WARNING AND SAFETY INFORMATION

Transcription

1 WARNING AND SAFETY INFORMATION WARNING 2016 Geeral warig, use, ispectio, maiteace ad safety iformatio for liftig ad ruig riggig compoets. Warig: This documet cotais importat iformatio for the safe ad proper istallatio ad use of your Ropeblock compoets.

2 Please keep this documet for referece. W&S Liftig ad ruig riggig Cotets WARNING, USE, INSPECTION, MAINTENANCE AND SAFETY INFORMATION FOR LIFTING AND RUNNING RIGGING COMPONENTS GENERAL Disclaimer Maufacturer cotact details Cotract iformatio DEFINITIONS HEALTH AND SAFETY WARNING LIMITATIONS OF USE Geeral Desig Service life Material WARNINGS AND INFORMATION ON USE Trasport Istallatio ad reevig Operatio Attachig the load Tuggig CERTIFICATION Geeral INSPECTION AND MAINTENANCE Ispectios ad maiteace Spare parts list GENERAL This W&S documet provides importat iformatio cocerig the trasport, istallatio, use, ispectio, maiteace ad safe use of your Ropeblock product. This iformatio is restricted to compoets used i liftig or ruig riggig systems. Compoets typically comprise a head fittig (hook, stud-eye, clevis) ad possibly sheaves ad are used for liftig, lowerig or pullig by applyig tesio to a wire rope or rope. Please examie your Ropeblock product, carefully read ad uderstad the iformatio preseted ad apply this iformatio i practice. If you do ot fully uderstad the iformatio, DO NOT PUT YOUR PRODUCT INTO SERVICE. Please call your sales represetative or Ropeblock B.V. directly. Please keep this iformatio documet for referece, or forward it with the product. DO NOT THROW AWAY. Disclaimer Your Ropeblock product is by default cosidered a tool or essetial part of the iteded applicatio ad therefore defied by the applicatio or system desiger or applicatio ower. I accordace with Machie Directive 2006/42/EC, it is therefore supplied as stadard without a CE mark ad EC declaratio. Where applicable, the product will become part of a CE-marked assembly. The product must the ot be put ito service util the full assembly has bee declared to coform to the provisios of 2006/42/EC. The party istallig Ropeblock products shall be competet ad qualified i the desig, costructio or maiteace of the relevat applicatio ad have the kowledge of the relevat regulatios ad stadards cocerig the applicatio/equipmet required for proper istallatio, or be declared competet by their employer. The party usig Ropeblock products shall be competet ad qualified i the operatio of the relevat applicatio ad have the kowledge of the relevat regulatios ad stadards cocerig the applicatio/equipmet required for proper operatio, or be declared competet by their employer. Ropeblock is ot resposible for ay misuse of the products or misiterpretatio of this documet. I case of ay doubt or problems, always cotact your sales represetative or Ropeblock B.V. 2 3

3 Maufacturer cotact details DEFINITIONS Ropeblock B.V. I Kampestraat 1 I NL-7575 ER Oldezaal I The Netherlads Ropeblock B.V. I PO Box 391 I NL-7570 AJ Oldezaal I The Netherlads T +31 (0) I F +31 (0) E sales@ropeblock.com I ropeblock.com Cotract iformatio Order cofirmatio is subject to Ropeblock s Geeral Terms ad Coditios of Sale ad Delivery. These coditios are filed with the Chamber of Commerce uder umber Acceptace of our products implies acceptace of the Terms ad Coditios i the cotract. Safe Workig Load (SWL) Allowable Lie Pull (ALP) Workig Load Limit (WLL) 1 Miimum Breakig Load (MBL) 2 Factor of Safety (FoS) Desig Dyamic Factor (DDF) The maximum load o the head fittig, as determied by a competet perso, which a item of Liftig Equipmet may raise, lower or susped uder particular (operatioal/dyamic) service coditios. The operatioal maximum lie pull, as determied by a competet perso, which a item of Liftig Equipmet ca be subjected to. For a sigle sheave block, this could also be referred to as SWL (as such, the ot o the head fittig). The maximum load o the head fittig, as deter mied by the maufacturer, which a item of Liftig Equipmet is desiged to raise, lower or susped uder ideal (static) service coditios with a give safety factor calculated agaist the MBL. The load, checked by the maufacturer agaist the miimum theoretical failure stregth of the material, at which a item of Liftig Equipmet is desiged to fail or break. (Or determied empirically i a laboratory breakig load test.) Factor determied as the ratio betwee MBL ad WLL. Also referred to as the Safety Factor (SF) or Desig Safety Factor (DSF). The factor specified by the desiger of the liftig appliace (e.g. crae). DDF is ot the same as DAF, which is defied separately ad applicable to a specific operatio. DDF = Desig load / SWL. 4 5

