Engineering Pty Ltd Overview of Cable Handling Products & Accessories Document ID: GENE-INFO-1512 Issue Date: December 2015 Revision No.: Issue A Revision 9 Engineering Pty., Ltd. P.O. Box 2354, Carlingford, NSW 2118 Fax: 02 9748 6637 Email: sales@gene-eng.com.au Website:
Engineering Pty Ltd Engineering Pty Ltd ACN 065 913 019 P.O. Box 2354, Carlingford NSW, 2118 AUSTRALIA Ph: 1300 782 482 or (61 2) 9748 6636 Fax: (61 2) 9748 6637 Email: sales@gene-eng.com.au Website: Dear Customer, Engineering () is an Original Equipment Manufacturer (OEM) that can provide turnkey services from investigation and concept development through to supply and commissioning of required equipment. can customise a system to suit your needs. We are committed to providing quality services and Australian made products in accordance with the customer s specified requirements, applicable laws, regulations and industry standards. provides an extensive range of equipment, services and accessories for all your cable installation needs. also offers design and consultancy services for most processes that occur on the jobsite. Outlined within this brochure are some of the items that manufactures. If you require further information on any item or about an item not seen in this document please contact a Engineering representative to discuss your needs. Yours Sincerely, The Team at Please note that Engineering s equipment is continuously evolving and improving. Engineering Pty. Ltd. reserves the right to make amendments to the design without notice. The photos shown within this document may not be identical to the system that you are enquiring about. All information is completely transferable unless stated otherwise and an amendment issued. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 2 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Table of Contents 1 Winches 5 1.1 Capstan Winches JE Series 5 1.1.1 Exchangeable Tension Limiting Capstans 6 1.1.2 JE-0005 5 kn Capstan Winch 6 1.1.3 JE-0010/20/30 10/20/30 kn Capstan Winches 7 1.1.4 JE-0050 50 kn Capstan Winch 7 1.2 Capstan Multipurpose Winch KJE Series 9 1.2.1 KJE-0020 20 kn Multipurpose Capstan Winch 10 11 1.3 Bull Winches BULL Series 12 1.3.1 BULL-0005 5 kn Bull Winch 12 1.3.2 BULL-0030 30 kn Bull Winch 13 1.4 Winch Options 14 2 Drumstands 15 2.1 DS Series Drumstands Drums up to 5,000 kg 15 2.2 DDS Series Drumstands Drums up to 8,000 kg 16 2.3 PDS Series Drumstands Drums up to 10,000 kg 17 2.4 HDDS Series Drumstands Drums up to 20,000 kg 18 2.5 Angled Drumstand and Cable Winding Machine 20 2.6 Trailer / Truck Mounted Drumstands 21 2.7 Floor Dispensing Stand 21 3 Cable Pusher Camtrack 22 4 Indexers / Overhead Guides 23 5 Cable Guide Beam 23 6 Split Ducts & Bell Mouth Rollers 25 7 Millipede Roller System 25 8 Box Rollers - 360 Enclosed 27 9 Gantry System Rollers 28 10 Moveable 2.5m Radius Corner Roller System 29 11 Moveable Tri-Cable Roller Stand 30 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 3 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 12 Adjustable Step Roller System 31 13 Cable Installation Accessories 32 14 Lifting Beams 34 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 4 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 1 Winches designs and manufactures winches in accordance with the relevant Australian Standards, NSW Network Utility Standards and Client s requirements. Operator safety, cable integrity and efficiency are the key issues considered in the design of all winches. Winches are designed to complement s drumstand and accessory range of products. The entire winch range can also be fitted with an electronic load cell and digital readout to allow the operator to monitor real time pulling tensions. Also a distance meter can be added to the system to allow Tension versus Distance to be plotted. offers professional services to undertake and analyse installation data and prepare a report of findings. winches can be custom designed to suit your specific winching needs and have electric, petrol, diesel or hydraulic power units. A vast array of accessories can be fitted to the winch to increase its versatility. 