ICS 27.

100
F 22
File No.: J687-2007

DL
PROFESSIONAL STANDARD OF

THE PEOPLE’S REBULIC OF CHINA

中华人民共和国行业标准
DL/T 5017-2007
Replace DL 5017-1993

Specification for Manufacture Installation and Acceptance

of Steel Penstocks in Hydroelectric and Hydraulic
Engineering
水电水利工程压力钢管制造安装及验收规范

Issued on July 20, 2007 Implemented on December 1, 2007

Issued by the National Development and Reform Commission of the People's

Republic of China
 Contents

Foreword .................................................................................................................................... I
1 Scope ...................................................................................................................................... 1
2 Normative References ............................................................................................................ 1
3 General Provisions ................................................................................................................. 3
3.1 Technical Data ............................................................................................................. 3
3.2 Material........................................................................................................................ 3
3.3 Requirements on Measuring Apparatus and Reference Point ..................................... 4
4 Manufacture of Steel Penstock............................................................................................... 4
4.1 Manufacture of Straight Pipe (Penstock), Bent Pipe and Convergent Pipe................. 4
4.2 Manufacture of Branch Pipe and Telescopic Joint ...................................................... 8
5 Installation of Steel Penstock ............................................................................................... 11
5.1 Fundamental Rules .....................................................................................................11
5.2 Installation of Buried Penstock...................................................................................11
5.3 Installation of Exposed Penstock ............................................................................... 12
6 Welding of Steel Penstock.................................................................................................... 12
6.1 Qualification of Welding Procedure .......................................................................... 12
6.2 Qualification of Welder ............................................................................................. 16
6.3 Fundamental Rule and Technological Requirements of Welding ............................. 16
6.4 Weld Inspection ......................................................................................................... 20
6.5 Defect Disposal and Repair Welding......................................................................... 22
7 Post-welding Stress-relief Treatment of Steel Penstock....................................................... 23
7.1 Fundamental Rules .................................................................................................... 23
7.2 Post-welding Stress-relief Treatment......................................................................... 23
8 Corrosion Protections for Steel Penstocks ........................................................................... 24
8.1 Surface Pretreatment.................................................................................................. 24
8.2 Painting ...................................................................................................................... 24
8.3 Quality Inspection of Painting Coat........................................................................... 25
8.4 Mellozing ................................................................................................................... 25
8.5 Quality Inspection of Mellozing Coat........................................................................ 26
9 Hydraulic Tests..................................................................................................................... 26
10 Packaging and Transportation ............................................................................................ 27
11 Acceptances........................................................................................................................ 27
11.1 Manufacture Acceptance ......................................................................................... 27
11.2 Installation Acceptance............................................................................................ 27
Annex A (Informative) Criteria of Property and Surface Quality of Steel Plates ................... 28
Annex B (Informative) Steel Plates Used For Penstock Production Abroad .......................... 39
Annex C (Informative) Allowable Deviation and Additional Value of Thickness of Steel Plate
................................................................................................................................................. 40
Annex D (Normative) Preparation, Dimension, Test Method and Approval Standard
Mechanical Property Test Plate in Qualification of Welding Procedure ................................ 41
Annex E (Informative) Recommended format of Welding Procedure Guide Book and
Qualification Report ................................................................................................................ 47
Annex F (Normative) Classification and Grouping of Steel Products by Chemical
Composition, Mechanical Property and Welding Property..................................................... 51
Annex G (Normative) Qualification of Welding Procedure for Stainless Steel Clad Plate .... 52
1
Annex H (Informative) Selection of Welding Materials for Steel Pipe .................................. 53
Annex J (Informative) Conversion Table of Air Dew Point ................................................... 59
Annex K (Informative) Inspection of Thickness and Binding Ability of Mellozing Coat...... 61

2
 Foreword
This standard is revised according to "Announcement on Printing and Distributing
Professional Standard Preparation Planning 2006 issued by the General Office of the National
Development and Reform Commission".
Since its implementation, DL 5017-1993 Specification for Manufacture Installation and
Acceptance of Steel Penstocks in Hydroelectric and Hydraulic Engineering has played an
important role in regulating and guiding the manufacture, installation and acceptance of steel
penstocks for hydroelectric and hydraulic engineering in China. With the development of
hydroelectric and hydraulic engineering, the specification for steel penstocks trends upward
large-scale and ultra-large scale application; new structural forms and materials (including
steel products, welding material and antiseptic substance) are extensively adopted; and the
manufacture installation and acceptance, and the technologies like welding and corrosion
protection are improved and innovated. The requirements of DL 5017-1993 have not met
fully of the engineering demand. This standard is revised and formulated on the base of DL
5017-1993 in combination of the construction experience and technological advance of steel
penstock in recent years. On the principles of striving state-of-art technology, economic
feasibility, safety and stability and operability, the standard further highlight and unify the
technical requirements of manufacture, installation and acceptance of steel penstocks for
hydroelectric and hydraulic engineering, for providing the sound and reliable technical base in
engineering construction.
In the revision press of this standard, the revision organizations carry out meticulous
investigation work, sum up the practical experience of large- and medium-scale engineering
construction at home and abroad in recent years, consider the application condition of new
material, process and technology, widely take the rationale advice and suggestion from steel
penstock staffs, and strengthen the coordination with the current national standards and
professional standards.
This standard replaces DL 5017-1993 from the implementation date.
In this standard, the main revisions to DL 5017-1993 are as:
-- Add the requirements in steel lining of discharge opening (hole) and scouring sluice.
-- Add the requirements in the minimal cold coiling diameter of high-tensile steel.
-- Add the requirements in the large-scale and ultra-large scale steel pipes which the
diameter is larger than 8m.
-- Add the requirements in the manufacture installation and acceptance of telescopic joint
for corrugated tube.
-- Add the requirements in dissimilar steel welding.
-- Add the requirements in stainless steel and stainless steel clad plate.
-- Add the requirements in the minor factors influencing the welding quality.
-- Add the requirements in grout hole of steel penstock.
-- Add the requirements of hardness test value of welding joints.
-- Add the requirements in test piece for welding of productive products.
-- Add the requirements on the deposited metal thickness and modify that the evaluation
of parent metal welds substitutes the thickness scope.
-- Add the conversion table of air dew point.
-- Add the informative annexes related to high-tensile steel, stainless steel and stainless
steel clad plate.
-- Modify the denotation of mechanical property symbols of steel products (denoted
according to the requirements of GB/T 228 "Metallic materials - Tensile testing at ambient
temperature").
-- Modify the requirements in welding materials.
-- Modify the requirements in high-tensile steel.
-- Modify the related procedures and requirements of qualification of welding procedure,
and add the requirements in the qualification of welding procedure for stainless steel clad
plate.

I
 -- Modify the requirements in positions of qualification of welding procedure.
-- Modify the normative references.
-- Modify the requirements in measuring apparatus and reference point.
-- Modify the requirements in steel plate grade number and group number.
-- Modify the requirements in welding of joints with bearing plate.
-- Modify the requirements in postwelding stress relief.
-- Modify the requirements in corrosion protection.
-- Modify the content and requirement of steel pipe hydraulic test (specify the rate of
pressure rise).
-- Modify the recommended format of welding procedure guide book and qualification
report.
Annexes D, F, G and I of this standard are normative.
Annexes A, B, C, E, H, J and K are informative in this standard.
This standard is proposed by the China Electricity Council (CEC).
The National Technical Committee on Standardization Administration of metal structure
and headstock gear for hydroelectric power station in power industry governs and is in charge
of the explanation of this standard.
Chief drafting organizations: Sinohydro No.7 Bureau Co., Ltd., State Grid Zhengzhou
Mechanical Design Research Institute.
Participating organizations: Planning and Design General Institute of Water Conservancy
and Hydropower, Power Industry Metal Structural Equipment Quality Detection Center.
Chief drafting staffs: Wan Tianming, Ma Yaofang, Xu Shaobo, Gong Jianxin, Chen
Kuichang, Zhao Congmao, Wang Fulin, Chen Dingchu, Liu Xuefang.
All relevant organizations are kindly requested to sum up and accumulate your
experiences in actual practices during the process of implementing this code. The relevant
opinions and advice, whenever necessary, can be posted or passed on to the Standardization
Center under the China Electricity Council (CEC) (No.1, Er Tiao, Baiguang Road, Beijing
100761, China).

II
 Specification for Manufacture Installation and Acceptance of
Steel Penstocks in Hydroelectric and Hydraulic Engineering
水电水利工程压力钢管制造安装及验收规范

1 Scope
This standard specifies the technical requirements of steel penstocks for hydroelectric
and hydraulic engineering.
This standard is applicable to the manufacture, installation and acceptance of steel
penstocks for large- and medium-scale hydroelectric junction engineering, and small-scale
hydroelectric junction engineering may reference this standard in combination of the physical
circumstances.
This standard is also applicable to the manufacture, installation and acceptance of steel
lining for scouring sluice and discharge opening (hole).
2 Normative References
The following standards contain provisions which, through reference in this text,
constitute provisions of this standard. For dated reference, subsequent amendments to
(excluding correction to), or revisions of, any of these publications do not apply. However,
the parties whose enter into agreement according to these specifications are encouraged to
research whether the latest editions of these labels are applied or not. For undated references,
the latest edition of the normative document is applicable to these specifications.
GB 150 Steel pressure vessels
GB/T 228 Metallic materials - Tensile testing at ambient temperature
GB/T 229 Metallic materials - Charpy notch impact test
GB/T 231.1 Metallic materials - Brinell hardness test - Part 1: Test method
GB/T 232 Metallic materials - Bend test
GB/T 470 Zinc ingots
GB/T 699 Quality carbon structural steels
GB/T 700 Carbon structural steels
GB/T 709 Dimension shape weight and tolerances for hot-rolled steel plates and
sheets
GB/T 711 Hot-rolled quality carbon structural steel plates sheets and wide strips
GB/T 713 Steel plates for boilers
GB/T 983 Stainless steel electrode
GB/T 985 Basic forms and sizes of weld grooves for gas welding manual are welding
and gas - Shielded are welding
GB/T 986 Basic Forms and Sizes of Weld Grooves for Submerged Arc Weld
GB/T 1220 stainless steel
GB/T 1591 Low-alloy high-tensile structural steel
GB/T 2649 Methods of sampling for mechanical properties tests of welded joint
GB/T 2650 Impact test methods on welded joints
GB/T 2651 Tensile test method on welded joints
GB/T 2652 Tensile test methods on weld and deposited metal
GB/T 2653 Bend test methods on welded joints
GB/T 2654 Hardness test methods on welded joints
GB/T 2975 Steel and steel products - Location and preparation of test pieces for
mechanical testing
GB 3190 Wrought Aluminium and Aluminium Alloy - Chemical Composition
GB/T 3274 Hot-rolled plates and strips of carbon structural steels and high strength
low alloy structural steels
GB/T 3280 Cold rolled stainless steel plate

1
 GB/T 3323 Methods for radiographic inspection and classification of radiographs for
fusion welded butt joints in steel
GB 3531 Low alloy steel plates for low temperature pressure vessels
GB/T 3863 Industrial oxygen
GB/T 4237 hot rolled stainless steel plate
GB/T 4340.1 Metallic materials - Vickers hardness test - Part 1: Test method
GB/T 4842 argon
GB/T 5117 Carbon steel covered electrodes
GB/T 5118 low-alloy steel covered arc welding electrode
GB/T 5293 Carbon steel electrodes and fluxs for submerged arc welding
GB/T 6052 Commercial liquid carbon dioxide
GB 6654 Steel plates for pressure vessels
GB 6819 dissolved acetylene
GB/T 8110 Welding electrodes and rods for gas shielding arc welding of carbon and
low alloy steel
GB/T 8165 Stainless steel clad plates sheets and strips
GB/T 8923 Rust grades and preparation grades of steel surfaces before application of
paints and related products
GB/T 9286 Paints and varnishes - Cross cut test for films
GB/T 9711.1~ GB/T 9711.3 Petroleum and natural gas industries-Steel pipe for
pipelines-Technical delivery conditions
GB/T 9793 Metallic and other inorganic coatings-Thermal spraying - Zinc, aluminium
and their alloys
GB/T 10045 Carbon steel flux cored electrodes
GB/T 11345 Method for manual ultrasonic testing and classification of testing results
for ferritic steel welds
GB 12174 Carbon rod for carbon arc air gouging
GB/T 12470 Fluxes for the submerged arc welding of low alloy steel
GB/T 12522 Stainless steel bellows expansion joints
GB/T 12777 General specification for metal bellows expansion joints
GB/T 13148 Specification for welding of stainless steel clad plate
GB/T 14957 Steel wires for melt welding
GB/T 14958 Steel wires for gas shielded welding
GB/T 14977 General requirement for surface condition of hot-rolled steel plates
GB/T 16270 High-strength structural steel plates and strips: products supplied in the
heat-treated or controlled rolled condition
GB/T 16749 Bellows expansion joints for pressure vessel
GB/T 17493 Low alloy steel flux cored electrodes for arc welding
GB/T 17853 Stainless steel flux cored wires
GB/T 17854 Stainless steel electrodes and fluxs for submerged arc welding
GB/T 19189 Quenched and tempered high strength steel plates for pressure vessels
GB/T 19866 Specification and qualification of welding procedures for metallic
materials - General rules
DL/T 678 General welding procedure specification for structural steel of power
station
DL/T 679 Code for welder technical qualification
DL/T 752 Code of the welding on dissimilar steel for power plant
DL/T 5358 Technical code for anticorrosion of metal structures in hydroelectric and
hydraulic engineering
SL 35 Rules on examination of hydrotechnics metal construction welder
JB 3092 Technical requirements on quality of flame cutting surface
JB/T 3223 Regulations on quality control of welding material
JB/T 4730 Nondestructive testing of pressure equipments
JB/T 4733 Explosive Stainless Clad Steel Plate for Pressure Vessels

2
 JB/T 6061 Nondestructive detection - welding seam magnetic particle testing and
acceptance grading
JB/T 6062 Nondestructive detection - welding seam penetration testing and
acceptance grading
JB/T 10045.3 Thermal cutting - Quality and dimensional deviation in the gas cutting
JB/T 10045.4 Thermal cutting - Quality and dimensional deviation of plasma cutting
YB/T 5092 Stainless steel wires for welding
HG/T 3661.1 Burning gases for welding and cutting - propene
HG/T 3661.2 Burning gases for welding and cutting -- propane
3 General Provisions
3.1 Technical Data
3.1.1 The manufacture, installation and acceptance of steel penstock shall have the following
material (data):
1 Design drawings and technical document
2 Quality certificate of main steel products, welding material and antiseptic substance
3 Arrangement drawing of hydraulic structure
3.1.2 The manufacture, installation and acceptance of steel penstock shall be conducted in
accordance with the requirements of the design drawings and the related technical documents;
any amendment hereof shall be done upon the design amendment advice or approved by the
design department in writing.

3.2 Material
3.2.1 The steel plates for steel penstock shall meet the requirements of the design document.
The property and surface quality hereof shall meet the relevant regulations of the related
current standards and the design documents, and the steel plates shall be accompanied with
the outgoing quality certificate. If the steel plates has no outgoing quality certificate or the
grade hereof is not clear, or there is doubt on the materials for them, these steel plates shall be
re-inspected, and they may be used upon passing the inspection. The sampling point and
sample preparation for the steel plate property test shall meet the requirements of GB/T 2975.
3.2.2 The designations of the steel products imported are detailed in Annex B and Table A.7
and Table A.8 in Annex A.
3.2.3 The defect detection shall be conducted for the steel plates for steel penstocks if the
ultrasonic inspection is necessary. And the approval standard is that the carbon steel and low
alloy steel shall reach Grade III. The high-tensile steel [Namely, the low-carbon high-strength
low-alloy steel with the yield lower limit ReL (or Rp0.2) ≥450N/mm2, and the tensile strength
lower limit Rm≥570N/mm2, similarly hereinafter] shall reach Grade II.
3.2.4 The steel plates shall be stored free from drenching and rustiness. The arrangement of
the support packing strip interval and the superposition of the steel plates shall be free from
deformation.
3.2.5 The technical requirements of the steel plates shall meet the requirements of GB/T 709,
GB 6654, GB/T 16270 and GB/T 19189, and the thickness deviation hereof is specified in
Annex C. the steel plate imported shall meet the requirements of GB/T, GB 6654, GB/T
16270 and GB/T 19189.
3.2.6 The welding materials shall have the outgoing quality certificates, and the technical
parameters hereof like chemical composition, mechanical property and diffusible hydrogen
content shall meet the following corresponding requirements:
1 The welding rod shall meet the requirements of GB/T 983, GB/T 5117 and GB/T 5118.
2 The welding wires shall meet the requirements of the standards - GB/T 5293, GB/T
8110, GB/T 10045, GB/T 14957, GB/T 14958, GB/T 17493, GB/T 17853, GB/T 17854 and
YB/T 5092.
3 The soldering flux shall meet the requirements of GB/T 5293, GB/T 12470 and GB/T
17854.
3.2.7 The quality of kryptol for carbon arc air gouging shall meet the requirements of GB
12174.

3
3.2.8 The gasses and argon gas for welding and cutting shall meet the quality requirements in
GB/T 4842, and they shall have the purity Ar≥99.9%; The carbon dioxide gas used shall meet
the quality requirement of GB/T 6052, and it shall have the purity CO2≥99.5%; The oxygen
used shall meet the quality requirement of GB/T 3863, and it shall have the purity O2≥99.5%;
The acetylene gas used shall meet the quality requirement of GB 6819, and it shall have the
purity C2H2≥98%; the propylene shall meet the quality requirement of HG/T 3661.1, and it
shall have the purity C3H6≥95.0%; the propane gas for welding and cutting shall meet the
quality requirement of HG/T 3661.2, and it shall have the purity C3H8≥95.0%.

3.3 Requirements on Measuring Apparatus and Reference Point

3.3.1 As for the measuring instruments used in the manufacture, installation and acceptance of
steel pipes, the measurement accuracy hereof shall meet the following requirements:
1 Steel tape with the accuracy not lower than Level II.
2 Theodolite with the accuracy of over Level DJ2.
3 Gradienter with the accuracy of over Level DS3.
4 Thermoscope with the accuracy of ±5℃ or higher level.
5 Layer thickness meter with the accuracy ± (3%H+1) μm or higher level.
6 Thermohygrometer with the temperature accuracy ±0.5℃ and the humidity accuracy
±2%RH, or higher level.
7 Gas flowmeter for welding with the accuracy of ±2% or higher level.
3.3.2 The measuring instruments shall be calibrated as required, and used within the expiry
date.
3.3.3 The reference points for measuring elevation and mileage and installing axial lines, and
the control points for installation shall be obvious, stable and convenient to use. And they
shall be clarified by the measurement department on field to the installation organization and
quality control department, and the measurement department shall provide the sketch drawing
of fiducial marks.
4 Manufacture of Steel Penstock
4.1 Manufacture of Straight Pipe (Penstock), Bent Pipe and Convergent Pipe
4.1.1 The laying-out for steel plates shall satisfy the following requirements.
1 The limit deviation steel plate laying-out shall meet the requirements of Table 4.1.1.

Table 4.1.1: Limit deviation of steel plate laying-out

Limit deviation
Item
mm

Width and length ±1

Relative difference of diagonals 2

Relative difference of homologous sides 1

Arrow height (curved part) ±0.5

2 The longitudinal seam of pipe joint shall not be arranged on the horizontal axis and
plumb axial line of pipe joint cross-section, and the included angle between the longitudinal
seam and the axial line shall be larger than 10°, and the corresponding arc line distance shall
be larger than 300mm and 10 times of pipe wall thickness.
3 The distance between the longitudinal seams of adjacent pipe joints shall be larger than
5 times of the plate thickness and 300mm.
4 The spacing of adjacent longitudinal seams on same pipe joint shall not be less than
500mm.
5 The spacing of circumferential seams, for straight pipe, should not be less than 500mm;
for bent pipe and convergent pipe, it should not be less than the larger one of the following
values:
1) 10 times of pipe wall thickness.
2) 300mm.

