This Specification specifies the technical requirements and acceptance standard for manufacture and erection of steel gates (including trash rack, ditto hereinafter) of water resources and hydropower projects.
This Specification is applicable to manufacture, erection and acceptance of steel gates in medium and large water resources and hydropower projects. For Small hydro projects, reference may also be made to it.
2 Normative References
The following normative references contain the provisions which, through reference in this text, constitute provisions of this Specification. For dated reference, subsequent amendments (excluding error correction) to, or revision of, any of these publications do not apply. However, parties to agreements based on this Specification are encouraged to investigate the possibility of applying the most recent editions of the normative references below.
For undated references, the latest editions of the normative document referred to applies.
GB/T 228 Metallic Materials-Tensile Testing at Ambient Temperature
GB/T 229 Metallic Materials-Charpy Notch Impact Test (eqv ISO 148)
GB/T 232 Metallic Materials-Bend Test (eqv ISO 7438)
GB/T 6402 Steel Forgings-Method for Ultrasonic Examination (neq JIS G587)
GB/T 6414 Castings-System of Dimensional Tolerances and Machining Allowances (eqv ISO 8062)
GB/T 6654 Steel Sheet for Pressure Vessels
GB/T 7233 Methods for Ultrasonic Testing and For Specifying Quality Levels of Steel Castings (neq BS 6208)
GB/T 7659 Carbon Steel Castings Suitable for Welded Structure (neq ASTM A 216)
GB/T 8110 Welding Wires for Gas Shielding Arc Welding of Carbon and Low Alloy Steels (neq ANSI/A WS)
GB/T 8923 Rust Grades and Preparation Grades of Steel surfaces before Application of Paints and Related Products (eqv ISO 8501-1)
GB/T 9286 Paints and Varnishes-Cross Cut Test for Films
GB/T 9443 Methods of Liquid Pentrant Testing and Classification of Indication for Steel Castings
GB/T 9444 The Methods for Magnetic Particle Testing and for Specifying Quality Levels of Steel Castings
GB/T 11345 Method for Manual Ultrasonic Testing and Classification of Testing Results for Ferritic Steel Welds
GB/T 11351 Mass Tolerances for Castings
GB/T 11352 Carbon steel Castings for General Engineering Purposes (neq ISO 3755)
GB/T 12470 Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding (neq ANSI/AWS A5.23)
GB/T 14408 Low Alloy Steel Castings for General Engineering and Structural Purposes
GB/T 15056 Evaluation Method on Cast Surface Roughness
GB/T 15826.1-9 Machining Allowances and Tolerances for Steel Open die Forgings (eqv DIN 7527)
GB/T 16253 Steel Castings for Pressure Purposes (eqv ISO 4991)
GB/T 17854 Stainless Steel Electrodes and Fluxs for Submerged Arc Welding (eqv JIS Z3324)
DL/T 679 Code for Welder Technical Qualification
DL/T 5039 Specification for Design of Steel Gate in Hydraulic and Hydroelectric Engineering
JB 4730 Nondestructive Testing of Pressure Equipments
JB/T 9179.1-8 Machining Allowance and Tolerance of Open Die forgings on Hydraulic Press
SL 35 Hydrotechnics Metal Structure Welder Examination Rules
3 General Provisions
3.1 Technical documents
3.1.1 The following documents shall be provided prior to manufacture of gates and embedded parts:
(1) Design drawings, including general drawings, assembly drawings and parts drawings, and technical documents.
(2) Quality certificates of steel materials, welding materials and antirust materials.
(3) Quality certificates of standardized parts and nonstandard parts provided by partners.
3.1.2 The following documents shall be provided prior to erection of gate and embedded parts:
(1) Design drawings, including general drawings, assembly drawings, parts drawings, relevant, civil structural drawings and relevant drawings of gates to hoists, and technical documents.
(2) Factory certificates of gates.
(3)Acceptance documents and quality certificates for gate manufacture.
(4) Shipping lists, inspection documents of arrival of goods and assembly number figures.
(5) Location layouts of control points for erection.