1.1 Capstan Winches JE Series capstan winches are tension limiting winches designed for hauling cables (via synthetic rope) from in ground pits and/or in open trenches lined with supporting rollers whilst positively anchored to a vehicle. The winches are fitted with 4 stroke petrol engines as standard but can be fitted with a variety of drive trains. Key features: Load rated frame range to suit application. All frames are protected via a roll cage. Portable self-contained modular units which can be set up and packed up easily and conveniently. The winch is easily moved into position by lifting the opened anchoring arm and wheeling it into any position by one person. Anchored to a vehicle via a tow ball, pintle ring. The winch can be pointed in any available direction about the anchor point for access to tight locations. Vehicle anchor point does not have to be directly in line with the winch. Maximum allowable hauling tension for vehicles offset to winch is dependent on vehicle GVM (gross vehicle mass). Anchoring arm can be folded and secured across to protect the prime mover during transit / storage. The roll cage allows for ease of lifting and also protects the elements from damage during transit or mechanical impact. Roll cage can be opened in front of the capstan to allow rope to be fed in/out of the winch 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 5 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd at any point along the ropes length, having the end of the rope accessible is not required. Capstan and anchoring point arranged in-line to minimise procession. The winches are fitted with a pigtail to allow the hauling rope to be offset away from the winch. This allows the Operator can stand away from line-of-action of the tensioned rope during hauling. Each modular unit if fitted with a clearly visible emergency stop button on top that is visible in a 360 horizontal plane. Exchangeable tension limiting capstans. All capstans are serrated and hard chromed for durability. Designed to haul with synthetic rope e.g. Aquatec, Dyneema or similar. Simple operation. 1.1.1 Exchangeable Tension Limiting Capstans To ensure cables are not over tensioned during the installation process, capstan winches are all fitted with exchangeable, colour coded, NATA pre-calibrated, locked-off, tamper proof, tension limiting modular capstans to limit the maximum line pulling force. Capstans can be changed over in less than three (3) minutes to allow the winch to pull a variety of different cable types and sizes without the risk of over tensioning. Rated maximum pulling force in kn Capstan Serial Number Coloured Background Rated pulling speed Recalibration Date Tension Limiting Capstan Compliance Plate 1.1.2 JE-0005 5 kn Capstan Winch The JE-0005 is a capstan winch with maximum line pull of 5 kn subject to the capstan being used. Pulling speed is limited to 28 m/min. Dimensions of the winch when the anchor arm is closed 1000 mm (L) x 530 mm (W) x 640 mm (H). 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 6 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 1.1.1 JE-0010/20 10/20 kn Capstan Winches The JE-0010/20 frame capstan winches have a maximum line pull of 10 kn and 20 kn respectively, subject to the capstan being used. Pulling speed is limited to 20 m/min on the JE-0010 and 9 m/min on the JE-0020. Dimensions of the winch when the anchor arm is closed 1300 mm (L) x 600 mm (W) x 700 mm (H). 1.1.2 JE-0050 50 kn Capstan Winch The JE-0050 has a 0-50 kn tension loading frame satisfying AS1418. Maximum capacity of 50 kn pulling force on pulse and 40 kn pulling force on continuous hauling. Hydraulically driven via flow adjustable hydraulic power pack and hydraulic lines. Low speed (9 m/min.) / high speed (18 m/min.) selector on winch easily accessible by operator. (Speeds quoted are when unit is new and will deteriorate if not maintained). 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 7 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Bi-directional rotation. Direction controller easily accessible by operator in positions Forward Neutral Reverse as desired. Dimensions of the winch when the anchor arm is closed 1350 mm (L) x 650 mm (W) x 820 mm (H). Dimensions of the hydraulic power pack vary on application. Optional removable load cell and digital readout for constant visual monitoring of tension during operation. Above: Examples of JE-0050 hydraulically driven capstan winch being used on site. Hydraulic power pack Pulling tension digital readout 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 8 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 1.2 Capstan Multipurpose Winch KJE Series s multipurpose capstan winches are modular systems designed for hauling cables (via synthetic rope) in a variety of different locations. The system consists of a main winching unit that is connected to an anchor unit selected to suit the task at hand. The KJE winch series is hydraulically driven via split system to allow for remote and difficult to reach locations. Key features: Portable modular units which can be set up and packed up easily and conveniently. Pulling from any direction (i.e. in-front, behind, above, below) available with minor adjustment of features. Different anchor units available as required, including: o Direct floor, wall or ceiling bolted unit with no adjustment, o Floor, wall or ceiling bolted unit providing low pulling height with 360 rotation on the bolting plane. o Floor, wall or ceiling bolted unit with 360 