Instruction Manual On Erection For No.2 CGL

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Instruction Manual on Erection for NO.2CGL
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11110620-2002072-WP002
INSTRUCTION MANUAL
ERECTION
No.2 CONTINUOUS GALVANIZING LINE
OF
SUNSCO
PROD. L.!'JE
OIVI 'ON
h'1/'10SHIMA wo?6°
SPECIFICATION No. 01100620-2002001-CS001
Jun. 2012
HITACHI ENGINEERING & SERVICES CO.LTD
I
11110620-2002072-WP002
Contents Pages
Chapter 1. General
1.1 General description . . . .. .. .. . .. .. . .. . .. . . .. . . .. . .. .. . . . .. .. .. . . .. .. . . . .. . 1-4
1.2 Item nomber list .. .. .. . . .. . . . .. . .. . .. .. .. . . .. . . . .. . .. . .. .. . .. . .. . .. . . . 1-6
Chapter 2. Bench mark and Center mark

2.1 Bench mark and center mark reference drawing ... ... 2-2
Chapter 3. The Standard Procedure of Equipment

3.1 Equipment instal/ation procedure 2-2
3.2 Foundation 3-3
3.3 Measuring instruments for inspection and measuring
methods of foundation .. .. 3-16
3.4 Liner for instal/tion . . .. . .. .. . .. ... .. . . . .. 3-40
3.5 Tightening of bolts 3-53
3.6 Instal/ation, centering and assembling of equipment 3-69
Chapter 4. The Standard Procedure of Piping

4.1 Scope ... . .. . .. .. ... . .. 4-1
4.2 Erection standard 4-2
4.3 Classification of piping 4-2
4.4 Erection procedure . .. . . .. .. . .. . .. . .. .. 4-3
4.5 Pickling 4-24
4.6 Transportation . .. . .. . . . .. . .. . .. . .. . .. . 4-29
4.7 Piping assembly 4-29
4.8 Flushing & blowing 4-35
4.9 Pressure test 4-77
4.10 Tightening 4-78
4.11 Instal/ation for utility pipin...................................................... 4-79
Chapter 5. Instal/ation Accuracy and Measuring Procedure

5.1 Installation accuracy 5-2
, Chapter 6. Detailed Instal/ation Procedure

6.1 Entry Section .
6-3
6.2 Pre Treatment Section .
6-20
6.3 Furnase Section .
6-26
6.4 After Pot Cooling Section'" . 6-29
1 - 1
2.
11110620-2002072-WP002
Contents Pages
6.5 Spm & Tension Leveller Section 6-34

6.6 Post Treatment Section 6-39
6.7 Exit section .. . .. . .. . . .. .. . .. .. . . .. . 6-48
6.8 Coupring Centerring 6-63
Chapter 7 Detailed Installation Procedure of Temper mill & Tension leveller Section
7.3.1 . Installation of shoe plate 7-24
7.3.2 Standing procedure of mill housings onto shoe plate 7-30
7.3.3 Installation of mill housing 7-33
7.3.4 Assembling the devices/parts around mill housing .. .. . 7-39
7.3.5 Mill piping 7-48
7.3.6 Roll changing device 7-49
7.3.7 Main mill drive and mill motor .. .. .. 7-56
7.3.8 Oil cellar equipment 7-60
7.4 Instaliation of Tensionleveler 7-63
7.5 Installation of Tensionleveler 7-64
11110620-2002072-WP002
NOTICE
(1) This instruction manual is prepared for better operation, handling and maintenance of
the equipment (machine) to help the persons who operate it usually.
(2) The persons in charge of this equipment are required to read carefully and understand
the contents of this manual prior to proceeding with installation, operation disassembly
or reassembly of the equipment. The photographs and figures inserted in the
descriptions show the foundation of handling and, some of them are typical ones, so the
photograph sand figures may slightly differ from the delivered equipment.
(3) The instruction manual does not cover all the problems, which are liable to occur in
operation and maintenance of the equipment. In other words, those problems, which are
not typical ones, are not shown in this manual. When you have a question or anything,
which is not clear, Please consult with our company or importer of the equipment without
hesitation.
(4) By observing various limits condition specified in this manual, use equipment properly
avoiding immoderate handling. Be sure to carry out checking and maintenance properly
in order to prevent trouble and accidents from occurring.
(5) Keep this instruction manual at a place convenient for the persons who are usually in
charge of operation, maintenance and checking of equipment. Please refrain from
offering even a part of the contents of this instruction manual to a third party or third
person without obtaining our agreement beforehand.
1-3
4
11110620-2002072-YVP002
CHAPTER 1. GENERAL
1- 4
11110620-2002072-i'iP002
1.1 General description
This instruction manual covers the installation procedure for the major equipment of
Continuous Galvanizing Line (CGL).
The manual, however, can't describe full details of all the steps necessary for installation
of all the equipment. Therefore or accordingly descriptions for small items expected to
be installed by the experience of erection Contractor (herein after called "the Contractor")
are not included in this manual.
As a result of careful consideration what is most important for the Contractor, we have
prepared this manual on the considering following important points or critical matters.
We hope that the Contractor will well understand this purpose, recognize the important
points for furnace erection and perform installation smooth, efficiently and safety.
1) Basic concept on erection
2) Installation sequence and precations
3) Required special jigs for installation
4) Installation target accuracy
This manual has been prepared incorporating Mitsubishi-Hitach's past experience on
similar plants and the installation conditions for SUNSCO-CGL. We request you to
perform installation based on this manual, however, these methods may need some
modifications to mmet the actual local conditions in the Vietnam and the Contractor.
In that case please inform and discuss with MH supervisor for successful completion of
the erection work.
1- 5
6
1.2 ITEM Number List 11110620-2002072-i'lP002
(1) Terminal
ITEM
DESCRIPTION
No.
MECHANICAL EQUIPMENT
4.1.1 Entry section
4.1.1.1 2229001 NO.1 Entry Coil Skid (Cradle roll included)

4.1.1.1 2229002 NO.2 Entry Coil Skid (Cradle roll included)
4.1.1.2 2300001 NO.1 Coil measuring device
4.1.1.2 2300002 NO.2 Coil measuring device
4.1.1.3 2222301 NO.1 Entry coil car
4.1.1.3 2222302 NO.2 Entry coil car
4.1.1.4 2214101 NO.1 Payoff reel
4.1.1.4 2214102 NO.2 Payoff reel
4.1.1.5 2031201 NO.1 Coil opener
4.1.1.5 2031202 NO.2 Coil opener
4.1.1.6 2230001 NO.1 Entry Deflector Pinch roll and Feed leveller with Reducer
4.1.1.6 2230002 NO.2 Entry Deflector Pinch roll and Feed leveller with Reducer
4.1.1.7 2031203 NO.1 Entry Threading Table
4.1.1.7 2031204 NO.2 Entry Threading Table
4.1.1.8 2273101 Double cut shear with pinch roll
4.1.1.9 2240901 NO.1 Crop disposal
4.1.1.10 2230003 Deflector Pinch Roll with Threading table
4.1.1.11 2294000 Welder
4.1.1.12 2232101 NO.1 Tension Bridle roll with Snubber Roll
4.1.1.13 Void
4.1.1.14 2245201 Entry looper (Rail, Clamp and other auxiliary parts)
4.1.1.14 2245201 Entry looper
4.1.1.15 NO.1 Steering System
4.1.1.15 2258501 a NO.1 Steering roll
4.1.1.15 2299901 b Hydraulic Unit
4.1.1.15 2299901 c CPC unit
4.1.1.16 2299902 c CPC unit
4.1.1.17 Void
4.1.1.18 2091401 Entry Structure
4.1.2 Pre Treatment Section
4.1.2.1 Degreasing Equipment

4.1.2.1-1 2286201 Alkali Dip Tank
4.1.2.1-2 2310101 Scrubber Tank
4.1.2.1-3 2286101 Hot Water Rinse Tank with Sub Tank
4.1.2.1-4 2248101 NO.1 Dryer
4.1.2.1-5 2291301 Cleaning Auxiliary Equipment
Sump Pit, Pump and Auxiliary Equipment
4.1.2.2 2299903 c CPC unit
4.1.3 Furnace section
1-6
7
ITEM Number List 11110620-2002072-WP002
(1) Terminal
ITEM
No. DESCRIPTION
4.1.3.1 2232102 No.2 Tension Bridle roll with Snubber Roll
4.1.3.2 2258901 Tensionmeter roll
4.1.3.3 2258902 Strip Support Table
4.1.3.4 Furnace (Furnace Maker Supply)
4.1.4 2181000 Coating Pot Section
4.1.5 Air Wiping Section (Air knife maker supply)

4.1.5.1 2288101 Air knife Equipment
4.1.5.1 2288102 Coating roll rig
4.1.5.1 2288103 Maintenance atand
4.1.5.1 2288104 Deflector roll for cold run
4.1.5.1 2288105 YG Transfer car
4.1.5.1 2043103 BLOWER AIR SUPPLY SYSTEM
4.1.5.1 2095010 Electrical Equipment for wiping unit
4.1.5.1 2012110 Instrumentation for wiping unit
4.1.5.1 2012410 Measuring Instrument for wiping unit
4.1.5.1 2096110 Attached Wiring for wiping unit
4.1.6 After Pot Cooling Section (Furnace maker Supply)

4.1.6.1 Pre Cooler Equipment (Furnace maker Supply)
4.1.6.2 Up pass cooler (Furnace maker Supply)
4.1.6.3 2139101 No.1 Top Roll
4.1.6.3 2139102 No.2 Top Roll
4.1.6.4 Down pass cooler (Furnace maker Supply)
4.1.6.5 Water quenching Equipment (Furnace maker Supply)
4.1.6.6 No.2 Dryer (Furnace maker Supply)]
4.1.6.7 No.4 Steering System
4.1.6.7 2258504 a No.4 Steering roll
4.1.6.7 2299904 c CPC unit
4.1.6.8 2139700 Coating Weight Gauge with Stand
4.1.6.9 2258101 No.1 Deflector roll
4.1.7 SPM & Tension Leveller Section
4.1.7.1 2232103 No.3 Tension Bridle roll

4.1.7.2 2210501 4H Skin pass mill
4.1.7.3 2248103 No.3 Dryer
4.1.7.5 2231502 Tension leveller
4.1.8 Post treatment section
4.1.8.1 2284901 After Treatment Unit (Spray Type)

4.1.8.1 1 2284901 Spray Tank with Seal Roll
4.1.8.1-2 2284901 No.1 & No.2 Wringer Roll
4.1.8.1-3 2284901 Chromate Supply Tank
4.1.8.1 4 2291302 Circulation Tank
1-7
ITEM Number List
11110620-2002072-YiP002
(1) Terminal
ITEM
No. DESCRIPTION
4.1.8.1-5 2248104 NO.4 Dryer
4.1.8.2 2258102 NO.2 Deflector roll
4.1.8.3 2284902
After Treatment Unit (Simple Coater Type)
4.1.8.4 2139103 NO.3 Top roll
4.1.8.4 2139104 No.4 Top roll
4.1.8.5 Indcution Strip heater (Furnace
4.1.8.6 Maker Supply)
2258103 NO.3 Deflector roll
4.1.8.6 2258104 No.4 Deflector roll
4.1.8.7 2091402
4.1.8.8 Steel structure and plaform for post treatment section
4.1.8.9 Fume Exhaust system for IH (Furnace Maker Supply)
4.1.9 Chemical Air cooler (Furnace Maker Supply)
Exit section
4.1.9.1 2245202 Exit looper (Tower Type)
4.1.9.2
NO.5 Steering System
4.1.9.2 2299905 c CPC unit
4.1.9.3 2258105 NO.5 Deflector Roll
4.1.9.4 2232106 NO.6 Tension Bridle Roll
4.1.9.5 2281901 Inspection table
4.9.1.6 2024300 Oiler (Roll Type) with Pinch roll
4.1.9.7 2273103 Exit Shear
4.1.9.8 2240902 NO.2 Crop Discharger
4.1.9.9 2258111 NO.1 Exit deflector pinch roll
4.1.9.9 2258112 NO.2 Exit deflector pinch roll
4.1.9.10 2031205 Exit Threading Conveyor
4.1.9.11 2031206 NO.1 Exit strip guide table
4.1.9.11 2031207 NO.2 Exit strip guide table
4.1.9.12 2213101 NO.1 Tension reel
4.1.9.12 2299906 Hydraulic Unit
4.1.9.12 2299906 NO.1 EPC Unit
4.1.9.12 2213102 NO.2 Tension reel with EPC Unit
4.1.9.12 2299907 Hydraulic Unit
4.1.9.12 2299907 NO.2 EPC Unit
4.1.9.13 2219201 NO.1 T/R Belt wrapper
4.1.9.13 2219202 NO.2 T/R Belt wrapper
4.1.9.14 2219203 NO.1 Exit coil car
4.1.9.14 2219204 NO.2 Exit coil car
4.1.9.15 2229003 NO.1 Exit coil skid
4.1.9.15 2229004 NO.2 Exit coil skid
4.1.1 0
Auxiliary Equipment
4.1.10.1 2040002 Lubrication system
4.1.10.2 2043002 Air Supply system
4.1.10.3 2041001 Hydraulic system
4.1.10.4 2010002 Interconnecting piping
4.1.1 0.5
Foundation bolt, nut and liner
4.1.1 0.6
Wiring within Machine
1-8
ITEM Number List
11110620-2002072-WP002
(1) Terminal
ITEM
No. DESCRIPTION
1 T MECHANICAL EQUIPMENT
4.1.10.7 12281930 1 Simple parts (Max.30ton)
1-9
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11110620-2002072-WP002
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11110620-2002072-WP002
Chapter 3.
THE STANDARD PROCEDURE OF EQUIPMENT
3-1
17
11110620-2002072-WP002
3.1. Equipment installation procedure
The equipment shall be installed according to the procedure shown in Table 1.
Table 1
No. Procedure Remarks
1 Foundation and building work This standard shall not apply
2 Announcement of the completion of

foundation work
3 Organization of foundation inspection

team
4 Foundation inspection and centering
5 Correction of foundations
6 Setting of liners for installation
7 Temporary installation of main The main equipments mean such

equipments equipments which serve as a basis for
installation of other equipment, or
equipment to be installed
independently.
8 Temporary centering of main

equipments
9 Grouting of anchor bolt holes Grouting is not necessary when

anchor bolts are embedded in
advance
10 Curing of grout applied to bolt holes
11 Centering of main equipments
12 Inspection of centering of main

equipments
13 Assembly
::\-?
11110620-2002072-WP002
Table 1 (Continued)
No. Procedure Remarks
14 Inspection of centering of auxiliary The auxiliary equipments mean such

equipments equipments to be installed with the
main equipment as the base. These
equipments are installed in the same
manner as the main equipments.
15 Grouting under the base of main

equipments
16 Curing of grout applied under the

base of main equipments
17 Assembly of accessories
18 Clearing
3.2. Foundation
3.2.1. Announcement of the completion of foundation work

The foundation work contractor shall announce the completion of
foundation work after performing the following items.
(1) Confirmation of the completion of foundation work

Make sure that all works relating to machine foundations, floors, etc.
have been completed.
(2) Cleaning of foundation surface

Remove temporary works, equipment and materials for work, jig
and tools, etc. from the foundations. Clean the foundation surface
of waste concrete, dust and other foreign matter.
3-3
11110620-2002072-WP002
(3) Clear marking of reference points for bench mark and center mark
Mark the reference point for bench mark in one place and the
reference points for center mark of the center line in two places
within the building. At the same time, place auxiliary bench marks
and center marks
(4) Marking of center line and height line of each equipment

Mark the line direction and the center line at right angles to the
line on the surface of the foundation for each equipment. Mark the
height lines on the pit side wall, cellar wall, building side wall, etc.
(5) Witnessing of the completion of foundation work

The personnel responsible for foundation work, work supervisor
and personnel responsible for installation work shall confirm the
completion of foundation work under the guidance of the
personnel responsible for foundation work.
Remarks: 1. In many cases, the reference points for bench mark for
foundation work and for center mark for the line center are
placed outside of the building. Accordingly, these reference
points must be transferred into the building to make foundation
inspection possible.
2. The roofing work and lighting work must have been completed
and all scaffolds must have been removed before the building
work is started.
Furthermore, the lower side walls, side walls and window glass
must have been installed to protect the piano wires and plump
bobs to be used for centering from the wind.
3-4
7n
11110620-2002072-WP002
3. Bench marks and center marks which have been placed by the
foundation work contractor are mostly for measurement and
inspection of foundation during the work and are of temporary
nature.
3.2.2. Inspection and centering of foundation
(1) The foundation is inspected for the center line and height line of
equipment placed by the foundation work contractor with
reference to the reference points for bench mark and center mark
of the line center and the center line of main equipment at right
angles to the line which have been placed by the foundation work
contractor in accordance with the foundation work drawing and
equipment foundation drawing.
(2) Centering of foundation is to set bench marks and center marks

for machine installation on the basis of the results of foundation
inspection and to determine the center line of each equipment, the
size of foundation surface, height, bolt hole center, etc. Bench
marks and center marks for equipment installation are used for
maintenance and inspection to be done after installation and are
of semipermanent nature.
Accordingly, they must be set with a high accuracy in accordance
with Para. 3.2.4 through 3.2.9.
3-5
21
11110620-2002072-WP002
(3) Generally, foundation inspection and centering are accomplished

at the same time to improve the centering accuracy and to reduce
the duration of installation.
Therefore, bench marks and center marks for machine installation
must be buried before centering of foundation.
Example: Fig. 1 below shows examples of bench mark and center mark.
Fig.1
Unit:mm
F.L:tO
a
co
en
ViewA.A
3-6
22
11110620-2002072-WP002
3.2.3 Role of site manager at the time of foundation inspection

The site manager shall conduct the following.
(1) Organization of foundation inspection team, consisting of the work

supervisor, foundation work contractor and installation work
contractor
(2) Determination of measuring procedure, scope of measurement

recording, assignment of duties and measuring instruments to be
used
(3) Determination and management of foundation inspection term,

foundation correction term and other necessary schedules
(4) Inspection, and study and judgment of inspection results
(5) Acceptance of foundation
(6) Giving instructions for the start of installation work
7) Witnessing the setting of bench marks and center marks for

installation and control for the maintenance of accuracy
(8) Determination of the time to deliver equipment and to install them

(in consideration of the time to start the operation of overhead
crane, curing period of foundation concrete, etc.)
Remarks: It is better from the standpoint of accuracy and efficiency to

inspect the foundation by the work supervisor and two contractors
jointly.
3-7
11110620-2002072-YVP002
3.2.4 Inspection and setting of bench marks

Inspect the auxiliary bench mark or height line marked by the
foundation work contractor with reference to the reference point for
bench mark.
For this inspection, measure the difference in height by means of a

level and record the measured value. At the same time, enter the
measured value beside the bench mark or the line. Then, set several
bench marks for equipment installation, adjusting their height at the top
(see Fig. 1) to F.L + 0 (2)
Note (2) "F.L + 0" is usually used to mean zero height from the
floor level. Its tolerance is + 0.3. "F.L" stands for floor
level which is the height of the virtual plane of the
operating floor.
3.2.5 Inspection and setting of center marks for line center

With reference to the reference points for center mark at the both ends
of the line center, collimate the auxiliary center marks or lines marked
by the foundation work contractor through a transit and record the
discrepancy.
Then, bury center marks for equipment installation at intervals of 30 to
50 m. Collimating them through a transit, scribe the lines.
For center marks which cannot be collimated through a transit, make
measurement by means of piano wire and plumb bob and scribe the
lines. The tolerance shall be less than 1.5 mm per 100 m. (see Figs.
13).
3-8
21L
11110620-2002072-WP002
3.2.6 Inspection of marked center lines at right angles to the line and setting
of center marks
Measure the center lines at right angles to the line, which have been
marked by the foundation work contractor, with reference to the line
center to see if they are really at right angles to the line. The tolerance
shall be +20".
For this measurement, scribe the lines at right angles using a transit or
a cross type square (see Fig. 2), measure the discrepancy from the line
marked previously and record the results. (When using a cross type
square, scribe the lines at right angles by extending them by the use of
a piano wire and plumb bob.)
Bury center marks for equipment installation at the both ends of the
center line at right angles to the line.
Collimating through a transit (or using a piano wire and plumb bob),
scribe the center.
Example: An example of cross type square is shown in Fig. 2.
3-9
2S
11110620 -20 02072-WPOO 2
Fig.2
Beam compasses
(1) Make the square from channel and angle.
(2) Scribe the line BO by attaching a straight edge.
(3) Using 3 to 5 m beam compasses, scribe five points A, B, C, 0 and

o at positions where OB=OO, BA=BC=OA=OC, and mark these
points with a punch.
(4) The cross type square shall be fixed horizontally on the foundation.
It shall be of such rigidity and construction that it is not distorted or
shakes under the weight of a worker who steps on it for centering.
3 - 10
11110620-2002072-iVP002
3.2.7 Inspection of distance between the equipments in the direction of the
line.
Inspect the distance between the center lines at right angles to the line
which have been set in parallel to each other for equipment installation
in para. 3.2.6.
For this inspection, scribe the center lines at right angles to the line on
the foundation surface, measure the distance between these lines with
a steel tape and record the results.
Measurement with a steel tape shall conform to Para. 3.3.5.
3.2.8 Inspection and setting of equipment center lines

Inspect the equipment center lines marked by the foundation work
contractor with reference to the line center and the center lines at right
angles to the line which have been set for the installation of equipment
in Para. 3.2.6. In this inspection, measure the marked line from the
respective center lines with a steel tape and record the results.
The procedure and accuracy of measurement are described in Para.
3.3.5.
Then, bury center marks for the installation of equipment at the both
ends of the equipment center line and scribe the lines in the same
manner with the same accuracy as described above.
3 - 11
7'7
11110620-2002072-WP002
3.2.9. Inspection and setting of center lines in parallel to the line, center lines
at right angles to the line and height lines in the cellar
With reference to the bench marks for equipment installation,
Center line and center lines at right angles to the line which have been
set in Paras. 3.2.4, 3.2.5 and 3.2.6, inspect the center lines in parallel
to the line, center lines at right angles to the line and height lines which
have been set by the foundation work contractor. In this inspection,
measure the distance between the line and the respective center line
and bench mark with a steel tape, piano wire, plumb bob and level and
record the results.
Then, selecting the best place for equipment installation and piping,
scribe the center line in parallel to the line, center lines at right angles
to the line and height lines.
Unless otherwise specified, the tolerance shall be less than 5 mm.
3 - 12
1III0620-2002072-WP002
3.2.10. Inspection of embedded bolts, anchor plates, anchor bolt holes,
embedded metals (3) and installing surfaces
Measure the positions, heights, shapes, installed conditions, etc. of
embedded bolts, anchor plates, anchor bolt holes, embedded metals
and installing surfaces of the equipment in accordance with the
drawings with reference to the line center, center lines at right angles to
the line, equipment center lines and bench marks which have been set
in Paras. 3.2.4 through 3.2.9.
Note 3) For inspection of embedded metals, get information, such

as the size, weld strength, embedding method, etc. of
each component from the foundation work contractor.
Test their adhesion to concrete by means of a test
hammer.
3.2.11. Study of overall accuracy of foundation

The work supervisor shall judge the foundation inspection records
described in Paras. 3.2.4 through 3.2.10 in accordance with Instruction
described followings (see 3.2.11-1). For rejected foundations, the
foundation inspection team shall determine the method of correction
and schedule through overall study and discussions and the work
supervisor shall order the foundation work contractor to correct such
foundation.
After correction, the foundations shall be inspected again.
3 - 13
29
11110620-2002072-WP002
3.2.11-1 I CONSTRUCTION TOLERANCE I
(Copied from Dwg. of Civil Work)
Construction tolerance shall meet the followings:
CD The accuracy described below should be maintained on the

foundation bolts.
G)-a In case of eye type anchor bolt

Unit: mm
ITEM BOX HOLE TYPE
DIRECT EMBEDDED TYPE
Distance from Center line of
box hole: 15 Center line of bolt
center line of
M36 or smaller 2
machine
M36 to M48 3
M56 or larger 4
Level Bottom surface of Top of bolt: +10
box hole: +50
0
0
(+10 toward the direction of (+10 toward the direction of protrusion)
depth)
Others Vertical of Inclination of bolt:
box hole: 2 mm/m or less
10 mm/m or less (However, the max. dimension of
inclination is to be 5 mm)
G)-b In case of hammer-head anchor bolt Unit: mm

HAMMER HEAD TYPE DOUBLE END
ITEM HAMMER HEAD TYPE FOR MAIN TIGHTENING
ELECTRICAL ROOM TYPE
Distance from Center line of anchor plate Center line of anchor Center line of
center line of
M36 to M56: :tA plate: :t:3 embedded sleeve
machine
pipe: 15
M64 or larger::t:4
Level Upper surface of anchor Upper surface of anchor Thickness of
plate: plate: concrete: 20
+10 +6
-0 -0
(+10 in direction toward top (+6 in direction toward
surface of concrete) top surface of concrete)
Verticality of 2 mm/m or less
10 mm/m or less
embedded sleeve
pipe (However, the max.
dimension of
inclination is to be
20 mm)
Others Levelness of upper surface of anchor palte : 1 mm/m
or less
-
.~o 3 - 14
11110620-2002072-WP002
(gl The following accuracy should be maintained on the

foundation and embedded steels.
(2)-a Machine foundation Unit: mm
TOLERANCE
ITEM
+0
Height of surface of foundation where machine is to be -10
(-Denotes the height
installed. toward lower level)
Height of surface of foundation where no machine

installed
Depth of pit and the position of wall surface against the :1:10
center line of pit.
Outside border of surface of foundation where machine is
to be installed.
:t 15mm/m
Perpendicularity of wall surface
(gl-b Construction of pit and culver!
TOLERANCE
ITEM
:t 20
Height of ceiling
:t 30
Position of wall surface perpendicularity of wall surface 5mm/m
Position of steel wall

:t10
Height of floor
Position of steel intermediate column
+20
0
Indentation of wall surface embedded from wall surface
(Denotes the protraction)
:t 30
Position of wall surface embedded steel
5mm/m
Perpendicularity of wall surface embedded metal
+50
Size of through-hole for piping 0
+40
Position of through-hole for piping
3 - 15
3/
11110620-2002072-WP002
3.3. Measuring instruments for inspection and measuring methods of foundation
3.3.1. Items to be measured

As the inspection and centering of the foundation are very important,
these works should be performed by skilled workers who have a
through knowledge of the construction and performance of measuring
instruments.
The measuring instruments to be used for this purpose and measuring
methods are as outlined below.
Remarks: Generally, the mechanism, and the performance of measuring

instruments of the measuring range is as given in Table 2.
Table 2
Measuring distance, m
rang
Item
Measuring
instrument
~ a 30 50 100 200 300
I I .. I
Transit I~, ;,;;.
Line center
Piano wire, Plump
, ';c.',,: '>' .
bob
Cross square, piano

wire, Plumb bob :
Right angle Geometric

center line ~ method 3:4:5
teel tape ] .
Transit
~.
..,. .,
Water level
Height
Y-Ievel ~
Steel tape Spring

Distance
balance
3 - 16
:?2
11110620-2002072-WP002
3.3.2 Measurement of line center and center lines at right angles to the line
by transit
The line center and the center lines at right angles to the line are
inspected by measuring the horizontal angle by a transit. The angle of
the line center must be zero degree and that of the center line at right
angles must be 90 degrees.
Errors to be crept in the measurement of horizontal angle are as given
in Table 3. It is essential to have a correct knowledge of the influence
of these errors on measured values and to measure the angle by the
elimination method to minimize the influence of errors.
Table 3
Error Cause of error Error elimination method

Mechanical Error in line of - Line of collimation is Average readings of
error collimation not at right angles to telescope in the normal
the horizontal axis. and reversed positions.
- Incomplete adjustment (Note 4)
of longitudinal cross line
Error in - Horizontal axis is not at Average readings of
horizontal axis right angles to vertical telescope in the normal
axis. and reversed positions.
- Incomplete adjustment
of horizontal axis
Cont'd
3 - 17
11110620-2002072-WP002
Table 3 (Continued)
Error Cause of error Error elimination method
Mechanical Error in vertical Bubble tube is not at right - No correction method

error axis angles to vertical axis.
- Adjust bubble tube.
- Incomplete adjustment If there is still error,
of bubble tube request repair to
maker.
. Defective construction
Eccentricity of - Vertical axis is not at . Average readings of

line of the center of horizontal verniers A and B (5).
collimation protractor.
- Defective construction
Error due to - Line of collimation is - Average readings of

misalignment not passing through the telescope in the
between optical center of protractor. normal and reversed
axis and line of positions.
- Defective construction
collimation
Eccentricity - Line of collimation does - Average readings of

not agree with optical telescope in the
axis. normal and reversed
positions.
- Incomplete adjustment
of axis of cross hairs
Error in Eccentricity - End of plumb bob does - Construct with great

not agree with care to minimize error.
handling
measuring point
correctly.
Incomplete - Foundation has not

leveling been constructed
horizontally.
3 - 18
11110620-2002072-Y'f'P002
Note (4). The normal and reversed positions of telescope are the
positions as shown in Fig.3(a). The telescope is shifted
from the normal position to the reversed position as shown
by the arrow.
Fig.3(a)
Height Bubbie tube

Reversal of telescope
scale of telescope
D D D
I
D Normal position
D
c=)
D D D D
! I
Horizontal
turning by
180 0
Reversed position
3 - 19
11110620-2002072-WP002
Note (5) Verniers A and B are shown in Fig. 3 (b).
Fig.3(b)
Horizontal protractor
(Vernier B)
Horizontal protractor
(Vernier A)
(1) Measurement of line center by transit

