JB/T 10384-2002 Steel castings for flow-through components of small and medium-sized turbines
Some standard content:
ICS29.140
Machinery Industry Standard of the People's Republic of China JB/T 10384---2002
Steel castings for water passage components of small and medium sizedhydraulic turbines
Issued on 2002-12-27
Implemented on 2003-04-01
Issued by the State Economic and Trade Commission of the People's Republic of China Foreword
１ Scope
2 Normative references
3 Ordering requirements.
4 Technical requirements
Manufacturing process
Chemical composition
Mechanical properties
Defects and welding repairs of castings
4.5·Surface quality of castings
5Inspection rules
5.1Chemical composition analysis
5.2Mechanical property inspection
Non-destructive testing.
6Re-inspection.
7Quality certificate,
8Marking, packaging and transportation
Figure 1Main dimensions of Francis runner,
Figure 2Inspection positions of Francis runner blades
Figure 3Inspection positions of blade inlet and outlet lines
Figure 4 Inspection of axial flow turbine blade profile
Figure 5 Inspection of bucket profile
Figure 6 Inspection of mixed flow and axial flow guide vane profilesFigure 7 Inspection of tubular and diagonal flow guide vane profilesFigure 8
Section of guide vane inside nozzle body
Figure 9 Type of single casting test block for mechanical properties
Table 1 Chemical composition of common materials for turbine steel castings, Table 2 Mechanical properties of common materials for turbine steel castingsTable 3 Tolerances of casting dimensions
Table 4 Required machining allowance (RMA) of castingsTable 5 Numerical tolerances of casting weight
Table 6 Classification of Mixed Flow Blade Castings
Table 7 Classification of Axial Flow and Crossflow Blade CastingsTable 8 Classification of Pelton Runner Castings
Table 9 Classification of Crossflow Guide Vane Castings,
JB/T 10384—2002
JB/T10384--2002
This standard is proposed by the China Machinery Industry Federation. Foreword
This standard is under the jurisdiction of the National Technical Committee for Standardization of Water Turbines. This standard was drafted by the Shenyang Foundry Research Institute, and Tianjin Electric Drive Design Institute, Dongfeng Electric Motor Factory, Chongqing Water Turbine Factory, and Shaoguan Zhongli Power Generation Equipment Co., Ltd. participated in the drafting. The main drafters of this standard are: Lou Yanchun, Gao Shangshu, Xia Shuzhuang, Hu Jianghong, Huang Qin, Dai Shousheng, Xu Qingjin, Lu Chuxun, and Yang Qingsheng. II
JB/T103842002
The flow parts of turbines are mostly made of cast high alloy steel, low alloy steel and carbon steel. The most important steel castings are blades, upper crowns, lower rings, movable guide vanes, impact runners, etc. It is of great significance to formulate standards for the manufacture and acceptance of steel castings. In 1989, the former Ministry of Machinery and Electronics Industry formulated and promulgated JB/DQ1554-1989 "Technical Conditions for Small and Medium-sized Water Turbine Castings", which played an important role in promoting technological progress in the turbine manufacturing industry and improving product quality. With the process of my country's technological progress and quality management in line with international standards, national standard management has undergone great changes, among which JB/DQ1554-1989 belongs to the category of cancellation. In order to adapt to the new industry management requirements and standardization of standards, this standard "Steel Castings for Flow Parts of Small and Medium-sized Water Turbines" is re-formulated. I
1 Scope
Steel castings for flow-through components of small and medium-sized turbines
JB/T 10384—2002
This standard specifies the ordering, manufacturing, test methods and inspection and acceptance rules for steel castings for flow-through components of small and medium-sized turbines. This standard applies to steel castings for small and medium-sized Francis, axial, tubular and Pelton turbines. Steel castings for other types of turbines may be used as a reference.
2 Normative references
The clauses in the following documents become clauses of this standard through reference in this standard. For dated references, all subsequent amendments (excluding errata) or revisions are not applicable to this standard. However, parties to an agreement based on this standard are encouraged to study whether the latest versions of these documents can be used. For undated references, the latest versions shall apply to this standard. GB/T222—1984 Sampling method for chemical analysis of steel and allowable deviation of chemical composition of finished products GB/T 223.3～784
Chemical analysis methods for steel and alloys
GB/T228—2002Methods for tensile testing of metals (eqyISO6892:1998)GB/T229-1994Methods for Charpy notched impact testing of metals (eqvISO148:1983)GB/T231-1984Methods for testing Brinell hardness of metalsGeneral purpose corrosion-resistant steel castings
GB/T 2100---2002
GB/T5677 Method for classification of steel castings by radiography and negative film grades GB/T6397-1986 Metal tensile test specimens GB/T6414 Dimensional tolerances and machining allowances for castings (eqvISO8062:1994) GB/T6967-1986 Medium and high strength stainless steel castings for engineering structures GB/T7233 Method for ultrasonic flaw detection and quality rating of steel castings GB/T9443 Method for rating of penetration flaw detection and defect indication marks of steel castings GB/T9444
Methods for magnetic particle inspection and quality rating of steel castings GB/T10969-1996 Technical conditions for flow-through components of hydraulic turbines (neqIEC193-1:1977) GB/T11351 Weight tolerance of castings
GB/T11352—1989 Carbon steel castings for general engineering 3 Ordering requirements
3.1 The supplier and the buyer shall specify the name, implementation standard, material grade, order quantity and supply status of the castings in the order contract and order agreement.
