en ZARGES Service Lift with winch and gripper from … · X Open the gripper manually or through a...

en ZARGES Service Lift with winch and gripper from Tractel GreifzugDaily inspection plan and record

N° TP-TG-EN

Imprint

ZARGES GmbHZargesstraße 782362 Weilheim, Germany

Tel.: +49 881 / 687-100Fax: +49 881 / 687-500E-mail: [email protected]: www.zarges.de

March 2016

3

Table of contents1 About these instructions ......................................................................................................................................41.1 Symbols used .....................................................................................................................................................................................................41.2 Structure of warnings ......................................................................................................................................................................................4

2 Safety ...........................................................................................................................................................................42.1 Personnel .............................................................................................................................................................................................................5

3 Information on the inspection record .............................................................................................................5

4 Procedure for triggering the gripper................................................................................................................6

5 Fitting seals ...............................................................................................................................................................65.1 Seal on the winch..............................................................................................................................................................................................65.2 Control box sealing ..........................................................................................................................................................................................6

6 Attaching inspection stickers ..............................................................................................................................7

7 General inspection steps ......................................................................................................................................77.1 Checking sealing ...............................................................................................................................................................................................77.2 Inspecting inspection stickers ......................................................................................................................................................................7

8 Inspection steps for components ......................................................................................................................88.1 Equipment overview .......................................................................................................................................................................................88.2 Inspecting the gripper for functionality ...................................................................................................................................................88.3 Checking the brakes of the winch and centrifugal force weight of the gripper ........................................................................9

9 What to do in case of emergency lowering ................................................................................................ 11

4

About these instructions

1 About these instructionsThis inspection plan is used for the regular checking of the service lift and is only valid in conjunction with the original operating instructions. It must be included with every service lift. Service lifts with Tractel Greifzug components (original operating instructions as old as or older than the revision from 1 July, 2015) must be provided with this inspection plan and seals immediately and before any further use. The inspection steps listed in this inspection plan must be carried out and recorded at least once for each day the service lift is used. The inspection must always be carried out before the first use of the service lift.

The operating instructions and this inspection plan must be followed precisely. Service records must be filled out without gaps, completely and carefully. Defects must be reported to the operator and the manufacturer of the service lift immediately. The service information (TBA6000) included with the operating instructions can be used for this purpose.

Each emergency lowering (see original operating instructions for definition) must be documented specifically in the inspection plan and reported to the operator and the manufacturer of the service lift. The service information included with the operating instructions can be used for this purpose. The service lift must be decommissioned until it has been examined by qualified and trained personnel.

The inspection stickers supplied with this document must be provided with the date of the initial commissioning, the date of the most recent servicing by qualified and trained personnel and the date of the last inspection by an expert, all in accordance with the documentation. The inspection stickers must be filled out at the intended location at the service lift before the lift is operated.

The seals (item number 61875) supplied with this document must be fitted by a person qualified by the operator and trained by ZARGES in accordance with the instructions in this inspection plan.

1.1 Symbols usedSymbol Meaning

"Important information" Information on preventing property damage, fostering understanding or optimising work flows

X Symbol for an action.

X If there are multiple steps with actions, follow them in the order presented.

1.2 Structure of warningsSignal wordType, source and consequence of the danger

f Measures for preventing the danger.

2 Safety

If the gripper and winch are not inspected properly, there is a risk of serious injury or death due to falling!The gripper and winch of the service lift must be fully functional. To ascertain their functionality, all the inspection steps listed in this inspection plan must be carried out and recorded on a daily basis before the first use of the service lift. If one of the inspections fails, the service lift must be decommissioned immediately. A corresponding sign must be attached at the main switch of the service lift.

Inspection steps to be carried out: à Chapter 7 “General inspection steps” on Page 7 à Chapter 8 “Inspection steps for components” on Page 8

If the gripper and winch are not serviced properly, there is a risk of serious injury or death due to falling!

5

Information on the inspection record

Contrary to any deviating inspection intervals of the manufacturer's operating instructions for the winch and gripper, they must be serviced and inspected annually by a qualified person who has been trained in this activity in accordance with the instructions from the manufacturer. Should service not have been performed for more than a year, it must be carried out immediately in accordance with the specifications of the manufacturer before the service lift may be used. During annual service, the drive and pressure rollers of the gripper (Tractel Greifzug) are also to be replaced with factory-new rollers impressed with the date of manufacture.Winches and grippers must undergo a general overhaul by the manufacturer or a specialist company authorised by the manufacturer in accordance with the manufacturer's specifications, however no later than after 10 years or 250 operating hours (whichever comes first).Should anything unusual be observed with regard to winches or grippers (e.g. strange noises, deformations etc.), the service lift must be decommissioned immediately and without further movement. The components must be examined immediately by qualified personnel who are trained in these activities from the component manufac-turer.