4 Desig load Proof Load (PL) Desig temperature Miimum operatig temperature Competet perso Load used for the purposes of desig, derived by combiig relevat characteristic load(s) (both static ad dyamic) with appropriate load factor(s). The desig load represets all foreseeable loads ad combiatios thereof (icludig all directios) that the liftig appliace will be subject to. Desig load shall ot be cofused with SWL. The predetermied test load, greater tha the SWL or WLL to which a item of liftig equipmet is subjected before acceptace for use. Referece temperature, specified by the desiger of the liftig appliace, used as a criterio for the selectio of material grades ad properties. Lowest temperature, determied by a competet perso, the item of Liftig Equipmet ca be operated at without compromisig safety. A competet perso as defied i ISO To determie fit-for-use the level Expert Egieer * is required. Alteratively, a qualified perso omiated as such by their employer. *Note: A expert egieer is a egieer with experiece i the desig, costructio or maiteace of craes, sufficiet kowledge of the relevat regulatios ad stadards ad the equipmet ecessary for carryig out the ispectio. Furthermore, a expert egieer is a egieer who is i a positio to judge the safe coditio of the crae ad to decide which measures shall be take i order to esure cotiued safe operatio. Particular service coditios are defied i combiatio with the applicable desig stadards or rules. 1 With regard to WLL, the cliet shall act as the competet perso to establish fit-for-use uder the give particular service coditios agaist the factor of safety of the item of liftig equipmet. 2 With regard to MBL, the cliet shall act as the competet perso to establish the SWL i cojuctio with the give particular service coditios. HEALTH AND SAFETY WARNING WARNING The party istallig Ropeblock products shall be competet i the desig, costructio or maiteace of the relevat applicatio ad have the kowledge of the relevat regulatios ad stadards cocerig the applicatio/equipmet required for proper istallatio, or be declared competet by their employer. The party usig Ropeblock products shall be competet i the operatio of the relevat applicatio ad have the kowledge of the relevat regulatios ad stadards cocerig the applicatio/equipmet required for proper operatio, or be declared competet by their employer. NEVER USE THE PRODUCTS IF THE CONDITIONS STATED IN THIS DOCUMENT ARE NOT FULFILLED OR IF YOU DO NOT UNDERSTAND THE INFORMATION PRESENTED. Durig trasportatio ad hadlig, a crushig, shearig or droppig hazard exists. Care shall be take whe istallig, workig with or repairig liftig or riggig equipmet. If istalled or used icorrectly or if a repair is executed icorrectly, loss of stability, fallig objects, isufficiet mechaical stregth or failure of parts could occur ad iflict ijury or death. Where your Ropeblock product has swivelig ad movig parts, there are potetial crushig, shearig or etaglemet hazards. Whe the product is i use do ot put hads: 1. Betwee sheaves, side plates, guards, wire rope or other movig parts. 2. I the area of becket, hook, hook ut or cross head. Workers must be made alert ad wear proper safety gear at all times. Take great care to avoid clothig becomig trapped or sagged. Pay attetio to sharp edges. Repairs shall be carried out by competet ad traied persoel oly. Power shall be switched off ad stored eergy elimiated, before repair activities are carried out. Work shall oly take place with the product o a firm surface with the product secured. Always follow local rules ad regulatios. 6 7

