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Power Industrial Standard of the People’s Republ ic of China

Specifications for manufacture,

Erection and Formal Acceptance of

Gate Hoists in Hydraulic and

Hydroelectric Projects

DL/T5019-94

Compiled by: Mid-South Design and Research Insti tute, Ministry of

Power Industry

Approved by: Min is try of Power Industry, P.R.China

Implementation Date: February 1st, 1995



Notice on Issuing Specifications for manufacture, Erection and Formal

Acceptance of Gate Hoists in Hydraul ic and Hydroelectr ic Projects by

Ministry of Power Industry of the People's Republic of China

DIANJI [1994] No.573

To power administrative bureaus, power bureaus, hydraulic and hydroelectric

research and design institutes, the hydraulic and hydroelectric planning and

design institute, the hydraulic and hydroelectric engineering company, the

hydroelectric project bureaus, hydroelectric manufacturers, defense

hydroelectric headquarters and related academies and institutes:

The Specifications for manufacture, Erection and Formal Acceptance of Gate

Hoists in Hydraulic and Hydroelectric Projects has been approved by the

Ministry of Power Industry as the recommended standard. It is hereby issued.The standard number is DL/T5019 and will be implemented from February 1st,

1995. At the same time, the Specifications on Manufacture, Erection and

Formal Acceptance of Metal Structures in Hydraulic Structures (SLJ,

DLJ201-80) will be terminated.

Problems and opinions arising in the implementation process shall be

submitted to the secretariat of the Technical Committee for Standardization of

Metal Structures in Hydroelectric Power Station, Ministry of Power Industry.

This standard is published by China Electrical Power Press.

September 26th, 1994



Contents

1. Subject Contents and Application Scope.....................................................1

2. Normative References .................................................................................13. General Provisions.......................................................................................3

4. Connection...................................................................................................6

5. Stationary Cable Hoist .................................................................................7

6. Screw Hoist................................................................................................22

7. Movable Gate Hoist ...................................................................................24

8 Hydraulic Hoists ..........................................................................................37

9. Acceptance Rules......................................................................................43

10. Sign, Packaging, Transportation and Storage .........................................44

Appendix A Test Conditions on Span of Bridge Framework, Door Panel and

Bridge Equipment (Supplementary)...............................................................46 Additional Explanations..................................................................................47



1. Subject Contents and Appl ication Scope

This standard has specified technical specifications on manufacture and

erection of the gate hoist in hydraulic and hydroelectric projects, acceptancerules, the test method and relevant regulations on the sign, packaging,

transportation and storage of hoists.

This standard is applicable to the electric-drive gate hoists for the hydraulic

and hydroelectric projects, including fixed hoisting gate hoists, screw gate

hoist, movable gate hoist and hydraulic hoist.

2. Normative References

GB699: Technical Requirements on Quality Carbon Structure Steel

GB700: Carbon Structure Steel

GB1591: Low-alloy Structural Steel

GB3077: Technical Specifications on Alloy Structural Steel

GB11352: Cast Carbon Steel Pieces for Common Projects

GB5680: Technical Specifications on High-manganese Steel Casting

JB/ZQ4297: Alloy Cast Steel

GB9439: Gray Cast Iron Pieces

ZBJ74003: Supersonic Flaw Detecting on Steel Boards for Pressure Vessels

GB5117: Carbon Steel Covered Electrode

GB5118: Low-alloy Steel Covered Arc Welding Electrode

GB983: Stainless Steel Electrode

GB5293: Flux for Submerged Arc Welding of Carbon Steel

GB12470: Fluxes for the Submerged Arc Welding of Low Alloy Steel

GB8110: Steel Welding Wire for CO2 Gas Shield Arc Welding

1



GB1300: Welding Wires for Welding

GB8923: Rusting and Derusting Grade of Steel Surface before Finishing

GB3181: Standard Specimen for Paint Film Colors

JB2299: Paint and Safety Signs of Elevating Machinery in Mines and

Projects

GB9286: Cross Cut Test on Pigmented Paint and Varnish Paint Film

GB985: Basic Type and Dimension of Welding Seam Grooves in

Autogenous Welding, Manual Electric Arc Welding andShielded Arc Welding

GB986: Basic Type and Dimension of Submerged Arc Weld Groove

SL36: General Specifications for Welding of Metal Structures in

Hydro-technics

GB3323: Radiography and Quality Grade of Fusion Welds

GBI1345: Analysis on Manual Supersonic Flaw Detecting Method and

Detection Result of Steel Welding Seams

GB3098.1: Mechanical Property of Fasteners: Bolts, Screws and Studs

GB3098.2: Mechanical Property of Fastener: Nut

GB/T1228: High-strength and Large Hex Bolts for Steel Structures

GB/T1229: High-strength and Large Hex Nuts for Steel Structures

GB/T1230: High-strength Steel Washer for Steel Structures

GB/T1231: Technical Specifications on High-strength and Large Hex Bolts,

Hexagonal Nuts and Washers

GB3632-3633: Technical Requirements for Sets of Torshear Type High

Strength Bolt Hexagon Nut and Plain Washer for Steel

Structures

GB1102: Round Strand Wire Rope

2



GB5972: Test and Rejection Standard of Steel Wire Ropes for Hoisting

GB6067: Safety Rules for Lifting Appliances

GB1800-1804: Tolerance and Fitting

GB5014: Flexible Dowel Pin CouplingGB/ZQ4382: Technical Specifications for Tooth Coupling

GB1184: Shape and Position Tolerance: Provisions on Unmarked

Tolerance

GB10095: Precision of Involute Cylindrical Gear

SD315: General Technical Specifications for Fixed Hoisting Gate Hoist

GB5796.4: Trapezoidal Thread Tolerance

GB10089: Precision of Column Worm and Worm Wheel

GB6414: Dimension Tolerance for Casting

GB197: Tolerance and Fitting of Regular Screw ThreadsGB4628: Column Wheel of Bridge Crane

GB3452.1: Dimension Series and Tolerance of Hydraulic Pressure and

Vapor-drive O-type Grommet

GB8564: Erection Technical Specifications on Water-turbine Generator

Units

GB1497: Primary Standard for Low-voltage Apparatus

GB/T13306: Tablet

GB4879: Rustproof Packaging

3. General Provisions

3.1 Design Principles

3.1.1 The design of gate hoists shall adopt the state-of-art technology and

featuring economically feasible, safe and reliable and convenient for

erection and maintenance. Also, the design shall be in accordance with

related design specifications of the state.

3.1.2 The structure and assembly form of the gate hoists shall be reasonableand simplified in accordance with relevant regulations on the railway

and road transportation of the state.

3.1.3 The accessories of the gate hoists shall be of serialization, unification

and standardization.

3.1.4 The working environmental temperature for the gate hoists shall be

-25-+40 degree.

3.2 Technical Materials

3.2.1 Before the manufacturing of the gate hoists, the following materials

3



shall be available:

(1) General plan, assembly drawings and detail drawings;

(2) Leave-factory quality certificates for primary materials;

(3) Leave-factory conformity certificates for bought-in components.

3.2.2 Before the erection of the gate hoists, the following materials shall be

available:

(1) Qualification proving documents and test reports for major parts

and structural members;

(2) Weld inspection record and non-destructive test report for the weld

assemblies;

(3) Flaw detection reports for large casting and forging;

(4) Heat-treatment test reports for major parts;

(5) Assembly inspection reports for key parts;

(6) Reports on the treatment method of significant deficiency and theafter-sales service test report of spare parts;

(7) Substitution advice notes of parts and materials;

(8) Design amendment advice notes for key design problems;

(9) Preassembling inspection report of products;

(10) Leave-factory test reports of products;

(11) Completion drawing, erection diagram and product maintenance

instruction book;

(12) Conformity certificates for bought-in components;

(13) Quality certificates and commercial invoice.

3.2.3 The manufacture and erection of gate hoists shall be carried out

according to the design drawing and relevant documents. If

amendments are needed, the written approval from the designer shall

be acquired.

3.3 Materials

3.3.1 Steel products adopted in the gate hoist shall be in accordance with

requirements of the design drawings. The carbon constructional qualitysteel and the carbon structure steel shall be in accordance with GB699

and GB700; low-alloy structural steel and alloy structural steel in

accordance with GB1591 and GB3077; casting carbon steels, high

manganese steel casting and alloy cast steel for common products in

accordance with GB11352, GB568 and GB 568; The gray cast iron shall

be in accordance with relevant regulations in GB9439. Steel products

shall have leave-factory quality certificates. Lack of the quality

certificate or the obscurity of the steel grade will result in re-check.

These products can only be used after they have been proved eligible.

3.3.2 The supersonic flaw detecting on steel products shall be carried out

4



according to ZBJ74003 if required.

3.3.3 Welding materials (electrode welding wire, flux) shall have the

leave-factory quality certificates. The chemical composition, mechanical

property and diffusible hydrogen content of electrodes shall meet

provisions in GB5117, GB5118 and GB983; the welding wire shall meetprovisions in GB8110 or GB1300 and the flux shall meet provisions in

GB5293 or GB12470.

3.4 Benchmark Point and Measurement Tools

3.4.1 Measurement tools and instruments used during the manufacture and

erection of gate hoist shall undergo regular detection by the legal

measuring control department.

