TSG 51:2023 Pressure Piping Components Type Test Regulation English
TSG TSG 51-2023
Regulation on safety technology for lifting appliances
起重机械安全技术规程
(English translation)
Issued by the State Administration for Market Regulation of the People's Republic of China
May 23, 2023
Contents
1 General (1)
2 Design (1)
3 Manufacture and modification (18)
4 Installation and repair (21)
5 Use management (23)
6 Inspection (25)
7 Supplementary provisions (35)
Annex A Special design requirements for lifting appliances (38)
Appendix a List of large-sized lifting appliances required to be equipped with a safety monitoring and management system (64)
Annex B Product certificate for lifting appliances (65)
Appendix ba Coding method for lifting appliances (66)
Appendix bb Product data sheet for lifting appliances (taking bridge crane as an example) (67)
Annex C Types, items, contents, methods and requirements of inspection for lifting appliances (73)
Appendix ca Comparison of inspection types for lifting appliances (109)
Appendix cb Comparison of inspection items for lifting appliances (114)
Annex D Notification of inspection findings for lifting appliances (117)
Annex E Type test report for lifting appliances (118)
Annex F Type test certificate for lifting appliances (129)
Appendix f Explanation of numbering for type test certificates of lifting appliances (131)
Annex G Supervision inspection report for installation, modification and major repair of lifting appliances (132)
Annex H Periodic (initial) inspection report for lifting appliances (136)
Formulations/amendments of relevant regulations and rules (140)
Regulation on safety technology for lifting appliances
1 General
1.1 Purpose
This Regulation is formulated in accordance with the Special Equipment Safety Law of the People's Republic of China and the Regulations on the Safety Supervision of Special Equipment, in order to ensure the safe use of lifting appliances, prevent and reduce accidents, protect the safety of people's lives and property, and promote economic and social development.
1.2 Application scope
This Regulation applies to lifting appliances covered by the Catalog of Special Equipment.
The production (design, manufacture, installation, modification, repair, the same below), use, inspection and testing of lifting appliances shall comply with the provisions of this Regulation.
The supervision and management of the installation and use of lifting appliances used in building construction sites and municipal engineering sites shall be carried out by the competent administrative department of construction in accordance with the provisions of relevant laws and regulations.
1.3 Informatization management
The manufacturing units, user units, inspection and testing institutions, and supervisory authorities of lifting appliances shall, in accordance with the information management requirements for special equipment, set up information platforms or fill in relevant information on the corresponding information platforms timely.
2 Design
2.1 Basic requirements
Basic requirements mainly include design documents, metal structure, operating mechanisms, major components, control system (electrical, hydraulic, pneumatic), cab, aisles, platforms, ladders, railings, safety protection devices, cranes for special purposes, etc.
The general design requirements include:
(1) Complying with the provisions of laws, regulations, safety technical specifications and the requirements of relevant standards;
(2) Complying with the service conditions and contract requirements;
(3) The foreseeable hazards at different stages of its expected life cycle shall be considered, and corresponding measures shall be taken to eliminate or reduce the risks;
(4) It shall be considered to have sufficient strength, rigidity and stability under all intended operating conditions;
(5) The design documents shall specify the design service life of the lifting appliance;
(6) The design documents shall be correct, complete and consistent.
The design of lifting appliances shall comply with the provisions of Articles 2.1 to 2.9 of this Regulation and the Special design requirements for lifting appliances (see Annex A).
2.2 Design documents
Design documents mainly include design specification, design drawings, design calculation, and instructions for installation, use, and maintenance.
2.2.1 Design specification
The design specification shall include at least the design basis, product functions, operating environment and main technical parameters, etc.
2.2.2 Design drawings
The design drawings shall include at least the general drawing, drawings of main structural components, drawings of main parts, assembly drawings, schematic diagrams of the control system, drawing lists, lists of purchased parts and lists of standard parts. Signatures for drafting, reviewing, approving, etc., shall be complete.