4
 3) 3.5 rδ (r - inside radius of steel pipe; δ - wall thickness of steel pipe)
4.1.2 After the laying-out of the carbon steel and low alloy steel plates, the symbols such as
segmenting, sectioning and blocking numbers of the steel pipes, direction of flow, horizontal
and vertical center lines, grout hole positions, groove angle and cut lines shall be marked by
steel seal, painting and dotting punch.
4.1.3 The high tensile steel plates must not be marked with saw, chisel or steel seal, and
dotting punch must not be arranged on the outside surface of the roll bending plates. Under
the following conditions, the dotting punch with the depth of less than 0.5mm may be used:
1 The dotting punch for verifying the laying-out accuracy may be done on the inside
surface of roll bending plate.
2 The dotting punch is arranged on the outside surface of the plate after roll bending.
4.1.4 The steel plate and welding groove shall be cut with automatic and semi-automatic
cutting machine, edge planer, or edge milling machine; the welding groove of the high-tensile
steel with great hardening trend should be processed with edge planer and edge milling
machine, and the superficial hardening layer and overheated structure on cut shall be grinded
away by a grinding wheel in the hot cutting treatment and the grinding thickness is not less
than 0.8mm. If the preheating cutting is required for steel plate, and the cutting shall be
conducted after preheating or testing.
4.1.5 The cutting quality and dimensional deviation shall meet the relevant regulations in
JB/T 10045.3, JB/T 10045.4 or JB 3092.
4.1.6 The slag and burr on cut surface shall be grinded off. the depth of the groove caused in
cutting shall not be larger than 0.5mm; if the groove depth is 0.5mm ~ 2mm, the groove shall
be burnished with a grinding wheel; when the groove depth is larger than 2mm, the groove
shall be planished upon weld repair. For suspicious positions, the magnetic particle inspection
or penetrant inspection shall be conducted according to the relevant regulations in JB/T 6061
or JB/T 6062.
4.1.7 The limit deviation of the welding groove dimension shall meet the requirements of
GB/T 985 and GB/T 986 or the design drawings.
4.1.8 The roll bending for steel plates shall satisfy the following requirements.
1 The roll bending direction shall be same to the calendering direction of the steel plate.
2 Before and during roll bending, the erosive scale and other sundries on the steel plate
surface shall be removed.
3 After roll bending, the tiles shall stand on the platform on free state. The clearance after
the curvature inspection with a sample plate shall meet the requirements of Table 4.1.8-1.
Table 4.1.8-1: limit clearance of sample plate and tile
Inner diameter of steel pipe (D) Chord length of sample plate Limit clearance of sample plate and tile
m m mm

D≤2 0.5D (and not less than 500mm) 1.5

2<D≤5 1.0 2.0

5<D≤8 1.5 2.5

D>8 2.0 3.0

4 The relation of the inner diameter and the wall thickness of steel pipe meet the
requirements in Table 4.1.8-2. The tile may be cold coiled; otherwise, the tile shall be hot
rolled or cold coiled before heat treatment.

5
 Table 4.1.8-2: minimal radius-thickness ratio of allowable cold coiling tile
Yield strength
Relation of inner diameter (D) and wall thickness (δ) of steel pipe
N/mm2

ReL (Rp0.2) ≤350 D≥33δ

350<ReL (Rp0.2) ≤450 D≥40δ

450<ReL (Rp0.2) ≤540 D≥48δ

540<ReL (Rp0.2) ≤800 D≥57δ

ReL (Rp0.2) >800 Determined by the test

5 The metal hammer must not be used to hammer steel plate during roll bending.
6 High strength quenched and tempered steel and high strength controlled rolled steel
should not be treated with flame straightening. If the flame straightening is used for rectifying
the curvature, the temperature of straightening heating must not be higher than the temper
point or controlled rolling completion temperature of the steel plate material.
7 The steel plates after welding should not be rolled or straightened with bending
machine.
4.1.9 The circle-rectifying of steel pipes shall be conducted on a platform, and the planeness
of the pipe orifice shall meet the requirements of Table 4.1.9.
Table 4.1.9: planeness of pipe orifice
Inner diameter of steel pipe (D) Limit deviation
m mm

D≤5 2

D>5 3

4.1.10 The perimeter difference of the steel pipe after circle-rectifying shall meet the
requirements of Table 4.1.10, and the axial butt-joint unfitness of pipe orifice on longitudinal
seam is not larger than 2mm.
Table 4.1.10: perimeter difference of steel pipe (mm)
Item Plate thickness (δ) Limit deviation

Difference of measured perimeter

Random plate thickness ±3D/1000, and ±24 limit deviation
and design perimeter

Perimeter difference of adjacent pipe δ<10 6

joints δ≥10 10

4.1.11 The limit deviation of radial butt-joint unfitness of steel pipe longitudinal seam and
circumferential seam shall meet the requirements of Table 4.1.11.
Table 4.1.11: limit deviation of radial butt-joint unfitness of steel pipe longitudinal seam and circumferential
seam (mm)
Type of welding seam Plate thickness (δ) Limit deviation

Longitudinal seam Random plate thickness 10% δ, And not larger than 2

δ≤30 15% δ, And not larger than 3

Circumferential seam 30<δ≤60 10%δ

δ>60 ≤6

Welding seam of stainless steel

Random plate thickness 10% δ, And not larger than 1.5
clad plate

6
 4.1.12 The sample plate is used for inspecting the curvature on longitudinal seam after
longitudinal seam welding, and the clearance hereof shall meet the requirements of Table
4.1.12.
Table 4.1.12: limit clearance of curvature on longitudinal seam
Inner diameter of steel pipe (D) Chord length of sample plate Limit clearance of sample plate and longitudinal seam
m mm mm

D≤5 500 4

5<D≤8 D/10 4

D>8 1200 6

4.1.13 After longitudinal seam welding, the actual periphery of the pipe orifice at both ends
shall be measured, and the number symbol of the actual periphery shall be marked on the
edge position of the corresponding pipe orifices.
4.1.14 The shape deviation of steel pipe cross-section meet the following requirements:
1 As for the pipe with round cross section, the deviation of the roundness (it refers to the
maximum value of the difference of two mutually perpendicular diameters of the pipe orifice
at same end) shall not be larger than 3D/1000, and the maximal deviation shall not be larger
than 30mm. At least two pairs of diameters shall be measured for pipe orifice at each end.
2 As for the steel pipe with oval cross section, the deviation from the design sizes to the
long axis (a) and the minor axis (b) shall not be larger than 3a (or 3b) /1000, and the limit
deviation is ±6mm.
3 As for the steel pipe with rectangular section, the deviation from the design sizes to the
long sides (A) and the minor sides (B) shall not be larger than 3A (or 3B) /1000, and the limit
deviation is not larger than 6mm; and at least two pairs of opposite sides shall be measured
and the diagonal difference is not larger than 6mm.
4 As for the steel pipe with regular polygon cross-section, the difference of the maximum
diameter and minimum diameter of the measured circumscribed circle shall not be larger than
3D/1000, the maximal difference shall not be larger than 8mm, and the limit deviation of the
difference to the normal value in the drawing is ±6mm.
5 The partial planeness of the steel pipe with non-round section is not larger than 4mm
per meter.
4.1.15 The limit deviation of the difference between the length and design length of the
single-section pipe is ±5mm.
4.1.16 If v-shaped groove with backing plate is adopted for the circumferential seam for steel
pipe installation, the limit deviation of the perimeter, roundness and curvature after
longitudinal seam welding on the pipe orifice inserted with backing plate meet the following
requirements:
1 The perimeter difference of a steel pipe after circle-rectifying shall meet the
requirements of Table 4.1.16.
2 When a stiffener is install for the steel pipe, and the difference of the measured
maximal and minimum diameters of the pipe orifice at same end shall not be larger than 4mm,
and at least 4 pairs of diameters of the pipe orifice at each end shall be measured.
3 After longitudinal seam welding, the sample plate specified in Article 4.1.12 shall be
used to inspect the longitudinal seam curvature, and the clearance hereof shall not be larger
than 2mm.
Table 4.1.16: perimeter difference of the steel pipe on the pipe orifice inserted with a backing plate (mm)
Item Plate thickness (δ) Limit deviation

Difference of measured perimeter and

±3D/1000, And±12 limit deviation
design perimeter

Perimeter difference of adjacent pipe δ<10 6

joints δ≥10 8

7
 4.1.17 The joints with backing plate should not be adopted for bent pipe, convergent pipe and
high-tensile steel pipe.
4.1.18 The inner-circle curvature of stiffener ring, supporting ring, thrust ring and
waterproofing ring shall be inspected with a sample plate, and the clearance hereof shall meet
the requirements of Table 4.1.8-1.
4.1.19 The clearance from the steel pipe external wall to stiffener ring, supporting ring, thrust
ring and waterproofing ring shall not be larger than 3mm.
4.1.20 The limit deviation of the installation perpendicularity of stiffener ring, thrust ring and
supporting ring for a steel pipe shall meet the requirements of Table 4.1.20.
Table 4.1.20: Installation perpendicularity of stiffener ring, thrust ring and supporting ring for a steel pipe
(mm)
Limit deviation of supporting Limit deviation of stiffener ring,
No. Item Sketch drawing
ring thrust ring, waterproofing ring

Perpendicularity of pipe wall

to supporting ring, stiffener
1 a≤0.01H, and not larger than 3 a≤0.02H, and not larger than 5
ring, thrust ring or
waterproofing ring

Perpendicularity of pipe axial

line to the plane formed by
b≤4D/1000, and not larger than
2 supporting ring, stiffener b≤2D/1000, and not larger than 6
12
ring, thrust ring or
waterproofing ring

Spacing deviation of two

3 ±10 ±30
adjacent rings

4.1.21 The butt-jointed seams for stiffener ring, supporting ring, thrust ring and waterproofing
ring shall be staggered over 200mm from the longitudinal seam of the steel pipe.
4.1.22 The seam avoiding holes on the inner-arc side of stiffener ring, supporting ring and
thrust ring shall be opened on the intersection position of the steel pipe longitudinal seam and
the jointing welding seam for steel pipe and stiffener ring / supporting ring / thrust ring.
4.1.23 The welding seam butt end for the seam avoiding holes and through-holes on stiffener
ring, supporting ring and thrust ring shall be seal welded.
4.1.24 The grout holes should be opened after roll bending, and the grout hole arranged in
high-tensile steel pipe should be opened by drilling.
4.1.25 As for special rolled steel pipe with polygon and square-circle section, whole or
adjacent pipe joints shall be preassembled on manufacture field.

4.2 Manufacture of Branch Pipe and Telescopic Joint

4.2.1 The laying-out, cutting and roll bending of branch pipe and telescopic joint shall comply
with the relevant regulations of Section 4.1 in this standard.
4.2.2 Branch pipes straped with girt strip should be pre-assembled or welded in a whole on
manufacture field, and the dimensions of the branch pipe after pre-assemblying and welding.

8
 Table 4.2.2: limit deviation of branch pipes straped with girt strip after pre-assemblying and welding (mm)
Dimension and plate
No. Item Limit deviation Sketch drawing
thickness (δ)

1 Pipe length (L1, L2) ±10

Roundness of pipe orifice of

2 main pipe and branch pipe 3D/1000, And not larger than 20
(D - inner diameter) Water flow direction
Difference of the measured
±3D/1000, and limit deviation±20;
perimeter and the design
3 perimeter difference of adjacent pipe
perimeter of main and
joints≤10
branch pipe orifice

Center distance of branch

4 ±10
pipe (S1)

Center height difference of D≤2m ±4

main and branch pipe 2<D≤5m ±6
5
(according go the inner
D>5m ±8
diameter D)

Perpendicularity of main and D≤5m 2

6
branch pipe orifice D>5m 3

Planeness of main and D≤5m 2

7
branch pipe orifice D>5m 3

Butt-joint unfitness of
8 Random thickness 10%δ, and not larger than 2
longitudinal seam

δ≤30 15%δ, and not larger than 3

Butt-joint unfitness of
9 30<δ≤60 10%δ
circumferential seam
δ>60 ≤6

4.2.3 The dimension of spherical shell plate for spherical shell branch pipe shall meet the
following requirements:
1 The limit deviation of the curvature of the spherical shell plate shall meet the
requirements of Table 4.2.3-1.
Table 4.2.3-1: limit deviation of curvature of spherical shell plate
Chord length of spherical shell plate Limit clearance between sample plate and
Chord length of sample plate
(L) spherical shell plate
m
m mm

L≤1.5 1

1.5<L≤2 1.5 3

L>2 2

2 The limit deviation of the geometrical dimension of the spherical shell plate shall meet
the requirements of Table 4.2.3-2.

9
 Table 4.2.3-2: limit deviation of geometrical dimension of spherical shell plate
Limit clearance between sample plate and spherical shell plate on any
Item position
mm
Chord lengths along length and width direction ±2.5
Relative difference of diagonals 4

4.2.4 The spherical branch pipe shall be assembled and welded as a whole in plant, and the
limit deviation of all dimensions of the spherical branch pipe after assembly or welding shall
meet the relevant regulations of Table 4.2.2, as well as the requirements in Table 4.2.4.

Table 4.2.4: limit deviation of spherical branch pipes after assembly and welding (mm)
Diameter (D)
No. Item Limit deviation Sketch drawing
m

Distance from main and branch pipe +10mm

1
orifice to spherical branch (L) -5mm

2 Branching angle ±30′

D≤2 8D/1000mm
3 Roundness of spherical shell 2<D≤5 6D/1000mm
D>5 5D/1000mm

D≤2 ±4D/1000mm
Distance from spherical branch top and
4 2<D≤5 ±3D/1000mm
bottom to center (H)
D>5 ±2.5D/1000mm

4.2.5 The curvature of inner and external casing for telescopic joint and the waterstop
compression ring after welding shall be inspected with sample plates (the chord length of
sample plate is detailed in Table 4.1.8-1), and the clearance on longitudinal seam shall not be
larger than 2mm; and the clearance on other position shall not be larger than 1mm. The upper,
middle and lower sections shall be inspected within the full length of the sleeve.
4.2.6 The limit deviation of the measured diameter and the design diameter of inner and
external sleeve for telescopic joint and waterstop compression ring is ±D/1000, and the limit
deviation is ±2.5mm. The limit deviation of the measured perimeter and the design perimeter
of inner and external sleeve for telescopic joint and waterstop compression ring is ±3D/1000,
and the limit deviation is ±8mm.
4.2.7 The difference of the maximal / minimum clearance and the mean clearance between
inner and external sleeve for telescopic joint shall not be larger than 10% of the mean
clearance.
4.2.8 The manufacture of the telescopic joint for corrugated pipe shall comply with the
relevant regulations in the design drawings or GB/T 12522, GB/T 12777 and GB/T 16749.
4.2.9 The water test under 1.5 times working pressure or gas tight test under 1.1 times
working pressure shall be conducted for telescopic joint for corrugated pipe; when water head
(H) is not larger than 25m, welding seam kerosene penetrant test only may be conducted.
4.2.10 The telescopic joints shall be protested from damage in the process of assemble,
packaging and transportation; the impurity like welding slag must not access into the sliding
pair and corrugated pipe of telescopic joint.

10
5 Installation of Steel Penstock
5.1 Fundamental Rules
5.1.1 The control points for steel pipe center, elevation and mileage shall be measured and
positioned in the permanent or subpermanent structures or firm rock nearby and obvious
marks shall be made before the steel pipe installation.
5.1.2 The allowance of the pipe adjuster in field installation should be cut by full-position
semi-automatic method.
5.1.3 The buttress for steel pipe shall have enough strength and stability, and the steel pipe
shall not have displacement and deformation in assembly process.
5.1.4 The members like temporary support and foot plate should not be welded on pipe wall at
will.

5.2 Installation of Buried Penstock

5.2.1 The limit deviation of the installation center of buried penstock shall meet the
requirements in Table 5.2.1.

Table 5.2.1: limit deviation of installation center of buried penstock

Limit deviation of Limit deviation of center of headend pipe orifice of
Inner diameter Limit deviation of pipe
orifice center of pipe joint and bent pipe connected with spiral case,
of steel pipe orifice center of pipe
No. initially installed telescopic joint, butterfly valve, ball valve and ball
(D) joints on other position
section valve
m mm
mm mm

1 D≤2 6 15

2 2<D≤5 10 20
5
3 5<D≤8 12 25

4 D>8 12 30

5.2.2 The limit deviation of the mileage of the initially installed section is ±5mm, and the
limit deviation of the mileage of bent pipe headend is ±10mm. the perpendicularity of the pipe
orifice (at both ends) of the initially installed section is ± 3mm.
5.2.3 The shape deviation of steel pipe cross-section meets the following requirements:
1 As for the steel pipe with round section, the deviation of the roundness (it refers to the
maximum value of the difference of two mutually perpendicular diameters of the pipe orifice
at same end) shall not be larger than 5D/1000, and the maximal deviation shall not be larger
than 40mm. at least two pairs of diameters shall be measured for pipe orifice at each end.
2 As for the steel pipe with oval cross section, the deviation from the design sizes to the
long axis (a) and the minor axis (b) shall not be larger than 5a (or 5b) /1000, and the limit
deviation is±8mm.
3 As for the steel pipe with rectangular section, the deviation from the design sizes to the
long sides (A) and the minor sides (B) shall not be larger than 5A (or 5B) /1000, and the limit
deviation is not larger than 8mm; and at least two pairs of opposite sides shall be measured
and the diagonal difference is not larger than 6mm.
4 As for the steel pipe with regular polygon cross-section, the difference of the maximum
diameter and minimum diameter of the measured circumscribed circle shall not be larger than
3D/1000, the maximal difference shall not be larger than 10mm, and the limit deviation of the
difference to the normal value in the drawing is ±8mm.
5 The partial planeness of the steel pipe with non-round section is not larger than 6mm
per meter.
5.2.4 When fixtures, lifting eye, internal support and other temporary members are dismantled
from the steel pipe, stamping method must not be adopted, and carbon arc air gouging or hot
cutting shall be adopted on the position over 3mm away from the pipe wall, and the residual
trace and burr on the steel pipe shall be planished after cutting, confirming the crack condition.

11
For high-tensile steel, magnetic particle defect detecting test and penetration defect detecting
test shall be conducted according to the relevant regulations of JB/T 6061 or JB/T 6062. The
cracks shall be grinded off by a grinding wheel, and re-inspected till complete removing.
5.2.5 The partial stain depth on steel pipe inner and external wall is not larger 10 % of the
plate thickness and 2mm, and the stains may be burnished with a grinding wheel for smooth
transition; otherwise, the weld repair shall be conducted according to the requirements of
Article 6.5.6.
5.2.6 The grouting construction of grout hole screw thread shall be conducted only upon the
protective cover is arranged for hollow screw thread.
5.2.7 When grout hole end-cap is made through melting welding, the groove depth of the
grouting end-cap should be 7mm ~ 8mm. as for parent metal with crack trend, the preheating
and postheating shall be arranged for welding. When grout hole end-cap is made through
adhesive rejoining method or strapping method, the enough argumentation and test shall be
conducted.
5.2.8 The overall appearance test shall be conducted after grout hole cap welding. The
magnetic particle defect detecting test or penetration defect detecting test shall be conducted
according to the relevant regulations in JB/T 6061 or JB/T 6062. For carbon steel and low
alloy steel, not less than 10% of the quantity shall be inspected; for high-tensile steel, not less
than 25% of the quantity shall be inspected. In case of crack, 100% inspection shall be
conducted.
5.2.9 The steel pipes shall be welded with buttress and cathead after installation, to prevent
displacement due to concrete pouring.
5.2.10 The mobile internal support should be adopted for steel pipe. When fixed support is
adopted, internal and internal supports should be connected for transition welding with joint
plate (or member bar) same or compatible to the steel pipe material.

