Rules for studies and/or works related to EM34.FL.

000 /B
________________________________________
fluid supplies and specific networks in the Standard
body shop ________________________________________

Status Applicable

IMPORTANTE NOTE : This document has been translated from French. In the event of any dispute, only the
French version is referred to as the reference text and is binding on the parties

Scope This document sets out the rules for the study and creation of fluid supply networks in
Renault bodywork assembly sites.

Scope Renault Group

Issued by 65304 - Standard Process Engineering

Confidentiality Not confidential

Approved by Position held Signature Application date

J. COANT Manager, Dept. 65304 02/2007

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 EM34.FL.000 /B

Version history

Version Updated Summary of the main modifications Written by

A 12/1997 First issue D. Papin
B 02/2007 Complete overhaul of document (1) D. Papin, dept. 65304

Replaces EM34.FL.000 /A of 12/1997

Availability Internally at Renault, on the intranet; http://gdxpegi.ava.tcr.renault.fr

Outside Renault, on the Internet: www.cnomo.com
E-mail: norminfo.moyens@renault.com

Reference Regulations :
documents
International :
European : EN 10921-1, EN 12560-3, EN 1514-2, EN 1514-3, EN 1759-1, EN
439.
French : FD A 84-441, NF X 08-002, NF X 08-100.
CNOMO : E07.02.410.N, E07.13.070.N, E07.13.520.N, E07.82.200.N, GE07-
001N, GE07-006N.
Renault : E03.10.105.R, E07.13.025.R, EB00.20.600, EB15.70.200,
EM34.DO.080, EM65.CM.001, GE01-010R, GE07-005R, GE07-
010R, GE07-039R, GE34.SP.016.
Other internal docs. : CDC 34 790, CGA.
Other external docs. :

Coding ICS: 23.040.01; 23.100.; 25.160.30

Class E34

Key words soudage, encollage, hydraulique, pneumatique, eau, refroidissement , welding, pasting,
hydraulic, pneumatic, water, cooling

Language English

(1) The following people contributed to the drafting of this document

Site Dept Name Site Dept Name
TCR 65304 P. Fouassier, Assystem

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 EM34.FL.000 /B

Contents

Page

Foreword ................................................................................................................................... 4

1 Glossary .................................................................................................................................... 4

2 Scope of the service and division of responsibilities between Renault and the supplier. 4
2.1 When the project manager is the integrator ............................................................................................... 4
2.2 When the project manager is Renault........................................................................................................ 5
3 Supplier quality monitoring ..................................................................................................... 5
3.1 Process and deliverables ........................................................................................................................... 5
3.2 Inventory measurements............................................................................................................................ 5
3.3 Standard inventory measurement drawings............................................................................................... 6
3.4 Standard study plan ................................................................................................................................... 7
3.5 Definition of study levels............................................................................................................................. 7
4 Price sheet............................................................................................................................... 10

5 Acceptance-testing................................................................................................................. 10

6 Symbols for fluids .................................................................................................................. 11

7 Bibliography............................................................................................................................ 12

8 List of cited documents ......................................................................................................... 13

Appendix 1: Price sheet....................................................................................................................... 14

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Foreword
This standard defines the requirements and the general rules for study and production of all the networks
and pipework needed to transport fluids up to the production equipment (units, stations) or the
surrounding areas.
This document has been written for knowledge-building purposes, in order to learn from Renault’s
experience on previous projects.

1 Glossary
APD Detailed Advance Project
APS Summary Advance Project
AC7 Compressed Air (7 bars)
AC12 Compressed Air (12 bars)
BD Database
CPESA Main manifold, ESA.
CZAC7-5 Local manifold, AC7
CZESA Local manifold, ESA
ND Nominal Diameter.
ESA Welding water supply
ESR Welding water return
GIT Pipe Lower Generator
PAP Gun Station
PGE Procedure guide drawing.
PRP Press Resistance Point.
RIA Automatic Fire Network
GMAW Gas Metal Arc Welding

2 Scope of the service and division of responsibilities between Renault

and the supplier
The service must be compatible with the Acceptance Test Checks (CER) procedure, in compliance with
guide GE34.SP.016.