3.1.3 Gates shall be manufactured and erected according to the design drawings and documents. If any modification is necessary, design modification notices shall be given in accordance with the relevant provisions of contracts.
3.2 Materials
3.2.1 The steel used for gates shall meet the requirements of design drawings and its properties shall satisfy the relevant provisions in Appendix A and factory quality certificates for it shall be provided. If there are no quality certificates, it shall be rechecked up to the standard and then may be used.
3.2.2 If ultrasonic flaw detection is necessary, it shall be carried out according to the standard GB/T 2970.
3.2.3 Factory quality certificates of welding materials (electrodes, welding wires and fusing agents) shall be provided. The mechanic properties and diffusible hydrogen contents of electrodes shall meet the standards GB/T 5117, GB/T 5118 or GB/T 983. The welding wires and fusing agents used for submerged arc welding shall meet the standards GB/T 5293, GB/T 12470 or GB/T 17854, and those for gas shielded welding shall meet the standards GB/T 8110.
3.3 Bench marks and measuring tools
3.3.1 The precision of all measuring instruments and steel rulers used for gate manufacture and erection shall meet the following requirements:
(1) Steel rulers with an accuracy not less than Grade l.
(2) Theodolites with accuracy above grade DJ2.
(3) Gradienters with accuracy above grade DJ3.
(4) Electronic total station, zenith and nadir telescopes with a measuring accuracy not less than one ten thousandth (1/10000).
The measuring tools and instruments shall be checked and calibrated regularly by legal metrological service.
3.3.2 The bench marks used for measuring elevations and axes and control points for gate erection shall be distinct, firm and easy to use
3.4 Marking, acceptance, packing and transportation
3.4.1 Manufacture and erection of gates and embedded parts shall be accepted in accordance with the relevant provisions in Chapter 10 Acceptance.
3.4.2 Gates shall be provided with identification markings with the following data:
(1) Name or emblem of manufactures.
(2) Product name.
(3) Type of gate or main technical parameters.
(4) Production date.
(5) Gravity centre and gross weight of gates.
3.4.3 Gate leaves shall be numbered in sections. The machined surface of them shall be reliably protected. Embedded parts may be packed up in bales and fastened firmly with steel frame and their accessories shall be encased in whole sets.
3.4.4 Whenever gates are lifted up, members of them shall be protected from being damaged or deforming. When trucked, gate leaves shall be placed steadily at proper positions and reinforced reliably. For transport of the members with over length, width and height, alerting plates shall be hanged up and close attentions shall be paid to protect roads, bridges, communication and electrical facilities from being destroyed.
4 Welding
4.1 Assessment of welding technology
4.1.1 Before manufacture and erection of gates, the units responsible for welding construction shall work out specifications for the welding procedure according to the gate structural features and quality requirements. The specifications will be subjected to assessment and welding work done with guidance of the specifications.
4.1.2 The welding technology assessment is to verify the validity and rationality of welding procedure specifications by testing the mechanical and other properties of welds.
4.1.3 The general process of welding technology assessment includes studying out welding technology guidance, welding specimens, preparing sample pieces, checking the specimens and sample pieces, testing welds whether has the required usage performance and finally bringing forward reports to evaluate the welding technology guidance.
4.1.4 The equipment and instruments used for welding technology assessment shall be at normal operating conditions. Steel and welding materials shall be up to the standards. The welders for specimens shall be skillful and have qualification certificates.