3.4.2 The reference point designed to measure the elevation and the

benchmark point of the erection ax shall be clear, steady and easy tohandle.

3.4.3 Pre-installation, the pressure gauge shall be verified. The full scale on

the surface shall be 1.5-2 times of the test pressure and the precision

class shall be no lower than Level 1.5.

3.5 Corrosion Protection of Metal Structures

3.5.1 Before the antiseptic treatment on the surface of the metal structures,

the rust, oxide skin, welding slag, grease contamination, dust and

moisture shall be eliminated.

3.5.2 The derusting grade of primary members like the door panel and

machine frame shall be in accordance with the Level S. 2.5.

Comparison shall be made visually by photos. After derusting, the

surface roughness shall reach 20-50um. The surface roughness shall

be detected by exclusively-used detection devices.

3.5.3 When painting is adopted for corrosion protection, the following

requirements shall be met:

(1) The paint color shall be in accordance with provisions in GB3181. All primers shall be iron red. The finish coat is commonly crocus,

but other colors will do as well. The rotation part shall be bright red,

while the warning part shall be painted in the rampway that is 45o

with the horizon and with the yellow and black alternately

according to JB2299.

(2) During the painting, two layers of primer with each paint film of

25-34um shall be coated. Then, two layers of finish coat shall be

coated with each paint film of 60-70um. The total paint film

thickness shall be no less than 200um.

(3) The adhesion of paint film shall be no lower than the first level

5



quality in GB9286.

(4) The painting shall be carried out under the temperature higher

than 5 . The painting site shall have good ventilation. If the

member surface is moisture or it is a dusty day or the burning day,

no painting shall be carried out.

4. Connection

4.1 Welding

4.1.1 The welding joints shall be in accordance with GB985 and GB986.

Special requirements shall be marked on the pattern.

4.1.2 For important welding, before the welding, the qualification of welding

procedure shall be carried out in accordance with relevant regulations inSL36.

4.1.3 Welding seams can be divided into three classes according to

significances:

First-class Welding Seam:

(1) Butt welding of the girder, end girder, bearing girder of pulley, beam

web of winch drum bearing and wing panel;

(2) Butt weld of web and wing panels of landing legs; butt weld

connected the landing leg and girder;

(3) Butt weld of blocked joint in hydraulic cylinder, the attachment weld

between the cylinder body and the flange;

(4) Butt weld of blocked joint of the piston rod;

(5) Butt weld of blocked joint of the winch drum;

(6) Butt weld of the lifting lug board;

Second-class Welding Seam:

(1) Fillet weld of the girder, end girder, bearing girder and landing leg;

(2) The fillet weld connected the girder and the end girder; the filletweld connected the landing leg and the girder;

(3) The fillet weld connected the lifting lug board;

Third-class Welding Seam:

Other welding seams uncovered in the first and second classes.

4.1.4 All welding seams shall undergo the visual examination. The

appearance quality shall be in accordance with SL36.

4.1.5 The internal defect inspection of the welding seam shall be in

accordance with SL36.

6



4.1.6 The radiographic inspection of the welding seam shall be assessed

according to GB3323, while the supersonic flaw detecting according to

GB11345.

4.2 Bolted Connection

4.2.1 The performance rate and materials of the bolt, screw and stud shall be

in accordance with GB3098.1, while for the nut, they shall be in

accordance with GB3098.2.

4.2.2 Materials for the high-strength bolt shall select 20Mn, TiB, 35VB or 40B

orderly. Materials for matching nuts and washers shall select the 45 and

35 steels orderly.

4.2.3 The non-shear pattern high-strength bolts, nuts and washers shall be in

accordance with GB/T1228-1231, while the shear-pattern high-strength

bolt connection shall be in accordance with gb3632-3633.4.2.4 The fitting dimension and limit deviation for the high-strength bolts and

screws shall refer to Table 4.2.4.

Table 4.2.4

Nominal Diameter 12 26 20 (22) 24 (27) 30Bolt

Limit Deviation ±0.43 ±0.52 ±0.84

Nominal Diameter 13.5 17.5 22 (24) 26 (30) (33)Bolt Hole

Limit Deviation +0.430 +0.520 +0.840

4.2.5 Within the high-strength bolt connection range, the processing method

for the member interface shall meet the design requirements. The

friction factor of the interface shall reach the set value. After the

derusting, the inorganic zinc rich paint shall be painted.

4.2.6 The screwing down of the high-strength bolts can be divided into the

initial screwing and the final screwing. The moment for the initial

screwing shall be 30% of the set moment strengthen, while the final

screwing shall have the set moment. The bolt shall be screwed down

from the middle to both ends symmetrically.

4.2.7 Before the torque-indicating wrench is used, its moment strength shallbe checked and examined. Also, regular test shall be carried out during

the service process.

5. Stationary Cable Hoist

5.1 Requirements on Manufactur ing Technology

5.1.1 Framework

7



5.1.1.1 Bearing plates (like bearing blocks, motor standard, retarder seat,

arrester seat) for assemblies of the framework shall be processed.

After the processing, the plane error shall be no greater than 0.5mm.

The error of relative heights between processed planes shall be nogreater than 0.5-1mm.

5.1.1.2 After the welding, the permissible deviation for the wing panels and

webs of the framework shall meet provisions in Table 5.1.1.

Table 5.1.1 (mm)

SN Items Diagram Permissible

Deviation

1 Horizontal

inclinationdegree of

the wing

panels of

the slab

and beam

(1) box

beam;

(2) joist

(1)≤b/200≤2.0

(2)≤b/150≤2.0(this value is

measured at the

long web)

2 Flatness ofthe

marginal

plate of box

beams or

joists

≤a/150≤2.0

3 Verticality

of the box

beam or

the I-beamweb

≤H/150≤2.0

(this value is

measured at the

long gusset or thenode)

8



4 Degree of

symmetry

of the box

beam or

the joistwing panel

relative to

the beam

ax

≤2.0

5 Flatness of

the box

beam or

the I-beam

web

Checked by the

1m-long leveling

rule

Within H/3 region

of the compressive

region, f ≤0.7δ andthe concave

convex of the

neighboring

gussets not

exceeding one

part

In rest regions,

f ≤1.0δ

5.1.2 Wire Rope

5.1.2.1 Wire ropes shall meet relevant provisions in GB1102.

5.1.2.2 Wire ropes shall be rolled into the disk type during leaving factory,

transporting and storing process. The surface shall be anointed and

both ends shall be tied down and pasted with labels saying the order

number and specifications. Those without labels shall not be applied.

5.1.2.3 If the length of the wire rope is insufficient, it can't be lengthened.

5.1.2.4 The rejection of the wire ropes shall meet GB5972.

5.1.2.5 Safe requirements on the fixation and connection of wire rope endsshall meet provisions in GB6067.

5.1.3 Pulley

5.1.3.1 The wall thickness on both sides of the casting pulley groove shall be

no less than the nominal dimension. The permissible value for the

wall thickness error shall be: for the external diameter less than or

equal to 700mm, no greater than 3mm; for the external diameter

greater than 700mm, no greater than 4mm.

9



5.1.3.2 Defect treatment after the processing of the casting pulleys:

(1) No welding up is allowed in the axle hole. But a slight shrinkage

porosity not exceeding 10% of the total area is allowed. Also, the

defect with the single area less than 25mm2 and depth less than 4mm

within the following range is allowed, but the number shall meet thefollowing requirements:

For the bore diameter less than or equal to 150mm, not exceeding two;

For the bore diameter greater than 150mm, not exceeding three;

And the spacing between neighboring two defects shall be no less

than 50mm. Qualified though it is, the defect edge shall be abated.

(2) The single defect area on the rope groove surface or the end surface

shall be no greater than 200mm2 after the good metal is exposed after

the cleaning. But its depth shall not exceed 20% of the nominal wall

thickness and its number shall not exceed two on one same

processing surface. After the welding up, no heat-treat is needed butpolishing is required.

(3) In case that defects have exceeded those stated in said provisions,

rejections is necessary.

5.1.3.3 If there are cracks on the pulleys, no welding up is allowed and the

pulley shall be rejected.

5.1.3.4 Assembled pulleys shall be able to be rotated by the hand and their

lateral swing shall be no greater than 1/1000 of the reel of the pulley

diameter.

5.1.4 Reel

5.1.4.1 After the reel has been cut forming the rope groove, the wall thickness

shall be no greater than the nominal thickness, but the difference

between wall thicknesses shall not exceed the following:

For the bottom diameter of the rope groove less than or equal to

700mm, no greater than 3mm;

For the bottom diameter of the rope groove greater than

700-1000mm, no greater than 5mm;For the bottom diameter of the rope groove greater than 1000mm, no

greater than 8mm;

5.1.4.2 The tolerance of the bottom diameter of the reel rope groove shall be

no greater than h10 stated in the GB1801. For the double-sustained

center medium-high delivery lift hoist, the tolerance of the bottom

diameter of the reel rope groove shall be no greater than h9. The

cylindricity tolerance of the bottom diameter shall be no greater than

half of the diameter tolerance.