2.1 When the project manager is the integrator

Service provided by the process integrator
For all networks, the integrator must supply:
 The local manifolds
 The machine connectors.
 The production machines (robots, PaP, etc.).
He must also supply, at the end of the study:
 The consumption sheets.
 The machine interconnection drawings.
 The requisite elements of the “study and layout file”, in compliance with standard EB00.20.600.

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2.2 When the project manager is Renault

Service provided by the tendering company
For all networks, the company must supply:
 The local manifolds.
 The connections between the local manifolds and the machines.
The requests for quotations, the studies and the works shall be defined according to the process
engineering specifications for the facility and approved by Dept 65304, General facilities.

3 Supplier quality monitoring

3.1 Process and deliverables

• Studies and procedure drawings

Before the beginning of the works, the supplier must supply three copies of the calculation notes and of
the following drawings:
 Fluid network pressure losses.
 Load calculations on the ground, floor plans, decks, frames, etc. (otherwise they must reinforce
the buildings at their own cost).
 The procedure drawings for the different parts of the facilities.
 The frame drawings pertaining to their batch.
 The details of support structures.
 The instructions for operation and maintenance of the various pieces of equipment constituting
the facility, and a list of spare parts.
Note
 The procedure documents are produced using the electronic formats specified in the facility's
process engineering specifications.
 The supplier must not start manufacturing, or order any equipment, before the procedure
drawings and calculation notes have been approved by Renault Dept 65304: General facilities.
 Furthermore, any supplier suggestions or planned modifications must be submitted to the
approval of Dept 65304: General facilities, before the performance of any works.

• Commissioning Report
The commissioning report shall indicate the adjustment characteristics (adjustment unit, instrumentation):
 Flow rates measured
 Configuration and set points of regulation systems.
 Adjustment of the safety units.
 Position of adjustment units.

3.2 Inventory measurements

General information
Before starting any studies and/or works on a body assembly shop construction project, a comprehensive
set of readings and measurements must be taken in the relevant area. If the supplier has existing
construction drawings, they must verify the compliance of the construction project with these drawings.

Measurement equipment
The inventory measurements are taken with conventional equipment (tape measure, decameter,
telescometer, theodolite, magnifying glass).

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Objects to measure
1. Overhead objects in the trusses and wall plates
 The heating units
 The specific ventilation units
 The ventilation ducts
 The “Fluid Networks” manifolds.
 The automatic fire networks (RIA).
 All types of manifolds, sub-manifolds and pipework.
 The electric networks for welding (“CANALIS”) and their housing units.
 The electric cableways.
 The expansion seals of the trusses.
 etc.
2. Overhead objects in the first-floor trusses and under the ground-floor floor
 The electric cableways
 The computer and telephone cables
 The electric networks for welding (“CANALIS”) and their housing units.
 The electrical cable channels.
 The “Fluid Networks” manifolds.
 The automatic fire networks (RIA)
 All types of manifolds, sub manifolds and pipework.
 The overall dimensions of the conveyors.
 The overall dimensions of the metal structures.
 The expansion seals.
 The ventilation ducts.
 The ventilation units.

Standard data to record concerning the objects

 Their position in the space (along the X, Y, and Z axes).
 Their volume.
 The pipework lower generators.
 Their lowest level (lowest point of the obstacle).
 Their level on the walkway surface.
 Their name (refer to Standard NF X 08-100).

3.3 Standard inventory measurement drawings

General points
 The rules apply only to inventory measurement drawings.
 The original blueprints and the hard copies must be clean and legible.

Formats used
Compliant with paragraph 3.4

Scales
 The scales allowed are 1:100 or 1:50. The General Facilties dept. (Dept 65304) specifies the
scale to be used to the Engineering Centre or to the supplier.
 Intermediate scales are not allowed.

Numbering of drawings
See paragraph 3.4.

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Drawing rules
General information
 The drawings shall comply with ISO standards on all the views.
 The existing elements shall be shown in red and using fine lines. Modifications shall be shown
in black.