5.3 Installation of Exposed Penstock

5.3.1 The curvature of the saddle support top surface is inspected with sample plate (the chord
length of sample plate is detailed in Table 4.1.8-1), and the clearance hereof shall not be
larger than 2mm.
5.3.2 The limit deviation of elevation, and longitudinal / transverse center of backing plate
with truck, wobble and sliding type buttress is ±5mm, and the parallelism between the
backing plate and the design axial line of the steel pipe shall not be larger than 2/1000.
5.3.3 The truck, wobble and sliding pedestal shall move flexibly free from blocking after
installation, and the contact surfaces shall contact properly and the partial clearance shall not
be larger than 0.5mm.
5.3.4 The deviation of the installation center of exposed penstock shall meet the requirements
of Table 5.2.1, and the deviation of the shape and roundness of the pipe orifice shall meet the
requirements of Article 5.2.3 after installation of exposed penstock.
5.3.5 The removing inspection for internal support, fixture and lifting eye of steel pipe, as
well as the treatment and weld repair of surface cavity on internal and external wall of the
steel pipe shall comply with the relevant regulations in the installation of buried penstock in
Section 5.2.
5.3.6 The installation of the telescopic joint for corrugated pipe shall comply with the
technical requirements of the product.
5.3.7 The ground electrode must not be connected with the pipe joint of the corrugated pipe
when the telescopic joint is welded.
5.3.8 The temporary fastener on telescopic joint shall be dismantled when the last healing
welding seam is welded between two anchor blocks.
6 Welding of Steel Penstock
6.1 Qualification of Welding Procedure
6.1.1 Before the manufacture and installation of steel penstock, the construction organization
shall prepare the welding procedure specification to guide the welding construction and

12
passing the qualification of welding procedure (hereafter referred to as qualification),
according to the quality requirement and material / and structural characteristic of steel pipes.
6.1.2 The "qualification", as the pre-production process validation test conducted on the base
of the steel product solderability test, shall be conducted after drawing out the welding
process guide book and before product welding.
6.1.3 The preparation, dimension, test method and approval standard of mechanical property
test plate in qualification of welding procedure are detailed in Annex D, and the
recommended format of welding procedure guide book and qualification report are detailed in
Annex E.
6.1.4 The "qualification" factors include key factor, supplemental factor and minor factor:
1 Key factors refer to the welding process factor affecting the tensile strength and
flexural property (corrosion resistance requirements for stainless steel) of welding joints.
2 Supplemental factors refer to the welding process factor affecting impact ductility of
welding joints, which need be supplemented when the impact test is required to conduct.
3 Minor factors refer to the welding process factors without obvious affect on the mechanical
property of the welding joint and corrosion resisting property of stainless steel.
6.1.5 To reduce the "qualification" quantity, the steel products may be classified and grouped
according to chemical composition, mechanical property and welding performance in Annex
F.
6.1.6 The "qualification" may not be conducted under one of the following conditions:
1 Qualified welding process with valid documentation.
2 When the key factors and supplemental factors don't change and the qualification of
steel products at higher grade is applicable to ones at lower grade in steel products classified
in Article 6.1.5.
3 The "qualification" of the steel products with same grade type may be substituted each
other.
6.1.7 Although the steel products of different grade making a welding joint are qualified
respectively, and the welding joint shall also be qualified. The welding joint made of steel of
Grade I and II may not be qualified of the parent metal at Grade II passes the qualification.
6.1.8 In the impact test of the heat-affected zone on test sample for dissimilar steel
qualification of welding procedure, two steels shall al be sampled and tested, and the welding
seam shall be tested. The qualification item and quantity are detailed in Table 6.1.20.
6.1.9 The welding position used in "qualification" may generally be flat welding position; for
"qualification" required with impact ductility, the welding position shall be vertical uphill
welding.
6.1.10 The "qualification" shall be redone if the welding method changes. .
6.1.11 If the following key factors change, the "qualification" shall be redone, although the
qualification has been conducted.
1 The type of steel product changes or the thickness goes beyond the application scope
specified in Table 6.1.19.
2 The first double-digit in type of electrode, welding wire designation or soldering flux
designation change.
3 The preheating temperature is over 50℃ lower than the qualification temperature.
4 The type of shielding gas is changed and the shielding gases are mixed in different
proportion, or the shielding gas is canceled and the mixed gas substitutes single gas.
5 The transition mode of the gas metal-arc welding is changed from jet arc, droplet arc or
pulse arc to short circuit arc; or inversely.
6.1.12 If the weldment required with impact ductility test has some key factor of a certain
"qualification" that has been conducted, and one or several of the following supplemental
factors are supplemented, a test sample for supplemental qualification may be welded
according the supplemented and changed supplemental factors, and only toughness test is
conducted for this test sample:
1 The temperature range and warmth-keeping time of postwelding stress-relief heat
treatment are changed.

13
 2 The maximal interlayer temperature is over 50℃ higher than the qualified interlayer
temperature.
3 The type or polarity of the electric current is changed.
4 The deposited metal volume of weld heat input or unit-length welding pass exceeds the
qualified scope.
5 Submerged arc welding or gas metal-arc welding is changed from single wire welding
to multiple-wire welding or inversely.
6 The welding rod with hydrogen controlled covering replaces the one with
non-hydrogen controlled covering.
7 Acid flux-cored wire is replaced with alky flux-cored wire.
8 Submerged arc welding or gas metal-arc welding is change from multi-pass welding to
single-pass welding.
9 The qualification position is changed to vertical uphill welding position.
6.1.13 If the key factors and supplemental factors in the "qualification" that has been
conducted are all same, and on the following minor factors are changed and the welding
procedure specification is only amended, the "qualification" may not be redone.
1 Groove form.
2 Groove root opening.
3 Cancel or add the welding seam backing plate in one side welding.
4 Cancel or add nonmetal or non-melt metal welding pad.
5 Diameter of welding wire (rod).
6 Welding positions except vertical upward welding.
7 Vertical upward welding or vertical down welding for root pass required with root
cleaning.
8 Change postheat temperature scope and warmth-keeping time after welding and before
postweld heat treatment.
9 Current or voltage.
10 Weaving welding or non-weaving welding.
11 Preweld cleaning and inter-layer cleaning method.
12 Root cleaning method.
13 Change waving amplitude, frequency and end staying time of welding rod and
welding wire.
14 Distance from current contact nozzle to workpiece.
15 Manual operation, semi-automatic operation or automatic operation.
16 Hammering or not hammering welding seam.
6.1.14 The postheating is not included in qualification of welding procedure. If postheating is
required, it shall be indicated in "welding procedure specification".
6.1.15 The butt-jointed seam test sample shall be used in the butt welding process
qualification; fillet weld test sample or butt-jointed seam test sample shall be adopted in the
fillet welding process qualification; butt-jointed seam test sample shall be used in the
composite welding process qualification; if the composite weld is required with
through-welding, the composite weld test sample shall be added.
6.1.16 The butt-jointed seam test sample or fillet weld test sample passing the process
qualification are used for welding fillet weld seam, and the effective range of the weldment
thickness is not limited.
6.1.17 When a weld seam is welded with two or ore welding method or welding process with
different key factor / supplemental factor, the qualifications may be respectively conducted
according to the welding method and process; or two or more welding methods or welding
processes are used for combination qualification.
6.1.18 The qualification of welding procedure for stainless steel clad plate may comply with
the relevant regulations of Annex G.
6.1.19 The effective range of the welding process of the qualified butt-jointed seam test
sample applicable to the parent metal thickness and weld metal thickness of the weldment
shall meet the requirements of Table 6.1.19.

14
Table 6.1.19: Effective range of the welding process applicable to the parent metal thickness and weld metal
thickness of the weldment (mm)
Thickness of test Scope applicable to parent metal Scope applicable to weld metal
sample parent metal thickness of weldment thickness of weldment
Application scope (δ) and thickness of
Minimum Minimum
test sample weld metal Maximum value Maximum value
a
value value
(t )

2δ, and not larger than Not 2t, and not larger than
Standard tensile 1.5≤δ (t) ≤8 1.5
12 limited 12
strength
Not
>540N/mm2 δ (t) ≥8 0.75δ 1.5δ 1.5t
Strength limited

level of Not
1.5≤δ (t) ≤10 1.5 2δ 2t
parent limited
Standard tensile
metal Not
strength 10<δ<38 5 2δ 2t
limited
2
≤540N/mm
Not 2t (t<20)
δ≥38 5 200b
limited 200b (t≥20)

Note: a t refers to the thickness of weld metal on test sample, molten with a welding method (or welding process).
b It is limited to the multi-pass welding of welding rod arc welding, argon tungsten-arc welding, plasma welding,
submerged arc welding and gas metal-arc welding.

6.1.20 The item and sample quantity of the mechanical property test for plate butt-jointed
seam test sample are detailed in Table 6.1.20.

Table 6.1.20: Item and sample quantity of the mechanical property qualification for plate butt-jointed seam
qualification sample
Thickness of Stretching and bend test Impact test
Type of test sample
Heat-affected
joint (δ) Stretching Face bending Back bending Side bending Weld zone
zone
mm

δ<20 2 2 2 — 3 3
Butting
δ≥20 2 — — 4 3 3

Note 1: When the flexural property of the parent metals on both sides of test sample welding seam, or between weld metal and
parent metal has obvious difference, longitudinal bending test should replace transverse bending test, and two test samples for
face bending and back bending are selected respectively in longitudinal bending test.
Note 2: When the thickness of parent metal is larger than 20mm, 4 side bend test samples may replace 2 test samples for face
bending and 2 test samples for back bending.
Note 3: If the toughness test is required, 3 samples shall be selected respectively on heat-affected zone and welding seam; for
dissimilar steel joint, 3 samples shall be selected respectively on heat-affected zone and welding seam. In the combined welding
methods (process), keyhole test samples shall be selected from weld metal and heat-affected zone with all welding methods
(process) adopted.

6.1.21 The test samples of composite weld and fillet weld shall meet the requirements of
Annex D, and weld appearance inspection shall be conducted for test samples. The surface
inspection shall be conducted according to the penetrant inspection standard in JB/T 6062,
and then the cross section macrographic examination shall be conducted for the test sample
chopped to 5 sections.

15
6.1.22 When hardness testing is required, the hardness of welding seam and heat-affected
zone of welding joint made of same steel is generally not larger than the Vickers hardness
number HV100g of the parent metal plus 100, and the values specified in Table 6.1.22. The
hardness inspection for welding seam and heat-affected zone of the welding joint made of
dissimilar steels shall comply with requirements of DL/T 752.

Table 6.1.22: allowable maximal hardness value HV100g of welding joint and heat-affected zone made of
dissimilar steels
Single-pass butt weld and Multi-pass butt weld and
fillet weld fillet weld
Type of steel
Not Not
Heat-treated Heat-treated
heat-treated heat-treated

Minimal yield strengthReL≤360N/mm2; chemical composition:

C≤0.24%, Si≤0.6%, Mn≤1.7%, S≤0.045%; other individual element
≤ 0.3%; sum of other elements ≤0.8% 380 320 350 320

Normalized steel or controlled and rolled grain refining steel with

the minimal yield strength ReL>360N/mm2

Quenched and tempered steel and precipitation reinforced steel

Negotiated Negotiated
except stainless steel (The steel with the minimal yield strength 450 420
specially specially
ReL>885N/mm2 Requires to be negotiated specially)

Steel: Cr≤0.75%, Mo≤0.6%, V≤0.3% Negotiated Negotiated

320 320
Steel: Cr≤10%, Mo≤1.26% specially specially

Negotiated Negotiated
Cr-Mo-V steel: Cr≤12.2%, Mo≤1.2%, V≤0.5% 350 350
specially specially

Ni≤4% 300 320 300

Negotiated
Nickel alloy steel (Ni≤10%) Negotiated Negotiated
Ni>4% specially 400
specially specially

Ferrite and martensite steel (10.5%≤Cr≤30%) Negotiated specially

Note: the ferrite steel and austenitic steel with tensile strength Rm≤432N/mm2may not be tested in hardness.

6.1.23 After qualification of welding procedure, the report on qualification of welding

procedure shall be prepared with overall evaluation (qualification); based on this, the welding
procedure specification is formulated for guiding manufacturing.

6.2 Qualification of Welder

6.2.1 The welder engaged in Class I and II seam welding shall pass the examination and got
the welder certificate issued by the corresponding administration according to the
requirements of DL/T 679, SL 35 or "Rules on the examination and management of welders
for welding penstock of boiler".
6.2.2 The steel type, welding method and welding position conducted by a welder shall match
the qualified items gotten by him / her in the welder examination.
6.2.3 The welders engaged in high-tensile steel and stainless steel clad plate welding and the
operator for manual carbon arc air gouging shall conduct theoretical and practical training.

6.3 Fundamental Rule and Technological Requirements of Welding

6.3.1 The welding seams are divided three classes according to the stress property, working
condition and significance.
1 Class I welding seam, including main stress welding seam:

16
 1) Longitudinal seam of steel pipe wall, circumferential seam of elastic cushion pipe
in dam, circumferential seam of exposed penstock (steel pipes not buried in concrete) in plant
building, reserved circumferential seam, healing circumferential seam of adjuster.
2) Longitudinal seam and circumferential seam of branch pipe wall, butt-jointed seam
of reinforcing member for branch pipe, composite weld seam on the connection of reinforcing
member and pipe wall.
3) Internal and external sleeve of telescopic joint, longitudinal seam of pressing ring,
attachment weld seam between external sleeve and end plate and between pressing ring and
end plate.
4) Bulkhead welding seam and attachment weld between bulkhead and pipe wall
5) Butt-jointed seam of supporting ring.
6) Butt-jointed seam of manhole neck pipe, and attachment weld seam between
manhole neck tube and neck ring flange / pipe wall.
2 Class II welding seam, including secondary stress welding seam:
1) Circumferential seam of steel pipe wall (not Class I welding seam).
2) Butt-jointed seams of stiffener ring, waterproofing ring and thrust ring.
3) Longitudinal and transverse (ring) weld seam of steel lining for scouring sluice and
discharge opening (hole)
3 Class III welding seam, welding seams excluding Class I and II welding seams.
6.3.2 The steel products which the standard tensile strength is larger than 540N/mm2 should
be used as welding test piece for productive products, and the mechanical property test shall
be conducted for weld joints, to verify the feasibility and effectivity of the process used in
production practice.
6.3.3 The welding rod, welding wire, soldering flux and shielding gas used in steel pipe
welding shall match the steel type welded, and the selection of welding materials are detailed
in Table H.1 of Annex H.
6.3.4 The selection of welding materials for stainless steel clad plate is detailed in Table H.2
and Table H.3 of Annex H.
6.3.5 In welding of same steels, for carbon steel, low alloy steel and high-tensile steel, the
mechanical property of weld metal shall be equivalent to the parent metal, and the tensile
strength hereof should not be larger than the tensile strength upper limit value of the parent
metal plus 30N/mm2; for stainless steel, the welding seam tensile strength shall not be lower
than the tensile strength of the parent metal, and the chemical composition shall be equivalent
to the parent metal.
6.3.6 The selection of welding material for stainless steel clad plate welding shall meet the
following requirements:
1 The base weld metal shall guarantee the mechanical property of the welding joint, and
the tensile strength hereof shall not be larger than the tensile strength upper limit value of the
parent metal plus 30N/mm2.
2 The covering weld metal shall guarantee the corrosion resisting property, and the main
alloying element content hereof shall not be lower than the lower value of the parent metal.
3 Transition welding seam with welding material of higher nickel and chromium content
shall be adopted between covering welding seam and base welding seam.
6.3.7 For the welding with the dissimilar steels including carbon steel, low alloy steel and
high-tensile steel, the welding material shall be selected according to the steel plate with
lower strength, and the welding process shall be selected according to the steel plate with
higher strength. The welding materials for stainless steel shall be adopted if above steels are
welded with stainless steel.
6.3.8 Reliable protective barrier and insulating measures shall be adopted for welding position
under the following conditions:
1 Wind speed: larger than 2m/s in shielded arc welding; larger than 8m/s in other
welding.
2 The relative humidity is larger than 90%.
3 Rainy or snowy weather.

17
 4 Environment temperature: under-20℃ for carbon steel; under-10℃ for low-alloy
structural steel; under 0℃ for high-tensile steel and stainless steel.
6.3.9 Before welding, the rust, slag, oil foot and water within 10mm ~ 20mm on groove and
both side shall be removed, and the fixing dimension, groove dimension and tack weld quality
shall be inspected. The defects like crack, air hole and slag inclusion on tack weld shall be
removed.
6.3.10 The welding materials shall be kept and baked according to the following
requirements:
1 Welding rod, welding wire and soldering flux shall be stored in special storerooms of
ventilation, drying and ambient temperature not lower than 5℃. The persons shall be
specially assigned for keeping, baking and dispensing them, and making the records on
observed temperature and welding materials dispensing. The baking temperature and time
shall meet the requirements of the welding material instruction book.
2 The welding rod and soldering flux after baking shall be stored in the thermostated
container at 100℃~ 150℃, and the electrode coating shall not have scaling and obvious
crack.
3 The welding rods used on field shall be encased in thermostat, and the keeping time of
welding rods in thermostat should not be larger than 4h. Otherwise, the welding rods shall be
re-baked. The times of baking repeating should not be larger than 2.
4 If sundries are mixed in soldering flux, the soldering flux shall be cleaned or replaced
wholly.
5 The rust and soil on welding wire shall be removed before using.
6 After being unpacked, the flux-cored wires should be used out in time. The moisture
protection measures shall be adopted for the welding wire loaded in electrode feeding
machine overnight. The welding wire not used within 2 ~ 3 days shall be sealed and returned
to the storage.
7 Other requirements shall comply with JB/T 3223.
6.3.11 In seam welding (including tack weld), the arch shall be generated and quenched in
groove and the arc crater shall be filled full for arc quenching. The inter-layer joints in
multilayer welding shall be staggered: for welding rod, semi automatic gas shielding welding
and self-shielding flux-cored wire welding, the welding pass joints shall be staggered over
25mm; for submerged arc welding, automotive consumable electrode shielded arc welding
and self-shielded flux-cored wire automatic welding, the joints shall be staggered over
100mm. the run-off plate which the material are same or compatible to welded material and
groove shall be arranged on the arc generating and quenching position of welding seam butt
end.
6.3.12 The tack welding meet the following requirements:
1 The welding process and welder requirement of the tack weld for Class I and II
welding seam are same to the ones for normal welding seams.
2 In the tacking for steel plate required with preheating, the width of 150mm around the
tack weld shall be preheated, and the preheating temperature shall be 20℃~ 30℃ higher than
the normal welding seam.
3 The tack weld position shall be 30mm away from the welding seam top and the length
hereof shall be over 50mm; for high-tensile steel which the standard yield strength (ReL) is not
less than 650N/mm2 or the standard tensile strength (Rm) is not less than 800N/mm2, the
length hereof shall be over 80mm, and at two layers of tack weld shall be made. generally, the
spacing of tack weld is 100mm ~ 400mm, the thickness should not be larger than half of the
normal weld thickness, and the maximal thickness should not be larger than 8mm. the tack
weld shall be positioned in a groove on post-welding side.
4 In formal welding operation, tack weld must not be reserved in Class I welding seam
for carbon steel and low alloy steel, or Class I and II welding seam for high-tensile steel.
6.3.13 The welding of fixture/tool, inner support, outer support, lifting eye and other
temporary members shall meet the following provisions:

18
 1 If pre-heating welding shall be conducted for steel plate, fixture/tool welding shall be
carried out according to the provisions in Article 6.3.15 of this standard. Preheating
temperature shall be by 20℃~ 30℃ greater than formal weld-seam preheating temperature.
2 The attachment weld of base material and such temporary members as fixture/tool shall
be over 30mm away from formal weld seam.
3 During fixture/tool welding, both arc starting and arc quenching points shall be on
fixture/tool.
6.3.14 During welding, the welder who are welding the same seam shall manage to keep the
same speed.
6.3.15 Weld seam preheating shall meet the following provisions:
1 The recommended minimal preheating temperature for usual steel designation is the
recommended one by steel mill or the one stated in Table 6.3.15.
2 Heat installation selections shall meet the following requirements:
1) Meet process requirements
2) Heated work piece is not harmfully influenced due to heating.
3) Uniform heating
4) Effective temperature control
3 Preheating zone width shall be 3 times plate thickness at both sides of weld center line
respectively and not less than 100mm. The temperatures are symmetrically measured the
places which are 50mm away from weld seam center. The measuring point interval of each
weld seam shall not be greater than 2m and the measuring points shall be at least 3 pairs.
Table 6.3.15: preheating temperature of weld seam
Q235 Q390, Q420 07MnCrMoVR
Plate Q345 Stainless steel and
Q295 15MnVR, 15MnVNR 07MnNiCrMoVDR
thickness 16MnR stainless steel clad plate
20g, 20R 15MnVB, 15MnTi Q460, 18MnMoNbR
mm ℃ ℃
℃ ℃ ℃

≥16 ~ 25 — — — —

>25 ~ 30 — — 60 ~ 80 80 ~ 120
50 ~ 80
>30 ~ 38 — 80 ~ 100 80 ~ 100

>38 ~ 50 80 ~ 120 100 ~ 120 100 ~ 150 120 ~ 150 100 ~ 150

Note 1: if ambient temperature is less than 5℃, higher preheating temperature shall be adopted.
Note 2: as for the weld seam free from preheating, if ambient relative humidity is greater than 90% or ambient
temperature: is less than; 5℃ for carbon steel and low alloy steel or 0℃ for stainless steel (austenite stainless steel may not
be preheated), such steels shall be preheated to above 20℃ before welding.