Contents Foreword Explanatory Notes to the Wording of This Specification 1 Scope 2 Normative References 3 General Provisions 3.1 Technical documents 3.2 Materials 3.3 Bench marks and measuring tools 3.4 Marking, acceptance, packing and transportation 4 Welding 4.1 Assessment of welding technology 4.2 Welder's qualification 4.3 Basic provisions of welding 4.4 Weld inspection 4.5 Weld repairing and treatment 4.6 Postwelding stress-relief heat treatment 5 Bolted Connection 5.1 Preparation of bolt holes 5.2 Preparation of bolts 5.3 Bolt tightening 6 Surface Corrosion Protection 6.1 Pretreatment of surface 6.2 Surface coating 6.3 Quality inspection of paint coats 6.4 Metal spraying 6.5 Quality inspection of metal coats 7 Manufacture of Gate and Embedded Parts 7.1 Manufacture of parts and individual members of gate 7.2 Castings and forgings 7.3 Manufacture of embedded parts 7.4 Manufacture of flat gate 7.5 Manufacture of radial gate 7.6 Manufacture of mitre gate 8 Erection of Gate and Embedded Parts 8.1 Erection of embedded parts 8.2 Erection of flat gate 8.3 Erection of radial gate 8.4 Erection of mitre gate 8.5 Gate testing 9 Manufacture and Erection of Trash Rack 9.1 Manufacture of trash rack 9.2 Erection of trash rack 10 Acceptance 10.1 General 10.2 Phase acceptance 10.3 Acceptance materials Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix I Appendix K Appendix L Appendix M Appendix N Appendix
1 Scope
This Specification specifies the technical requirements and acceptance standard for manufacture and erection of steel gates (including trash rack, ditto hereinafter) of water resources and hydropower projects.
This Specification is applicable to manufacture, erection and acceptance of steel gates in medium and large water resources and hydropower projects. For Small hydro projects, reference may also be made to it.
2 Normative References
The following normative references contain the provisions which, through reference in this text, constitute provisions of this Specification. For dated reference, subsequent amendments (excluding error correction) to, or revision of, any of these publications do not apply. However, parties to agreements based on this Specification are encouraged to investigate the possibility of applying the most recent editions of the normative references below.
For undated references, the latest editions of the normative document referred to applies.
GB/T 228 Metallic Materials-Tensile Testing at Ambient Temperature
GB/T 229 Metallic Materials-Charpy Notch Impact Test (eqv ISO 148)
GB/T 232 Metallic Materials-Bend Test (eqv ISO 7438)
GB/T 699 Quality Carbon Structural Steels
GB/T 700 Carbon Structural Steels
GB/T 983 Stainless Steel Covered Electrodes (neq ANSI/AWS A5.4)
GB/T 985 Basic Forms and Sizes of Weld Grooves for Gas Welding, Manual Arc Welding and Gas Shielded Arc Welding
GB/T 986 Basic Forms and Sizes of Weld Grooves for Submerged Arc Welding
GB/T 1182 Geometrical Tolerancing - Generalities, Definitions, Symbols, Indications on Drawings (eqv ISO 1101)
GB/T 1184 Geometrical Tolerancing-Geometrical Tolerance for Features without Individual Tolerance (eqv ISO 2768-2)
GB/T 1231 Specifications of High Strength Bolts with Large Hexagon Head, Large Hexagon Nuts, Plain Washers for Steel Structures
GB/T 1591 High-Strength Low Alloy Structural Steels (neq ISO 4950)
GB/T 1800.2 Limits and Fits-Bases-Part 2: Basic Rules of Tolerances, Errors and Fits
GB/T 1801 Limits and Fits-Selection of Tolerancezones and Fits (eqv ISO 1829)
GB/T 2970 Thicker Steel Plates-Method for Ultrasonic Inspection
GB/T 3077 Alloy Structural Steel (neq DIN EN 10083-1)
GB/T 3323 Radiographic Examination of Fusion Welded Joints in Metallic Materials
GB/T 4237 Hot-Rolled Stainless Steel and Plate (neq JIS G4303)
GB/T 5117 Carbon Steel Covered Electrode (eqv ANSI/AWS A5.1)
GB/T 5118 Low Alloy Steel Electrodes (neq ANSI/AWS A5.5)
GB/T 5216 Structural Steels Subject to End-Quench Hardenability Requirements
GB/T 5293 Carbon Steel Electrodes and Fluxs for Submerged Arc Welding (eqv ANSI/AWS A5.17)
GB/T 5680 Austenitic Manganese Steel Castings
