
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7.5.2 Assembly instruction

The manufacturer of incomplete machines has to prepare an assembly instruction for the declaration of incorpo-
ration according directive 2006/42/EG. With the contract documents, the Client will provide an assembly instruc-
tion (DG981008) where it is clearly marked which evaluations must be done by the Contractor. The completed
and signed document must be send to the Client’s e-mail address mentioned in the assembly instruction.

7.6 Steel structure principle drawings

The steel structure principle drawings are the basis for the design of the steel structure, that means planning,
dimensioning and manufacture. They mainly include:
 Main supports of the steel structure
 Suggestions for reinforcement bracings (where possible)
 Machine loads of the Contractors scope of supply
 Unfactorized static/dynamic loads (without safety margins)
 Tabular indication of dynamic load, dead load and live load as well as extraordinary load
(e.g. extinguishing water, explosions). Effective direction of loads must be indicated with the
coordination system provided by the Client.
 Recommendations for surface loads considering also maintenance and repair
 Specifications for admissible bending, where necessary with regard to plant techniques
 Special requirements on dimensions for steel profiles (e.g. due to size or fixing of foot plate),
where necessary for the machine construction
 Requested grating area for walkways and maintenance platforms
 Stairways and ladders to access walkways and maintenance platforms
 Openings and gaps
 Position of guard rails
 Position of toe/kick plates
 Special fixing details of machines
 Required holes for machine/equipment mounting and base plates
 Reference of steel structure to machine layout by showing dimensions between main
machine axes and main steel structure axes.
 Reference of one main steel structure column to plant reference point
 Levels indication for steel structure in reference to plant reference level

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7.7 Engineering & manufacture drawings
7.7.1 Engineering documents

Engineering documents include the essential indications concerning the requirements from the delivery item of
the Contractor necessary for the later dimensioning and construction by the respective specialist company. Engi-
neering indications are mostly schematic and comprise general descriptions. In particular, they do not include a
binding dimensioning of the objects of equipment.

7.7.2 Layout plan for insulation (arrangement/survey)

Preparation of plans for the necessary insulations with:

 Graphic description of the individual insulation areas
 Indication of the recommended material qualities
 Indication of the recommended insulation thickness
 Exemplary indications with regard to the design of details areas (e.g. maintenance openings)
 Indication of surface temperatures of the areas to be insulated
 List of machines/components to be insulated including type, thickness and required square
meter of insulation.

7.7.3 Manufacture drawings

Manufacture drawings are prepared for the local provision of delivery items by the Client / End Customer. They
include the necessary indications for the manufacture of the respective facilities by specialist companies. Differ-
ence is made between manufacture drawings for sheet metal works, for equipment (e.g. conveying elements)
which may also include drive elements and electrical equipment, and for the steel structure.

7.7.4 Manufacture drawings for sheet metal works, piping and ducts

These consist in particular of

 Design drawings for the manufacture
 Assembly drawings / overviews
 Piece lists with dimensions and weight
 Indications with regard to materials and their processing (e.g. weld seam indications)
 Tolerance indications
 References to special norms (e.g. flange rows)
 Specifications for the production documentation (to be prepared by the manufacturer) -
content, e.g. dimensional check, weld inspection, material test certificate
 Document list

7.7.5 Workshop drawings for equipment

These consist in particular of

 Workshop drawings for the manufacturer
 Assembly drawings / overviews
 Piece lists and dimensions
 Indications with regard to materials and their processing (e.g. weld seam indications)
 Position plans for the electrical equipment
 Connection points for special components provided by the Contractor (according the the
stipulated scope of supply)
 Specifications for the production documentation (to be prepared by the manufacturer) -
content, e.g. dimensional check, weld inspection, material test certificate
 Document list

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7.7.6 Workshop drawings for steel structure

These include the preparation of the static calculation with:

 Graphic description of the static systems with beam- and node numbering
 Documentation of the load assumptions and their graphic description
 Overview and load case groups respectively –combinations with the partial security
coefficients
 Stress analyses with normal-, shear- and comparison stresses
 Deformation proofs / usability proofs
 Stability proofs such as flexural buckling and torsional buckling
 Verification of the anchorages to the local foundation as well as detailed design indications
(no calculations of the foundation)
 Norm: EN 1993 (Eurocode 3)

From here result the required manufacture drawings:

 Assembly master drawings / Overviews including indications of the required screws per
connection
 Outlines of gratings or contours of all gratings
 NC data in the DSTV format
 Piece lists (drawing-related) in Excel- (XLSX), Word- (DOCX) or text format (txt), divided into
steel structure and railing
 Screw lists, not drawing-related, but related to areas (e.g. forming station, dryer…)

7.8 Data and documents, electrical

7.8.1 Data / documents for electrical engineering & design

To be provided to the Client’s project management as data files. Contractors, whose scope of supply does in-
clude the electrical control system, are released from several of the items below. These items are marked with
“(not if control system in scope)”. In any case the documentation provided, must be sufficient, to design, build
and commission the complete electrical and control system.

7.8.1.1 Basic data for power supply

Such as low voltage distribution feeds, emergency power, medium voltage power. (incl. simultaneous & load
factors)

7.8.1.2 Data for electrical and control rooms

Especially space needed in electrical rooms for control cabinets, in control rooms as well as heat energy created
by electrics in rooms as engineering data for air conditioning.

7.8.1.3 Cable routing

Providing a proposal for the main cable raceways along the plant equipment.

7.8.1.4 Motor location drawings

Which show positions of all motors at the equipment layout drawings in plan and elevation in conjunction with
motor lists. Motors numbers must be absolutely identical in drawings and lists.