Representation
The following elements must feature on the drawing:
 All the obstacles mentioned in paragraph 3.2.
 The floor space covered by the obstacles and their relative positions in the space shall be drawn
to scale.
 The names of the obstacles (e.g.: pipe DN 100 AC + identification CZ.AC7-5).
 The lowest point(s) of the obstacle(s).
 Their level on the walkway surface. The GIT for all pipework types.
 A key to the symbols used.
Schematic representations and symbols
Information block
Compliant with Standard EB15.70.200.
Verification of inventory measurement drawings
 Before the submission of the documents to the General Facilities dept. (Dept. 65304), the
drawings must be verified on site on completed if necessary.
 After verification, the drawings are signed by the Engineering Centre Manager or supplier
manager who produced the inventory measurement drawings.
3.4 Standard study plan
General information
 The drawings shall comply with ISO standards.

Formats used
The standard formats are A0 to A3.
Notes
 The use of A0 and A1 formats is preferred to A2 or A3 formats.
 The use of A4 drawings and non standard drawings is prohibited.
Scales allowed in general
 1:250, 1:200, 1:100, 1:50, 1:20, 1:10, 1:5.
 Intermediate scales are not allowed.
Scales used for the study
 1:250, 1:200, 1:100, 1:50 for APS.
 1:50, 1:20, 1:10, 1:5 for APD and PGE.
Numbering of drawings
The ”General Facilties” departement (Dept. 65304) provides the drawing numbers.
 For the “Fluid connections” drawings of the integrators, the Renault Contract manager supplies a
reference number.
3.5 Definition of study levels
General information
Before beginning any studies, the General Facilities Dept. (Dept. 65304) shall specify the study level.
There are three study levels:
 APS
 APD
 PGE

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Presentation rules
 All existing elements and new structures shall be represented on all the views of the drawing(s).
Fine red line
 Existing elements of the general facilities (trusses, wall plates, girders, posts, building meshing,
walkways, gun stations, various obstacles, etc.).
Thick black line
 New structures to be installed.
3.5.1 Summary Advance Project (APS)
Input data
The input data is supplied by the General facilities dept. (Dept. 65304):
 Layout drawing for different process solutions.
 Provisional list of equipment.
 Capacity of the cooling station.
 Labelled drawing of existing networks
 Table of existing fluid consumption from database.
List of tasks:
 Supply the new units in relation to the existing network.
 Verify the capacity of the existing networks during the ”whistle” period.
 Plan the replacement and/or extension of existing networks, the creation of new networks.
 Check the capacity of the station.
 Assess the investment cost.
Output data:
 To be established on the basis of the layout drawing
 Overprint of existing ESA/ESR, AC7, AC12 networks.
 Indication of networks to be modified in diameter, extended or created.
 Assess the current consumption and estimate future consumption.
 Confirm the capacity or non-capacity of the cooling station.
 Establish which obstacles are to be moved.
3.5.2 Detailed Advance Project (APD)
General information
 The “Process” solution is chosen.
 The APD studies are based on the contents of the APS.
Input data
The input data is supplied by the General facilities dept. (Dept. 65304):
 General layout drawing.
 Installation drawing by unit (to be created or moved).
 List of equipment to be supplied with ESA/ESR, AC7 bar.
 Set of forecast files labelled by unit and/or by machine.
 Number of weld spots and throughput (by vehicle and by unit).
List of tasks
 Establish drawings of the main manifold and/or local manifolds that are to be created or modified.
 Compare the estimated consumptions with the APS phase consumptions.
 Analyze the possible impacts on the capacity of the cooling station.
 Distribute the network drawing to the “Machine Integrators” for each unit.
 Name the pipework with labels such as "CPESA" or "CZESA” for the database.
 Specify the investment cost by Unit.
 Orientate and manage the Fluid connections of the “Machine Integrators”.
 Insert the provisional consumption values into the database.

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Output data
The drawing shall show:
 The framework and basic structure of the building, with the aisles.
 The outline of the unit.
 Existing and/or future obstacles identified.
 The corresponding vertical cross-sections (longitudinal and transversal).
 Single-line diagrams of the existing and future ESA/ESR, AC7 and AC12 networks, with labels
(taken from the Database), diameters, the GIT and the capacity flow.
 A key to the “Fluid” symbols.