6.3.16 If stiffening ring, water-proof ring, supporting ring and manhole are welded on the
steel plate for which preheating is needed, preheating shall be carried out according to the
same preheating temperature with formal welding.
6.3.17 Weld inter-pass temperature shall not be less than preheating temperature; the weld
inter-pass temperature, for carbon steel and low alloy steel, shall not be higher than 230℃;
and not higher than 200℃ for dead-hard steel.
6.3.18 For such weldment as low alloy steel and dead-hard steel with great cold crack
sensibility, post-heating measures shall be taken according to the following provisions:
1 Post-heating should be carried out for dead-hard steel and low alloy steel with its
thickness greater than 38mm.
2 Post-heating temperature is 250℃ ~ 350℃ for low alloy steel and 150℃ ~ 200℃ for
dead-hard steel. Post-heating shall be carried out immediately after welding. Insulation
duration shall be at least 1 hour. If stress-relief heat treatment is carried out immediately after
welding, post-heating disposal may not be carried out.
6.3.19 After unilateral welding for bifacial weld seam, reverse back gouging shall be carried
out. If back chipping is carried out with carbon arc air gouging, after back gouging,

19
carburized layer and surface defect on gouge shall be grinded away. If preheating is needed
for weld seam, preheating shall be carried out before gas-gouging back gouging.
6.3.20 The assembling interval of V-shaped welding groove with backing plate shall be
controlled within 6mm ~ 15mm. The assembling interval of unsymmetrical X-shaped welding
groove or Y-shaped welding groove should be controlled within 0 ~ 3mm. If partial interval is
greater than 6mm and less than 20mm, overlay welding is allowed on both sides/one side of
groove; but the following provisions shall be met:
1 Metal material shall not be filled into interval.
2 After overlay welding, renovation with grinding wheel shall be conducted.
3 Surface defect detecting shall be carried out for the overlay-welding seam according to
overlay welding length and interval dimension.
6.3.21 If groove interval is greater than the provisions for partial interval in Article 6.3.20 of
this standard, overlay welding renovation shall be carried out after special study.
6.3.22 The complete-penetration composite welding for stiffening ring, thrust ring,
water-proof ring, supporting ring and steel pipe wall shall meet the design provisions; what's
more, the allowable leg of a fillet weld on pipe wall sticking side is 1/4 ring plate thickness
and not greater than 9mm.
6.3.23 If interior fault detecting can not be carried out for such important weld seams as
supporting ring or manhole, welding shall be carried out according to Type I weld seam
process.
6.3.24 If weld heat input requirements are specified for steels, welding shall be carried out
according to weld heat input scope.
6.3.25 Refer to the provisions in DL/T 678 for other technical requirements for welding.
6.4 Weld Inspection
6.4.1 Appearance inspection shall be carried out for all weld seams. The appearance quality
shall meet the provisions in Table 6.4.1.

20
 Table 6.4.1: weld appearance inspection (mm)
Weld seam classification

Serial number Item I II III

Allowable defect dimension

1 Crack Not allowable

Depth being not greater than 0.1δ and length

2 Surface inclusion Not allowable being neither greater than 0.3δ nor greater than
10

3 Undercut Depth not greater than 0.5 Depth not greater than 1

Neither being greater than 0.2+0.02δ nor

4 Incompletely welding Not allowable greater than 1, the defect total length per 100
weld seams being not greater than 25

5 pores being allowable for the ones with their

5 Surface pore Not allowable diameter less than 1.5 within each meter within
range; the interval being not less than 20

6 Welding beading Not allowable —

7 Splashing Not allowable —

Welding δ≤25 Δh=0 ~ 2.5

seam Manual welding 25<δ≤50 Δh=0 ~ 3 —
8
surplus δ>50 Δh=0 ~ 4
height Δh Automatic welding 0~4 —

Over-covering each side slope opening by 1 ~ 2.5 and the transition being
Butt-joint Manual welding
smooth
9 weld
Over-covering each side slope opening by 2 ~ 7 and the transition being
width Automatic welding
smooth

10 Leg of a fillet weld K If K≤12, K −+12 ; if K>12, K −+13

Note 1: δ is the symbol of steel plate thickness.
Note 2: manual welding refers to welding rod arc welding, CO2 semiautomatic welding, self-shielded cored
semi-automatic welding as well as manual TIG welding etc; automatic welding refers to union melt welding, MAG
automatic welding, MIG automatic welding etc.

6.4.2 Nondestructive testing personnel shall hold a corresponding technical qualification

certificate which is signed and issued by such related state departments as electricity
department, water conservancy industry, quality technical supervision department and
nondestructive testing institute. Weld quality shall be evaluated by Grade II (or above)
nondestructive testing personnel.
6.4.3 Ultrasonic inspection or radiographic inspection may be carried out for interior weld
seam fault detection. If doubt is discovered in one test method, the interior weld seam fault
may be re-examined with another test method. Defect detecting test may be carried out for
weld surface according to the related provisions of magnetic particle inspection in JB/T 6061
or jointly with the related provisions in JB/T 6062.
6.4.4 The percentage of nondestructive inspection length in weld seam full length shall be at
least the specification in Table 6.4.4.

21
 Table 6.4.4: percentage of nondestructive inspection length in full length
Ultrasonic inspection% Radiographic inspection%
Steel type
Type I Type II Type I Type II

Carbon steel and low alloy

100 50 25 10
steel

Dead-hard steel
Stainless steel 100 100 40 20
Stainless steel clad plate

Note 1: if ultrasonic inspection is conducted for Type I weld seam of steel pipe, retesting may be carried out with
radiographic inspection as required.
Note 2: fault detection position shall include all T-shape weld seams and some weld seams by each welder.

6.4.5 If there is delayed crack inclination for steel bar, nondestructive inspection shall be
carried out 24 hours after welding; for dead-hard steel, if its lower limit of tensile strength Rm
≥800N/mm2, nondestructive inspection shall be carried out 48 hours after welding.
6.4.6 The inspection and evaluation of radiographic inspection are carried out according to the
provisions in GB/T 3323. If the inspection grade is Grade B, evaluation is not less than Grade
II for Type I weld seam, it is qualified; and evaluation is not less than Grade III for Type II
weld seam, it is qualified. The inspection and evaluation of ultrasonic inspection are carried
out according to the provisions in GB 11345. If the inspection grade is Grade B, evaluation is
Grade I for Type I weld seam, it is qualified; and evaluation is not less than Grade II for Type
II weld seam, it is qualified. Nondestructive inspection quality evaluation for weld surface
may be carried out according to Standard JB/T 6061 or Standard JB/T 6062.
6.4.7 If forbidden defect is discovered in weld-seam partial nondestructive inspection,
supplementary defect detecting shall be carried out in defect extension direction or at
questionable position; if forbidden defect is still discovered after supplementary fault
detection, fault detection shall be carried out for the welded positions on this weld seam or the
entire weld seam (welded by this welder).
6.5 Defect Disposal and Repair Welding
6.5.1 If such dangerous defects as interior or surface cracks of weld seam are discovered,
repair welding may only be carried out after reason analyzing, reason identification and
measure preparation.
6.5.2 Interior defect of weld seam shall be cleared away with carbon arc air gouging or
grinding wheel; and a groove being convenient for welding shall be grinded with grinding
wheel. Before repair welding, inspection shall be carried out. If the defect is crack, defect
detecting shall be carried according to relevant provision of magnetic particle in JB/T 6061 or
jointly with the relevant provisions in JB/T 6062. After crack is affirmed to be eliminated,
repair welding may only be carried out.
6.5.3 If pre-heating or post-heating shall be conducted for the repair welding seam, preheating
shall be carried out according to the provisions in Article 6.3.15, this standard before repair
welding; preheating temperature shall be by 20℃~ 30℃ greater than formal weld-seam
preheating temperature. After repair welding, post-heating shall be carried out according to
the provisions in Article 6.3.18, this standard.
6.5.4 Post- reworked weld seam shall be re-examined with radiographic inspection or
ultrasonic inspection. Rework times at the same location should not be larger than 2 times and
once for dead-hard steel; otherwise, before repair welding, reliable technical measures shall
be taken, which shall specially be studied. Post-reworked weld seam shall be re-examined
with ultrasonic inspection or radiographic inspection.
6.5.5 Steel plate surface of stainless steel and dead-hard steel shall be free from arc scratch or
hard-object percussion scar. Any scratch or percussion scar shall be burnished into a groove.
If post-burnishing depth is greater than 2mm, repair welding shall be carried out.

22
6.5.6 If pipe-wall surface cavity depth is greater than 10% plate thickness or greater than
2mm, before repair welding, the cavity shall be grinded into a groove which is convenient for
welding with carbon arc air gouging or grinding wheel. If preheating and post-heating are
needed, they shall be carried out according to the provisions in Article 6.3.15 and Article
6.3.18 of this standard. After repair welding, the repair welding section shall be flatted with
grinding wheel. Inspection shall be conducted carefully to find out whether there is any crack.
As for dead-hard steel, defect detecting shall be carried out according relevant provisions of
magnetic particle in JB/T 6061 or jointly with the relevant provisions in JB/T 6062.
7 Post-welding Stress-relief Treatment of Steel Penstock
7.1 Fundamental Rules
7.1.1 Post-welding-heat-treatment stress-relief should not be carried out for dead-hard steel.
7.1.2 Post-welding stress-relief treatment for steel pipe and branch pipe shall be carried out
according to the provisions in drawings or designing technological documents.
7.2 Post-welding Stress-relief Treatment
7.2.1 Temperature for post-welding stress-relief heat treatment of carbon steel and low alloy
steel shall be determined according to the provisions in drawings; if the temperature is not
specified in drawings, the temperature may be 580℃ ~ 650℃ (determining by such factors as
steel bar characteristic and weld-ability test achievement). Brittleness temperature area shall
be avoided for the heat treatment of the steel bar with temper brittleness.
7.2.2 If integral stress-relief heat treatment is carried out for the steel pipe and branch pipe of
carbon steel and low alloy steel in furnace, in-furnace temperature shall be less than 300℃
when work piece is loaded into furnace or taken out from furnace; the heating speed, constant
temperature duration and cooling speed shall be controlled according to the following
requirements.
1 Heating speed: after temperature rises to 300℃, heating speed shall neither be greater
25
than 220 × ℃/h nor be greater than 220℃/h, but the speed may not less than 50℃/h.
δ
2 Constant temperature duration: 2 minutes ~ 2.5 minutes for per millimeter wall
thickness of carbon steel and at least 30 minutes; during insulation, various temperature
differences shall not be greater than 50℃.
3 Cooling speed: after constant temperature, cooling speed shall neither be greater than
25
275 × ℃/h nor greater than 275℃/h, but the speed may not less than 50℃/h. If the
δ
temperature is less than 300℃, natural cooling may be carried out.
Among the aforementioned formulae is the maximal plate thickness of welding joint
(mm).
7.2.3 If it is hard to conduct in-furnace integral stress-relief heat treatment for the steel pipe
and branch pipe of carbon steel and low alloy steel, partial stress-relief heat treatment may be
carried out. Heating width shall be over 6-times maximal plate thickness area on both sides of
weld seam center. The speed and duration of heating, insulation and cooling are the same with
whose of in-furnace integral stress-relief heat treatment; inside and outside wall temperatures
shall be managed to be even; insulating shall be carried out outside heating zone so as to
reduce temperature gradient; prevent greater heat stress and base material
organization/property influence.
7.2.4 After each stress-relief heat treatment, stress-relief heat treatment curve shall be
provided with. After partial stress-relief heat treatment, at least one stress-relief effect and
hardness measurement record shall be offered. Welding joint rigidity requirements are stated
in Article 6.1.22, this standard.
7.2.5 If explosion stress-relief treatment is adopted for steel pipe and branch pipe; before
construction, appropriate stress-relief criteria parameter shall be determined via explosion
stress-relief process test directly towards specific material and structure so as to ensure that
the mechanical property and stress-relief effect of welding joint will meet design/relevant
requirements.

23
 7.2.6 If vibration aging stress-relief process is adopted; before construction, appropriate
vibration stress-relief criteria parameter shall be determined via process test so as to ensure
that the mechanical property and stress-relief effect of welding joint will meet design/relevant
requirements.
8 Corrosion Protections for Steel Penstocks
8.1 Surface Pretreatment
8.1.1 Before surface pretreatment for steel pipe, such adherent contaminations as iron rust, oil
stain, water logging, omitted welding slag and splashes shall be cleared away.
8.1.2 The abrasives for surface pretreatment by abrasive jet /casting derusting shall be clean
and dry; if such abrasives as metal abrasives, alumina (adamantine spar), carborundum and
corundum are used, their granularity range should be 0.5mm ~ 1.5mm; if artificial mineral
abrasives and natural tribolite are adopted, they shall be selected according to such technical
requirements as surface roughness.
8.1.3 The compressed air used for abrasive jet derusting shall be filtered and oil-water
removed.
8.1.4 After abrasive jet /casting derusting for the inner wall of exposed pipe and buried
penstock, the derusting grade, being evaluated according to photo visualization, shall satisfy
Grade Sa2.5 specified in GB/T 8923. The requirements of various derusting grades in GB/T
8923 are stated in Annex I. After derusting, the surface roughness shall be Ry40µm ~
Ry70µm for routine anti-corrosive paint and Ry60µm ~ Ry100µm for thick-motar heavy
anti-corrosive paint and metal thermal spray painting. Surface roughness is determined with
tracer-needle contour-graph or visually evaluated with comparative templet.
8.1.5 After abrasive jet /casting derusting for the outer wall of exposed pipe and buried
penstock, the derusting grade shall meet the criteria specified in Table 8.1.5 according to the
diversities of cement-paste anticorrosion or painting anticorrosion.

Table 8.1.5: corrosion-prevention quality requirements of steel-pipe outer wall surface

Surface roughness Ry
Part Painting support Derusting grade
µm

Exposed pipe outer wall Spray painting Sa2.5 40 ~ 70

Buried penstock outer wall Modified cement mucilage Sa1 —

8.1.6 After derusting for steel pipe, the steel pipe shall be cleaned by compressed air blowing
or with a cleaner. Before painting, if contamination or rust return is discovered on steel plate
surface, the steel pipe shall be re-handled till the former derusting grade reaches.
8.1.7 Derusting shall not be carried out; if relative humidity in air is greater than 85%,
ambient temperature is less than 5℃ and steel plate surface temperature is expected to be by
over 3℃ less than air dew point. The conversion table of air dew point is placed in Annex J.
8.1.8 Other technical requirements for steel pipe corrosion prevention are stated in the
provisions in DL/T 5358.

8.2 Painting
8.2.1 After derusting, steel bar surface shall be painted within 4 hours and within 12 hours
maximally on a fine day and in normal condition.
8.2.2 The used painting shall meet the provisions in drawings. Painting layers, per layer
thickness, successive-layer painting interval duration, painting mixing method and painting
notice shall meet the provisions in design document or the relevant provisions.
8.2.3 Steel pipe node shall be painted with workshop prime paint within 200mm on both sides
of circumferential seam installation and within 100mm around grout hole and drain hole.
After site welding and surface pretreatment according to requirements, painting may be
carried out.

24
 8.2.4 Painting shall not be carried out; if relative humidity in air is greater than 85%, steel
plate surface temperature is by over 3℃ less than air dew point or greater than 60℃, or
ambient temperature is less than 10℃.

8.3 Quality Inspection of Painting Coat

8.3.1 Such defects as skips, sagging and wrinkle during painting are discovered, they shall be
disposed timely; what's more, wet-film thickness shall be measured with wet film thickness
gauge. Before each layer painting, the former coat appearance shall be inspected.
8.3.2 During post-painting appearance inspection, coat surface shall be smooth, with even and
identical color; but without any wrinkle, bubble, sagging, pinhole, crack and skips etc.
Cement paste coat thickness shall be basically the same; coat adherence shall be firm and be
free from powder.
8.3.3 Internal coat quality shall meet the following provisions:
1 Paint film thickness is determined with a coating layer thickness meter. If steel pipe
diameter is great, at least 3 test points shall be arranged for per 10m2 surface; if the diameter
is small, at least 1 test point shall be arranged for per 2m2 surface; and 1 test point shall be
arranged for every other 1.5m circle at both end and middle of single pipe. 85% test point
thickness of paint film shall meet design requirements; if the test point can't meet the desired
thickness, its minimum thickness shall be not less than 85% design thickness.
2 For thick-motar paint, pinhole on both sides of installation circumferential seam is
mainly inspected according to specified voltage; if any pinhole is discovered, it shall be
painted complementarily after it is burnished with emery paper and elastic grinding wheel
sheet.
3 If paint film thickness is insufficient or pinhole exists in paint film, re-examination
shall be carried out after reworking and solidifying.
4 Adhesion inspections
1) If paint film thickness is greater than 120μm, sampling inspection shall be carried
out for the coat according to the following processes: two cutting intersection lines, being cut
into backing material, with 60° separation angle is cut with a inserted tool on the coat; the cut
opening is firmly bonded with adhesive tape; then the adhesive tape is quickly torn vertically;
if coat is free from peeling, the coat is qualified.
2) If paint film thickness is less than 120μm, two-mutually- perpendicular-groups of
parallels with equal distance (1mm ~ 2mm) are drawn on coat surface with exclusive cutter to
form into several grids. Then adhesion grade of paint film is inspected according to the
provisions in Table 8.3.3 in GB/T 9286; if paint film meets the first three grade, it is qualified.

Table 8.3.3: inspection of paint film adhesion

Grade Inspection result

0 Cutting edge is completely smooth and free from any one grid falling off

1 A little amount of sheets separates at cutting in-fall and obviously affected grid area is not greater than 5%

2 Over 5% coat falls off apparently along cut edge or cut in-fall but the apparently affected area is not greater than 15%

Partial or all coat falls off with large fragments along coat cut edge is apparently greater than 15% or partial/all coat peeling
3
at grid different parts is apparently greater than 15%; but apparently affected grid-drawn area is not greater than 35%

Both coat peeling with large fragments along cut edge or partial/all falling off of some grids are apparently greater than
4
35%, but the affected grid-drawn area is apparently not greater than 65%

5 The peeling degree can not even be identified according to Grade 4

8.4 Mellozing
8.4.1 The wires used fro mellozing shall meet the following requirements:
1 Zinc wire shall meet the quality requirements of Zn - 1 in GB/T 470 and Zn ≥99.99%.
2 Aluminium wire shall the quality requirements of L2 in GB 3190 and Al ≥99.5%.
3 Aluminium content in allumen wire shall be 13% ~ 35% and the rest is zinc.