7.8.1.5 Device location drawings

Which show positions of all field devices including junction boxes, local panels etc. at the equipment layout draw-
ings in plan and elevation in conjunction with device lists. Device numbers must be absolutely identical in draw-
ings and lists. For preinstalled equipment either the drawing or list should indicate which devices are pre wired.

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7.8.1.6 Motor lists
All motors must be listed with motor ID number. Power, voltage, current, special features and requirements have
to be included. Use the Client’s standard excel sheet template for the motor list.

7.8.1.7 Device lists

All electrical field components (sensors, valves, control units, transmitters etc.) must be listed with device ID
number. Voltage, current, special features and requirements have to be included. Use the Client’s standard excel
sheet template for the device list.

7.8.1.8 Functional description (not if control system in scope)

Consisting of but not limited to:

 Description of safety and functional interlocks, sequence of startup and shut-down, operating
conditions and sequences, layout data such as speeds, acceleration ramps etc.
 Schematics showing equipment & process with functional location of sensors and actors /
motors.
 P & ID´s and control loop schematics in areas consisting of process measurement and loop
control.
 Data sheets of all devices, to be supplied by Contractor.

7.8.1.9 Terminal strip and termination drawings of the shop pre wiring (not if control system in scope)

The numbering of the shop pre-installation needs to be coordinated with the Client.

7.8.1.10 Summary of cable length “(only if control system in scope)”

Listing of all designed cable types used and its length summary to allow Client to order all standard cables.

7.8.1.11 Miscellaneous

All other documentation necessary to design and build the control system or parts of it respectively for plant en-
gineering, which may be known by the Contractor or requested by the Client for example risk analy-
sis/assessment regarding “EN ISO 12100+ 13849 1/2”.

7.8.2 Electrical documentation for field installation and commissioning

This documentation only needs to be provided in case the Contractor supplies the electrical control system or
parts of it. For installation and commissioning all information is required, which enables the Client to install and
commission the equipment supplied with qualified personnel without extra assistance from Contractor. Required
are:

7.8.2.1 Functional description

As described above.

7.8.2.2 Motor location drawings

As described above.

7.8.2.3 Device location drawings

As described above.

7.8.2.4 Data sheets

For all Contractor supplied electrical & control components.

7.8.2.5 Terminal strip and termination drawings

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7.8.2.6 Circuit diagrams

Complete with adequate descriptions, comprehensively showing the functionality of the control system.

7.8.2.7 Cable lists

Per control area, detailing all cables for connections between the Contractor supplied electrical and control com-
ponents. Type of cables, no. and size of conductors, and approximate length have to be included to the list data.
Contractor supplied cables of the shop pre wiring must be indicated as such.

7.8.2.8 Configuration data, parameters, software

Description and / or prescription of any and all data which are needed during erection and commissioning for
adjustment and tuning together with explanation how to obtain specific data / values. All application software
including its documentation.

7.8.2.9 Miscellaneous

All other documentation required to install and commission the control system or parts of it, which may be known
by the Contractor or requested by the Client.

7.8.2.10 As build revisions on site

All documents and data have to be maintained and continuously updated by the Contractor during construction
and commissioning on site. When leaving the site 1 set each of updated documents must be handed over to the
Client and to the End Customer. Contractor is obliged to update the originals and submit them as revision to the
manuals after commissioning in accordance with the contractual provisions for submitting of manuals.

7.9 Spare / wear parts list and drawings

7.9.1 Spare / wear parts list

The Client’s standard Excel template has to be used for the spare parts quotation.

7.9.2 Spare / wear parts drawings

The drawings must contain position numbers for all relevant spare / wear parts. Those have to comply with those
used in the spare / wear parts list.

7.10 Erection and start-up instructions

For erection and start-up, all necessary information must be provided to enable the End Customer to install and
start-up the supplied equipment without Contractor’s assistance. Required are:

7.10.1 Erection and start-up data

Transport information:
 Lists of the equipment supplied including item no.
 Numbers of the cases / container
 Total weight of the delivery
 Dimensions and weight of the heaviest individual part
 Dimensions and weight of the largest individual part
 storage space required
 special instructions for transport, unloading and storage

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Personnel required:
 Personnel of the Contractor, necessary for erection supervision
 Personnel of the Contractor necessary for start-up
 Personnel of the End Customer, necessary for erection and start-up.

The qualification of the personnel of the Contractor has to be listed according to the following categories: me-
chanics, electricians, welders, pipe fitters, laborers and operators.

Schedule:
 Indication of the time required for erection of the scope of supply of the Contractor
 Indication of the time required for start-up of the scope of supply of the Contractor

Information on tools, maintenance and transport:

 cranes and other hoisting equipment to transport the delivered machines on site, including
the time required
 tools and auxiliary equipment necessary for erection of the delivered machines, e.g.
electrical and oxyacetylene welding equipment, frames, cleaning equipment.
 The Client must be informed about first fillings and lubrications for the erection and start-up
which is not included in the scope of supply.

7.10.2 Erection drawings

With parts lists, identification numbers and corresponding match marking on equipment components.

7.10.3 Instructions for erection and start-up

With all necessary information to enable installation and start-up of the supplied equipment.

7.10.4 Installation and start-up sequence as Gantt-chart (MS-Project)

The Contractor has to supply a detailed installation and start-up schedule for the respective scope and precondi-
tions (Format: Gantt-Chart / Microsoft Project). The following information should be contained:
 Plant component – Local supply (defined milestones)
 Mechanic installation (as sum of single tasks)
 Single tasks for complete scope of supply
 Electric installation (as sum of single tasks)
 Commissioning (as sum of single tasks)
 Period of optimization (as sum of single tasks)

7.11 Operation manuals

The Client must submit manuals for the entire plant to the End Customer in a uniform mode. Therefore, the Con-
tractor must supply his manuals according to the Client’s company standard DG298503.

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