3.2 The ordering party must provide the supplier with the ordering drawings and indicate the product size, tolerance, surface roughness and test items. 3.3 When inquiring and placing orders, the supplier and the buyer shall negotiate to determine the location and quantity of the test blocks and the method, location and level of non-destructive testing. 3.4 When inquiring and placing orders, the supplier and the buyer shall negotiate to determine the method of line detection, which may refer to GB/T10969--1996 standard, but the influence of grinding and machining allowance on the roughness of castings shall be considered. 4 Technical requirements
4.1 Manufacturing process
4.1.1 Smelting
When inquiring and placing orders, the supplier and the buyer shall negotiate to determine whether to use one of the methods such as medium frequency furnace, electric arc furnace, refining, or a combination of methods for smelting. 1
JB/T10384—2002
If the ordering party has no special requirements, it can be decided by the supplier. 4.1.2 Heat treatment
Steel castings must be heat treated. Unless otherwise agreed upon when placing an order, the heat treatment process shall be determined by the supplier. Commonly used heat treatment processes are the following:
Carbon steel
Annealing;
Normalizing:
Normalizing and tempering.
Low alloy steel
Annealing;
Normalizing and tempering.
Martensitic stainless steel
Normalizing and tempering.
The number of repeated normalizing shall be agreed upon by the supplier and the buyer during the inquiry and ordering. If the ordering party has no special requirements, it shall be determined by the supplier. The number of tempering is unlimited.
4.2 Chemical composition
The chemical composition shall be implemented in accordance with GB/T2100-2002, GB/T6967-1986, GB/T11352---1989 standards and shall comply with the provisions of Table 1. When other material grades are selected, it shall be implemented in accordance with the ordering contract between the supplier and the buyer. Table 1 Chemical composition of common materials for turbine steel castings Type
Ultra-low carbon martensitic
ZG200—400°
ZG230—450°
ZG270-—-500c
ZG20SiMn
ZG06Cr13Ni4Mo
ZG06Cr13Ni6Mo
ZG06Cr16Ni5Mo
ZG00Cr13NisMo
Steel steel ZG00Cr16NiSMo
Chemical composition without range is the upper limit value of the composition. b Using AOD, VOD and other refining methods.
Chemical composition (mass fraction)
11.5~13.5
11.5~13.5
15.5~~17.5
11.5~13.5
15.5~17.5
0.40~1.00
0.40~1.00
0.40~1.00
0.40~1.00
0.40~1.00
For every 0.01% reduction in carbon, an increase of 0.04% manganese is allowed. For ZG200-400, the maximum increase is 1.00%, and for the rest, the maximum is 1.20%. d Casting and welding structure w (C) ≤ 0.06%.
Residual elements.
4.3 Mechanical properties
Mechanical properties shall be implemented in accordance with GB/T2100-2002, GB/T6967-1986, GB/T11352-1989 standards and shall comply with the provisions of Table 2. When other material grades are selected, they shall be implemented in accordance with the order contract between the supply and demand parties. 4.4 Defects and welding repair of castings
If the defects on the casting surface are not greater than the following and are within the grinding or processing allowance, welding repair is not required. However, those confirmed as cracks 4.4.1
must be welded.
JB/T10384—2002
The maximum size of nonlinear defects on the casting surface is not greater than 6mm, or the total area of defects within the range of 105mmx148mm is not greater than 70mm2. 4.4.1.1
Table 2 Mechanical properties of common materials for turbine steel castings Type
Carbon steel
Low alloy steel
Low carbon martensitic
Stainless steel
Ultra-low carbon martensitic
Stainless steel
Material brand
ZG200——400b
ZG230—450b
ZG270—500b
ZG20SiMn
ZG06Cr13Ni4Moc
ZG06Cr13Ni6Moc
ZG06Cr16Ni5Moc
ZG00Cr13Ni5Moc
ZG00Cr16Ni5Moc
Ob MPa
Minimum value
8s (%)
w (%)
217~286
221~286
221~286
221~330
221~330
Note 1: The required properties are measured from a 28mm thick standard test block. If the casting thickness is much greater than 28mm, it should be negotiated in accordance with the provisions of 5.2.1.2. Note 2: Room temperature is 23℃±5℃;
a Refining methods such as AOD and VOD are used.
b Unless otherwise agreed upon at the time of ordering, the supplier may choose either the reduction of area or the impact absorption energy. Unless otherwise agreed upon at the time of ordering, hardness is a reference value and is not used as an acceptance condition. O, if measurable, is the upper yield strength, otherwise it is 0.2% yield strength; 0 tensile strength;
85- elongation:
section shrinkage:
impact absorption energy, which is the arithmetic mean of three specimens. The impact absorption energy of one specimen is allowed to be lower than the specified value, but it shall not be lower than 2/3 of the specified value.
