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In accordance with the requirements of Notice of National Development and Reform Commission Office on Printing and Publishing Professional Standard Project Plan in 2008 (FAGAIBANGONGYE [2008] No. 1242), the standard drafting group has revised this standard through the extensive investigation and study, careful summarization of practical experience and on the basis of widely soliciting for opinions.
The main technical contents of this standard are: project classification and quality evaluation, penstock manufacture, penstock installation, installation of plain gate, installation of radial gate, installation of mitre gate, installation of trash rack, installation of fixed winch hoist, installation of mobile hoist, installation of hydraulic hoist and installation of screw type hoist.
The main technical contents revised in this standard are as follows:
——the "excellent" grade evaluation standard of unit works is revised.
——the clause of "project classification and quality evaluation" is added.
——the quality evaluation standard of unit works is revised.
——the installation quality evaluation standard of plain roller-chain gate is supplemented.
——the installation quality evaluation standard of eccentric-hinged compression-type or pressure-filled radial gate is supplemented.
——the original "bridge type hoist installation work" is deleted.
——the original "hoist track installation work" is deleted.
——the original “Annex 1 Penstock manufacture works” is deleted.
The National Energy Administration is in charge of the administration of this standard, which was proposed by and is under the routine management of the Hydropower and Water Resources Planning and Design General Institute. The Technical Committee for Hydropower Steel Structure and Hoists of Energy Industry of the Standardization Administration of China is in charge of the explanation of specific technical contents. In case of any comment or suggestion in the process of implementing this standard, please send it to the Hydropower and Water Resources Planning and Design General Institute (Address: No. 2, North Alley, Liupukang, Xicheng District, Beijing, 100120).
Chief drafting organization of this standard: Sinohydro Bureau 8 Co., Ltd.
Participating drafting organizations of this standard: Mechanical and Electrical Company of SinoHydro Bureau 8 Co., Ltd. and Tianjin Institute of Hydroelectric and Power Research.
Chief drafters of this standard: Fan Yilin, Wang Qimao, Zeng Hui, Wang Jianwen, He Yinghong, Du Yi, Li Dongsheng, Zhang Jiang and Zhang Sheng.
Main examiners of this standard: Lin Zhaohui, Chen Hong, Hu Baowen, Fang Hanmei, Yao Changjie, Zhang Weiming, Zhao Yongping, Li Lili, Wan Tianming, Luo Wenqiang, Jin Xiaohua, Liao Yongping, Yu Xiquan, Long Zhaohui, Yang Qinghua, Li Lin and Li Shisheng.
Contents
Foreword i
1 General provisions 1
2 Terms and symbols 1
2.1 Terms 1
2.2 Symbols 2
3 Project classification and quality evaluation 2
3.1 Project classification 2
3.2 Quality evaluation 4
4 Penstock manufacture 5
4.1 Quality evaluation conditions 5
4.2 Inspection items and standard for evaluation 6
5 Penstock installation 17
5.1 Quality evaluation conditions 17
5.2 Evaluation of unit works for installation of embedded penstock 17
5.3 Evaluation of unit works for installation of exposed penstock 20
6 Installation of plain gate 21
6.1 Quality evaluation conditions 21
6.2 Evaluation of unit works for installation of embedded parts 22
6.3 Evaluation of unit works for installation of gate leaves 22
7 Installation of radial gate 35
7.1 Quality evaluation conditions 35
7.2 Evaluation of unit works for installation of embedded parts 35
7.3 Evaluation of unit works for installation of gate leaves 36
8 Installation of mitre gate 44
8.1 Quality evaluation conditions 44
8.2 Evaluation of unit works for installation of embedded parts 44
8.3 Evaluation of unit works for installation of gate leaves 45
9 Installation of trash rack 47
9.1 Quality evaluation conditions 47
9.2 Evaluation of unit works for installation of embedded parts and trash rack leaves 48
10 Installation of fixed winch hoist 49
10.1 Quality evaluation conditions 49
10.2 Evaluation of unit works for installation of fixed winch hoist 50
11 Installation of mobile hoist 52
11.1 Quality evaluation conditions 52
11.2 Evaluation of unit works for installation of mobile hoist 53
12 Installation of hydraulic hoist 63
12.1 Quality evaluation conditions 63
12.2 Evaluation of unit works for installation of hydraulic hoist 63
13 Installation of screw type hoist 66
13.1 Quality evaluation conditions 66
13.2 Evaluation of unit works for installation of screw type hoist 66
Annex A Quality evaluation forms for unit works 68
Explanation of wording in this standard 70
List of quoted standards 71
Explanation of provisions 72
Quality Grade Evaluation Standard of Unit Works of Hydropower Projects - Part 2: Installation of Hydraulic Steel Structures and Hoists
1 General provisions
1.0.1 This standard is prepared with a view to regulating the quality grade evaluation of unit works for Installation of Hydraulic Steel Structures and Hoists of Hydropower Projects, so as to ensure quality, safety and applicability, technology advancement and economic rationality.