5.1.4.3 The cast iron reel and welded reel shall undergo the aging treatment.

The cast steel reel shall undergo the annealing treatment.

10



5.1.4.4 Defect treatment after the processing of reels:

(1) In case that the partial air bubbles and pores on the processing

surface have the diameter no greater than 8mm, depth no greater

than 20% of the nominal wall thickness (the absolute value no greaterthan 4mm) and no more than one in every 100mm and no more than

five of the total on the whole processing surface of the reel and no

welding up, the reel can be treated as qualified.

(2) After the elimination of the defect, the range allowed to be welded up

is shown in Table 5.1.4.

Table 5.1.4 (mm)

Material Reel

Diameter

Area of A Single

Defect (mm2)

Defect Depth Quantity

Cast Steel (Iron) ≤700 ≤200 ≤25% thickness ≤5

Cast Steel (Iron) >700 ≤250 ≤25% thickness ≤5

The defects on the same section and within 100mm range shall be no more

than two. After the welding up, no heat treatment is needed, but polishing is

required.

5.1.4.5 If there are cracks on the reels, no welding up is allowed and the

pulley shall be rejected.

5.1.5 Coupling

5.1.4.4 Defect treatment after the processing of gear coupling:

(1) No welding up is allowed on the tooth surface and the tooth groove. In

case that there are no more than one defect on the processing surface

of the gear and its length, width and depth don't exceed 20% of the

modulus with the absolute value no greater than 2mm, or the radial

slenderness defect width no greater than 1mm, the length no greaterthan 80% of the modulus with the absolute value no greater than 5mm,

the distance to the end face of the gear not exceeding 10% of the gear

width and no more than three gears having such defects on one

coupling gear surface, the gear coupling is qualified, but the edge of

the defect shall be abated.

(2) No welding up is allowed in the axle hole. In case that the single

defect area in the axle hole doesn't exceed 25mm2 and the depth

doesn't exceed 20% of the nominal wall thickness, its number shall

be:For the bore diameter less than or equal to 150mm, not exceeding two;

11



For the bore diameter greater than 150mm, not exceeding three;

And the spacing between neighboring two defects shall be no less

than 50mm. Qualified though it is, the defect edge shall be abated.

(3) Defects in other parts, after the good metal is exposed after the

cleaning, shall have the single area no greater than 200mm and depthnot exceeding 20% of the nominal thickness and the number not

exceeding two on the same processing surface. Welding up is

allowed.

(4) If defects exceed the said provisions or cracks turn up, the coupling

shall be rejected.

5.1.5..2 Before the processing of steel castings, the annealing treatment shall

be carried out.

5.1.5.3 The assembly of the elastic coupling shall meet provisions in GB5014.

The assembly of the gear coupling shall meet provisions inJB/ZQ4382.

5.1.6 Braked Wheel and Arrester

5.1.6.1 The concentricity tolerance of the braked wheel external circle and

the axle hole shall be no greater than level-8 in GB1184. The

roughness (Ra) of the working surface of the braked wheel shall be

no greater than 1.6μm.

5.1.6.2 The heat treatment hardness of the braked wheel brake surface shall

be no lower than HRC35-35 and the hardness penetration shall be no

less than 2mm.

5.1.6.3 Defect treatment after the processing of braked wheels:

(1) Defects like the air bubbles, pores or cracks are not allowed to happen

to the brake surface. No welding up is allowed.

(2) No welding up is allowed in the axle hole. In the axle hole, if the single

defect has the area not exceeding 25mm, the depth not exceeding

4mm, the defect number not exceeding two and the spacing greater

than 50mm, the braked wheel is qualified. But the defect edge shall beabated.

(3) Defects in other parts, after the good metal is exposed after the

cleaning, shall have the single area no greater than 300mm and depth

not exceeding 30% of the nominal thickness and the total number not

exceeding three on the whole processing surface (except the brake

surface and the axle hole). Welding up is allowed.

(4) If the defects exceed the said provisions or cracks turn up, the

coupling shall be rejected.

5.1.6.4 The circular runout of the assembled braked wheel shall meet

12



requirements in Table 5.1.6-1.

Table 5.1.6-1

Braked Wheel Diameter (mm) 100 200 300 400 500 600Circular Runout (μm) 80 100 120 120 120 150

5.1.6.5 During the assembling of the arrester, the displacement of the braked

wheel ax to that of the brake block shall not exceed the following

values:

(1) When the braked wheel diameter is less than or equal to 200mm, no

greater than 2mm;

(2) When the braked wheel diameter is less than or equal to 200mm, no

greater than 3mm;

(3) The actual contact area of the brake band and the braked wheel shallbe no less than 75% of the total area.

5.1.6.6 The brake band and the brake block shall be joined tightly. The edge

of the brake band shall be trimmed according to the brake shoe. The

rivet for fixation shall have the head embedded into the brake band of

more than 1/3 of the thickness.

5.1.6.7 The gap between the braked wheel and the brake shoe shall meet

provisions in Table 5.1.6-2.

Table 5.1.6-2 (mm)

Braked Wheel Diameter Allowable Value

Type 100 200 300 400 500

Short Stroke TJ2 0.4 0.5 0.7

Long Stroke JCZ 0.7 0.7 0.8 0.8

Hydraulic Pressure Electromagnetic 0.7 0.7 0.8 0.8

Hydraulic Pressure Handspike 0.7 0.7 0.8 0.8

5.1.7 Gear and Retarder

5.1.7.1 The precision of the exposed gear shall be no lower than level 9-8-8

in GB10095. The roughness of the surface shall be no greater than

6.31μ, while for the retarder, the two shall be no lower than level

8-8-7 in GB10095 and no greater than 3.2μ m respectively.

5.1.7.2 Defect treatment after the processing of gears:

(1) No welding up is allowed on the gear surface and the gear groove.

There are no more than one defect on the processing surface of thegear and its depth don't exceed 20% of the modulus with the absolute

13



value no greater than 2mm, or the radial slenderness defect width no

greater than 1mm, the length no greater than 80% of the modulus with

the absolute value no greater than 5mm, the distance to the end face

of the gear not exceeding 10% of the gear width and no more than

three gears having such defects on one gear surface, the gear isqualified, but the edge of the defect shall be abated;

(2) No welding up is allowed in the axle hole, but it is allowed that the

slight shrinkage porosity not exceeding 10% of the total area and the

number of the single defect shall not exceed that stated in Table

5.1.7-1. The edge of the defect shall be abated.

Table 5.1.7-1

Gear Diameter

(mm)

Defect Area

(mm2)

Defect Depth Neighboring

Spacing (mm)

Quantity

≤500 ≤25 ≤20% wall thickness >50 ≤3

>500 ≤50 ≤20% wall thickness >60 ≤3

(3) The range allowing welding up of the defects (gear end face excluded)

is shown in Table 5.1.7-2:

Table 5.2.7-2

Gear Diameter

(mm)

Defect Area

(mm2)

Defect Depth (mm) Quantity (on one

processing surface)

≤500 ≤200 ≤15% wall thickness ≤2

>500 ≤300 ≤15% wall thickness ≤2

(4) No crack or welding up is allowed on the gear surface and the gear

groove.

5.1.7.3 The heat treatment hardness of the gear surface shall meet the

following requirements:

(1) For the soft gear-surface gears, for the pinion, the thickness shall be

no lower than HB240 and for the gearwheel, no lower than HB190.

The hardness error between the both shall be no less than HB30.

(2) For gears having medium-hard gear surfaces and having hard gear

surfaces, the hardness of the gear surface is similar.

5.1.7.4 The casting of the retarder shall meet specifications on casting and

undergo aging treatment to eliminate the internal stress.

5.1.7.5 The engaged contact pattern percentage value of the involute gearshall refer to Table 5.1.7-3. It is not allowed to adopt the toothing

14



method to get the stated contact area.

Table 5.3.7-3

Precision Class7 8 9Gear Type Measuring Point

Contact pattern percentage ought to be no

less than

Height of Tooth 45 40 30Cylindrical

Gear Tooth Length 60 50 40

5.1.7.6 The minimum side gap of the involute gear shall refer to Table

5.1.7-4.

Table 5.7.1.4 (mm)

Incorporation Form I II

Lower than 58 0.085 0.170

50-80 0.015 0.210

80-120 0.130 0.260

120-200 0.170 0.340

200-320 0.210 0.420

320-500 0.260 0.530

500-800 0.340 0.710800-1250 0.420 0.850

1250-2000 0.530 1.060

2000-3150 0.710 1.400

Center Distance

3150-5000

Minimum side gap

0.850 1.700

Note: I: the standard guarantee side clearance; II: the maximum guarantee side gap.

5.1.7.7 The top clearance of the involute gear shall refer to Table 5.1.7-5.

5.1.7.8 Before the sealing of the retarder, the joint face (the lip included) of

the two retarders shall be coated with a layer of hydraulic sealadhesive, but it is unallowed to place any gasket. The sealment

flowing outside shall be cleaned.

Table 5.5.7-5

Gear Pressure Angle Standard Clearance (C) Maximum Clearance

20o Standard Tooth 0.25mn 1.1C

Note: mn: the modulus of the gear in the normal direction.

5.1.7.9 For the assembled retarders, the clearance between joint surfaces, atany position, shall not exceed 0.03mm and ensure no oil leakage

15



during the operation.