GB/T 6060.1 Roughness Comparison Specimens-Cast Surfaces
(eqv ISO 2632-3)
GB/T 6402 Steel Forgings-Method for Ultrasonic Examination (neq JIS G587)
GB/T 6414 Castings-System of Dimensional Tolerances and Machining Allowances (eqv ISO 8062)
GB/T 6654 Steel Sheet for Pressure Vessels
GB/T 7233 Methods for Ultrasonic Testing and For Specifying Quality Levels of Steel Castings (neq BS 6208)
GB/T 7659 Carbon Steel Castings Suitable for Welded Structure (neq ASTM A 216)
GB/T 8110 Welding Wires for Gas Shielding Arc Welding of Carbon and Low Alloy Steels (neq ANSI/A WS)
GB/T 8923 Rust Grades and Preparation Grades of Steel surfaces before Application of Paints and Related Products (eqv ISO 8501-1)
GB/T 9286 Paints and Varnishes-Cross Cut Test for Films
GB/T 9443 Methods of Liquid Pentrant Testing and Classification of Indication for Steel Castings
GB/T 9444 The Methods for Magnetic Particle Testing and for Specifying Quality Levels of Steel Castings
GB/T 11345 Method for Manual Ultrasonic Testing and Classification of Testing Results for Ferritic Steel Welds
GB/T 11351 Mass Tolerances for Castings
GB/T 11352 Carbon steel Castings for General Engineering Purposes (neq ISO 3755)
GB/T 12470 Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding (neq ANSI/AWS A5.23)
GB/T 14408 Low Alloy Steel Castings for General Engineering and Structural Purposes
GB/T 15056 Evaluation Method on Cast Surface Roughness
GB/T 15826.1-9 Machining Allowances and Tolerances for Steel Open die Forgings (eqv DIN 7527)
GB/T 16253 Steel Castings for Pressure Purposes (eqv ISO 4991)
GB/T 17854 Stainless Steel Electrodes and Fluxs for Submerged Arc Welding (eqv JIS Z3324)
DL/T 679 Code for Welder Technical Qualification
DL/T 5039 Specification for Design of Steel Gate in Hydraulic and Hydroelectric Engineering
JB 4730 Nondestructive Testing of Pressure Equipments
JB/T 9179.1-8 Machining Allowance and Tolerance of Open Die forgings on Hydraulic Press
SL 35 Hydrotechnics Metal Structure Welder Examination Rules
3 General Provisions
3.1 Technical documents
3.1.1 The following documents shall be provided prior to manufacture of gates and embedded parts:
(1) Design drawings, including general drawings, assembly drawings and parts drawings, and technical documents.
(2) Quality certificates of steel materials, welding materials and antirust materials.
(3) Quality certificates of standardized parts and nonstandard parts provided by partners.
3.1.2 The following documents shall be provided prior to erection of gate and embedded parts:
(1) Design drawings, including general drawings, assembly drawings, parts drawings, relevant, civil structural drawings and relevant drawings of gates to hoists, and technical documents.
(2) Factory certificates of gates.
(3)Acceptance documents and quality certificates for gate manufacture.
(4) Shipping lists, inspection documents of arrival of goods and assembly number figures.
(5) Location layouts of control points for erection.
3.1.3 Gates shall be manufactured and erected according to the design drawings and documents. If any modification is necessary, design modification notices shall be given in accordance with the relevant provisions of contracts.
3.2 Materials
3.2.1 The steel used for gates shall meet the requirements of design drawings and its properties shall satisfy the relevant provisions in Appendix A and factory quality certificates for it shall be provided. If there are no quality certificates, it shall be rechecked up to the standard and then may be used.
3.2.2 If ultrasonic flaw detection is necessary, it shall be carried out according to the standard GB/T 2970.
3.2.3 Factory quality certificates of welding materials (electrodes, welding wires and fusing agents) shall be provided. The mechanic properties and diffusible hydrogen contents of electrodes shall meet the standards GB/T 5117, GB/T 5118 or GB/T 983. The welding wires and fusing agents used for submerged arc welding shall meet the standards GB/T 5293, GB/T 12470 or GB/T 17854, and those for gas shielded welding shall meet the standards GB/T 8110.