This is an example in which center marks at points A, C and E on
the line center are transferred to the points Band D. First, set a
transit at Point C and align the vertical axis of the transit to the
center mark using an optical bob and a shifting device. Confirm
points A and E through collimation. Then, collimate Point A with
the telescope in the normal position, scribe Point B' with the
vertical axis fixed, and scribe Point D' with the telescope reversed.
After that, collimate Point A with the telescope in the reversed
position, scribe Point B" with the vertical axis fixed and scribe
Point D" with the telescope reversed.
If Point B' does not agree with Point B" and Point D' with Point D",
determine Points Band D on the center line and scribe them. (For
construction of transit, refer to Fig. 7.)
3 - 20
3b
11110620-2002072-WP002
(8) Shows center mark
FigA
$
A '~
B"
$
c
~;$
D'
E
0 0
O o 0 0
00 0 00 00 0 0
0000000000
Remarks: Collimation by transit
To collimate the measuring point exactly through a telescope, the
followings must be done.
(1) If the measuring point can be directly collimated, it is not

necessary to put up a pin. If direct collimation is impossible, a pin
is put up at the measuring point and this pin is collimated. For this
purpose, a sewing needle or nail is used for distances up to 100m,
a scriber of pencil size for distances up to 200m, and a round bar
with an end finished precisely to a conical shape for distance in
excess of 200m. (In short, the pin should be of such diameter
which can be seen larger than the cross hairs in the telescope.)
(2) Put up a pin vertically at the measuring point.
(3) Place white paper or a screen behind the pin to provide a better
view of the pin (see Fig. 5).
(4) Adjust the eyepiece so that the cross hairs in the telescope can be
seen clearly when a white wall or the sky is looked in.
(5) Adjust the focus by means of the focusing knob so that the pin at
the measuring point is in focus. (see Fig. 10).
3 - 21
.~'7
11110620-2002072-WP002
(6) Moving the telescope up or down so that the tip of the pin agrees
with the horizontal line of the cross hairs, tighten the vertical clamp
screw and make fine adjustment by means of the verticality fine
adjusting screw.
(See Fig. 5 (a).)
Fig.5
Up .•
White a er
Dow 1 --- ~~
Pin
------------------------------------------ Focussin knob
_ ..----
(a) (b)
(7) Turning the vertical axis of the transit so that the tip of the pin or
the center line aligns with the longitudinal line of the cross hairs,
tighten the upper and lower clamp screws and make adjustment
by means of the upper or lower fine adjusting screw.
(see Fig. 5 (b))
(8) When a new center mark is to be set, put a pin at the point to be
scribed, make adjustment by means of the focusing knob and by
moving the telescope up and down in the manner as described in
Steps (5) and (6) above so that the tip of the pin agrees with the
horizontal line of the telescope cross hairs.
3 - 22
11110620-2002072-WP002
Then, move the pin so that the longitudinal line of the cross hairs
agrees with the pin. At this time, never touch the upper and lower
clamp screws and fine adjusting screw. If the longitudinal line
agrees with the pin, mark the tip of the pin (see Fig. 6 (a) (b)).
Fig.6
..
(a) (b) (c)
(9) As it is feared that marking of the tip of the pin may be erased by
scratching or rusting, punch marks at the center and at four points
on the circumference as shown in Fig. 6 (c) to facilitate the
detection of center mark in the future. Any unnecessary marks
may cause error in the future. Such marks should be eliminated.
(10) The person who is making measurement through a transit should

carry a transceiver or hand microphone so that he can give
instruction to the person putting up a pin when the distance
between them exceeds 50 m.
(11) When changing the direction of the telescope to the left or the
right at the time of collimation, do not hold the telescope directly
but turn it by holding the supporting frame by both hands.
(12) During measurement, check from time to time to see if the bubble
in the bubble tube is in the correct position or check for deviation
from the center mark using an optical bob or plumb bob.
3 - 23
11110620-2002072-iVP002
(2) Measurement of the center line at right angles to the line by the
transit repetition method
Measurement of the center line at right angles to the line by the
transit repetition method is accomplished as shown in Fig. 7.
Fig. 7. Measurement of the center line at right angles to the

line by the transit repetition method and an example of
transit mechanism
Telesco e
Dial )
line center
A
D
~-............ Lower clamp

~f~
Center line
at right
angles to
'n---«~
IJ I \\
screw
Shifting
device
the line
Center mark
c (Zero point)
CD Install a transit so that the 0 point of the center mark aligns with
the vertical axis of the transit exactly.
@ Set the vernier to any graduation slightly larger than 0 00'00" (for
example: 0 02'00"), tighten the upper clamp screw and loosen the
lower clamp screw. Collimate Point A, read the angle (aO) on the
scale and record it.
@ Tighten the lower clamp screw, loosen the upper clamp screw and
collimate Point B. Read a 1 on the scale and record it.
3 - 24
11110620-2002072-WP002
@ Loosen the upper screw, tighten the lower screw and Collimate
Point A again (do not read the scale).
@ Loosen the upper screw, tighten the lower screw and collimate
Point B again. At this time, the scale will register a 2 but it is not
necessary to read the scale at this time.
@ If Steps (4) and (5) are repeated 3 times, the angle at Point B will
be nearly equal to 360 . Take this value as a4, then
LAOB = a4-aO
4
(J) Measure LAOB by turning the telescope clockwise in the normal

position and clockwise in the reversed position, and average the
readings. If more accurate value is required, measure the angle by
turning the telescope counter clockwise in the normal and
reversed positions and average these four reading. This
measuring method is called the repetition method or multiple
angle method.
@ Measure and correct the scribed point B by the amount

corresponding to OB tan (90o-LAOB), or
- {(gO - AOB)"
OB x 206265" 1
@ Determine Point D according to the method described in Para.
3.3.1 (1).
3 - 25
41
11110620-2002072-WP002
Reference 1.
The classification of transits according to the accuracy of horizontal angle
and errors in measurement are as shown below.
Classification Reading on horizontal protractor
Transit of class 3 20"
3 - 26
11110620-2002072-WP002
3.3.3 Measurement of height by level

Shown Fig. 8 is an example in which Points Band C are measured
from the bench mark at Point A on the foundation.
Fig.8
As shown in Fig. 8, compare the height of Point A with that of Point B

and the height of Point A with that of Point C by changing the position
of a level. For this measurement, collimate Point B from Point A and
Point A from Point B and then Point C from Point A and Point A from
Point C, and record the heights.
Then, changing the position of the level, measure and compare the
heights of points Band C. Check these heights to see if they agree with
the above - mentioned records of measurement.
,
3 - 27
<£3
11110620-2002072-WP002
Remarks 1. In this method of measurement by a level, errors are reduced

as the distance up to the measuring point is decreased, but are
increased as the distance is increased (see Fig. 9).
Let us assume that an error corresponding to one graduation of

the bubble tube of the level has crept in. In this case, the error
in measurement will be as follows.
For class 3 measurement

(bubble tube sensitivity:40"/2mm)
: 2mm at 10m, 4mm at 20m
For class 1 measurement

(bubble tube sensitivity: 1O"/2mm)
:O.5mm at 10m, 1mm at 20m
Fig.9
Remarks 2 : Type of level

The following types of levels are generally used for installation
3 - 28
11110620-2002072-WP002
Table 4
Bubble tube
Type Use Features
sensitivity
Ordinary Confirm the bubbles in the level

measurement 40"/2mm
Tilting should be matched while
level measuring.
Precision
10"/2mm
measurement
No close adjustment before

Automatic Ordinary measurement. Measurement can
level measurement - be done in about 0.5 sec because
of compensator incorporated.
Remarks 3 Precautions in measuring the height by level

Points requiring attention in measuring the height by a level are
given in Table 5.
Table 5
No. Precautions Reason
1 Set a level at the center between the To eliminate error in axis of

measuring points. collimation. Error is eliminated as
focusing of telescope is changed.
2 Set a level on the firm ground. To prevent settlement, inclination or

(Do not set on iron plate, support, vibration during measurement.
etc.)
3 Perform measurement with the cross To eliminate parallax.

hairs in the telescope visible clearly. (Correction of errors due to parallax
is impossible.)
4 Use a steel ruler with clear To eliminate reading errors and

graduations as a leveling rod. Set the errors due to inclination.
ruler vertically.
5 Measure from both ways and make For confirmation of measuring

the difference in measured values accuracy
zero. If difference is caused, replace
the level.
3 - 29
ItS
11110620-2002072-rfP002
Remarks 4 For measurement in such places where the measuring point is

not visible, a water level is used.
Fig. 10
••
Wall
Steel ruler
Glass tube
Water surface
~,
00 Transparent
, ,0..
. 0
0-
~
vln I hose Water
~ 0 .0 . 0 . 0 ,0'. 0'0' ~ 0 .0
0 ... 0".00'. O.
000 Bench mark
This instruction does not specify water leveling.
3 - 30
11110620-2002072-WP002
3.3.4. Method of measuring the line center and the center lines at right angles
to the line by piano wire and plumb bob
Measurement by means of piano wire and plumb bob is performed
when collimation through a transit is impossible because of the
configuration of the foundation. An example of this measurement is
,-
shown in Fig. 11.
Fig.11
Wei ht Piano wire
Wei ht2
Marking
thread
~ . 00 00 ~. O.
o ~ o .
~O
.
. 0 ..
0 ..0
0
00
Center mark
00
Center mark
o 0 O.~ O.~O
00 0 .... 0 ...
Center mark
CD Batter board: The batter board should be easy to use and

compatible with the space at the site. Generally, shape steel
welded structure is used.
@ Weigh!: The weight should be heavy enough to secure the batter

board. Generally, the weight of more than 100 kg is used for each
place.
@ Leading thread: Placed in an oil pot with a weight attached.
@ Marking thread :Cotton thread (About 0.3mm dia.) with

Plump bob.
3 - 31
11110620-2002072-WP002
Remarks 1. Method of scribing the center using piano wire and plumb bob.
The method of scribing the center using piano wire and plumb
bob is shown in Fig. 12.
Fig.12
Piano wire
..
Clearance of After punching the center point,

about O.5mm encircle it by compasses to
provide a better view and
) Scribing center
punch four points.
3 - 32
11110620-2002072-WP002
Remarks 2. Causes of errors in measurement by piano wire and plumb bob
and countermeasures
Causes of errors in measurement by piano wire and plumb bob
and countermeasures are summarized in Table 6.
Measurement shall be made by the method in which errors are
minimized.
Table 6
Cause Countermeasure
Piano wire bent or twisted Replace piano wire.
0
t:
roo Tension of piano wire insufficient. Select a weight compatible with wire diameter.
c::
Influence of wind Perform measurement when it is not blowing.
Influence of wind Minimize the distance (50m max.)
Shield wind by putting up tent or the like.
Influence of inertia Check marking thread for verticality with
reference to leading thread.
Scribe after stopping swinging of plumb bob
and keeping it at rest for few seconds.
Plumb bob not processed accurately. Precisely processed plumb bob should be used
(see Attached Fig 2).
Correct measuring position can not Space sufficient for measurement should be
be taken. provided.
(Space directly below the line of sight of
.0
0 marking thread and plumb bob end)
.0
.0 Knots or joints of marking thread Replace marking thread.
E
:J
i5: Difference of suspending direction of Suspend same direction.
marking thread to piano wire
~
Piano wire ~
~ '::!j
'::!j (i>
(i>
Marking
lherad ./'
(
t
3 - 33
11110620-2002072-WP002
Reference 2. The relation between the diameter and strength of piano wire
and the weight is shown as follows.
Material: JIS-SWPA
Cross-sectional
Wire diameter Breaking load Weight of weight
mm are~ N(kgf)
mm kgf
0.20 0.031 78(7.95) 3
0.32 0.0804 187(19.10) 8
0.42 0.1256 295(30.10) 12
0.52 0.19635 453(46.20) 20
0.60 0.28274 623(63.50) 26
3 - 34
11110620-2002072-WP002
3.3.5. Measurement of distance between equipment

The accuracy of measurement of distance in foundation inspection
shall be strict for the center lines of major equipment but may be less
strict for other center lines.
Measuring instruments to be used and precautions in measurement are
given in Table 7.
Table 7
Measuring
Item Precautions
instrument
Distance between center Steel tape Use calibrated steel tape.
lines of major equipment Spring balance
Never fail to apply specified tension.
Distance in excess of 20
m Correct for difference from basic
length and temperature.
Measure more than 5 times and
average the results.
Distance other than Steel tape Use JIS B7512 Class 1 or
those shown above Spring Balance equivalent.
Never fail to apply tension to steel
tape.
Steel ruler Use JIS B7516 Class 1 or
equivalent
Convex scale Use for brief measurement under
2m
Remarks: Calibration
When measuring distances in excess of 20 m, compare the
steel tape with the standard tape in advance. Compare them by
the same method at the same temperature and tension and
determine what correction is required after measurement.
This comparison is called calibration. Perform calibration
according to the following steps (see Fig. 13).
3 - 35
sl
11110620-2002072-WP002
(1) Select a flat floor for measurement.
(2) Place measuring plates (steel plates with scribed cross line) at two
points which are at a distance of 50 m from each other as
measured by a standard tape (6) (for example, calibrated value 50
m + 0.95 mm at a tension of 15 kgf and at a temperature of 15 C).
Do not move the measuring plates before calibration is finished.
(3) Connect a spring balance and poles to the standard tape and
apply tension to the tape by inclining the poles.
When the tension has reached the specified value (15 kgf in this
case), the measuring persons on the both sides read the scales
"a" and "b" in agreement with the scribed line of the measuring
plates upon receiving a signal from the recording man.
(4) Read "a" and "b" five times with the standard tape and five times
with the steel tape to be calibrated. Calculate the average of
respective readings. At the same time, read the temperatures t
and t' C on the thermometer.
Fig.13
(Measuring
(Pole,,\erso~ Tape
Thermometer
eX X::o ~~~:oSn~ri~~
/II
Spring
balance
/(POle
man) ~I-------------------j= ~ c;- man)
(Recording man)
Measuring
late
+a Ta e -b
o 50
Distance between scribed lines

of measurin lates
3 - 36
11110620-2002072_WP002
(5) Obtain the correction value for the calibrated scale by the following
equation.
D=(L+ ll.L)+(b-a)+aL(t-to) (1)
L + ll. f. = D - (b' - a') - aD (I' - to) (2)
Where
D: standard distance between scribed lines of measuring plates (mm)
L: standard distance in 50m (mm)
ll.L: correction value at the time of calibration by standard tape in 50m

(mm)
b: average of 5 readings of standard tape at 50 mm side (mm)
a: Average of 5 readings of standard tape at 0 m side (mm)
CI:': coefficient of linear expansion of standard tape

(steel tape) (= 0.0000115)
t: temperature at the time of measurement by standard tape (0C)
to: temperature at the time of calibration by standard tape (generally 15)

(0C)
ll. f.: correction value for steel tape to be calibrated in 50 m(mm)
b': average of 5 readings of steel tape being calibrated at 50 m side (mm)

(Readings are minus values in case when the tape is elongated, but
plus values when the tape is contracted, as shown in Fig. 15.)
a': average of 5 readings of steel tape being calibrated at 0 m side (mm)
t': temperature at the time of measurement by steel tape to be calibrated

(0C)
(6) If it can be considered that the steel tape to be calibrated is elongated

or contracted uniformly over 50 miters, the correction
value will ~6 mm per 1m.

3 - 37
11110620-2002072-WPOO~
Note (6) The standard tape is such a tape which is almost free from errors
and for which the measuring method is clearly specified and the
inspection record is attached.
Reference 3. Errors in measurement and countermeasures Measured values

of angle, length, level, etc. may vary slightly each time the
measurement is made. The causes of such variations and
countermeasures are given as follows.
3 - 38
11110620-2002072-YiP002
Item Description Countermeasure
Error arising from 1. Erroneous handling of 1. Measure with care.

carelessness measuring instruments
2. Change measuring person.
2. Error arising from illusion
3. Measure again at different
of measuring person
time or on different day.
3. Error in recording
4. Increase measuring
Constant error 1. Personal error frequency.
2. Physical error due to 5. Measure with different type

temperature, tension, light, of instruments.
etc.
6. Change measuring
3. Error arising from method.
incomplete adjustment of
instruments
Accidental error Errors other than those shown As it is impossible to eliminate

above these causes, increase
measuring frequency, plot
measured values on a graph
and determine the most
reliable value.
(-)error 0( » (+ )error
3 - 39
11110620-2002072-WP002
3.4 Liner for installation
3.4.1 Selection of liners for installation

Unless otherwise specified in the drawing, the required quantity,
arrangement, shape and size of liners and the processing method under
liner shall be calculated and selected as described below.
3.4.1.1 Calculation of area

Assuming that the total load applied to the foundation are carried by the
liners and grout, the area of liner is calculated by the following equations.
(3)
(4)
(5)
where
W : total load applied to the foundation N(kgf)
w 1: weight of equipment N(kgf)
W2: anchor bolt tightening force N(kgf)
W3: external load (dynamic load) N(kgf)
A1 : area of liner for installation (cm2)
A2 : area of grouted portion (Area of base-Area of liner for installation)

(cm2)
(J 1: allowable stress of liner N/cm2 (kgf/cm2)
(J 2: allowable stress of grouted portion N/cm2 (kgf/cm2)
(J 3: allowable stress of liner in case when static load only is applied at

the time of installation N/cm2 (kgf/cm2)
.fb 3 - 40
11110620-2002072-WP002
However, a" a 2 and a 3 are dependent on the material used and the
liner setting method employed, which are given in Table 8.
Table 8. Foundation strength
Padding method Grinding method

When non-shrink When ordinary Surface to be
Stress
~ cement is used cement is used ground
Allowable stress of a 1 Concrete strength Concrete strength Concrete strength
liner x 1/3 x1/3xO.6 x1/3xO.7
785 N/cm2 490 N/cm2 588 N/cm2
(80 kgflcm2) (50 kgf/cm2) (60 kgf/cm2)
Allowable stress of
grouted portion
a2 Concrete strength
X1/3XO.6
- --
490 N/cm2
(50 kgflcm2)
Allowable stress of a3 Concrete strength Concrete strength Concrete strength
liner in case when x 1/2 x1/2xO.6 X1/2XO.7
static load only is 1177 N/cm2 735 N/cm2 834 N/cm2
applied during (75 kgf/cm2) (85 kgflcm2)
(120 kgf/cm2)
installation
Notes: - The coefficient of shrinkage of grout employing ordinary cement is

as small as 0.16%. The adhesion of cement is well exhibited in the
grout. According to past experience, this grout carries considerably
large loads, making a contribution to the prevention of sound and
vibration. The allowable stress of this grout is said to be 29-78
N/cm2 (3 to 8 kgf/cm2), though it cannot be determined exactly .
• - The allowable stress of the portion grouted by the grinding method

is the same as that in case when non-shrink cement or ordinary
cement is used under the padding method.
3 - 41
11110620-2002072-WP002
Remarks: 1. The equipment is installed more than one month after placing of
concrete. Assuming that the standard compression strength of
2 2
concrete is 2352 N/cm (240 kgf/cm ) and the safety factor is 3, the
allowable stress ((]",) of foundation concrete is taken at 785 N/cm2
(80 kgf/cm\
2. The non-shrink cement used for grouting expands during hardening

to such an extent where the equipment base is not deformed, thus
reducing the load to be carried by the installation pads.
3. The efficiency of pressure-receiving area of grout is assumed to be

60%.
4. All loads to be applied to the foundation during about 20 days from

the centering of equipment to hardening of grout is static. Only when
non-shrinking cement is used for grouting, therefore, the safety
factor is taken at 2.
5. The strength of pad in which ordinary cement is used is 60% of that

of the pad in which non-shrinking cement is used.
6. In the case of grinding method, rub the liner to the foundation

surface so that they come into contact for more than 70% of the
entire surface.
3 - 42
11110620-2002072-WP002
3.4.1.2 Determination of liner arrangement

Liners must be placed in the following places. However, omission may
be allowed if liners in one place can serve as liners for other place or
when the weight of equipment is light. Furthermore, liners shall be
installed so as to ensure the passage of grout.
(1) On the both sides in the vicinity of anchor bolts
(2) Directly below main bearings
(3) Directly below the base frame if this frame deflects at the time of
installation
3.4.1.3 Determination of liner shape

As liners are installed by hand, their weight should be such that they can
carried by both hands. Liners being conventionally used are 1/2 to 4
times as wide as the palm of the hand. As the width increases, the
thickness of the lowermost liner increases, ranging from 12 to 35 mm, To
install liners efficiently, liners of shapes as shown in Table 9 are widely
used. Liners of different shapes and sizes may be used for the same
equipment.
3 - 43
11110620-2002072-WP002
Table 9
No. Type Shape Merits and demerits
1 Thick and thin flat 1. Easily available and cheap in

liners are placed one
upon another
/ price
I ~
2. Adjustment not easy
3. Adjustment can be made only

within the thickness of liners
inserted and fine adjustment is
difficult.
4. Accuracy becomes unstable as

the number of liners increases.
2 Taper liners are place 1. Cost increases because of

one upon another. Driving
tapering.
direclion
(Taper:
1/25-1/50) 2. Adjustment can be done
tC -~
efficiently.
3. Fine adjustment easy
4. After centering, welding is

required to prevent liners from
sliding down.
3 Taper liners are Driving Resistant to impact load.

d~on
placed on flat liner
Other merits and demerits are the
(Taper: same as those of taper liners.
1/25-1/50) I~
to 3 - 44
11110620-2002072-WP002
3.4.1.4 Determination of processing under the liner

The methods of processing under the liner and their merits and demerits
are as shown in Table 10.
Table 10
No. Type Shape Merits and demerits
1 Padding Pad 1. Liners can be installed even after

method equipment is installed.
2. Leveling easy and efficient
~ ~
0 0 . 0o . 00.0 0
3. The quantity of liners can be
decreased, but padding material
Driving
0
consumption increases.
direction
• I 4. Good adhesion between liner
I~
and padding material. Allowable
. ~
0 o. o 0.0 .0
load is the largest.
0 .0
0.00.0 5. Most advanced method.
2 Grinding
method
~: Ii .0.0 0 .0 n°ci .
1. Must be done before equipment
is installed.
~
0
lr-
.
2. Not efficient as grinding of
0 .0 .
0
0
0 0
0
0
concrete surface takes much
time .
3. Grinding produces dust, exerting
Driving an adverse effect on working
direc~1 environments.
~SZ I Ilr- 4. The number of liners is
0
.0 0 . . 0 increased as compared with the
.00
0 . 0 0 0 padding method but pad is not
required.
Driving j 5. Allowable load decreases
dir~ depending on the roughness of
I~ ground concrete surface or the
o . o. . o .0
. 0 00
roughness of the lower surface
0 0 0 0 of liner in contact with the
concrete.
6. Several types of flat liners with
different thicknesses are
required for adjustment of
foundation height.
3 - 45
11110620-2002072-WP002
3.4.2 Liner installation
3.4.2.1 Determination of liner position

After inspection and centering of the foundation for the equipment to be
installed, mark the outer contour of the equipment base by measuring its
distance from the center line with a steel tape and determine the pad
position.
3.4.2.2 Roughening of the installing surface

The installing surface means the surface to be covered by the equipment
base and a frame-like area of 100 to 150 mm in width along the base
which are to be grouted. Roughening is done to improve the adhesion of
grout by removing laitance from the concrete surface.
The concrete surface is roughened by chipping by 10 to 20 mm. For this
purpose, an air-operated or motor-operated pick hammer is used.
Exercise care so that chips resulting from chipping do not enter anchor
bolt holes.
Roughening is not required for such installing surfaces as the surface
under the oil tank and the surface under the support for which grouting is
not done, as well as the place where liners are installed by the grinding
method.
3 - 46
62
11110620-2002072-WP002
3.4.2.3 Processing under liners
(1) Preceding padding method

The padding procedure is as shown below.
(a) Chip the concrete as shown in Fig. 14 from the place to be padded.
(b) Clean the concrete surface to be padded with compressed air,

wash it with water to keep it sufficiently moist and remove excess of
water.
(c) Prepare wooden frames which are larger by 60 to 80 mm in width

than the flat liner. Charge the mixed padding material into the
frames and tamp it until the water comes up to the surface. In some
cases, padding may be done without using frames (see Fig. 14).
(d) Set the liners to the specified height from the bench mark, using a
level. At the same time, adjust the horizontality of the liner in all
directions correctly by the use of a level. The tolerance of height
shall be less than -0.3 mm and that of horizontality less than 0.1
mm/m in the case of main equipment. For auxiliary equipment, the
height tolerance shall be less than -0.3 mm but the tolerance of
horizontality shall be less than 0.5 mm/m.
(e) Usually, more than 36 hours are required for curing of the pad. If
the atmospheric temperature is below 5 C, keep the pad warm by a
suitable means. In the hot season, keep the pad sufficiently moist.
(f) The mixing ratio (percent by weight) and weight of padding material
per cubic meter is as shown below.
Non-shrinking Ordinary Sand Water

cement cement
Mixing ratio 1 1 1 0.33-0.35
Weight 750 kg 750 kg 750 kg 250 kg
••
3 - 47
11110620-2002072-WP002
(g) The standard size of pad is as shown in Fig. 14
Fig. 14 (Unit: mm)
G) When form is used ~ When form is not used
Pad liner
Lt'l
I
Specified N
height o
N
I
o
~
Chip
Q) Installing height of pad
H1 = H-(H2 + H3)
Where
M
I
H: center height of temporarily
1:
installed equipment
N
I Height specified in drawing
I
H1: [ installing height of pad,
/
-0.3
0 0 0 0
o 0 L (06-0.7)L 0 H2: combined height of liners
00 0 0 0 0 0 Adjusting allowance: more ]han
[ +0.3
H3: center height of equipment specified in the drawing (to be

confirmed by checking the actually installed equipment)
L: length of longer side of taper liner
3 - 48
11110620-2002072-WP002
(2) Sub sequent Padding method

Sub sequent padding method generally applies following 3 cases.
Equipments which bottom face of base black skin.
Equipments which are shall and light.
Equipments which don't require high installation
accuracy.
Installation procedure is as follows.
(a) Chip the padding place according to Fig. 15.

Chip the foundation, so that space under to base become more
than 75 mm because of setting pad after placing the base.
Liner
.I
Fig.15
(b) Arrange necessary liners for centering machine base. Select the
place of padding easy for centering work. (Refer to Fig.15)
(c) Tighting anchor bolt, machine base shall be aligned. Accuracy shall
comply with final centering. If anchor bolts are not fixed, grout and
caring shall be done according to 2.6.2 & 2.6.3.
(d) Clean the concrete surface to be padded with compressed air,

wash it with water to keep it sufficiently moist and remove excess of
water.
3 - 49
11110620-2002072-WP002
(e) Tamping the mixed padding material, pile up so that clearance

between base and liner becomes "A" dimension in Fig. 16.
A=B-10 (mm)
Fig.16
Pad material is same as that of preceding pad (2.4.2.3(1 )(f))
(f) Reverse the pile of taper liner and hit the liner by hammer to press
down the pad until the upper face of liner support the bottom face
of base by reaction of pad. No crack and collapse are allowed.
"£" dimension shows the hitting length to lift the base by 0.3 mm
after pad hardening. (Refer to Fig.17)
Fig.17
(g) Usually, more than 36 hours are required for caring of the pad.
If the atmospheric temperature is below 5 C, keep the pad warm by
a suitable means. In the hot season, keep the pad sufficiently
moist.
(h) After pad hardening, taper liners shall be returned to normal

condition and final centering shall be carried out.
3 - 50
6("
11110620-2002072-WP002
Fig.18
(3) Grinding method

Installation of liners by the foundation grinding method is accomplished
as shown below (see Fig. 19).
Fig.19
Flat liner
( for adjustment of )
\foundation height
Flat liner
rMore than
. .70
00'0 0 0
.. 00 .. O'J~' .0000' 0 J~. 'OO'J~O'O
00 O. 0 0..) 0.0000 0..) 0.00..)
(a) Before roughening the foundation surface, mark the place where
liners are installed. Do not roughen the surface in this place.
(b) Flat liners made from gas-cut and chamfered steel plate are better
than those made from sheared iron plate (sheared steel plate may
be subject to bending).
(c) Adjust the height of the foundation by inserting flat liners as shown
in Fig. 19.
(d) Perform rough grinding by means of a smoothing hammer.
(e) Grind the upper surface of the foundation by 5 to 10 mm until the

laitance layer is completely removed.
3 - 51
'7
11110620-2002072-WP002
(f) The horizontal accuracy of grinding shall be 0.1 mm/m.
(g) Apply red lead to the bottom surface of liner and rub the liner
against the surface to be ground. Grind the surface of the
foundation at points where red lead was transferred from the liner
until the foundation surface comes into contact with the liner for
more than 70% of the entire surface .
••
3 - 52
11110620-2002072-WP002
3.5 Tightening of bolts
3.5.1 Tightening of anchor bolts

Unless otherwise specified in the drawings or specification, anchor bolts
shall be tightened as described below.
3.5.1.1 Tightening force

The tightening force of anchor bolt is determined depending upon the
shape of threads and the processing method of material. In the case of
anchor bolts produced by the ISO standard, however, the tightening
force is calculated by the following equation.
P = (J A (6)
where P: tightening force N(kgf)

(J: tensile stress of bolt [generally 69-98 (7 to 10)] N/mm2
2
(kgf/mm )
A: effective cross-sectional area of thread (mm2)
The tightening force calculated for each nominal diameter of thread using
equation. (6) is as shown in Table 11.
3 - 53
11110620-2002072-WP002
Table 11
Effective
Nominal cross-sectional area, Tightening force,
diameter of A PKN(kgf)
thread
mm2
M 12 84.3 5.82-8.26 (590-840)
M 16 157 10.8-15.4 (1100-1570)
M 20 245 16.8-24.0 (1710-2450)
M 24 353 24.2-34.6 (2470-3530)
M 30 561 38.4-55.0 (3920-5610)
M 36 817 56.0-80.1 (5710-8170)
M 42 1121 76.9-110 (7840-11200)
M 48 1473 101-144 (10300-14700)
M 56 2030 139-199 (14200-20300)
M 64 2676 183-262 (18700-26700)
M 72x6 3460 237-339 (24200-34600)
M 80x6 4344 298-426 (30400-43400)
M 90x6 5591 383-548 (39100-55900)
M 100x6 6995 480-685 (48900-69900)
M 110x6 8556 586-838 (59800-85500)
M 125 x6 11191 768-1089 (78300-111000)
M 140 x6 14181 937-1383 (99200-141000)
M 160x6 18716 1285-1834 (131000-187000)
3 - 54
70
11110620-2002072-WP002
3.5.1.2 Tightening tools and method of measurement

Tightening tools for anchor bolts are generally selected according to the
nominal diameter of thread.
It is, however, essential to use tools which are best-suited for the space
where tightening is done.
The tools required for tightening of anchor bolts and the methods of
measurement are shown in Table 12.
Table 12
Nominal dia.
Tool Method of measurement
of thread
M12
M16
M20 Spanner with long handle Torque -

Wrench
M24
Impact
M30
Wrench
M36
M42 Knocking spanner

5kg hammer -
M48
M56 Experience
and intuition
M64
Knocking spanner
M72X6 10-kg hammer
(or 150kg Dolley bar) Nut rotation
M80X6
angle method
M90x6
Bolt
Knocking spanner
M100 X6 stretching
200kg Dolley bar
method
M110 X6
M125 x6
Knocking spanner Jack
M140 X6
500kg Dolly bar
M160 X6
3 - 55
71
11110620-2002072-WP002
(1) Torque wrench method

The torque wrench method is a method of measuring the tightening force
by means of a torque wrench. In this method, the tightening torque must
be calculated by Equation (7) .
•
T = kdp (7)
where T: tightening torque N . mm(kgfmm)

K: coefficient of torque
d: nominal diameter of thread (mm)
P: tightening force N(kgf)
Remarks: 1. The coefficient of torque, K, in equation (2) varies with the coefficient
of friction at the contact surface of threads and the coefficient of
friction at the contact surface of nut bottom. If these two coefficients
are assumed to be 0.15, the coefficient K will be 0.2. The following
values were published as the results of experiments (Study Report
on Proper Tightening of Screws, published from the Japanese
Screw Study Association in 1972). For threads which are completely
• degreased and washed, K is 0.2492 + 0.0432. For the
above-mentioned threads which are applied a thin coat of machine
oil,KisO.192 + 0.01961.
2. When tightening a screw for the first time, the tightening torque must
be below the standard value because of the roughness, torsion,
error in shape, etc. of thread contact surface and nut bottom contact
surface. When it is tightened or loosened two or three times, the
tightening force will become the standard value.
Accordingly, insufficient tightening may result unless anchor bolts
are tightened as described above or in consideration of the
above-mentioned.
3 - 56
11110620-2002072-WP002
(2) Method based on experience and intuition

