ANDROMEDA PLAITED & WOVEN STEEL CABLES DIVISION. Conformité Européenne

Size: px

Start display at page:

Download "ANDROMEDA PLAITED & WOVEN STEEL CABLES DIVISION. Conformité Européenne"

Aubrey Henderson
6 years ago
Views:

1 ANDROMEDA PLAITED & WOVEN STEEL CABLES DIVISION Technical File #SF105 Superflex Steel Strops for Lifting Aluminium Billets in European smelters Conformité Européenne 1/11

3 INDEX 1 PRODUCT DESCRIPTION p 4/11 2 RELEVANT STANDARDS p 4/11 3 EQUIVALENT STANDARDS p 4/11 4 GENERAL ARRANGEMENT DRAWING p 4/11 5 LOAD CHART p 5/11 6 RECOMMENDED USAGE p 5/11 7 RISK ASSESSMENT p 6/11 8 PARTS LIST p 6/11 9 MARKINGS AND LABELS p 6/11 10 TESTING, PROOF LOADING & INSPECTION p 7/11 11 QUALITY CONTROL & COMMISSIONING PROCEDURES p 7/11 12 SLING IDENTIFICATION p 7/11 13 PROCEDURAL FLOWCHART p 8/11 14 ATTACHMENT 1 General Arrangement p 9/11 15 ATTACHMENT 2 In-Use p 10/11 16 ATTACHMENT 3 Discard Criteria p 11/11 3/11

4 1. PRODUCT DESCRIPTION Superflex strops are steel slings used where a secure choke grip is required. They are made from Superflex steel cable which is plaited from twelve wire ropes of 2070 MPa grade in a four by three configuration. One application is in the Australian aluminium smelting industry, where Superflex strops have been used for over twenty years. The design has been adapted over that time to optimise performance in this specialised field. The reason for their use in this industry is superior flexibility providing secure grip as well the ability to work at the temperatures present in aluminium billets. Customer feedback indicates that these strops may exceed one thousand lifts before replacement. All components are attached to the sling and there are no loose parts, which enables a fast operation. 2. RELEVANT DIRECTIVES & STANDARDS a) Superflex cable is designed to Australian Standard (AS) Steel Wire Ropes Product Specification for both plaited or braided wire rope or cable. b) Superflex slings are assembled to AS Wire Ropes Slings Product Specification and treated as wire rope slings. c) Superflex slings are subject to the recommendations of AS Wire Rope Slings Care and Use as per conditions of use. d) Termination methods for aluminium ferrules fitted to Superflex slings conform to EN Terminations For Steel Wire Ropes. e) Superflex slings conform to The Supply of Machinery (Safety) Regulations 2008 (SOMSR) as well as Machinery Directive 2006/42/EC Essential Health and Safety Requirements (EHSRs) that both include section Lifting Accessories and their Components Superflex slings have a working coefficient of five (5). f) Superflex slings to BS EN ISO Safety Of Machinery General Principles for Design Risk Assessment and Risk Reduction. 3. EQUIVALENT STANDARDS There are no equivalent relevant standards that relate to this product. 4. GENERAL ARRANGEMENT DRAWING The fittings shown on the Lifting Strop Diagram in Attachment 1 are the upper ferrule and heart thimble, and the tubular thimble at the lower end that enables the easy choking onto the load. The ferrule is made from aluminium and terminates the upper end of the strop. The thimble in the other end is steel and enables the sling to choke down tightly onto the load. Both fittings are integral to the strop assembly and cannot be removed. The strop (sling) is assembled in choke configuration and is ready to fit onto the billet. 4/11

5 5. LOAD CHART The following chart shows the designated load capacities for different sizes of strops: Cable and sling information Cable number Cable size WLL choked (tonnes) Normal length (metres) Dimensions of ferrules and fittings Ferrule dia x length after pressing Pin size for top thimble mm Width of double thimble at top 1 Two mm x Three mm x Three 5 14 mm x Four 0 16 mm x Four 5 18 mm x NOTES: Normal length. This is a default length, customer can specify any length required The standard Factor of Safety used on Superflex Strops is five. 6. RECOMMENDED USAGE These slings are designed to lift aluminium billets within the specific usage guidelines below Slings are to lift loads within their capacity stamped into the ferrule; Maximum operating temperature not to exceed three hundred degrees celsius (300 C); Slings shall not be used in corrosive chemicals without consultation with the manufacturer; Slings must be discarded when their condition triggers one of the Discard Criteria (refer attachment 3). Storage To maximise the working life of Superflex slings they should be stored by hanging up in a dry place. Additional lubricant is not usually necessary. 5/11