2.2.3 Design calculation
The design calculation shall at least include the followings:
(1) Analysis and calculation of loads and load combinations;
(2) Strength, rigidity and stability design calculation of the complete machine structure, main structural components and their connections. If overturning of the complete machine is possible, the overturning stability of the complete machine in a free-standing state shall be calculated, including overturning stability in both the load plane and the lateral direction;
(3) Design calculation or selection calculation of operating mechanism components, mainly including motors, reducers, brakes, couplings, wire ropes, lifting attachments, drums, pulleys, chains, sprockets, traction sheaves, wheels, screws (nuts), rack and pinion pairs, open gears, toothed belts, slewing bearings, etc.;
(4) Design calculation or selection calculation of the electrical system, mainly including low-voltage electrical components (such as circuit breakers, contactors, fuses, etc.), cables, frequency converters, resistors, etc.;
(5) Design calculation or selection calculation of the hydraulic system, mainly including power components, actuating components, control components, energy storage components, and hydraulic auxiliaries of the hydraulic system;
(6) Design calculation or selection calculation of the pneumatic system, mainly including power components, actuating components, control components, energy storage components, and pneumatic auxiliaries of the pneumatic system;
(7) Design calculation or selection calculation of safety protection devices, mainly including load limiters, moment limiters, anti-falling safety devices, wind-resistant and anti-skid devices, safety catches, overspeed downward protection devices, height limiters, etc.;
(8) The design service life shall be specified according to the classification of use, load condition, operating environment, etc., of the lifting appliance.
2.2.4 Instructions for installation, use and maintenance
The instructions for installation, use and maintenance shall meet the needs of installation, use, repair, maintenance, etc., and shall include at least the following:
(1) Product overview;
(2) Main technical performance parameters, intended use, requirements for the operating environment and design service life;
(3) General drawing, schematic diagram of the control system, etc.;
(4) Installation instructions and requirements;
(5) Instructions for storage, transportation, maintenance, and a list of replaceable wearing parts;
(6) Operating procedures and requirements for operators such as drivers and signal persons;
(7) Foundation load diagram (wheel loads, etc.) or foundation load parameters, requirements for the crane runway, load‑bearing capacity and stiffness requirements for the operating site of mobile cranes, and ground levelness requirements for crawler cranes;
(8) Safety precautions, including at least the location of safety warning signs, risk prevention and avoidance of misoperation instructions, and instructions for handling substances that may cause environmental pollution.
2.3 Main metal structure
It mainly includes main structural components, materials for main structural components, design of main structural components, welding, static stiffness, bolted and pinned connections, surface treatment of structural components, etc. For the special design requirements for lifts and mechanical parking equipment, see A1 of Annex A to this Regulation.
2.3.1 Main structural components
Main structural components include main girder, end carriage, leg, trolley frame, standard section, boom, gantry, elephant trunk frame, shear legs, cargo, hook beam, mast, column, cross beam, longitudinal beam, etc.
2.3.2 Materials for main structural components
(1) The selection of materials for main structural components shall take into account the importance, load characteristics, stress state, type of connection, ambient temperature, corrosion, wear, impact, fatigue, brittle aging, weldability, steel thickness and other factors of the structure under the intended working environment.
(2) Main structural components shall be made of killed steel with mechanical properties not lower than Q235 as specified in GB/T 700-2006 Carbon structural steels or 20 steel as specified in GB/T 699-2015 Quality carbon structure steels.
(3) In T‑, cruciform and corner welded joints, where the thickness of the steel plate exceeds 40 mm and there is a high tearing tensile force (including high restraint tensile stress) acting in the through‑thickness direction, the steel plate at that location should have guaranteed through‑thickness (Z‑direction) tear resistance, and the reduction of area in the through‑thickness direction shall not be less than the allowable limit for Z15 grade specified in GB/T 5313‑2010 Steel plates with through‑thickness characteristics. The through‑thickness performance grade of the steel plate shall be determined comprehensively according to the joint type, plate thickness, depth of penetration or weld size, joint restraint during welding, preheating and post‑heating conditions, etc.
(4) When a steel plate thicker than 50 mm is used for welded load‑bearing members and acts as a tension or bending member, additional tensile and impact toughness tests with transverse sampling shall be carried out and shall meet the design requirements.
2.3.3 Design of main structural components
(1) In design, materials, structural forms and construction measures shall be reasonably selected to meet the requirements for strength, rigidity, stability and other safety‑related aspects during transportation, installation and use; structures of lifting appliances used outdoors shall have measures to prevent water accumulation.
(2) Priority shall be given to effective lightweight measures such as optimized design of main structural components, selection of light new materials, and optimization of structural connection methods, so as to reduce the dead weight and external dimensions of the lifting appliance, reduce blind areas during lifting, and expand the range of use.