In this method, the tightening torque or force is determined based on
experience and intuition. This method has been widely employed so far.
Generally, the following items are determined based on experience and
intuition. They usually require a great deal of skill.
Tool used Experience and intuition
Spanner with long handle Length of handle and required physical

strength
Hammering spanner Reaction felt in the hand when a

hammering spanner is struck with a
Hammer hammer, sound produced at this time,
and rebounding height of the hammer
Lever block
Hammering spanner Sound produced when a hammering

spanner is struck with a lift hammer,
Lift hammer rebounding height, and swing of lift
rope at that time
Lever block
Impact wrench Operating air pressure, tightening

time, reaction force applied to the hand
••
3 - 57
73
11110620-2002072_IYP002
Remarks
How to cultivate experience and intuition
Clamping bolts of various sizes (bolts of the same material and finish as
anchor bolts are desirable) are fixed vertically near the floor in the
• similar manner as anchor bolts are fixed. This condition is illustrated in
Fig. 20. Inserting steel plates, tighten the nut up to the specified
tightening force and put matchmarks on the bolt and nut. The specified
tightening force is measured by the heating expansion tightening
method or nut rotational angle method. Using these bolts, train the
intuition for tightening and loosening torques.
Fig.20
Structure 'oint weld
Circular washer
Sto er
Reference 4. Method of tightening up to the specified tightening force
••
3 - 58
11110620-2002072-WP002
(1) Tightening the nut, determine the snap position (the point where tensile
stress starts to be applied to the bolt) by sense and put matchmarks for
this point on the bolt and nut (see Fig. 21).
• (2) Calculate the angle of rotation of nut using equations (8) through (10),
and tighten the nut further by the angle thus calculated. Instead of
tightening with a spanner, it may be allowed to tighten the nut by hand
after heating the bolt stem to 100 to 150 C.
This is the specified tightening position. Put matchmarks for this position
on the bolt and nut (see Fig. 21).
~ 360 X P/D (l/kt + like) (8)

Fig. 21 '"
kt 1t 14 X d2 X EblR ( 9)
1t 14 { (B+t)'-D') Eb
ke (10)
-"
",c:
c: _
00 where
R
Approximate
:';:;Q) equation
"'-'"
~
0c: ~ : angle of rotation of nut
0::",
(deg. )
Matchmark
P : specified tightening force
for snap
osition (kgf)
p : thread pitch (rrun)

II
r /' '"
I
I kt : spring modulus of
N Irrun (kgf/rrun)
thread
ke : spring modulus of material to

~ be tightened N/rrun(kgf/rrun)
d
-- 0< d : diameter of bolt stem (mm)

[
- Eb : modulus of longitudinal
elasticity of bolt N/rrun'
•• (kgf/rrun',young modulus)
Llll)
I, B+ t ,I
3 - 59
11110620-2002072-WP002
e: effective length of bolt (mm)
B: width of nut across corner (mm)
• t: thickness of iron plate to be tightened (mm)
0: diameter of bolt hole (mm)
Ep: modulus of longitudinal elasticity of iron plate to be

2 2
tightened N/mm (kgf/mm )
Reference 5. The tightening torque is larger than the loosening torque, and there
exists the following relation between these torques. Accordingly,
learn this relation during practice.
T1 = 0.8Tf (11)
where T1: loosening torque N. mm (kgf . mm)

Tf: tightening torque N. mm (kgf . mm)
(3) Nut rotational angle method

In this method, the amount of elongation required to produce the
specified tightening force described in Para. 2.5.1 is converted into the
elongation of bolt and is measured in terms of the angle of rotation of nut.
As it is difficult to calculate the spring constants of thread and material to
be tightened, the tightening force for anchor bolt cannot be used without
converting it into the elongation of bolt. Accordingly, conduct test using
one of several anchor bolts and tighten it by the specified tightening force
based on intuition. Measure the angle of rotation of nut from the position.
The remaining bolts can be tightened to the specified force by observing
this angle of nut rotation.
3 - 60
76
11110620-2002072-I'YrJ002
(4) Bolt stretching method Fig.22 (Unit: mm)
In this method, the anchor bolt <1>570

is stretched by the amount Bolt stretching
corresponding to the specified nut
tightening force by means of a

screw jack or hydraulic jack Piston
Hyd.
inserted at the tip of the anchor } jack
bolt threads.
Oil pressure
After that, the jack is removed, inlet
thus introducing the specified
tightening force into the bolt.
However, this method cannot be
<I>1 5 Bush
applied if threads are short. An
example of this method is Nut
shown in Fig. 22.
Su art
M 80
Frame
Anchor bolt
----
3.5.1.3 Inspection of anchor bolt tightening
It is difficult to judge visually if the anchor bolt has been tightened as

specified. If the worker gets skilled, however, he can judge it from the sound
and rebounding of the hammer by tapping the nut side with a hammer.
Generally, hammers to be used for anchor bolt tightening inspection are of
the following sizes.
M24 and smaller : Test hammer

M30-M48 : Hand hammer
M56-M80 : 5kg hammer
M90 and larger : 10kg hammer
3 - 61
7'7
11110620-2002072-'rVP002
3.5.1.4 Anchor bolt tightening control
Anchor bolts play an important role for equipment and their replacement is
nearly impossible. In addition, measurement at the time of tightening and
inspection after tightening are very difficult, depending largely on workers'
experience. Accordingly, anchor bolts must be tightened only by experienced
workers. Other precautions are as described below.
(1) Remove concrete, rust - preventive oil, rust, etc. adhering to threads.
Correct dents, remove burrs with a file, apply a small amount of seizure
preventive agent (machine oil, molybdenum disulfide, grease, etc.) and
tighten the bolt.
(2) Bolts, such as anchor bolts of rolling mill sole plate, which cannot be
retightened because of the presence of piping or the like, or bolts which
cannot be retightened because of sealing, shall be tightened additionally
after they have been tightened to the specified torque.
(3) The dolly bar must be long in lifting length to stabilize horizontal shock. In
addition, the hammer head must be attached with hemp rope which
should be pulled by several men to increase the hammering force.
3 - 62
11110620-2002072-WP002
(4) The hammer head anchor bolt shall be provided with a mark indicating
the direction of hammer at the bolt top as shown in Fig. 23.
Fig. 23
]===~~
(5) The longitudinal direction of long holes of hammer - head bolt for
embedded anchor plate shall be at right angles to the line as shown if Fig.
24. If wooden hammer - head bolts of actual size are used, inspection
can be conducted easily.
Fig. 24
Liner center
----~ [I]
0, r-;::;l
~
, i @] @] @] @]
\
.._._._ _.--.L._._._._._ _._._._._._._ -L. '-'-'-'-'-'-'-'-'-'-'-'-'-'-'-'.'.'.'-'.'-'-'-'-'-'-'-._._._._._._._._ _ .
@]!@] ! @] @]! @] @]
@]:@] [I]
_._._._.~.-._.-!-._._._._._.~._._._.-._._._.-
!!
: [I]
!
:i
.
@]!@] l !
fOl i; fOl Center line at right angles
~ ;
~ to the line
;
;
;
3 - 63
79
11110620-2002072-WP002
3.5.2 Tightening of ordinary bolts
Unless otherwise specified in the drawing or specification, ordinary bolts (7)

shall be tightened as follows.
Note (7) ordinary bolts mean bolts other than anchor bolts.
3.5.2.1 Tightening force of ordinary bolts
The tightening force of ordinary bolts is calculated by equation (6) given in

Para.3.5.1.1. In this equation, however, a is the tensile stress of bolt (60 to
70% of the yield point of bolt material) in N/cm2 (kgf/cm2). The tightening
force for each nominal diameter of thread as classified by strength is given in
Table 13.
3 - 64
11110620-2002072-WP002
Table 13 Unit: kN (kgf)

NOMINA EFFEC-T STRENGTH
L IVE 4T 8.8 10.9 12.9
THREAD CROSS YIELD POINT
DIA. AREA 226N/mm' 628N/mm' 883N/mm' 1059N/mm'
Amm' (23kgf/mm') (64kgflmm') (90kgflmm') (108kgf/mm')
M12 84.3 11.4 ( 1160) 31.8 (3240) 44.7 (4560) 53.6 (5470)
13.3 (1360) 37.1 (3780) 52.1 (5310) 62.5 (6370)
M16 157 21.3 (2170) 59.2 (6040) 83.2 (8480) 99.8 (10200)
24.8 (2530) 69.0 (7040) 97.0 (9890) 116 (11800)
M20 245 33.2 (3390) 92.3 (9410) 130 (13250) 156 (15900)
38.8 (3960) 108 (11000) 151 (15400) 182 (18600)
M24 353 47.9 (4880) 133 (13600) 187 (19100) 224 (22800)
55.8 (5690) 155 (15800) 218 (22200) 262 (26700)
M30 561 76.1 (7760) 211 (21500) 297 (30300) 356 (36300)
888 (9060) 247 (25200) 347 (35400) 416 (42400)
M36 817 111 (11300) 308 (31400) 433 (44200) 519 (52900)
129 (13200) 359 (36600) 505 (51500) 606 (61800)
M42 1121 152 (15500) 422 (43000) 594 (60600) 712 (72600)
177 (18000) 493 (50300) 693 (70700) 831 (84700)
M48 1473 200 (20400) 555 (56600) 780 (79500) 936 (95400)
233 (23800) 648 (66100) 910 (92800) 1092 (111400)
M56 2030 275 (28000) 765 (78000) 1075 (109600) 1290 (131500)
321 (32700) 892 (91000) 1255 (128000) 1505 (153500)
M64 2676 363 (37000) 1008 (102800) 1418 (144600) 1700 (173400)
423 (43100) 1176 (119900) 1654 (168700) 1984 (202300)
M72x6 3460 469 (47800) 1304 (133000) 1833 (189600) 2198 (224100)
547 (55800) 1521 (155100) 2139 (218100) 2565 (261600)
M80x6 4344 589 (60100) 1637 (166900) 2301 (234600) 2760 (281400)
687 (70100) 1910 (194800) 2685 (273800) 3220 (328300)
M90X6 5591 758 (77300) 2107 (214900) 2962 (302000) 3553 (362300)
884 (90100) 2458 (250600) 3456 (352400) 4145 (422700)
M110X6 8556 1160 (118300) 3224 (328800) 4533 (462200) 5436 (554300)
1354 (138100) 3761 (383500) 5288 (539200) 6343 (646800)
M125x6 11191 1517 (154700) 4217 (430000) 5929 (604600) 7111 (725100)
1770 (180500) 4920 (501700) 6917 (705300) 8296 (846000)
M140x6 14181 1923 (186100) 5343 (544800) 7513 (766100) 9011 (918900)
2243 (228700) 5234 (635700) 8765 (893800) 10512 (1071900)
Figures in the upper column indicate the tightening force in case when the tensile
strength of bolt is 60% of the yield point of bolt material, but figures in the lower
column indicates the force in case when the tensile stress is 70% of the yield
strength of material.
3 - 65
~I
11110620-2002072-i'¥P002
3.5.2.2 Tightening tools and tightening force measuring method for ordinary
bolts
Tightening tools used for ordinary bolts are given in Table 14. The tightening
• • force measuring method shall conform to 3.5.1.2 (1) through (4) .
Table 14
Nominal bolt diameter

Strength classification Tool Measuring method
4T 6T ST 10T
M12 M12 M12 M12
Spanner with
\ \ \ \ long handle Torque -
M24 M20 M16 M16 Wrench
M30 M24 M20 M20 Knocking Impact
\ \ \ \ spanner 5kg Wrench -
42 M36 M30 M30 hammer
M4S M42 M36 M36 Knocking c:

spanner10kg 0
hammer (or "":; '0

0
M~4 M~6 M~S M42 150kg Dolly bar) ~ .c:
'0 Q)
c: E
M72X6 M64 M56 M4S Knocking ro OJ
OJ
spanner200kg u 0>
c:
c:
hammer Dolly OJ ro
Mgdix6 M72ix6 M54 M56 bar
'0
0
'C
OJ
a.
roc:
.c:
Q) x 2
MSOX6 M72X6 M64 Knocking w
E 2
M110x6
spanner500kg
'"
c:
e
hammer Dolly E '5
M901x6 Ms6x6 M721x6 bar Jack B z
.=
OJ
M125X6 M110x6 M90X6 MSox6

Burner,
Knocking -
<J)
0
to
spanner (Shrink
M14~X6 M149x6 M14~X6 tightening
M14~X6
(8) )
Note (8) The shrink tightening method is a kind of bolt tightening methods
utilizing the angle of nut rotation. In this method, the bolt stem is
stretched through heating by a burner of heater, thus introducing
tightening force into the bolt.
3 - 66
11110620-2002072-WP002
3.5.2.3 Precautions in tightening of ordinary bolts
(1) The bolts to be used shall be of the material, diameter and length as
specified in the drawing.
(2) The external and internal threads shall be free from dust, rust _
preventive oil, etc., and shall be applied with a seizure preventive agent
(machine oil, molybdenum disulfide, grease, etc.) before tightening.
(3) When tightening a group of bolts, tighten all bolts in the group uniformly.
An example of tightening order is shown in Fig. 25.
Fig. 25
(4) First, tighten all bolts uniformly with a torque lower than the specified
torque. Finally, tighten them at the specified torque.
(5) To ensure that all bolts are tightened without omission, mark the bolt
which has been tightened at the specified torque.
(6) When tightening plated bolts, do not apply oil or grease unless
specifically indicated.
(7) When specified in the drawing, never fail to lock all bolts (with wire lock,
lock washer, bent washer, etc.) correctly.
3 - 67
11110620-2002072-\'VP002
3.5.3 Retightening of bolts
(1) Retighten anchor bolts one month after the start of trial run.
, (2) Ordinary bolts shall be retightened as needed in accordance with the

instructions from the supervisor.
(3) Be careful that all bolts are retightened correctly.
3 - 68
11110620-2002072-WP002
3.6 Installation, centering and assembling of equipment
3.6.1 Preparations for equipment installation
Before installing the equipment, make the following preparations.
(1) Roughen the foundation surface and clean the flat liner surface on the
pad.
(2) Prepare and maintain anchor bolts, nuts and washers in good condition.
(3) Remove water from anchor bolts holes, clean these holes and cut the
protruding portion of sheathing material.
(4) Insert anchor bolts (eye bolts, L-bolts, etc.) into anchor bolt holes. An
example of temporary fixing of the upper portion of hammer head bolt is
shown in Fig. 26.
Fig. 26
Ai IA
•
0 0
0 0
0
,,---------- ----------" ,
0 0 ,,, ,,
,, ,
0
0 ,, ,,,
0 ,, ,,
,, ,--
, -- - --I , ,,
0 ,, , ,
0 ,, !.._- - --,
0 0 0 ,,
, ,
0 0
I ,
\..•. _--------- --------_ ..."
0 0
0
0 View A-A
0 0
0
0
0 0 0
0 0
0 0 0
0 0
3 - 69
11110620-2002072-YiP002
(5) Determine the overlapped height of liners for installation.
Determine this height as shown by H2 in Fig. 14-(3).
(6) Remove rust - preventive oil applied to the lower surface of the machine
base.
(7) Remove rust - preventive oil from the portion of the equipment at which
measurement of centering is made.
(8) Study the centering procedure with reference to drawings, specifications,

manuals, etc.
(9) Have a correct understanding of centering accuracy and prepare

measuring instruments.
(10) Examine the operating range of overhead crane and study the methods
for transportation and assembling.
(11) Study scaffoldings to be used for works at elevation.
(12) Study the interference with adjacent equipment, piping and other
structures.
3 - 70
11110620-2002072-WP002
3.6.2 Temporary installation
Temporary installation includes temporary placement and temporary
centering.
(1) Temporary installation is performed when anchor bolts are not directly
embedded and centering must be done in two stages, i.e. temporary
centering and final centering.
(2) Temporary placement
Temporary placement means such a condition where the equipment is

placed on liners for installation and anchor bolts are inserted. Insert
anchor bolts into bolt holes by lifting them by means of a centering hook
as shown in Fig. 27 so that their axis agrees with that of the holes made
in the equipment base.
Fig. 27
Centering hook
(made of wire)
Base
"'U[?J
o '.0
o
. 0 0
o o
Anchor bolt hole
3 - 71
11110620-2002072-IVP002
(3) Temporary centering
Temporary centering is the work to roughly align the temporarily placed

equipment to the line center, equipment center line and specified height
in accordance with the drawing.
Anchor bolts are kept suspended and are not fixed.
Primary centering is done in the like manner as final centering. The
tolerance of primary centering is generally as follows.
Specified height 0 mm
-0.3
Error with respect to line center Less than 1 mm
Error with respect to equipment Less than 1 mm

Center line
3 -72
11110620-2002072-IVP002
3.6.3 Grouting of anchor bolt hole and curing time
(1) Grouting of anchor bolt holes means filling anchor bolt holes with grout to
fix the anchor bolts of primary installed equipment to the foundation.
• Before grouting, check the following points .
(a) Cleaning of anchor bolt holes and moistening with water
(b) Verticality of anchor bolts
(c) Alignment of anchor bolt axis with the center of the hole in the base
(d) Removal of water standing in anchor bolt holes
(2) The standard mixing ratio and curing time of grout is as shown in Table
15. When using ready - mixed concrete, select a suitable concrete with
reference to Table 15.
Table 15
Mixing ralio (wt. %)

Curing
Flow
Appii-calion Nonshr-in lime Remarks
(mm)
k Cement Sand Gravel Waler (day)
maleri-al
Anchor bait - 1 2 - 0.50-0.55 More

than 7
A
(630kg) (1260kg) (315-345kg) 250
hole Under
equipment - 1 1 1.5 0.45-0.50 -260
B
(580kg) (580kg) (870kg) (260-290kg)
base
1 1 1 - 0.48-0.50 More C
(750kg) (750kg) (750kg) (360-375kg) lhan 3
1 1 1 1.5 0.48-0.53 D
(520kg) (520kg) (520kg) (780kg) (250-275kg)
3 - 73
11110620-2002072-WP002
Remarks 1. The weight in kg required for 1 m3 is shown in parentheses.
2. The standard size of gravel shall be 5-10 mm.

If grouting allowance is more than 150 mm, gravel of more than 10
mm in size may be used.
3. A and C apply to a small amount, band C apply to a large amount in

remarks.
(3) For mixing and curing, pay attention to the following points.
(a) Hand mixing should be avoided. If hand mixing is unavoidable, add
water after making sure that cement, sand and gravel have been
sufficiently mixed. Then, knead the mixture so that water is diffused
uniformly.
(b) When a small mixer with a peripheral speed of 1 m/sec is used,
mixing takes 2 to 4 minutes. In such cases, attempt to charge water,
cement, sand and gravel in the same quantity at the same pitch as
rapidly as possible.
(c) While pouring, tamp the grout with a rod.
(d) During the curing period, protect the grout from direct rays of the sun,
rain, frost, etc. and keep it moist.
(e) Do not give vibration, impact and load to the grout during curing.
(f) The method and period of curing in the winter must be specified
separately.
3 - 74
11110620-2002072-'lVP002
3.6.4 Final centering and inspection
3.6.4.1 Final centering

Final centering of main equipment shall conform to Table 16. For final
centering of auxiliary equipment, centering of coupling is also required.
Table 16
Step Item Measuring Caution

instrument
1 Level View from bench mark.

Height
Steel Ruler View from adjacent equipment.
Discrepancy from line Align to equipment center mark. If there is no

center mark, measure from datum level for
center Piano wire,
measurement.
Plumb bob,
2
Discrepancy from Transit Ditto. Measure the distance between shaft
center line at right ends.
angles to the line
3 Precision level, Results of measurement by precision level

Levelness. Straightedge should agree and difference should be zero.
Block
• If the distance between levelness measuring points is great, use both a

straight edge and precision level.
Reference 6. Method in which piano wires are stretched on the line center and
the equipment center line and plumb bobs are suspended, thus
aligning the equipment to the tip of the plumb bobs (See Fig. 28)
The centering accuracy shall be zero (-+-0.3 mm) through visual
observation.
3 - 75
r,/
11110620-2002072-WP002
Fig. 28
Piano wire
Steel ruler
Piano wire
.............
Center mark
~ -----------------------
jr\---
Patch"
Center mark
o 0 0
Center Mark
'Patch : Tin plate or the like to be attached to the wooden part on which scribing is
made. This patch is installed at each bearing as shown in Fig. 28 and is
used for centering after determining its center by means of calipers from
the inside of the bearing case.
Reference 7. Method for centering rotating bodies such as datum roll of roller
table and tension reels by means of piano wires and swing jigs.
(See Fig. 29.) The centering accuracy shall be about 0.05 mm per
1.5 m (90°+7")
3 - 76
11 I l0620-2002072-WP002
Fig 29
Roller
Piano wire
on line center
1\"
Inside
[J:============================== :: o '" micrometer
Swing jig
Piano wire
on line center
Swing
I
3.6.4.2 Inspection of final centering
Final centering shall be inspected under the condition where anchor bolts
have been sufficiently tightened and all liners for installation are carrying the
•• load uniformly. After making sure that final centering has been done correctly,
measure each inspection item and record the results. Judgment shall be
passed by checking the results of inspection against the installation accuracy
standard. The following items shall be generally inspected, although they
may vary with equipments.
3 -77
93
11110620-2002072-WP002
(1) Height
(2) Discrepancy from the line center
(3) Discrepancy from the center line at right angles to the line
(4) Levelness
(5) Distance between shaft ends
(6) Shaft horizontality
(7) Tooth contact, backlash of gears
(8) Clearance between sliding surfaces
(9) Clearance between rolling surfaces of bearing, etc.
Etc.
3.6.4.3 Welding of liners for installation (taper liner)

If inspection results are satisfactory, perform welding of taper liners
immediately to prevent their movement (see Fig. 30).
Fig. 30
~ Weld
C)
o
o C) C6 C)
o
C)
3 - 78
11110620-2002072-WP002
3.6.4.4 Centering of shaft coupling
After final centering of main equipment, auxiliary equipment are installed.

At this time, the shaft coupling of the main equipment must be aligned with
those of auxiliary equipment. This procedure is shown in Figs. 31 and 32.
1
Fig. 31 (Unit: mm)
100
(1) Align the coupling of the
auxiliary equipment driving
Drive 0'
shaft to that of the main shaft
equipment driven shaft of aux.
equip.
visually.
(2) Turning the driving shaft, Direction

read the dial gauge and of reading
record the measured value 90' 180'
(see Fig. 31(a)). (Specify

0
the direction of reading and
(a)
record in this order.)
0
(3) Turning the driven shaft by 270' -30-$20 90'

180 , read the dial gauge
60
again in the same manner
I
as in Step (2) and record 180' 0'
(b)
the results (see Fig. 32 (a)).
90'
(c) 0'
Amount of
180'
--.
correction:5
270'
Amount of
correction:25
3 - 79
11110620-2002072-WP002
(4) Obtain the arithmetical mean of the values measured as shown in Figs.
31 (a) and (b) (see Fig. 31 (c)).
(5) Based on the results of Fig. 31 (c), correct the position of the auxiliary
equipment so that the drive shaft aligns with the driving shaft. (See the
arrow mark showing the amount and direction of correction in Fig. 31 (c).)
Fig. 32
Driven shaft
of main
Drive shaft of equipment 0'
aux. equipment
270' 90'
->
Reading 180'
Bearing clearance direction
Bearing
shifting jig
clearance
•.•
3 - 80
II J I0620-2002072-WPOO2
0°
(6) Turning the drive shaft,

measure the clearance
(a) 270° 90°
between the shaft coupling
surfaces by means of a feeler
gauge or dial gauge and
record the results. At this 180°
time, the bearing clearance of 0°
the drive shaft should be

shifted to one side (see Fig.
32 (a)). (b) 270° 90°
180°
0°
(e) 270°
..
3 - 81
97
11110620-2002072-WP002
(7) Turning the driven shaft by
180 , measure the clearance
Fig. 33
again in the like manner as
in Step (6) and record the
results. (See Fig. 32(c).)
(8) Obtain the arithmetic mean

of records as shown in Figs.
32 (a) and (b) (see Fig. 32
(c)).
(9) Based on the results of Fig. 32 (c), correct the inclination of the drive
shaft so that it aligns with the driven shaft.
(10) For the purpose of rechecking, perform measurements (2) through (5)
and (6) through (9) simultaneously.
(11) If the shafts can be rotated easily or are rotated at a high speed, turn the
driven and drive shafts simultaneously and read the dial gauge and
record results. If the dial gauge reading is zero, the error of parallelism of
both shafts will be zero. If any reading is obtained on the dial gauge, the
half of this value corresponds to the error in parallelism (see Fig. 33).
(12) The centering accuracy of shaft coupling shall conform to Tables 19 and
20.
If the required accuracy is different from tables 19 and 20, it shall be
described the reason (rotating speed, operating conditions etc.) and
required accuracy in the individual procedure.
3 - 82
11110620-2002072-WP002
Table 19. Error in parallelism of both shafts
(Deflection at the periphery)
Unit'mm
Type of shaft coupling Tolerance. *.
Gear type shaft coupling 0.10
Flange type flexible shaft coupling 0,08
Flange type fixed shaft coupling 0.05
* These values are readings of dial gauge. Accordingly, the misalignment of

shaft centers is the half of the tolerance shown in this table.
** Measurement is made, rotating the both shafts. Accordingly, the error of

roundness at the outside diameter is eliminated.
Table 20. Angular error between both shafts

(Difference in clearance between shaft coupling surfaces)
Unit:mm
Type of shaft coupling Tolerance
Gear type shaft coupling 0.10 for boss outside diameter up to 500 mm.
0.02 is added for every increase of 100 mm in
diameter.
Flange type flexible shaft coupling 0.08 for flange outside diameter up to 500 mm,
0.015 is added for every increase of 100 mm in
diameter,
Flange type fixed shaft coupling 0.05 for flange outside diameter up to 500 mm.
0,010 is added for every increase of 100 mm in
diameter.
3 - 83
11110620-2002072-WP002
Remarks:
1. As the shaft deflects, the shaft coupling of the auxiliary equipment should be
aligned so as to meet the deflection of the shaft of the main equipment as
shown in Fig. 34 (a).
If the inclination of the shaft of the auxiliary equipment has an adverse effect
on the performance of that equipment, however, an angular error in the shaft
coupling may be allowed as shown in Fig. 34 (b). However, this shall be limited
to gear type shaft coupling and flange type flexible shaft coupling.
Fig. 34
(b)
(a)
Aux. equip. r--r/~

Main equip.
Aux. equip.
Main equip.
2. Even if the outer periphery and edge surface of shaft coupling which are the
datum surface (measuring surface) for centering are finished precisely, an
error of about 0.05 to 0.1 mm in roundness or deflection of the edge surface
may be caused because of an error in turning or deformation resulting from
key assembling.
3. When the main equipment and auxiliary equipment are connected by means of
a gear type shaft coupling with an intermediate shaft of more than 1 m in
length inserted, centering of shaft coupling is accomplished using piano wire,
plumb bob and level. In such cases, the tolerance shall be less than 0.5 mm.
3 - 84
/80
11110620-2002072-WP002
4. For centering of shaft coupling, a dial gauge attached to a magnetic base may
be used for measurement. In such cases, however, the reading to be obtained
when the magnetic base is installed with its surface up may differ from that
when the base is installed with its surface down.
• Accordingly, such a dial gauge should be used after test.
Reference: The rubber tire type shaft coupling is highly flexible. Accordingly,
centering of such coupling is done by measuring the outer
periphery by a dial gauge. However, the clearance between the
surfaces may be measured with a steel ruler if the speed is low
(see Fig. 35).
Fig. 35
,.•... ---- .•...

/ ,,.•.. -- .•..,\
J
, ,••
3 - 85
/0/
11110620-2002072-WP002
3.6.5 Assembling of equipment components
(1) The equipment is assembled with reference to the drawings.

Thoroughly remove the rust - preventive paint applied at the shop during
disassembly for transportation. Remove rust, dents and burrs on the
installing surface.
(2) Matchmarked parts shall be installed with reference to the matchmark

table.
(3) Assemble the sliding parts, rotating parts, bearings, etc. after applying
the specified oil or grease uniformly in accordance with the
recommended oil list.
(4) Before assembling gears, check the major portions for tooth contact by
applying red lead, measure and record the backlash.
(5) Assemble the sliding and rotating parts, while rotating them by hand. If
measurement of clearance is possible, measure it by a gauge and record
the results.
(6) Lift the parts so that their center of gravity comes under the crane hook.
If the part is lifted with its center of gravity shifted, it cannot be fitted
smoothly, inviting danger. Eye bolts or the like for lifting should be used
after checking their strength.
(7) Lifting or temporary placement of heavy, long parts shall be

accomplished, exercising care so as not to cause distortion.
(8) When inserting or assembling parts, use wooden hammers so as not

cause damage to the finished portions. Place the parts slowly on suitable
sleepers. Precision parts shall be suitably covered.
'.
3 - 86
11110620-2002072-WP002
3.6.6 Assembling of steel structures
(1) Check the structures for deformation of members caused during

transportation. If any deformation is detected, correct it before
assembling.
(2) In most cases, on - site assembling of steel structure begins with the
erection of main columns. To prevent the columns from falling down,
keep bracing wires attached or supporting steel attached until anchor
bolts are fully tightened.
(3) Install structure joints, paying attention to the matchmarks on splice

plates.
(4) Use aligning pins which have been delivered from the shop. They shall
be driven in as appropriate.
(5) Measure the verticality of steel structure with a plumb bob, but the height
and levelness with a level.
3.6.7 Preparations for grouting under the equipment base
(1) Clean the concrete surface and sprinkle water thereon.