5.1.7.10 After the filing out of the bearing hole, no back taper shall happen. No

processing or grinding shall be taken on the joint surface of the

retarder.

5.1.7.11 The misalignment of the external edges of the joint surfaces of the

retarder shall not exceed the following:

(1) When the retarder total center distance is less than or equal to 500mm,

no greater than 2mm;

(2) When the retarder total center distance is greater than 500mm, no

greater than 3mm;

(3) When the retarder total center distance is greater than 1000mm, no

greater than 4mm;

5.1.7.12 If the retarder rotates without load at the speed no lower than theworking speed, without disturbance from other noises, on the contour

line of the shell split surface, at the place 1m to the back and forth of

the retarder, the noise shall be no greater than 85dB (A).

5.1.7.13 The retarder shall undergo the no-load breaking-in trial run in the

plant. After the completion of the said checks, the impurity shall be

filtrated by the 70-mesh net. Under the 120-135 , the impurity shall

be dried for 1h and cooled for 20-30min. The weight shall not exceed

the cleanliness indices in Table 5.1.7-6.

Table 5.1.7-6

Retarder Total Center

Distance (mm)

250 350 400 500 600 650 750 850 1000

Impurity Content No

Greater Than (mg)

70 100 150 200 350 380 500 800 1000

5.1.8 LT-type Speed Regulator

5.1.8.1 The concentricity tolerance of the circular conical surface and theaxle hole for the movable taper sleeves and the fixed wimble seat

shall be no greater than level 8 in GB1184. The roughness on the

working surface shall be no greater than ±6μm.

5.1.8.2 When castings are adopted for the movable taper sleeves, the

unevenness difference of the wall thickness of the external surface

unprocessed having the same semi-diameter shall be no greater than

2mm. The dynamic balancing test shall be carried out. Only after they

prove to be qualified can they be applied. When the weldments are

adopted, the weld quality must meet requirements on the drawing.5.1.8.3 The materials for the dihedral pry and shaft pin shall be no lower than

16



Q275. For the parts with threads shall have no defect like the crack,

stripping or burr.

5.1.8.4 The friction brake band and the movable pyramidal face must be

joined tightly. The screwhead shall have the buried depth in

accordance with the design requirements. After the processing, thedegree of taper of the pyramidal face shall have the error not

exceeding ±0.25o.

5.1.8.5 The actual contact area between the brake band and the anchorage

pyramidal face shall be no less than 75%.

5.1.8.6 After the assembling of the speed regulator, the axial movement of

the right and left taper sleeves shall be equal. The movement of the

swing flyball dihedral level shall be flexible. No blockage shall

happen.

5.1.9 Sliding Bearing

5.1.9.1 On the surface of the bearing friction, no bumping, pore, air bubble or

crake and other defects shall appear.

5.1.9.2 The oil gallery and oil hole must be smooth. The burr and sharp edge

shall be eliminated to prevent the scraping of the ax.

5.1.9.3 The contact angle of the journal and the bushing shall be 60o. The

contact area in every 1cm2 shall be no less than one point.

5.1.9.4 The top clearance between the journal and the bushing shall meet

provision in Table 5.1.9. The side clearance shall be 50%-75% of the

top clearance.

Table 5.1.9 (mm)

Journal Diameter D Top Clearance Journal Diameter D Top Clearance

50-80 0.07-0.14 180-260 0.12-0.23

80-120 0.08-0.16 260-360 0.14-0.25

120-180 0.10-0.20

5.1.10 Rolling Bearing

5.1.10.1 Before the assembling, the bearing must be washed by the clear

kerosene and the blown by the compressed air. It is not allowed to

use the cotton rag or cotton yarn for erasion. In case that the

wrapping paper hasn't destroyed, lubricating oil not hardened,

preservative oil in the antirust period and bearing used for the

consistent fat, the bearing can be free of washing before the

assembling. After the assembling, lubricating oil taking up 65%-80%

of the cavity shall be poured in.5.1.10.2 Assembled bearings, if unable to be assembled immediately, shall be

17



5.2.2.4 Checks shall be made on the platform elevation of the hoist to make

sure the deviation not exceeding ±5mm and the horizontal deviation

no greater than5/1000.

5.2.2.5 The erection of the hoist shall have the centering according to thelifting ax. The longitudinal and transverse ax deviation shall not

exceed ±3mm.

5.2.2.6 The length of the wire rope wound on the reel, when the sustained

center at the lower limit position shall be no fewer than four circles on

the reels, with two for fixation and two as safety loops. When the

sustained center is in the upper limit position, the wire rope shall not

wound to the reel.

5.2.2.7 For hoists with double sustained centers, the suspending distance

error shall not exceed ±3mm. After the wire rope is strained, the two

suspending shaft axes shall be in the same horizontal level with theheight difference not exceeding 5mm in the hole, For the

medium-and-high delivery lift hoist, the overall journey range shall not

exceed 30mm.

5.2.2.8 When two layers of wire ropes are wound on the reel, the wire ropes

shall be wound on the reel by layers orderly. No stacking or

gutter-chaos shall happen. Also, adjustments shall be made to make

the wire ropes of two reels shall enter the second layer. For the

medium-and-high delivery lift hoist adopting the free double-deck for

winding, during the winding of the second layer, the angle of reversal

shall be no greater than 2o and no less than 0.5

o. For the high lift hoist

adopting the row rope mechanism, the motor coordination shall be

ensured to restore the smooth transition.

5.2.2.9 Functions of the instrument-type height indicator shall meet the

following requirements:

(1) The indicating accuracy no lower than 1%;

(2) Functioning in the adjustable fixed value limit position, automatic

cut-out of the main circuit and alarming;

(3) Height detecting elements shall function in moisture protectionand anti-interference;

(4) Functioning in the correction of indication and the zero setting.

5.2.2.10 Functions of the combined load controller shall meet the following

requirements:

(1) The system accuracy no lower than 2% and the sensor precision

no lower than 0.5%;

(2) When the load reaches 110% the rated start-stop force,

functioning in the automatic cut-out of the main circuit and

alarming;

19



(3) The scale or numeral display of the receiving instrument shall

match the start-stop force.

(4) When two or more sustained centers are monitored, the

instrument shall be able to display the respective start-stop force

of the sustained center;(5) The sensor and its circuits shall function in moisture protection

and anti-interference.

5.2.2.11 The lubrication of rotatable parts like the retarder, the exposed gear,

bearing and hydraulic brake shall select the lubrication oil according

to the operation behavior and the temperature.

5.2.3 The erection of the electric equipment on the hoist shall meet relevant

regulations in SD315.

5.3 Trial Run

5.3.1 Test Requirements on Electric Equipment

Before the power-charging test, all connection lines shall be checked to meet

provision on the design. The insulation resistance of the whole circuit shall be

greater than 0.5MΩ before the test. In the test, the temperature rise of the

electromotor and the electric elements shall not exceed the respective

allowable values. The test shall adopt the self-contained electric equipment. In

the test, burnt components like contacts shall be replaced.

5.3.2 No-load Test

In the no-load test of the hoist, three time turnarounds of the upper and down

by the whole journey shall be carried out. Check and adjust the following

electric and mechanical parts:

(1) The electromotor shall run calmly and the degree of unbalance of the

three-phase current shall not exceed ±10%. The current value shall be

measured.(2) The electric equipment shall have no abnormal heat evolution.

(3) The limit switch (including the water filled flat crush opening connection

point) shall be checked and adjusted to make the movement reliable and

correct.

(4) The height indication and cargo indication shall be able the correctly

reflect the journey and weight. When the upper and lower limit positions

have been reached, the master switch shall be able to send signals and

automatically cut off the power to shut down the hoist.

(5) During the operation of all mechanical parts, no impulsive sound and other

abnormal sounds shall happen. At any part, the wire rope shall have no

20



friction with other parts.

(6) During the declutching, the brake block shall be opened totally. The

clearance shall meet the requirements. The declutching current value

shall be measured.

(7) For the stop gate hoists, when the DC declutch is adopted, thedeclutching DC current and the temperature of the electromagnetic coils

when the declutching has continued for 2min shall be checked and

recorded.

5.3.3 Load Test

The load test on the hoist is commonly carried out under the design head

behavior. The strobe shall fluctuate twice up and down in the full journey in the

anhydrous or still water gate slot. For the movable water start-stop main gate

or the movable water closed stilled water started emergency gate, twicefluctuations shall be carried out under the design head movable water behavior.

For the stop gate, under the design head movable water behavior, the guide

vane opening of the unit having 100% load rejection behavior, the total journey

quick-acting shutoff test shall be carried out.

During the load test run, the following electric and mechanical parts shall be

checked:

(1) The electromotor shall run calmly and the degree of unbalance of the

three-phase current shall not exceed ±10%. The current value shall be

measured.

(2) The electric equipment shall have no abnormal heat evolution.

(3) All protective equipment and signals shall be correct and reliable.

(4) During the operation, all mechanical parts shall have no impulsive sound.

The open gear jointing behavior shall meet requirements.

(5) No skidding, burned taste or smoking shall happen to the arrester.