(3) In the design documents, the material designation shall be indicated; where necessary, the mechanical properties, chemical composition and other additional guaranteed items of the material shall also be indicated; the required weld form, dimensions, weld quality grade and requirements for welding operations shall be indicated.
2.3.4 Welding
2.3.4.1 Welding consumables
The electrodes, welding wires and fluxes used for welding shall ensure that the comprehensive mechanical properties of the weld are equivalent to those of the base metal.
2.3.4.2 Requirements for welded connection design and detailing
(1) Appropriate weld forms shall be selected and requirements for weld quality shall be specified in order to meet the design requirements for strength and fatigue.
(2) For welded connections subject to severe dynamic loading or complex stress, measures shall be taken to reduce or eliminate welding residual stresses.
(3) For welded connections governed by fatigue strength, measures to reduce fatigue stress shall be taken, such as improving the joint geometry and reducing the stress concentration level.
2.3.4.3 Weld quality
2.3.4.3.1 Visual appearance
The appearance of welds in main structural components shall be free from visible defects such as cracks, porosity, solid inclusions, lack of fusion and lack of penetration. The surface quality of critical welds shall reach grade B as specified in GB/T 19418-2003 Arc-welded joints in steel - Guidance on quality levels for imperfections and shall be indicated in the design documents; other welds shall reach grade C.
2.3.4.3.2 Non-destructive testing
When the weld quality of main structural components needs to be examined using one or more non-destructive testing methods, the corresponding testing methods and requirements are as follows:
(1) For radiographic testing (RT), the quality level shall be level 2 as specified in GB/T 37910.1-2019 Non-destructive testing of welds - Acceptance levels for radiographic testing - Part 1: Steel, nickel, titanium and their alloys.
(2) For ultrasonic testing (UT), the quality level shall be level 1 as specified in JB/T 10559-2018 Non-destructive testing of lifting appliances - Ultrasonic testing of steel welds.
(3) For magnetic particle testing (MT), the quality level shall be level 1 as specified in GB/T 26952-2011 Non-destructive testing of welds - Magnetic particle testing of welds - Acceptance levels.
(4) For penetrant testing (PT), the quality level shall be level 1 as specified in GB/T 26953-2011 Non-destructive testing of welds - Penetrant testing of welds - Acceptance levels.
Standard
TSG 51-2023 Pressure Piping Components Type Test Regulation (English Version)
TSG 51:2023 Pressure Piping Components Type Test Regulation English
TSG TSG 51-2023
Regulation on safety technology for lifting appliances
起重机械安全技术规程
(English translation)
Issued by the State Administration for Market Regulation of the People's Republic of China
May 23, 2023
Contents
1 General (1)
2 Design (1)
3 Manufacture and modification (18)
4 Installation and repair (21)
5 Use management (23)
6 Inspection (25)
7 Supplementary provisions (35)
Annex A Special design requirements for lifting appliances (38)
Appendix a List of large-sized lifting appliances required to be equipped with a safety monitoring and management system (64)
Annex B Product certificate for lifting appliances (65)
Appendix ba Coding method for lifting appliances (66)
Appendix bb Product data sheet for lifting appliances (taking bridge crane as an example) (67)
Annex C Types, items, contents, methods and requirements of inspection for lifting appliances (73)
Appendix ca Comparison of inspection types for lifting appliances (109)
Appendix cb Comparison of inspection items for lifting appliances (114)
Annex D Notification of inspection findings for lifting appliances (117)
Annex E Type test report for lifting appliances (118)
Annex F Type test certificate for lifting appliances (129)
Appendix f Explanation of numbering for type test certificates of lifting appliances (131)
Annex G Supervision inspection report for installation, modification and major repair of lifting appliances (132)
Annex H Periodic (initial) inspection report for lifting appliances (136)
Formulations/amendments of relevant regulations and rules (140)
Regulation on safety technology for lifting appliances
1 General
1.1 Purpose
This Regulation is formulated in accordance with the Special Equipment Safety Law of the People's Republic of China and the Regulations on the Safety Supervision of Special Equipment, in order to ensure the safe use of lifting appliances, prevent and reduce accidents, protect the safety of people's lives and property, and promote economic and social development.
1.2 Application scope
This Regulation applies to lifting appliances covered by the Catalog of Special Equipment.
The production (design, manufacture, installation, modification, repair, the same below), use, inspection and testing of lifting appliances shall comply with the provisions of this Regulation.
The supervision and management of the installation and use of lifting appliances used in building construction sites and municipal engineering sites shall be carried out by the competent administrative department of construction in accordance with the provisions of relevant laws and regulations.