(a) Clean the surface with compressed air to remove dust before grouting
is started.
(b) If the concrete surface is stained with oil or grease, chip the surface.
(c) Remove rust - preventive paint, oil or grease applied to the lower
surface of equipment completely.
(d) After cleaning, spray a sufficient quantity of water to the concrete
surface. Water shall be sprayed 5 to 6 hours before grouting is
started.
(e) If a considerable quantity of water is remaining on the concrete
surface at the time of grouting, remove it.
..
3 - 87
11110620-2002072-WP002
(2) Assembling of frames
(a) Assemble frames to a height enough to fill the grout up to the top of
the equipment base (see Fig. 36).
(b) Frames shall be highly rigid. They shall be assembled so that they are
not deformed or deflected under the load of grout or under vibration
to be given by a vibrator.
(c) Fill the clearance between the form and the foundation surface with
cement mortar.
Fig. 36
r- Frame
Foundation surface
Fill with cement mortar
..
3 - 88
/o'/.
11110620-2002072-WP002
3.6.8 Grouting under the equipment base and curing time
(1) Mixing and curing time

Mixing and curing of grout shall conform to Table 15 on page 3-73.
(2) Precautions in grouting

When performing the grouting operation, pay attention to the following
items in addition to precautions given in Para. 3.6.3. (3).
(a) Pour the grout successively from one direction so as not to leave air
pockets.
(b) Do not stop grouting until grouting for one area is finished.
(c) After grouting, level the upper surface with a finishing trowel as finish
coating is not applied.
(d) The grouting allowance shall be as follows unless otherwise specified.
Heavy equipment 100 mm

Medium equipment 70 mm
Light equipment 50 mm
(3) Precautions in curing

(a) After application, the grout shall be cured sufficiently in such a
manner that it is not subject to temperature changes, low-
temperature drying, load changes or shocks that may impair its
hardening.
(b) If the grout has attained a sufficient strength even in the course of
curing, frames may be removed.
(4) Grouting materials

After finished align and centering of equipment, pre-mixed type
non-shrinkage grouting should use to equipment and structure base.
3 - 89
lOS
11110620-2002072-WP002
Attached table 1
Examples of tools and measuring instruments necessary for installation work.
No. Name Specification Q'ty Remarks
1 Transit 2
2 Level 5
3 Precision level Length : 200-250 mm
Sensitivity : 0.02 mm/m 2 For machine
centering For
0.1 mm/m 20 liner centering
4 Precision square level Length : 200-250 mm 5
Sensitivity : 0.02 mm/m
5 Straight edge Length : 5-6 m 2 For shape refer
to attached
Accuracy : 0,02 mm/m
drawing 1
Length :3 m 3
Accuracy : 0,02 mm/m
Length :2m 2
Prepare gauge
block for
Accuracy : 0.02 mm/m
straight edge
Length :1m 2
Length : 0,5 m 5
6 50 x 40 x 100mm block Accuracy : 5/1000 mm 10
3 - 90
/06
11110620-2002072-WP002
7 Steel ruler 600 mm 2
1,000 mm 10
1,500 mm 2
2,000 mm 2
8 Steel tape JIS Class 1 calibrated
50 m 2
30 m 3
20 m 3
9 Convex rule 2m 30
10 Vernier calipers 200 mm 3
600 mm 1
11 External micrometer 0-25 mm 1 each With

reference bar
25-50 m
50-75 mm
75-100 mm
100-125 mm
125-150 mm
12 Diai indicator 11100 mm (scale) 8
13 Lever type dial test 11100 mm (scale) 2
indicator
14 Feeler gauge Thick 5
Thin 20
I
3 - 91
11110620-20021172-rtP002
15 Scriber
20
16 Hydraulic skip jack and 490 kN (50 tonI) 4 each
17 journal jack 294 kN (30 tonI) 4 each
98 kN (10 tonI) 4 each
18 Screw center jack 49 kN (5 tonf) 4
10 kN (1 tonf) 10
19 Chain block 98 kN (10 tonI) 2
49 kN (5 tonI) 5
20 kN (2 tonI) 5
10 kN (1 tonf) 10
20 Shackle Nominal: 12 - 90 4 each
6 - 490 kN (0.6 - 50 ton)
21 Wire rope q, 65, q, 50, q, 32, q,24, q, 20,
q, 16, q, 12, q,10
22 Eye bolt M12 - M80 6 each Use of M10 is

prohibited.
23 Electric welder 24 kVA 10
10 kVA 10
24 Gas welder lVith a complete

Welding tip #7, #9, #12 10 each
at of necessary
ccessories, such
s rubber hose and

ressure reducing
alva
3 - 92
11110620-2002072-WPOO?
25 Gas culler Cutting tip #1 5 sets lwith a complete set of
necessary accessories,
#2 10 sets
such as 20 safety
oggles, rubber hose an

#3 5 sets
pressure reducing valve
26 Propane burner 2
27 Pipe vice 5
28 Pipe thread culler 2
29 Pipe culler For steel pipe, for OST pipe, 2 each
and for copper pipe
30 Pipe wrench 200 - 1200 mm 3 each
31 Chain pipe wrench Less than 100A 1 each
Less than 175A
32 Pickling tank 6 thick x 1200 wide x 800 high X When cleaning is
6000 long (Acid tank only is lined with one using chemical
lead or rubber cleaning agent,
manufacturer's
equipment are used.
Therefore, items 32
to 35 are not
necessary.
33 Neutralizing tank Same size as above 1
34 Water washing tank Same size as above 1
35 Oil tank Same size as above 1
3 - 93
/rf(
11110620-2002072-YiP002
36 Pump for flushing 300 - 500 liter/min. 2
37 Tank for flushing Capacity: 1000 - 4000 liters 2
3 - 94
I/O
11110620-2002072-WP002
Attached Drawing 1
Examples of Sizes of Straight Edge
E E
Gas - cast hole
3R
o u
Grind Grind
Material: FC200
M
•
H
J
B
Unit. mm
A B C 0 E F G H K WT
CD1000 120 50 12 85 90X9=810 10-60 8 13 15.1 k9
<2)2000 150 50 12 100 100X 18=1800 19-80 8 13 35.2kg
@3000 180 60 15 75 150 x 19=2850 20-100 10 15 68.7kg
@4000 200 70 18 85 160 x 24=3840 25-100 13 18 134.2kg
<ID5000 250 90 18 100 200 x 24=4800 25-150 13 18 201.0kg
The out - of - plumb and out - of - parallelism of the surfaces K and L shall be
less than 0.02 mm/m.
3 - 95
//1
11110620-2002072-WP002
An example of Plumb - Bob

Attached Drawing 2
• •
CD \/\/\7
Hatched portion hardened
0
0
0> .~
~ :2:
/ 15
23
70 30
100
@ \/\/\7
12
o
o
0>
Plumb - bob
Mark Name Malerial
CD Body SK-10or
15 SUJ-2
(g) Cap BSBM
3 - 96
//z
Jigs supplied by the erection Contractor (sample)
JIGS for ERECTION 11110620-2002072-WP002
TURN - BUCKLE
PLATE for WEDGE
GUIDE and STOPPER
PIPE GUIDE
+
~
PUNCH for BOLT

HOLE ADJUSTING EYE PLATE JACK BOLT
•
JIGS for CENTERING
C J,
SWING JIG BEAM COMPASS
OIL POT
SPRING
REEL FOR PIANO WIRE

STAND for PIAN WIRE
3 - 97
/13
11110620~2002072-WP002
Chapter 4.
THE STANDARD PROCEDURE OF PIPING
4-1
11110620-2002072-WP002
4. Piping Standard
4.1 Scope
This standard specifies the standard procedure and accuracy of onsite piping
work.
4.2 Erection standard

Erection shall be made in accordance with related drawings and
specifications and shall comply with this standard unless otherwise specified.
4.3 Classification of piping

The piping is classified as shown below according to the purpose of use,
place of erection, material and method of connection.
4.3.1 Classification according to uses of fluid (by system) and materials is defined
in "Specification for Piping Material".
4.3.2 Classification according to the place of installation

•
(1) Intermediate piping
This piping is also called the intermediate piping, connecting piping or
exterior piping. This piping is used to connect the piping attached to the
equipment to the piping around the units in the cellar. The intermediate
piping may include strainers, valve stands, various types of valves, gauges,
etc. for equipment.
(2) Piping attached to equipment

This piping is also called the interior piping or piping around the equipment.
This piping is attached to the equipment proper.
(3) Utility yard piping

'. This piping is also called the interior piping along with building, columns.
4.3.4 Classification according to the method of connection
(1) Welding type (Butt weld, Socket weld etc.)
(2) Compression type
4-2
I/~
11110620-2002072-WP002
Flared type
Ring type
Bite type
(3) Screwed type
4.4 Erection procedure
4.4.1 Planning and preparations

Planning and preparations shall be made on the following items.
(1) Checking of drawings and specifications

(confirmation of the scope of onsite fabrication)
(2) Checking of piping route and embedded metals for supports
(3) Study of procedure and process of various piping works
(4) Study of pipe processing and assembling
(5) Study of cutting, beveling and welding conditions and welding method
(6) Planning of pickling procedure, time for pickling, pickling equipment, etc. and
necessary preparations
(7) Planning of flushing procedure, time for flushing, flushing equipment, etc.
and necessary preparations
(8) Planning of pressure test procedure, time for pressure test, test equipment,
etc. and necessary preparations
4-3
11110620-2002072-WP002
4.4.2 Piping procedure by systems
The general procedure for steel pipe erection by systems is described below.
(For screwed type processing, refer to Para. 4.4.6.)
• (1) Oil piping
Temporary piping"" --+ Welding_

Pickling _ Final piping"" _ On line flushing"" _ Pressure lest*4
L Off line flushing"" ~ Final piping"'.-' ~t
Notes: * 1 Temporary piping means such piping which has been sized and
tack - welded at the time of onsite prefabrication and positioning.
*2 Final piping means such piping which has been finally assembled
after removal of temporary piping.
*3 Select one of off line flushing or on line flushing depends on the

condition.
*4 Pressure test is conducted to inspect piping for leakage after

pressure rise.
(2) Centralized grease lubrication piping

Temporary piping -+ Welding -+ Pickling -+ Final piping -+ Grease Blow
General precautions
Copper pipe or OST shall be used for branch piping.
Before trial run, make sure that the piping is filled with grease up to each
grease port.
(3) Air piping

Temporary piping -+ Welding -+ Final piping -+ Cleaning by air blowing -+
Leak test
c.
4-4
1/7
11110620-2002072-WP002
4.4.3 Precautions in piping
(1) Precautions in intermediate piping are as follows
• • (a) Piping work shall be started after making sure that all units such as tank,
pump, filter, accumulator, cooler and valve stand have been installed .
•
(b) First, install pipes temporarily. Install supports (increase the number of
supports if necessary) in accordance with the drawing so that the
temporarily installed piping can be supported correctly.
(c) Align the both flanges so that the weight of pipe is not applied to the flange
of the equipment, and provide supports.
(d) After pipe installation, determine the piping length so that undue force is
not applied to the equipment.
(e) As the bend is deformed when an internal pressure is applied, support the
bend so as to prevent its deformation.
(f) Make sure that there is no clearance between the flange surfaces to
prevent the suction of air through the connection between the pipe and the
pump suction port.
(g) After pickling, assemble the pipes in such a manner that over force is not
applied to the equipment. At this time, make sure that the pump is aligned
with the motor exactly.
(h) During temporary piping, protect the equipment from dust.
(i) Perform piping so as to minimize air pockets. Where air pockets are
unavoidable, air vents shall be provided.
(2) Installation of support
(a) Position and weld pipe supports with reference to the line center, center
line of equipment and bench marks in accordance with the foundation
drawing, piping diagram, support list, etc.
(b) Support length shall be added uneven dimension of wall to the dimension
of erection drawing and support style list.
(c) Support shall not be installed directly to the tank.
4-5
II~
11110620-20 02072-WPOO 2
(3) Check the following items before piping route is decided by the base support.
(a) There shall be no interference between the pipe and the pipe duct and
between the conduit tube and its support.
• •
(b) There shall be no interference between the pipe and the foundation,
column, beam, stairs, door or other structures.
(c) There shall be no interference between the pipe and the mechanical or
electrical equipment.
(d) The gradient of oil return piping shall be smooth.
(e) All embedded metals are installed exactly as specified.
(4) In some cases, the oil cellar will be partitioned with fireproof walls for fire
prevention (however, the piping line is kept open during the installation work
and is closed after the completion of work). In consideration of the pipe
closing operation and ease of maintenance, therefore, supports, fittings and
valves shall be installed at a distance of more than 0.8 meters from the pipe
end to be closed.
,
(5) The space in the oil cellar is used for many purposes as described below,
although this may vary with the duration of piping works. As work control in
this space is very difficult, close process control, place control, safety control
and machinery and materials control are of prime importance. It will be
effective to relieve the congestion of works by preparing part of piping to be
assembled in the cellar at some other places.
(a) Yard for storage of piping materials
(b) Pipe fabrication
(c) Mounting and removal of supports
(d) Transportation of machinery, materials and pipe

'.
(e) Safety passage for workers
(f) Area for work of equipment
(g) Area for electrical and instrumentation works
4-6
119
11110620-2002072-WP002
(h) Fire prevention work
(i) Area for flushing work
(6) Equipment, materials, etc. are carried in or out of the oil cellar through the
service hatch. The piping directly below the service hatch should be installed
in the final stage or removed temporarily as needed .
•
(7) If the piping is bent at more than two points, the erection and removal of
piping becomes difficult. Furthermore, as air cannot be discharged out on the
piping at the time of pickling, resulting in poor pickling.
(8) Precautions in erection of piping atlached to equipment
(a) Anchor blocks for grease lubrication piping, etc. shall be installed at such
points where they do not interfere with roll change and cylinder operation.
(b) Instruments, switches, etc. shall be installed in places easy to see and
piping shall be brought up to these places.
(c) The longitudinal and cross cylinder piping shall be symmetrical and shall be
installed at equal length to improve the synchronism of cylinders.
4.4.4 Welding type pipe processing

Welding type pipe processing shall be made according to the following
procedure.
(1) Check the piping route on the site in accordance with the piping diagram.
For example, mark the gradient of piping, flange position, support position,
etc. on the side walls of the oil cellar and ascertain the take - over points with
related equipment.
(2) After checking the quantity of pipe, valves, joints, packing, bolts, etc., assort
and stock them in such a manner that they are not used erroneously.
(3) Store and handle pipes with care so as to prevent rusting of steel pipe, gas
pipe, etc. and deformation of pipes under external force.
(4) In principle, pipe shall be cut by a pipe cutler, high - speed cutting machine,
etc. Cut the pipe at right angles, chamfer the cut end and remove foreign
matler.
4-7
120
11110620-2002072-WP002
(5) In principle, beveling shall be made by machine. When the bevel is simple in
shape, it may be formed by a grinder after gas cutting.
(6) If the pipe to be bull welded is carbon steel pipe, it is desirable to use a
penetration electrode for the first pass.
(7) In principle, the radius of bending shall be more than 3 times the pipe
diameter.
(8) The tolerance on pipe bending shall be as follows
(a) Allowance of elliptical of pipe dia. shall be defined by elliptical ratio and
max. valve is shown in Table 1.
Elliptical ratio = a~b X 100%
where 0: outside diameter of pipe before bending (mm)

a: larger diameter after bending (mm)
b: smaller diameter after bending (mm)
Fig.1
.c
D
a
Section X-X
Table 1
Nominal dia. Ellipticity

%
0 ~ 40A 10
0 ;;:: 50A 5
4-8
/2./
11110620-2002072-WP002
(b) Shape tolerance
The shape tolerance means the maximum difference between the
circumference with the normal radius and the circumference of bent pipe.
Fig. 2
The shape tolerance shall be less than 5 mm, regardless of the pipe
diameter.
(c) Tolerance on bending angle
Fig. 3
unit: mm
1000
In principle, the maximum tolerance shall be +5' for +0, i.e., 1.5 mm for a
length of 1,000 mm.
4-9
/22
11110620-2002072-WP002
(9) Installation of pipe and flange
(a) The flange shall be installed at right angles to the pipe center line, using a
flange square, level or the like.
Fig. 4
Flan e 5 uare
(b) Bolt holes in each flange shall be as shown in Fig.5

and 6.
Fig. 5 Fig. 6
Good Bad Good Bad
(c) The tolerance on inclination of flange surface shall conform to Table 2.
Table 2
Pipe diameter Tolerance D

O(A) (mm)
O;i; 100 0.4
100<0:0;200 0.6
0<200 0.8
4 - 10
11110620-2002072-WP002
(d) When welding a slip-on flange, install it so that the hole in the flange inside
agrees with the pipe.
(e) Care shall be exercised so as not to cause damage to the flange surface or
• • to protect it from spatter.
(10) Welding of pipe to pipe or fitting
(a) Weld a pipe to a fitting, such as elbow, tee and reducer, or to another pipe,
paying attention to the rectangularity, straightness and torsion.
Fig. 7 Bevel setting Fig. 8. Butting
Fig. 9 Welding of elbow Fig. 10. Welding of tee
4 - 11
11110620-2002072-WP002
Table 3 Standard for pipe welding bevels
Unit: mm
Type and
No. Range Form Remarks
application
g;>; 1/2t
Inside discrepancy shall be
t;>;4
( CU2 ~lJ less than t x 0.2 (Max.1.5)
g;>;4, h;>;3, a 70
a Inside discrepancy shall be
less than tx 0.2 (Max.1.5)
~
4<t;>; 19
( ~ ,\/
.c
-ll- g
Circumfere-n
tial
butt welding
1
of pipes
If t>19, U-bevel is desirable. V-

or U-bevel may be selected on
the site, taking into
consideration of time and cost
for beveling, welding and
40° :!: 2°
stress relieving.
r ---. Inside discrepancy shall be
less than
tx 0.2 (Max.1.5)
3~5R
1 1 g;>;4
25;;;t>19
~
\(J h;>;3
.c
-ll-
g
4 - 12
/2S
11110620-2002072-WP002
Table 3 (Continued)
Type and
No. a Iication Range Form Remarks
'- "
./
dd';:;;350 X
r
Welding of
z'- C
branch pipe
(Welding of
J
pipes of
2 tn q,d'
different to = tn or ts
n d'
diameters at 1.6:t1
1.6:t
right angles)
""
45°:t 5°
..,
'" =t~ =t~
Section X Section Z
Welding of
branch pipe More than
(Welding of 60°
pipes of dd';:;; 350
different
diameters at
an angle)
3
to=tnorts
\,
.
",
..•.,
Section X Section Y
Section Z shall be the same as in

welding at right angles.
4 - 13
/26
- -------- -------
11110~?()-?I'\O?(H?_WDI)O?
Table 3 (Continued)
Type and
No. a lication Range Form Remarks
Welding of
branch pipe
(Welding of
pipes of x
d<35D
different (
z (
diameters at
f)
right angles)
</Jd
to = 6 or D.7t,
whichever is smaller
Section X Section Z
3
Welding of
branch pipe more than 60'
(Welding of
pipes of d<35D
different
diameters at
an angle)
2"'1
2",1
Section X Section Z Section Y
4 - 14
;;'7
11110620-2002072-WP002
Table 3 (Continued)
Type and
No. a lication Range Form Remarks
d
d
6<tc<9
tm ~ 0.090+3
tc shall be minimized.
+1
g 1.5 However, g = 0 for
'" "T
hydraulic piping
More than 5
For high
pressure
Welding of
pipe stand,
1. Weld of the inside shall not
drain pipe
4 be finished.
and pressure
gauge seat
2. tc =6
(Leg length:9mm)
g "T 1.5 However, g = 0 for
hydraulic piping
tc ~ t
For low
g "T 1.5 However,
pressure
g = 0 for
hydraulic piping
Welding of
L ~ 1.1 tn
socket joint, d ~ 1.5 However, g = 0 for
g ~
L
valve and tn hydraulic piping
5 other
0
accessories ~
All
to pipe --'
4 - 15
11110620-2002072_WP002
Table 3 (Continued)
No.
Type and
application Range Form Remarks
I tn Inside weiding can be omitted

for air piping and water piping
'/ of less than

'"'
0.98Mpa (10kg/cm') or 80A.
'"'
C7 l = tn
'"
15
«
I In
'"'. f---- L
I = In
More than 2 /
/
Welding of ~
6
steel plale
20.6 Mpa
flange to I tn
(210kgf/cm') B flange for JIS
pipe
hyd. piping
'"' 7'
",-
Min.' I d I ;;; 11
When tn ;:;; 6,
'"' i/ 11 ;;; In
= When In > 6,
"-
t1 = 6
('
'"'
I~
Buildup is finished by grinding or
machining.
4 - 16
11110620-2002072-WP002
Table 3 (Continued)
Type and
No. a Iication Range Form Remarks
Min.
4 f tn .pd
::
6 Ditto
Dillo
4 - 17
/30
11110620-2002072-WP002
(b) The discrepancy at the butted portion of pipes shall be minimized and
uniform all over the circumference.
(c) The tolerances on interracial and angular sizes shall conform to Table 4.
When connecting to the existing piping, however, the pipe shall be welded
after onsite adjustment.
::t 5 •
Table 4
Unit:mm
~
:t: 5 •
Item ( (length) Tolerance
Dimension «1000 :t2.0

I- - M
c>J
1000;;;;«5000 :t3.0
\ '-
'-....1
1'-.. I 5000;;;;( :t4.0
f1
Angle «5000 l/1000x 1.5
l2
where (: size for £1, £2, (3, and t4'
(11) In principle, holes in the pipe take-out port, boss connections for air vent, etc.
shall be made by drilling.
Burrs formed on the main pipe inside shall be removed by filing.
(12) Welding of pipes

Pipes shall be welded according to the following procedure.
(a) Varnish, oil, paint, rust, etc. adhering to the bevels, pipe inside and fitting
inside shall be removed completely before welding.
'.
4 - 18
/3/
11110620-2002072-WP002
(b) When the atmospheric temperature is below 5°C, preheat the base metal
within 100 mm from the weld zone to a temperature above 36°C. If the wall
thickness of pipe exceeds 12.7 mm, preheat the pipe, regardless of the
atmospheric temperature. Preheating shall conform to Table 5.
Table 5. Preheating temperature

•
Wall thickness t, mm
t< 12.7 12.7 < t
Carbon steel
CarbonsteelTS~451 N/mm' (46 kgf/mm') Not required 50°Cor higher
CarbonsteelTS>451 N/mm' (46 kgf/mm') 100°C or higher
Remarks: 1. When welding steels of different kinds, a higher temperature

shall be used.
2. Preheat the lower side of bevel on the opposite side of the

surface to be welded in a width of approximately 100 mm.
(c) Unless otherwise specified, the welding electrode mentioned in Table 6 or

equivalent shall be used. Only the quantity of electrodes that will be used
for the day shall be brought to the site. As water or moisture serves as a
cause of blow hole or other defects, the electrode to be used shall be dried
sufficiently.
Table 6
SGP STPT SUS

WELO STPY STPG 304, 316
~
0308-16
Arc 04301 04316
0316-16
TG308
Tig TGS-50 TGS-50
TG316
4 - 19
/J2.
11110620-2002072-WP002
(d) The surface of the reinforcement of weld shall about on the base metal
smoothly and shall not be finished unless otherwise specified. The joint
welding shall be welded with great care.
The height of the reinforcement at the center of weld zone shall conform to
Table 7.
Table 7
Thicknessof base Heightof

metai,t reinforcement,h
-\EI t ;;;; 12
12<t;;;; 25
h ;;;; 1.5
h ;;;; 2.5
(e) Precautions in welding

When performing welding, the following precautions shall be observed.
Slag and impurities on each bead shall be completely removed

before the following bead is formed.
Defects in each bead, such as cracks and blow holes, shall be

removed completely.
The penetration bead shall be minimized. Attention shall be paid

to dropping. The welding current and voltage shall be appropriate.
Take care of undercut and overlap.
4 - 20
133
11110620-2002072-WP002
4.4.5 Compression type processing
(1) The pipe shall be bent by a pipe bender. In principle, the pipe shall not be
bent by hand. The radius of bending R shall conform to Table 8 in
consideration of the unevenness of wall thickness and other factors ,
regardless of the nominal size of pipe and the processing method.
Table 8
Bending
radius R
R
Copper pipe R ;;;; 3D
OST R ;;;; 4D
(2) In principle, pipe shall not be subject to heat bend. If bending is complicated
and the radius of cold bending is small or if a pipe bender cannot be used,
pipe is bent at a temperature of 400 to 450°C.
(3) Pipe of less than 6 mm in diameter shall be cut by a metal saw, but pipe of
more than 6 mm by a pipe culler. Cutting shall be made so that the cut end
of pipe is at right angles. The cut end shall be chamfered.
(4) Fillings shall be used for connection.
(a) Ring fitting

After tightening, loosen the nut and check the ring to see if has been fixed
at a proper position.
4.4.6 Screwed type processing

Screwed type processing is performed for pipe to be connected to
small-diameter pipe for water, air, oil and oil mist as well as to screwed parts.
The procedure is as follows.
(1) In principle, the pipe shall be cut by machine such as pipe culler and
high-speed culling machine. The pipe shall be cut at right angles and the
pipe end shall be chamfered.
4 - 21
11110620-2002072-WP002
(2) Precautions in processing
The following precautions shall be observed during processing.
(a) A sufficient amount of cutting oil shall be applied during the threading
operation.
(b) Do not cut threads deep at a time, but feed the threading tool little by little.
(c) The threading length shall not be greater than required.

The length shall conform to Fig. 11 and Table 9.
(d) During threading, set the threads to matching threads.
(e) Apply rust-preventive oil to threads.
Fig. 11
Taper
a
p
Taper external
Center ax i s thread
of thread
4 - 22
/3S
11110620-2002G72-WP002
Unit: mm
Table 9
Nominal Out Numb Heig-ht Pitch Len-g Basic diameter of external thread Basic From
pipe size side -er of of th of length basic
dia. of thr-ea thre-ad effe-c Outside Effective Minor dia. from diameter
pipe ds ti diameter dia. of thread pipe end toward
(per -ve D d2 d1 larger
25.4 thr-ea diameter
mm) d Basic diameter of internal thread side
Outside Effective Major dia.

A B d n hi P L diameter dia. of thread a f
D d2 d1
6 1/8 10.5 28 0.581 0.9071 8 9.728 9.147 8.566 3.97 2.5
8 1/4 13.8 19 0.856 1.3368 11 13.157 12.301 11.445 6.01 3.7
10 3/8 17.3 " " " 12 16.662 15.806 14.956 6.35 "
15 1/2 21.7 14 1.162 1.8143 15 20.955 19.793 18.631 8.16 5.0
20 3/4 27.2 " " " 17 26.441 25.279 24.117 9.53 "
25 1 34.0 11 1.479 2.3091 19 33.249 31.770 30.291 10.39 6.4
32 1 1/4 42.7 " " " 22 41.910 40.431 38.952 12.70 "
40 1 1/2 48.6 " " " " 47.803 46.324 44.845 " "
n
50 2 60.5 " " 26 59.614 58.135 56.656 15.88 7.5
65 2 1/2 76.3 " " " 30 75.184 73.705 72.223 17.46 92
H H
80 3 89.1 " " 34 87.884 86.405 84.926 20.64
n
90 3 1/2 101.6 " H
35 100.330 98.851 97.372 22.23 "
100 4 114.3
H
" " 40 113.030 111.551 110.072 25.40 10.4
125 5 139.8 " H H

44 138.430 136.951 135.472 28.58 11.5
n H
150 6 165.2
H
" " " 168.830 162.351 160.872
175 7 190.5
H H
" 54 189.230 187.751 180.272 34.93 14.0
H
200 8 216.3
H
"
H
57 214.630 213.151 211.672 38.10
n H
225 9 241.8
H
" " " 240.030 238.551 237.072
250 10 267.4 H
" " 60 265.430 263.951 262.472 41.28 "
300 12 318.5 " " " 65 316.230 314.751 313.272 " 17.5
Remarks: This Table conforms to JIS 8-0203-1982
4 - 23
/36
11110620-2002072-WP002
4.5 Pickling
4.5.1 Preparation
Before commencement of pickling such preparations as described below
shall be completed.
(1) Match mark shall be put according to match mark list.
(2) Equipments, instruments (valve, measuring device, pressure gauge, flow

meter, bolt etc.) attached to piping shall be removed.
(3) Cutting part of each piping shall be free from any burr.
(4) Each gasket, O-ring shall be removed.
(5) No missing part of welding shall be confirmed.
(6) Slag, welding spatter shall be removed.
(7) Protection of flange surface for transport shall be confirmed.
(8) All threads shall be removed or protected by acid resisting paint etc.
4.5.2 Pickling
(1) Following items shall be confirmed by pickling company before pickling work.
a) Confirmation of match mark which is pickling and alkali solution resistant
b) Removal of valve, measuring device, pressure gauge, flow meter and bolt etc.
c) Removal of any burr for cutting portion
d) Removal of gasket, O-ring
e) No missing part of welding
f) Removal of slag, spatter
g) Protection of threads by anti-acid material (vinyl tape, rubber tape etc.)
h) Soaking of bending pipe in the pickling tank and necessity of air vent
i) Removal of varnish
4 - 24
11110620-2002072-WP002
(2) Pickling work shall be done according to maker's standard procedure.
(3) Anti-rust work after pickling
a) Selection of anti-rust liquid shall be determined considering the condition of

packing, storage, duration, liquid used. Generally, durable period in house is 6
months for anti-rust oil and 2 weeks for anti-rust detergent. However filling
oil or flushing shall be desirable as soon as possible after pickling.
(4) Inspection and judgment
a) Inspection time To be done as soon as possible after anti-rust work
b) Inspection item Following items shall be done
Over pickling (Especially threads, Flange face, O-ring groove)
Complete removal of rust inside of pipe
Non-uniform pickling and adhesion of foreign matters.
Condition of anti-rust oil distribution
Damage and distortion
c) Judgment
Acceptable unless abnormality mentioned above is confirmed visually.
4.5.3 Classification of pickling and flushing
Table 10 prescribes the classification of pickling and flushing.
4 - 25
/38
11110620-2002072-WP002
Table 10 Pickling and flushing for various piping
Flushing
Pick- Primary flushing at work shop

No. Name of system Primary Secondary Remarks
ling Machi- Interconn- flushing flushing at
Unit at site site
nery ecting piping
1 Mill Hydraulic System 0 0 0 0 0 0
2 Auxiliary hydraulic 0 0 0 0 0 0
3 Gear lubrication 0 0 0 0 0 0
4 Roll coolant Sendimir Blow
0 - - - - working oil
Non-ferrou
Ditto
5 such as
alminium,
0 - - - -
0
copper
Cold mill Ditto
(mineral oil) 0 - - - -
0
Cold mill "1 "1

Blow
Ditto
soluble, water
- - - - No rusty
tallow base 0 pipe shall

0
oil be used
Hot mill Blow
(water water
- - - - -
system)
0
4 - 26
/39
11110620-2002072-WP002
5 Oil mist Supply pipe Blow

Blow
of oil working
- working oil
0 - - oil
0
0
Supply pipe Blow air Ditto

of mist 0 - - -
0 0
6 Cooling water Blow
water/air
- - - - -
7 Steam Blow
- - - . -
water/air
8 Air >3 >3

Blow
Blow air Blow air
air
- - - No rusty
0 0 pipe shall
0
be used
g Dry air for force motor >4

Blow
valve Blow N, Blow air
. N, SGP-W
- -
0 0 shall be
0
used
Note:
1. Explanation of abbreviation
o : Perform pickling and flushing
: do not need pickling and flushing
2. Do not perform primary flushing at site for the machinery such as unit,
machine and pipes which were already cleaned with primary flushing at works.
4 - 27
lip)
11110620-2002072-WP002
3. Use *4 SGP-W from dry air generator/air source to filter and SUS304TP shall
be adopted from filter to force motor valve.
4. Pipes which are added "pipe adjusting allowance", shall be pickled and
flushed by erection constructor after pipe length adjusting and welding at site.
4.5.4 Pickling and pickling process for piping material
Necessity of pickling for carbon steel (CS) and stainless steel (SUS) and their
pickling process are shown in Table 11.
Table 11 Necessity of pickling and pickling process
Carbon steel CS SUS304 SUS304+CS
Butt weld and

Butt weld Socket weld SUS pipe CS block
socket weld
1 Degreasing 0 0 0 0 0
2 Water rinse 0 0 0 0 0
3 Pickling 0 0 - - 0
4 Water rinse 0 0 - - 0
5 Neutrarization 0 0 - - 0
6 Drying 0 0 - - 0
7 Rust prevent. 0 0 - - 0
Perform pickling for pipe and block

Remarks "3
before welding. and execute
Perform back-purge at their welding.
• back-purge at
welding
Note:
4 - 28
IIf!
11110620-2002072-WP002
Explanation of abbreviation
o : Perform pickling
- : Do not need pickling
*1. The flanges, covered with rust and welded with buttering, shall be performed
pickling, written above.
*2. The oxidation-film, caused at butt welding between buttering-flange and SUS
pipe, shall be removed by hand grinder.
*3. If do not act back-purge at welding, the pickling progress item 1 to 6 shall be
performed.
4.6 Transportation
Transportation shall be accomplished in due consideration of the following
points.
(1) In principle, trucks or other types of car shall be used for transportation. It is
prohibited to transport the pipe under the condition where it is lifted by a
crane truck or the like.
(2) Measures shall be taken to prevent the deformation, damage, etc. of the
flange surface during transportation.
(3) The pipe end shall be closed with a wooden plug, vinyl sheet or the like to
prevent the infiltration of foreign matter during transportation. The bevels
shall be applied with a rust preventive agent for rust prevention and shall be
protected by steel band or the like to prevent damage during transportation.
4.7 Piping assembly
4.7.1 Final piping

Final piping shall be performed according to the following procedure.
(1) Assemble the piping in accordance with the drawing and specification or
according to the match marks or serial numbers of pipe.
4 - 29
11110620-2002072-IVP002
(2) In principle, final piping shall be done after the installation of supports,
brackets, etc. If it is unavoidable to assemble the piping before the
installation of supports, brackets, etc., never fail to install temporary supports
to prevent the application of undue loads to the fittings, etc.
(3) Final piping shall be made in consideration of the parallelism and distance
between pipes, valve arrangement, ease of maintenance and appearance.
(4) Pay attention to the direction of flow and do not form hollows.
(5) When arranging straight pipes, particularly when expansion joints are used,
centering shall be made carefully.
4.7.2 Precautions in the use of hose with fittings

The hose with fittings is used in combination with the mating fittings. If the
hose with fittings for high pressure is used erroneously, its life is remarkably
shortened and an accident may be caused. The hose shall be assembled,
paying attention to the following points.
(1) As the hose changes its length up to 4% when the pressure is increased, it
shall be installed with a certain degree of sag so that the stress is not
developed between the fitting and the hose when the length of hose is
changed.
Fig. 12
--EfE@;"---I-----+l
m Bad
~-~ Good
(2) If the flexible hose comes into contact with the foundation, equipment, piping,
etc., measures shall be taken to prevent their contact.
(3) Position of anchor block at site shall be determined after the installation of hose.
4.7.3 Installation of accessories

Install the accessories, paying attention to the following points.
4 - 30
/'13
11110620-2002072-WP002
(1) Before installing the accessories, make sure that they are free from foreign
maller. If any foreign maller is present, clean them.
(2) Before installing valves, check their number, type, the protective cover for
removal, etc. Install them with due consideration of the flow direction, handle
direction, etc.
(3) Install instruments. such as orifices and control valves, carefully after
checking the flow direction, type, etc.
(4) In principle, control valves and other instruments shall be substituted by short
pipes until flushing of all lines is completed. When inserting short pipes, care
shall be exercised so as not to cause damage to the filling surface.
4.7.4 Installation of supports

Install the supports according to the following procedure.
(1) Unless otherwise specified, welding of supports to the piping directly is

prohibited.
(2) Supports shall be installed in consideration of passage, valve operation and

handling.
(3) Supports shall be rigid enough to withstand the weight of piping and loads
resulting from vibration and operation.
(4) The piping with expansion joints shall be installed using fixed supports and
guide supports so that expansion load is applied to the axis.
4.7.5 Gaskets
Gasket shall be classified and stored by gasket list according to the drawing
and specification confirming flow, pressure, temperature.
4.7.6 Flange tightening

The flange shall be tightened, paying allention to the following points.
(1) Align the both flanges with care.
(2) Clean the flange and packing surfaces.
4 - 31
111 J0620-2002072-WP002
(3) Insert the packing at the center correctly. O-rings and the like to be inserted
in the grooves shall be installed so that they do not protrude from the
grooves.
(4) Tighten bolts and nuts reliably without applying undue force so that the
packing is applied with uniform force.
Use bolts and nuts after checking their sizes and materials.
(5) A seizure preventive agent shall be applied to stainless steel bolts and bolts
to be used in high-temperature sections.
4 - 32
IllS
11110620-2002072-WP002
(6) Slotted flange with "0" ring shall be fitted at upstream side. (See A in sketch
below)
In case liquid flows from top to down, slotted flange with "0" ring shall be
fitted at downstream side. (See B in sketch below)
•• L
A I"
Upstream ~f-----J Downstream
O-ring side!
4.7.7 Tightening of the pipe to be screwed.