5 LIMITATIONS OF USE Geeral NEVER STAND UNDER THE LOAD. The Safe Workig Load (SWL), Allowable Lie Pull (ALP) ad Workig Load Limit (WLL) shall ever be exceeded. Uless otherwise stated, oly fully reeved crae blocks may be loaded up to the rated SWL or WLL. For partial reevig, the load shall always be symmetrically distributed to elimiate tilt, fleet agles ad cosequet side loadig. Reevig shall be carried out by competet persoel oly. Always uderstad the weight you are liftig ad the SWL or WLL of your system ad compoets. The SWL or WLL shall exceed the weight of the iteded load you pla to lift, icludig its riggig. Swivels ad overhaul balls may be loaded up to the rated SWL or WLL ad should oly be used with rotatio-resistat wire ropes. If i doubt, cotact your wire rope sales represetative for further guidace. Capacity ratigs apply to ew products or products cosidered to be i a as ew coditio by a competet ad qualified perso. Capacity may be affected by wear, misuse, corrosio, impact deformatio or modificatio. Hook blocks, overhaul balls ad swivels shall be used oly i vertical lift as they are oly desiged for this purpose. Side loadig may create uacceptable stresses i the compoet. Swivels may be used i ay orietatio whe specifically desiged for this. Riggig blocks shall be used i accordace with desig specificatios ad are geerally iteded for tesio ad pullig. Blocks shall ot be used for towig uless specifically desiged ad marked for that purpose. Horizotal ad vertical lead sheaves shall be used as idicated i the product descrip tio or drawigs. Shock or side loadig shall ot be applied uless the product is desiged for this purpose. Skew loadig shall be kept to a miimum for udetermied loads. The ceter of gravity of the load shall be aliged with the hook shak ceterlie. (See the sectio o lashig of the load.) The load shall always be placed i the seat or bowl of the hook or eye. NEVER AT THE POINT. The latch shall ever be allowed to carry the load. Desig Your Ropeblock product was desiged i accordace with the stadards ad desig rules as stated i the cotract ad/or drawigs ad/or with kowledge of idustry stadards (i part or whole) where applicable ad ca as such be cosidered state-of-the-art. Desig parameters such as SWL or WLL, load group or factor of safety, wire rope size, weight ad desig or operatig temperature must be visible o the product tag plate, or be egraved, or be traceable back from the certificate or cotract by its serial umber. DO NOT USE YOUR PRODUCT WITHOUT THIS INFORMATION. WLL equipmet is by default desiged with a FoS of 4:1 uless specified otherwise o the tag plate. Appropriate overhaul weight, if required, may vary due to crae desig, geometrical desig, materials, wire rope selectio, ad evirometal circumstaces such as temperature. Sheave bearigs should have separate lubricatio chaels if your Ropeblock product is to be used i a maritime, offshore, or otherwise sigificatly corrosio aggressive eviromet. Service life Geerically desiged products (WLL products) should meet their ormal service life whe used i their iteded applicatio. Check with your sales represetative for iformatio. Specifically desiged products (SWL products) should meet their iteded service life accordig to the prescribed desig stadard or 3rd party rules from the applicatio or system desiger. The service life of Ropeblock products will sigificatly deped o the actual itesity 8 9