1.3 Informatization management
The manufacturing units, user units, inspection and testing institutions, and supervisory authorities of lifting appliances shall, in accordance with the information management requirements for special equipment, set up information platforms or fill in relevant information on the corresponding information platforms timely.
2 Design
2.1 Basic requirements
Basic requirements mainly include design documents, metal structure, operating mechanisms, major components, control system (electrical, hydraulic, pneumatic), cab, aisles, platforms, ladders, railings, safety protection devices, cranes for special purposes, etc.
The general design requirements include:
(1) Complying with the provisions of laws, regulations, safety technical specifications and the requirements of relevant standards;
(2) Complying with the service conditions and contract requirements;
(3) The foreseeable hazards at different stages of its expected life cycle shall be considered, and corresponding measures shall be taken to eliminate or reduce the risks;
(4) It shall be considered to have sufficient strength, rigidity and stability under all intended operating conditions;
(5) The design documents shall specify the design service life of the lifting appliance;
(6) The design documents shall be correct, complete and consistent.
The design of lifting appliances shall comply with the provisions of Articles 2.1 to 2.9 of this Regulation and the Special design requirements for lifting appliances (see Annex A).
2.2 Design documents
Design documents mainly include design specification, design drawings, design calculation, and instructions for installation, use, and maintenance.
2.2.1 Design specification
The design specification shall include at least the design basis, product functions, operating environment and main technical parameters, etc.
2.2.2 Design drawings
The design drawings shall include at least the general drawing, drawings of main structural components, drawings of main parts, assembly drawings, schematic diagrams of the control system, drawing lists, lists of purchased parts and lists of standard parts. Signatures for drafting, reviewing, approving, etc., shall be complete.
2.2.3 Design calculation
The design calculation shall at least include the followings:
(1) Analysis and calculation of loads and load combinations;
(2) Strength, rigidity and stability design calculation of the complete machine structure, main structural components and their connections. If overturning of the complete machine is possible, the overturning stability of the complete machine in a free-standing state shall be calculated, including overturning stability in both the load plane and the lateral direction;
(3) Design calculation or selection calculation of operating mechanism components, mainly including motors, reducers, brakes, couplings, wire ropes, lifting attachments, drums, pulleys, chains, sprockets, traction sheaves, wheels, screws (nuts), rack and pinion pairs, open gears, toothed belts, slewing bearings, etc.;
(4) Design calculation or selection calculation of the electrical system, mainly including low-voltage electrical components (such as circuit breakers, contactors, fuses, etc.), cables, frequency converters, resistors, etc.;
(5) Design calculation or selection calculation of the hydraulic system, mainly including power components, actuating components, control components, energy storage components, and hydraulic auxiliaries of the hydraulic system;
(6) Design calculation or selection calculation of the pneumatic system, mainly including power components, actuating components, control components, energy storage components, and pneumatic auxiliaries of the pneumatic system;
(7) Design calculation or selection calculation of safety protection devices, mainly including load limiters, moment limiters, anti-falling safety devices, wind-resistant and anti-skid devices, safety catches, overspeed downward protection devices, height limiters, etc.;
(8) The design service life shall be specified according to the classification of use, load condition, operating environment, etc., of the lifting appliance.
2.2.4 Instructions for installation, use and maintenance
The instructions for installation, use and maintenance shall meet the needs of installation, use, repair, maintenance, etc., and shall include at least the following:
(1) Product overview;
(2) Main technical performance parameters, intended use, requirements for the operating environment and design service life;
(3) General drawing, schematic diagram of the control system, etc.;
(4) Installation instructions and requirements;
(5) Instructions for storage, transportation, maintenance, and a list of replaceable wearing parts;
(6) Operating procedures and requirements for operators such as drivers and signal persons;
(7) Foundation load diagram (wheel loads, etc.) or foundation load parameters, requirements for the crane runway, load‑bearing capacity and stiffness requirements for the operating site of mobile cranes, and ground levelness requirements for crawler cranes;
(8) Safety precautions, including at least the location of safety warning signs, risk prevention and avoidance of misoperation instructions, and instructions for handling substances that may cause environmental pollution.
2.3 Main metal structure
It mainly includes main structural components, materials for main structural components, design of main structural components, welding, static stiffness, bolted and pinned connections, surface treatment of structural components, etc. For the special design requirements for lifts and mechanical parking equipment, see A1 of Annex A to this Regulation.
