January 2013
Original operating manual winner inox
PCWI Stainless steel pump chain These PCWI Stainless steel pump chains in welded systems are, because of their construction, suitable for lifting pumps and breathers in the water and sewage sectors. This product meets the requirements of the EU Machinery Directive 2006/42/EC and is only to be used after reading and understanding the operating manual. The operating manual must always be available to the user until the pump chains are discarded. It is updated continuously and is only valid in its latest version, which can be downloaded from the following link www.pewag.com.
Type
WLL
Master link
[kg]
Dimensions AWI
Transition link
[mm]
Dimensions BWI
Chain type
[mm]
[mm]
SL* Number of links
Segment length L* [mm]
Length of master links/ end links
Weight SL*
PCWI 4
320
AWI 8
8x60x35
BWI 5
5x26x13
WOX 4x16
55
992
60
0,42
PCWI 5
500
AWI 10
10x80x50
BWI 7
7x36x16
WOX 5x16
53
1000
80
0,68
PCWI 6
750
AWI 13
13x110x60
BWI 7
7x36x16
WOX 6x18
45
992
110
1,05
PCWI 7
1000
AWI 13
13x110x60
BWI 9
9x44x20
WOX 7x21
37
975
110
1,33
PCWI 8
1250
AWI 16
17x110x60
BWI 10
10x44x20
WOX 8x24
33
999
110
1,83
PCWI 10
2000
AWI 18
19x135x75
BWI 13
13x54x25
WOX 10x30
25
993
135
2,91
PCWI 13
3200
AWI 22
23x160x90
BWI 16
17x70x34
WOX 13x39
17
963
160
4,84
PCWI 16
5000
AWI 26
27x180x100
BWI 20
20x85x40
WOX 16x48
13
974
180
7,38
Static test coefficient = 2,5; Safety factor = 4 *SL consisting of 1AWI/2BWI/WOX/links in standard length of approx.1000 mm.
Conditions of use Use purposes: these pump chains are designed for lifting pumps and breathers in the water and sewage sectors. Load: the load must only act in the longitudinal direction with a maximum working load limit specified in the table above or on the identification tag. The chain links must be aligned in the direction of the load. Admissible operating temperature: -40°C – 400°C. Impacts: the load must be applied without any impact or shock loading. Edge load: must be avoided. In case of possible edge load, the load factors described in the table below must be taken into consideration • PCWI Stainless steel pump chains must be only used by competent personnel. • PCWI Stainless steel pump chains must be checked before each use for visible signs of damage.
Original operating manual for pewag winner inox PCWI Stainless steel pump chain
1
January 2013
Restrictions of use
Inspection before each use
Under certain conditions, the use of PCWI Stainless steel pump chains is restricted (see table below). The table below describes certain loads with their corresponding reduction factors. Safe working load values can be calculated by multiplying the working load limit with the reduction factor defined in the table. If more restrictions of use can be applicable during a lifting process, all corresponding reduction factors must be taken into account. The use with chemical substances (e.g. acids, alkalis, as well as the fumes released by these substances), food, cosmetics or pharmaceutical products is only allowed under certain conditions and each individual case requires the prior approval of pewag – especially with food, cosmetic and pharmaceutical products. Surface coating procedures are also only to be carried out after consulting with pewag.
the safe working condition of the pump chain must be visually checked before each use. During the inspection, pay attention to visible signs of damage. In the case of doubt or when one or more withdrawal criteria are met (see below), the pump chain must be taken out service and inspected by a competent person.
Reduction factors Temperature*
-40°C to 400°C
above 400°C to 600°C
above 600°C to 700°C
Reduction factor
1
0,75
0,5
Impact loading
slight impacts
medium impacts
strong impacts
created, for example, when accelerating during the lifting or lowering movement
created, for example, when the chain is loaded but it slips while adjusting to the shape of the load
created, for example, when the load falls onto an unloaded chain
Reduction factor
1
0,7
nicht zulässig
Edge load
R = larger than 2x chain-Ø
R = larger than chain-Ø
R = chain Ø or smaller
Reduction factor
1
0,7
0,5
* The use at temperatures below -40°C and above 700°C is forbidden!
All instructions given in this operating manual assume the absence of extremely dangerous conditions. Such extremely dangerous conditions include offshore activities, lifting of people and potentially dangerous loads, such as liquid metals or nuclear material. In these cases, the admissibility and extent of the risks are to be assessed by pewag.
Inspection before the first use
Inspection after extraordinary events Extraordinary events – e.g. accidents, overheating, overloading, collision, influences of acids or chemical substances – affect the safe working condition of the pump chain. In these cases, the chain must immediately be taken out of service and inspected by a qualified person.
before the first use, following criteria must be applied: • the delivered pump chain corresponds to the ordered chain; • test certificate, certificate of compliance and declaration of conformity are provided; • all informations given on the pump chain (marking, working load limit) coincide with the information given by the test certificate and the certificate of compliance; • if necessary, all the details about the pump chain must be given to a chain file; • this operating manual has to be always available to the user and must be read and understood by the corresponding personnel.