Sealing tape made of teflon or liquid packing shall be used in the portion to
be screwed in. However, teflon sealing tape shall not be used where the
temperature exceeds 250°C, and shall not be heated to a temperature above
250°C.
When using teflon sealing tape, pay attention to the following points.
(1) Do not unscrew. When unscrewed, replace the tape and clean the internal
threads.
(2) Wind the tape by two turns in the screwing direction from the second or third
thread from the tip so that waste tape do not enter the pipe. When liquid
packing is used, apply it from the second or third thread.
4.7.8 Inspection after piping assembly

After piping assembly, never fail to inspect the piping in accordance with the
inspection list. If any defects are detected, make corrections. Major
inspection items are as follows.
(1) Errors in piping assembly
(2) Interference with equipment, foundation, conduit tube, etc.
(3) Removal of slag and negligence of welding
(4) Negligence of packing insertion, erroneous use of bolts, negligence of bolt

tightening
4 - 33
/'1-6
11110620-2002072-WP002
(5) Flow direction, position, material, type and handle direction of valves
(6) Negligence of tightening of hanger supports and fixed bands, removal of set
bolts of spring hangers and expansion joints
(7) Installation of pressure gauges, air vent, etc.
•• (8) Removal of temporary blind flanges and piping for testing
(9) Checking of the installing position of supports and removal of temporary

supports
,
•
4 - 34
Illl0620-2002072-WP002
4.8 Flushing & Blowing
4.8.1 Scope of Application

This standard specifies the procedure and inspection method of flushing
work for oil feed piping, oil lubricating piping, hydraulic piping, grease feed
piping, grease lubricating piping and air piping to be carried out during the
process of piping work.
4.8.2 Work Standard

As for the standard, refer to Table 12, 13.
4 - 35
~
Table 12 Judgement standard for 1st flushing (Primary flushing)
Hydraulic Judgement by measuring

] System
Filter
No. Lubrication Recommended Measuring
value apparatus
HIAC-P305.
1 Auxiliary Hydraulic NAS 12 Class 2011
Conta-meter etc.
Hydraulic
2 NAS 10 Class Ditto 2011
(HYROP, Roll Bender)
Hydraulic
3 NAS 8 Class Ditto 1011

(Nozzle flapper type electro ~
MOOG) ~
hydro servo valve. o
0)
I\,)
150-200 mesh and any foreign matter are not
Gear lubrication 150-200 mesh o
4 included. I
I\,)
o
Morgoil bearing lubrication Ditto 150-200 mesh o
5 I\,)
o
-.l
Grease Ditto 150-200 mesh I\,)
6 I
::IE
-0
o
o
I\,)
4 - 36
~
Table 13 Judgement standard for 2nd flushing (Secondary flushing)
Hydraulic Judgement by measuring

] System The method to better cleaness
No. Lubrication Recommended Measuring of working oil
value apparatus
HIAG-P305.
1 Auxiliary Hydraulic NAS 12 Glass Use temporary filter
Gonta-meter etc.
Hydraulic
2 NAS 9 Glass Ditto -
(HYROP, Roll Bender)
Hydraulic
3 NAS 6 Glass Ditto - ~

(Nozzle flapper type electro
~
hydro servo valve. MOOG) o
0>
N
4 Gear lubrication Operate all pumps simultaneously and By pass filter 200 mesh (74 J,1 ) o
I
perform secondary flushing more than and foreign matter are not N
o
8 hours. included. o
N
o
-..j
5 Morgoil bearing lubrication Ditto Ditto N
I
::Il!:
"U
o
o
N
4 - 37
11110620-2002072-WP002
4.8.3 Object
Flushing is executed for the purposes of removing foreign matter mixed in the
piping system and discharging it to the outside of the system, to prevent
deterioration of oil property, early abnormal wear of equipment or biting of
foreign matter by equipment, clogging of filter, etc .
4 - 38
11110620-2002072-t'lP002
4.8.4 Work Procedure
4.8.4.1 Time for Execution of Flushing Work

In principle, flushing circuits shall be assembled as specified, as soon as
pickling work is completed and then flushing shall be carried out for the
••
circuits.
4.8.4.2 Scope of Flushing Work

Flushing shall be carried out for all going and returning main pipes and
branch pipes of the piping.
However, for the following piping, the primary flushing may be omitted in
some cases.
(1) Attached piping to auxiliary equipment, instrumentation equipment and main

equipment, which are delivered as completed products.
(2) Short pipes, small dia. pipes, branch pipes, etc. for which flushing circuits are
difficult to form, but of which inside cleanness can be confirmed by visual
inspection, or water or air blowing .
•
• 4.8.4.3 Work Procedure
(1) General oil flushing
a) First oil flushing
Object: Foreign materials in pipings at piping manufacturing in site and

factory shall be cleaned.
b) Second oil flushing
Object: Foreign materials in system at site piping work shall be cleaned.
* Oil flushing of system including pump, tank etc. by job power source
shall be done using job oil or equivalent oil after whole assembly is
completed
4 - 39
11110620-2002072-WP002
c) Flushing category
Tank Pump Oil

Filter V I Stand
Cooler
Filt I Uni I Oil Remark
First Tempora- Tempora- Tempora- By - Pass By - Pass By - Pass FL. 0 Flushing of only
Oil ry ry ry pipings
Flushing
Second Job Job Job Oil Oil Job Job Oil By - Pass of
Oil Through Through Cylinder
Flushing
4.8.4.4 Flushing Work Plan

Flushing work shall be planned on the basis of the flushing procedure
mentioned in the Items 3.8.4.5 - 3.8.4.6.
Data, materials, instruments and equipment shown in Table 14, shall be
required to be prepared .
4 - 40
toJ
11110620-2002072-WP002
Table 14
Item Data, materials, instruments
No. and equipment to be prepared Matters to be decided
1 Piping diagram, piping drawings, oil list, tank Quantity and brand of flushing oil,
"
and pump drawings and valve and instrument assembly method of flushing circuits,
drawings flushing procedure (heating, hammering,
." etc.), pump capacity, tank capacity, site
of flushing work, filter mesh, inspection
method, criterion for acceptance and
name of person who makes judgment.
2 Installation work schedule, piping work Daily work schedule and personnel
schedule, electric and instrumentation work allotment for the following work.
schedule, trial operation schedule and
manning table for flushing work. Equipment inspection, tank cleaning,
pump operation, oil replacement,
adjustment of oil quantity and oil
temperature, hammering, sampling,
analysis, recording and report for foreign
matter, analysis and record of oil, water,
steam and air pipings, transportation,
fire prevention, fire extinguishing and
cleaning.
3 Materials, instruments and equipment for Means and schedule of acquisition of

flushing essential instruments and equipment.
Pump, tank, kerosene oil, flushing filter, oil

pan, pipes for temporary piping, hoses, stop
flanges, orifices, magnets, valves, reducers,
headers, sponge, deer skins, hammers,
vibrators, various kinds of wrench, power
source (including cable, switches, etc.), water
source (including pipe, hose and valve), air or
nitrogen source (including pipe, hose and
valve), steam source (including pipe, hose
and valve), analysis equipment, recording
paper, transportation car, fire extinguishing
equipment, thermometers, etc.
4 - 41
11110620-2002072-WP002
4.8.4.5 Flushing Circuit
There are three kinds of circuit as shown in Table 15.
Table 15
Item
Kind of circuit Method
No.
1. Off-line Pickled pipings are connected in series on a clean concrete

surface, and flushing oil shall be circulated by a temporarily
installed tank pump for flushing.
(It is better that separate circuits are provided for the main
pipe line and branch pipe line).
2. On-line Pickled pipings are regularly installed and connected and
flushing oil shall be, as a rule, circulated by a temporarily

installed tank pump.
However, flushing shall be carried out by by-passing the

actuator, valve stand, actuator and lubricating places of
machinery.
3. Combination of off-line The main pipe shall be flushed by the on-line method and the
and on-line branch pipe shall be flushed by the off-line method, or vice
versa (depending on the workability, or the conveniences of

flushing work) .
4 - 42
ISS
11110620-2002072-WP002
4.8.4.6 Selection of Circuit

The flushing circuit must be decided upon comprehensive examination on
the following respective items as well as difficulty of circuit assembly work.
(1) Inclusion of foreign matter
(2) Oil recovery method
(3) Difficulty of hammering
(4) Preparing conditions of flushing equipment and materials and utilities
(5) Flushing work schedule
(6) Whether piping removal is adequate or not
(7) Available space (site area) for flushing work
(8) Existence or non-existence of congestion of work.
(9) Area not allowed to carry out welding work, or to use fire
(10) Fire extinguishing equipment
4 - 43
11110620-2002072-WP002
4.8.4.7 Precautions on Circuit Assembly
(1) For assembling of temporary piping, by-pass piping or short pipes, mutual
diameters of joining pipes shall be of the same size as far as possible.
In case reducers are used unavoidably, eccentric reducers shall be used as
shown in the following Fig. 13.
Fig. 13
Good Not good Not good
Foreign matter
will remain
F==t
Foreign
matter
is apt to
remain
(2) Temporary piping, hose, etc. for flushing must have been fully cleaned by
pickling and blowing.
(3) The return pipe is larger than the discharge pipe in diameter, and flushing oil
does not flow filling the pipe interior with the oil. As a result, the upper face of
the inside of the pipe is not flushed. Therefore, the pipe should be flushed
using a stop valve or orifice as shown in Fig. 14.
Fig. 14
Stop valve
Orifice
Flushing oil tank

Flushing oil tank
Flushing oil filter Flushing oil filter
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11110620-2002072-WP002
4.8.4.8 Examples of Circuit (for reference)

Examples of flushing circuit are shown in Figs. 15, 16 and 17 for reference.
Fig. 15 shows the on-line of oil lubricating system.
It is preferable that oil is flowed by by-passing the cooler, at first, and when
foreign matter collected by the flushing filter has proved completion of the
first stage of flushing, flushing is carried out simultaneously for both of the
• piping and cooler by flowing oil in the cooler. Fig. 16 shows the on-line of
hydraulic system. If the pipings are arranged on the concrete surface,
flushing can be carried out also by the off-line method. Fig. 17 shows the
on-line of grease lubricating system. For the grease lubricating system, only
the main pipe is flushed and for the branch pipes, a proper amount of grease
is pushed out through the pipe at the time of grease feeding. For the piping
after the distribution valve, grease will be filled before its connection.
Fig. 15
0=-
Temporary
I I " T I I I
Lubricating places
piping or
hose
of machinery
IllIi.L11
0=- Sluice valve
Pressure
tank
I
I
I
I
I
,
I
~ular
---.:p l---
\ ,
.••.•••
I
I
I
I
I
I
pump tank
I
I
I
I
r.• : •.1
r ,
I
I
I
:
Temporary
piping or
hose
1---: :----l-7~I :
I : /'_\ : vI.... I Flushing
'--- ..•..
J?)-_.J L J filler
Stem or
Flushing pump heater
Cooler Oil tank for

flushing
[XH:g)-{X]
4 - 45
/.f8
11110620-2002072-WP002
Fig, 16
Flushing
(1)
'0
filter
'iii
15. (1)
'0
'iii
(1)
"-
'0.
steam:jr -5
heater ~
~
> I:E-- '"

Flushing pump and tank
"gl
'"
001
(1)
21
~ --j>~
(1)
Open(close)
,_, Regular pump tank

,ll Close
(open)
(1)
'0
,---{ p 1---,
I \ ,
'--------------~'
I , •
, "-,,, , I
'iii I
I
I
I
,
,
I
,
(1) I I , ,
II-.J l_.~""',..
"-
"'1 ..: I
'0. : I :....oc •• 4 : I
c:
'iii
:
~)--.J
,••- ••
I__ •••••••
: I
L
:
l
Temporary
::;; Temporary Flushin filter piping
i in of hose or hose
Steam or
heater
Flushing pump and tank
4 - 46
11110620-20Q2072-WP002
Fig. 17
•
Distributing
valve
or hose
Branch i e
Main i e ,------
,
OJ ,,
,,
ro>> ,,
,
: .
,-----: ,,-..~ ::
l---{ p: --,
: :
( ! :
! -
I
0;
I
,
,-----,'
'.. _..'
_
Flushing
Temporary
filter
i e or hose
Flushin
Flushin tank
4 - 47
J 1110620-2002072-WP002
4.8.5 Flushing Oil, pump, tank and filter
4.8.5.1 Flushing oil
The flushing oil Note-1 should be selected according to the fluids to be used.
Generally, for the primary flushing oil, low viscOSity oil should be employed.
The flushing oil made by the oil manufacturers are aalmost equivalent to No. 90
turbine oil in JIS K 2213 NO.1, to which soluble ability has been provided.
Determine the oil brand properly through discussion with the oil manufacturer
concerned.
Note-1 ; When soluble oil, water + glycol, phosphoric acid ester, kerosine, etc. are
the fluid used, they should be wmployed for flushing oil. (That is, the fluid used is
the flushing oil.)
The amount of flushing oil is to be calculated from the following formula (1).
=
OF 1.2 . (0 TL +0 P) ----------------------------------------------( 1)
Where: OF : Amount of flushing oil
OTL : Minimum oil amount in tank
(Suction pipe and heater are taken into account)
OP : Amount of oil remaining in pipe
Remark: "1.2" in the above formula is coefficient taken by estimating leak and
reserve oil amount of 20 %.
For the secondary flushing oil, oil used for the normal service operation should be
used.
The oil brands and amount of oil are in accordance with the recommenced oil list.
4.8.5.2 Flushing pump
(1) The completely or temporarily installed pump is used for the flushing pump of
ON-line circuit.
However, for OFF-line, the latter one is used.
4 - 48
/6/
11110620-2002072-WP002
(2) A gear pump is the best for use, and it should be confirmed that the pump
packings and seals are of oil resisting type, and there are no stains and foreign
matters inside the pump.
(3) A pump capable of causing turbulent flow at the discharge pipe side is better.
Generally, turbulent flow limit and flowing velocity in pipe is obtained from the
following formula (2) and the capacity is decided by the formula (3).
V=0.2' J1 /0 ----------------------------------(2)
Q ~ 6 .V .A -----------------------------------(3)
Where: V : turbulent flow limit and flowing velocity in pipe (m/s)
J1 : Dynamic viscositty of oil (centi- stork cm2/s)
0: Inside dia. of pipe (cm)
Q : Capacity of flushing pump (£/min)
A : Sectional area of pipe (cm2)
Remarks 1. Numeral value "0.2" in the above formula (2) : value obtained by
dividing reynolds number 2000 (turbulent flow limit) by 10000 for the
unit conversion of cst, sec, cm and m.
Numeral value "6" in the above formula (3) : Unit converted value of
cm, m, sec. and min.
2 : The dynamic viscosity of oil at each temperature (cm2/s or SSU) is

as shown in Table. 16.
4 - 49
/62
11110620-2002072-WP002
Table 16 Dynamic viscosity of oil
JISK2219 No.6
JISK2213 No.1 JISK2213 No.2 JISK2213 No.3
class 2
Temperature
No. 90 Turbine No. 140 Turbine Lubricant oil

No. 180 Turbine
(Oc)
oil oil oil
(Gear oil)
cst SSU cst SSU cst SSU cst SSU
15 93 427 215 995 290 1344 1070 5100
25 54 259 115 531 154 713 690 3200
37.8 (100° F) 32 148 616 281 796 364 282 1306
50 19 94 35 164 44 216 175 810
60 14 72 24 114 30 139 80 370
3 : The following velocity of more than 2 m/s is required for moving

foreign matters in pipe.
4 : The relation between pipe diameter and pump discahrge capacity

for the required flowing velocity is as shown in Fig. 18.
.
•
4 - 50
163
11110620-2002072-WP002
2272
2220. ~
/
Flow ,.100'" 3.0 m" ~,/'
/
15~
1704
/
/
/
/
/
Pump /
1110
/
discharge /
capacity /
/
(flmin)
I
Flow velocity 1.5 m/s
54
25A 32A 50A 65A BOA 100A 125A 150A
• Pipe diameter (mm)
Fig. 18
4 - 51
/6t;.
11110620-2002072-WP002
5 : The flushing velocity for valuable systems, recommended by us, is

indicated in Table 17.
.. Table 17 Flow velocity of flushing
No. Name of system Flow velocity
1 Gear lubrication More than 2 m/s
2 Morgoil bearing lubrication More than 2 m/s
Auxiliary Main pipe More than 2 m/s

3
hydraulics Branch pipe More than 4 m/s
Hydraulic screw Main pipe More than 2 m/s

4
down Branch pipe More than 4 m/s
5 Grease More than 2 m/s
(4) If the pump with tha capacity obtained from formula (3) is unavailable, turbulent
flow or pulsating flow should be made by aeration (compressed air blow) or the
pump parallel operation.
Reference: As a unit exclusively used for flushing, a portable one, in which pump,
motor and filter have been, combined is available. The capacity is
mostly 200 l'lmin to 400 £Imin.
4.8.5.3 Flushing oil tank
There are two cases using the flushing oil tank. in one case the tank built as
specified in the drawing is used, and in the other case the exclusive flushing oil tank
is used. It is desired that the pump suction pipe, flushing oil filter, manhole, drain
pipe and heater should be attached to the later tank. The capacity is approximately
1000 to 4000 liters, and it is selected based on the following formula (4).
QFT =5 . (Q P)---------------------------------------------------( 4)
Where: QFT : flushing oil tank capacity
(QP) : Amount of oil in pipe
4 - 52
1M-
11110620-2002072-WP002
4.8.5.4 Flushing oil filter
This filter is used for checking the flushing effect and is a box furnished with wire
netting (100 Tyler meshes) as shown in Fig, 19.
.. It is installed at the tank side of the return pipe and has to be removable.
A=Q/(6' Vn' K. d)-------------------------------------------(5)
Where: A : Required area of filter (cm2)
Q : Pump capacity (R/min)
K : Coefficient of effective area of filter
This is a coefficient determined according to the viscosity of oil,

amount of foreign matters, emergency stop of pump, etc. and is about
1/3 in general.
d : Filter penetration ratio (about 0.34 in Tyler 100 mesh filter)
Vn : Flowing velocity of oil passing through filter (m/s)
(about 0.2 m/s)
Remark: "6" in the formula (5) above is a value obtained by converting the unit,
llcm", "m", Ilf", usee" and "minI!,
Return pipe
_____ Support
Outer frame (Preferable to fit a

grip for easy removal
Reinforced wire netting

: (Bolted on outer frame)
Inside wire netting

(Over tyler 100 meshes)
4 - 53
;£6
11110620-2002072-WP002
Fig. 19
Reference 1 : The standard sieves (JIS standard sieve and overseas standard
sieve) used generally for flushing are shown in Table 18.
4 - 54
/t7
~
-
"\1
Table 18 Standard sieves
JIS Standard sieve Overseas standard sieve
Sieve opening Wire ASTM TYLER DIN
Nominal
Tolerance % Penetration Nominal
dimension Sieve Sieve
Dimension Dia. Toleranc % Nomina Nominal dimension
J1 openin openin
mm mm emm NO.1 mesh (sieve
Average Max. gmm gmm
opening)
74 0.074 +7 60 0.053 +0.010 34.0 No. 200 0.074 200 0.074 0.080
88 0.088 +7 40 0.061 +0.010 34.9 No. 170 0.088 170 0.088 -
105 0.105 +6 40 0.070 +0.010 36.0 No. 140 0.105 150 0.104 0.100
125 0.125 +6 40 0.087 +0.015 34.8 No. 120 0.125 115 0.124 0.125 -o
a>
149 0.149 +6 40 0.105 +0.015 34.3 No. 100 0.149 100 0.147 0.160
'"o
I
177 0.177 +6 25 0.141 +0.015 31.0 No. 80 0.177 80 0.175 -
'"
o
o
210 0.210 +6 25 0.153 +0.015 28.8 No. 70 0.210 65 0.208 0.200
'"
o
-.j
250 0.250 +6 25 0.174 +0.015 29.3 No. 60 0.250 60 0.246 0.250 '"I
:E
"U
o
o
4 - 55
'"
11110620-2002072-WP002
4.8.6 Flushing
4.8.6.1 Primary flushing
(1) This primary flushing is performed for peeling and removing the sticking articles
through variatiion viscosity of oil or exoansion / contraction of pipe while raising
and lowering the flushing oil temperature properly between ordinary temperature
and 60°C.
Reference: Calculation of heater capacity
The heater capacity for raising the oil temperature to the required
level is expressed by the following formula.
q=a' C' S' (QF)(t1-tO) (kcal)----------------------(6)
1 kcal=0.001163 kWh
W=0.001163' q/H (kW) '. (0.0005' a. (QF)(t1-tO))/H (kW)-----(7)
Where: q : Quantity of heat required for raising oil temperature to the specified
level (kca I)
a : Coefficient provided taking heat radiation into consideration
(1.5 in summer, and 2.0 in winter)
C : Specific heat of flushing oil (about 0.45 to 0.6 kcal/kgOC)
S : Specific gravity of oil (about 0.9)
(QF) : Amount of flushing oil (R)
t1 : required oil temp. ("C)
t2 : Oil temp. before heating ("C)
W : Heater capacity (kw)
H : Heating time (hr)
(2) Carry out hammering at a proper interval, and at locations where it is hard to
perform hammering, install vibrators at the required places.
4 - 56
d9
11110620-2002072-WP002
Moreover, make arrangement not to put hammering or vibrator impact on the

cast iron joints and valves. Also, be careful not to deform the pipes by the
sticking force of hammer.
Referernce 1 : Example of specification of vibrator

.
•
Table 19 Example of vibrator spec.
Vibration motor or electric magnetic

Type
vibrator
Number of vibrations 3000/3600 rpm (50/60Hz)
Amplitude 1.5~4 mm
25A~80A: 50W
Pipe dia. : Output 80 A~150A: 100W
150A~200A: 200W
Reference 2 : How to use vibrator
(a) Install the vibrator at the bottom of vertical pipe, bent portions where
foreign matters are apt to accumulate in the main piping.
(b) when the piping is long (the length at which effective vibration is
generated is about 10m though it depends on the installing conditions),
install a few vibrators. When moving the vibrators, do it beginning with
that at the pump side one after another.
(3) For the general primary flushing cycle. refer to Fig. 20.
Remarks
1. Hammering should be effected mainly on the pipe welded sections, bent

sectionsd and relatively long horizontal sections along the oil flowing
••
direction staring from the pump side .
2. Aeration may be performed in either case which the pump is stopped or

which oil is being delivered. Use an air filter to prevent contamination by air.
2
Where the air source is unavailable, use nitrogen (5~7 kg/cm ).
4 - 57
/70
11110620-2002072-WP002
Hammering Aeration
7DOC .............................................................................................................................................
C riticaI te mp.
6DOC Oil draining

••
p Adequate
Tem ./
°C temp. range
Pump sto
sampling,
Ordinary
Filter cleaning
temp.
DOC
1~2 hr <E-71 Time (hr)

•
8~12 hr
( )
Fig. 20 General primary flushing cycle
3. Raise the oil temperature while operating the pump.
4. Keep the oil temperature at BO°C max. taking the pump performance and
deterioration of oil into account.
Reference: Aeration
(1) Aeration is made with the object of making forcible turbulent flow of
the flushing oil in the pipe in order to accelerate peeling and
discharging of foreign matters adhering the inner wall of pipe.
The air volume should be such that oil in the return pipe becomes
turbulent flow or pulsating flow, and if the volume is too much, there
is possibility of overflow of oil from the filter and atomization being
caused.
When blowing air into the pipe with the pump stopped, install a
check valve or close the valve at discharge side to prevent
counterflow toward the tank. Refer to Fig. 21.
4 - 58
/7/
11110620-2002072-WP002
Utilization of branch pipe Utilization of flange
~
Oil
Check valve
• Tank ( -~
.
,
lOil
~or nitrogen
_._.-.-._._._._._._._._._._._.-._._._._._._._._.-._._.-'-'-'-'-
Utilization of pressure gauge connecting port
I Air or nitrogen
:I' Pump
_~_~O;l
Fig. 21
(2) Cautions on aeration
(a) Use the air drawing pipe of SA to 15A, and install at the pump
discharge side.
(b) Fit a check valve on the pump discharge side and fit a valve and a
check valve on the air piping.
(c) Use dry and clean air.
(d) Intermittent aeration is effective.
(e) Aeration with the pump stopped is for 5 to 10 minutes.
(f) In the case of aeration, be sufficiently careful with the internal

pressure of pipe.
4 - 59
11110620- 20 02072-WPOO 2
4.8.6.2 Secondary flushing
(1) The secondary flushing is made while delivering the oil specified in the drawing
to each equipment (return the piping to its normal condition) and circulating.
• In this secondary flushing, no hammering is performed as a rule .
(2) For the secondary flushing, high viscosity oil specified in the drawing is used, so
•
caution should be taken not to overflow from the flushing oil filter.
(3) Where the secondary flushing is required for the hydraulic oil piping, operate the
actuator at the minimum working pressure for flushing. In this case, install an
in-line filter in the return pipe.
4.8.6.2.1 The method of secondary flushing procedure at site
4.8.6.2.1.1 The outline of secondary flushing procedure at site.
Table 20 denotes the outline of secondary flushing at site. According to the points
written in the table, make completely flushing plan for each system piping.
4 - 60
11110620-2002072-WP002
Table 20 Secondary flushing procedure at site
In line filter
No. Name of system Flushing oil Flushing circuit Pump, tank
or temporary
1 Mill hydraulic Working oil to Bypass: at manifold All regular pump

20 j1 ->5 j1
system be used connecting point operation
Bypass: at P-BLK
Ditto Ditto Ditto
connecting point
2 Auxuiliary Bypass: at cylinder

Ditto Ditto Ditto
hydraulics connecting point
3 Gear lubrication Bypass: at entry
system Ditto 200 mesh valve of reducer flow Ditto

in the casing
4 Roll coolant Take off the nozzle
system Ditto Regular and blow, return oil Ditto

to tank through filter
5 Oil mist Off the connecting

Working oil to
- points at generator Ditto
be used
and M.CK then blow
6 Steam Off the connecting -

Steam or air - points at machinery
then blow
7 Air Off the connecting
Air - points at machinery -

then blow
8 Cooling water Off the connecting
Water or air - points at machinery -

then blow
9 Air system for Off the connecting
FM'v Air Regular filter points at machinery -

then blow
4 - 61
17'1-
" 110620-2002072-WPOO?
Note:
1. It must be decided at the conference, whether the flushing oil to be altered to

new oil or not, after completed the secondary flushing.
2. Include the hydro-static pump systems in the morgoil bearing lubricating

systems.
3. Air blowing of the force motor valve air system which to be used cooling, shall
be executed before attach the force motor valves to their places.
4. Prepare the spare filter or the bypass blocks according to the regulations.
(1) Inspection items before charge the working oil.
The following items must be checked as to inside of tank.
(a) The painting or surface treatment.
(b) Cleanliness of tank especially corner, back side of rib, inside of suction and
return pipes.
(c) Smooth-ness of float suction movement.
(d) Check the parts which to be fixed to inside of tank.
(e) Tightness of man-hole cover clamping bolts and sluice valve clamping bolts.
(f) Check the necessary treatments of pipes such as pickling or primary flushing.
(2) Inspection of the pipes between tank and pump
(3) Contamination and charge the working oil
(a) The contamination of oil shall be determined at the conference which attend
engineers concern flushing and the figures of contamination are decided by
Table 13.
(b) Oil used of secondary flushing shall be changed to new oil, therefore changing
of oil shall be concluded before flushing.
(4) Preparation bypass circuit
(a) When use connector and hoses, adopt same or stronger ones than that of
4 - 62
11110620-2002072-WP002
regular ones.
(b) Flange joints are desirable, but may also use screwed joints.
4.8.6.2.1.2 The order of secondary flushing
(Example for auxiliary hydraulic, roll bender and hydraulic screw down, etc.)
,•
(1) At secondary flushing, perform the primary side pipes of every valve stands at
first.
(2) Second, execute secondary side pipes of every valve stands through every valve
stands.
Pipes secondary
2 3 /Actuator ~ side 0
r.~.~._.:-.~.~es
['" .. , seco~:$._
{"
$.,
..
..
r:.$._ ...$/,
{" ..
i i side i '1 i .\
"' I ,.'-'-,_. ..•..•. "'. .i .-.-........."' .i
i l .0/.............. . ~" I J (. - .....•...•. ~. I 1
~._.-.-._ ..--:;" :"'":;: \ \~._._._._./. i ,.:;: \\ ~._._.-._./
Valve stand (( ("; )) i Valve stand! .) ) i Valve stand
y":::-:::::::::) ;;;p~_ ,
l\:::::::::::::':,/~~~;;; : \''::::::::::::::''/', ',,-
•.••..
Bypass primary side G.,fvalve
stand ~_._._._.- _._._.- _._._._._._ . " \
(0 Returnpipe Drainpipe i \
\
Pipes primary Temporary i I
~
side filter \ .
•.••.. _._._, /
Tank
Filter
';',.,!! .-.-.,../
. W~rcooler
Cleaningcircuitwhich shall be operated
duringflushing
Fig. 22 Example of secondary flushing order
4 - 63
1'76
11110620-2002072-riP002
Note:
1. The secondary flushing shall be performed the order of 1,2,3,4 at every valve
stand.
2. Primary side pipes mean the pipes which connect entry side of valve stands.
3. Secondary side pipes mean the pipes which connect delivery side of every
valve stands.
(3) Determine the flow velocity of flushing oil by Table 17, then decide the numbers
of pipes, consider of pump exhaust and pipe size.
4.8.6.2.1.3 As for regular pump
(1)Generally, set the pump pressure to the pressure indicated in the drawing. But,
normally the pressure at secondary flushing, set to a lower pressure than that of
working pressure.
(2)Operate the spare pumps when the pump quantity is not enough. Set the pump
pressure by adjusting relief valve, when the pressure is controlled by pressure
regulating circuit.
(3)Operate the pumps by manual control, not use automatic operation.
(4)ln case that, if the tank capacity is small, prepare cooler circuit because of,
violent oil temperature rise.
During flushing the oil temperature shall be kept under 60°C,
(5)ln order to clean the flushing oil, running cleaning circuit pumps during flushing.
4.8.6.2.1.4 The work during secondary flushing
(1) Always check the oil leakage.
(2) Take care the pressure fluctuation.
(a) When pressure go up gradually, inspect plug of filter.
4 - 64
1'77
11110620-2002072-WP002
(b) When pressure go up or go down suddenly, stop the pump operation and
investigate the cause, then take countermeasure for that.
(3) In order to keep, the oil temperature under 60°C, operate the cooler circuit. if the
oil temperature not go down, in spite of works, mentioned above, stop the pump
and suspend flushing temporary.
(4) Change the magnet valve about 10 to 20 minutes interval and reverse flow
direction of A, B ports.
(5) Set "open" position of the by-pass valve of accumulator, had already charged
with N2 gas, and perform flushing of accumulator circuit.
(6) As for the pressure tank of morgoil and gear lubrication, first fill the oil into
pressure tank, then exhaust oil by means of charging compressed air into tank,
thus washing inside of tank. Repeat this way several times.
(7) The completion of secondary flushing is determined by the control values, shown
in Table 13. But the total flushing time, we aimed, are generally as follows.
First step Second step