4.4.1.2 The length of linear defects and point linear defects on the casting surface shall not exceed 10mm. If the defects of the casting reach one of the following conditions, it is considered to be a major defect, and other defects are non-major defects. Major defects must be 4.4.2
welded.
When the depth of the casting defect exceeds 20% of the thickness of the section. If the thickness is less than 20mm, it is calculated as 20mm. When the area of a single defect in the casting exceeds 6500mm. 4.4.2.3 When the area of a single defect on the surface of the blade or bucket exceeds 10% of the area of the surface. 4.4.3 Welding repair of castings
4.4.3.1 The welding rod for welding repair shall be the same material as the casting or the welding rod with similar composition to the casting. When the ordering party has special requirements, the supply and demand parties shall negotiate and determine at the time of inquiry and ordering. 4.4.3.2 Welding repair of casting defects shall be performed by welders with operation certificates. Before welding repair, the defects shall be cleaned and then welded. 4.4.3.3 For major defects, non-destructive testing (usually magnetic powder or penetration) shall be carried out before welding repair to ensure that the defects are completely removed, and the whole welding repair process shall be recorded. After welding repair, stress relief heat treatment shall be carried out, and the weld repair part shall be re-tested according to the original flaw detection standard to confirm the quality of welding repair. When the ordering party requires, the supplier shall provide the inspection record to the ordering party. 4.4.3.4 When the ordering party has special requirements for major defects, the terms agreed upon by the supply and demand parties shall prevail. 4.5 Casting surface quality
4.5.1 General requirements
4.5.1.1 There shall be no flash, burrs, or sand sticking on the casting surface. 4.5.1.2 The geometric shape and size of the casting shall comply with GB/T6414. It shall meet the requirements of the order drawing. The dimensional tolerance of qualified castings shall not be lower than CT14 grade according to Table 3; the machining allowance shall not be lower than K grade according to Table 4. 4.5.1.3 The weight tolerance of qualified castings shall comply with GB/T11351. Table 3 Casting dimensional tolerances not less than MT14 grade as specified in Table 5
Basic dimensions of rough castings
For wall thickness, a rough first-grade tolerance is adopted, and the minimum is not less than CT14 grade 11
Casting dimensional tolerance grade CT
For dimensions not exceeding 16mm, the general tolerances of CT13 to CT14 are not adopted. For these dimensions, individual tolerances should be marked. Table 4
Required machining allowance of castings
(RMA)
Maximum size
aThe maximum outline dimension of the casting after final machining. 4
Required machining allowance grade
Unit: mm
Unit: mm
Nominal weight kg
>10～40
>40～100
>100～400
>400～1000
>1000～4000
≥4000～10000
>10000 ~40000
Table 5 Casting weight tolerance values
Weight tolerance grade MT
Note: The weight tolerance values in the table are the sum of upper and lower deviations, that is, half is the upper deviation and half is the lower deviation.
JB/T10384—2002
The surface roughness of castings is not greater than Ra100um for machined surfaces; for non-machined surfaces, sand casting can select Ra (25~4.5.1.44
100) μm.