3.5.3 Procedure guide drawing (PGE)

General information
The PGE studies are based on the contents of the APD.
Input data
Input data is supplied by the General Facilities dept. (Dept. 65304):
 Definitive detailed layout drawing.
 Contract sheet specifying the construction projects to be carried out.
 Specific consumption sheets after studies.
 Machine Integrator Fluids connections drawing.
 “Process Fluids” drawing from the APD.
List of tasks
 Insert the precise consumption values into the database after the study.
 Measure the deviations between the standard consumption of the APS, the forecast
consumption of the APD and the exact consumption measured after the study.
 Verify the flowrate capacities of the main manifolds and the sub manifolds provided by the
Machine Integrators.
 Validate the diameter and routing of local manifolds provided by the Machine Integrators (electric
cable channels, canalis, metallic structures, handling equipment, etc.).
 Complete the APD Drawing with the connections for the welding equipment, other than those
provided by the Machine Integrators (gun station, PRP, GMAW, etc.).

Output data
The drawing shall show:
 The same information as on the APD drawing.
 Details of the support structures.
 Sealing valves.
 Adjustment taps.
 Level changes.
 Monitoring and measurement equipment.
 Drain points, vents.
 Welding machines, with symbols
 Keys to symbols.
 The ESA/ESR consumption summary table.
 The standard information blocks, with the appropriate labels.
 The identication information of the main manifold and the local manifold.

3.5.4 Fluid interconnection drawing (networks towards the machines or facilities)

Must comply with standard EB00.20.600.

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3.5.5 "General Facilities" process engineering specifications

 They are written on A4 paper.
 Their title shall indicate:
 The plant
 The vehicle
 The unit
 The contract No.
 The subject.
 The process engineering specifications are contractually binding and shall be attached to the
contract.
 They shall describe the routing of the pipework for fluids.
 They shall specify the reference and type of tooling (valves, manometer, etc.).
 They shall mention particularities concerning connection and fluid drainage.
 They shall indicate the phasing of the works to be performed.
 They shall describe any elements or facts not dealt with elsewhere.
 They shall refer to drawings, standards, specifications and labels (diagrams, views) in use.

4 Price sheet
 It shall be detailed.
 It shall give quantified values.
 It shall specify all the work involved (the supply and the labour)

Note
See Appendix 1 for the price sheet, which is also avaliable in native format in our IT databases.

5 Acceptance-testing
Provisional acceptance
The conditions for provisional acceptance must be set on a case-by-case basis, in collaboration with the
Contracts department (Renault Purchasing), or, if this is not possible, in compliance with the CGA of the
contracts department.

Final acceptance
The definitive acceptance of the projects and facilities must be pronounced only after the works have
been completed (taking into account the time delay related to the signing of the contract), if the result of
the tests is satisfactory, and after the following elements have been checked:
 Finished product compliant with drawings and itemised quotation approved by Renault
 Quantity of equipment installed
 Quality of equipment and materials, including installation conditions
 Compliant with regulations and standards in force on the date of acceptance
 After completion of the works, and at the latest by the acceptance stage, the supplier shall
submit the technical files, including:
 The description and operating principle of the facility, with schematic diagrams and a flow
chart
 The labels and identifiers used on the diagrams must be the same as those used on the
procedure drawings and on the installed equipment
 One copy of all the procedure drawings grouped together.
Warranty
The warranty conditions are defined on a case-by-case basis in collaboration with the Contracts
department.
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6 Symbols for fluids

The different networks are represented differently according to the fluid they transport. The diagrams are
compliant with:
 Standard EM34.DO.080.
 The symbols below, taken from the CAD library, Dept. 65304: "Bodywork layout"

X ESA X ESA EXISTING NETWORK (FINE LINE)

X ESA X ESA NETWORK TO BE CREATED (DARK, THICK LINE)