6 of use, or possible misuse. Moitorig for wear ad reduced capacity is essetial for cotiued safe operatio (see the sectio o ispectio ad maiteace). Material For geerically desiged products (WLL products), the operatig temperature limits are -30 C / +80 C ad -40 C / +80 C for hoists i mobile crae use (as described i EN 13000) with steel or iro sheaves*. The structural materials i these blocks provide suitable ductility for use at the stated temperatures with 100% capacity ad at ormal speed of operatio. *Note: -30 C / +50 C applies for equipmet with ylo (Pa6G) sheaves. For use i applicatios or eviromets other tha those origially iteded, please cotact your sales represetative or Ropeblock B.V. Products specifically desiged i accordace with prescribed desig stadards or 3rd party rules (SWL products) will possess adequate ductility i their materials as specified at the referece desig temperature i those stadards or rules. Compoets from grade 8 upwards must ot be used i highly alkalie (>ph10) or acidic coditios (<ph6). Comprehesive ad regular examiatio shall be carried out whe they are used i severe or corrosio iducig eviromets to prevet hydroge embrittlemet ad cosequet severe loss of ductility ad/or premature failure. All Ropeblock products are asbestos-free. If i doubt, please cotact your Ropeblock sales represetative for the relevat drawigs ad iformatio. WARNINGS AND INFORMATION ON USE Trasport The products shall be hadled with care. Depedig o the surface it is placed o, the product may tilt ad tip over, roll or slide. A potetial crushig hazard exists. Liftig or lashig poits shall be used for their iteded purpose oly. NEVER USE IN OR WITH THE APPLICATION. Use other liftig equipmet to hadle the product if required. Istallatio ad reevig Always verify that the product is i its proper ad iteded coditio suitable for your applicatio. Reevig shall be performed o a firm surface to prevet the block from tippig over. Oly fully-reeved crae blocks may be loaded up to the rated SWL or WLL. For partial reevig, the loads shall always be symmetrically distributed to elimiate tilt, fleet agles ad cosequet side loadig. Reevig shall be carried out by competet persoel oly. Typical efficiecy losses for sheaves with roller bearigs ad wire rope are 2% per wire rope bed. Actual efficiecy losses may vary due to crae desig, load, block weight, geometrical desig, material, wire rope selectio ad evirometal coditios. Admissible fleet agles shall be moitored accordig to the relevat stadards. They are typically 4 for o-rotatio resistat wire rope ad 2 for rotatio resistat wire rope. The wire rope selected for your applicatio shall be suitable for the Ropeblock product ad the dimesioal factors i your system. Reevig shall be i accordace with the crae or system desiger s diagram. The sheave groove geometry shall ot hider proper fuctio with the prescribed wire rope. Accordig to EN 13135, for a ew build the radius should be withi half the omial wire rope size + mi. 5% / + max. 12%. Check your actual sheave radius with the omial wire rope size before istallatio

7 Avoid wire rope from becomig damaged durig istallatio. The wire rope shall be seated i the groove of the sheave before closig the reeve guides. Make sure all reeve guards are closed ad secured. Poor wire rope istallatio may affect the proper fuctioig of your Ropeblock product resultig i cablig (rotatio of the block util the wire ropes are etagled). Overhaul balls ad swivels should oly be used with rotatio-resistat wire ropes. If i doubt, cotact your wire rope sales represetative for further guidace. Esure your ed-of-lie switch is fuctioig properly or other meas have bee implemeted to prevet two-blockig. The lower block shall ot come ito cotact with the upper block or sheave arragemet of the crae uless a receiver o the crae, the crae ad the block itself were desiged for this purpose. Make sure all optioal features (additioal weights, sheaves, pis, etc.) are properly secured. If i doubt, cotact your sales represetative or Ropeblock. Liftig poits o optioal features are desiged for ONE uit oly. NEVER PICK STACKED UNITS WITH ONE LIFTING POINT. Do ot add compoets or mass to the product uless it has bee desiged by Ropeblock ad iteded for this purpose. Crae blocks shall be used i vertical lift. Shock or side loadig shall ot be applied. Prevet your product from comig ito cotact with ay structure or object durig a lift sice this could result i a loss of load. Skew loadig the hook shall be kept to a miimum for udetermied loads. The ceter of gravity of the load shall be aliged with the hook shak ceterlie. Esure that the hook rotates freely uder load, ad that your reevig is able to geerate the required couter mometum for the thrust bearig to prevet cablig. Do ot rotate hooks, eyes or other suspesios with oly a washer (i.e. without a bearig) uder load. Esure you are followig the applicable local ad atioal regulatios. Attachig the load The lashig or riggig arragemet of the load shall be limited to a 90 icluded agle betwee two sligs ad the maximum sigle slig agle (from vertical) shall be less tha 45 for sigle hooks ad less tha 60 for ramshor hooks. Forces i sligs shall be limited to the followig: Operatio Always follow the prescribed ispectio protocols ad esure that the product coditio complies with the requiremets for the job ad the product has bee properly maitaied. The Safe Workig Load (SWL), Allowable Lie Pull (ALP) or Workig Load Limit (WLL) shall ever be exceeded. To esure structural itegrity of the product, oly fully closed ad properly fitted products may be put ito operatio i your system. All locks, pis ad retaiers shall be properly assembled ad/or tighteed prior to ay operatio to elimiate potetial fallig objects or loads that may iflict ijury or death. Always uderstad the weight you are liftig ad the SWL or WLL of your system ad compoets. The SWL or WLL shall exceed the weight of the iteded load you pla to lift, icludig its riggig. Skew loadig shall be avoided by adjustig the riggig arragemet below the hook to allow the ceter of gravity of the load to lie up with the ceterlie of the hook shak. The hook shall receive symmetrical vertical loads to miimize additioal stress due to the bedig of the hook shak