(6) The reading of the cargo indicator and the height indicator shall be able to

reflect the start-stop forces under different opening of the strobe. The error

shall not exceed ±5%.(7) For the stop-gate hoist, the rapid closing time shall not exceed the

designed allowable value, commonly, 2min.

The maximum speed for the quick-acting shutoff shall not exceed 5m/min.

The maximum rotation speed of the electromotor (or speed regulator) shall

not exceed twice of the rated speed of the electromotor.

The friction surface of the centrifugal speed regulator shall have the

maximum temperature not exceeding 200 .

When the DC power supply is adopted for the declutching, the maximum

temperature of the magnet spools shall not exceed 100 .

21



5.3.4 After the said tests, no crack, permanent deformation, loosening or

damage of connections shall happen to the parts of the mechanism. No

abnormal heat evolution shall happen to the electric parts.

6. Screw Hoist

6.1 Manufacture

6.1.1 Screw

6.1.1.1 The straightness error of the screw shall be selected according to the

level D tolerance in GB1184, but shall not exceed 0.6mm in every

l000mm. For the length not exceeding 5m, the full-length straightnesserror shall not exceed 1.5mm; for length not exceeding 8m, not

exceed 2mm. The thread tolerance shall be manufactured according

to the level 9c in GB5796.4.

6.1.1.2 The pitch error (including the cyclic error) shall be no greater than

0.025mm and the pitch maximum accumulative error shall be: no

greater than 0.035mm within 25mm; no greater than 0.05mm within

100mm; no greater than 0.07mm within 300mm. In every increased

300mm, the error can be added by 0.02mm, but the full-length

accumulative error of the lead screw shall not exceed 0.15mm.

6.1.1.3 The working surface of the thread shall be smooth and free of burr. Its

roughness value shall be no greater than 6.3μm.

6.1.2 Nut

6.1.2.1 The thread tolerance shall be manufactured according to level 9H in

GB5796.4.

6.1.2.2 The working surface of the screw thread shall be smooth and free of

burr. Its roughness shall be no greater than 6.3μm.

6.1.2.3 The concentricity of the nut thread ax and the bearing external circleand the verticality of the thrust bearing composition plane shall be no

lower than the precision of level 8 in GB1184.

6.1.2.4 No air bubble, hole or crack shall be found on the working surface of

the screw thread of casting nuts.

6.1.3 Worm

6.1.3.1 The manufacturing accuracy of the worm shall be no lower than level

8b in GB10089.

6.1.3.2 No defect or welding up shall be found on the tooth surface of the

22



worm.

6.1.4 Worm Wheel

6.1.4.1 The manufacturing accuracy of the worm wheel shall be selectedaccording to GB10089, and no lower than level 8b.

6.1.4.2 After the casting worm wheels have been processed mechanically to

the nominal dimension, if defects like the air bubble and pore are

found out, treatment shall be made according to 5.1.7.2.

6.1.5 Engine Case and Airframe

6.1.5.1 The dimensional deviation of the engine case and the airframe shall

meet provision in GB6414.

6.1.5.2 Defects that influence the strength and injuring the appearance of theengine case and the airframe are not allowed to exist. But these

defects are allowed to be welded up. After the welding up, the heat

treatment shall be carried out.

6.1.5.3 No crack or welding up is allowed on the engine case and the

airframe.

6.1.5.4 The clearance of the engine case joint surfaces, at any part, shall not

exceed 0.03mm and ensure no leakage of oil during the operation.

6.2 Field Installation

6.2.1 The distance deviation between the longitudinal and transverse ax of

the screw hoist base plate and the measured lifting ax from the actual

position shall not exceed ±2mm and the elevation difference not exceed

±5mm.

6.2.2 The base plate shall be closely contacted with the sole plate, with the

clearance at any part not exceeding 0.5mm.

6.2.3 After the erection of the screw, the straightness of the external diameter

bus bar shall be no greater than 0.6/1000 and the full length not exceed

1/4000 of the screw.

6.3 Trial-run

6.3.1 The no-load test shall be carried out in the plant. If the screw is overlong

and there is difficulty for the trial run in the plant, as agreed by both

parties, the test can be carried out on the site. Before leaving the factory,

the nut can rotate in the full journey along the screw. It is important to

ensure the favorable contact and no blockage shall happen.

The no-load test shall check:

23



(1) whether the spare part assembly is in accordance with the design and

requirements in the general technical standards;

(2) The hand-operated part shall be able to rotate flexibly and calmly. No

blockage shall happen. The hand-operated and electric dual-purpose

mechanisms shall have the electric blocking devices reliable and safe.(3) Whether the movement of the travel switch is correct and delicate.

(4) Whether there is oil leakage in the interface of the engine case.

(5) Whether there if vibration or other abnormal phenomena during the

positive and negative operation of the electromotor.

(6) For the double-motor-driven hoists, they shall be electrified separately and

the direction of rotation shall match the fluctuation direction of the screw.

6.3.2 In the load test, the strobe shall be started and stopped twice in the total

journey.

Commonly, no load test shall be carried out in the factory. Only when the new

products are produced or there are requirements from users, according to the

mutual agreement, the load test shall be carried out in the plant or on the

operation site. The test shall check:

(1) The hand-operated part shall be able to rotate flexibly and no blockage

shall happen.

(2) The transmission spare parts shall rotate smoothly and no abnormal

sound, heat evolution and oil leakage shall happen.

(3) Whether the height indicating scale is accurate and the movement of the

up and down travel switch is reliable and delicate.

(4) For screw hoists installed with the overload protection devices and the

altitude reading devices, special tests on the signal sending and receiving

shall be made to ensure the delicate movement, correct indication and

safety and reliability.

(5) For the double-sustained-center hoists, the synchronized operation test

on the two screws shall be carried out to ensure that the two screws have

the lifting stokes matched. For the double-motor-driven hoists, whether

the operation is calm and the current is balanced.

7. Movable Gate Hoist

7.1 Manufacture

7.1.1 The tolerance for members of the door panel and the bridge framework

after they are welded shall be in accordance with Table 5.1.1 of 5.1.1.2.

7.1.2 The manufacture and assembly requirements of the steel wire rope,

pulley, winch drum, coupling, braked wheel, arrester, gear and the

retarder shall be in accordance with provisions stated in 5.1.2-5.1.7.

24



7.1.3 The technical specifications of the instrument-type height indicator and

the load controller shall be in accordance with provisions in 5.2.2.9 and

5.2.2.10.

7.1.4 The assembling of the sliding bearing and the antifriction bearing shall

be in accordance with provisions in 5.1.9 and 5.1.10.7.1.5 The manufacture and assembly of the wheel shall be in accordance

with:

Table 7.1.5-1

Tire Tread

Diameter

Rigidity of Medial Surface of

Pavement and Rim (HB)

Rigidity HB 260

Layer Depth

≤400 ≥15

>400300-380

≥20

(1) For wheels with the stop board and the rim internal surfacedemanding heat treatment, their performance shall be in accordance

with provisions in GB4628. The heat treatment rigidity shall be in

accordance with provisions in Table 7.1.5-1.

(2) After the cast wheels have been processed to the nominal dimension,

if sand holes or air holes are discovered, they shall be treated

according to the following:

1) In the axle hole, the gentle shrinkage porosity with the area not

exceeding 10% of the total and the individual defect in Table

7.1.5-2 are allowed, but the defect shall be abated.2) Except the step board and the rim medial surface, the defects

shall have the area not exceeding 3cm2 after the elimination and

have the depth not exceeding 30% of the wall thickness, with no

more than three on the same processing surface. Welding up is

also allowed. After the welding up, no heat treatment is needed

and the defects shall be polished.

Table 7.15-2

Wheel Diameter (mm) Area (mm2) Depth (mm) Spacing (mm) Quantity

≤500 ≤25 ≤4 >50 ≤3

>500 ≤50 ≤6 >60 ≤3

3) On the tire tread and the rim medial surface, no more than five

pocks with d≤1mm (when D≤500) or d≤1.5mm (when D>500) and

the depth ≤3mm. No other defects are allowed and no welding is

allowed also.

4) No crack, chap or peeling shall be found on the wheel.

(3) The post-installed wheels shall have the tolerance of the diameterrunout and the ending beat no lower than Level 9 and Level 10 in

25



GB1184.

(4) The post-installed wheels shall be able to turn flexibly.

7.1.6 The manufacture and assembly of the automatic pylon shall be in

accordance with:(1) The deviation between the center distance of the automatic pylon

sustained center and the location center shall be no greater than

2mm.

(2) The surface of the rotation axis and the pin roll surface of the

automatic pylon shall undergo the antiseptic treatment and be

able to rotate flexibly.

(3) A certain clearance shall be kept between the locking body and

the hanging body unhitch segment.

(4) The hydraulic unit and signal device of the hydraulic automatic

pylon shall be waterproof. The power supply sockets shall haveno leakage.

(5) The automatic pylon shall undergo the static balancing test before

leaving the factory.

7.2 Assembly and Erection

7.2.1 The bridge framework and the door panel shall reach the following

requirements after their assembly:

(1) The girder midspan camber shall be F= (0.9-1.4)L/1000 and the

maximum camber shall be within the L/10 range (Fig. 7.2.1-1 and

Fig. 7.2.1-2). The upwarp degree of the cantilever end shall be F0=

(0.9-1.4)L/350 (or (0.9-1.4) L/350). The camber and the upward

degree shall be measured when there is no solar temperature

influence. The detection conditions shall refer to Appendix A.

