Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Contents
1. Subject Contents and Application Scope .....................................................1
2. Normative References .................................................................................1
3. 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
2. Normative References
GB699:
GB700:
GB1591:
GB3077:
GB11352:
GB5680:
JB/ZQ4297:
GB9439:
GB5118:
GB983:
GB5293:
GB12470:
GB8110:
GB1300:
GB8923:
GB3181:
JB2299:
GB9286:
GB985:
GB986:
SL36:
GB3323:
GBI1345:
GB3098.1:
GB3098.2:
GB/T1228:
GB/T1229:
GB/T1230:
GB/T1231:
GB5972:
GB6067:
GB1800-1804:
GB5014:
GB/ZQ4382:
GB1184:
GB10095:
SD315:
GB5796.4:
GB10089:
GB6414:
GB197:
GB4628:
GB3452.1:
GB8564:
GB1497:
GB/T13306:
GB4879:
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 reasonable
and 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 the
after-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 quality
steel 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
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 in
SL36.
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 fillet
weld 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
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 no
greater 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
SN
1
Items
Horizontal
inclination
degree of
the
wing
panels of
the
slab
and beam
(1)
box
beam;
(2) joist
Flatness of
the
marginal
plate of box
beams or
joists
Verticality
of the box
beam
or
the I-beam
web
(mm)
Diagram
Permissible
Deviation
(1) b/2002.0
(2) b/1502.0
(this
value
is
measured at the
long web)
a/1502.0
H/1502.0
(this
value
is
measured at the
long gusset or the
node)
Degree of
symmetry
of the box
beam
or
the
joist
wing panel
relative to
the beam
ax
Flatness of
the
box
beam
or
the I-beam
web
2.0
Checked by the
1m-long leveling
rule
Within H/3 region
of the compressive
region, f0.7 and
the
concave
convex
of
the
neighboring
gussets
not
exceeding
one
part
In rest regions,
f1.0
Material
Cast Steel (Iron)
Cast Steel (Iron)
Table 5.1.4
(mm)
Reel
Diameter
700
>700
Area of A Single
Defect Depth Quantity
2
Defect (mm )
200 25% thickness
5
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 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
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 depth
not 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 in
JB/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 1.6m.
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 be
abated.
(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
Defect Area
(mm2)
25
Defect Depth
20% wall thickness
>500
50
Neighboring
Quantity
Spacing (mm)
>50
3
>60
(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 Defect Area Defect Depth (mm) Quantity
(on
2
(mm)
(mm )
processing surface)
500
200 15% wall thickness
>500
300 15% wall thickness
one
2
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 gear
shall refer to Table 5.1.7-3. It is not allowed to adopt the toothing
14
Cylindrical
Gear
Measuring Point
Height of Tooth
Tooth Length
Precision Class
7
8
9
Contact pattern percentage ought to be no
less than
45
40
30
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
Center Distance Lower than 58 Minimum side gap
50-80
80-120
120-200
200-320
320-500
500-800
800-1250
1250-2000
2000-3150
3150-5000
I
0.085
0.015
0.130
0.170
0.210
0.260
0.340
0.420
0.530
0.710
0.850
II
0.170
0.210
0.260
0.340
0.420
0.530
0.710
0.850
1.060
1.400
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 seal
adhesive, 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, at
any position, shall not exceed 0.03mm and ensure no oil leakage
15
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, the
degree 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
covered by the clean oiled paper to prevent the scrap iron and grit
entering the bearing.
5.1.10.3 The fitting surface of the ax and the bearing must be coated with a
layer of clean grease before the assembly.
5.1.10.4 The bearing shall cling to the shaft shoulder or the distance sleeve.
No clearance is allowed.
5.1.10.5 The end face of the bearing race shall be parallel with both ends of
the gland. After the screwing down of the bolt, joints shall be evenly.
The axial clearance of rolling bearings shall be adjusted according to
the stated clearance on the design. Four sides shall be equal. The
assembled bearing shall be able to rotate flexibly.
5.2 Assembly and Erection
5.2.1 Shop Assembly
5.2.1.1 Products shall be assembled integrated in the plant. Before leaving
the factory, they shall undergo the no-load simulation test. If
conditions permit, the rated load test shall be carried out. After they
have been checked qualified, they can leave the factory.
5.2.1.2 All spare parts shall pass the check. Bought-in components and
cooperation parts shall have the conformity certificate before the
assembly.
5.2.1.3 After the emplacement of spare parts, all binding bolts shall be
screwed down. The spring washer shall contact the complete turn
and the bearing surface of the nuts and spare parts.
5.2.1.4 Before leaving the factory, the instrument-type height indicator and
the load controller shall undergo the check and provide product
adjustment explanations.
5.2.2 Field Installation
5.2.2.1 After arriving at the site, products shall undergo overall checks
according to relevant regulations in this standard. They have to pass
the check before they are erected.
5.2.2.2 The retarder shall undergo the cleaning check. The oil level of the
lubrication oil in the retarder shall match the oil scale. The oil level
shall be no lower than the tooth height of the lowest tooth in the
high-speed gearwheel, but no higher than twice the tooth height. The
retarder shall rotate flexibly, but the oil seal and joint line shall have
no oil leakage.
5.2.2.3 Checks shall be made to make sure whether the built-in position of
the foundation bolt, the embedded depth of the bolt and the length of
the exposed part are correct.
18
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 the
lifting 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 the
height 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 0.5o. 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 protection
and 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
21
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 straightness
error 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 6.3m.
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 6.3m.
6.1.2.3 The concentricity of the nut thread ax and the bearing external circle
and 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 selected
according 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 the
engine 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.