8 If there is foreseeable misuse of skew loadig, this shall be limited to the maximum permitted fleet agles of the wire rope i your system. The skew load factor shall at all times be less tha (50/40 load distributio i a ramshor hook.) Skew loadig may iduce poor hook swivellig performace. Whe cosidered applicable to your applicatio, detailed lashig limits aalysis should be udertake i accordace with EN ad be commuicated to the operators. The lashig or riggig arragemet shall at all times be i accordace with acceptable practice ad be appropriate to the applicatio ad iteded lift. CERTIFICATION Geeral The followig certificates or other documets, where applicable, have bee provided with the product: Test report EN (Product proof loaded accordig to ILO 152) Hook certificate DIN Documets per cotract The wire rope sligs shall be selected to be appropriate to the hook ad its seat-bedig radius. This D/d radio shall be i accordace with acceptable practice. Depedig o the wire rope, a D/d 1 typically applies for 6x19 or 6x37 Flemish eye sligs (loop) ad greater tha this for basket hitches. Check the D/d ratio ad the effect o slig capacity with your wire rope or slig maufacturer. Alteratively, use master liks or other hardware to esure your sligs maitai the required stregth for the lift. We recommed usig hardware that matches the shape of the hook to prevet damage to the hook seat or bowl. The use of fibre sligs should be verified with the maufacturer of the slig. Latches shall be closed durig the lift. NEVER LOAD A LATCH. Tuggig If there is tuggig, this shall be such that the riggig, ad cosequetly the Ropeblock product, is free from sigificat forces perpedicular to the vertical hoistig forces from the load. Perpedicular forces are a side load ad create a bedig momet. Uless specifically idicated, your product is ot desiged for this. Tuggig lies are iteded oly to hold the product i positio