2.1 PersonnelThe inspection steps of this inspection plan may only be carried out by a qualified service lift operator and in the presence of another qualified person (for further information, see original operating instructions).The persons at the wind power station (WPS) must be able to make an emergency call at any time.The service, maintenance and initial commissioning of the service lift and other work on the service lift may only be carried out by personnel who have been trained by ZARGES and qualified for these activities. Work on winches and grippers may only be carried out by personnel who have received the relevant training by the manufacturer.Service and maintenance of the winch and gripper may only be carried out by the component manufacturer themselves or by trained personnel authorised by the component manufacturer. A general overhaul may only be carried out by the component manufacturer themselves or by personnel author-ised by them (see original operating instructions and manufacturer's operating instructions for the winch and gripper).A ZARGES service lift may only be operated by personnel who have been instructed in proper operation and be-haviour in case of emergency as part of their operator training. The participation of qualified and trained opera-tors in such training must be confirmed with a certificate. The certificate must be renewed every 2 years.

3 Information on the inspection recordThe results of the inspection steps must be documented in the inspection record. The inspection record is located in the Appendix of this document.

X Enter the WPS number, service lift serial number, gripper type and winch type in the intended field of the inspection record.

X Enter the date of the inspection. X Tick the "Seals" and "Stickers" fields to confirm that they have been inspected and tick all inspections under

"Gripper" and "Winch" to confirm that they have been carried out. X If an inspection has failed and a component is not functional, tick the "Out of service" field. X If all inspections have been completed successfully and all components are functional, tick the "Ready for

operation" field. X Tick the "Catch" field if a catch has occurred. X Tick the "Emergency lowering" field if emergency lowering has occurred. X Enter the company and name of the inspector in block letters. X Enter the signature of the inspector. X Enter any special items of note in the "Notes" field.

6

Procedure for triggering the gripper

4 Procedure for triggering the gripperThe gripper may be triggered, in particular with higher towers (hub height over 80 m), if: à Lift movement due to the elasticity of the suspension cable while starting or stopping (stop-and-go move-

ment) is incorrectly detected at the safety cable as lift movement at an excessive speed.In this case, the gripper can be recommissioned. For this purpose:

X Open the gripper manually or through a short upward movement using the hand crank and the brake venting lever.

X Document the catch in the inspection plan.If an upward movement is not possible (e.g. due to suspension device breakage, lack of traction, damaged sus-pension cable or similar malfunction causes) or if the gripper is triggered again:

X Send the gripper to the manufacturer to be examined in accordance with the specifications of the manufactur-er (see original operating instructions of the service lift and gripper).

X Do not commission the service lift again until the cause of the fault has been verifiably eliminated. X Tick the "Catch" field in the inspection plan, document it separately and inform the operator and manufacturer

of the service lift.

5 Fitting seals

5.1 Seal on the winch X Clean the area around the opening for overload

setting with alcohol (or similar). X Fit the seal over the opening for overload setting.

5.2 Control box sealing X Clean the area with alcohol (or similar). X Fit the seal on the control box.

7

Attaching inspection stickers

6 Attaching inspection stickers

ZARGES service lifts must be provided with inspection stickers the next time annual service is carried out, but no later than April 2017.

X Have the inspection stickers filled out according to the available documen-tation by an expert the first time they are attached: à Date of initial commissioning à Date of last servicing à Date of last inspection à Date of next servicing (faces upward)

X Attach the inspection stickers to the inspection sticker strip (item number 35104380000) in the intended location (see figure).

X Attach the inspection sticker strip in the intended location next to the type plate in the service lift.

7 General inspection steps

7.1 Checking sealingBefore each use by the operating personnel, ensure that:

X The seal over the opening for overload setting is in place and not broken (see Chapter 5).

X The seal at the control box is in place and not broken (see Chap-ter 5).

If the seal is not in place or is broken: X Decommission the service lift immediately. X Attach a corresponding sign at the main switch of the service lift. X Have the respective component inspected and repaired by the manufacturer or a qualified person who has

been trained in this task.