1.0.2 This standard is applicable to the quality grade evaluation of the installation of steel gate, trash rack and hoist of hydropower projects as well as the unit works for manufacture and installation of penstock.
1.0.3 The quality evaluation of unit works shall be carried out after the results of the inspection items meet the requirements of corresponding acceptance specifications, and shall be provided with complete, full and accurate construction records.
1.0.4 The quality grade evaluation of unit works for installation of hydraulic steel structures and hoists of hydropower projects shall not only comply with the requirements of this standard, but also comply with those stipulated in the current relevant national standards.
2 Terms and symbols
2.1 Terms
2.1.1 unit works
the minimum complex unit of one or several work type(s) of the installation of hydraulic steel structures and hoists of hydropower projects divided according to the design structure, construction deployment and quality evaluation requirements, which is the basic unit for construction quality evaluation
2.1.2 partitioned project
the installation project which can be combined to exert a certain function in a structure or building
2.1.3 unit projects
the projects consisting of several partitioned projects and provided with independent construction conditions or independent functions
2.1.4 main items
the inspection items having a significant effect on the safety, use function and environmental protection of unit works, which are marked by △ in the evaluation forms of this standard
2.1.5 general items
inspection items other than main items
2.1.6 qualified items
the main items with 100% of the measured points meeting the qualified standard, or general items with more than 90% of the measured points meeting the qualified standard, while the measured values of the remaining points shall not be greater than 1.2 times the permissible deviation of the qualified standard
2.1.7 excellent items
the qualified items, of which more than 90% of the measured points have reached the excellent level
2.2 Symbols
P Sa——the surface treatment grade of local blast-cleaning in case of site construction;
RZ——the surface roughness symbol, indicating the sum of the mean of five maximum contour peak heights and that of five maximum contour valley depths within the sampling length;
Sa——the grade of derusting through blasting or ejecting in case of factory manufacture;
δ——the plate thickness or pipe wall thickness;
△——the symbol of a main item.
3 Project classification and quality evaluation
3.1 Project classification
3.1.1 The quality grade evaluation items of hydropower project should be classified into unit works, partitioned projects and unit projects.
3.1.2 The quality grade evaluation items of installation of hydraulic steel structures and hoists should be classified according to the requirements of Table 3.1.2.?
Table 3.1.2 Classification of quality grade evaluation items of Installation of Hydraulic Steel Structures and Hoists
Unit projects Partitioned projects Unit works
Spillway projects Installation of gate and hoist Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of embedded part of radial gate
Installation of radial gate leaf
Installation of fixed winch hoist
Installation of hydraulic hoist
Installation of screw type hoist
Installation of mobile hoist
Spillway tunnel (hole) project Installation of gate and hoist Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of embedded part of radial gate
Installation of radial gate leaf
Installation of fixed winch hoist
Installation of hydraulic hoist
Installation of screw type hoist
Installation of mobile hoist
Overflow dam (hole) project Installation of gate and hoist Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of embedded part of radial gate
Installation of radial gate leaf
Installation of fixed winch hoist
Installation of screw type hoist
Installation of hydraulic hoist
Installation of mobile hoist
Dam water diversion project Installation of gate and hoist, installation and manufacture of penstock and installation of trash rack Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of hydraulic hoist
Installation of mobile hoist
Installation of embedded part of trash rack
Installation of trash rack leaf
Manufacture of a single joint or a penstock segment; installation of penstocks in a concrete-poured segment or a position, such as installation of bend pipe, inclined pipe and horizontal pipe
Diversion tunnel project Installation of gate and hoist, installation and manufacture of penstock and installation of trash rack Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of hydraulic hoist
Installation of mobile hoist
Installation of fixed winch hoist
Installation of embedded part of trash rack
Installation of trash rack leaf
Manufacture of a single joint or a penstock segment; installation of penstocks in a concrete-poured segment or a position, such as installation of bend pipe, inclined pipe and horizontal pipe
Power plant project Installation of gate and hoist Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of fixed winch hoist
Installation of hydraulic hoist
Installation of mobile hoist
Ship lock project Installation of gate and hoist Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of embedded part of radial gate
Installation of radial gate leaf
Installation of embedded part of mitre gate
Installation of mitre gate leaf
Installation of fixed winch hoist
Installation of hydraulic hoist
Installation of mobile hoist
Diversion project Installation of gate and hoist Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of hydraulic hoist
Installation of fixed winch hoist
Water intake project Installation of gate, hoist and trash rack Installation of embedded part of plain gate
Installation of plain gate leaf
Installation of hydraulic hoist
Installation of fixed winch hoist
Installation of mobile hoist
Installation of embedded part of trash rack
Installation of trash rack leaf
3.2 Quality evaluation
3.2.1 The quality evaluation grades of unit works are classified into qualification grade and excellent grade.
3.2.2 A unit work will be evaluated as qualified when all of its testing items meet the requirements of qualified items.
3.2.3 A qualified unit work will be evaluated as excellent when the excellent rate of its main or general items is above 70%.