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Reasonably foreseeable misuse PCWI Stainless steel pump chains must not be used as two-leg chain slings. They are also not suitable for lifting people. PCWI stainless steel pump chains must not be used in explosionprotected areas or under other circumstances than those described in Conditions of use and Restrictions of use. Do not subject PCWI Stainless steel pump chains to heat, welding or drilling processes.
Original operating manual for pewag winner inox PCWI Stainless steel pump chain
January 2013
Assembly instructions The assembly of the PCWI Stainless steel pump chain with the pump or the breather must only be executed by a qualified person. The connecting component - e.g. shackle – must be suitable for lifting loads.
Safety precautions to be taken by the user Gloves must be worn during the whole process. When conditions with restrictions of use take place, working load limit values must be reduced by the above reduction factors in order to assure the required security level.
Residual risks Overloading because of exceeding the working load limit or not reducing the working load limit when influences under severe conditions such as temperature, edge load or impact occur, can lead to failure on the pump chain. Other factors are inappropriate use with chemical substances, food, cosmetic or pharmaceutical products, strong vibrations with heavy load, transverse loading, and the use of uninspected, knotted or twisted pump chains. In such cases, the load could fall.
Withdrawal: • Broken parts, deformation, notches, cracks of all types. • Signs of heat. • In the case of doubts about the safety and correct functioning of the chain. • Missing or illegible identification tag. • Unrecognizable identification marking of the components. • Wear: the mean diameter dm is permitted to be 90% of the nominal size dn. Dm is determined as the mean value of the diameters d1 and d2 measured at right angles on the corresponding cross section (see figure). The chain must be discarded if
dm = d1 + d2 ≤ 0,9 dn 2 • Elongation of the chain: the chain must be discarded if the inside pitch of the link t>1,05tn, whereas tn is the nominal pitch from the chain link (see figure). • If wear or chemical material removal (e.g. pitting) occurs and the tolerable change of measure is transgressed (see following table). Maximal zulässige Maßänderung bezogen auf das Nennmaß:
Designation
Measure
Maximal permitted change
WOX Chain
dn
-10%
t
+5%
d
-10%
t
+10%
Links AWI, BWI
How to act in case of accidents or damages After deformation of the chain because of overloading or other extraordinary events, take the lifting assembly out of service for inspection or repair by a qualified person.
Maintenance, Inspections and Repairs Maintenance: PCWI Stainless steel pump chains shall be cleaned regularly. Inspections: PCWI Stainless steel pump chains need to be inspected in a clean condition – they must be free of oil and dirt. Painting is only permissible if an evaluation of the chain condition is possible. When cleaning, do not subject PCWI Stainless steel pump chains to processes which cause material embrittlement, overheating (e.g. flame cleaning), material abrasion (e.g. sand blasting), etc. Surface cracks or other defects must not be covered. PCWI Stainless steel pump chains must be checked before each use for visible signs of damage. Once a year an inspection must be carried out by a competent person. However, this period must be shortened up in view of the conditions of use – e.g. because of frequent use with maximum working load limit or under conditions with restrictions of use, excessive wear or corrosion. It is recommended to subject PCWI Stainless steel pump chains every two years to a crack test. There are different ways of crack testing: subjecting the pump chain to a load test with 1.5 times the working load limit, followed by a visual inspection or a dye-penetration method.
Repair: PCWI Stainless steel pump chains are only to be repaired by a qualified person. Welding, heat treatments, as well as the straightening of bent links are not permitted. Inspections and repairs have to be documented and the corresponding reports have to be retained during the service life of the pump chain.
Storage pewag winner inox PCWI Stainless steel pump chains shall be stored cleaned and dried. While stored, they must not be exposed to chemical, mechanical or thermal influences.
Original operating manual for pewag winner inox PCWI Stainless steel pump chain
3
January 2013
Declaration of conformity In accordance with the requirements established in Annex II, part A, of the EU Machinery Directive 2006/42/EG and in the Machinery Safety Regulations (MSV) 2010 for components in lifting accessories: The person authorised to compile the technical documentation in accordance with Annex VII part A: DI Bernhard Oswald; Mariazeller Straße 143; A-8605 Kapfenberg This is to inform you that the product mentioned in this original operating manual complies with all the essential requirements of the EU Machinery Directive 2006/42/EC. This declaration has no legal effect if any changes to the product are introduced without pewag’s approval. Following Norms are applied and fulfilled: EN 818 Part 4 modified. This product must not be put into service until this operating manual has been read and understood. Kapfenberg, 2010-01-25 pewag austria GmbH Joachim Haidacher
pewag austria GmbH A-8020 Graz, Bahnhofgürtel 59, Phone: +43 316 6070-0, Fax: +43 316 6070-100 office@pewag.com, www.pewag.com
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Original operating manual for pewag winner inox PCWI Stainless steel pump chain
Technical changes and misprints are subject to alteration.