Total
No. Plant flushing
Flushing Filter to Flushing Filter to
time (hr)
time (hr) be used time (hr) be used
1 Plant new made 12 20ji 12 5ji 24
2 Plant modified 6 20 ji 6 5ji 12
(8) The interval parts of hydro screw down devices are not flushed at secondary
flushing period. But, after completion of secondary flushing and then just before
the force motor valves to be attached, the internal parts of manifold shall be
flushed together with pipes around the main jacks.
(9) So as not to flush the internal parts of "proportional electro hydraulic reducing
valve" and "proportional electro hydraulic flow control valve", the valves,
mentioned above, to be removed or the flushing fluid to be by-passed.
In case that, if the valves are removed, flush the circuit after fixed the bypass
4 - 65
11110620-2002072-WP002
plates.
(10) As for flushing of valve stands, the solenoid valves mounted on them shall be
operated by manual control.
, . In order to that, explained above, it would be better preparing the jig to be used
changing the ports of valves.
4.8.7 Inspection and judgement
4.8.7.1 Inspection
Inspection is made for confirming the oil flushing effect and judging the completion
time.
4.8.7.1.1 Inspection interval
Inspection should be made at interval of 15 to 30 minutes at the beginning of oil

feeding.
After the amount of foreign matters has decreased to some extent, the inspection
may be performed at intervals of 1 to 2 hours.
3.8.7.1.2 Inspection procedures
Perform the inspection following the procedures below.
(1) After recording oil temp. and oil pressure, stop the pump.
(2) Close the return port valve, and remove the filter.
(Where the return port valve is not provided, wait until oil returns completely or
apply other filter.)
(3) Clean the filter with clean kerosine, and collect accumulating foreign matters
4 - 66
11110620-2002072-WP002
while blowing air inside.
(4) Sort the collected foreign matters, and keep them on record as shown in Fig.
23.
•
(5) Keep the collected foreign matters in transparent polyethylene bag as shown in
Fig. 24.
Moreover, when requested to attached the picture of foreign matters in the

report of flushing, take the picture of them as shown in Fig. 25.
4 - 67
/~
11110620-2002072-WP002
Date 10/1 10/3
Time -
6hr 11h 26r ~1h 39h
Total hour of oil feeding • • • •• .-

Vibrator ..--. ..--.
Hammering •••••••••••• •••• •••••••• •••••••••••• ••••
Aeration •••••••• •••• •••• ••••••••
Frequency of sample <ID (J) @
Oil temp .C
60 -
50 -
40 -
30 -
20 -
10 -
-
-\
Oil pressure kg/cm2 • • • • • •
Flowing velocity • • • •
Sand and soil 0 @
l!! Scale x x 0 0
"
~
E
c: Spatter and 0 0
Cl " 0
.~
slug
.E
"C
U
~
" wooden rubbish @ @
(5 " 0
u and fiber
Paint and steel o 0 @ @
Remarks: x ,~,O and @ are marks which represent transition of reduction

in amount of foreign matters.
x : 1 to 2 times as much as the initial amount
4 - 68
j{j'/
11110620-2002072-WP002
/:;. : 1/2 times as much as the initial amount
o : 1/4 times as much as the initial amount
@ : Almost none
Fig. 23
Collected foreign Picture of collected
matters foreign matters
Freguency of Frequency of
Measure
samplinQ data Transparent samplinq data
Sampling date polyethylene bag Sampling date

Total hour Total hour
Witness Witness
Fig. 24 Fig. 25
.,
4 - 69
;;;;
.."
Table 21 Arrangement after flushing
No. Procedures Detail of work Remarks
(1) At the down location of piping. drain oil by disconnecting the flange.
1 Draining of flushing oil Allowable remaining amount of oil under
(2) Drain carefully the cooler and strainer.
3%
(3) Record accurately the refilling amount and collected amount of oil.
2 Restoration of piping Restore to the normal piping. Verify that blind plate has been removed.
3 Tank cleaning and checking the Carry out these procedures prior to filling of the oil specified in the drawing. Use a vinyl sponge
Interior
4 Filling of oil specified in the Be careful so that foreign mailers do not get into the oil specified in the drawing.
drawing
5 Final confirmation Check for leak by oil feeding.
6 Arrangement after work Arrange neatly the tools, waste oil drum, stained rags, etc.
7 Preparation of report Prepare the report allaching the confirmation sheet of completion of flushing to the
-o
0)
records of inspection and judgement of flushing. /'\)
o
I
/'\)
o
o
/'\)
o
-....
/'\)
I
~
-0
o
o
4 - 71 /'\)
11110620-2002072-WP002
4.8.8 Safety precautions in flushing work
(1) Any other person except the personnel in charge should not operate the power
source and valves.
••
(Put the cautions plate on valves)
,•
(2) Do not feed oil before informing all persons. Moreover, post the indication
"Under oil feeding" at the related sections.
(3) Perform the following items to prevent a fire completely.
(a) Functional test of fire extinguishing equipments
(Carbonic acid gas spraying device, sprinkler, etc.)
(b) Preparation of fire extinguishers.
(c) Welding and gas culling sparks guard.
(d) Making clear strict prohibition of use of fire around oil tank fume .
•
(e) Clear indication of emergency exit.
(f) Making clear the detailed countermeasures in an emergency.
(4) When using a heater for heating the flushing oil, pay attention to the following
items.
(a) Do not overheat (over 50°C)
(b) When a throw-in type heater is used, use many heaters with relatively small
capacity to prevent local over-heating.
(c) While oil is being heated, keep the heat generating part under oil level.
(5) To prevent slipping while the persons are working do not leave the oil asset is for
long time, and wipe off it with rags and the like or apply neutralizing agent.
4 -72
11110620-2002072-WP002
4.8.9 Blowing Procedure of Grease pipe
(1) Blowing of grease pipe shall be divided to main pipe and branch pipe from
distribution valve .
Plug
(2) Confirmation items before blowing
a) Piping shall be completely assembled after pickling and anti-rust treatment.
b) Sequence check of unit, control panel and power source shall be completed.
c) Installation of barrel pump, grease pump shall be completed.
d) Grease of 180 e drum and 18 e pails can shall be prepared.
e) Manual grease gun or air grease gun shall be prepared for blowing
downstream of distribution valve.
f) Walky-talky for communication (pump start, stop) shall be prepared.
4 -73
/~
11110620-2002072-WP002
(3) Grease blowing of main piping
a) Removing piping between the outlet of grease pump and V-type strainer,
temporary hose shall be connected to the outlet of barrel pump and line
1 & 2.
b) Flanges of end point of each main pipe and end plug of distribution valve
shall be opened. And grease collecting sheet (Vinyl, Paper etc.) shall be
laid not to deteriorate the site.
c) Confirming the oil level of reduction gear of pump, check the rotation
direction of motor by jogging pump.
d) Running barrel pump continuously, fill the grease to main piping.
e) Blowing of grease shall be done from the opening of piping near the pump.
f) When about 100 cc for 10A size piping, about 500 cc for 32A size piping is
blowout, stop the pump.
g) Check the grease (change of viscosity, existence of foreign matters,

change of color) which blew out.
h) If any abnormality is not found, it can be recovered to original setting plug

or flange.
i) All branch end of line shall be blown out in order.
j) After the completion of blowing for one line, transfer the temporary hose to
other line and blowing shall be done by same method.
(4) Grease blowing down stream of distribution valve.
a) Removing the connection of outlet of distribution valve (pipe, hose) and

changing portion, fill the grease by grease gun from valve side.
b) Blowout about 50 cc from the opening of charging portion.

Checking the grease blowout, recover the piping if no abnormality.
c) All charging portions shall be blown out.

* 1 Blowing down stream of distribution valve is an important check point
before commissioning to confirm the fill of grease at each charging portion.
4 -74
11110620-2002072-WP002
(5) After blowing, all piping shall be recovered before the preparation of leak test.
a) After filling the grease to piping between grease pump and Y-strainer blow
out of grease shall be done from the plug of Y-strainer for the purpose of air
vent.
b) Proof test, leak test and operation of distribution valve shall be confirmed by
grease pump operation .
4 - 75
11110620-2002072-WP002
4.8.10 Air blowing procedure

Air piping and some portion of water piping shall be cleaned by air blowing.
(1) Blowing shall be done from the source side to the branch side using job
compressor or temporary compressor.
(2) In case of the large size piping or the big capacity of piping, compressor
capacity might be lack.
a) After installation of temporary valve (same size as piping or 1 size down),

increase the pressure to normal operating valve.
b) Subsequently, stopping the compressor, blowing shall be done by opening

temporary valve.
In case there is no temporary valve due to the large size due of piping end,
packing blow shall be done. Packing material shall be low grade paper
(Thickness about 2.5 mm) and tightened by mating flange.
When normal pressure is obtained, pouring water on paper, blow shall be
done by explosion.
{ Low grade paper
Rising
pressure
All bolt shall

/ Pouring water makes
the paper explode.
be tightened
Low grade paper (Generally called chip Ball Paper) has the character of
moisture absorption and melted by moisture absorption.
In case pressure can not reach the specified value, paper shall be double
layer.
4 -76
11110620-2002072-WP002
4.9 Pressure Test
4.9.1 Pressure test shall be done more than ten minutes at the pressure of max.
operating pressure to find leak or other abnormalities due to the defects of
welding and material.
(1) Pressure test shall be done after assembly of piping.

Regarding the piping which can not be carried out pressure test after
assembly, they shall be done before assembly.
(2) Pipe end or intermediate shall be divided by blind plate and blind flange,
never use valve.
If stop by valve, mutual agreement of sections concerned is necessary.
(3) Pressure test shall be basically done with water.

If water is difficult to use, air or oil can be used instead of water.
(4) Pressure test shall be bellows unless otherwise specified.
Water pressure Test Nor. Pressure x 1.5 limes
Air tighllest Nor. Pressure x 1.25 limes
* Here, high pressure gas facilities shall not be included.
(5) Test shall be judged by lead or pressure drop keeping specified pressure and
specified time
(6) Pressure shall be increased gradually to specified value never increased

vapidly.
(7) After inspection, drain the water immediately and drying, anti-rust work shall
be done if necessary.
(8) Basically test shall not be done if ambient temp is below 5°C.
(9) More than 2 pressure gauges, which max. indication shall be 1.5 - 2.0
times of test pressure.
(10) When pressure test shall be done after assembly of piping, attention shall be
paid to the protection equipments and instruments and basically blind plate
shall be inserted to connection flange.
4 - 77
11110620-2002072-WP002
4.9.2 Leak Test
(1) Leak test shall be done with fluid (Oil = Job oil, Equivalent oil gas = Air, Liquid
= Water etc) at the pressure of 1.1 times normal pressure after pressure test
is completed.
(2) If there is explosion plate, safety valve, reducing valve in line, safety
countermeasure, that is, removal or insert of blind plate, shall be considered.
(3) Pressure shall be increased gradually.
(4) Regarding pressure control valve, open by-pass valve and valve before and
behind fully and keep the same pressure at both side.
* Preliminary Leak Test:
It is preferable to check the connection portion of gasket by soap before
leak test at air pressure.
(2 - 3 kgf/cm2)
4.10 Tightening
Tightening shall be done for following cases.
(1) All flange bolts shall be re-tightened after the completion of pressure test.
(2) This work shall be done one month after commissioning.
(3) This work shall be done as necessary.
4 - 78
11110620-2002072-WP002
4.11 Installation for utility piping
4.11.1 Assembly of piping
(1) Material, dimension and existence of mistake for spool shall be checked.
Also support shall be installed at specified portion including level.
(2) Assemble the max. dia. piping at horizontal position at first and subsequently
short, shall size piping shall be assembled
(Rule, Level, Square Y-Level, Transit shall be used.)
(3) Parallel, distance between neighboring piping shall fully considered to look
suitable.
(4) Uneven portion (Pocket) at horizontal line shall not be allowed.
(5) Assembly and centering for moving portion like expansion shall be done
carefully considering operating conditions.
(6) All piping shall be conditions that tension or compression force does not
occur except the instruction of use of coil- spring in drawing.
(7) All piping shall be installed so that they elongate, shrink freely without
damaging the joint portions and hanger portions.
(8) When piping are installed, mis-use of gasket, bolt, nut shall be avoided to
clarify.
4.11.2 Installation of Valve
(1) Before the installation of valve, check the flange surface whether there is any
damage or not, or parallel of flanges.
(2) Removing the protection cap and cleaning the inside of piping by air blow,
install the valves.
(3) Flow direction is specified for ball valve and check valve.
(4) Valve handle shall be installed considering dwg and the condition of
circumference.
4 -79
11110620-2002072-WP002
4.11.3 Piping for tank and heat exchanger
(1) Large size or high place piping shall be installed after assembling on floor
and finishing the specifies test and proof test.
(2) When piping spools are installed, blind flange for proof test shall no be used
instead of temporary gasket.
Distortion parallel of flange surface results in the poor accuracy of piping.
(3) When weld at site, applied spools shall be installed correctly to the nozzle of
equipment.
Welding at site by temporary tightening loses the accuracy of flange ends
and result in the leak.
4 - 80
/93
11110620-2002072-WP002
4.11.4 Piping around pump
(1) Connection of piping shall be started from the piping rack or equipment side
and installed to the connection nozzle of pump after installing the supports.
Weight of piping shall not be supported by pump body or temporary support.
.
•
(2) Protection of pump nozzle shall not be removed until piping shall be installed
finally.
If piping work can not be carried out unless protection cover shall be
removed, blind gasket or plate which has specified thickness.
(3) At proof test of piping, blind plate shall be installed to the piping side flange
after removing piping installed.
When blind plate is inserted between nozzles and piping, centering of
rotating machine (Pump etc.) parallel of flange shall be checked to confirm
the no discrepancy.
4.11.5 Rack piping
(1) Installing rack piping preceding other connecting piping to equipment, they
T
shall be the datum for the dimension adjust at site.
(2) When piping is installed, welded position shall not be on the rack or beam.
(3) Tee, Elbow etc. shall be assembled on floor.
.•
4 - 81
11110620-2002072-WP002
4.11.8 Pressure test
(1) More than 2 pressure gauges for test (max. indication shall be more than 1.5
times and less than 2.0 times of test pressure) shall be used.
(2) It's not preferable to carry out test less than 5°C of ambient temp ..
(3) Water pressure test shall be carried out at 1.5 times max. operating pressure.
When water is used for gas line, check of support strength shall be done.
(4) Air pressure test shall be done at 1.25 times max. operating pressure.
Basically, test shall be carried out from high pressure side to low pressure
side.
(5) Handling of valve
a) In case handling of valve is necessary to carry out line set, pressure rise,
pressure relief, valve shall not be tightened too much even if leak from
valve occurs.
b) When valve leak, open valve by sight hammering and blow (2~3 times).
In case leak does not stop, check the component and repair by opening
• bonnet portion before overall air tight test.
4 - 83
11110620-2002072-WP002
4.11.9 Blowing of piping
(1) Cleaning per each line shall be specified separately.
(2) In case of water washing, water quantity, pressure, condition of blow point
• and waste water treat shall be planned .
(3) Air Blow
a) Compressor capacity and procedure of air accumulation shall be planned.
b) Safety countermeasure at blow point shall be planned.
c) Information to the concerned people shall be required due to the

occurrence of noise.
d) If compressor capacity is small comparing piping volume, blow shall be

carried out by installing temporary valve or explosion of ball paper at blow
point.
In this case, explosion press shall be 2-5 kgflcm2 .
4 - 84
'7
11110620- 20 02072-WP002
.
,
Chapter 5.
INSTALLATION ACCURACY AND MEASURING PROCEDURE
5-1
'.
'<>
""
• •
litem I Main l .Jment l
5-1 Iinstallation allowance for major equipment I l ~
Target of installation allowance
Equipment name Measuring part Discrepancy to line center DiScrepance 10 machioery center ~ne Squareness to pass center Levelness Height Measureing tool
Installation Measuremg Installa Ion I Measureing InstaIratlOn I Measurelng Installation Measuremg fnstarTatlon Measurelng
allowance "'oint allowance Doint allowance "'oint allowance Doint allowance noint
NO.1,2 Entry threading Carry over table :t:1.0mm Roll middle :t1.0mm Roll shaft O.5mml Roll Roll O.3mml Heig Roll top to.3mm Roll top Y-Level , Piano wire, Plumb bob
table center width
Steel ruler, Steel tape, Thickness
Guide table Motor coupling O.1mm Coupling O.1mm Coupling to.5mm Coupling gauge. Dial Gauge, Internal micro~
Deflection at Deflection at Face
shaft center face clearance meter
Double cut shear With Shear body to.5mm Frame center t1.0mm Upper knife O,05mm/m Upper knife O.05mm/m Knife holder ::to.5mm Knife holder Y-Level, Piano wire. Plumb bob
pinch roll Parallelism
Exit shear O.1mm/M Upper knife gauge, Dial Gauge, Internal micro~
Verticality & swing face
meter
Pinch roUfor shear to.5mm Roll middle :I:0.5mm Roll shaft to.5mmJM Roll top to.5mmJm Roll top to.5mm Roll top
center
Mater coupling O.1mm Coupling O.1mm Coupling to.5mm Coupling

shaft center face clearance
Deffector roll Bridle frame to,3mm Body to.3mm Body O.3mml Frame Brg. to.3mm 8rg. case top Y~Level , Piano wire. Plumb bob
Height of 4~ case top
point Steel ruler, Steel tape. Thickness
Tensionmeter roll Roll to.3mm Roll middle to.5mm Roll shaft O.05mmJM Roll edge O.05mmJM Roll edge to.3mm Roll top gauge, Dial Gauge, Internal micro~
center
Roll top meter, Swing jig t:
Top roll Reducer to.3mm Casing cente to.3mm Shaft center O.1mml Roll Casing O.1mmJM Base face O.3mm Shaft center •••:...
width
~
Coupling O.05mm Coupling to.1mm Coupling to.5mm Coupling
Deflection at Deflection at Face ~
shaft center face clearance I
Steering roll Roll to.5mm Pivot center to.5mm Pivot center O.05mm/M Roll middle O.1mmJm Roll top to.5mm Pivot center Y-Level, Piano wire, Plumb bob
:;
CPC unit
~
CPC sensor t1.0mm Casing t1.0mm Casing 1.0mmJm Casing 1.0mm/m Casing t1.0mm Casing gauge. Dial Gauge, Internal micro-
~
meter, Precision level \)
Steering roll
I:
,~
;~
1 1 Item I Main Equipment I
5-2
•• .• • •.
"'<":> 5-1 I Installation allowance for major equipment I I "
Equipment name Measuring part Discrepancy to line center Discrepance to machinery center line Squareness to pass center Levelness Height Measureing tool
installatIon Measurelng Installation I Measurelng InstallatIon Measurelng Insta latlon Measuremg Installation I Measuremg
allowance nOlnl allowance noint allowance ooinl allowance noint allowance ooin!
Alkali dip Tank to.5mm Tank inside :t1.0mm Center mark O.5mm Center mark 1.0mm/Tank Tank edge to.3mm Tank top Y-Level, Piano wire. Plumb bob
width center width
Scrubbing unit
Sleel ruler, Steel tape,
HCD electolyic cleaning Roll to.5mm Roll middle t1.0mm Roll shaft O.5mm Center mark O.OSmm/m Roll top to.3mm Roll top Dial Gauge, Internal micrometer,
unit center
Swing jig
Hot water rince unit Coupling O.OSmm Coupling O.1mm Coupling to.Smm Coupling
Dryer
shaft cenler face clearance
Entry looper Rail to.Smm Rail side to.Smm Rail edge 1.0mml Rail Base rail O.Smml Pair Rail top to.Smm Rail top Y.Level , Piano wire, Plumb bob
edge
:f:1.0mml Steel ruler, Steel tape, Thickness
Parallelism
Delivery looper Rail guide gauge, Dial Gauge, Internal micro.
Drum to.Smm Drum middle to.Smm Drum center O.3mmf Shaft center O.3mml Base top to.Smm Shaft lop meter
Distance of Height of 4-
Brg. case point
Reducer to.3mm Casing cente to.3mm Shaft center O.1mml Span Casing O.1mm/M Base face O.3mm Shaft center
Motor base to.3mm Base mark to.3mm Base mark O.3mmf Base top O.3mm Base top
Height of 4.
point
Motor cpupling O.OSmm Coupling O.1mm Coupling to.Smm Coupling
I--
Deflection at Deflection at Face -~
Feed leveller With reducer frame
shaft center
to.3mm Frame
face
to.3mm Frame
clearance
to.3mm Roll top Y.Level , Piano wire, Plumb bob

-",CD
Roll to.3mm Roll middle to.Smm Roll shaft O.05mm/M Roll edge O.OSmm/M Roll edge fO.3mm Roll lop Sleel ruler, Sleellape ,Thickness ~~
center
Roll lop gauge, Dial Gauge, Internal micro- <p
Reducer to.3mm Casing cente to.3mm Shaft center O.1mm/M Base face O.3mm Shaft center meier, Precision level
Tension bridle
Coupling
Bridle frame
O.OSmm
Deflection at
shaft center
to.3mm
Coupling
Frame
O.1mm
Deflection at
face
to.3mm
Coupling
Frame
to.Smm
Face
clearance
Coupling
O.3mml
Height of 4-
point
Brg. top O.3mm Brg. top Y.Level, Piano wire, Plumb bob

*
~
h
~
Roll to.3mm Roll middle to.Smm Roll shaft O.05mm/M Roll end O.OSmm/M Roll end to.3mm Roll lop gauge, Dial Gauge, Internal micro- ~
center
Roll top meter, Precision level :)
:>
Reducer to.3mm Casing cente to.3mm Shaft center O.1mml Span Casing O.1mm/M Base face O.3mm Shaft center
- ..,
.
I litem I Main Equipment

I S~1 Iinstallation allowance for major equipment I "
5-3
.•
~
Equipment name Measuring part Discrepancy to line center DisCl'eparlC8 10 mact1inery center line Squareness to pass center Levelness Height Measureing tool
Instanatlon I Measuremg Installation Measurelng Installation I Measuremg Installation Measurelng Installation Measuremg
allowance oint allowance ooinl allowance Doinl allowance Doinl allowance noint
Tension bridle Coupling :i:O.3mm Coupling :to.1mm Coupling fO.5mm Coupling
shaft center face clearance
Entry transfer car Car rail :to.5mm Rail side .t1.0mm Rail edge :to.1mml Rail span O.5mml Pair Rail top :to.5mm Rail top Y-Level, Piano wire, Plumb bob
Distance
Delivery transfer car
between rail Steel ruler, Steel tape, Thickness
NO.1,2 Entry coil car
gauge, Internal micro-maier
No.1 ,2 Delivery coil car
No.1.2 Pay-off reel Base t1.0mm Base center to.2mm Dalum side O.O.1mm/M Entry slide O-O.1mm/M Slide base to.5mm Slide base Y-Level • Piano wire, Plumb bob
mark I Cyl. slide face Toe out face Toe up liner top liner top
NO.1,2 Tension reel
Steel ruler, Steel tape,
-
Reel
Drive motor O.1mm Coupling O.1mm Coupling

O-O.1mm/M
Toe out
to.5mm
Mandrel
Coupling
O-O.1mm/M
Toe up
Mandrel Dial Gauge,
Swing jig
Internal micrometer,
--
-
0
coupling Deflection at Deflection at Face 0>
shaft center shaft center clearance In case of outboad use, please I\)
Pump motor O.1mm Coupling
confirm to SV. 0
O.1mm Coupling to.5mm Coupling
coupling
I
I\)
shaft center shaft center clearance
0
0
I\)
-
0
I\)
I
~
"'0
o
o
I\)
5-4
11110620-2002072-WP002
,.
Chapter 6
DETAilED INSTAllATION PROCEDURE

OF
TERMINAL SECTION
•
•
6- 1
11110620-2002072-WP002
Chapter 6. Installation Procedure(Check sheet) for each equipment
6.1 Entry Section P6-3
6.2 Pre Treatment Section P6-20

•
.
6.3 Furnase Section P6-26
6.4 After Pot Cooling Section P6-29
6.5 Spm & Tension leveller Section P6-34
6.6 Post Treatment Section P6-39
6.7 Exit Section P6-48
6.8 CouplingCenterring P6-63
P6-2
z03
IV
~ 6.1 .. Check sheet if Centeri'ng & Alignment -_NO.2 CGL i.:INE:
CUSTOMER IHES-SUNSCOI PROJECT NO, DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x 1.250mmW
x 25Ton x 120/170m/min
2229001/2300001 NO.1 ENTRY
MAKER IDH CO .. LTO ITEM NO. EQUIPMENT DATE 20
/2222301 COIL SKID / CMD
1 3 5
x XX XXX
""0 tOOOOlt
--,---
"'.IC,_!l<>I!.t" •••2Cr'l>',!!' ~ •• ~••• _, AOJUS''''ur
~--- PO".Il()/l
--,-
IN; cro,!••
• • • • •
Y 1~~ Yl
Xl XXi XXXi
2 4 6
RAIL HIGH DISTANCE BETWEEN THE RAILS
--
o
No. RESULT SIGNED BY 0>
SPEC FINISH SPEC FINISH N
o
I
N
o
2 o
N
3 o
-..j
FL -1528 :l:0.5mm 1100 :l:0.5mm N
4 I
::IE
"'tl
5 o
o
6 N
P6-3
,.. •
~
Check sheet Of ~entering' & Alignment - 1\10.2 CGL LINE
CUSTOMER IH.E.S-SUNSCOI PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x 1.250mmW
2229002/2300002 NO.2 ENTRY
MAKER IDH CO .. LTD ITEM NO. EQUIPMENT DATE 20
1 3 5
x XX XXX
AUla (/MIt«;
",l
,
c._1/01 .,..• •••.2 Cj" \.0< ••
~ """,,T AlUJS"oOl~r l'OSITO'lI< lH: ~,t~llR
" " " " I;
I'r');' :
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I , , ,
~- ~"--,
y YI
Xl XXI XXXI
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Center line X-Xl Piano wire/Pivot Distance :to. 1mm
of the frame o
Center I
Center line XX-XXl Piano wire/Pivot Distance :to.l mm I\)
of the frame
o
Center o
Centering Center line XXX-XXXt Piano wire/Pivot Distance :to.t mm
of the frame I\)
Measurement
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Results 90' Direction y-yt O.lmm/M --l
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ITEMS I\)
Center Distance :1:0.1mm o
Center line X-Xl Piano wire/Pivot
ot the frame I
Center I\)
Cenler line XX-XXl Piano wire/Pivot Distance :1:0.t mm o
of the frame
o
Center Distance :1:0.I mm N
Center line XXX-XXXI Piano wire/Pivot
Centering of the frame o
Measurement -.j
Center Piano wire/ N
Results 90' Direction Y-Yl 0.1mm/M
of the frame Tapeline I
==
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o
High Top of the base Top of the base Y-Ievel :l:0.5mm o
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MAKER IDH CO .•LTD ITEM NO. 2214101 EQUIPMENT NO.1 PAY OFF REEL DATE 20
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Center 1\)
Center line
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---J
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of th drum Tapeline
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o
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MEASUREMENT I
DIVISION PLACES POSITION USE THE TOOLS OBJECTIVE FINISH SIGNED BY N
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o
Center line
Center
X-Xl Piano wire/Pivot Distance :l:0.05mm o
of th drum N
Center Piano wire/
o
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Measurement I
Results Level Top of the drum CENTER Water level :l:O.lmm =e
-0
High Top of the base (A)-(D) Y-Ievel :l:0.5mm o
o
N
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CUSTOMER IH.E.S-SUNScol PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x 1.250mmW
x 25Ton x 120/170m/mln
2031201 NO.1 COIL OPENER
MAKER IDH CO.,LTD ITEM NO. EQUIPMENT DATE 20
/2230001 / NO.1 EDPR
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Front .0
Center line X-Xl Piano wire/Pivol Distance :to.05mm
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Center Piano wire/ o
Centering 90' Direction Y-Yl 0.05mm/M -..j
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Top
Results Level CENTER Water level :to.05mm :2:
of the roll
-0
Top o
High (A)-(D) Y-Ievel :to.5mm
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N
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CUSTOMER IH.E.S-SUNSCOI PROJECT NO. I DH-520 PROJECT NAME NO.2 CGL LINE
NO.1 ENTRY
MAKER I IDH CO .. LTD I ITEM NO. I 2031203 I EQUIPMENT
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DATE 20
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o
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N
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Resulls ;E
I -0
Top o
High I of the roll
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DOUBLE CUT
MAKER IDH CO .. LTD ITEM NO. 2273101 EQUIPMENT DATE 20
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DIVISION PLACES POSITION USE THE TOOLS OBJECTIVE FINISH SIGNED BY I
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Front o
Center line
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X-Xl Piano wire/Pivot Distance :1:0.1mm o
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Center Piano wire/
:l:0.05mm/M
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Centering 90' Direction Y-Yl -..J
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Results
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CUSTOMER IH.E.S-SUNScol PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT X 1.250mmW
X 25Ton X 120/170m/min
NO.1 TENSION
MAKER IDH CO .•LTD ITEM NO. 2232101 EQUIPMENT
BRIDLE ROLL
DATE 20
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ITEMS o
Front o
Center line I of the roll
X-XI Piano wire/Pivot I Dislance :to.05mm I\)
o
-I
Center Piano wire/
Centering 90' Direction I of fhe roll
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DH-520 PROJECT NAME NO.2 CGL LINE 0.3-3.2mmT x l,250mmW
CUSTOMER IH.E.S-SUNSCOI PROJECT NO.
MAKER IDH CO.,LTD ITEM NO. 2245201 EQUIPMENT ENTRY LOOPER DATE 20
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MAKER IDH CO.,LTD ITEM NO. 2245201 EQUIPMENT ENTRY LOOPER DATE 20
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ITEMS
PLACES
Center
POSITION USE THE TOOLS OBJECTIVE FINISH SIGNED BY
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Center ro
Center line YY-YYl Piano wire/Pivot Distance :to. 1mm
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Centering Center line YYY-YYYl Piano wire/Pivot Distance :to.l mm N
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Results 90. Direction X-Xl :to.l mm/M C>
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CUSTOMER IH.E.S-SUNScol PROJECT NO.
NO.1 STEERING
MAKER IDH CO .•LTD ITEM NO. 2258501 EQUIPMENT DATE 20
ROLL
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Front
X-Xl Piano wire/Pivot I Distance :l:0.05mm o
N
Center Piano wire/