4.5.2 Francis turbine runner blades
4.5.2.1 See Figure 1 for the main dimensions.
Guide vane centerline
Figure 1 Main dimensions of Francis runner
4.5.2.2 The grinding or machining allowances for the front and back sides of the blades and the machining allowances for the periphery shall be agreed upon by the supplier and the buyer. The line deviation corresponds to the grinding or machining allowance, which can be the sum of both sides. If the supplier and the buyer do not specify clearly, the supplier shall take the value according to (0.30～0.45)%D2. 4.5.2.3 Blade inlet profile: for low specific speed turbines, at least two sections shall be checked for each blade; for high specific speed turbines, at least three sections shall be checked for each blade; the template shall extend from the top of the blade along the front and back sides of the blade by 0.1D2 (see Figures 2 and 3). 4.5.2.4 Blade outlet profile: for each blade, at least three sections shall be checked; the front outlet profile shall extend from the tail end of the blade along the blade by 0.1D2; the back outlet profile shall extend from the tail end of the blade along the blade by 0.15D2 (see Figures 2 and 3). Note: If the total length of the blade inlet and outlet profile templates is greater than the blade section length, the total length of the template shall be selected according to the principle that it shall not be less than 2/3 of the blade section length. 4.5.2.5 The blade head shape shall be checked with a template on the same section as in 4.5.2.3; the length of the template shall not be less than 0.03D2 (see Figures 2 and 3). JB/T10384—2002
Exit section
(shape of outlet tail)
Figure 2 Inspection position of mixed flow runner blade
Inlet section
(shape of head)
Outlet angle
Figure 3 Inspection position of blade inlet and outlet profile
Inlet angle
4.5.2.6 The classification regulations for blade castings of cast-weld structure shall be implemented in accordance with Table 6. 4.5.2.7 The thickness of the blade outlet edge less than 5mm can be thickened to 5mm on the back, or the two parties can agree according to the casting process requirements. The allowable deviation of the thickness of other parts is (8-4)%T (when the calculated value is less than 2mm, it is calculated as 2mm). T is the design thickness plus the grinding or processing allowance of the front and back.
Line deviation
Gap between frontal line and combined template
Surface roughness Ra
Table 6 Classification of Francis blade castings
Maximum value
Qualified products
4.5.3 Axial and tubular turbine runner blades First-class products
±0.175%D2bzxZ.net
JB/T10384-2002
Superior products
±0.15%Dz
4.5.3.1 The frontal line of the blade shall be checked with no less than four radial (equidistant) section finished combined templates or other methods with equal accuracy agreed upon by the supply and demand parties. When the combined template is used to check the frontal line, adjust the position of the blade and the combined template, and the template shall be adjusted once to complete the entire inspection. (See Figure 4)
Axis allowable adjustment ±0.2%D
Angle allowable adjustment ±0.25°
Combined template radially positioned according to this surface
Figure 4 Axial turbine blade profile inspection
4.5.3.2 The lengthening of the water inlet and outlet edges of the blade is (0.25~0.35)%D1. The thickening of the water outlet edge is agreed upon by both parties according to the casting process, and the machining allowance of the outer edge of the blade is selected according to Table 4. The grinding or machining allowance of the front and back of the blade is agreed upon by both parties. The profile deviation corresponds to the grinding or machining allowance, which can be the sum of both sides. If the supply and demand parties do not specify it clearly, the supplier shall take the value of (0.30~0.45)%D. 4.5.3.3 The deviation of the blade thickness T is + (8%T+5mm) to -3%T. T is the design thickness plus the grinding or machining allowance of the front and back. 4.5.3.4 The grading regulations for axial flow and tubular blade castings shall be implemented in accordance with Table 7. 4.5.4 Pelton turbine runner
4.5.4.1 The inspection of the inner surface profile of the pelton shall be carried out by using a three-dimensional composite sample with no less than 2/3 of the total profile number after deducting the grinding allowance of the inner surface of the pelton, or a single-sided sample with at least four sections in the longitudinal and transverse directions after deducting the grinding allowance of the inner surface of the pelton. Table 7 Classification requirements for axial and cross-flow blade castings Items
Line deviation
Gap between front line and combined template
Surface roughness Ra
Qualified products
±0.225%D1
Line inspection
Notch cut edge
Maximum value
First-class products
±0.175%D
Figure 5 Line inspection of water bucket
(See Figure 5)
Superior products
4.5.4.2 The grinding allowance of the water bucket shall be determined by negotiation between the supplier and the buyer when placing an order. The grinding allowance of the inner surface of the water bucket shall generally not be less than 2mm. 4.5.4.3 The deviation of the outer line of the water bucket is 1%W. 4.5.4.4 The pitch of the bucket on the pitch circle is the arithmetic mean after measurement one by one, and its deviation is (1.0～一3.0)%. 4.5.4.5 The deviation of the pitch circle diameter of the runner is ±0.20%D1. 4.5.4.6 The classification of bucket runner castings shall be implemented in accordance with Table 8. Table 8 Classification of bucket runner castings
Gap between inner surface profile and combined template
Surface roughness Raμm
4.5.5 Guide vane
Qualified product
Maximum value
Excellent product
4.5.5.1 The grinding or processing allowance of the guide vane plate body shall be determined by negotiation between the supply and demand parties. The single-sided grinding or processing allowance can be (0.02～0.04)da, generally not less than 2mm.
4.5.5.2 Mixed flow and axial flow guide vanes
The gap between the rough profile of the guide vane body and the sample plate should be polished or machined accordingly. 4.5.5.3 Crossflow guide vanes
a) The front profile of the guide vane should be checked with no less than four radial (equidistant) section finished product combination samples. During the inspection, the position of the guide vane and the combination sample plate should be adjusted. The back side should be checked with a block sample plate with a section corresponding to the front sample plate. After the adjustment, all inspection and measurement are completed (see Figure 7).
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