26



(2) The horizontal bending of the girder shall be f ≤ L/2000, but the

maximum shall not exceed 20mm (Fig. 7.2.1-1). This value shall be

measured on the web about 100mm to the upper cover plate.

(3) The lateral deviation of the girder upper cover plate shall be b≤ B/200

(Fig. 7.2.1-3). This value is allowed to be measured on the gusset

before the installation of the track.

(4) The vertical deflection of the girder web shall be h≤ H/500 (Fig. 7.2.1-1).

This value shall be measured on the long gusset.

27



(5) The difference between the diagonals of the bridge framework shall

be |D1-D2|≤5mm (Fig. 7.2.1-1).(6) The waving degree of the girder web shall be no greater than 0.7

within H/3 of the upper cover plate and no greater than 1.0 (Fig.

7.2.1-5) in the rest, when inspected by the 1m leveling rule.

(7) In the span direction, the verticality of the landing leg shall be h1≤

H1/2000 (Fig. 7.2.1-6) with the direction of tilt symmetric. If other

methods can guarantee the span of the gate hoist, this item can not

work as the inspection one.

28



(8) The relative difference of two landing legs calculated from the wheel

working face and the flange surface of the landing legs shall be no

greater than 8mm.

7.2.2 The erection of the trolley track shall be in accordance with:

(1) The tolerance value (Fig. 7.2.1-1) of the trolley span, when the track

gauge less than or equal to 2.5m, shall not exceed ±2mm; when the

track gauge greater than 2.5m, shall not exceed ±3mm.

(2) The relative difference between the trolley span T1 and T2 (Fig.

7.2.1-1), when the track gauge less than or equal to 2,5m, shall not

exceed ±2mm; when the track gauge greater than 2,5m, shall not

exceed ±3mm.

(3) The height difference of the trolley tracks on the same cross section,

when T≤2.5m, C≤3mm; when T>2.5m, C≤ 5mm (Fig. 7.2.2-1).

(4) The position deviation between the center line of the trolley track and

that of the waybeam web, when S<12mm, d≤6mm; when S≥12mm,

d≤1/2S. For the girder and girder truss, d=1/2S (Fig. 7.2.2-2).

29



(5) For the symmetric box beam of the track, the linearity of the center line

of the trolley track shall be no greater than 3mm (if there is walkingplatform, the bending shall only face the direction of the walking

platform).

(6) The trolley track and the cart girder top flange plate shall be joint tightly.

If partial spacing is greater than 0.5mm and the length exceeds 200mm,

the backing board shall be added.

(7) The trolley track joints shall meet the following requirements:

(1) The height difference on the joints of the trolley track shall be

C≤1mm (Fig. 7.2.2-3).

(2) The crossrange dislocation of the joints of the trolley track shall be

g≤1mm (Fig. 7.2.2-4).

(3) The clearance on the head of joints of the trolley track shall not be

greater than 2mm.

(8) The lateral local bending of the trolley track shall be no greater than

1mm in any 2m range.

7.2.2 The erection of the cart shall be in accordance with:

(1) No suspension phenomenon shall be found in the contact between

the cart wheel and the track surface

(2) Rails shall be inspected eligible before being laid.

30



(3) Before the lifting of the track, the installation datum line of the track

and the actual center line shall be decided. The benchmark line

deviation, when the span is less than or equal to 10m, shall not

exceed 2mm; when the span greater than 10m, shall not exceed

3mm.(4) The track gauge deviation shall meet the following requirements: when

the span is less than or equal to 10m, the division shall not exceed

±3mm and otherwise, not exceed ±5mm.

(5) The longitudinal straightness error of the track shall not exceed

1/1500. The difference between the summit and the lowest point on

the total travel shall be no greater than 2mm.

(6) The relative differences of elevations crossing two parallel tracks,

when the span is less than or equal to 10m, shall be no greater than

5mm at the pillar and otherwise, no greater than 8mm.

(7) The lapping positions of two parallel tracks shall be staggered with thedistance unequal to the wheelspan of the former and hinder one.

When the crosspiece is adopted on the joint, the deviation on the left,

right and upper of the joint shall be no greater than 1mm. The joint

clearance shall be no greater than 2mm.

(8) The erection of tracks shall be in accordance with requirements. The

comprehensive review shall be carried out the fastening conditions of

all bolts.

(9) The car bumper on the track shall be installed before the lifting of the

bridge machine (or gate hoist). Two car bumpers and buffers of the

same span shall be contact. Deviations shall be adjusted.

31



7.2.2 The erection of the running systems shall be in accordance with:

(1) When the bridge framework span is less than or equal to 10m, the

span deviation shall be no greater than ± 3mm and the relative

differences between spans on both sides shall be no greater than

3mm and otherwise, the deviation shall be no greater than ±5mm and

the relative difference shall be no greater than 5mm (Fig. 7.2.1-1).

(2) When the gate hoist span is less than or equal to 10m, the span

deviation shall be no greater than ± 3mm and the relative differences

between spans on both sides shall be no greater than 5mm and

otherwise, the deviation shall be no greater than ±8mm and the

relative difference shall be no greater than 8mm (Fig. 7.2.4-1).

32



(3) The measurement point of the span shall refer to 7.2.4-2. The pull

value and the corrected value adopted for measuring the span shall

refer to Appendix A.

(4) The vertical deflection of the wheel shall be a≤ l/400, l is the

measurement length (Fig. 7.2.4-3), which is measured when thewheel is aerial.

(5) The lateral deviation of the wheel shall be P≤ l/1000 and l is the

measurement length. The deflection directions of a pair of wheels on

the same axial line shall be reversing (Fig. 7.2.4-4).

(6) Under the same end girder, the coordination difference between

wheel, shall be no greater than 2mm for two wheels, no greater than

3mm for three or more wheels. Under the same compensating beam,

the coordination difference shall be no greater than 1mm (See Fig.

7.2.4-5). )

7.2.5 The erection of electric equipment shall be in accordance with:

7.2.5.1 The electric equipment in the control room shall have no nude or

charged part. Electric equipment on the trolley and the walking

platform shall have the protection covers or rails when the gate hoists

are used indoor and have rain hood when they are used outdoor. The

erection of the electric equipment shall be fixed with the verticality no

greater than 12/1000. A passage longer than 500mm shall be kept in

front of the equipment.

33



7.2.5.2 The superposition of resistance boxes shall not exceed four layers,

and otherwise, the boxes shall be fixed by the support. Relevant heat

radiation measures shall be taken. The expansion line of the resistor

shall be fixed.

7.2.5.3 The steel tubes for threading shall have no rust or burr on the internalwall. Antirust paintings shall be painted. The bending radius of the

pipe shall be greater than five times of the diameter (two ends of the

pipe are free from this). The orifice shall be sealed and the pipe

number shall be written according to drawings when leaving the

factory. The threading pipes can only undergo the sawing and adopt

the pipe clamps as joints. No joint shall be found on the conducting

wire in the pipes. There shall be wire-mouth protection device on the

orifice. The line pipe and neck groove can adopt the spot welding

spot welding for their fixation on the metal spare parts, but no burning

through is allowed. The position of the orifice of the outdoor gate hoiststeel tubes and the neck groove shall be able to prevent the direct

entry of the rainwater.

7.2.5.4 An individual slide wire fixer and electric conductor shall be able to

receive 2kV of the alternating voltage for one minute for the pressure

test.

7.2.5.5 All electrical equipment uncharged enclosure or support shall have

reliable earthing. When the construction bolt is adopted for earthing,

the bolt shall have a favorable contact with the interface. Reliable

electric connections shall be found between the trolley and the bridge

framework, between the gate hoist and the track (the wire core of the

trolley power supply cable can work as the ground lead of the cart

and the trolley).

7.3 Trial Run

7.3.1 Inspections before Trial Run:

(1) Inspections shall be carried out over the erection and lubrication

conditions of the mechanical parts, connected components, protectorsand lubrication systems. The result shall be in accordance with

requirements. All sundries along the track shall be eliminated.

(2) The fixation of the steel wire rope ends shall be checked. The twisting

direction in the winch drum and the pulley shall be right.

(3) Whether the wiring of the cable drum, the center electric conduction

device, the slide wire, the transformer and electric motors is correct,

whether there is looseness phenomenon and whether the earthing is

good shall be inspected.

(4) For the bi- motor-driven hoisting mechanism, whether the electromotor

is in the correct rotation direction and whether the rotation rate is

34



synchronized shall be checked. The hoisting mechanism with two

sustained centers shall make the steel wire ropes on both sides

equilong to the utmost.

(5) Whether the electromotor is in the correct rotation direction and

whether the rotation rate is synchronized shall be inspected.(6) The braked wheels of all mechanism shall be rotated by hand. The

last ax (like axletree, barrel arbor) shall rotate one circle and no

locking phenomenon shall happen.

7.3.2 The no-load test run hoisting mechanism and the running mechanism

shall be operated up and down three times in the journey. The following

electric and mechanical parts shall be inspected:

(1) The electromotor shall run smoothly and the three-phase current

shall be balanced.