3.2.4 The quality grade evaluation of unit works shall comply with the following conditions:
1 All construction items of a unit work have been completed and accepted.
2 All quality-related defects have been treated or provided with treatment opinions approved by the supervision organization.
3.2.5 The quality grade evaluation of unit works shall be carried out according to the following procedures:
1 The construction organization conducts the self-inspection for the construction quality of unit works completed, and apply for acceptance by the supervision organization after passing the self-inspection.
2 After receiving the application, the supervision organization shall conduct the sampling re-inspection and the acceptance. The construction quality of important concealed unit works and key part unit works shall be jointly accepted by a team composed of the representatives of organizations such as the construction, design, supervision and construction organizations.
3 The unit works shall be subjected to quality grade evaluation after passing the acceptance.
3.2.6 The quality grade evaluation of unit works shall include the following data:
1Procedure documents such as construction drawings, construction schemes, construction records and acceptance data.
2 Quality inspection record form and quality grade evaluation form for unit works filled in by the construction organization.
3 The sampling re-inspection data on which quality opinions are signed by the supervising engineer.
3.2.7 The format of quality evaluation form for unit works should comply with the requirements of Annex A hereof.
4 Penstock manufacture
4.1 Quality evaluation conditions
4.1.1 Before being delivered, the penstock shall be inspected according to the current national standard GB 50766 Code for manufacture installation and acceptance of steel penstocks in hydroelectric and hydraulic engineering, and subjected to delivery recording as well as quality grade evaluation for unit works in accordance with those specified in Clause 3.2.
4.1.2 The unit division for quality grade evaluation of penstock manufacture shall comply with the following requirements:
1 For straight pipes, bend pipes and gradient pipes, a joint or a segment is regarded as a unit.
2 An expansion joint is regarded as a unit.
3 A bifurcation is regarded as a unit.
4.2 Inspection items and standard for evaluation
4.2.1 The quality evaluation standard of penstock circumference and joint length shall comply with the requirements of Table 4.2.1.
?
Table 4.2.1 Quality evaluation standard of penstock circumference and joint length (mm)
Item No. Item Quality standard Remarks
Qualified Excellent
△1 Difference between the actual circumference and the design circumference ±0.003D, with absolute value ≤24 ±0.0025D, with absolute value ≤20 Circumferential installation seam without backing
±0.103D, with absolute value ≤12 ±0.0025D, with absolute value≤10 Circumference of backing of the V-groove at circumferential installation seam
△2 Circumference difference of adjacent pipe joints δ<10 ≤6 ≤5 Circumferential installation seam without backing
≤6 ≤5 Circumference of backing of the V-groove at circumferential installation seam
δ≥10 ≤10 ≤9 Circumferential installation seam without backing
≤8 ≤7 Circumference of backing of the V-groove at circumferential installation seam
3 Difference between the length of a single-joint penstock and the design length ≤5 ≤4 —
Note: D——the inside diameter of the circular-section penstock, mm.
4.2.2 The quality evaluation standard of flatness of penstock orifice shall comply with the requirements of Table 4.2.2.
Table 4.2.2 Quality evaluation standard of flatness of penstock orifice (mm)