6 7. RISK ASSESSMENT The following risks are present when using lifting strops and the associated risk reductions are to be employed: Hazard [Risk strategy]: Elimination, reduction or protective device 1 Overload [Elimination] Do not exceed the WLL stamped in ferrule. 2 Overheating [Elimination] Do not allow sling to lift billets exceeding 300 degc. 3 Overhead lifted object [Elimination] Clear personnel from the lifting and handling area. 4 Worn out or damaged strop [Elimination] Retire the sling when any of the DISCARD CRITERIA have been exceeded. 5 Small wires may eventually be exposed on the surface of the sling 6 Superflex slings are made from over nine hundred individual wires. During the working life of a slings some of these wires may break exposing a wire end on the surface of the sling. This can be a hazard to users if they handle or inspect the slings with bare hands. Also the slings are supplied with wire tails exposed which is required for inspection. [Reduction] To reduce the chance of hand pricks, use gloves when handling Superlfex strops [Reduction and preventative device] The location of the tails are shown in the Lifting Strop Diagram. To reduce the likelihood of injury when handling the slings gloves should be worn. Note: this is a residual risk as the strops are still usable with some broken wires. 8. PARTS LIST All product components are shown on the General Arrangement Drawing and there are no additional separate parts or components. 9. MARKINGS AND LABELS Each sling has the following markings stamped into the upper aluminium ferrule: a) WLL (working load limit) in tonnes (1000kg) b) ANDROMEDA (manufacturer) c) Test number (proof load) d) Date of test. 6/11

7 10. TESTING, PROOF LOADING & INSPECTION Each strop is proof loaded as per the requirements of AS to twice the WLL. The test results are recorded on a Test Certificate which is forwarded to the customer with the invoice for the goods. The test procedure conforms with the requirements of NATA and LEEA and AS requirements. These are verified to comply with ISO/IEC 17025:2005 General Requirements for the Competence of Testing and Calibration Laboratories. NATA accredited registration #16960 NOTE. These slings are proof loaded in a special test bench in a choked configuration. This reproduces twice the actual forces which they will be subject to in service. The strop should be inspected by a competent person for visual damage prior to use. 11. QUALITY CONTROL & COMMISSIONING PROCEDURES Andromeda Industries Pty Ltd (Andromeda) tests (proof loads) and subsequently certifies lifting equipment manufactured. The laboratory is audited by National Association of Testing Authorities, Australia (NATA) and verified to comply with ISO/IEC 17025: 2005 General Requirements for the Competence of Testing and Calibration Laboratories. NATA accreditation number is SLING IDENTIFICATION Andromeda manufactures a range of Superflex Slings and Strops as well as a range of Flat Woven Steel Slings. Since 1995 it has been standard Company procedure to fit a STEEL TAG to all slings as a means of identification. This is usually achieved by use of a small wire rope pressed into the ferrule. However due to a request by the Australian smelter industry in 2010, tags are not fitted to these strops due to the remote possibility of the tag detaching and falling into the casting pit. For this reason no tags are fitted to the strops and the ID stamped into the ferrule instead. 7/11

8 13. PROCEDURAL FLOWCHART The following flowchart identifies relevant SOMSR clauses that have been adhered to, documentation produced and resulting manufacturing actions - colour coded for clarity. PART 1 - Preliminary - Section (2) 2 Machinery definition PART 2 - Application Section 4 (2) (d) components or equipment (including slings and their components) which (i) - (iv) PART 3 - General prohibitions and obligations Section 7 (1) - (3) Compile technical file, draw up EC declaration of conformity and affix CE marking PART 3 - General prohibitions and obligations Section 10 Machinery not referred to in Annex IV then following conformity assessment procedure with internal checks on manufacture prescribed in PART 8 PART 7 A. Technical file for machinery 1(a) only and 2. PART 8 Annex VIII Assessment of conformity Draw up technical file - Ensure manufacturing compliance with technical file SCHEDULE 2 PART 1 - Annexes to the directive (relevant sections / clauses below) Contents of instructions Definitions Mechanical strength Lifting accessories and components Fitness for purpose Lifting accessories Instructions Lifting accessories PART 2 Annex II - Declarations 1. Content 1-5 and 8-10 Compiled TECHNICAL FILE Internal QA process Refer attached RELEVANT STANDARDS and QUALITY CONTROL AND COMMISSIONING PROCEDURES RISK ASSESSMENT Signed EC DECLARATION OF CONFORMITY Available online Identification stamped into ferrule Operating instructions included with strops and online Strop load chart PART 3 Annex III CE marking Affix CE marking Legend SOMSR document reference Documentation produced Manufacturing actions 8/11

