NB/T 10495-2021Code for manufacture, installation and acceptance of shiplift (English PDF)

Foreword

This document was issued on 7 January 2021 by the National Energy Administration of the PRC and takes effect on 1 July 2021.

It is a NB/T standard: recommended rather than compulsory, but it is the text a Chinese reviewer applies when assessing a submission.

It is classified under ICS 27.140, Chinese classification P26.

NB/T 10495-2021 Code for Manufacture, Installation and Acceptance of Shiplift is an energy industry standard of the People's Republic of China, issued by the National Energy Administration on 2021-01-07 and implemented from 2021-07-01.

Classification data printed on the cover: ICS 27.140, CCS P 26; the standard carries the engineering construction classification mark P and is a recommended (/T) energy industry standard.

The standard was published by Announcement No. 1 of 2021 of the National Energy Administration, which approved and released 320 energy industry standards, including this code (Attachment 1), 113 foreign-language editions of energy industry standards, starting with Carbon steel and low alloy steel for pressurized water reactor nuclear power plants — Part 7: Class 1, 2, 3 plates (Attachment 2), and 5 amendment notices of energy industry standards (Attachment 3). The announcement is dated 7 January 2021.

In the catalogue of industry standards annexed to the announcement (Attachment 1), NB/T 10495-2021 is listed as item 12, with no superseded standard and no adopted international standard, approval date 2021-01-07 and implementation date 2021-07-01.

This code was developed in accordance with the Notice of the National Energy Administration on Issuing the 2015 Plan for the Formulation and Revision of Energy Sector Industry Standards (Guo Neng Ke Ji [2015] No. 283). The drafting group carried out extensive investigation and research, summarized practical experience and prepared the code on the basis of wide consultation.

The main technical contents of this code are: general provisions; terms; basic requirements; manufacture and installation of lock head gates and hoists; manufacture of metal structures and mechanical equipment in the ship chamber section; installation of metal structures and mechanical equipment in the ship chamber section; electrical equipment; and commissioning and acceptance.

This code is under the administration of the National Energy Administration, was proposed by China Renewable Energy Engineering Institute, and its specific technical contents are interpreted by the Energy Industry Standardization Technical Committee on Hydropower Metal Structures and Hoists (NEA/TC21).

Comments and suggestions arising during the implementation of this code should be sent to China Renewable Energy Engineering Institute, No. 2 Liupukang North Street, Xicheng District, Beijing, postcode 100120.

Chief development organizations: China Gezhouba Group Co., Ltd.; China Renewable Energy Engineering Institute; China Gezhouba Group Electromechanical Construction Co., Ltd.; China State Shipbuilding Corporation Wuhan Shipbuilding Industry Co., Ltd.; China Gezhouba Group Machinery and Ship Co., Ltd.

Participating development organizations include: Huaneng Lancang River Hydropower Inc.; China Three Gorges Corporation; Wuchang Shipbuilding Heavy Industry Group Co., Ltd.; China Erzhong (Deyang) Heavy Equipment Co., Ltd.; the 712th Research Institute of China State Shipbuilding Corporation; Xi'an Aerospace Automation Co., Ltd.; Wuhan Marine Machinery Plant Co., Ltd.; Taiyuan Heavy Industry Co., Ltd.

Structure of the Code

The code is organized in eight chapters: 1 General Provisions; 2 Terms; 3 Basic Requirements; 4 Manufacture and Installation of Lock Head Gates and Hoists; 5 Manufacture of Metal Structures and Mechanical Equipment at Ship Chamber; 6 Installation of Metal Structures and Mechanical Equipment at Ship Chamber (from page 44); 7 Electrical Equipments; 8 Commissioning and Acceptance; followed by Appendix A, the explanation of wording, the list of quoted standards and the explanation of provisions.

6.1 Embeded Parts — requirements for the embedded parts of the ship chamber section, beginning on page 44.

6.2 Main Wire Rope Hoist Lifting System and Winch — beginning on page 48.

6.3 Rack and Pinion Drive System and Safety Mechanism — beginning on page 51.

6.4 Hydraulic Drive System and Safety Mechanism — beginning on page 57.

6.5 Ship Chamber Structure — beginning on page 60.

6.6 Ship Chamber Equipment — beginning on page 64.

6.7 Counterweight System — beginning on page 69.

Chapter 7 Electrical Equipments begins on page 72.

7.1 Assembling in Factory — beginning on page 72.

7.2 Site Installation and Test — beginning on page 72.

Chapter 8 Commissioning and Acceptance begins on page 79.

