November 2002

Ladle turretInstructions for delivery and inspection

SN 926

1 Field of application and purpose

The basis for manufacture and inspection are the Manufacturing Instructions SN 200, but these specify only general minimumrequirements. The manufacture of highly stressed components, however, makes special requirements on the suitability forwelding, ductility and resistance to brittle fracture.The specification for delivery and services applies to the manufacture and inspection of welded ladle turrets for continuouscasting and converter equipment. The instructions for delivery and inspection specify the acceptance-relevant requirementsand conditions for the material procurement, manufacture, assembly/installation and inspection of a ladle turret.

2 Material

2.1 General

The material used must always be weldable material in conformity with valid DIN EN standards. The use of equivalentmaterials specified in other standards (e.g. ASTM, BS, JIS, GB-China) is allowed only upon approval by SMS Demag. Allmaterials must be identified/plate-stamped in such a way that tracing back is possible. All materials used must be certified byan inspection document as in 3.1.B of DIN EN 10204.Material certificates must be submitted to SMS Demag for approval prior to the processing of the material.

2.2 Standard materials S235J2G3 and S355J2G3

The material must comply with the specifications of DIN EN 10025. The plates must be supplied in normalized or anequivalent state achieved by normalizing rolling. The heat treatment state must be certified in the inspection document.

2.2.3 Additional requirements

- Use of sufficient quantities of nitrogen-fixing elements (e.g. >0.02%) in the alloy to guarantee resistance to ageing.

- The internal structure of the plates is checked with ultrasonic testing and must comply with SEL 072, class 3, for the surfaceand the edge zone.

- The gauge deviation is subject to class A as in DIN EN 10029.- The plates made of the materials S235J2G3 and S355J2G3 marked in the drawing/bill of materials must meet therequirements for improved deformation properties perpendicular to the product surface as in DIN EN 10164, quality level Z15.Important: If this requirement/recommendation has not been taken into account in the order, the plates with improved throughthickness properties must be checked for absence of defects (lamellar tearing) in the seam areas after welding using anappropriate non-destructive testing method (e.g. ultrasonic testing)

3 Welding

3.1 Filler metals

The filler metals must have been tested for suitability (DB/VdTV) and must meet all requirements made on the base material(e.g. strength and ductility properties). All materials used must be certified at least by a test report 2.2 as in DIN EN 10204.

3.2 Demands made on the manufacturer

The manufacturer must have proved the suitability of his equipment, processes and personnel by analogy with DIN EN 729-3.All welding work in the shop and on the site must be performed and supervised (welding supervision as in DIN EN 719) onlyby qualified personnel (welders qualification as in DIN EN 287/1418). When a comprehensive form of verification as in DIN18800 is presented, the requirements are considered fulfilled in their entirety.Welding procedure specifications (WPS) and welding procedure approval records (WPAR) as in DIN EN 288-3 must besubmitted to SMS Demag for approval before the beginning of manufacture.

Continued on pages 2 to 4

Bearbeitet: Normung/Standardisierung 2.49.00

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3.3 Specifications for welding

As a basic rule, the general recommendations for the welding of metallic materials as in DIN EN 1011 must be followed toensure proper manufacture and supervision.The requirements below must be met in addition to the manufacturing instructions of SN 200:- The preheat, interpass and preheat maintenance temperatures are measured on the basis of DIN EN ISO 13916.- The symbolic representation of the weld seams in the drawings must be made as specified in DIN EN 22553.- The weld edges must be prepared as specified in DIN EN 29692.- Rebaking of filler metals is made in conformity with the instructions given by the filler metal manufacturers. Upon rebaking,the welding rods are kept in the quiver at a temperature of 100 to 150 C.- Auxiliary welds for stiffening elements, lifting lugs etc. must be completely removed. The surfaces of the areas concernedmust be ground without notches and checked for absence of cracks with a suitable testing method.- The suitability for welding of the materials used must be checked before welding by the responsible welding supervisor.- Then the preheat temperatures are determined on the basis of the carbon equivalent (CEV = C + Mn/6 + Cr+Mo+V/5 +Ni+Cu/15), plate thickness and the welding procedure used.

4 Manufacture

The building, welding sequence and testing schedules to be drawn up by the manufacturer must be submitted to SMS Demagfor examination and approval in due time before the beginning of manufacture. Bills of materials, which may be required forplate material procurement, and the documentation required for manufacture (e.g. workshop drawings) must be drawn up bythe supplier.The ladle turret is manufactured in the following welding assemblies (post, intermediate ring with bearing brackets, lifting arm,ladle holding unit, weighing equipment and, as optional units, cross-beam and cover lifting linkage) and associatedattachments (roller bearing slewing ring, drive, locking system, lifting cylinder, guide lever, ladders, platforms, covers,hydraulic system, grease lubrication system, pipework, cabling and, as optional equipment, lifting and slewing cylinders of thecover lifting linkage).All listed welding assemblies must be manufactured as specified in the building and welding sequence schedule.Jack rings required for handling in the workshop must be attached with full penetration weld; the rings can remain on thecomponent provided they are not in the way during operation, otherwise, they must be completely removed and the weldingspots ground free from toolmarks.The material stamp must be transferred prior to separating only by authorised qualified personnel.Hydraulic pipelines must be pickled after welding.The obtained manufacturing dimensions and surface qualities must be recorded and will be checked by SMS Demagpersonnel.