9 14. Attachment 1 ALUMINIUM BILLET LIFTING STROP DIAGRAM General Arrangement Only Varies 60mm - 80mm Varies / adjustable eye Varies 32mm dia & 77mm long 68mm dia & 163mm long TOP VIEW Superflex steel cable: varies from ND 10mm ND 18mm Aluminium swaged ferrule termination Steel thimble fixed in eye Adjustable eye (choker) Steel thimble (captured) SIDE VIEW Twin cable Varies depending upon sling length and billet diameter NOTES: 1. Strop assembly supplied complete as shown 2. ND stands for Nominal Diameter 3. 10mm ND cable is Superflex Two-5 cable 4. 18mm ND cable is Superflex Four-5 cable 5. Strop is assembled ready to lift aluminium billets as described 6. Diagram not to scale. 9/11

15. Attachment 2 ALUMINIUM BILLET LIFTING STROP

10 15. Attachment 2 ALUMINIUM BILLET LIFTING STROP DIAGRAM In-use Steel thimble fixed in eye Aluminium swaged ferrule termination Superflex twin steel cable: varies from ND 10mm ND 18mm Steel thimble (captured) Adjustable eye (choker) Aluminium billet FRONT VIEW SIDE VIEW PHOTOGRAPH 10/11

16. Attachment 3 ANDROMEDA INDUSTRIES PTY LTD PLAITED AND WOVEN DIVISIONS QUALITY MANUAL Issue Date Oct 2014 Rev 2 Discard Criteria QMS - 574 Page 9 of 11 DISCARD CRITERIA FOR SUPERFLEX SLINGS AND

11 16. Attachment 3 ANDROMEDA INDUSTRIES PTY LTD PLAITED AND WOVEN DIVISIONS QUALITY MANUAL Issue Date Oct 2014 Rev 2 Discard Criteria QMS Page 9 of 11 DISCARD CRITERIA FOR SUPERFLEX SLINGS AND STROPS The decision to discard any sling is the responsibility of the rigger or other persons using it. However, we have set out some guidelines below that may help with this decision making. We generally recommend that Superflex slings be discarded when they show signs of any of the following: Mechanical damage There are more than the equivalent of one of the small cords (the basic wire ropes comprising the plaited cable) broken at any one location on the sling. This is equivalent to 80 broken wires within one cable diameter along the axis There are more than 150 broken wires distributed over a length equal to 5 cable diameters. There is major scuffing or abrasion on the sides of the ferrules. There are signs of heavy impact loads. This will be indicated by crushing or flattening of the sling, although broken wires may not be visible. It is known to have been severely overloaded (more than three times its WLL) This may not be obvious on visual inspection. Other damage caused by environmental effects Corrosion. Internal corrosion will appear as swelling of the wire cords. This can be caused by immersion in acid baths or similar. External corrosion will appear as discoloration of the zinc coating, usually a flaky white powdery appearance. Effects of high temperatures. At temperatures up to about 300 deg C, the steel wires will not loose tensile strength, but the lubricant (petroleum jelly) and the polypropylene cores in each of the small cords will progressively evaporate. This will cause the sling to feel stiff and dry. At higher temperatures, 400 to 500 deg C the steel will be approaching tempering temperatures, and progressive reductions of tensile strength will result. There will be an obvious flaking off of the zinc coating when this has happened. This will lead to rust formation and general degradation. The overall view is that degradation requiring discard is nearly always obvious. This is one of the main advantages of steel slings, and one of the factors that make them so safe to use over long periods of time. This guide cannot cover all aspects of sling usage, so the main consideration is common sense in usage. DISCARD CRITERIA FOR ANDROMEDA STEEL FLAT WOVEN SLINGS We generally recommend that these slings be discarded when There are more than 2 small cords (the basic wire ropes comprising the woven belt) broken at any one location on the sling. There are more than 100 broken wire filaments distributed over a length of strap equal to its width that is in a square area of the strap. Detrimental corrosion is present There are signs of heavy impact loads It is known to have been severely overloaded It has been heated above 400 deg C Copyright resides in these pages Publication #SF105 Technical File Superflex Steel Strops for Lifting Aluminium Billets in European Smelters Andromeda Industries Pty Ltd Text, design, drawings, artwork by Raymond McLaren and Zelman McLaren June 2017 Moonbi NSW Australia. 11/11

FLAT WOVEN STEEL SLINGS

Andromeda Industries Pty Ltd Brochure & technical sheet # 081-10 FLAT WOVEN STEEL SLINGS The various designs, based on flat woven steel cable Heavy duty slings for general lifting purposes requiring reduced