(2) The electric equipment shall have no abnormal heatingphenomenon. The contact of the controller shall have no

cauterization.

(3) The action of the limit switch, the protector and the interlocking

device shall be correct and reliable.

(4) The cart and the trolley are running, no trail-gnawing shall be

found between wheels.

(5) When the cart and the trolley are running, the electric conduction

device shall run calmly without locking, jumping or badly sparkling

phenomena.

(6) All mechanical part shall have impulsive sound or other abnormal

sounds during their running.

(7) The brake block shall depart from the braked wheel without any

friction during the running process.

(8) All bearings and gears shall have favorable lubrication with the

bearing temperature not exceeding 65 degrees.

(9) Without the noise jamming, the noises produced by all systems

shall be no greater than 85dB (A) when measured at the drivers

seat (window closed).

7.3.3 Static Load Test:

The static load test aims to test the bearing capacity of all assemblies and

metal structures of the gate hoist.

When the trolley with a rated load (gradually mounting up to the rated load) is

operated on the overall length of the door panel or the bridge framework, the

door machine and the bridge machine performances shall reach the design

requirements. After the loads are removed, the trolley shall be stopped on the

girder midspan and the cantilever end. The measuring benchmark point shall

35



be decided. The trolley then shall lift the load of 1.25 times of the rated one to

100-200mm above the ground for no less than 10min. After the removing of

the loads, the inspection over whether the permanent deformation happens to

the door panel or the bridge framework shall be carried out. This action shall

be carried out three times and no permanent distortion shall be found on thedoor panel or the bridge framework. The trolley shall be driven to the landing

leg of the gate hoist or the span end of the bridge framework. The actual upper

bend value and the upwarp value shall be no less than 0.7/1000L of the

midspan and than 0.7/350L1 (0.7/350L2) on the cantilever end. Then, the

trolley shall be kept on the midspan and the cantilever end. It shall lift a rated

load and inspections over the deflection value (calculated from the upper bend

value and the upwarp value) of the girder shall be carried out. The value shall

be no greater than 1/700L of the midspan and 350L1 (or 1/350L2) on the

cantilever end.

After the static load test, all parts of the gate hoist shall have no phenomena

like the failure, looseness or damage of connections that influence the safety

and function of the gate hoists shall happen.

7.3.4 Dynamic Loading Rest:

The dynamic loading rest aims to inspect the working performance of the

systems and arrester of the gate hoists. The dynamic loading rest shall adopt

the load 1.1 times of the rated one. The test shall adopt the system

combination method according to the design requirements. Two systems shall

be operated at the same time. Repeated start, running, parking, co-rotation,

reversal shall be carried out for one hour. All systems shall be flexible and

reliable. The limit switch, security protection interlocking devices and the

anticreep device shall act correctly and reliably. No flaw shall be found in the

spare parts. No looseness shall be found on the joint.

7.3.5 The test block for the loading test shall adopt the special test block.

when the lifted rated load exceeds 2000kN and there is difficulty

adopting the special test block, the hydraulic pressure dynamometershall be used for the static load test.

7.3.6 Gate hoists that haven't undergone experimentation in the factory shall

meet the following requirements before leaving the factory:

(1) General Preassembling: the trolley (steel wire ropes and hooks

excluded), landing leg and lower separator, landing leg and the girder

and the running gear shall be preassembled. The integrity of the spare

parts and the correctness of the physical dimension shall be examined.

The preassembling sign shall be marked. If the landing leg and the

girder are not preassembled, reliable techniques shall be adopted to

36



ensure the correctness of the physical dimension.

(2) Non-load Running Test: the running systems shall undergo the

experiment when the wheel is aerial. The hoisting mechanism shall

undergo the experiment when there is no steel wire rope or hook.

The non-load running test shall make all systems rotate positively and

reversely for more than 30min accumulatively. All systems shall run

normally after the test.

8 Hydraulic Hoists

8.1 Manufacture

8.1.1 Manufacture of Oil Cylinder:

8.1.1.1 The manufacture of the cylinder body shall meet the following

requirements:

(1) The roughcast for the cylinder body shall give preference to the

integrated segment seamless steel pipes and can also adopt the

progressive welding seamless steel pipes, forgings or castings.

(2) The tolerance of dimension of the cylinder body internal diameter

shall be no lower than H9 in GB1801, the roundness tolerance no

lower than level 9 in GB1184 and the straightness tolerance of the

internal surface bus bar shall be no greater than 0.2/1000.

(3) On the flange end of the cylinder body, the tolerance of the

circular runout shall be no lower than level 9 in GBI184 and the

squareness tolerance between the flange end surface and the

cylinder body ax shall be no lower than level 7 in GB1184.

(4) The roughness of the internal surface of the cylinder body, when

the grommet is adopted for the plunger, no greater than 0.8μm;

when other sealing elements are adopted, no greater than 0.4μ m.

8.1.1.2 The manufacture of the cylinder lid shall meet the followingrequirements:

(1) The cylindricity tolerance of the coordination parts between the

cylinder lid and related parts shall be no lower than level 9 in

GB118. the concentricity tolerance shall be no lower than level 7.

(2) The squareness tolerance of the coordination end surface

between the cylinder lid and the cylinder body and the cylinder lid

ax shall be no lower than level 7 in GB1184.

8.1.2 The manufacture of the plunger shall meet the following requirements:

(1) The external diameter tolerance of the plunger shall be no lower

37



than e8 in GB1801.

(2) The concentricity tolerance of the plunger external diameter

versus the inner bore shall be no lower than level 8 in GBI184.

(3) The cylindricity tolerance of the plunger external diameter shall be

no lower than level 9 in GB1184.(4) The squareness tolerance of the plunger end surface versus the

ax shall be no lower than level 7 in GB1184.

(5) The roughness of the plunger external circle cylinder shall be no

greater than 0.8μm.

8.1.3 The manufacture of the cylinder shaft shall meet the following

requirements:

(1) The external diameter tolerance of the cylinder shaft guide

segment shall be no lower than e8 in GB1801.

(2) The roundness tolerance of the cylinder shaft guide segment shallbe no lower than level 9 in GB1184. The straightness tolerance of

the external diameter busbar shall be no greater than 0.1/1000.

(3) The squareness tolerance between the cylinder shaft end face

contacting with the plunger and the countershaft axle line shall be

no lower than level 7 in GB1184.

(4) The screw thread of the cylinder shaft shall adopt the precision of

level 6 in GB197.

(5) The roughness of surface of the external diameter of the cylinder

shaft guide segment shall be no greater than 0.4μm.

(6) The surface of the cylinder shaft shall adopt the overlay welding

stainless steel for antirust. After the processing, the stainless steel

layer thickness shall be no less than 1mm.

(7) The surface of the cylinder shaft undergoes the chroming for

antirust. 0.04-0.05mm creamy white chromium shall be plated and

0.04-0.05mm hard chromium shall be plated. The coating

thickness on a single side shall be 0.08-0.10mm.

8.1.4 The manufacture of the guide sleeve shall meet the following

requirements:(1) The guide surface coordination tolerance of dimension shall be no

lower than level H9 and level e8 in GB1801.

(2) The cylindricity tolerance of the guide surface shall be no lower

than level 9 in GB1184.

(3) The concentricity tolerance of the guide surface and the

coordination surface shall be no lower than level 8 in GB1184.

(4) The roughness of the guide surface shall be no lower than 0.4μ.

8.1.5 Sealing materials shall meet the following requirements:

(1) The sealment properties of the o-rings shall meet provisions in

38



GB7038 or GB7039.

(2) The dynamic sealing pieces shall have performances in resisting

the tearing strength, high voltage, proofing oil, water, low

permanent deformation, small frictional resistance, no adhesion

and ageing resistance.

8.1.6 The fastener for the upper and lower flanges and the fasteners for the

sealing devices shall undergo the antiseptic treatment. As required,

the stainless steel can be adopted. The galvanization or black finish

can be used to the surface as well. No pit or strip is allowed on the

screw thread. The buckling in a small part shall not exceed two.

8.2 Assembly

8.2.1 Hydraulic elements shall have quality certificates and providecertification of quality and in-plant records. They shall also have tidy

and beautiful outline and no damage.

8.2.2 Before the assembly of the hydraulic cylinder, kerosene shall be used

to clean the spare parts. Hydraulic elements shall be decomposed and

cleaned according to circumstances. No rapture shall happen to the

spring in the valve. The valve body shall be able to freely fluctuate and

no blockage shall happen.

8.2.3 During the assembly, the surface of the spare parts shall have no

bumping or friction mark. It is prohibited to adopt the iron rod to knock

the spare parts. The fasteners shall be screwed down according to the

order.

8.2.4 The oil seal shall be compressed to the design size. The joints of two

neighboring oil-tight joints shall be staggered higher than 90o.

8.3 Shop Test

8.3.1 Oil for Test

8.3.1.1 If the rated operating pressure of the tested hydraulic cylinder isgreater than or equal to 16MPa, the kinematic viscosity of the oil shall

be 25-32mm2/s; while less than 16MPa, 17-23mm2/s.