3.3 Bench marks and measuring tools
3.3.1 The precision of all measuring instruments and steel rulers used for gate manufacture and erection shall meet the following requirements:
(1) Steel rulers with an accuracy not less than Grade l.
(2) Theodolites with accuracy above grade DJ2.
(3) Gradienters with accuracy above grade DJ3.
(4) Electronic total station, zenith and nadir telescopes with a measuring accuracy not less than one ten thousandth (1/10000).
The measuring tools and instruments shall be checked and calibrated regularly by legal metrological service.
3.3.2 The bench marks used for measuring elevations and axes and control points for gate erection shall be distinct, firm and easy to use
3.4 Marking, acceptance, packing and transportation
3.4.1 Manufacture and erection of gates and embedded parts shall be accepted in accordance with the relevant provisions in Chapter 10 Acceptance.
3.4.2 Gates shall be provided with identification markings with the following data:
(1) Name or emblem of manufactures.
(2) Product name.
(3) Type of gate or main technical parameters.
(4) Production date.
(5) Gravity centre and gross weight of gates.
3.4.3 Gate leaves shall be numbered in sections. The machined surface of them shall be reliably protected. Embedded parts may be packed up in bales and fastened firmly with steel frame and their accessories shall be encased in whole sets.
3.4.4 Whenever gates are lifted up, members of them shall be protected from being damaged or deforming. When trucked, gate leaves shall be placed steadily at proper positions and reinforced reliably. For transport of the members with over length, width and height, alerting plates shall be hanged up and close attentions shall be paid to protect roads, bridges, communication and electrical facilities from being destroyed.
4 Welding
4.1 Assessment of welding technology
4.1.1 Before manufacture and erection of gates, the units responsible for welding construction shall work out specifications for the welding procedure according to the gate structural features and quality requirements. The specifications will be subjected to assessment and welding work done with guidance of the specifications.
4.1.2 The welding technology assessment is to verify the validity and rationality of welding procedure specifications by testing the mechanical and other properties of welds.
4.1.3 The general process of welding technology assessment includes studying out welding technology guidance, welding specimens, preparing sample pieces, checking the specimens and sample pieces, testing welds whether has the required usage performance and finally bringing forward reports to evaluate the welding technology guidance.
4.1.4 The equipment and instruments used for welding technology assessment shall be at normal operating conditions. Steel and welding materials shall be up to the standards. The welders for specimens shall be skillful and have qualification certificates.
Contents of DL/T 5018-2004
Contents
Foreword
Explanatory Notes to the Wording of This Specification
1 Scope
2 Normative References
3 General Provisions
3.1 Technical documents
3.2 Materials
3.3 Bench marks and measuring tools
3.4 Marking, acceptance, packing and transportation
4 Welding
4.1 Assessment of welding technology
4.2 Welder's qualification
4.3 Basic provisions of welding
4.4 Weld inspection
4.5 Weld repairing and treatment
4.6 Postwelding stress-relief heat treatment
5 Bolted Connection
5.1 Preparation of bolt holes
5.2 Preparation of bolts
5.3 Bolt tightening
6 Surface Corrosion Protection
6.1 Pretreatment of surface
6.2 Surface coating
6.3 Quality inspection of paint coats
6.4 Metal spraying
6.5 Quality inspection of metal coats
7 Manufacture of Gate and Embedded Parts
7.1 Manufacture of parts and individual members of gate
7.2 Castings and forgings
7.3 Manufacture of embedded parts
7.4 Manufacture of flat gate
7.5 Manufacture of radial gate
7.6 Manufacture of mitre gate
8 Erection of Gate and Embedded Parts
8.1 Erection of embedded parts
8.2 Erection of flat gate
8.3 Erection of radial gate
8.4 Erection of mitre gate
8.5 Gate testing
9 Manufacture and Erection of Trash Rack
9.1 Manufacture of trash rack
9.2 Erection of trash rack
10 Acceptance
10.1 General
10.2 Phase acceptance
10.3 Acceptance materials
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
Appendix I
Appendix K
Appendix L
Appendix M
Appendix N
Appendix