25
 4 Magnesium content in magaluma wire shall be 4.8% ~ 35% and the rest is aluminium.
5 Wire shall be smooth, clean and free from any rust, oil or fold; its diameter is φ3.0mm.
8.4.2 Arc spraying should be adopted for spray painting; while if arc spraying can't be
achieved, flame plating may be adopted;
8.4.3 The following thicknesses may be adopted as mellozing thickness according to different
spray painting material jointly with operational environment:
1 The thickness of allumen layer, magaluma layer, Al-RE (such as CeAl) alloy layer
should be 100µm ~ 120µm.
2 The thickness of aluminium spraying layer or zinc spraying layer should be 120µm ~
150µm.
8.4.4 After derusting, steel bar surface shall be painted within 4 hours and within 8 hours
maximally on a fine day and in normal condition.
8.4.5 Spray painting shall not be carried out; if relative humidity in air is greater than 85%,
steel plate surface temperature is by over 3℃ less than air dew point, or ambient temperature
is less than 5℃.
8.4.6 Spray painting shall be even and carried out for several times; each spraying thickness
should be 25µm ~ 60µm; and the spraying bundle of two adjacent spray-painting shall be
vertical to each other and get crossed.
8.4.7 After spray painting and coat is qualified (by inspection), the coat shall be sealed with
painting in time. Before painting, dust on coat surface shall be cleaned up. Painting should be
carried out when there is a certain temperature in the coat; if coat has cooled, the painting may
properly be warmed.

8.5 Quality Inspection of Mellozing Coat

8.5.1 Appearance test shall be carried out for mellozing layer; coat surface shall be even and
free from such phenomena as sundries, peeling, bubbling, pore space, sag, crest, unstable
metal-fusion coarse-particle adhesion, block dropping, ground-material bare spot or crack. If
any apparent appearance defect is discovered during spray painting, spray painting shall be
stopped; little inclusion may be picked out and scrapped with cutter and large area defect shall
be rooted out and then be sprayed again.
8.5.2 For mellozing coat its thickness determination and binding ability inspection method are
stated in Annex K.
9 Hydraulic Tests
9.0.1 The test pressure for steel pipe/branch pipe hydraulic test shall be determined according
to drawings and designing technological documents. If calibre and ballast are comparatively
large, the cocks used for test shall be ellipsoid cocks.
9.0.2 During pressure test, water temperature shall be above 5℃.
9.0.3 For hydraulic test may only be carried out after manufacturing; inspection of physical
dimension and weld quality as required and after the submitted quality indexes meet the
corresponding requirements. Before hydraulic test tube is filled with water, restraining release
treatment shall be carried out for such facilities which may change the restraining boundary
condition of structures themselves as the fixtures/tools connected to the tested structure,
temporary support components, brackets and hoisting equipments; such defects as crator and
scratch on structures shall be repaired and burnished; besides, overall check shall be carried
out.
9.0.4 During pressure test of exposed pipe or branch pipe, pressure shall be added in grades
and increased to operation pressure gradually. After operation pressure reaches, the condition
shall be kept for over 30 minutes and steel pipe inspection shall be carried out. Gauge hand
shall be stable (by observing) and free from any vibration. If it is in sound condition, pressure
loading may be continued. Pressurization sped should not greater than 0.05MPa/min. After
maximum test pressure reaches, the condition is kept for over 30 minutes, when the indicative
pressure on pressure meter shall be the same. Then the pressure is lowered to operation
pressure and the condition is kept for over 30 minutes. The whole test process shall be free

26
from any water seepage, concrete crack, anchor block abnormal displacement and other
abnormalities.
9.0.5 After hydraulic test of steel pipe and branch pipe are finished according to specified
procedure, system external pressure shall be unloaded to the deadweight pressure of the water
in steel pipe via the overflowing control valve of pressurizing system; the water in steel pipe
may only be discharged after the exhaust (blow-down) pipe valve at the upper end of pipe
segment is affirmed to be opened.
9.0.6 If testing system shall be disposed during test process due to some problems, the
disposal may only be carried out after the systemic pressure is unloaded to zero pressure via
the overflowing control valve in pressurizing system; during the disposal if such operations as
welding, hot cutting, carbon arc air gouging, heat shape rectifying shall be carried out, they
may only be carried out after in-pipe water is completely drained off.
10 Packaging and Transportation
10.0.1 Steel pipe tile shall supportably be transported in sections and firmly strapped to
prevent overturning and deformation. Such attachments as supporting ring, stiffening ring,
waterproofing ring, thrust ring and connecting plate shall be strapped into bundles and marked
with name & serial number with oil paint, then such attachments may be transported in
bundles.
10.0.2 False-work or frame may be added to prevent tile overturn and deformation during
transportation process. During tile piling, some cushion shall be stemmed between tiles.
Support shall not directly be welded onto tile and the support shall be fixed with such
connecting pieces as fixture/tool and bolt.
10.0.3 During shaped pipe section transportation, false-work may be added in pipe section
according to the rigidity. Support saddle holder or stow-wood strip is added outside pipes to
protect pipe section and its groove from damage.
10.0.4 If steel pipe or tile is tied or transported with steel cable, cushion shall be added
between the touch position of cable and steel pipe/tile. During erection and transportation,
coat shall not be damaged.
11 Acceptances
11.1 Manufacture Acceptance
11.1.1 After steel penstock engineering completion, engineering acceptance shall be carried
out. Manufacturing and installation quality shall meet the provisions in drawings and in this
standard.
11.1.2 During manufacture acceptance, construction organization shall offer the following
data:
1 Steel penstock manufacture drawings
2 Outgoing quality certificate of primary materials
3 Design and modification notice letter
4 Final inspection and test determination record during manufacturing
5 Nondestructive inspection report of weld seam
6 Anti-corrosive inspection data
7 Significant defect disposal record and relevant-meeting summary record
11.2 Installation Acceptance
During installation acceptance, construction organization shall offer the following data:
1 Steel penstock engineering completion drawings
2 Outgoing quality certificate of primary materials
3 Design and modification notice letter
4 Final inspection and test determination record during installation
5 Nondestructive inspection report of weld seam
6 Anti-corrosive inspection data
7 Significant defect disposal record and relevant-meeting summary record

27
 Annex A
(Informative)
Criteria of Property and Surface Quality of Steel Plates
A.1 Steel Plate Property
A.1.1 The property of carbon steel and low alloy steel shall meet the provisions in Table A.1
~ Table A.4.
Table A.1: chemical composition of carbon steel
Chemical composition
% De-oxidation
Designation Grade
Si S P method
C Mn
Not greater than

A 0.14 ~ 0.22 0.30 ~ 0.65 0.050 0.045 F, b, Z

B 0.12 ~ 0.20 0.30 ~ 0.70 0.045 0.045 F, b, Z

Q235 0.30
C ≤0.18 0.35 ~ 0.80 0.040 0.040 Z

D ≤0.17 0.35 ~ 0.80 0.035 0.035 TZ

Note 1: Designation representation: steel designation consists of such four factors as the letter representing yield
strength, yield strength value, quality grade symbol and de-oxidation method symbol, for instance, Q235A.F
Note 2: Symbols: Q; the first letter of "qu" (steel-bar yield strength) in Bopomofo; A, B, C and D are quality
grade symbols respectively; F- effervescing steel; b; balanced steel; Z; degasified steel; TZ; special degasified
steel.
Note 3: In the representation method of designation constitution, "Z" and "ZT" indicates "omit".

28
 Table A.2: mechanical property of carbon steel
Tensile test Impact test Cold bending test B = 2a (180°)

Steel plate
Yield strength ReL Elongation A V-shaped
thickness
N/mm2 % Temperature ballistic work
mm
℃ (longitudinally)
Steel plate thickness Steel plate thickness
Tensile J
Designation Grade mm mm Sample >4 >60 >100
strength
>16 >40 >60 >16 >40 >60 direction ~ ~ ~
RmN/mm2
≤16 ~ ~ ~ <16 ~ ~ ~ 60 100 200

40 60 100 40 60 100

Bending center
Not less than Not less than Not less than
diameter d

A — Longitudinally a 2a 2.5a
B 375 20
Q235
C 235 225 215 205 ~ 460 26 25 24 23 0 27 Horizontally 1.5a 2.5a 3a
D 20

Note 1: in cold bending test, B is width and A is plate thickness.

Note 2: horizontal sample of steel plate shall be adopted for tensile and bending test.
Note 3: Charpy impact test is calculated according to the arithmetical mean of three samples in one group. One sample
monodrome is allowed to be less than the specified value but not less than 70% specified value.
Note 4: steel bar is generally delivered in hot rolling state; but it (except Class A steel) may also be delivered in controlled
rolling (symbol, TMCP) state or normalized state according to demander's requirements and by mutual consent.
Note 5: for other technical requirements, see the provisions in GB/T 700.

Table A.3: chemical composition of low alloy steel

Chemical composition

Serial %
Designation
number S P
C Mn Si V Ti
Not greater than

1 Q295 ≤0.16 0.80 ~ 1.50 ≤0.55 0.02 ~ 0.15 0.02 ~ 0.20 0.045 0.045

2 Q345 0.12 ~ 0.2 1.00 ~ 1.60 0.20 ~ 0.55 0.02 ~ 0.15 0.02 ~ 0.20 0.045 0.045

3 Q390 ≤0.20 1.00 ~ 1.60 ≤0.55 0.02 ~ 0.20 0.02 ~ 0.20 0.045 0.045

4 Q420 ≤0.20 1.00 ~ 1.70 ≤0.55 0.02 ~ 0.20 0.02 ~ 0.20 0.045 0.045

5 Q460 ≤0.20 1.00 ~ 1.70 ≤0.55 0.02 ~ 0.20 0.02 ~ 0.20 0.035 0.035

29
 Table A.4: mechanical property of low alloy steel
180°bending test; Impact test
Thickness or Tensile Yield Elongation
D; bending center V-shaped ballistic
Serial diameter of strength strength ReL A
Designation diameter; Temperature work (longitudinally)
number steel bar plate Rm N/mm2 %
A; sample ℃ J
mm N/mm2
Not less than thickness Not less than

≤16 390 ~ 570 295 23 d=2a

>16 ~ 25 390 ~ 570 275 23 d=3a
1 Q295B >25 ~ 36 390 ~ 570 275 23 d=3a 20 34
>36 ~ 50 390 ~ 570 255 23 d=3a
>50 ~ 100 390 ~ 570 235 23 d=3a

≤16 510 ~ 660 345 22 d=2a

Q345B 20 34
>16 ~ 25 490 ~ 640 325 21 d=3a
C 0 34
2 >25 ~ 36 470 ~ 620 315 21 d=3a
D - 20 34
>36 ~ 50 470 ~ 620 295 21 d=3a
E - 40 27
>50 ~ 100 470 ~ 620 275 20 d=3a

≤16 490 ~ 650 390 20 d=2a

Q390B 20 34
>16 ~ 25 490 ~ 650 370 20 d=3a
C 0 34
3 >25 ~ 36 490 ~ 650 370 20 d=3a
D - 20 34
>36 ~ 50 490 ~ 650 350 20 d=3a
E - 40 27
>50 ~ 100 490 ~ 650 330 20 d=3a

≤16 520 ~ 680 420 19 d=2a

Q420B 20 34
>16 ~ 25 520 ~ 680 400 19 d=3a
C 0 34
4 >25 ~ 36 520 ~ 680 400 19 d=3a
D - 20 34
>36 ~ 50 520 ~ 680 380 19 d=3a
E - 40 27
>50 ~ 100 520 ~ 680 360 19 d=3a

≤16 550 ~ 720 460 17 d=2a

Q460C >16 ~ 25 550 ~ 720 440 17 d=3a 0 34
5 D >25 ~ 36 550 ~ 720 440 17 d=3a - 20 34
E >36 ~ 50 550 ~ 720 420 17 d=3a - 40 27
>50 ~ 100 550 ~ 720 400 17 d=3a

Note 1: 20℃ Charpy impact test shall be carried out for steel bar according to demander's requirements, which shall
be indicated in contract; ballistic work shall meet the provisions in Table.
Note 2: 0℃, -20℃ and -40℃ Charpy impact tests may be carried out for steel bar according to demander's
requirements and mutual consent; the ballistic work of longitudinal sample shall not be less than 27J. During -20℃ or
-40℃ impact test, the sulfur and phosphorus content in steel shall not be greater than 0.035 respectively; and the steel
shall be fine-grained steel.
Note 3: Charpy impact test is calculated according to the arithmetical mean of three samples in one group. One
sample monodrome can be less than the specified value but not less than 70% specified value.
Note 4: horizontal sample of steel plate shall be adopted for tensile and cold bending tests.
Note 5: steel bar is generally delivered in hot rolling state. According to customer's requirements and
supplier/demander's arrangement, steel bar may also be delivered in such states as controlled rolling (TMCP),
normalizing, normalizing + tempering or thermal refining.
Note 6: for other technical requirements, see the provisions in GB/T 1591.

30
A.1.2 chemical composition and mechanical property of carbon-steel & low-alloy-steel heavy
plate used for pressure vessel shall meet the provisions in Table A.5 and Table A.6.

Table A.5: chemical composition of carbon steel and low alloy steel (both of which are used for pressure
vessel)
Chemical composition

Serial %
Designation
number C S P
Mn Si V Mo Nb
≤ Not greater than

1 20R 0.20 0.40 ~ 0.90 0.15 ~ 0.30 — — — 0.030 0.035

2 16MnR 0.20 1.20 ~ 1.60 0.20 ~ 0.60 — — — 0.030 0.035

3 15MnNbR 0.18 1.20 ~ 1.60 0.20 ~ 0.55 — — 0.010 ~ 0.040 0.015 0.025

4 15MnVR 0.18 1.20 ~ 1.60 0.20 ~ 0.60 0.04 ~ 0.12 — — 0.030 0.035

5 15MnVNR 0.20 1.30 ~ 1.70 0.20 ~ 0.55 0.10 ~ 0.20 — — 0.030 0.035

6 18MnMoNbR 0.22 1.20 ~ 1.60 0.15 ~ 0.50 — 0.45 ~ 0.65 0.25 ~ 0.50 0.030 0.035

7 13MnNiMoNbR 0.15 1.20 ~ 1.60 0.15 ~ 0.50 — 0.20 ~ 0.40 0.005 ~ 0.02 0.025 0.025

8 15CrMoR 0.18 0.40 ~ 0.70 0.15 ~ 0.50 — 0.45 ~ 0.60 — 0.030 0.030

31
 Table A.6: mechanical property of carbon steel and low alloy steel (both of which are used for pressure
vessel)
Thickness Cold
Yield V-shaped
or Tensile Elongation bending
strength ballistic work
Serial diameter strength A Temperature test
Designation Delivery state ReL (horizontally)
number of steel bar Rm % ℃ B=2a
N/mm2 J
2
plate N/mm 180°
mm Not less than Not less than

6 ~ 16 400 ~ 530 245 26 d=2a

17 ~ 25 235 25
1 20R 26 ~ 36 225 24
390 ~ 520 d=2.5a
38 ~ 60 215 23
>60 ~ 100 195 22
20 31
6 ~ 16 510 ~ 655 345 21 d=2a
Hot rolling, 17 ~ 25 490 ~ 635 325 20
2 16MnR control 26 ~ 36 490 ~ 635 305 19
d=3a
rolling 38 ~ 60 470 ~ 620 285 19
(TMCP) or >60 ~ 100 450 ~ 590 265 18
normalizing 10 ~ 16 530 ~ 650 370
3 15MnNbR 17 ~ 36 530 ~ 650 360 20 20 31 d=3a
>36 ~ 60 520 ~ 640 350

6 ~ 16 530 ~ 675 390 18

17 ~ 25 510 ~ 655 375 17
4 15MnVR 20 31 d=3a
26 ~ 36 510 ~ 655 355 17
38 ~ 60 490 ~ 635 335 17

6 ~ 16 570 ~ 710 440 18

17 ~ 25 550 ~ 690 420 18
5 15MnVNR Normalizing 26 ~ 36 550 ~ 690 420 18 20 34 d=3a
38 ~ 60 530 ~ 670 400 18
>60 ~ 100 530 ~ 670 400 18

Normalizing 30 ~ 60 590 ~ 740 440 17

6 18MnMoNbR 20 34 d=3a
+ tempering >60 ~ 100 570 ~ 720 410 17

≤100
Normalizing 570 ~ 720 390 18
7 13MnNiMoNbR >100 ~ 0 31 d=3a
+ tempering 570 ~ 720 380 18
120

Normalizing 6 ~ 60 295 19
8 15CrMoR 450 ~ 590 20 31 d=3a
+ tempering >60 ~ 100 275 18

Note 1: 20R, 16MnR V-shaped room-temperature ballistic work may be delivered according to 34J basing on
demander's requirements and supplier/demander's agreements.
Note 2: -20℃ V-shaped impact test may be carried out for supplier/demander's agreement according to
demander's requirements jointly with supplier/demander's agreement; ballistic work shall not be less than 20J.
Note 3: Room-temperature Charpy ballistic work is calculated according to the arithmetical mean of 3 samples,
among which, 1 sample value is allowed to be less than the specified value, but not less than 70% specified value..
Note 4: Steel plate dimension shall meet the provisions in GB/T 709.

32
 Note 5: Ultrasonic testing may be carried out for steel plate according to demander's requirements. The method
and guarantee grade of ultrasonic flaw detecting are negotiated by supplier and demander, which shall be indicated
in contract.
Note 6: According to demander's requirements, steel plate, whose thickness is greater than 16mm, may be
inspected sheet by sheet.
Note 7: Other technical requirements are stated in Standard GB 6654.

A.1.3 Rm ≥600N/mm2 grade dead-hard-steel plate property shall meet the following
provisions.
A.1.3.1 Steel chemical composition shall meet the provisions in Table A.7 and Table A.9.
A.1.3.2 According to demander's requirements, both mechanical property and cold bending
property tests may be carried out for steel plates sheet by sheet; and the results shall meet the
provisions in Table A.8 and Table A.10.
A.1.3.3 Other technical requirements of steel plate shall meet the provisions in GB 6654,
GB/T 19189 and GB/T 16270.

Table A.7: chemical composition of dead-hard steel used for Rm ≥600N/mm2 grade container
Chemical composition
Serial
Designation %
number
C Si Mn P S Cr Ni Mo V Others
WDB620, ADB610D,
AH610E, B610CF-L1,
B610CF-L2, 0.15 ~ 1.00 ~ 0.02 ~
1 ≤0.07 ≤0.025 ≤0.010 ≤0.60 ≤0.50 ≤0.30 B≤0.003
WDL610E, 0.40 1.60 0.08
WSD610E,
07MnNiCrMoVDR
CF62, WDL610D,
0.15 ~ 1.20 ~ 0.02 ~
2 WSD610C, WSD610D, ≤0.09 ≤0.025 ≤0.010 ≤0.30 ≤0.40 ≤0.30 B≤0.003
0.40 1.60 0.08
07MnCrMoVR
CF80, WSD790C, 0.15 ~ 1.20 ~ 0.40 ~ 0.02 ~
3 ≤0.15 ≤0.020 ≤0.015 ≤0.80 ≤0.55 B≤0.003
WSD790D 0.40 1.60 1.40 0.08
WSD1000C,
0.15 ~ 1.20 ~ 0.40 ~ 0.02 ~
4 WSD1000D, ≤0.20 ≤0.020 ≤0.015 ≤1.00 ≤0.60
0.40 1.60 1.60 0.08
WSD1000E
0.12 ~ 0.15 ~ 0.60 ~ 0.40 ~ 0.70 ~ 0.40 ~ 0.03 ~ Cu ~ 0.03
5 (America)T-1 ≤0.04 ≤0.035
0.21 0.35 1.0 0.65 1.0 0.6 0.08 B ~ 0.004
0.12 ~ 0.15 ~ 0.10 ~ 1.0 ~ 2.0 ~ 0.20 ~ Cu≤0.25
6 (America)HY-80 ≤0.025 ≤0.025 ≤0.03
0.18 0.35 0.40 1.80 3.25 0.60 Ti≤0.02
0.12 ~ 0.15 ~ 0.10 ~ 1.00 ~ 2.25 ~ 0.20 ~ Cu≤0.25
7 (America)HY-100 ≤0.025 ≤0.025 ~ 0.03
0.20 0.35 0.40 1.80 3.50 0.60 Ti≤0.02
0.1 ~ 0.60 ~ 0.40 ~ 4.75 ~ 0.30 ~ 0.05 ~
8 (America)HY-130 ≤0.12 ≤0.010 ≤0.005 —
0.35 0.90 0.70 5.25 0.65 0.10
0.15 ~ 0.60 ~ 0.40 ~ 0.40 ~ 0.30 ~ Cu0.15 ~
9 (Japan)WEL-TEN80 ≤0.16 ≤0.030 ≤0.030 ≤0.10
0.35 1.20 0.80 1.50 0.60 0.50
10 (Japan)HT-80 0.11 0.26 0.93 0.014 0.005 0.59 0.95 0.45 — B ~ 0.001
B~
11 (Japan)HT-100 0.11 0.22 0.90 0.012 0.005 0.58 2.32 0.53 0.042
0.0013
0.15 ~ 0.35 ~ 0.30 ~ 3.50 ~ 0.20 ~
12 (Japan)NS80C ≤0.10 ≤0.015 ≤0.010 ≤0.10 Cu≤0.15
0.40 0.90 1.00 4.5 0.60
Note 1: If the service temperature of one steel plate is less than - 20℃, the lower limit of Ni content in the steel plate is 0.20%.
Note 2: Cold crack sensitivity index Pcm = C+Si/30+Mn/20+Cr/20+Ni/60+Mo/15+V/10+5B (%).
Note 3: "America" and "Japan" in the designation row in the Table indicates that the corresponding steel bar is from abroad;
otherwise, the steel bar is home-made.