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Centering 90' Direction I
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Measurement ::lE
Top
Results Level I of the roll
CENTER Water level I :to.05mm "'0
Top
o
High I (A) Y-Ievel I :to.5mm o
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CUSTOMER IH.E.S-SUNScol PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE
NO.2 STEERING
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MEASUREMENT
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Front o
Center line
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X-Xl Piano wire/Pivot Distance :!:0.05mm I\)
o
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Top
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of the roll "U
Top o
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of the base
N
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CUSTOMER IH.E.S-SUNSCOI PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE
-j'LO,2 CGL tiNE-
SPECIFICATION I 0.3-3.2mmT x 1.250mmW
MAKER IDH CO .•LTD ITEM NO. 2286201 EQUIPMENT ALKALI DIP TANK DATE 20
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MAKER IDH CO .. LTD ITEM NO. 2310101 EQUIPMENT SCRUBBER TANK DATE 20
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MEASUREMENT
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N
Center line
Center
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of fhe roll o
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Top
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of the roll
:IE
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o
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CUSTOMER IH.E.S-SUNSCOI PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x l,250mmW
HOT WATER RINSE TANK
MAKER IDH CO.,LTD ITEM NO. 2286101 EQUIPMENT DATE 20
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Results Level CENTER Water level :l:0.5mm ~
of the roll
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N
P6-22
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Top o
High (A)-(D) Y-Ievel :l:0.3mm o
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P6-23
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MAKER IDH CO .. LTD ITEM NO. 2045001 EQUIPMENT FUME SCRUBBER DATE 20
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o
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o
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Top o
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Center line X-Xl Piano wire/Pivot Distance :to.05mm
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I
Measurement
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Results Level CENTER Water level :to. I mm "'0
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o
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MAKER IDH CO .. LTD ITEM NO. 2232102 EQUIPMENT WITH SNUBBER ROLL DATE 20
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CUSTOMER IH.E.S-SUNSCOI PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x t.250mmW
MAKER IDH CO .•LTD ITEM NO. 2232103 NO.3 TENSION
EQUIPMENT DATE
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CUSTOMER IH.E.S-SUNScol PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I O.3-3.2mmT x 1.250mmW
MAKER iDH CO .. LTD ITEM NO. 2231502 EQUIPMENT TENSION LEVELLER DATE 20
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MAKER IDH CO .. LTO ITEM NO. 2258102 NO.2 DEFLECTOR
EQUIPMENT DATE
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CUSTOMER IH.E.S-SUNScol PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x 1,250mmW
MAKER IDH CO .•LTD ITEM NO. 2139103 EQUIPMENT NO.3 TOP ROLL DATE 20
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CUSTOMER IH.E.S-SUNScol PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x 1,250mmW
MAKER IDH CO.,LTD ITEM NO. 2258104 NO.4 DEFLECTOR
EQUIPMENT DATE
ROLL 20
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o
-.j
of the roll
N
Centering I
Measurement ~
Top '1J
Results Level
of the roll
CENTER Water level :l:O.05mm o
Top
o
High (A)-(B) Y-Ievel :l:O.5mm N
of the roll
P6-48
tv . Check sheet Of Sentering & Alignment - ~IO.2 CGL LINE
cl SPECIFICATION I 0.3-3.2mmT x 1.250mmW
CUSTOMER IH.E.S-SUNSCOI PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE
NO.5 DEFLECTOR
ROLL
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MEASUREMENT o
ITEMS o
N
Center o
Center line
of the roll
X-Xl Piano wire/Pivol Distance :to.05mm -..j
Centering 90' Direction Y-Y1 0.05mm/M I
01 the roll Tapeline
Measurement ~
Top 1J
Results Level CENTER Water level 0.05mm
of the roll o
Top o
High (A)-(D) Y-Ievel :to.3mm N
at the base
P6-49
~
, ICUSTOMCRIH.E.s-suNscol
. Check sheet
PROJECT NO. r 0' Sentering & Alignment - '10.2 CGL LINE
DH-520 r PROJECT NAME 1 NO.2 CGL :"E
NO.6 TENSION
SPECIFICATION 0.3-32mmT"
DATE 20
.250mmW
2232106 EQUIPMENT BRIDLE ROLL

ITEM NO.
MAKER IDH CO .. LTD
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Center
of the roll
X-Xl Piano wire/Pivot
Distance :l:0.05mm N
,
Piano wire/ 0.05mm/M ::e
Center Y-Yl Tapeline "tJ
Centering 90' Direction of the roll
0.05mm
o
Measurement Top CENTER Water level o
Level N
Resulfs of the roll
:l:0.3mm
Top (A)-(D) Y-Ievel
High of the base
P6-50
'"~ . Check she_et 0+ Senterind & Ali'QDment - "10.2 CGL LINE
O.3-3.2mmT x 1.250mmW
CUSTOMER H.E.S-SUNSCO PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION
INSPECTION
TABLE
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Measurement
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Results o
Top o
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01 the roll
P6-51
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.check sheet Of Sentering & Alignment - ~IO.2 CGL LINE
MAKER IDH CO .•LTD ITEM NO. OILER WITH
2024300 EQUIPMENT DATE
PINCH ROLL 20
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FINISH SIGNED BY
o
o
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01 the roll
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o
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Y-Yl 0.05mm/M
01 the roll
Measurement
Results Level
Top
CENTER
Tapeline
Water levei
'"::E1
of fhe roll :to.05mm
"U
Top o
01 the base o
P6-52 '"
v Check sheet 0+ Sentering" & AlitJnment - '10._2 CGL LINE
~
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MAKER IDH CO.,LTD ITEM NO. EQUIPMENT DATE 20
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Center line X-Xl Piano wire/Pivot Distance :f:0.5mm N
of the roll o
.....,
Center Piano wire/
Centering 90' Direction Y-Y1 0.5mm/M N
of the roll Tapeline t
Measurement
Top ::IE
Results Level CENTER Waler level :f:0.5mm
of the roll -0
Top o
High
of the base
(A)-(D) Y-Ievel :f:0.5mm o
IV
P6-53
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CUSTOMER IH.E.S-SUNScol PROJECT NO. I DH-520 I PROJECT NAME I NO.2 CGL LINE I SPECIFICATION 0.3-3.2mmT x 1.250mmW
MAKER I IDH CO .. LTD I ITEM NO. I 2031205 I EQUIPMENT I

EXIT THREADING
CONVEYOR
-
I DATE 20
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MEASUREMENT N
DIVISION PLACES POSITION USE THE TOOLS OBJECTIVE FINISH
ITEMS SIGNED BY o
Center
o
Center line X-XI Piano wire/Pivot Distance :to.5mm N
of the roll o
-.j
of the roll Taneline I
Measurement
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Results "'0
Top
o
of the base N
P6-54
tv
e,.. . Check sh£et Of Sentering' & Alignment - "'0.2 CGL LINE
'" CUSTOMER IH.E.S-SUNSCOI PROJECT NO. DH-520 PROJECT NAME NO.2 CGL LINE SPECIFICATION I 0.3-3.2mmT x 1,250mmW
2258111/ NO.1 EXIT DEFLECTOR PINCH
MAKER IDH CO .. LTD ITEM NO. EQUIPMENT ROLL /STRIP GUIDE TABLE DATE 20
2031206
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DIVISION PLACES POSITION USE THE TOOLS OBJECTIVE FINISH SIGNED BY I\J
ITEMS o
Center o
Center line
at th drum
X-Xl Piano wire/Pivot Distance :l:0.3mm I\J
o
Center Piano wire/ --J
Centering 90' Direction Y-Yl :l:0.3mm/M I\J
at th drum Tapeline
Measurement I
Results Level Top of the drum CENTER Water level :l:0.05mm ::IE
"U
Top of fhe base (A)-(D) Y-Ievel :l:0.3mm
o
High o
I\J
P6-55
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2258112/ NO.2EXIT DEFLECTOR PINCH
MAKER IDH CO .. LTD ITEM NO. EQUIPMENT ROLL ISTRIP GUIDE TABLE DATE 20
2031207
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DIVISION PLACES POSITION USE THE TOOLS OBJECTIVE FINISH SIGNED BY I
ITEMS N
Center o
Center line I 01 th drum
X-Xl Piano wire/Pivot I Distance :to.3mm o
N
Center o
Centering 90' Direction I
of th drum
Y-Y1
Piano wire/
Tapeline
:to.3mm/M ....•
Measurement N
Resuits I Top of the drum :to.05mm I
Level CENTER Water level
:lIE
"U
High I Top of the base (A)-(D)
I Y-Ievel I :to.3mm o
o
P6-56 N
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2213101/ NO.1 TENSION REEL!
2219201 T/R BELT WRAPPER
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Center line X-Xl Piano wire/Pivol Distance :to.05mm N
of th drum o
--l
Center Piano wire/
Centering 90' Direction Y-Y1 0.05mm/M N
of th drum Tapeline I
Measurement
Results Top at the drum :to. I mm
:::E
Levei CENTER Water level -0
C>
High Top of the base (A)-(D) Y-Ievel :to.5mm C>
~
P6-57
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. Check sheet Of Sentering' & Alignment - 1\'0.2 CGL LINE
r-
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, CUSTOMER iH.E.s-sUNscoi PROJECT NO. DH-520

I PROJECT NAME NO.2 CGL LINE SPECIFICATION O.3-3.2mmT x 1.250mmW
MAKER I IDH CO .. LTD I ITEM NO. I 22223031

2229003
I EQUIPMENT NO.1 EXIT COIL
DATE
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Center line
of th drum
X-Xl Piano wire/Pivot Distance :to.5mm
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o
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Centering Cenfer line
of th drum
XX-XXl Piano wire/Pivot Distance :to.5mm I
Measurement ::IE
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Results 90' Direction Y-YI 0.5mm/M
at th drum Tapeline o
:to.5mm
o
High Top of the base (A)-(D) Y-Ievel N
P6-61
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r-- .Check sheet 0+ Sentering & AliQillIle_nt - '10.2 CGL LINE
MAKER IDH CO .. LTD ITEM NO.
EQUIPMENT DATE
2229004 CAR 1 SKID 20
1 3 5
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SIGNED BY o
Center o
Center line X-Xl Piano wire/Pivot
of th drum Distance :l:0.5mm N
Center o
Centering Cenfer line XX-XX1 --J
of th drum Piano wire/Pivot Disfance :l:0.5mm N
Measurement
Results Center I
90' Direcfion Y-Yl Piano wire/
of th drum 0.5mm/M :DE
Tapeline "U
High Top of the base (A)-(D) Y-Ievel
o
:l:0.5mm o
N
P6-62
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6.8 Measurement of IVlechanical Installation Commuction Check Sheet
Name of Facility H.E.S.-SUNSCO NO.2 C.G.L TERMINAL DATE 2012.
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
~ ~/ A Within 0.05mm IDH
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DEVICE NAME ITEM NO. l-A 1-8 1-C 1-D 2-A 2-8 2-C 2-D
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P6-63
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Measurement of Mechanical Installation Constn..ldion Check Sheet
I
ENTRANT SIGNATURE
i 3
SPEC' (1,2,3)
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DEVICE NAME ITEM NO. 1-A 1-8 1-C 1-0 2-A 2-8 2-C 2-D
NO.1 EDPR 2030001 R/U ~

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Measurement of Mt;~hanical Installation ConstrLJdion Check Sheet
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
~. ~/ A Within 0.05mm IDH
H.E.S.
-. - ~- -r- B D
-- . --- -
- -- - -
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DEVICE NAME ITEM NO. 1-A 1-B 1-C 1-0 2-A 2-B 2-C 2-D
NO.1 TENSION
-a-
2232101 R/U
BRIDLE ROLL1
NO.1 TENSION
2232101 R/U
BRIDLE ROLL2
C>
NO.1 TENSION I\)
2232101 U/M
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Measurement of Mt::chanical Installation Construction Check Sheet
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
A Within 0.05mm IDH

~/
H.E.S.
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-- - -- - - -- - -
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NO.2 TENSION
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P6-66
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M'easurement of fvlc;chanical Installation Construction Check Sheet
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
~.~/ A Within 0.05mm IDH
H.E.S.
-- ,- --- B D
- - -- - - --- --
'{ -~
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DEVICE NAME ITEM NO. 1-1\ 1-B 1-C 1-0 2-1\ 2-B 2-C 2-D
NO.3 TENSION
BRIDLE ROLL1
NO.3 TENSION
2232103 R/U
2232103 R/U
--
f--
BRIDLE ROLL2 f--
NO.3 TENSION
2232103 R/U
BRIDLE ROLL1 ~
NO.3 TENSION I
2232103 R/U
BRIDLE ROLL2 ~
NO.3 TENSION
2232103 U/M
BRIDLE ROLL1 ~
NO.3 TENSION
2232103 U/M ~
BRIDLE ROLL2
I
NO.3 TENSION
2232103 U/M
BRIDLE ROLL1 ~
NO.3 TENSION
2232103 U/M ~
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P6-67
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M"easurement of Mtjchanical Installation Construction Check Sheet
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
_~ / A Within 0.05mm IDH
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NO.4 TENSION 2232104 R/U

BRIDLE ROLL1 :::
NO.4 TENSION 2232104 R/U :

BRIDLE ROLL2 ::>
NO.4 TENSION 2232104 R/U ~
BRIDLE ROLL1 ...,
NO.4 TENSION 2232104 R/U ~

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NO.4 TENSION 2232104 U/M ~
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BRIDLE ROLL2 I
NO.4 TENSION 2232104 U/M :;

BRIDLE ROLL1 ::5
BRIDLE ROLL2
P6-68
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" Measurem ent of fvlc;chanical Installation Canst! uction Check Sheet
"
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
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NO.5 TENSION I\)
2232105 R/U
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o
NO.5 TENSION .~
I
2232105 U/M
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P6-69
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Measurement of rvlt:chanical Installation Construction Check Sheet
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
~ ~/ -
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H.E.S.
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DEVICE NAME ITEM NO. l-A 1-B 1-C 1-0 2-A 2-B 2-C 2-D
NO.6 TENSION ~
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NO.6 TENSION
2232106 R/U
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P6-70
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Measurement of Nrc:chanical Installation Construction Check Sheet
3 ENTRANT SIGNATURE
10 20 SPEC' (1,2,3)
~
~/ A Within 0.05mm IDH
H.E.S.
-- ~- .~. .- B D
- - -- -
- -- - -
-
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DEVICE NAME ITEM NO. 1-A 1-8 1-C 1-D 2-A 2-8 2-C 2-D
NO.1 TENSION REEL 2213101

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NO.2 TENSION REEL 2213102 -
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P6-72
11110620-2002072-WP002
Chapter 7
Installation procedure of equipment
2?ft. 7-1
11110620-2002072-WP002
Contents
Chapter 7. Installation procedure of equipment
7.1 Common method of alignment for mechanical equipment 7-3
7.2 The installation flow chart of skin pass (temper) mill 7 -23
7.3 Installation procedure of skin pass mill 7 -24
7.3.1 Installation of shoe plate 7 - 24
7.3.2 Standing procedure of mill housings onto shoe plates 7 - 30
7.3.3 Installation of mill housing 7 - 33
7.3.4 Assembling the devices/parts around mill housing 7 - 39
7.3.5 Mill piping 7 -48
7.3.6 Roll changing device 7 - 49
Main mill drive and mill motor 7 - 56

7.3.7
Oil cellar equipment

7 -60
7.3.8
7-63
7.4 Installation of Tension leveler
Installation of Tension leveler for Changing device

7-64
7.5
P7 - 2
11110620-2002072-WP002
7.1 Common methods of alignment for mechanical equipment
Alignment
No. Applications
methods
1. LN-1 Alignment of the base liner
2. BA-1 Height of the base

Rough level of the base
3. BA-2 Final level of the base
4. BA-3 Center of the base

Squareness of the base
5. BA-4 Height of the base

Final level of the base
6. RO-1 Center of the machine

Squareness of the roll (shaft)
7. RO-2 Squareness of the roll

Center distance of the roll (shaft)
8. RO-3 Height of the roll (shaft)

Level of the roll (shaft)
9. SH-1 Alignment of shoe plate
10. RA-1 Height, level and pitch of the rail
11. CU-1 Alignment of the shaft

Center of the machine
12. CU-2 Alignment of the machine (long distance)
13. SW-1 Squareness of the roll (shaft)
14. SW-2 Squareness of the shoe plate
15. SW-3 Measuring the verticality by a way adapting an ear phone
NOTE The jigs and instruments, used alignments written above, shall be prepared by the
erection constructor.
P7 - 3
11110620-2002072-WPOO?
Alignment method LN-1
Precision level
Adjustment of
Base Liner
Base liner for

Scale installation Scale "Y" level
F.L /
Elevation mark
Pad
P7 - 4
11110620-2002072-WP002
Alignment method BA-1
o
Y -level
h Man's
- -.- - ---------- --- - --- - - - - - - ---:i r eye
I
Steel straight ruler
Frame
P7 - 5
11110620-2002072-WP002
Frecision Level
.0 0 0
Straight Edge
279 P7 - 6
11110620-2002072-WP002
Machine
Center
Piano wire
Center mark
2120
11110620-2002072-WP002
Alignment method BA.4
Reducer
Gear coupling
,
./
Precision level
P7 - 8
11110620 ..•2002072-WP002
Alignment method RO-1
Piano wire
Center mark
"'
- ...:::.:= ~ Manis
- eye
Plumb bob
P7 - g
11110620-2002072-WP002
Piano wire
Spring Blance
Tape Measure
11110620-2002072-WP002
Precision level
Y-Ievel
---
P7 - 11
11110620-2002072-WP002
Alignment method RA-1
Machine
center
Scale
"Y" - level
<1 CJr-----~
,//AJ:\/77
5./ /( tl '( ,
Plumb bob
Rail
P7 - 13
11110620-2002072-WP002
Alignment method CU-1
Dial indicator
Motor Side Hub of gear couplin/jSoll Side
Motor side
Roll side
\ Lever type dial indicator
Less than 1M
Holding jig
n
-,,
,
\ I
) ,
I
.'.
-+-
Hub of gear couplin
Motor side
Roll side
P7 - 14
11110620-2002072-WP002
Alignment method CU-2
Distance
Between flange face
Piano wire
Man's eye
1~-
""-- -
-
"Y" level Plumb
Machine
center bobs
Basic Side Aligned side

II
Adjust to
conform piano-
wire and
flange center
NOTE This method to be applied when the distance, between coupling flange faces, is more
than 1.000 mm.
P7 - 15
11110620-2002072-WP002
Alignment method SW-1
Inside micrometer
I
G;>
Swing Jig
g
\\ Center mark
P7 - 16
11110620-2002072.,..WP002
Alignment method SW-2
Example of an application of Swing Jig to Mill Housing centering including its shoe plate.
Piano wire
Swing jig
:."... "
PL
I
Mill housing
Straight edge
Shoe plate
~ Pass & piano wire
N
230
A micrometer to be fixed 260
~
here at measuring N
For Shoe Plate
For Mill Housing
P7 - 17
2ttO
11110620-2002072-WP002
Swing Jig for Mill Housing
20 1160
580
2 x 2-M12L60 / \ 2 x 2-M12L35
2-M12L65
\ 2x2-M16L60
2 x 2-M20L150
a
a
;:
2-M12L65
I
2-M12L50
Swing Jig Sketch
12 No 4 BLOCK 2
11 No 1 BLOCK 1
10 DIAL INDICATION 2
9 DIAL INDICATION 1
8 No 2 BLOCK 1
7 No 8 BLOCK 2
6 No 9 LEVER 1
5 No 10 SHAFT 1
4 No 7 BOLT 2
3 No 6 BRACKET 2
2 No 2 BLOCK 2
1 No 3 SEAT 4
ITEM DRAWING NO. DESCRIPTION Q'TY REMARKS
(Part drawings for Swing Jig attached herewith.)
P7 - 18
11110620-2002072-WP002
I 28 I . z
I
- 2
•• S w
,
2
,,
/
• L,
• ,
, <f:1t~.(~
I
i
I
,
I
rlIIIIN' ~C' ,J~ - ~I
••• n' ,
I
.,
,
"I
~,.,.;
h/)".ml
I 1
"" '"'~.
,..--~- -"
T,
• " -
in/(J
Jt4I"",!N-,z8 JO- I ".&S',7. 8 I I I 'mo • a/.
""
Dwg No 1 Dwg No 2
Dwg No 3 Dwg No 4
z
-
, I-I I I
,
,, z i .l:"ol'AW - 14.T
• " ,
li:t ,..
-
I, "''''''''N- 1#.' ,.~
Dwg No 5 Dwg No 6
P7 - 19
11110620-20(j2072-:WPOOa
2
/
lJl
.;:1 .-
.
, !,
i?:i
~
M
"
,~ 8
2-W2CttV/ ." .
Dwg No 7 Dwg NoB
3 ,S
o
2- 2
z • ,,,,,~
.
I ". 1L
J lLl(~ 1
, ,
I
i,,~ ".1' /8 /0"
ZJ. Z.$.l
N, Js, /. 7/
! .XMAN -oor 67
I • 2 i i l •
/ 8 I !.<YA. ! i ! .'
'nIP /(&II/1/i -. 0f.I, a.,. - '//J
3.' .2/
Dwg No 9
Dwg No10
P7 - 20
11110620-2002072."WP004
Measuring the verticality by a way. adopting an ear phone SW-3
Piano
wire -
Bolt
Inside
microme er
(with holder)
Oil tank
CD The subject to be measured
CD Ear-phone
'1'1'1 0 Dry cell
0 0
CD
Insulated tape
Bolt
7 CD Inside micrometer with stand
0 Piano wire
CD CD Plumb bob or weight
CD Oil can
P7 - 21
.;,ri4
11110620-2002072-WP002
9.1.1 Cautions concerning erection work to be performed by the erection constructor.
There are many work and items to be performed by the erection constructor.
For the purpose of smooth erection progress, some of them are listed up here, which have to
be performed during the erection.
(1) Chip off top surface of the foundation where the pads for erection liners are
made.
(2) Tolerance of installation accuracy
Allowable tolerance of installation accuracy are specified generally in this section.
But it is necessary to consult with Hitachi supervisor in case that installation of the
equipment are not kept in the specified tolerance.
Each allowable tolerance shown in this section shows the allowabie maximum vaiue.
Therefore, each measured value should be within these allowable tolerance.
(3) Weld liners and shims to be used for adjusting height of the machinery, after
completion of installation.
(4) Fill the grease or oil specified and decided by customer to the couplings, connecting
machinery and their drives.
(5) Appiy the oil or grease specified and decided by customer to the sliding surface of the
machinery or their drive chains.
(6) When erection constructor wants to use thin straight liners thinner than 3 mm consult
M.H supervisor whether they can be used or not and receive his advice.
(7) Fill the oil or grease specified and decided by customer to the tanks, reducers, and
oiiers etc., before the testing.
(8) Weld stoppers fixing sensors or preventing loosening of nuts, by the direction shown in
the drawings.
NOTE: "Erector" shall mean the company or corporation who performs the installation
work in accordance with the construction contract.
P7 . 22
7 2 The installation flow chart of Skin pass ITemper) Mill
11110620-2002072-WP002
examine NO
accuracy of the mill Re-adjust the level of
housing shoe plate
."--------~r
II
roll changer
II I fix
rails
J
assemble spindle
drive side work side Place

•
Place
erect install delivery Mill
rails rails cross brake-roll entry anti-crimping sel
assemble tension roll & entry, delivery valve stand
meIer & delivery tension motor & guide
guide roller roller
Fix
Mill
work & backup roll
piping
around machinery
inter connecting pipe
piping
around machine &
inler connecting pipe
fix
electric device &
sensors
flushing
no load assemble rolls

test
load test
P7-23
11110620-2002072-WP002
7.3 Installation procedure of skinpass mill
7.3.1 Installation of shoe plate
(a) Install the shoe plates with the elevation marks and center marks
embedded on the foundation as specified in this instruction.
(b) Check the size of liners when they are set, and put them by applying
pads to both sides of foundation bolts. After half hardened the pads
their level and height to be adjusted.
(see Fig. 1.2-1)
(c) Place the delivery side shoe plate and entry side shoe plate on the liners
and roughly set them in position shown in the drawing.
(d) Mark the center line and pass direction on the top surfaces of both shoe
plates.
(see Fig. 1.2-2)
Precision level
Base liner for "Y" level

Scale installation Scale
F.L /
Elevation mark
Pad
Adjustment of Base Liner
Fig. 1.2-1
P7-24
11110620~2002072-WP002
(e) Stretch the piano wire above pass center line and mill center line and
suspend plumb bobs from the piano wires.
(I) Adjust the shoe plate center line to tips of plumb bobs suspend from the
piano wire.
Measure and adjust the height and level of the shoe plate with "Y" level,
precision level and scale in combination.
(g) As shown Fig. 1.2-3, 4, measure "8" dimension from mill center and
adjust the position of delivery shoe plate by the dimension specified in
this instruction.
(h) As shown Fig. 1.2-3, 4, stretch the piano wire above mill center.
Measure work side "8" dimension and drive side "8" and adjust
parallelism of the shoe plate in respect to mill center.
(i) After finish installation of the delivery side shoe plate as datum-side, the
entry side shoe plate is to be installed.
OJ To facilitate erection of mill housing onto the shoe plates, make the
distance between shoe plate 0.3 mm to 0.5 mm larger than the distance
across the legs of housings.
(k) Measure and adjust the above distance by using a thickness gauge of
0.3 mm to 0.5 mm in addition to pitch gauge or inside micrometer.
(I) Measure and adjust height and level of the entry and delivery side shoe
plates with "Y" level, straight edge, precision level and scale in
combination.
(m) For correcting the plumbness of mill window, relative height of both shoe
plates shall be readjusted, if necessary.
, 9k P7-25
11110620-2002072-WP002
Material flow
Pass center
Piano \\'ire
Plumb
bob
Precision
level
Scale
o
Y-leyel
e Shoe plate
",6"
S\n.igh\
F.L
center eo g-e
mark Inside \
micrometer
Bcen1e.:- Datun shoe plate

mark
Fig. 1.2-2
299 P7-26
11110620-2002072-WP002
Measuring points and/or methods
Refer to Fig. 1.2-2, 3, 4 and 5.
Measuring item Measuring point Position Tool to be used

Pass direction Center of shoe plate A Plumb bob, scale,
piano wire
Parallelism of side surface Squareness of datum shoe I Swing measuring jig
plate against pass line center (See: item 1.3 No.14:
SW-2),
Micro meter
Dial indicator
Side surface of datum shoe B Inside micrometer,
plate piano wire, plumb-bob
Side surface of opposite shoe C Pitch gauge,
plate 0 Thickness gauge,
Straight edge"
Inside micrometer
Height Top surface of shoe plate H "Y" level,
steel rule
Level Top surface of Individual E Precision level
shoe plate F
Overall G Straight edge,
Block gauge,
Precision level
Tolerance in installation accuracy
Name of
No. Measuring items Tolerance Remarks
machines
1 Shoe plate 1. Level of shoe plate (E, F) 0.05 mm/M
2. Relative height between shoe plate and :l:0.5mm
pass line (H)
3 Relative height between entry and 0.05 mm/M
delivery plates (G)
4. Parallelism of side surface of shoe plates :1:0.05 mm/M
against mill centers (B)
5. Center of shoe plate (A) :l:0.5mm
6. Side surface of datum shoe plate (B) :l:0.5mm
7. Side surface of opposite shoe plate (C, :l:0.5mm

D)
.300 P7-27
11110620-2002072-WP002
Straight edge
D
B
)
Pass direction
<
-.E[r.-.-._.-.-.- !
------00-
G
B
( )
D
Datum shoe plate
"c:
.8
<Jl
(j) : Center mark
~
H :Precision level
Elevation mark
~
Pass line center
'[
H H
Piano wire
, Fig. 1.2-3 Example of skin pass mill
jo/
P7-28
11110620-2002072-WP002
4- AbbreV'iadon
-e-
drive sid. I Center
!.... e'"e I
mark
Entry side p "s s

Delivery side
. E.ntry s..ide
o• -.:./
I
dcli"'ery side
straightedge
squareness E.F o shoe plo[c

B
"ork side
F.L
1' ':.~.~'
H ~
"Po .;.':'
B ,---,---- .:":,:
.. ,, ele.2lion
::,' mark
"
I ..
. .... :,:.:~:,'
... :,::. ',' ',.:.': /:;:;', :.... ',
"
',.
; '. . rn..•,----- plumb bol:>
----
..•...:~:
", ., '1"1.' '"'I
Fig. 1.2.4
Fig. 1.2.5 Measurement of leveling accuracy of both shoe plates
P7.29
11110620-2002072-WP002
7.3.2 Standing procedure of mill housings onto shoe plates
1. Transportation of mill housing into mill yard