8.1 General Requirements — beginning on page 79.

8.2 Pre-assembling and Test in Factory — beginning on page 79.

8.3 Site Commissioning and Test — beginning on page 80.

8.4 Acceptance — beginning on page 84.

Appendix A Requirements for Materials and Nondestructive Testing of Racks, Columns and Pinions — beginning on page 85.

Explanation of Wording in This Code — page 89.

List of Quoted Standards — page 90.

Addition: Explanation of Provisions — page 95.

1 Scope

NB/T 10495-2021 governs the manufacture, installation and acceptance of shiplifts on Chinese hydropower and navigation projects. A shiplift carries vessels past a dam in a water-filled chamber raised and lowered as a single moving mass of thousands of tonnes, and its safety depends on precision in every component - the racks and pinions or wire ropes and counterweights that carry the chamber, the locking and safety devices that hold it if a drive fails, and the gates that seal it against the reservoir. The code sets the general provisions and defined terms, then the general requirements on materials and their certification, welding procedure and welder qualification, corrosion protection, and embedded parts. It covers manufacture component by component: the gates and hoists of the upper and lower heads, the ship chamber structure, the rack and nut columns, the wire ropes, sheaves and counterweights, the hydraulic systems, and the electrical and control equipment, with the dimensional tolerances and the factory inspection and testing for each. Installation on site follows, with the survey control, the alignment of rack columns and guides to the tolerances that a vertically moving chamber demands, and the assembly sequence. Commissioning covers the no-load, balanced-load and full-load trials and the testing of the safety systems. Acceptance at each stage and the handover documentation close the code.

2 Terms

2.0.11 service gate of ship chamber: the gate arranged at the upstream and downstream ends of the ship chamber which, when closed, seals the water body in the ship chamber and, when opened, forms the waterway through which vessels enter and leave the ship chamber.

2.0.12 bulkhead gate of ship chamber: the gate arranged on the ship chamber and used for the maintenance of the service gate of the ship chamber.

3 Basic Requirements

3.1 Technical documents. 3.1.1 The following documents shall be available for the manufacture of a shiplift:

3.1.1 Item 1: design drawings, mainly including general drawings, assembly drawings and part drawings.

3.1.1 Item 2: quality certificates of steel, welding materials and protective (coating) materials.

3.1.1 Item 3: quality certificates of purchased standard parts and non-standard subcontracted parts.

3.1.1 Item 4: electrical schematic diagrams, component layout drawings, internal and external wiring diagrams, software flow charts and software function description documents.

3.1.2 The following documents shall be available for the installation of a shiplift:

3.1.2 Item 1: design drawings, mainly including equipment layout drawings, assembly drawings and the relevant drawings of the hydraulic structures.

3.1.2 Item 2: the manufacturer's shipping list, arrival acceptance documents and assembly numbering drawings.

3.1.2 Item 3: the location drawing of the control points used for installation.

3.1.2 Item 4: the operation flow chart of the shiplift and the application software flow chart.

3.1.2 Item 5: factory acceptance documents and test reports.

3.1.3 The manufacture and installation of a shiplift shall comply with the design; where modification is required, a design modification notice shall be issued.

3.2 Materials, tools and instruments. 3.2.1 Steel plates and section steels used for manufacture and installation shall meet the design requirements and the following requirements:

3.2.1 Item 1, carbon steels: quality carbon structural steel and carbon structural steel shall comply with the relevant provisions of the current national standards GB/T 699 Quality carbon structure steels and GB/T 700 Carbon structural steels.

3.2.1 Item 1, alloy steels: low alloy structural steel, alloy structural steel and steel for pressure vessels shall comply with the relevant provisions of the current national standards GB/T 1591 High strength low alloy structural steels, GB/T 3077 Alloy structure steels and GB/T 713 Steel plates for boilers and pressure vessels.

3.2.1 Item 1, stainless steels: hot-rolled stainless steel plates and strips and stainless steel seamless tubes shall comply with the relevant provisions of the current national standards GB/T 4237 Hot rolled stainless steel plate, sheet and strip, GB/T 14975 Seamless stainless steel tubes for structure and GB/T 3090 Stainless steel small-diameter seamless tubes; steel materials shall be supplied with mill quality certificates.

3.2.1 Item 2: steel materials shall be inspected on entering the factory, and their quality shall comply with the contract, the product technical standards and the current national standard GB/T 17505 Steel and steel products — General technical delivery requirements.

3.2.1 Item 3: steel materials shall be re-tested as specified in the contract. Steel materials with unclear grade marking or questionable material shall be re-tested and may be used only after the re-test results comply with the relevant standards.