2.3.1 Main structural components
Main structural components include main girder, end carriage, leg, trolley frame, standard section, boom, gantry, elephant trunk frame, shear legs, cargo, hook beam, mast, column, cross beam, longitudinal beam, etc.
2.3.2 Materials for main structural components
(1) The selection of materials for main structural components shall take into account the importance, load characteristics, stress state, type of connection, ambient temperature, corrosion, wear, impact, fatigue, brittle aging, weldability, steel thickness and other factors of the structure under the intended working environment.
(2) Main structural components shall be made of killed steel with mechanical properties not lower than Q235 as specified in GB/T 700-2006 Carbon structural steels or 20 steel as specified in GB/T 699-2015 Quality carbon structure steels.
(3) In T‑, cruciform and corner welded joints, where the thickness of the steel plate exceeds 40 mm and there is a high tearing tensile force (including high restraint tensile stress) acting in the through‑thickness direction, the steel plate at that location should have guaranteed through‑thickness (Z‑direction) tear resistance, and the reduction of area in the through‑thickness direction shall not be less than the allowable limit for Z15 grade specified in GB/T 5313‑2010 Steel plates with through‑thickness characteristics. The through‑thickness performance grade of the steel plate shall be determined comprehensively according to the joint type, plate thickness, depth of penetration or weld size, joint restraint during welding, preheating and post‑heating conditions, etc.
(4) When a steel plate thicker than 50 mm is used for welded load‑bearing members and acts as a tension or bending member, additional tensile and impact toughness tests with transverse sampling shall be carried out and shall meet the design requirements.
2.3.3 Design of main structural components
(1) In design, materials, structural forms and construction measures shall be reasonably selected to meet the requirements for strength, rigidity, stability and other safety‑related aspects during transportation, installation and use; structures of lifting appliances used outdoors shall have measures to prevent water accumulation.
(2) Priority shall be given to effective lightweight measures such as optimized design of main structural components, selection of light new materials, and optimization of structural connection methods, so as to reduce the dead weight and external dimensions of the lifting appliance, reduce blind areas during lifting, and expand the range of use.
(3) In the design documents, the material designation shall be indicated; where necessary, the mechanical properties, chemical composition and other additional guaranteed items of the material shall also be indicated; the required weld form, dimensions, weld quality grade and requirements for welding operations shall be indicated.
2.3.4 Welding
2.3.4.1 Welding consumables
The electrodes, welding wires and fluxes used for welding shall ensure that the comprehensive mechanical properties of the weld are equivalent to those of the base metal.
2.3.4.2 Requirements for welded connection design and detailing
(1) Appropriate weld forms shall be selected and requirements for weld quality shall be specified in order to meet the design requirements for strength and fatigue.
(2) For welded connections subject to severe dynamic loading or complex stress, measures shall be taken to reduce or eliminate welding residual stresses.
(3) For welded connections governed by fatigue strength, measures to reduce fatigue stress shall be taken, such as improving the joint geometry and reducing the stress concentration level.
2.3.4.3 Weld quality
2.3.4.3.1 Visual appearance
The appearance of welds in main structural components shall be free from visible defects such as cracks, porosity, solid inclusions, lack of fusion and lack of penetration. The surface quality of critical welds shall reach grade B as specified in GB/T 19418-2003 Arc-welded joints in steel - Guidance on quality levels for imperfections and shall be indicated in the design documents; other welds shall reach grade C.
2.3.4.3.2 Non-destructive testing
When the weld quality of main structural components needs to be examined using one or more non-destructive testing methods, the corresponding testing methods and requirements are as follows:
(1) For radiographic testing (RT), the quality level shall be level 2 as specified in GB/T 37910.1-2019 Non-destructive testing of welds - Acceptance levels for radiographic testing - Part 1: Steel, nickel, titanium and their alloys.
(2) For ultrasonic testing (UT), the quality level shall be level 1 as specified in JB/T 10559-2018 Non-destructive testing of lifting appliances - Ultrasonic testing of steel welds.
(3) For magnetic particle testing (MT), the quality level shall be level 1 as specified in GB/T 26952-2011 Non-destructive testing of welds - Magnetic particle testing of welds - Acceptance levels.
(4) For penetrant testing (PT), the quality level shall be level 1 as specified in GB/T 26953-2011 Non-destructive testing of welds - Penetrant testing of welds - Acceptance levels.