1-1)Mill housing weight with project block
• (a)Work side mill housing -------17 tons (Including Project Blocks and others)
(b)Orive side mill housing -------17 tons (Including Project Blocks and others)
1-2)Transportation route of the mill housings from a entrance of factory to the mill yard
should be planed in advance by checking (1) Road load resistance for the trailer and
the mill housing, (2) Road corner radius, (3) Road width and height of obstacles, (4)
slop and others.
2. Unpacking and temporary store place
2-1)lt is recommendable that unpacking and cleaning two mill housings are temporarily
stored at front of skinpass mill area.
2-2)Unpack the covers such as polystyrene sheets, thin steel plates and wooden plates for
transportation on the mill housings.
2-3)Remove antirust oil and clean all the surfaces of the mill housings with kerosene, at this time be
careful of fires.
2-4 )Check damage on all the surfaces of mill housings during transportation. Then all the
housings should be protected with thin oil from rusting during the installation.
3 Building up mill housing for OS-Housing
3-1)Put eight pieces of the protectors for the sling wires should be mounted onto the top
and bottom parts of NO.1 OS-HS and put the sling wires to the NO.1 OS-HS as
shown in Fig 2. 2-1
Protect
Pass Center
Pass center.- . -. __ .- -._._._.
~~~
I
I
Fig. 2.2 - 1
P7-30
11110620-2002072-WP002
3-2)Then bring the housing to the mill center and above the housing shoes by using over
head crane and keep it at height about 1 m from the shoes, then check the housing
legs and the shoe surfaces whether there are burrs, shaves, flaws or not and clean
them. Coat thin turbine oil onto the areas of the shoes contacted with the housing legs.
3-3)Gradually and slowly hang it down onto the shoes aligning the center between the
shoes. Before just touching with the shoes, about 150 mm height from the shoes to the
legs, stop hanging it down at a moment, center it to the housing shoes, also check
divided dimension from pass center to the housing center and stop swing motion of the
housing, then slowly down it onto the shoes. Do not give big shocks to the shoes by
the housing, quietly & slow down, in order to preventing the movement of the shoes
from the shocks.
3-4)Finally settle the OS-HS in the drawing position by pushing it with oil jacks (5 tons' 2
pieces.) toward WS or OS and toward delivery side. Then check the no gaps between
the side surfaces of the entry shoe and the housing leg, then measure dimension from
pass center to housing center.
3-5)Tighten up foundation bolts M 72 with a shock spanner and a hammer, then take off the
sling wire from the top of the housing using temporary scaffold. In this case, be careful
not drop the protections and the sling wires.
4 Building up mill housing for WS housing

4-1 )Put down the WS-HS on the shoes at about 3 mm wider from the pass center.
4-2)Mount the inner rails for the back up roll and the top separator for the housings between
WS and OS housings, then tighten the rails and the top separator to the drive side
housing first. At this stage, scaffolds should be assembled around the mill housings.
4-3)Push WS housing to OS until completely touching with back up rails and push it to entry
side until contacting with the side surface of the entry shoe. Tighten up all the bolts for
the inner rails for the back up roll and the top separator to WS housing. And also tighten
the foundation bolts M72 and the nuts with a shock spanner and a hammer.
4-4)Extend a piano wire at pass center. Measure and confirm the divided dimensions
between the piano wire and the inside surfaces of the both mill housings with a straight
ruler. Their difference should be within :to.5 mm. If not within allowance, the housing
should be readjusted.
4-5)Tighten up all the foundation bolts M72 & M55 with about 50 to 70 percents of designed
torque with a shock spanner and a hammer. The final tightening of foundation bolts by
designated torque should be carried out by using hydraulic wrench and so on after
completion of below Items 9.3.3 measuring and grouting all the housing shoes.
P7-3l
11110620-2002072-WP002
4-6)Recheck the gaps between the side surfaces of the entry shoe and the housing leg
and the divided dimension mentioned above Item 4-4) if within the tolerance.
P7-32
11110620-2002072-WP002
7.3.3 Installation of mill housing
(1)Installation procedure of mill housing
(a)Generally, install the drive side housing first.
(b) When installing the housings onto the shoe plate, it is necessary to
move the housings to the specified positions on the shoe plate.
Therefore, clean and recondition the contacting surfaces of housings so
that there will be no burr and no flaw.
(c) Apply turbine oil to the contacting surface in order to prevent galling
which might be caused when moving the housing on the shoe plate.
(d) When the drive side housing is moved to the specified position, make
the side surface of housing leg closely contact to the side surface of the
delivery side shoe plate.
(e) Move the housing by using screw jacks.
(f) When the above work is completed, tighten temporarily the housing to
the shoe plate with the tightening bolts.
(g) Install the work side housing. The installation procedure is the same
way as applied to the drive side housing.
(h) To facilitate assembly of top separator into the space between the
housings, make temporary set the work side housing.
(i) Temporarily set the work side housing to the position, 1 mm to 2 mm
larger than the distance from drive side housing, then make the side
surface of housing leg closely contact to the side surface of the delivery
side shoe plate.
Ul Mount the separator in its place.
(k) Moving the work side housing to the specified position by using screw
jacks.
Tighten the inner rails for back up roll and top separator with the
tightening bolts.
P7-33
11110620-2002072-WP002
(I) Check again that the side surface of housing leg is closely contact with
the side surface of the delivery side shoe plate.
(m) Tighten the housing to the shoe plate with the tightening bolts.
(2) Summary of measuring procedure and items
Posi- Tool to be
No. Measuring item Measuring point Remarks
tion used
1 Stability of housing ieg Housing leg surface and A Thickness

and hoe plate. top surface of shoe gauge
plate
2 Contactness of side Side surface of housing B Thickness

surface of housing leg leg and side surface of gauge
shoe plate
3 Level of housing (1 ) Bottom surface of C Straightedge

housing window Precision
(2) Inclination of both level
bottom surfaces
4 Plumbness of housing Housing window D Piano wire When it is

window surfaces surfaces on datum side Inside necessary to
(delivery side) micrometer plumbness,
readjust the
shoe plate.
5 Straightness of both Housing window E Piano wire

housing window surfaces on datum side Inside
surfaces (delivery side) micrometer
6 Parallelism of each stand measured on datum G Piano wire

project block surface Inside
micrometer
Swing jig
7 Discrepancy between Inside surface of F Piano wire

pass center and inside housings Steel rule
surface of housings (Guide mounting
surfaces)
NOTE Refer to Fig. 1.4-1 attached to next page.
P7-34
Jlll0620-20Q2072-WP002
A E B A
/
E
P:lSS
~
I '8 S/ 1J\ LL
Deli ....er).
sId.
I
-@)
, A
A
I ./
B B
A
'--r
LL
I
!:nt:ry side
.....•. E
I B B.I' ;
, A A
datum side
(Delivery side) /'
/' -W.-
p i.ano
wire
't'
(A)
housing
piano wire
Piano wire of
pass line center
,D
, pass
Swing )lg for measure
S:2.S~ ________ . of each stand parallelism
line
C
Datum project
shoe plate
dZlum side
(Delivery side)
(8)
Fig. 1.4-1
P7-35
11110620-2002072-WP002
(3) Details of measuring procedure and measuring items
(a) Using thickness gauges, measure and check the stability between the
housing leg surfaces and top surfaces of shoe plate.
("A" and "8" in Fig. 1.4-1 (A»
(b) Measure and check the level of bottom surface of mill window.
(UC" Fig. 1.4-1 (8»
Applying the straight edge to the bottom surface of mill windows.
Measure and check the level of each housing with precision level placed
on the straight edge in the mill center direction.
(c) Measure and check the stand parallelism by using swing jig (see: -item
1.3 No. 14 : SW-2). Set swing jig on the datum project block surface at
the height of pass line. ("G" Fig. 1.4-1 (8»
If the parallelism could not got within allowable value, rectify it by moving
the datum shoe plate with the housing.
(d) Measure and check the straightness of housing window surfaces.
Stretch a piano wire from work side to drive side exactly above the mill
center line at about the same height of pass line shown in Fig. 1.4-2 and
measure the straightness using an inside micrometer as follows.
(i) As shown in Fig. 1.4-2 stretch the piano wire exactly above the mill
center line.
(ii) Check the straightness of window surfaces by measuring the
distance between the piano wire and window surface at the
positions of P, Q, Rand S using the following equations.
(iii) Equations for straightness and parallelism of housing window
surfaces.
T=IP~QI
u IR~81
=
).9 P7-36
11110620-2002072-WP002
P + (R + S + W)
Q_
v= 2 2
L
W Constant value = (window width difference between W.S and D.S shown
in the drawing) x ~
(iv) After measuring the value at "P", "Q", "R" and "S", make sure that
the differences of them are kept in the allowance specified and
indicated in the drawings.
wor}~ side drive side
~Iill center line
Fig. 1.4-2
(e) Measure and check the plumbness of housing window surfaces
(i) Measure the plumbness of housing window surfaces on the datum
side, which is delivery side.
(ii) As shown in Fig. 1.4-1 (B), suspend a piano wire at an arbitrary
distance from the housing window surface and measure the
distance between window surface and the piano wire with an inside
micrometer ("0" in Fig. 1.4-1 (B))
(iii) When the plumbness of window surface exceeds the tolerance,
adjust the plumbness by adjusting the installation taper liners
inserted under the bottom surface of shoe plate.
P7-37
310
11110620-2002072-WP002
(f) Measure and check the discrepancy of center lines between pass center
and inside surface of housings ("F" in Fig. 1.4-1 (Al) with tape roles.
(4) Tolerance in installation accuracy
No. Name of machines Measuring items Tolerance Remarks

1 Mill housing 1. Stability of housing leg (A) more than 80% of
total contact area
2. Contactness of side (Delivery side/Datum
surface of housing leg (B) side)
Thinner than 0.04mm
thickness gauge
(Entry side)
0.3~0.5 mm
3. Level of housing (C) :1:0.1 mm/M
4. Plumbness of housing :1:0.1 mm/M
window surface (D)
5. Straightness of both V;:;;; 0.1 mm/M
housing window surfaces
(E)
6. Parallelism of housing T, U ;:;;;0.2 mm/M
window (E)
7. Discrepancy between pass :l:0.5mm
center and inside surface
of housings (F)
P7-38
]//
11110620-2002072~WP002
7.3.4 Assembling the devices/parts around mill housing
(1) Hydraulic main cylinder
(a) Clean and check bottom surface of mill windows, then mend burr or flaw,
if any.
(b) Place main jacks to its place.
(c) Take care for invading of any foreign matter into the hydraulic pipes.
(2) Upper Back up roll balance
(a) Take care safety of workers, due to the assembling work at high place.
(b) Assemble bracket(inciude cylinder)and top arm,
Then assemble main carrier beam
(c) Suspend crane wire from the crane positioned above the mill housings,
then lift it up carefully to the place to be composed.
(d) After tightened the assemblies to the position, attach the brackets which
were already attached by the hydraulic cylinders.
(e) Finally connect hydraulic cylinders and wedges.
(3) Inner rail
(a) Assemble the inner rails. Care for slipping of crane wire when lift them
up .
P7-39
11110620-2002072-WP002
Shoe plate installation record
Work side
Pass
<~-
[ Datumshoe~ Drive side
_I _I Piano wire (Pass center Line)

er !Sl
FL-60
Mill center
Unit : mm
[:=J : designed
j/.3
P7-40
11110620-2002072-WP002
Mill housing installation record
Unit: mm
u
lI)
lI)
co
CL
W.S
(
I I )
I I D.S
housing housing
Piano wire
I Mill ce nter
I I
I I I
II I
0 1
(
Q)'"
)
0
~
.~
0
c
co
i:i:
P7-41
11110620-2002072-WP002
Mill Housing of inspection record
1. Plumbness of housing window surface Tolerance: 0.10 mm/M
measure measure
W.S ( ) D.S ( )
distance distance
.:4> center center
between between
top 1 £,
L
B.R 2
bottom 3 £,
B.R 4
Plumbness. M
L= M
straightness of L distance between

2. Straightness of both housing window surface
straighness of each
(
L=
l-
A B C D ~ I, ~ .s
f- f- - top
BUR-CK
I I top
BUR-CK
ws D.S tolerance
straightness of each 0.2/M ;:; A - Band C - D

1 ( 1 ) 1 £, £,
A B C D
I(A;B)_(C+D)
L, distance between 0.1/M;:; L 2
3, Plumbness of housing side surface Tolerance: 0,15 mm/M
WS
h,
~ Entry Delivery
~ 2
h,l 1
~ 3
h,l 2
3
Plumbness h, + h, =
4. Bottom surface (Each and both level : WS~DS)

•
tolerance
Pass direction 0.10 mm/M
Mill center
direction 0.20 mm/M
P7-42
11110620-2002072-WP002
(4) Entry side
(a) Anti-crimping roll
Assemble anti crimping roll and its hydraulic cylinders, brackets, arms
and pedestals etc, to the places, directed by the drawing.
(Examine accuracy of the roller Level paralletion, height)
(b) Deflector rollers
Assemble deflector roll, brackets frame and etc, to the place, directed
by the drawing (Examine accuracy of roller and housing level
parallelioin height).
(5) Delivery side
(a) Bottom IMR
Assemble polisher and its hydraulic cylinder, brackets guide and drive
systems etc. to the places directed by the drawing.
(b) Tension meter rollers
Assemble tension meter roll and its hydraulic cylinder, brackets frame
and Loadcell etc, to the place, directed by the drawing. (after complete
assembling work, check levelness and parallelism of the roller)
(c) Top IMR
Assemble polisher and its hydraulic cylinder, brackets guide and drive
systems to the place directed by the drawing. (after complete
assembling work, check levelness and parallelism of the roller)
P7-43
11110620-2002072-WP002
Anti crimping roll Mill entry side
Measuring
No. Measuring item Tools to be used Tolerance
point
1 Relative height to pass line A Y-Level to.5 mm

Steel rule
2 Roller position to the B Straight edge to.5 mm

center Steel ruler
3 Level of roller C Precision level to.05 mm/M
4 Parallelism of roller to 0 Straight edge to.05 mm/M

housing window surface Inside micrometer
Roll center
I
~D~ ~~~~ ['~
I B
~+----
Pass center
Steel ruler
Pass line_~"
'-
b
.
1-
Inside micrometir
r \
A
K
Y. Level
P7-44
3/7
11110620-2002072-WP002
Deflector roll Mill entry side
Measuring
point
1 Relative height to pass line A Y-Level :l:0.5mm

Steel rule
2 Roller position to the B Straight edge :1:0.5mm

center Steel ruler
3 Level of roller C Precision level :1:0.05mm/M
4 Parallelism of roller to D Straight edge :1:0,05mm/M

Dial indicator
Pass direction Pass direction
I
D.S
'roiect block '-I 0 0 -I I VV.S
Proi,ct block
D.S
Proiect block I
I
Roll center
1
1
ws
I Proiect block
'-'-'-'-1 ._._._._.
-+--c~tRoll
Precision 1
-,- 1 B
Pass center
Micrometer or
indicator
Steel ruler
Y. Level
A.
Straight edge
Pass line
P7-45
5/8'
Deflector .wringer roll Delivery side
Measuring
point
1 Relative height to pass line A Y-Level :!:0.5mm

Steel rule
2 Roller position to the B Straight edge :!:0.5mm

center Steel ruler
3 Level of roller C Precision level :!:0.05 mm/M
4 Parallelism of roller to D Straight edge :!:0.05 mm/M

Pass direction
D.S
-1-- Project block
D Pass line
L---
_._-.-- _.- Roll
Precision level
Pass center
D D
1
1
1
1 B
-j"
Roll center
Steel ruler
Y. Level
\ A
Micrometer or
indicator
D
! Pass line
• Straight edge
P7-46
11110620-2002072-WP002
Mill tension meter roll and wringer lanti-crimping roll Installation record
I
I
I
--l--
I
L
I
I
Parallelism of roller
-
Anti-crimping roll
_._.-._'-'-'-'-'
ascent condition
of roll
W.S
'housirig l-v
.
--l...-
;
I
-vI
Mill cen ter
_._.-._._._._._.4._._._._._._._._._.
D.S
housing b" ,
OJ
c
Straight edge
I Ul
Ul
ell
I
I D.
= I
I
L 0
~ .,
,
s-
I
I
I
I
I I
I ~
Level of roller and /:

Top surface of height .~
o
C
ell
c::
P7-47
J~O
11110620-2002072-¥fP002
9.3.5 Mill piping
These are including skin pass hydraulic oil piping, air piping, grease piping and around
mill stand.
:
Attach these to the places, shown by the drawings.
General performance, attention and clamping method etc. are written in chapter III, in
this manual. 80, refer it when they are assembled.
P7-48
)1/
11110620-2002072-WP002
7.3.6 Roll changing device
Note Before installation of the new roll station (D.S), the mill motor and the main mill drive
shall be erected.
(a) Place the installation liners to both sides of the foundation bolts.
(b) Make pads for the liners, after half hardened the pads adjust their levelness and height
based on the elevation marks by means of "Y" level, scale, and precision level in
combination.
(See Fig. 4.1)
(c) Drive side (New roll station)
(1) Place the bases of new roll station on the liners, mentioned above, and tighten
foundation bolts, then perform alignment of the bases.
(2) Adjust the levelness and height of the bases, based on the elevation mark or pass
line (P.L), by means of the taper liners, inserted between installation liners and bases.
And confirm its installing accuracy by using precision level, "Y" level and scale.
(3) Measure the relative distance of the bases from the pass center and the mill center by
using "Y" level, scale, piano wire and plumb bobs in combination.
(4) After completion of the work, explained above, clamp the foundation bolts tightly.
(5) Next, clamp the frames which to supports the pusher car at its position, then place the
•
hydraulic cylinder, in its position.
Perform alignment of them.
P7-49
11110620-2002072-WP002
Scale
"Y" level
Precision level straight ed ge
'p
rail
Plumb bob
Fig. 4.1
P7-50
11110620-2002072-WP002
(6) After that, confirm their erection accuracy are kept in the installing tolerance.
The inspection steps and instruments to be used, are the same to those explained
above.
(7) Finally, assemble pusher, piping and attach electric instruments to the places, shown
in the drawings.
(8) Perform spot welding to the liners and the taper liners, inserted between the base
liners and the bases.
Also welding the others such as stoppers which preventing loosening of nuts, etc.
(d) Work side
(1) Place rails and bases of the carriage and the changing car on the embed plate and
fasten the clamping bolts roughly, then perform alignment of the rails by means of
piano wire, plumb bob, scale, precision level and "Y" level in combination.
(2) Adjust the levelness and height of rails based on the elevation mark or pass line (P.L),
by means of the adjusting liners, inserted between the seats and rails.
And confirm its accuracy by using precision level, "Y" level, scale and plumb bob, etc.
(3) Measure the relation distance of the rails from the pass center and the mill center by
means of "Y" level, scale, piano wire and plumb bobs in combination.
(4) Place the base of the damper bracket on the embed plate and perform their alignment.
After that mount the damper bracket on them.
Finally to inspect its erection accuracy.
P7-51
11110620-2002072-WP002
(f) Tolerance in installation accuracy of roll changing device
Measuring
Measuring item Tools to be used Tolerance
point
1 Relative height pass line A Y-Level :to.50 mm/M

Steel roller
Scale
2 Relative distance pass B Steel ruler :to. 50 mm/M

center
3 Discrepancy between mill C Steel ruler :to. 50 mm/M

center and rail interval Piano wire
Plumb bob
4 Level of rail D Y-Level :to.10 mm/M

(1) Pass direction Steel ruler :to.20 mm/M
(2) Mill center direction Precision level
P7-53
t • •
~
(1) Unit:mm
II I I
Pass center line
G- . __ ...
,
I I ';cl_1
_~J__, ---.
:l
.1_._-_._._. Mill ccnter line
i L.
:r~
-'-fj
,! i i-,
. l..;_1 :---,
!
ell_I
j
---
?----S;cl rullcr y- level
--"
I_I A
I_I AI_IAIII_IA 7K o
Ol
f'\)
o
{~Jl~.:C:J.~'--"::=":::::::-=-=--:::::::::'--:'_-- I
f'\)
o
~ o
f'\)
o
-..I
Mill pass line f'\)
I
::E
-0
o
i=f~'.=.~=::.-=-)- ,=~!:.=).'< o
f'\)
1 , I', I
'1,Ll,J.-h-"- .- 'f
nrr - I ; iii iIi
1'7-54
tv
'"
~ • •
(2) Roll changing work side (installation method, record) Unit:mm
Precision level
Pass center line :'-'j'-"-!
iii
: rt,O:
Lj! ,I
._j o cl_1 c
,i , I _j' ..
'I'"
.J;L..
_~l ,'I'"..
_ ..].1 ...ill:r:--'----
I_I
1
r~, , __ " __ -•.... "

" • _.,.J~
'j'"
: 1 :
! "'1
'-"-',
"
,
I
'.
L
'I
r-
'0, ,I
j
cl_1
I .
L.. .. _.!_ .. 'Ij... :
.--_. _ ... .1i ... - J
Steel ruler
Y. Level
B
;4 _ "
......~..'1-'_._.~~;;;~~~-1;;1;'
-_ _._ ~-
11
o
I==I~I_I 0)
N
o
c c I
4 N
1 Ti o
o
N
o
-.J
N
;if---,-{ 1~'1 I
I!! :',
: '•....
II
_----~------
/~
~
"U
,: ,i~ o
o
MiJl center line J
I'?
''J
1'7-55
11110620-2002072-WP002
7.3.7 Main mill drive and mill motor
(a) Set the installation liners to both sides of the foundation bolts, and make pads for them.
(b) After half hardened the pads, adjust their levelness and height based on the elevation
mark by means of "Y" level, scale and precision level in combination.
(See Fig. 4.2)
(c) After hardened the pads completely, mount the casing on them.
(1) Adjust levelness of the casing
Place the precision level on the top surface of bottom casing and adjust the levelness
by means of the taper liners, inserted between bottom of casing and the installation
liners.
(2) Adjust height of the casing
Measure height of the bottom casing top surface with "Y" level, based on the
elevation mark or pass line (P.L).
If necessary adjust the height with the taper liners, explained above.
(3) Adjust through center of the casing
Stretch a piano wire above the mill center and hang down plumb bobs from the piano
wire.
Then let match the output shaft center to the tips of plumb bolts, mentioned above.
(4) Adjust relative distance of the main mill drive.
• Measure the distance from pass center to main mill drive by tape measure and adjust
to the distance, indicated in the drawings.

11110620-2002072-YiP002
(5) Confirm that its installation exactness is kept in the allowance, fasten the foundation
bolts stiffly.
(6) Examine the backlash and tooth bearing of gears from its inside checking windows.
(7) Also confirm that there are no forein matters and unusual phenomenon in the casing.
(8) Perform spot welding to the installation liners and taper liners.
(9) Finally attach piping and electric instruments to the places, shown in the drawings.
And fix the spindle coupling.
(10) Mill motor
The centering of mill motor is performed by using couplings, mounted on the input shaft
of main mill drive and motor shaft in accordance with Electrical supplier's instruction.
P7-57
]]0
•...
--
l.v ~
Measuring points and tolerance installation accuracy, record
I Entry I
I Delivery I
Measuring points Position Tools to be used Tolerance
(1) Level of casing A Precision level :to.10 mm/M
(2) Alignment of gear shaft center B Steel ruler :to.5mm

through the mill center Piano wire H
Plum bob
(3) Tooth contact area Red lead outside More than

Pass line
micrometer 60 percent
-i-
As same percentage _.+s
as work shop
i
inspection i
••
(4) Dimension from pass center C Piano wire 0~+1.0mm •
line to machine center Plum bob
Steel tape I!I 0)
"tl
(5) Specified height of bottom H Y. Level :to.5 mm o
casing Steel ruler
~ & :11
Unit:mm
Fig. 4-2
1'7-58
1111062 0- 20 02072-WP002
Pass center line

Casing(level seat)
Top A
Bottom
I
-='
Top
B
B I Bottom
I
Plano
. wire mill center
::: ====:li ----
-----""
i i C
I Bottom
Dnve
. Side Housing
Fig. 4-3
P7-59
11110620-2002072-WP002
7.3.8 Oil cellar equipment
(a) Scope
• This procedure specifies the installation procedure for the oil cellar equipment, such as
pumps, valve stands, tanks and accumulator stand.
(b) Alignment of the oil cellar equipment
(1) In case that the equipment are an unit type such as the pump unit and the main pipe
is of rather small sized bore.
Check that the center of the foundation bolt hole of the common bed, shall be
matched to the bolt hole center.
(2) Incase of manufacturing the prefabricate pipings at the site, the center line of the max.
dia. pipe and the flange face shall be made as shown in the drawing, in principle, on
basis of line center, and center line, across line center at right angle and elevation
marks.
(3) Centering of the coupling of each pump shall be executed again to check whether
eccentricity, due to pipings has occurred or not after the piping work is finished.
After fixing its coupling centering, drill and reams dowel pin to pump and moter.
(4) Installation accuracy
Position: :t2.0mm, Horizontality: O.2mm/m, Height: :t2.0mm
PHD
11110620-2002072-WP002
(c) Tank
(1) The erection liners shall be arranged so as to touch the under part of web on the tank
bottom.
• (at intervals of about 600 mm)
(2) Since the tank is of tightly closed and rust preventive type, attention must be paid so
that it shall not be opened during installation.
(3) As the tank is necessary to open in case of fitting the internals and the accessories,
the same oil as the filling oil shall be coated over the inside of tank in this case.
Further, they may be assembled and fitted immediately before filling up oil depending
on an atmosphere of the cellar.
(4) After the tank is installed, the float suction, oil gauge and heater shall be assembled
into the tank and the thermometer, ladder and instrument detecting ends (heater, oil
level) shall be fitted.
(5) Installation accuracy
Position: :t2.0mm, Horizontality: 0.2mmfm, Height: :t2.0mm
~6~~
_.- . 1=
fF+ I
Illl
' , I
I
I'--L-----
,. ~1" • l
2 --------_....I-J
P7-61
11110620-2002072-WP002
(d) Accumulator and valve stand
(1) Precaution on installation
The inside of machinery, mentioned above, shall be flushed only final stage of
• secondary flushing, not flush at primary stage.
'- •. - ------_____ _.J....J
P7-62
'" •
Equipment name
7.4 Ilnstallation Procedure for major equipment Tension leveUer Proper
1. Installation order
(1) Install screw jack ....•housing assembly ....•pass-line roU •...•screw jack drive •...•
:i~
F
unit changing rail •...•dust proof cover.
2. Installation procedure '"

(1) line center shalt be checked by measuring the distance between the piano wire of
line center and the center of leveller housing. Pass center line
(2) Right angled line center shall be checked by measuring the housing center marking
Pass line
which were marked OS and W$ housing.
(3) Right angled of roU shall be checked entry pass roll by swing jig.
c=) ';-~e~~
..itBD
(4) levelness and height shall be adjusted on the housing pass-line marking by Y-Ievel.
Scale
(5) Final check of horizontality shall be measured entry and delivery bottom rail by
precision level.
3. Installation accuracy
Precision
.-?'y Lev$1
F1W,S
F2D,S
Measurinl item Target
Measurinl point Positio Measureing method
accuracy
Mill housing marking A1 Piano .•••
ire,Plumb bob. t
line center Visually"O"
Screw jack A2 Ruler TIL Center line
Millhousing center
Position marking 61,62 Visualty"O" Piano .•••
ire,Plumb bob,
Sere .•••jack ::t:O.5mm Ruler
~ ~
Right angled M.UhGusinJcenter rnarlIinJ 51 Piano wire.S .•••
ing jig, D,S W,S ~
Entry pu.l"'e rull O.05mm/M
52 Inside micrometer
MIll housing level H1 :!: m
Hei&ht marking H2
::t:02mm
:to.5mm
Y-Ievel, Ruler o
H3 CT>
Housing out side surfaee{maehine)
!')
levelness Upper surface of rail Fl.2,3 O.05mm/M Precision level
o
4. Recod unit:mm I
I')
Measurinlt item Measurinlt point Positior Drowing measure recod
Pass line roll
o
Line center
Mill housing markine A1
1045
o
Screw iack A2 N
o
Position
M,IIhousinc center
markinll
B1
,B2 565
Precision Level
.....•
Right anlled
sere .•••jack
MoIlIou.inJcenter merl<inJ 51
O.05mm/M
'"~
I
Entry Pe" line ron 52
v
Height
Mill housing level
marking
H1
H2 175 to pua line
o
H3 o
Pass center line !')
Levelneu Upper surface of rail Fl,2,3 O,05mm/M
P7-63
~
• •
Item Equipment name

7.5 Ilnstallation Procedure for m<ijor equipment Tension leveller Changing Device
1. Installation order
(1) Install and centering of rail.

B4
(2) Setting of unit changing device assembly.
(3) Fit accessories.

B6 B8
2. Installation procedure
B5 B7
(I) Car rail of datum rail shall be installed parallel to the line center of levelling mill and
opposite rair shall be installed by rail gauge on the datum of datum rail.
• ~, B3
(Z) Line center shall be checked by measuring the distance between rail end and piano ~
wire of WS housing center. 4 Recod (Rail width) Unit:mm
(3) Levelness and height shall be checked on the upper surface of rail by Y-Ievel. Measureing item Measureing point Point Drawing measure recod
61
3. Installation accuracy 700.5
63
Meuureing item Installation 62
Measureing point Point Measureing tool Right-angled 555,5
allowance Rail center 6'
line center
A1 Piano wire,Plumb bob. Rail center 65
Line center Rail end Visually~O~ Position
A2 Ruler 66
350
Right-angled
67
Rail center 81.82 PllnO wire'plumb bob. 68
line center Visually~O~
Rail center 83,84 Ruler
Position
Heiiht Upper lurfaee of rlil Hl,H2 ::t:O.5mm

Upper surflce of rail Y-level, Ruler
Levelness Hl,H2 O,lmmiM
1 H2Delivery I 1 H4Deliverv I
~
I HIE""" I I H3En"" I
5 Recod (Rail herghtJine center)
Measureing item Measureing point

Unit:mm ,',..,
.r,p._ .._ .._. .J -
o
."
Point Drawing measure recod
H1
-.:.:. ~-----._-~
----------
N
H2
H3 o
Heiiht Upper surface of rail H' I
Levelness Upper surface of rail 350
H5 N
H6
H7
o
H8 o
Al N
line center Rail end
A2
5425 o
--J
N
I
::IE
"'0
o
o
N
P7-64
•

Instruction Manual On Erection For No.2 CGL

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Instruction Manual On Erection For No.2 CGL

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i1:Jct SUNSCO »I1

rJiSf,]; NO.2 CGL

Instruction Manual on Erection for NO.2CGL

\"\II \>-Cl-l\ METALS M4C,7,i

No.2 CONTINUOUS GALVANIZING LINE

SPECIFICATION No. 01100620-2002001-CS001

HITACHI ENGINEERING & SERVICES CO.LTD

Chapter 2. Bench mark and Center mark

Chapter 3. The Standard Procedure of Equipment

Chapter 4. The Standard Procedure of Piping

Chapter 5. Instal/ation Accuracy and Measuring Procedure

, Chapter 6. Detailed Instal/ation Procedure

6.5 Spm & Tension Leveller Section 6-34

1.1 General description

Continuous Galvanizing Line (CGL).

are not included in this manual.

1) Basic concept on erection

2) Installation sequence and precations

3) Required special jigs for installation

4) Installation target accuracy

This manual has been prepared incorporating Mitsubishi-Hitach's past experience on

the erection work.

4.1.1 Entry section

4.1.1.1 2229001 NO.1 Entry Coil Skid (Cradle roll included)

4.1.2 Pre Treatment Section

4.1.2.1 Degreasing Equipment

4.1.3 Furnace section

4.1.4 2181000 Coating Pot Section

4.1.5 Air Wiping Section (Air knife maker supply)

4.1.6 After Pot Cooling Section (Furnace maker Supply)

4.1.7.1 2232103 No.3 Tension Bridle roll

4.1.8 Post treatment section

4.1.8.1 2284901 After Treatment Unit (Spray Type)

Chapter 2. BENCH MARK & CENTER MARK

IfJ'CI I" Cli i

'" NO.2 PAY OFF REEL ~o'

NO.1 TENSION BRIDLE ROLL

2375 2 4800 2075l5nJ 4425 ,

NO.2 DEFLECTOR ROLL r---- 1-----, '\ -- ,,

NO.4 TOP ROLL

-. NO.1 EXIT STRIP GUIDE TABLE .Q:..~1'iI

NO.2 TENSION REEL & BELT \\\RAPPER

AflER AOJJSTING LEVEL

.. ".. . .... " .~

THE STANDARD PROCEDURE OF EQUIPMENT

No. Procedure Remarks

1 Foundation and building work This standard shall not apply

2 Announcement of the completion of

3 Organization of foundation inspection

4 Foundation inspection and centering

6 Setting of liners for installation

7 Temporary installation of main The main equipments mean such

8 Temporary centering of main

9 Grouting of anchor bolt holes Grouting is not necessary when

10 Curing of grout applied to bolt holes

11 Centering of main equipments

12 Inspection of centering of main

14 Inspection of centering of auxiliary The auxiliary equipments mean such

15 Grouting under the base of main

16 Curing of grout applied under the

3.2.1. Announcement of the completion of foundation work

(1) Confirmation of the completion of foundation work