3.2.1 Item 4, ultrasonic testing: where ultrasonic testing of steel is required, it shall be carried out in accordance with the current national standard GB/T 2970 Ultrasonic testing method for thick steel plates or NB/T 47013.3 Nondestructive testing of pressure equipments — Part 3: Ultrasonic testing.

3.2.1 Item 4, through-thickness properties: steel plates with Z-direction (through-thickness) property requirements shall comply with the current national standard GB/T 5313 Steel plates with through-thickness characteristics. For steel plates requiring ultrasonic testing or Z-direction properties, the type, location and proportion of testing and the acceptance criteria shall be agreed between supplier and purchaser.

3.2.2 Covered electrodes, welding wires, fluxes and shielding gases shall match the steel grades to be welded, shall have quality certification documents and package markings, shall be inspected and accepted before use, and shall comply with the following requirements:

3.2.2 Item 1: covered electrodes shall comply with the current national standards GB/T 5117 Non-alloy and fine grain steel covered electrodes, GB/T 983 Stainless steel covered electrodes and other applicable standards.

3.2.2 Item 2, submerged arc welding: wires and fluxes for submerged arc welding shall comply with the current national standards GB/T 5293 (classification of solid wires, tubular cored electrodes and wire-flux combinations for submerged arc welding of non-alloy and fine grain steels), GB/T 12470 (the same for creep-resisting steels) and GB/T 17854 (classification of wire-flux combinations for submerged arc welding of stainless steels), and other applicable standards.

3.2.2 Item 2, gas shielded welding: welding wires for gas shielded welding shall comply with the current national standards GB/T 8110 Welding wires for gas shielding arc welding of carbon and low alloy steels, GB/T 10045 Non-alloy and fine grain steel flux cored electrodes and GB/T 17853 Stainless steel flux cored electrodes, and other applicable standards.

3.2.2 Item 3, carbon dioxide: carbon dioxide for gas shielded welding shall comply with the current national standard GB/T 6052 Industrial liquid carbon dioxide, with a purity of not less than 99.5%.

3.2.2 Item 3, argon: argon shall comply with the current national standard GB/T 4842 Argon, with a purity of not less than 99.99%.

3.2.2 Item 3, mixed gas: argon-carbon dioxide mixed gas shall comply with the current industry standard HG/T 3728 Welding gas mixtures — Argon-carbon dioxide.

3.2.3 Measuring instruments used for manufacture, installation and acceptance shall comply with the following requirements:

3.2.3 Item 1: the accuracy of steel tape measures shall not be lower than Class I.

3.2.3 Item 2: the accuracy of theodolites shall not be lower than grade DJ2.

3.2.3 Item 3: the accuracy of levels shall not be lower than grade DS2.

3.2.3 Item 4: the accuracy of thermometers shall not be lower than 5.0 degrees Celsius.

3.2.3 Item 5, total station: the angle measurement accuracy of the total station should not be lower than 0.5 arc seconds, and its distance measurement accuracy shall not be lower than (1 + 1 x D x 10^-6) mm, where D is the measured distance in mm.

3.2.3 Item 5, laser zenith plummet: the nominal accuracy of the laser zenith plummet shall not be lower than 1/40000 for measuring distances below 100.0 m, and not lower than 1/20000 for measuring distances above 100.0 m.

3.2.3 Item 6: the accuracy of coating thickness gauges shall not be lower than (3% of delta + 1.0) µm, where delta is the actual thickness of the measured coating in µm.

3.2.3 Item 7: the measuring accuracy of flow meters for welding gases shall not be lower than 2%.

3.2.4 All measuring instruments used for manufacture, installation and commissioning shall be verified as qualified according to the regulations and used within their period of validity.

3.2.4 (continued) Measuring meters installed on mechanical and electrical equipment and meters related to safety protection shall be verified as qualified according to the regulations and shall be within their period of validity when put into service.

3.3 Bolt, pin and key connections. 3.3.1 The materials, preparation, inspection and tightening of ordinary bolts, high-strength friction-grip bolts, nuts and washers shall comply with the relevant provisions of the current industry standard NB/T 35045 Code for manufacture, installation and acceptance of steel gate in hydropower projects.

3.3.2 Torshear type high-strength bolt connection sets shall comply with the current national standard GB/T 3632 Sets of torshear type high strength bolt hexagon nut and plain washer for steel structures.

3.3.3 The type and specification of pins shall comply with the design and the equipment technical documents.