8.3.1.2 Test Oil Temperature: during the type approval test, 50±5 ; during

the leave-factory test, 20±50 .

8.3.1.3 Filtration Precision of Test Oil: for the plunger pump, no lower than

20μm; for the vane pump and gear wheel pump, no lower than 30μ m.

8.3.1.4 The test oil shall be capable of antirust.

8.3.2 Pressure Gauge for Test

39



8.3.2.1 Precision: during the type approval test, error no less than ±0.5%;

during the leave-factory test, no less than ±1.0%.

8.3.2.2 The measurement range shall be 140%-200% of the maximum

pressure value.

8.3.3 Leave-factory Test on Hydraulic Cylinder

8.3.3.1 No-load test: under the no-load condition, the hydraulic cylinder moves

back and force twice. No externally oil leakage or crawling shall

happen.

8.3.3.2 Minimum movement pressure test: without the load, the hydraulic

pressure is increased to the lowest starting pressure during the inching

of the cylinder shaft. Its value shall be no greater than 0.5MPa.

8.3.3.3 Voltage-withstanding Test: when the rated pressure of the hydraulic

cylinder is less than or equal to 16MPa, the test pressure shall be 1.5times of the rated pressure; while for greater than 16MPa, 1.25 times.

The test pressure shall last more than 10min, but no externally oil

leakage, permanent deformation or destroy shall happen.

8.3.3.4 Externally Oil Leakage Test: under the rated pressure, the plunger is

stopped on one end of the oil cylinder. The pressure shall be

maintained for 30min and no leakage shall happen.

8.3.3.5 Internal Leakage Test: under the rated pressure, the plunger is

stopped on one end of the oil cylinder. The pressure shall be

maintained for 10min. The internal leakage quantity shall not exceed

those stated in Table 8.3.3.

Table 8.3.3

Oil Cylinder Internal

Diameter (mm)

Oil Leakage

Amount (mL/min)

Oil Cylinder

Internal Diameter

Oil Leakage

Amount (mL/min)

900 31.80 280 3.10

820 26.40 250 2.50

710 19.80 220 1.90

630 15.60 200 1.55

560 12.30 180 1.25

500 9.80 160 1.00

450 8.00 140 0.75

400 6.50 125 0.55

360 5.10 110 0.45

320 4.00 100 0.40

8.3.4 During the operation, the noise of the oil pump station shall be lower

than 85dB (A).8.3.5 The leakage test on the oil container and the quality requirements on

40



cleaning shall meet relevant regulations in GB8564. Pipelines shall be

cleaned in the plant with the cleaning quality meeting relevant

regulations in GB8564.

8.3.6 Qualified hydraulic cylinders, oil containers and pipelines shall have

their exposed hydraulic fluid connections sealed by the oil-proof plugs.

8.3.7 Check of Electric Equipment:

(1) All electric elements shall have product qualification certificate.

They shall have beautiful outline and no damage.

(2) The operating mechanism and its accessories shall be operated

flexibly. The opening and closing of auxiliary switch contacts shall

be correct.

(3) The insulation resistance of the electric circuits shall be no less

than 0.5MΩ.

8.4 Erection

8.4.1 The distance deviation between the longitudinal and transverse ax of

the hydraulic hoist framework and the measured lifting ax from the

actual position shall not exceed ±2mm and the elevation difference not

exceed ±5mm. For the double-sustained-center hydraulic hoist, the

height difference of the bearing surface shall not exceed ±0.5mm.

8.4.2 Clearance on the built-up surface of the framework steel beams and the

thrust bearings shall be no greater than 0.05mm. The partial clearance

shall be no greater than 0.1mm and the depth shall not exceed 1/3 of

the width of the built-up surface. The accumulative length shall not

exceed of the perimeter. The horizontal deviation of the thrust bearing

superface shall be no greater than 0.2/1000.

8.4.3 Before the installation, whether the cylinder shaft has deformed shall be

checked. Under the vertical status of the cylinder shaft, the verticality

shall be no greater than 0.5/1000 and the full length not exceed 1/4000

of the shaft. Whether there is bumping or galling on the inwall of the oil

cylinder shall be checked.

8.4.4 During the lifting of the hydraulic cylinder, the number of supportingpoints or sustained centers shall be decided according to the diameter,

length and weight of the hydraulic cylinder to prevent deformation.

8.4.5 When the cylinder shaft is connected with the strobe (or drawbar)

hoisting eyes and when the strobe is released to the bottom, about

50mm clearance shall be kept between the plunger and the bottom end

cover of the oil cylinder to ensure the rigor closing of the strobe.

8.4.6 The bending, cleaning and erecting of the pipelines shall meet relevant

provisions in. The installation of the pipelines shall reduce the

resistance and have the layout clear and reasonable.

8.4.7 The upper and lower off contacts and water-filled connection points of

41



9.2 Erection Final Acceptance

9.2.1 The inspection shall be carried out by the erection department of the

manufacturer according to the pattern and this standard. Only after the

inspection result is eligible can acceptance be carried out.

9.2.2 The erection department shall hand over all technical materials

provided by the manufacturer besides the following technical materials:

(1) Erection completion drawing;

(2) Design amendment advice;

(3) Final determination records and debugging records of the

installation dimension;

(4) Weld inspection reports and related records;

(5) Treatment records of significant deficiencies during the erection

process;(6) During the leave-factory acceptance, all materials provided by the

manufacturer.

9.3 Warranty Period

The manufacturer shall promise that products shall work normally within 24

months calculated from the operation day but within a period not exceeding 18

months calculated from the delivery time as long as the user has carried out

safe keeping and reasonable installation and correction operation. Or, the

manufacturer shall provide free repair or replacement.

10. Sign, Packaging, Transportation and Storage

10.1 Sign

The tablet shall be made on the obvious part of the gate hoist in accordance

with GB/T13306. It shall read as the product type and title, leave-factory

number, main technical parameters, manufacturing date and manufacturername.

10.2 Packaging

10.2.1 Accessories fixed on the machine frame shall have nude packing if the

weight hasn't exceeded the limit when leaving the factory. During the

nuke-packing transportation, safety protection measure and moisture

proof measures shall be adopted. For the hydraulic hoists, measure to

prevent the distortion of the piston rod shall be taken.

10.2.2 The packaging of precision components, regulator cubicles and

44



instruments shall be in accordance with GB4879.

10.2.3 The attachment papers for the gate hoist shall be complete and placed

in the packing box after being sealed by the plastic bag.

10.3 Transpor tation

When gate hoists are transported openly or in cases, they shall be placed

steadily. Measures shall be taken to prevent distortion in accordance with

relevant regulations of land transportation, sea transportation and air

transportation. For precision components, regulator cubicles and instruments,

moisture proof measures shall be taken.

10.4 Storage

10.4.1 Products shall not be placed in the open air naked. If they have to beplaced naked, the electromotor, arrester and electric control cabinet

shall be dismantled and stored in the storehouse. The mainframe

machinery shall adopt the rain-proof, antirust and windproof measures.

Measures shall be taken to prevent distortion of hydraulic hoists. The

hydraulic hoists shall be kept in the storehouse and guarded by people.

10.4.2 For the long-term storage, the products shall be cleaned once each

year. Preservative oil shall be coated.

45



Appendix A Test Condit ions on Span of Bridge Framework,

Door Panel and Bridge Equipment

(Supplementary)

A.1 Test Condi tions for the Br idge Framework and the Door Panel

A.1.1 The midspan camber of the girder and the upwarp degree of the

cantilever required in this standard shall be the value of the installed

bridge framework and the door panel.

A.1.2 When the gradienter is adopted for measuring, measurement distancefrom the lens shall be more than 2m.

A.1.3 Measurement shall be carried out without the influence from the

sunshine.

A.2 Detect ion Condi tions of Span of the Br idge Machine and Gate Hoist

A2.1 During the measurement, the pull value and the corrected value stated in

Table A1 shall be adopted.

Table A1

Span (m) Pull Value

(N)

Section Size of Steel Tape (mm*mm)

10*0.25 13*0.2 15*0.2 15*0.25

Corrected Value

10-12 1 1 0.5 0.5

13-14 1 1 0.5 0

15-16 1 1 0.5 -0.5

17-18

100

1 0.5 0 -1.0

Note: The corrected values in this table have deducted the elastic elongation generated by the added

50N as stated in Detection Rules on Steel Tapes (JJG4-89).

A2.2 During the measurement, the temperature of the steel tape and the crane

shall be the same. The steel tape shall not swing and shall drop naturally.

A2.3 The actual span of the crane will be the reading on the steel tape, plus

the corrected value in this table and the measured corrected value

( positive or negative, eligible after the test by the first-class

measurement department ) of the steel tape.

46



Addit ional Explanations

This standard is proposed by the Hydropower Development and Rural

Electricity Department of the Ministry of Power Industry.

This standard is under jurisdiction of the Technical Committee for

Standardization of Metal Structures in Hydroelectric Power Station, the

Ministry of Power Industry.

This standard is drafted by Mid-South Design and Research Institute of the

Ministry of Power Industry.

This standard is mainly drafted by Xue Ruibao.

dlt 5019-94 specification for manufacture-erection and formal acceptance of gate hoist in hydraulic...

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