9 INSPECTION AND MAINTENANCE Ispectios ad maiteace Ispectios should be carried out daily or weekly or, if your Ropeblock product is used ifrequetly, each time it is used by the operator. Examiatio of the product by a competet ad traied perso should be carried out mothly to check for damage, corrosio ad the free movemet of sheave ad safety latch. Thorough examiatio of the product by a competet ad traied perso should be carried out aually or periodically depedig o usage itesity as see fit by the applicatio desiger or ower. Depedig o local regulatios, hook ad hook-ut are to be dismatled, ispected ad re-tested (proof loaded) at least every 4 or 5 years. WITH THE MANDATORY DISMANTLING INSPECTION OF THE HOOK, THE OVERALL BLOCK AND COMPONENTS WITH SHEAVE AND BEARINGS SHOULD BE INSPECTED FOR PROPER FUNCTIONING AND CONDITION. Particular attetio shall at least be paid to the followig: The hook shall be replaced if its throat opeig is elarged by more tha 10% from its certified dimesio (Y-measuremet). Wear of sheaves should be evaluated agaist 5% wear of omial sectio thickess ad 0.15xd i accordace with the DIN stadard. Repair or modificatio by weldig, flame torch, or other sigificat heat iducig method is strictly prohibited uless prior coset i writig has bee obtaied from Ropeblock. Comprehesive ad more itese regular examiatio must be carried out whe your product is used i severe or corrosio iducig eviromets. High-grade steels may be susceptible to hydroge embrittlemet ad loss of ductility. Check for cracks. Where stailess steel boltig is used, check for cathodic corrosio. If your block was fitted with retaiig or securig wires, check that these are preset, itact ad correctly fitted. If the holes i the cross head, side plates, becket or eyes are elarged by more tha 5% from omial, the part shall be replaced. Items that are out of origial tolerace, bet, deformed or misaliged shall be replaced. Employ soud egieerig practice to evaluate ad decide. Cotact your sales represetative for advice. Wear i the hook, ceter pi, becket or threads of hook ad ut. Play i the bearigs. Spacer bolts, uts ad lych pis. Cracks i welds. The coditio of safety latch ad grease ipples. Wear i holes i side plates ad becket. Wor sheaves. Cotamiatio (dust, dirt, humidity) or corrosio of the roller bearigs. Deformed or missig items or the presece of secodary retetio. If cracks or heavy gouges are apparet, the crae block shall ot be used ad competet opiio sought. Repairs should be udertake by gridig smooth i the surroudig area oly. If it is grooved ad its sectio reduced by more tha 5% from its omial dimesio, the item shall be replaced. NDT of hooks shall follow surface ispectio i accordace with EN class 3. Ay replacemet parts shall be purchased from Ropeblock B.V. All repairs shall be carried out by traied ad competet persoel ad great care shall be take i the re-assembly of the equipmet ad fasteig or securig parts such as grub screws, lych pis, etc. Check ad refit oly correct sizes ad threads. Nyloc uts, should be replaced. Whe properly maitaied ad kept at adequate grease levels, cylidrical roller bearigs are desiged to ru oe millio cycles uder their full dyamic catalogue ratig ad were selected to suit the perceived applicatio. The thrust bearig is statically rated. Depedig o the actual itesity of use ad cumulative load throughout the product s life, fleet agles ad evirometal iflueces, the umber of cycles could be higher or lower. With it, the effective life of the product itself compared to its origial desig life ca be affected. Uder severe (evirometal, usage) coditios, more itese ispectio ad maiteace should be implemeted. As a geeral rule, sheaves, cross heads, bearigs ad bodies should be greased through ipples at these positios at least oce a moth or every 250 hours of service. Lubricate util ew grease is visible. Heavy duty or high performace equipmet should receive 16 17

10 re-lubricatio weekly. For sub-sea equipmet, always remove the air-vet plug before the greasig operatio to prevet jammig. Broze bearigs should be greased every two weeks, or after 8 hours of cotiuous service. Check your product specificatios or drawigs for the locatio o your Ropeblock product. Plai joural sheave bearigs for submersible use must be greased less tha oe week prior to their first use. This is to reactivate the proper fuctioig of the bushig ad combat potetially ageig ad solidified grease. Uless stated otherwise, re-lubricatio, as well as maiteace, should be doe with lithium or lithium/calcium based EP2 grease with a strog adherece to metallic surfaces, excellet protectio agaist corrosio ad resistace to wear ad should be suitable for the required operatig temperatures. Retestig shall be doe accordig to the requiremets i the origial test certificate ad will oly apply to a fully reeved compoet. For spare parts or iformatio, or i the evet of ay problems or doubt, always cotact your sales represetative or Ropeblock B.V. Spare parts list The recommeded spare parts list idicates whe the parts of the crae block should be replaced, or at least ispected ad cleaed. If you do ot have this, it is available o request. High quality ad safe compoets for the global liftig- ad wire rope idustry ropeblock.com 18 19

11 Ropeblock B.V. I Kampestraat 1 I NL-7575 ER Oldezaal I The Netherlads Ropeblock B.V. I PO Box 391 I NL-7570 AJ Oldezaal I The Netherlads E sales@ropeblock.com I T +31 (0) I F +31 (0) I ropeblock.com