Tire Tread
Diameter
400
>400
Table 7.1.5-1
Rigidity of Medial Surface of
Pavement and Rim (HB)
300-380
Rigidity HB 260
Layer Depth
15
20
(1) For wheels with the stop board and the rim internal surface
demanding 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)
4)
On the tire tread and the rim medial surface, no more than five
pocks with d1mm (when D500) or d1.5mm (when D>500) and
the depth 3mm. No other defects are allowed and no welding is
allowed also.
No crack, chap or peeling shall be found on the wheel.
(3) The post-installed wheels shall have the tolerance of the diameter
runout 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 have
no 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 T2.5m, C3mm; 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, d6mm; when S12mm,
d1/2S. 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 walking
platform, 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
C1mm (Fig. 7.2.2-3).
(2) The crossrange dislocation of the joints of the trolley track shall be
g1mm (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 the
distance 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
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 the
wheel 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). )
7.2.5.2 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 internal
wall. 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 hoist
steel 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, protectors
and 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
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 the
door 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 dynamometer
shall 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
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 0.8m;
when other sealing elements are adopted, no greater than 0.4 m.
8.1.1.2 The manufacture of the cylinder lid shall meet the following
requirements:
(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 0.8m.
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 shall
be 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 0.4m.
(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
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
8.2.2
8.2.3
8.2.4
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 1.5
times 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
Oil Leakage
Oil Cylinder
Oil Leakage
Diameter (mm)
Amount (mL/min) Internal Diameter 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
the height indicator and the master switch shall be adjusted initially.
8.4.8 Test oil filtration precision: for the plunger pump, no lower than 20m;
the vane pump, no lower than 30 m.
8.5 Trial Run
8.5.1 Checks before Trial Run:
(1) All sundries in the gate slot shall be cleared to ensure no blockage to
the strobe and the drawbar.
(2) The framework shall be fixed stably. When the welding is adopted for
fixation, whether the weld joints have reached the requirements shall
be checked. For the anchor bolt fixation, whether the screw caps are
loosened shall be checked.
(3) The debugging shall be carried out to each component and equipment
in the electric circuit in accordance with relevant regulations in
GB1497.
8.5.2 In the first starting of the oil pump, all overflow valves of the oil pump
shall be opened. After 30-40min idle rotation, no abnormal phenomena
shall happen to the pump.
8.5.3 When the idle operation of the oil pump turns normal, the pressure
gauge shall be monitored. The overflow valves shall be wound
gradually to fill oil to the pipe system. The air shall be exhausted during
the oil filling. After the pipeline is filled with oil, the oil pump overflow
valve shall be adjusted to make the oil pump continue to operate for
15min under the 25%, 50% and 100% of the working pressure. No
vibration, noise or excessive temperature rise shall happen.
8.5.4 After the said tests, the oil pump overflow valve shall be adjusted to
make the pressure reach 1.1 times of the working pressure, when the
oil shall be discharged. No excessive vibration and noise shall happen.
8.5.5 The starting valves of the oil pump valve blocks shall act within 3-5s
after the starting of the oil pump to load the oil pump. Otherwise, the
pressure on the spring or the bore diameter of the oil hole shall be
adjusted.
8.5.6 If there is no water, the lifting gate shall be operated by hand once to
check the deceleration status of the cushioning device and whether
there is blockage or not. The wide-open time of the strobe and oil
pressure shall be recorded.
8.5.7 The cam bit of the master controller shall be adjusted to make the
electric terminal of the master controller switch on. During the
disconnection, the position of the strobe shall meet requirements on the
design, but the actual opening of the filling valve on the gate shall be
adjusted to more than 30mm less than the designed opening.
The height indicator shall be adjusted to make the hand correctly point
42
9. Acceptance Rules
9.1 Leave-factory Acceptance
9.1.1 The inspection shall be carried out by the quality examination
department of the manufacturer according to the pattern and this
standard. Only after the inspection result is eligible can acceptance be
carried out.
9.1.2 The user is entitled to carry out acceptance over the products set by set
according to provisions in this standard.
9.1.3 Special requirements from users on products shall be stated in the
purchase contract and the acceptance shall be carried out as required.
9.1.4 During the acceptance, the manufacturer shall provide users with the
following technical materials:
(1) Completion general plan, drawings of vulnerable parts, part
assembly drawing and maintenance instruction book;
(2) Preassembling inspection report and leave-factory test reports of
products;
(3) Qualification certificates and re-check records of primary materials;
flaw detection reports and heat-treatment reports on large casting
and forging;
(4) Weld inspection reports and related records;
(5) Design amendment advice note and substitution advice note of
parts and materials;
(6) Reports on the treatment records of significant deficiency and the
after-sales service test report of spare parts;
(7) Quality certificate, conformity certificates for bought-in
components and commercial invoice.
43
45
A.1 Test Conditions for the Bridge Framework and the Door Panel
A.1.1
A.1.2
A.1.3
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.
When the gradienter is adopted for measuring, measurement distance
from the lens shall be more than 2m.
Measurement shall be carried out without the influence from the
sunshine.
A.2 Detection Conditions of Span of the Bridge Machine and Gate Hoist
A2.1 During the measurement, the pull value and the corrected value stated in
Table A1 shall be adopted.
Span (m)
10-12
13-14
15-16
17-18
Table A1
Pull Value Section Size of Steel Tape (mm*mm)
(N)
10*0.25
13*0.2
15*0.2
15*0.25
Corrected Value
1
1
0.5
0.5
100
1
1
0.5
0
1
1
0.5
-0.5
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
Additional 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.
47