Upon final acceptance, oil fills are drained (hydraulic oil, gear oil) and the ladle is taken apart into assemblies, cleaned andcoated.

Assemblies: - Covers, ladders and platforms- Lifting cylinder- Self-contained lubricating packages- Post with gear rim, drive and locking mechanism- Turret intermediate ring with bearing brackets- Lifting arms- Guide lever- Ladle holding unit with weighing equipment- Pipework and cabling must be separated at the points provided, the pipelines must be closed at

the points of separation.

Additional assemblies if ladle is equipped with cover lifting linkage:- Cross-beam with ball turning attachment and swivelling cylinders- Lifting column with lifting cylinder- Lifting arm- Chain suspension gear- Ladle cover

All information on the intermediate and final checks to be made are specified in the SMS Demag checking schedule. Suitableinstruments for the specified inspections such as levelling instrument, spirit level 0.1 mm/m, dial, depth, pressure gauges etc.,must be made available by the manufacturer.

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5 Heat treatment after welding

Stress-relief heat treatment of the components is required only if specified on the drawing or if heat post-treatment is requiredfor reasons of manufacture (to be determined by the manufacturer).Stress-relief heat treatment after welding takes place at a temperature between 550 and 600 C. The holding time must be 2minutes for each millimeter of wall thickness (weld seam). The heating and cooling down rates must not exceed 50 Kelvin/h.The temperature must be monitored with thermocouples and documented.

6 Inspection

The welds of all components must be visually inspected as specified in DIN EN 970 and DIN EN 25817, the inspections mustbe documented. Surface defects such as weld undercuts, arc strikes, welding spatter, sharp-edged scratches are notpermitted; they must be completely removed by grinding and the absence of defects proven by surface crack detection(magnetic particle or dye penetrant testing).The exact scope of non-destructive testing is specified in SN 200 (minimum requirements) and indicated in the drawing.Additional requirements for jack rings (workshop handling): 100% ultrasonic testing of the tie-in weldsThe standards to be applied for performance and evaluation are specified in SN 200.All assembly, dimensional, functional, pressure/tightness and visual checks to be made are described in a separate checkingschedule. This checking schedule is drawn up by SMS Demag und handed over to the manufacturer in due time before thebeginning of manufacture. The checking schedule signed by the manufacturer and SMS Demag is part of the documentation.All inspections must be certified by an inspection certificate as in DIN EN 10204, 3.1.B or inspection report as in 3.2.

7 Documentation

All inspection and testing documents must be plainly marked with the order number and handed over to SMS Demag with thedelivery of the equipment units.Radiographs must be stored for at least 10 years by the manufacturer and made available for review when necessary.The followig reports/records are required:

- Inspection certificates for base materials and filler metals- Heat treatment reports- Records of non-destructive visual, dye penetrant, magnetic particle, ultrasonic and X-ray testing. - Record on pressure/tightness testing- Dimension certificates- Welding instructions and building, welding sequence and inspection/testing schedules- Reports on functional testing- Reports on coating

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Applicable standards

SN 200 Manufacturing Instructions of SMS DemagDIN EN 287 Approval testing of welders, fusion weldingDIN EN 288-3 Specification and approval of welding procedures for metallic materials

Welding procedure tests for the arc welding of steelsDIN EN 719 Welding coordination; Tasks and responsibilitiesDIN EN 729-3 Quality requirements for welding; Standard quality requirementsDIN EN 970 Non-destructive examination of fusion welds; Visual examinationDIN EN 1011-1 Recommendations for welding of metallic materials General instructions for arc weldingDIN EN 1011-2 Recommendations for welding of metallic materials Arc welding of ferritic steelsDIN EN 1418 Welding personnel Approval testing of welding operators for fusion welding and resistance weld

setters for fully mechanized and automatic welding of metallic materialsDIN EN 10002-5 Tensile testing of metallic materials; method of test at elevated temperatureDIN EN 10028-2 Flat products made from steel for pressure purposes; non-alloy and alloy steels with specified elevated

temperature propertiesDIN EN 10028-3 Flat products made from steel for pressure purposes; weldable fine grain steels, normalizedDIN EN 10029 Hot rolled steel plate 3 mm thick or above; tolerances on dimension, shape and mass

DIN EN 10164 Steel products with improved deformation properties perpendicular to the surface of the productDIN EN 10204 Inspection documents for metallic productsDIN EN 10222-4 Steel forgings for pressure purposes; Weldable fine grained steels with high proof strengthDIN EN 10228-3 Non-destructive testing of steel forgings - Ultrasonic testing of ferritic or martensitic steel forgingsDIN EN 22553 Symbolic representation on drawingsDIN EN 29692 Metal-arc welding with covered electrode, gas-shielded metal-arc welding and gas welding; joint

preparations for steelDIN EN ISO 13916 Welding Guidance on the measurement of the preheat, interpass and preheat-maintenance

temperaturesSEL 072 Ultrasonically tested heavy plate; technical delivery specifications