33
 Table A.8: mechanical property of dead-hard steel used for Rm ≥600N/mm2 grade container
Tension test Impact test
Cold
Sampling AKV
Serial Delivery Test bending
Designation direction and Rm ReL A J
number state temperature test
position N/mm2 N/mm2 % Mean Single
℃ 180°
value value

WDB620 0
ADB610D - 10
AH610E - 20
B610CF-L1
1 620 ~ 780 ≥490 ≥17 ≥47 — d=3a
B610CF-L2
WDL610E - 40
WSD610E
07MnNiCrMoVDR

CF62 0
Horizontally,
B610CF, B610E
at 1/4
WDL610D
2 thickness 610 ~ 730 ≥490 ≥17 ≥47 — d=3a
WSD610C - 20
Control point
WSD610D
rolling
07MnCrMoVR
(TM
CF80 0 ≥31
CP)
WSD790C - 20 ≥33
3 +Tempering 785 ~ 930 ≥685 ≥15 — d=3a
WSD790D
or thermal - 40 ≥33
WSD790E
refining
WSD1000C
930 ~
4 WSD1000D ≥790 ≥12
1130
WSD1000E

617 ~
5 (America)T-1 725 ~ 951 ≥16 - 46 ≥68 — —
686

≥81
540 ~
6 (America)HY-80 — ≥19 - 85 ≥81 — —
686
— ≥41

7 (America)HY-100 — ≥675 ≥20 — — —

882 ~
8 (America)HY-130 ≥895 ≥14 - 18 ≥68 — —
1029

9 (Japan)WEL-TEN80 784 ~ 93l ≥686 ≥16 - 18 ≥35 — —

Note: "America" and "Japan" in the designation row in the Table indicates that the corresponding steel bar is
from abroad; otherwise, the steel bar is home-made.

34
 Table A.9: chemical composition of dead-hard steel used for some welded vessels
Chemical composition
Serial
Designation %
number
C Si Mn P S Cr Ni Mo V Others
1 14MnMoVN 0.14 0.30 1.41 0.012 0.025 — — 0.47 0.13 N0.015
0.12 ~ 0.15 ~ 1.30 ~ 0.45 ~ Nb ~ 0.04
2 14MnMoNbB ≤0.03 ≤0.03 — — —
0.18 0.35 1.80 0.70 B ~ 0.001
0.35 ~ 0.03 ~ RE0.10 ~
3 15MnMoVNRE ≤0.18 ≤0.60 ≤1.70 ≤0.035 ≤0.030 — —
0.60 0.08 0.20
0.09 ~ 0.20 ~ 0.90 ~ 0.30 ~ 0.08 ~ 0.03 ~
4 HQ60 ≤0.030 ≤0.025 ≤0.30 —
0.16 0.60 1.50 0.60 0.20 0.08
0.09 ~ 0.15 ~ 0.60 ~ 0.30 ~ 0.30 ~ 0.20 ~ V+ B0.0005 ~
5 HQ70 ≤0.030 ≤0.030
0.16 0.40 1.20 0.60 1.00 0.40 Nb≤0.10 0.0030
0.10 ~ 0.15 ~ 0.60 ~ 0.60 ~ Cu 0.15 0.20 ~ 0.03 ~ B0.0005 ~
6 HQ80C ≤0.025 ≤0.015
0.16 0.35 1.20 1.20 ~ 0.5 0.40 0.08 0.0050
0.10 ~ 0.15 ~ 0.80 ~ 0.40 ~ 0.70 ~ 0.30 ~ 0.03 ~
7 HQ100 ≤0.030 ≤0.030 —
0.18 0.35 1.40 0.80 1.50 0.60 0.08
8 HQ130 0.18 0.29 1.21 0.025 0.006 0.61 0.03 0.28 — B0.0012
9 12Ni3CrMoV 0.105 0.27 0.45 0.010 0.005 1.04 2.78 0.21 0.08 —
10 10Ni5CrMoV 0.10 0.20 0.50 0.010 0.005 0.50 4.50 0.50 0.07 —
Note 1: if the service temperature of one steel plate is less than - 20℃, the lower limit of Ni content in the steel
plate is 0.20%.
Note 2: cold crack sensitivity index Pcm = C+Si/30+Mn/20+Cr/20+Ni/60+Mo/15+V/10+5B (%).

Table A.10: mechanical property of dead-hard steel used for some welded vessels
Tensile test Impact test
Serial Delivery Test
Designation Rm ReL A AKV
number state temperature
N/mm2 N/mm2 % J
℃
1 14MnMoVN ≥690 ≥590 ≥15 - 40 ≥27
2 14MnMoNbB ≥755 ≥686 ≥14 - 40 ≥31
3 15MnMoVNRE — ≥666 — - 40 ≥27
- 10 ≥47
4 HQ60 ≥590 ≥450 ≥16
Control - 40 ≥29
rolling - 10 ≥39
5 HQ70 ≥680 ≥590 ≥17
(TMCP) + - 40 ≥29
tempering - 10 ≥47
6 HQ80C ≥785 ≥685 ≥16
or thermal - 40 ≥29
7 HQ100 refining ≥880 ≥950 ≥10 - 25 ≥27
8 HQ130 1313 1370 10 20 ≥64
- 25 ≥41
9 12Ni3CrMoV 745 ~ 870 688 ~ 799 ≥17
- 84 ≥16
10 10Ni5CrMoV 925 ~ 945 825 ~ 840 ≥21 - 20 195 ~ 240
Note 1: the stress-relief heat treatment condition for HQ60, HQ70 and HQ80C are 920℃ quenching +680℃
tempering, 920℃ quenching +680℃ tempering and 920℃ quenching +660℃ tempering respectively; if bending
center diameter D=3a (a, steel plate thickness ), samples shall be perfect after 180° cold bending.
Note 2: the stress-relief heat treating regime of high-strength high-ductility steel 12Ni3CrMoV is optional:
910℃ normalizing, 910℃ normalizing +660℃ tempering, 910℃ water quenching +660℃ tempering, 910℃
water quenching +690℃ tempering.

A.1.4 the property of stainless steel and stainless-steel clad plate shall meet the provisions in
Table A.11 ~ A.16.

Table A.11: chemical composition of austenitic stainless steel

Chemical composition
Designation %
C Si Mn P S Ni Cr Mo
0Cr19Ni9 ≤0.08 ≤1.00 ≤2.00 ≤0.035 ≤0.030 8.00 ~ 10.50 18.00 ~ 20.00 —
00Cr19Ni11 ≤0.03 ≤1.00 ≤2.00 ≤0.035 ≤0.030 9.00 ~ 13.00 18.00 ~ 20.00
1Cr18Ni9 ≤0.15 ≤1.00 ≤2.00 ≤0.035 ≤0.030 8.00 ~ 10.00 17.00 ~ 19.00 —
0Cr18Ni10Ti ≤0.08 ≤1.00 ≤2.00 ≤0.035 ≤0.030 9.00 ~ 13.00 17.00 ~ 19.00 —
1Cr18Ni9Ti ≤0.12 ≤1.00 ≤2.00 ≤0.035 ≤0.030 9.00 ~ 13.00 17.00 ~ 19.00 —

35
 Table A.12: mechanical property of austenitic stainless steel after solid solution treatment
Tensile test Hardness test
Tensile
Designation Yield strength
strength Elongation A
Rp0.2 HB HRB HV
Rm %
N/mm2
N/mm2
0Cr19Ni9 ≥206 ≥520 ≥40 ≤187 ≤90 ≤200
00Cr19Ni11 ≥177 ≥481 ≥40 ≤187 ≤90 ≤200
1Cr18Ni9 ≥205 ≥520 ≥40 ≤187 ≤90 ≤200
0Cr18Ni10Ti ≥205 ≥520 ≥40 ≤187 ≤90 ≤200
1Cr18Ni9Ti ≥205 ≥520 ≥40 ≤187 ≤90 ≤200

Table A.13: cladding and basic material Standards for stainless steel clad plate
Clad material Basic material
GB/T 1220 GB/T 700 GB/T 699
Standard Standard
GB/T 3280 GB/T 1591 GB/T 3274 GB/T 713 GB 6654
number number
GB/T 4237 GB 3531
0Cr13 Q235 - A
0Cr13A1 Q235 - B
Typical 0Cr17 Typical 20
steel 0Cr17Ti steel 20R
designation 0Cr19Ni9 designation 20g
0Cr18Ni10Ti Q345
00Cr19Ni11 16MnR
0Cr17Ni12Mo2 15MnNbR
Typical 00Cr17Ni14Mo2 Typical 15MnVR
steel 00Cr22Ni5Mo3N steel 15CrMoR
designation 0Cr18Ni12Mo2Ti designation 16MnDR
1Cr18Ni12Mo2Ti 15MnNiDR

Table A.14: area binding ratio of stainless steel clad plate (from GB/T 8165)
Binding ratio
Interface binding grade Class Un-composite state
%
BI
Grade I BR I 100 Without any un-binding area
RI
BII Single un-binding area length
Grade II BRII ≥99 being not greater than 50mm and
RII area being not greater than 20cm2
B III Single un-binding area length
Grade III BR III ≥95 being not greater than 75mm and
R III area being not greater than 45cm2
Note 1: if the binding ratio of stainless steel clad plate can't meet the specified one in the Table, repair welding
may be carried out for the cladding with insufficient composite; and this repair shall meet the requirements in the
following Note 2.
Note 2: clad steel plate is divided into Grade I, Grade II and Grade III according to the ratio of un-binding area
and total area as well as single un-binding area. Grade I clad steel plate applies to the structural member with
serious processing requirements and without any un-binding area; Grade II clad steel plate is applicable to the
structural members which allows small un-binding area existence; Grade III clad steel plate is used for clad
material, which is used as common structural member for corrosion-resistant layer.
Note 3: symbols, B; explosion method, R; rolling method, BR; explosion and rolling.

36
 Table A.15: mechanical property of stainless steel clad plate
Interface shear/cut
Yield strength
Property resistant strength Jb Tensile strength Rm Elongation A Ballistic work AKV
ReL
grade N/mm2 N/mm2 % J
N/mm2
≥
Grade I Not less than the lower limit
Not less than
210 Not less than the of base steel plate criteria and Shall meet the
Grade II the nominal
nominal value of no greater than the upper limit provisions of base
value of base
Grade base steel plate ** steel plate ****
200 steel plate ***
III 35N/mm
Note: * the lower limit of clad steel plate/steel strip yield strength may also be calculated according to formulae
(A.1):
t1 ReL1 +t 2 ReL 2
ReL = (A.1)
t1 + t 2
Where, ReL1; lower limit of clad-sheet-steel yield strength, N/mm2;
ReL2—Lower limit of base-steel-plate yield strength, N/mm2;
t1—Clad steel plate thickness, mm;
t2—Base steel plate thickness, mm;
** The lower limit of clad steel plate/steel strip tensile strength may also be calculated according to formulae
(A.2):
t1 Rm1 +t 2 Rm 2
Rm = (A.2)
t1 + t 2
Where, Rm1; lower limit of clad-sheet-steel tensile strength, N/mm2;
Rm2—Lower limit of base-steel-plate tensile strength, N/mm2;
t1—Clad steel plate thickness, mm;
t2—Base steel plate thickness, mm;
*** If cladding-elongation nominal value is less than base nominal value; clad steel plate elongation is less than
base one but not less than cladding nominal value; it is allowable to cut away cladding and then take tensile test for
base; the base elongation shall not be less than base criteria.
**** Ballistic work test is not carried out for clad sheet steel cladding.

Table A.16: bending properties of stainless steel clad plate

Bending center diameter d Test result
Thickness Sample width Bending
mm mm angle Inward Outward
Inward bending Outward bending
bending bending
a<20mm, d=2a a<20mm, d=2a
≤25 b=2a 180° Bending portion
a≥20mm, d=3a a≥20mm, d=3a
outside shall be free
Base thickness is processed Base thickness is from any crack;
to 25mm; bending center processed to 25mm; composite interface shall
>25 b=2a 180° diameter is determined bending center diameter is be free from any
according to base steel plate determined according to de-lamination
criteria base steel plate criteria
Note: "a" is clad steel plate thickness.

A.2 Steel Plate Surface Quality

A.2.1 Steel plate surface quality shall meet the following provisions:
A.2.1.1 Steel plate surface shall be free from any air bubble, scar, rip, crack, fold, inclusion or
embedded iron scale. Steel plate shall be free from any de-lamination.
A.2.1.2 Such partial defects as thin iron scale, iron rust, in-apparent roughness and scratch
(both of which are caused by iron scale falling off), texture due to rolling, all of which will
not hinder surface defect inspection, are allowed to exist on steel plate surface; but the
unevenness shall not be greater than a half steel plate thickness tolerance and not greater than
permissible minimum thickness.
A.2.1.3 Repair welding and blocking must not be carried out for defects on steel plate surface,
while such defects shall be dealt with chisel or grinding wheel. The processing area shall be
smooth and without any arris; the processing depth shall neither be greater than the negative
variation range of steel plate thickness nor be greater than the permissible minimum thickness
of steel plate.
A.2.1.4 Trimming steel plate edge shall be free from any saw-tooth unevenness; but it is
allowable for individual hair seam with its depth being not greater than 2mm and its length

37
being not greater than 25mm. If edge fissure and other defects exist in trimming-cut-free steel
plate, the horizontal depth of such defects shall not be greater than half steel plate width
deviation; what's more, steel plate width shall not be less than the nominal width.
A.2.1.5 Other provisions for steel plate surface quality shall meet the requirements in
Standard GB/T 14977.

38
 Annex B
(Informative)
Steel Plates Used For Penstock Production Abroad
Table B.1: Steel plates abroad commonly used for manufacturing steel penstock

Graded
Product Graded Graded Graded Tensile
intensity Tensile Tensile Product
Product standard or intensity scale Product standard intensity scale Tensile intensity scale
Country standard or scale(Yield strength
grade of steel (yield
strength
or grade of steel (yield strength) strengthN/mm2
standard or
(yield strength)
strength
steel grade strength) N/mm2 N/mm2 grade of steel N/mm2
strength)N/mm2 N/mm 2
N/mm2
N/mm2
JIS 510,
490 or above
G3116, G3115, 480, 490 JIS G3115 520, JIS G3116
490
G3103, G3118 530
SM570Q
Japan SM400 400~510 HT-590
SHY685NS-F
HT60CF
SM490B 490~610
SPV490Q
570~720 HITEN780B 780~930
WEL-TEN80
HITEN610U2
WEL-TEN62CF
310,
ASTM 490
340, ASTM A737
A285 350 ASTM or above
ASTM A515, 510, 794~931
ASTM A455, T-1
America A285, A516, 480, 490
A299
520,
725~951
360,
A537, 530
A515, 370,
A737
A516, 380 HY-130 882~1029
A422,
510,
310, DIN 17155 520,
Germany DIN17175 340, DIN 17155 460, 470 530
350
P500M 490 610~740

39
 Annex C
(Informative)
Allowable Deviation and Additional Value of Thickness of Steel Plate
Table C.1 allowable deviation of thickness of steel plate (mm)
Width
>100 >120 >150 >170 >180 >200 >230 >250 >260 >280 >300 >320 >340 >360
Normal Minus >750
600~75 0 0 0 0 0 0 0 0 0 0 0 0 0 0
thicknes deviatio ~100
0 ~120 ~150 ~170 ~180 ~200 ~230 ~250 ~260 ~280 ~300 ~320 ~340 ~360 ~380
s n 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
Positive deviation
6~7.5 0.45 0.55 0.60 0.6 0.75 0.75 0.75 0.80
>7.5~10 0.75 0.75 0.85 0.85 0.90 0.90 0.90 1.00 1.15 1.15 1.15
>10~13 0.75 0.75 0.85 0.85 0.95 0.95 0.95 1.05 1.25 1.25 1.25 1.55
>13~25 0.75 0.75 0.85 0.95 1.15 1.35 1.35 1.55 1.65 1.75
>25~30 0.85 0.85 0.95 1.05 1.25 1.45 1.55 1.65 1.75 1.85
>30~34 0.95 1.05 1.05 1.15 1.35 1.55 1.65 1.75 1.95 2.05
>34~40 0.25 1.15 1.25 1.35 1.45 1.55 1.75 1.85 1.95 2.15 2.25
>40~50 1.35 1.45 1.55 1.65 1.75 1.95 2.05 2.15 2.35 2.45
>50~60 1.65 1.75 1.85 1.95 2.05 2.15 2.15 2.25 2.35 2.55
>60~80 2.55 2.55 2.55 2.55 2.65 2.75 2.85 2.85 2.85 2.85 2.95 2.95
>80~100 2.95 2.95 2.95 2.95 3.05 3.05 3.05 3.15 3.15 3.15 3.15 3.15
>100~12
3.25 3.25 3.25 3.35 3.45 3.45 3.55 3.55 3.55 3.55 3.55 3.55
0

Table C.2 additional value of thickness of steel plate (mm)

Width
Normal 600~ >750 >1000>1200>1500>1700>1800>2000>2300>2500>2600 >2800 >3000 >3200 >3400 >3600
thickness 750 ~1000~1200~1500~1700~1800~2000~2300 ~2500~2600~2800 ~3000 ~3200 ~3400 ~3600 ~3800
Additional value of thickness for weight calculation
6~7.5 0.10 0.15 0.18 0.18 0.25 0.25 0.25 0.28
>7.5~10 0.25 0.25 0.30 0.30 0.32 0.32 0.32 0.38 0.45 0.45 0.45
>10~13 0.25 0.25 0.30 0.30 0.35 0.35 0.35 0.40 0.50 0.50 0.50 0.65
>13~25 0.25 0.25 0.30 0.35 0.45 0.55 0.55 0.65 0.70 0.75
>25~30 0.30 0.30 0.35 0.40 0.50 0.60 0.65 0.70 0.75 0.80
>30~34 0.35 0.40 0.40 0.45 0.55 0.65 0.70 0.75 0.85 0.90
>34~40 0.45 0.50 0.55 0.60 0.65 0.75 0.80 0.85 0.95 1.00
>40~50 0.55 0.60 0.65 0.70 0.75 0.85 0.90 0.95 1.05 1.10
>50~60 0.70 0.75 0.80 0.85 0.90 0.95 0.95 1.00 1.05 1.15
>60~80 1.15 1.15 1.15 1.15 1.20 1.25 1.30 1.30 1.30 1.30 1.35 1.35
>80~100 1.35 0.35 1.35 1.35 1.40 1.40 1.40 1.45 1.45 1.45 1.45 1.45
>100~120 1.50 1.50 1.50 1.60 1.60 1.65 1.65 1.65 1.65 1.65 1.65 1.65

40
 Annex D
(Normative)
Preparation, Dimension, Test Method and Approval Standard
Mechanical Property Test Plate in Qualification of Welding
Procedure
D.1 Abutting joint specimen preparation
D.1.1 The size of plate-like abutting joint sample shall meet the requirement of samples for
cutting and for the cut position, please see figure D.1.