rotation on the bolting plane and height adjustment as required. o Pole mounted units. o Wheel mounted units that can be connected to a vehicles tow ball or other suitable anchor vehicle. Can be fitted with a load cell for constant visual tension monitoring or data logging as required. Variable speed bi-directional rotation on serrated and hard chromed capstan for durability. Each system is driven by a hydraulic power unit connected to the winch via a moveable controller fitted with a directional control valve (DCV) with emergency stop button that is visible in a 360 horizontal plane. This allows for the winch to be located as far away from the hydraulic power unit as is practicable. The winches are fitted with a pigtail to allow the hauling rope to be offset away from the winch. This allows the Operator can stand away from line-of-action of the tensioned rope during hauling. Designed to haul with synthetic rope e.g. Aquatec, Dyneema or similar. Simple operation. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 9 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 1.2.1 KJE-0020 20 kn Multipurpose Capstan Winch Hydraulically driven via an independent flow adjustable hydraulic power unit with an integral 4 Stroke petrol engine or 11kW electric motor and hydraulic lines. Other power trains available on newly manufactured systems. Maximum pulling speed 10 m/min in accordance with cable manufacturers specification. Other pulling speeds possible for newly manufactured systems. The Multipurpose Winch can be stripped down into several key components so that it can be carried and setup in hard to reach locations (example of winch in a tunnel and on a gantry shown below). Optional removable load cell and digital readout for constant visual monitoring of tension during operation. Above: KJE-20 Multipurpose winch with wheel mounted, vehicular anchored unit. Above Right: Bolted & 360 rotation anchor unit. Right: Bolted, 360 rotation and height adjustable anchor unit. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 10 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Right: KJE-0020 winch anchored to floor of cable tunnel. The hydraulic power unit is located on the surface of the tunnel to keep fuel emissions in an open area. The winch was stripped to its modular components and lowered into the tunnel via a small manhole then reassembled for use. Above: KJE-0020 anchored to a post on a gantry almost 20m above the ground. The winch was stripped to its modular components, lifted onto the gantry in an elevated work platform and reassembled for use. The hydraulic power unit remained on the ground. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 11 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 1.3 Bull Winches BULL Series Bull winches are designed for hauling underground or overhead cables via synthetic rope whilst positively anchored to a vehicle or the ground. The rope passes through dual capstans and onto a tensioned rope winding spool ensuring the Operator does not directly handle the rope during hauling and is physically separated from the loaded pulling components of the winch. This feature makes the Bull winch ideal for high load applications. Bull Winches can be designed and manufactured to suit client s needs. Key features: Range from 5 kn and greater. The Operator does not handle tensioned rope and does not stand in the line-of-action of the tensioned rope and is protected by guarding. Units can be either anchored to the floor (e.g. a substation basement) or mounted on a truck or trailer. Each modular unit if fitted with a clearly visible emergency stop button on top that is visible in a 360 horizontal plane. Variable speed bi-directional rotation on dual serrated and hard chromed capstans. Designed to haul with synthetic rope e.g. Aquatec, Dyneema or similar. Automatic rope winding on removable spool. Winch fitted with manual indexer as standard to guide rope onto spool. Suitable for aerial or underground work. Single Operator simple operation. Bull winch can be lifted and moved as required via a crane or forklift. 1.3.1 BULL-0005 5 kn Bull Winch Left: 5 kn electric variable speed drive Bull Winch fitted with Ø10 mm Spectra rope. This winch was also fitted with a mechanical and electronic brake for use on vertical lifts. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 12 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 1.3.2 BULL-0030 30 kn Bull Winch Hydraulically driven via an independent flow adjustable hydraulic power unit with an integral 4 Stroke petrol engine and hydraulic lines. Other power trains available on newly manufactured systems. Maximum pulling speed 12 m/min in accordance with cable manufacturers specification. Other pulling speeds possible for newly manufactured systems. The 30 kn hydraulic drive Bull Winch pictured below is designed to be stripped down into several key components so that it can be carried and setup in substation basements that have not been constructed with bulk goods access points. Independent support frame to be anchored onto floor or mounted onto truck, trailer etc. NOTE: If mounted onto truck / trailer, client to confirm the structural integrity of the anchoring vehicle to ensure that the winching load can be adequate transferred to the ground. Optional removable load cell and digital readout for constant visual monitoring of tension during operation. Hydraulic power pack 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 13 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Above: Example of a 30 kn Hydraulic drive Bull Winch fitted with Ø16 mm Aquatec rope mounted on to a truck bed. 1.4 Winch Options Customised design to suit specific customer requirements to winch standards and codes as set by statutes and regulations for any industry. Data logger to record actual load, distance and/or velocity during hauling operation, including alarms to warn and/or stop hauling operation. Variable speed drive train. Different calibrated tension limited capstan colour coded for easy identification by operator. Rope winding drum for rolling up rope and preload for reactive tension on capstan. Larger diameter capstan to manufacturers specification (600mm +) available for optic fibre or high voltage cable installation. Jockey pulley complete with frame to guide rope to capstan. Different energy type prime movers available (e.g. for hazardous, underground locations). Larger hauling capacities configured as modular units to be located on or behind a truck or vehicle because of height or space limitations as in capital cities. Variety of different guarding options to suit application. Truck and trailer mount installation. Drive train configured for pipe-cracking used for tunnelling ducts. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 14 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 2 Drumstands designs and manufactures drumstands to complement their winches so that they have the ability to operate together as a system. Customised drumstands can be designed in accordance with relevant Australian and network standards to suit customer s requirements. Drumstands are modular systems allowing them to be flat packed for transport and storage. An additional benefit of the modular system is the ability to augment the drumstand to suit a variety of different drum sizes and types. drumstands are available in a variety of sizes and can be fitted with a drive or brake as required. They can be supplied with a trailer or be truck / trailer mountable at customer s request. Drumstands can function in tandem with another drumstand for unspooling and re-winding cable and when used in combination with a Indexer, a fully automated winding system can be established. Key features: Drums are generally mounted by their bore and locked onto an arbor minimising the effect of out-of-balance and pre-damaged drums. Arbors are hollow providing increased strength and reduced mass. Easy rotation of the arbor on roller bearing assemblies. Drumstand are modular units that form a stable, rigid frame structure. Is a simple mechanical system that can be easily flat packed for transport and/or storage. Ability to be augmented to suit a variety of drum sizes, masses and types. Drum changeover is a quick and straight forward process. Units can be either placed on flat ground or secured on a truck or trailer. Can be fitted with a drive or brake as required. When un-laden are easily moved by forklift or hiab truck. 2.1 DS Series Drumstands Drums up to 5,000 kg DS Series Drumstands were initially designed for the telecommunications industry. They are light duty units with a dry mass of approximately 350-450 kg (depending on final arrangement selected). The DS Series key features: Light duty frames and rollers for handling drums up to 5,000 kg. Drumstands can handle maximum drum diameter of 2,800 mm and maximum widths of 1,200 mm (on Model DS-120) and 1,500 mm (on Model DS-155). Can be fitted with a drive or brake as required. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 15 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Arbor and cones can be handled by one person. Above: Examples of DS-120 drumstand. Photograph on right is fitted with a Band Brake. 2.2 DDS Series Drumstands Drums up to 8,000 kg DDS Series Drumstands are a medium duty framed system fitted with medium duty rollers accommodating drums up to 8,000 kg in mass primarily aimed at power distribution. The units have a dry mass of approximately 450 750 kg (depending on final arrangement selected). Key features: Frames and rollers for handling drums up to 8,000 kg. In its standard setup the Drumstand can handle maximum drum diameter of 2,800 mm and maximum width of 2,000 mm (on Model DDS-20). Larger diameters can be accommodated by inserting packers. Can be fitted with a drive or brake as required. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 16 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 2.3 PDS Series Drumstands Drums up to 10,000 kg PDS Series Drumstands are a heavy duty framed system fitted with heavy duty rollers accommodating drums up to 10,000 kg in mass in its basic arrangement. The units have with a dry mass of approximately 1,100 1,400 kg (depending on final arrangement selected). Key features: Frames and rollers for handling drums up to 10,000 kg. In its standard setup the Drumstand can handle maximum drum diameter of 2,800 mm and maximum widths of 2,000 mm (on Model PDS-20) and 2,500 mm (on Model PDS-25). *Note: When narrow drums are placed on wide systems the safe working load is reduced. For narrower drums, the uprights can be adjusted in to maintain the safe working load. Larger diameters can be accommodated by inserting packers. Can be fitted with a drive or brake as required. This system can be augmented to carry drums up to 20,000 kg. Refer to 2.4 HDDS Series for details. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 17 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 2.4 HDDS Series Drumstands Drums up to 20,000 kg HDDS Series Drumstands are a heavy duty framed system fitted with heavy duty rollers and reaction arms to accommodate drums up to 20,000 kg in mass. The units have with a dry mass of approximately 1,300 1,600 kg (depending on final arrangement selected). Key features: Frames and rollers for handling drums up to 20,000 kg. To ensure the rigidity and stability of drumstands carrying drums of this mass, modular reaction arms and outriggers can be fitted to any / all sides of the drumstand. Drumstand is fitted with an electric variable speed drive as standard that connects via the arbor. The drive is able to fold away from the drumstand to allow for loading / unloading. In its standard setup the Drumstand can handle maximum drum diameter of 3,600 mm and maximum widths of 2,000 mm (Model HDDS-20) and 2,500 mm (on Model HDDS-25). *Note: When narrow drums are placed on wide systems the safe working load is reduced. For narrower drums, the uprights can be adjusted in to maintain the safe working load. Larger diameters can be accommodated by inserting packers. Above: HDDS Drumstand with reaction arm, outriggers and drive holding drum Ø3.2 m x 2.4 m wide x 15,600 kg gross mass. Above: HDDS Drumstand reaction arm with drive holding drum Ø3.0 m x 1.5m wide x 14,500 kg gross mass. Note that upright has been adjusted in to handle a heavy, narrow drum. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 18 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 19 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 2.5 Angled Drumstand and Cable Winding Machine The drumstands can also be manufactured in an Angled Drumstand arrangement. The stands are able to raise and lower drums rolled between the uprights without the need of a forklift or crane. The original need for this stand came about due to a tightly spaced warehouse environment and forms part of a near zero tension winding system for optic fibre. However the drumstand can be used in all normal drumstand applications. Above: The Angled drumstand (left) works in tandem with an indexer and driven DS model drumstand to automatically payout optic fibre from one drum to another. Below: Small drumstand and winding machine used for paying out short runs of small communications cable. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 20 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 2.6 Trailer / Truck Mounted Drumstands Drumstands can be fitted with corner casts to connect to container locks on trailers or trucks. This system allows the drumstand to be quickly and easily loaded and secured to the vehicle and does not require a dedicated vehicle to hold the drumstand. Above: Trailer, Drumstand with brake & Overhead Guide. Can hold drum Ø2.8m x 1.7m wide x 6.0t gross mass. 2.7 Floor Dispensing Stand Floor dispensing stands roll the cable drum from the drum flanges. Example unit shown can carry two drums each being Ø900 x 750 mm wide x 1,000 kg gross mass. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 21 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 3 Cable Pusher Camtrack Cable pushers are used to aid in long or difficult cable installations by acting as an intermediate pulling / pushing device. s cable pusher is a two part system comprising of a hydraulically driven pusher and an independent diesel powered hydraulic power unit. The cable pusher can handle cable of diameter 55-150mm and comfortably push / pull 20kN at a max speed of 12 m/min (higher speeds available on new systems). A load cell is fitted to the system providing a real-time visual display of the loads being exerted. The hydraulic power allows the speed of the cable pusher to be adjusted and can be operated remotely so that the operator can keep a close eye on the installation while still controlling the system. If required it can be adjusted to pull higher loads for cable extraction on client s request. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 22 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 4 Indexers / Overhead Guides Indexers are used support and laterally index cable when dispensing cable from one drum onto another. Indexers can either be motor powered or hand powered and can be designed to index cable from small telecommunications cable up to large power cable. The below example shows a hand indexer with four (4) independent roller units on a common guide rail. 5 Cable Guide Beam s Cable Guide Beam (as shown on the proceeding page) supports cable leaving the drumstand and entering the duct. It allows all personnel to stand in a safe place, clear of the cable during the installation process. It also provides a good opportunity to safely examine the cable as it unrolls from the drum. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 23 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Above: Example showing cable coming off drumstand and into a conduit via a cable guide beam held in position by an excavator. As the cable enters the conduit heavy duty cable hauling lubricant is being placed on the cable sheath. Above: Example of cable being hauled from a substation transformer bay into the substation basement. The cable unspools from the drumstand via a cable guide beam which guides the cable through the transformer bay open point. The cable then feeds onto a 180 gantry millipede roller to bend the cable around and into the conduit. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 24 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 6 Split Ducts & Bell Mouth Rollers manufactures split ducts in a variety of sizes and arrangements to suit client needs. split ducts are machined from a single billet making them strong and durable. Split ducts with permanent rollers. Number of rollers on each assembly to suit client requirements. Left: Split ducts with permanent rollers. Split duct sizes in this photo (above) are Ø90, Ø100, Ø117, Ø125 & Ø150. Split ducts can be manufactured to any size as per client s requirements. Split ducts connected via a bolted connection. Above: The roller assembly houses three (3) rollers (on approximate R1.5m curve) and is attached to the split duct via a bolted connection. Any of a series of different sized split ducts can be used on the same roller assembly depending on the job at hand. This photo shows Ø125, Ø150 & Ø214 mm split ducts that have been used with this roller assembly. Smaller roller assemblies can be manufactured depending on client needs. 7 Millipede Roller System The Millipede Roller System (Millipede) is a flexible roller system that has the capability of being adjusted and secured to suit the radius required for cable installation. The primary use for the Millipede is to facilitate changes in direction of the cable being installed through open pits, trenches and cuttings. However, it can be used wherever cable requires support during the installation process, both indoors and outdoors. A cross-section of the Millipede shows that the cable is supported on three (3) sides with rollers allowing the cable to take its natural path during installation and not putting undue stresses on the cable sheath. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 25 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Rollers support the cable on three sides. The flexibility of the millipede rollers allow them to fold away from the cable after it is installed leaving the cable in position. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 26 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 8 Box Rollers - 360 Enclosed Box rollers contain six (6) rollers arranged to protect the cable on all sides. The roller is supplied with toggles so that it can be split in half to release the cable. Alternatively the halves can be used on their own as straight rollers. The example below shows how the box rollers are set-up with Millipede rollers to produce an S arrangement. Box roller used in combination with the Millipede. Box roller supports cable on all sides. The below examples show the box rollers being used in/under substation basements for hauling cable directly into position in one setup. Rollers are anchored or propped to the floor. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 27 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 9 Gantry System Rollers Fixed Radius and adjustable Millipede segments can be set up on a gantry system to guide cable off drums or act as a pit entry or exit roller. This system allows the cradle supporting the Millipede segment to freely travel laterally along a beam (to minimise side loading on the cable) or be pinned at a fixed position to guide the cable towards a specific location. It is also possible to connect several cradles together if bundling of cables is required. Gantry frames can be manufactured to suit. Segment is able to pivot 20 each way from horizontal. Four rollers provide stable movement along gantry beam. Support guide rollers can be installed here for high load applications. Gantry system c/w adjustable millipede to bend cable around 180 within a transformer bay. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 28 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 10 Moveable 2.5m Radius Corner Roller System Fixed 2.5 metre Radius Millipede segments can be assembled together on a moveable frame to form a 90 Corner Roller System for indoor and outdoor use. For instance, the Corner Roller System can be anchored to the floor of sub-stations for internal installations. This system can support from one (1) to three (3) cables (depending on cable type and size) on individual Millipede chains pitched 400 mm apart. The entire system can be easily moved using a pallet jack or forklift with access from both sides of the frame. Additional flexibility is provided in the ability for each of the three (3) Millipede chains can to pivot independently. Millipede chain can be assembled on any one or all height positions. Pallet jack or forklift access available from both sides. Multiple rollers to distribute load. Each Millipede chain can pivot approx. 30 each way from its rest position. Fixed 2.5m radius produced for a 90 corner. Pallet jack or forklift can be used to move entire assembly. Access available from both sides. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 29 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 11 Moveable Tri-Cable Roller Stand Individual link components of the Adjustable Millipede can be assembled together to form a Tri-Cable Roller Stand. This stand can be either supplied with wheels (to allow moveability) or with legs to anchor to the ground. (As shown in the following drawings). The heights of the rollers on the stand are aligned with the roller heights on the Corner Roller System. Together the stand and Corner Roller System are an effective way of installing cables into buildings and then manoeuvring the cables to their desired location. The stand can also be used to support cables off the ground to aid with cable jointing. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 30 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 12 Adjustable Step Roller System When it is required that support be provided to cables across floors, down steps, down inclines etc. the Adjustable Radius Millipede can be inverted and fitted onto compound mounts. The mounts (as shown in the following drawings) can be pivoted and tilted about their own axis to take up changes in floor level and orientation. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 31 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 13 Cable Installation Accessories supplies accessories and consumables to suit all your cable hauling needs including rollers, ropes & splicing services, swivels, shackles, cable hauling socks, reusable hauling eyes, duct blowers, duct scrubbers, duct sponges, cable mandrels and hauling lubricants. can also design and manufacture any special items needed e.g. pit lid openers and star picket removers. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 32 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd Above (left to right): (1) Pit lid opener & star picket remover. (2) Pull back being used on site anchored by an excavator arm. (3) Special double eyed, double ended stainless steel sock. Above: s single core and three core reusable hauling eyes pull directly from conductor. *NB: Pictures above do not show hauling eye completely sealed and fitted. 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 33 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L
Engineering Pty Ltd 14 Lifting Beams To cover lifting needs in the yard and on site, can design and manufacture lifting / spreader beams and jibs to suit client requirements. Pictured below is a standard 10 tonne WLL lifting beam and a one (1) tonne WLL forklift mounted lifting jib. For further information please contact us on: Phone: 1300 782 482 Fax: +61 2 9748 6637 Email: sales@gene-eng.com.au 2015 Engineering Pty Ltd GENE-INFO-1512 - Page 34 of 34 This document is not to be issued, copied or tabled to a third party without the written permission of Engineering P/L