X ESA X ESA BRANCH ON EXISTING NETWORK

X ESA X ESA THROTTLE VALVE

X ESA X ESA TS TAP

X ESA X ESA CONTROL VALVE

X ESA X ESA CONTROL TAP

X ESA X ESA VALVE BETWEEN CLAMPS

X ESA X ESA TAPPED VALVE

X ESA X ESA RISE/FALL AT 90°

X ESA X ESA RISE/FALL AT 45°

X ESA X ESA CAP

X ESA X ESA CONVEX BOTTOM

X ESA X ESA SET OF CLAMPS

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7 Bibliography
TITLE STANDARD
Metallic frames for buildings. Specific equipment. EM65.CM.001
Symbols for fluid networks. EM34.DO.080
Design rule for removable attachments CDC 34 790
Colours. Rigid piping. Identification of fluids by conventional colours. NF X 08-100
Reduced set of colours. Names and list of CCR colours. Secondary samples. NF X 08-002
Clamps and their assemblies – Circular clamps for tubes, tapping devices, connections and EN 10921-1
accessories (PN) – Part 1: steel clamps
Clamps and their assemblies – Circular clamps for tubes, tapping devices, connections and EN 1759-1
accessories (Class) – Part 1: steel clamps, NPS ½ to24
Clamps and their assembly – Seals for "Class" clamps– Part 3: PTFE non-metallic envelope EN 12560-3
seals
Clamps and their assembly – Seals for "PN" clamps – Part 2: spiral seals for use with steel EN 1514-2
clamps
Clamps and their assemblies – Seal dimensions for "PN" clamps – Part 3: PTFE non-metallic EN 1514-3
envelope seals
Protective-gas pipework for welding EN 439
In-plant gas distribution network: Safety rules for design, production and use. FD A 84-441
CER procedure application guide. GE34.SP.016
Guide to standardized steel names. GE01-010R
Stainless steel tubes implementation guide GE07-006N
Guide to selecting materials for fluid distribution pipework. GE07-001N
Technical guide to taps GE07-010R
Fluid distribution: the basics GE07-039R
Hose GE07-005R
Interconnection and grounding of ground cables E03.10.105.R
Fluid distribution under pressure. Pipes. Instructions E07.13.025.R
Steel tubes for piping E07.13.070.N
Slender austenitic stainless steel tubes longitudinally welded for piping. E07.13.520.N
Valves: Selection, scope of use E07.82.200.N
Rigid piping. Conventional colours. Fluid identification E07.02.410.N
Technical documentation of facilities. Structure, content and identification EB00.20.600

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8 List of cited documents

NOTE : For undated documents, the latest version shall apply
EB15.70.200 : Industrial machines, facilities and tools. Mechanical file drawings. - General
requirements (for BEDs) - Supports (for BEDs and APFs).
CGA : Purchasing terms and conditions.
+ the documents mentioned in paragraph 7.

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 EM34.FL.000 /B Appendix 1 Information

Appendix 1: Price sheet

PRICE SHEET
Request for quotation N°. Date
SUPPLIER Contract no. Page: /

PLANT
Quote n°. Drawing(s) n°.
This quotation is compliant
With the technical specification
DESCRIPTION UNIT QUANTITY Unit price TOTAL
Supply & fitting
Manifolds energy supply

304L stainless steel tube DN XXX m.

Branching pipe DN XXX u.
Elbows DN XXX u.
Offset adapter bushing DN XXX u.
Collar + Blue Point Clamp DN XXX u.
Valves DN XXX u.
Bottom of pressure can DN XXX u.
ESS T3Ao Tube DN XXX m.
Valve ¼ T BS DN XXX u.
Branching pipe DN XXX u.
GF Straight coupling DN XXX u.
Bending DN XXX Ens
Plug DN XXX u.
Looping Ens
Assembly support Kg
Protection of tubes and marking Ens
Naming of networks Ens
Cutting-off and draining of the networks Ens
Work outside normal hours
Sub-total
Supply of energy to equipment
Following the standard labels
1- Power Supply to Resistance-welding stations + u.
pneumatic jig
See no.
2- Power Supply to Resistance-welding stations u.
See no.
3- Power Supply to GMAW stations u.
On standard support
See no.
4- AC7 supply to Maintenance stations with valve u.
Lubrication regulation filter
See no.
5- Power Supply to Machines u.
See no.
6- AC7 air supply u.
See no.
7- Mastic pumps u.
See no.
8- S.O.A.-type control panel:AC7, CO2, O2, u.
C2h2.(B 00 101-0)
See no.
Studies Hrs
Support, protection of tubes & marking. Ens.

Tests, startup Ens.

Sub-total
Supplementary charge for work done outside normal
working hours
TOTAL

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