Note: Discarded length of both ends of the sample: manual welding, 30mm each end; automatic welding 50mm
each end (sample without run-off plate)
Figure D.1: cut position for test

D.1.2 Visual examination, supersonic flaw detecting or radiographic inspection shall be done
to samples after welding, if the above test proved qualified, mechanical testing shall be done.
D.1.3 Visual examination shall conform to relevant regulations in Table 6.4.1.
D.1.4 The radiographic inspection of the sample shall conform to regulations in GB/T 3323,
the radiographic quality shall be not less than class B and the weld quality shall be not less
than level; the supersonic flaw detecting shall conform to regulations in GB/T 11345, the
inspection level shall be class B and the weld quality shall be not less than levelⅠ.
D.1.5 hardness test sample and test
D.1.5.1 The position of hardness measurement shall refer to figure D.2.

Center distance of two adjacent dents: 1.0 mm

Center distance of two adjacent dents: 0.5mm mm
Figure D.2 rigidity position measurement

D.1.5.2 For other technical requirements and related testing methods, please refer to GB/T
231.1, GB/T 4340.1, GB/T 4675.5, GB/T 2654.
D.1.5.3 The hardness of welding joint shall conform to the regulations in article 6.1.22 of this
standard.
D.2 Shape and size of abutting joint mechanical property sample.
D.2.1 Tensile sample

41
D.2.1.1 Test sample with scapulet could be used for abutting joint test sample.
D.2.1.2 For test sample with scapulet, please see figure D.3.
D.2.1.3 The test sample shall be produced by mechanical processing or grounding and surface
work-hardening or superheat of the material shall be prevented. In the tested range, slashes or
scratches in the transverse direction are not allowable.
D.2.1.4 Reinforcement of the sample shall be cut to be flush with base material through
mechanical process and the thickness S of the sample shall be equal to or similar with the
thickness δ of base material. If the thickness of the sample was more than 30mm, several test
samples taken from dissimilar thickness areas of the joint could be used instead of individual
samples of complete thickness in the joint, but the thickness of each sample shall be less than
30mm and the samples shall cover all kinds of thicknesses of the joint (for detail, please refer
to Table 4 in GB/T 2649). In such a case, the position of the test sample in the welded sample
thickness shall be marked.
250 or as required

S—Test sample thickness (mm); W—Stretched test sample parallel side width≧25mm;
hk—Maximum width of the welding seam, mm; h—Clamping length, determined according
to grip of testing machine (mm)
FigureD.3: Abutting joint with scapulet test sample

D.2.1.5 Specimen with thickness less than or equal to less than or equal to 30mm, the
full-thickness test piece shall be used for experiment.
D.2.1.6 Testers, sample size and performance measurement for the test shall all conform to
the regulations in GB/T 228, GB/T 2651 and GB/T 2652.
D.2.2 bend specimen
D.2.2.1 Sample size and roughness of surface of face bend or back bent in longitudinal or
transverse direction shall conform to the regulations in figure D.4 and for specimen with side
bent in transverse direction, please refer to regulations in figure D.5.
D.2.2.2 Length of face bent or back bent test sample in longitudinal or transverse direction
L=D+2.5S+100mm (Where D is flexural center diameter in mm), Length of specimen with
side bend in transverse direction L=D+105mm, not less than150mm.
D.2.2.3 Width of face bent or back bent test sample in longitudinal or transverse direction
B=38mm; Thickness of side bend specimen S=10mm, Width B of specimen with side bent in
transverse direction is in the direction of sample thickness δ.
D.2.2.4 Arris of plane of stretching of test sample R<2.
D.2.2.5 Testers, sample size and performance measurement for the test shall all conform to
the regulations in GB/T 232 and GB/T 2653.

42
 Plate

Plate

Face bent Back bent

(a) Plates transverse face-bend test; (b) Plates transverse back-bend test; (c) Plates
longitudinal face bent and back bent test
Figure D.4: Test sample of plates face bent and back bent in longitudinal or transverse direction

Figure D.5: Length of specimen of plates with side bend in transverse direction

D.2.3 Keyhole specimen

D.2.3.1 10mm×10mm×55mm test sample with V breach shall be taken as standard sample,
the size and deviation of the sample shall conform to the regulation in figure D.6, the bottom
of the sample breach shall be smooth and apparent scratches parallel with axes are not
allowable.
D.2.3.2 Test sample shall be produced via mechanical processing or grounding and strain
hardening or superheat of the materials of the finished surface shall be prevented.
D.2.3.3 The opening of the test sample could be in welding seam or heat-affected area
according to the test requirement, the axes of the sample opening shall be vertical to the weld
surface and for the sampling location, please refer to figure D.7.

43
 Reserved

图 D.6 Vnotched impact specimen Reserved

Heat affected zone Weld seam are

Weld seam are

Heat affected zone

If the thickness of the sample was more than 30mm, several test samples taken from
dissimilar thickness areas of the joint could be used instead of individual samples of complete
thickness in the joint, but the thickness of each sample shall be less than 30mm and the
samples shall cover all kinds of thicknesses of the joint (for detail, please refer to Table 4 in
GB/T 2649).
Note1: δ≤60mm, δ1=1mm~2mm; δ>60mm, δ2=δ/4.
Note2: For both sides welding, δ2 is measured from the steel surface of the back weld
surface.
(a) keyhole specimen hitting zone position ;(b)weld seam keyhole specimen position
Figure D.7: keyhole specimen cutting position
D.2.3.4 If megascopic defects such as pores, slag inclusion were detected in the openings of
the samples, this sample could not be used for experiment.
D.2.3.5 The tester, test requirement shall conform to the relevant regulations in GB/T 229,
GB/T 2650.
D.3 Mechanical testing method and criterion of acceptability.
D.3.1 Tensile test
D.3.1.1 If base material of test sample was of the same grade of steel, the tensile strength of
each sample shall be not less the lower limit of the material grade of steel of the base material.
D.3.1.2 If the base materials were of two different grades of steel, the tensile strength of each
sample shall be not less than the lower standard lower limits.
D.3.2 Bend test

44
D.3.2.1 The welding seam center of the sample shall direct to the flexural center axis. For side
bend test, if there were defects on the test sample surface, the severely defected side shall be
selected as the plane of stretching.
D.3.2.2 Bend sample shall be bent with the angle shown in Table D.1, single crackle of defect
more then 3mm in length in ant direction on the plane of stretching is not allowable, craze of
the sample arris is commonly neglected, but the length of arris craze caused by slag inclusion
or other welding defect shall be calculated.

TableD.1 Regulation for bend test size

Sample thickness Flexural center Support saddle

Base material types of welding seam sides S diameter D distance Bend angle
mm mm mm

Base materials with extensibility standard lower 10 40 63

range value A >= 20% S<10 4S 6S+3

1000 − 5A
10 180°
Base materials with extensibility standard lower A D+2S+1.5
range value A< 20% S (200 − A)
S<10
2A
Note 1: Bend angle of welding with backing joint shall conform to the regulations of the both sides welding.
Note 2: The bend angle of special-shaped steels shall conform to regulations of low-ductility steel.

D.3.3 Impact test temperature and acceptance value of impact absorbing energy shall conform
to the design or relevant regulations. Impact absorbing energies on average of 3 samples in
one team shall be not less than the smallest standard value and the impact absorbing energy of
only one sample could be less than the standard value, but not less than 70% of the standard
value. Impact absorbing energy at normal temperature shall be not less than 27J.
D.4 Preparation for dihedral welding seam specimen.
D.4.1 For the size and test sample of dihedral specimen, please refer to figure D.8 and Table
D.2.
TableD.2 Component thickness of the fillet weld sample (mm)
Wing panel thickness δ1 Web thickness δ2

≤3 ≤δ1

>3 ≤δ1 and ≤3

At least 300
At least 150

At least 150 macroscopic sample

Figure D.8: fillet weld specimen and test sample (mm)

45
 D.4.2 For the size and test sample of plates composite welds specimen, please refer to Figure D.9
and Table D.3.

Table D.3: Plates composite welds sample thickness

Wing panel thicknessδ3 Web thicknessδ4 Applicable effective range of weldment base material thickness

<20 ≤δ3 Wing panel thickness <20 and web thickness<20

≥20 ≤δ3, and ≥20 Wing panel thickness ≧20 and web thickness≧ 20

At least300
At least150
Un-complete Complete
At least 150
penetration penetration

300 at least
150 at least

Half penetration Full penetration

150 at least

Figure D.9: plate composite welds specimen and test sample (mm)

D.4.3 After the welding of assessment-specimen of fillet weld and plates composite weld,
visual examination and magnetic particle inspection shall be carried out according to JB/T
6061 or JB/T 6062. If qualified, cut 25mm away at each end of the specimen and equally
divided the remaining part in 5 sections as shown in figure D.8, figure D.9.
D.4.3.1 Fillet weld reaches the standard: no crackle and incomplete fusion in the weld metal
and heat-affected zone.
D.4.3.2 Plate composite welds reaches the standard: no crackle and incomplete fusion in the
weld metal and heat-affected zone and penetration degree of the root of weld conform to the
design regulation.

46
 Annex E
(Informative)
Recommended format of Welding Procedure Guide Book and
Qualification Report
TableE.1 Welding procedure guide book recommend format(Code Name: PWPS)
Name:
Welding procedure guide book number: Date: Qualification of welding procedure report number:
Welding method:

Welding joint: Diagram: (joint form, groove form and size, layer of weld, weld pass lay out and order)
Groove form:
Pad(materials and standard):
Other requirements:

Base material:
Type number Team number Type number Team number Welding and standard number Steel number
Standard number Steel number Welding thickness range:
Base material: butt-jointed seam Fillet weld
Weld metal thickness range: Butt-jointed seam Fillet weld
Other requirements:

Welding material:
Type of electrode
Welding wire trademark
Welding rod drying parameter
Shielding gas
Material standard
Welding rod standard
Welding wire standard
Flow rate
Type Tungsten electrode type and standard
Type Flux trademark
Welding wire drying parameter
Other requirements:
Filler metal size

Welding seam(welding wire)deposited metal chemical composition

%

Weld
material C Si Mn P S Cr Ni Mo V Ti Nb
trademark

Welding position:
Butt-jointed seam position Direction of welding
Fillet weld position

Warm-up, inter-pass temperature:

Preheating temperature(allowable minimum value) ℃ Warm up time min
Inter-pass temperature(allowable maximum value) ℃ Type of heating
Post-welding stress-relief heat treatment:
Temperature range ℃ Holding time min
Electrical properties:
Kind of current: Polarity:
Welding current range A Arc voltage V

Welding procedure standard parameter requirements: (List current and voltage scope in the following table according to the
welding position and thickness)

47
 Welding rod
Welding current Shielding gas
(wire) Arc Welding Weld heat
Weld Welding
Electric voltage speed Flow input
layer method
Trademark Diameter Polarity current V cm/min Type rate kJ/cm
A L/min

Basic requirements for weld joint:

1 Outer inspection Criteria for evaluation examination
2 Nondestructive testing Verify mode Criteria for evaluation examination
3 Mechanical property

Impact test
Tensile strength
Yield strength ReL(Rp0.2) Bend Test
Rm
2
N/mm angle(°) Opening type Opening position temperature
N/mm2
℃

Other examinations

Origination Date Examination Date Approval Date

48
 TableE.2 Qualification of welding procedure report recommend format(Code number: PQR)
Name: Welding procedure guide book number:
Qualification of welding procedure report number: Degree of mechanization(Handiwork, semi-transfer, automation)
Welding method:

Joint diagram: (Groove form, weld layer and order)

Base material:
Material standard Grade of steel
Team number Type and team number

Filler metal:
Material standard Weld material trademark
Weld material trademark Weld metal thickness

Welding position:
Butt-jointed seam position Direction: (Up or down)Fillet weld position Direction: (up or down)

Warm-up, inter-pass temperature:

Preheating temperature: ℃ Inter-pass temperature: ℃
Post-welding heat-relief treatment:
Heat-relief temperature ℃ Holding time min

Shielding gas:
Type and proportion Flow rate L/min

Electrical properties:
Kind of current: Polarity:
Welding current A Arc voltage V
Other requirements:

Technical measures:
Welding speed cm/min Multi-pass welding or single-run welding(each side)
Multiple welding or diplonema welding Other requirements:

Welding parameter

Welding rod
Welding current Shielding gas Weld
Weldin (wire) Arc Welding
heat
Weld layer g Electric voltage speed Flow
Trademar input
method Diameter Polarity current V cm/min Type rate
k kJ/cm
A L/min

Operative technique:

Outer inspection conclusion:

Sample index Appearance defects Results of rating

Survey report
Inspection institute
number

Nondestructive test conclusion:

Sample indexing Method of Weld defect Rating Results Metallurgical Joint rigidity

49
 detection of rating phase Base Weldin
macrography material g seam

Inspection institute Survey report number

Tensile test Test report number

Test sample Test sample Cross-sectional Breakin Tensile

Fracture position
Sample indexing width thickness area g load strength
and feature
mm mm mm2 kN N/mm2

Bend test Test report number

Flexural center
Test sample thickness Bend angle
Sample indexing Test sample type diameter Test result
mm (°)
mm

Impact test Test report number

Impact
Opening Test absorbing
Sample indexing Sample size Opening type Remark
position temperature℃ energy
J

Hardness testing result(HV) Test report number

Welding seam Heat-affected zone Base material

Metallographic examination result Test report number

macrographic Microcosmic Other examinations

Conclusions of other examinations

Conclusion: This assessment weld and examine specimen, measure the property as required and make sure the test data sheet is
accurate.
Results of rating: (Qualified, incompetent)

Welder name Welder code name Welding date

Examinatio Approva
Origination Date Date Date
n l

Third party examination

50
 Annex F
(Normative)
Classification and Grouping of Steel Products by Chemical
Composition, Mechanical Property and Welding Property
TableF.1 Steel classification and grouping
Type of Type Team
Steel number illustration Corresponding standard
steel number number

GB/T 700, GB/T 699, GB/T 713,

Ⅰ-1 Q235, 10, 20, 25, 20g, 20R,
Carbon GB 6654, GB/T 3274
Ⅰ
steel Ⅰ-2 Q255 GB/T 700, GB/T 711, GB/T 3274

Ⅰ-3 Q275 GB/T 700, GB/T 711, GB/T 3274

GB 150, GB/T 9711, GB/T 1591,

Ⅱ-1 Q345, 16MnR, X46
Low alloy GB 6654, GB/T 3274, GB 3531
Ⅱ
steel Q390, 15MnNbR, 15MnVR, GB 150, GB/T 9711, GB/T 1591,
Ⅱ-2
15MnVNR, X52 GB 6654, GB/T 3274, GB 3531

Ⅲ-1 Q420, X60, X65 GB 150, GB/T 9711, GB/T 16270

Q460, HQ60, X70, 18MnMoNbR, GB 150, GB/T 9711,

Ⅲ-2
14MnMoV GB/T 16270, GB 6654

07MnNiCrMoVDR, WDB620,
ADB610D, AH610E, WDL610E,
Dead-hard Ⅲ-3 WSD610E, B610CF-L1, B610CF-L2, GB 150, GB/T 19189
Ⅲ
steel 07MnCrMoVR, CF62, B610CF,
B610E, WDL610D, WSD610C, WSD610D

GB 150, GB/T 9711,

Ⅲ-4 Q500, Q550, X80
GB/T 16270, GB/T 19189

GB 150, GB/T 9711,

Ⅲ-5 Q620, HQ70, HQ70R, 14MnMoVN
GB/T 16270, GB/T 19189

Q690, HQ80C, DB685R, CF80,

WSD790C, WSD790D, WSD790E, GB 150, GB/T 9711,
Dead-hard Ⅲ-6
Ⅲ 14MnMoNbB, 14CrMnMoVB, GB/T 16270, GB/T 19189
steel
12Ni3CrMoV, 10Ni5CrMoV, X100, X120

Ⅲ-7 WSD1000C, WSD1000D, WSD1000E GB 150, GB/T 19189

Ⅳ-1 0Cr19Ni9, 00Cr19Ni11, 1Cr18Ni9, 1Cr18Ni9Ti GB/T 4237, GB/T 3280,GB/T 1220
Stainless Ⅳ-2 0Cr13, 0Cr13A1 GB/T 4237, GB/T 3280,GB/T 1220
Ⅳ
steel 00Cr17Ni14Mo2, 0Cr18Ni12Mo2Ti,
Ⅳ-3 GB/T 4237, GB/T 3280
00Cr22Ni5Mo3N

Ⅴ-1 0Cr13+Q235, 0Cr13+Q345(16MnR) GB/T 8165, JB/T 4733

0Cr19Ni9+Q235, 0Cr19Ni9+Q345
Ⅴ-2 GB/T 8165, JB/T 4733
Stainless (16MnR), 00Cr19Ni11+Q345(16MnR)
clad steel Ⅴ 00Cr17Ni14Mo2+Q345(16MnR),
plate 0Cr18Ni12Mo2Ti+Q345(16MnR),
Ⅴ-3 GB/T 8165, JB/T 4733
00Cr22Ni5Mo3N+Q235,
00Cr22Ni5Mo3N+Q345(16MnR)

51
 Annex G
(Normative)
Qualification of Welding Procedure for Stainless Steel Clad Plate
G.1 General Provisions
G.1.1 This procedure qualification regulation can be applied to stainless steel products mad
via rolling, explosion rolling, explosion and bead method.
G.1.2 Qualification of welding procedure of stainless clad-steel-plate shall conform to this
regulation as well as qualification of welding procedure in section 6.1 in this standard.
G.2 Qualification of welding procedure rules
G.2.1 The test sample shall be made by stainless clad steel plate (including sub-base and
covering).
G.2.2 Qualified welding procedure is applicable to weldment (Including base materials and
weld metals) The effective range of thickness shall be respectively calculated according to the
thickness of test sample covering and sub-base.
G.2.3 The covering weld metal thickness minimum value of the qualified welding procedure
is applicable to weldment in the effective range shall be taken as the covering weld metal
thickness of the test sample.
G.2.4 When do stretch and bend test on the test sample, stainless clad steel plate welding
joints(including sub-base, transitional welding seam and covering) shall all be examined and
for impact test, only welding joints of the sub-base shall be examined.
G.2.4.1 The tensile sample shall include the complete thickness of covering and sub-base.
G.2.4.2 For the qualification of welding procedure of transitional welding seams and covering
welding seams, if the key factors were different, 4 side bend specimens shall be taken; if the
same as many side bend specimens as possible shall be taken or 2 back bent samples and 2
face-bent test specimen shall be taken. For back-bent test, sub-base weld metal is stretched
and for bend test size, please refer to Table G.1.
G.2.4.3 Impact test shall only be done in weld zone and heat-affected zone.

TableG.1 Bend test size

Flexural center Seating plane
Test sample thickness S Bend angle
Bend specimen type diameter distance
mm (°)
mm m

Side bend specimen 10 40 63

Face bent, back bent test 180

S 4S 6S+3
sample

G.2.5 The qualified indicator of mechanical testing

G.2.5.1 Tensile test: tensile strength Rm of each sample shall meet calculation of formulae
(A.2) in the foot note of "clad steel plate mechanics property" in Table A.15 of annex A.
G.2.5.2 Bend test: if the test sample bent to the specified angle, no crackle or defect of 3mm
is allowable in any direction on the plane of stretching except the arris crazes of the sample.
For side bend specimen made via rolling, explosion rolling and explosion method, retest is
allowable if there crackles or compound interface did not attach the defect layer.
G.2.5.3 Impact test: the average value of the normal temperature impact absorbing energy of
3 test samples in each area shall conform to the coincidence pattern or regulations in the
relative technique documents, be not less than 27J and at least the impact absorbing energy of
1 sample could be less than the specified value but not less than 70% of the specified value.