Item No. Item Quality standard
Qualified Excellent
1 Flatness of penstock orifice D≤5000 ≤2 ≤2
D>5000 ≤3 ≤2
4.2.3 The quality evaluation standard of pipe joint section shape shall comply with the requirements of Table 4.2.3.
Table 4.2.3 Quality evaluation standard of pipe joint section shape (mm)
Section shape Quality standard Remarks
Qualified Excellent
Circular Roundness ≤0.003D and ≤30 Roundness ≤0.003D and ≤25 Circumferential installation seam without backing
When the penstock is equipped with a stiffening ring, the difference between the maximum and minimum diameters of the pipe orifice at the same end is not greater than 4 When the penstock is equipped with a stiffening ring, the difference between the maximum and minimum diameters of the pipe orifice at the same end is not greater than 3 For the V-groove with backing at circumferential installation seam, at least 4 pairs of diameters are measured at the pipe orifice of each end
Oval The permissible length deviation of the major axis a and the minor axis b of the oval is ±0.003a or ±0.003b, of which, the absolute value is not greater than 6 The permissible length deviation of the major axis a and the minor axis b of the oval is ±0.003a or ±0.003b, of which, the absolute value is not greater than 5 —
Rectangle The permissible length deviation of the long side A and the short side B is ±0.003A or ±0.003B, of which, the absolute value is not greater than 6 and the diagonal difference is not greater than 6 The permissible length deviation of the long side A and the short side B is ±0.003A or ±0.003B, of which, the absolute value is not greater than 5 and the diagonal difference is not greater than 5. —
Regular-polygon The permissible deviation of circumcircle diameter is ±6; the difference between the maximum and minimum diameters is not greater than 0.003D and not greater than 8 The permissible deviation of circumcircle diameter is ±6; the difference between the maximum and minimum diameters is not greater than 0.003D and not greater than 7 —
Non-circular The local flatness of penstock is not greater than 4 per meter. The local flatness of the penstock is not greater than 3 per meter. —
4.2.4 The installation quality evaluation standard of the support ring, stiffening ring, thrust ring and dam ring shall comply with the requirements of Table 4.2.4.
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Table 4.2.4 Installation quality evaluation standard of the support ring, stiffening ring, thrust ring and dam ring (mm)
Item No. Item Quality standard Sketch
Support ring Stiffening ring, thrust ring and dam ring
Qualified Excellent Qualified Excellent
1 Perpendicularity a of support ring or stiffening ring to pipe wall a≤0.01H and ≤3 a≤0.02H and ≤5
2 Perpendicularity b of the plane formed by support ring or stiffening ring to the pipe axis b≤0.002D and ≤6 b≤0.004D and ≤12
3 Permissible deviation of spacing C between two adjacent ring plates ±10 ±30
For each item listed above, eight points shall be measured per circle
Note: For each item in the sketch, eight points shall be measured per circle.
4.2.5 The quality evaluation standard of the radial misalignment of longitudinal seam and circumferential seam shall comply with the requirements of Table 4.2.5.
Table 4.2.5 Quality evaluation standard of the radial misalignment of longitudinal seam and circumferential seam (mm)
Item No. Item Quality standard
Qualified Excellent
△1 Radial misalignment of longitudinal seam 0.1δ and ≤2.0 0.1δ and ≤1.5
2 Radial misalignment of circumferential seam δ≤30 0.15δ and ≤3.0 0.1δ and ≤2.0
30<δ≤60 ≤0.1δ ≤0.08δ
δ>60 ≤6.0 ≤5.0
△3 Misalignment of composite stainless steel plate weld 0.1δ and ≤1.5 0.1δ and ≤1.0
4.2.6 The quality evaluation standard of the post-welding deformation of longitudinal seam shall comply with the requirements of Table 4.2.6.
Foreword i
1 General provisions
2 Terms and symbols
2.1 Terms
2.2 Symbols
3 Project classification and quality evaluation
3.1 Project classification
3.2 Quality evaluation
4 Penstock manufacture
4.1 Quality evaluation conditions
4.2 Inspection items and standard for evaluation
5 Penstock installation
5.1 Quality evaluation conditions
5.2 Evaluation of unit works for installation of embedded penstock
5.3 Evaluation of unit works for installation of exposed penstock
6 Installation of plain gate
6.1 Quality evaluation conditions
6.2 Evaluation of unit works for installation of embedded parts
6.3 Evaluation of unit works for installation of gate leaves
7 Installation of radial gate
7.1 Quality evaluation conditions
7.2 Evaluation of unit works for installation of embedded parts
7.3 Evaluation of unit works for installation of gate leaves
8 Installation of mitre gate
8.1 Quality evaluation conditions
8.2 Evaluation of unit works for installation of embedded parts
8.3 Evaluation of unit works for installation of gate leaves
9 Installation of trash rack
9.1 Quality evaluation conditions
9.2 Evaluation of unit works for installation of embedded parts and trash rack leaves
10 Installation of fixed winch hoist
10.1 Quality evaluation conditions
10.2 Evaluation of unit works for installation of fixed winch hoist
11 Installation of mobile hoist
11.1 Quality evaluation conditions
11.2 Evaluation of unit works for installation of mobile hoist
12 Installation of hydraulic hoist
12.1 Quality evaluation conditions
12.2 Evaluation of unit works for installation of hydraulic hoist
13 Installation of screw type hoist
13.1 Quality evaluation conditions
13.2 Evaluation of unit works for installation of screw type hoist
Annex A Quality evaluation forms for unit works
Explanation of wording in this standard
List of quoted standards
Explanation of provisions