52
 Annex H
(Informative)
Selection of Welding Materials for Steel Pipe
TableH.1 Selection of the steel pipe welding materials
Welding rod arc welding Submerged arc welding
Serial Type of Welding wire / flux
Trademark Type of electrode Equivalent to AWS Equivalent to AWS
Number steel Conform to GB type combination trademark Conform to GB type
illustration type type
illustration
Q235, 20R, 20g CHE422R E4303 CHW-S1/CHF431 F4A2-H08A F6A0-EL12
J422 CHW-S1/CHF301
CHE426R E4316 E6016
Carbon TL-46 E7016
1
steel J426
CHE427R E4315 E6015
TL-427
J427
Q295, Q345, 16MnR, X46 CHE506R E5016 E7016 CHW-S1/CHF431 F4A2-H08A F6A0-EL12
CHE507R E5015 E7015 CHW-S1/CHF301 F4A4-H08MnA F6A0-EL12
J507 CHW-S2/CHF103 F5A2-H08MnA F6A4-EM12
TL-507 CHW-S2/CHF301 F7A0-EM12
CHE507RH E5015-G E7015-G TSW-12KM×TF-565 F7A2-EM12K
CHE507NiLHR CHW-S12/CHF101 F6A4-EM12K
TL-507Ni CHW-S12/CHF301 F7A0-EN12K
J507RH
Low alloy
2 J507R
steel
Q390, 15MnNbR, CHE506R E5016 E7016 CHW-S3/CHF101 F5A2-H10Mn2 F7A2-EH14
15MnVR, 15MnVNR, X52 CHE507R E5015 E7015 CHW-S3/CHF102 F5A4-H10Mn2
CHE507RH E5015-G E7015-G TSW-50G×TF-565 F8A4-EG-G
CHE556H E5516-G E8016-G CHW-S3/CHF331 F7A2-EH14
J556RH CHW-S4/CHF303 F5A2-H10MnSi F7A0-EM13K
CHE557R E5515-G E8015-G CHW-S9/CHF101 CHW-S9Welding wire: CHW-S9Welding
J557 CHW-S9/CHF102 H08MnMoA wire: Ea2
TL-65Z CHW-S9/CHF105
07MnNiCrMoVDR, CHE62CFLH E6015-G E9015-G CHW-S7/CHF101
WDB620, ADB610D, R TSW-60G×TF-600 F8A4-EG-G
B610CF-L1, B610CF-L2, J607RH F8P6-EG-G
Dead-hard AH610E, WDL610E, CHE607RH TSW-60G×TF-585 F8A4-EG-G
3
steel WSD610E, 07MnCrMoVR, CHE607NiR E6016-G E9016-G F9A4-EG-G
B610CF, B610E, WDL610D, TL-80
WSD610C, WSD610D, Q460, J606RH
Q500, Q550, HQ60, X70,

53
 X80, 18MnMoNbR, 14MnMoV
Q620, HQ70, HQ70R, CHE557MoV E6015-G E9015-G CHW-S7/CHF113 F62P4-H08Mn2 F62P4-EA3-A3
14MnMoVN, Q690, HQ80C, CHE707 E7015-D2 E10015-D2 CHW-S7/CHF115 MoA F69P2-EA3-A3
DB685R, CF80, WSD790C, J707 CHW-S10/CHF102 F69P2-EA3-A3 CHW-S10Welding
WSD790D, WSD790E, CHE707Ni E7015-G E10015-G CHW-S10/CHF104 CHW-S10Welding wire: wire: Ef3
14MnMoNbB, 14CrMnMoVB, CHE757 E7515-G E11015-G CHW-S10/CHF105 H10Mn2NiMoA CHW-S10Welding
12Ni3CrMoV, 10Ni5CrMoV, CHE757Ni CHW-S10/CHF102 CHW-S10Welding wire: wire: Ef3
X100, X120 J757Ni CHW-S10/CHF104 H10Mn2NiMoA
CHE758 E7518-G E11018-G CHW-S10/CHF105
TL-118M E7518-M E11018-M
CHE80C E7515-G
CHE807 E8015-G
CHE807RH
J807
WSD1000C, WSD1000D, CHE857 E8515-G E12015-G
WSD1000E, HQ100, HQ130, CHE857Cr
30CrMo, 35CrMo CHE857CrNi
J857
Dead-hard
3 J857Cr
steel
J907Cr E9015-G
J107 E10015-G
J107Cr
CHE858 E8518-G E12018-G
0Cr19Ni9, CHS102R E308-16 E308-16
00Cr19Ni11, CHS107R E308-15 E308-15
Stainless 1Cr18Ni9, CHS132R E347-16 E347-16 Flux CHF260 and CHF601 conform to international F308 - H0Cr21Ni10 with
4
steel 1Cr18Ni9Ti, CHS137R E347-15 E347-15 corresponding stainless steel welding wires
0Cr18Ni12Mo2Ti, CHS002R E308L-16 E308L-16
00Cr22Ni5Mo3N CHS202R E316-16 E316-16
CHS207R E316-15 E316-15
CHS212R E318-16 E318-16
CHS307 E309-15 E309-15
CHS312 E309Mo-16 E309Mo-16
CHS2209 E2209-16 E2209-16
CHS232 E318V-16
Stainless CHS237 E318V-15 Flux CHF260 and CHF601 conform to international F308 - H0Cr21Ni10 with
4
steel CHK202 E410-16 E410-16 corresponding stainless steel welding wires
CHK207 E410-15 E410-15
0Cr13, 1Cr13, 2Cr13
CHS107 E308-15 E308-15
CHS207 E316-15 E316-15
CHK307 E430-15 E430-15
0Cr13Al, 0Cr17, 0Cr17Ti CHS107 E308-15 E308-15
CHS207 E316-15 E316-15

54
 Table H.1 (Continue)
MAG/MIG welding CO2 shielded welding Self-protecting flux-cored wire
Flux-cored wire Solid welding wire
Serial Type of Welding wire Equivalent
Trademark Conform Welding wire Welding wire Conform Equivalent Welding wire Equivalent
Number steel number to AWS Conform to Equivalent to Conform to
to GB type number number to GB to AWS number to AWS
illustration type GB type AWS type GB type
illustration illustration type type illustration type
Carbon Q235, 20R, 20g CHW-50C2 ER50-2 ER70S-2 TWE-611 E431T-G E61T-G CHW-50C2 ER50-2 ER70S-2 JC-28 E501T-8 E71T-8
1
steel CHW-50C3 ER50-3 ER70S-3 CHT711 E501T-1 E71T-1 CHW-50C6 ER50-6 ER70S-6 Stiffener
Q295, Q345, TM-54 ER50-4 ER70S-4 TWE-711 TM-56 welding only
16MnR, X46 JQ.MG50-4 JQ.Y501-1 JQ.MG50-6 TWE-707-0 E500T-7 E70T-7
Q390, 15MnNbR, CHW-50C6 ER50-6 ER70S-6 JQ.Y507-1 E500T-5 E70T-5 CHW-50C8 ER50-G ER70S-G JC-29 E501T8-K6 E71T-K6
Low alloy 15MnVR, TM-56 JQ.YJ507Ni-1 TM-58 JC-29X
2
steel 15MnVNR, X52 JQ.MG50-6 TWE-711Ni E501T-1L E71T-1J JQ.MG50-Ti JC-29Ni1 E501T8-Ni1 E71T8-Ni1
CHW-50C8 ER50-G ER70S-G JQ.YJ501Ni-1 E551T-Ni1 E71T-Ni1 CHW-65C ER55-G ER80S-G
TM-58 JQ.MG55-B
JQ.MG50-Ti
07MnNiCrMoVDR, CHW-65A ER55-G ER80S-G JQ.Y601-1 E551T1-Ni1 E81T1-Ni1 JC-29Ni1 E501T8-Ni1 E71T8-Ni1
WDB620, CHW-60C JQ.YJ601Ni-1 E601T1-K1 E81T-K1 JC-29Ni2 E501T8-Ni2
ADB610D, CHW-65C TWE-911Ni2 E601T1-Ni2 E91T1-NI2 E71T8-Ni2
B610CF-L1, TM-60
B610CF-L2, JQ.MG55-B
AH610E, WDL610E,
WSD610E,
Dead-hard 07MnCrMoVR,
3
steel B610CF, B610E,
WDL610D,
WSD610C,
WSD610D, Q460,
Q500, Q550, HQ60,
X70, X80,
18MnMoNbR,
14MnMoV

55
 Table H.1 (Continue)
Self-protecting flux-cored
MAG/MIG Weld CO2Shielded welding
wire
Flux-cored wire Solid welding wire

Serial Type of
Trademark Welding wire Welding
Number steel Equivalent Welding wire Conform Equivalent Welding Conform Equivalent
number Conform to GB type Conform to GB Equivalent to wire
to AWS type number to GB to AWS wire to GB to AWS
illustration type AWS type number
illustration type type number type type
illustration

Q620, HQ70, HQ70R, CHW-70C ER69-G ER100S-G JQ.Y707Ni-1 E90T-5

14MnMoVN, Q690,
HQ80C, DB685R, CF80,
WSD790C, WSD790D,
Dead-hard
3 WSD790E, 14MnMoNbB,
steel
14CrMnMoVB,
12Ni3CrMoV,
10Ni5CrMoV,
X100, X120
0Cr19Ni9, 00Cr19Ni11, CHM-308 H0Cr21Ni10 ER308 TFW-308L E308LT1-1 E308LT1-1
1Cr18Ni9, 1Cr18Ni9Ti, CHM-308 H00Cr21Ni10 ER308L TFW-309L E309LT1-1 E309LT1-1
0Cr18Ni12Mo2Ti, CHM-309 H1Cr24Ni13 ER309 TFW-309MoL E309LMoT1-1 E309LMoT1-1
00Cr22Ni5Mo3N CHM-309L H0Cr24Ni13 ER309L TFW-316L E316LT1-1 E316LT1-1
CHM-316 H0Cr19Ni12Mo2 ER316 TFW-317L E-317LT1-1 E-317LT1-1
Stainless ERM-316L H00Cr19Ni12Mo2 ER316L TFW-347L E-347LT1-1 E-347LT1-1
4
steel CHM-317 H00Cr20Ni14Mo3 ER317
CHM-347 H0Cr20Ni10Nb ER347
MIG-2209 ER2209
0Cr13, 1Cr13, 2Cr13 CHM-410 H1Cr13 ER410
0Cr13Al, 0Cr17, 0Cr17Ti MIG-430 ER430

56
 TableH.2 Selection of welding rods for stainless clad steel plate welding rod arc welding

Composite steel combination illustration Mer Transitional area Covering

E4303 E309-16(E1-23-13-16) E309-16(El-23-13-16)
Q235+0Cr13
E4315 E309-15(E1-23-13-15) E309-15(El-23-13-15)
Q345+0Crl3 E5015
15MnVR+0Crl3 E5515-G
Q235+0Crl8Ni9Ti E4303
E309-16(El-23-13-16) E347-15(E0-19-10Nb-15)
Q235+0Cr19Ni9 E4315
E309-15(El-23-13-15) E347-16(E0-19-10Nb-16)
Q345+lCrl8Ni9Ti
E5015
16MnR+00Cr19Ni11
E5515-G
15MnVR+1Crl8Ni9Ti
Q235+Crl8Nil2Mo2Ti E4315
E309Mo-16 E318-16
Q345+Crl8Nil2Mo2Ti E5015 (E1-23-13-Mo2-16) (E0-18-12Mo2Nb-16)
15MnVR+Crl8Nil2Mo2Ti E5515-G
Note: GB/T 983- 1985 type in the parentheses.

TableH.3 Selection of welding materials for stainless clad steel plate welding rod arc welding and submerged arc welding
Welding rod arc welding Submerged arc welding
Base material illustration
Trademark illustration Conform to GB type Welding wire / flux combination trademark trademark Conform to GB type
CHE422R, CHE426R, CHE427R
CHW-S1/CHF431
Q235, 20, 20g J422, J426, J427 E4303,E4315 F4A2-H08A
CHW-S1/CHF301
TL-46, TL-427
CHE506R, CHE507R, CHW-S1/CHF431
CHE507RH, CHE507NiLHR CHW-S1/CHF301
Sub-base
J507, J507RH, J507R CHW-S2/CHF103 F4A2-H08A
Q295, Q345, 16MnR, E5015
TL-507, TL-507Ni CHW-S2/CHF301 F4A4-H08MnA
15MnNbR, 15MnVR E5515-G
CHE556H, CHE557R TSW-12KM×TF-565 F5A2-H08MnA
J556RH, J557 CHW-S12/CHF101
TL-65Z CHW-S12/CHF301
CHS302, CHS307, CHS312, CHS2209 E309-16, E309-15 H00Cr29Nil2TiAl/CHF601
Transition layer F308-H0Cr21Ni10
A302, A307, A312 E309Mo-16, E2209-16 H00Cr29Nil2TiAl/CHF260
CHS102, CHS107
0Crl8Ni9Ti, A102, A107
E308-16, E308-15 H0Crl9Ni9Ti/(CHF601OrCHF260)
0Cr19Ni9, CHS132, CHS137
Covering E347-16, E347-15 H00Cr21Ni10(CHF601OrCHF260) F308-H0Cr21Ni10
00Cr19Ni11, A132, A137
E316-16, E316-15 H00Cr29Nil2TiAl/(CHF601orCHF260)
1Crl8Ni9Ti, 0Crl3 CHS202, CHS207
A202, A207
CHS202, CHS207 H0Crl8Nil2Mo2Ti/(CHF601orCHF260)
Crl8Nil2Mo2Ti, A202,A207 E316-16, E316-15 H0Crl8Nil2Mo3Ti/(CHF601orCHF260)
Covering Crl8Nil2Mo3Ti CHS212 E318-16 H00Cr21Ni10/(CHF601orCHF260)
F308-H0Cr21Ni10
A212 H00Cr29Nil2TiAl(CHF601orCHF260)

57
 Annex I
(Normative)
Derusting Grade of Steel Surface before Painting

The four derusting grades have been specified in GB/T 8923 and for written depiction, please refer to Table I.1.

TableI.1 Derusting grades of steel surface

Derusting method Derusting grade Requirements of each derusting grade

Low-grade jetting or slinging derusting

Sa1
No attachments such as visible grease, dirt, scales, rust, paint coating on the steel surface. See photoBSa1, CSa1 and DSa1

Thorough jetting or slinging derusting

Sa2 No visible grease, dirt on the steel surface; attachments such as scales, rust, paint coating shall be fundamentally cleaned out and the remaining shall be solidly
adhere to the surface. see photo BSa2, CSa2 and DSa2
Jetting or slinging
Extraordinarily thorough jetting or slinging derusting
derusting
Sa2.5 No attachments such as visible grease, dirt scales, rust, paint coating and any remaining marks shall be merely visible punctuated or banding splashes. See
ASa2.5, BSa2.5, CSa2.5 and DSa2.5

Jetting or slinging derusting for the cleanness of the steel surface

Sa3 No attachments such as visible grease, dirt, scale, rust and paint coating on the steel surface and the surface shall show even metallic color. see photo ASa3,
BSa3, CSa3 and DSa3

Note: see photo GB/T 8923.

58
 Annex J (Informative) Conversion Table of Air Dew Point
TableJ.1 Conversion table of air dew point
Free air temperature

Relative humidity ℃

RH －5 0 5 10 15 20 25 30 35 35
% Atmosphere dew point
℃

95 －6.5 －1.3 3.5 8.2 13.3 18.3 23.2 28.0 33.0 38.2

85 －7.2 －2.0 2.6 7.3 12.5 17.4 22.0 27.0 32.0 37.1

80 －7.7 －2.8 1.9 6.5 11.5 16.5 21.0 25.9 31.0 36.2

75 －8.4 －3.6 0.9 5.6 10.4 15.4 19.9 24.7 29.6 35.0

70 －9.2 －4.5 －0.2 －4.6 9.1 14.2 18.5 23.3 28.1 33.5

65 －10.0 －5.4 －1.0 3.3 8.0 13.0 17.4 22.0 26.8 32.0

60 －10.8 －6 －2.1 2.3 6.7 11.9 16.2 20.6 25.3 30.5

55 －11.5 －7.4 －3.2 1.0 5.6 10.4 14.8 19.1 23.0 28.0

50 －12.8 －8.4 －4.4 －0.3 4.1 8.6 13.3 17.5 22.2 27.1

45 －14.3 －9.6 －5.7 －1.5 2.6 7.0 11.7 16.0 20.2 25.2

40 －15.9 －10.3 －7.3 －3.1 0.9 5.4 9.5 14.0 18.2 23.0

35 －17.5 －12.1 －8.6 －4.7 －0.8 3.4 7.4 12.0 16.1 20.6

30 －19.9 －14.3 －10.2 －6.9 －2.9 1.3 5.2 9.2 13.7 18.0

Note1: steel pipe temperature

27
T = 4+ t
19
Where,
T——Temperature for the empty steel pipe in the sun;

59
 t——Free air temperature.
Note2: Humidity: humidity is the content of moisture in the air, in the physics definition, air humidity shows the moisture content or the
humidity level of the air.
Physical quantity of humidity.
Relative humidity: Relative humidity is the ratio between the actual aerial humidity and saturated humidity in the same
temperature.

Ma
RH = × 100%
Mg
Where,
RH——Relative humidity,%;
Ma——Moisture content in the air;
Mg——Maximum moisture capacity in the air.

60
 Annex K
(Informative)
Inspection of Thickness and Binding Ability of Mellozing Coat
K.1 Metallic coating thickness inspection

TableK.1: Coating cutting size table

Examined coating thickness Approximation area of cutting area Distance between cuttings
mm mm×mm mm

<200 15×15 3

>200 25×25 5

K.1.1 Metallic coating thickness inspection method shown as follows.

K.1.1.1 If the effective surface area is above 1m2, test the thickness with the thickness tester,
measure the coating thickness of 10 selected spots on the datum plane and get the average; for
the distribution of survey points, please refer to figure k.1; if the effective surface area is less
than 1m2, measure the coating thickness of spot3, 4, 5 on the datum plane and get the average,
for survey points, please refer to profile K.2.

FigureK.1: 10 points position measurement figure

FigureK.2: measurement of 3, 4 and 5 points

K.1.1.2 3~12 datum planes could be laid out on tube-surface of each corrugated bar according
to the steel pipe caliber size and pipe joint length.
K.1.1.3 Re-spraying shall be done, if the measured coating thickness was less than 80% of the
design value.
K.1.1.4 Other regulations shall meet the requirements in GB/T 9793.
K.2 Binding ability shall be considered for metallic coating inspection.
K.2.1 Metallic coating inspection method shown as follows.
K.2.1.1 As shown in figure k.3, cut the coating into square lattice with hard-edge cutter and
for the size of the lattice, please refer to Table K.1.

61
 FigureK.3 Shape of the cutting edge

K.2.1.2 Keep 90° between cutting edge and coating surface as shown in Figure K.4. The
coating shall be completely cut off from the surface after the cutting.

FigureK.4: Cutting angle

K.2.1.3 Paste adhesive tape on the clathrate coating surface, press with 500g roller or with
hand, then as shown in figure K.5, hold one end of the adhesive tape, quickly and suddenly
unzip the adhesive tape in the vertical direction to the coating surface and examine if coating
stripped.
K.2.1.4 If there was no part stripped from the coating ,it is considered as qualified, if there
were fractured coating on the adhesive tape between the coatings instead of between the
coating and the mer surface and the mer was not exposed, it is also considered as qualified.

Press with hand Vertically pull

Coating surface
Base surface

Coating
Cut into lattice size

FigureK.5 Adhesive tape unzip mode

62