The inspections and results must be documented in the inspection record immediately after the inspection. X Tick the "Seals" field after the inspection has been carried out. X If the inspection failed, tick the "Out of service" field. X Enter any special items of note in the "Notes" field.

7.2 Inspecting inspection stickers

X Before each use by the operating personnel, ensure that: à The date of the initial commissioning is located on the sticker. à The date of the next servicing is located on the sticker and has not

expired. X Observe national regulations and, if necessary, ensure that the date of

the inspection by the expert is located on the sticker and has not expired.

In case of faults, malfunctions, damage, missing or expired inspection stick-ers or other defects:

X Decommission the service lift immediately. X Attach a corresponding sign at the main switch of the service lift. X Get caught up on expired inspection by an expert immediately. X Record the issue separately, report it to the manufacturer and operator

and have it examined by a qualified person who has been trained by ZARGES.

The inspections and results must be documented in the inspection record immediately after the inspection. X Tick the "Stickers" field after the inspection has been carried out. X If the inspection failed, tick the "Out of service" field. X Enter any special items of note in the "Notes" field.

8

Inspection steps for components

8 Inspection steps for components

8.1 Equipment overview

1 Hand lever2 EMERGENCY STOP button3 Viewing window4 Centrifugal force weight5 Plug6 Gripper7 Winch8 Opening for brake venting9 Opening for overload setting

8.2 Inspecting the gripper for functionalityBefore each use of the service lift, ensure that the gripper (6) is triggered as prescribed by clamping the safety cable. For this purpose, carry out the following steps in order:

X Visually inspect to ensure that the gripper (6) is properly secured to the service lift.

X Set the hand lever (1) to position A. à The gripper (6) is open.

X Press the EMERGENCY STOP button (2). X Ensure that the hand lever (1) is set to position B. X Ensure that the safety cable cannot be pulled

upward. à The gripper (6) is closed.

X Open the brake of the winch using the brake venting lever (10) until the full weight of the lift is suspended in the gripper.

The lift must be held by the gripper. X Move upward with the hand wheel (11) until the

gripper can be opened.��

��

X Set the hand lever (1) to position A. à The gripper (6) is open.

X Pull the safety cable upward with a jerk. X Ensure that the hand lever (1) is set to position B. X Ensure that the safety cable cannot be pulled

upward. à The gripper (6) is closed.

1

23

5

4

6 7

98

A B

B

A B

B

9


The gripper (6) is not closing, and the safety cable can be pulled up: X Decommission the service lift immediately. X Attach a corresponding sign at the main switch of the service lift. X Inform the operator and manufacturer of the service lift. X Have the gripper (6) inspected and repaired by authorised and qualified specialist personnel.

The inspections and results must be documented in the inspection record immediately after the inspection. X Tick the "Trigger" field after the inspection has been carried out. X If the inspection failed, tick the "Out of service" field. X Enter any special items of note in the "Notes" field.

8.3 Checking the brakes of the winch and centrifugal force weight of the gripper

DANGER!Serious injury or death due to falling as a result of a non-functioning brake.

X Press the EMERGENCY STOP button. X Disconnect the power supply to the winch via the main switch. X Decommission the service lift immediately. X Attach a corresponding sign at the main switch of the service lift. X Inform the operator and manufacturer of the service lift. X Have the winch and gripper examined and repaired by authorised and qualified specialist personnel.

DANGER!Risk of serious injury from falling objects.

X Do not remain under suspended loads. X Cordon off the area of danger.

Before each use of the service lift, ensure that à The centrifugal force weight (4) rotates during movement of the lift à The brake grips and holds the service lift on the suspension cable

For this purpose, carry out the following steps in order:

X Visually inspect to ensure that the winch (7) is properly secured to the service lift.

X Ensure that the plug (5) is positioned correctly at the motor.

X Set the hand lever (1) to position A. à The gripper (6) is open. X Move the service lift up approx. 2 metres. X Look in the viewing window to ensure that the centrifu-

gal force weight (4) rotates during lift movement. à In general, the centrifugal force weight (4) must be

observed through the provided viewing window during each movement of the lift.

2.

1.

1.

10


The centrifugal force weight (4) is not turning: X Stop lift movement immediately. X Press the EMERGENCY STOP button (2) immediately.

à The hand lever (1) jumps from position A to position B.

à The gripper (6) closes, and lift movement stops. X Disconnect the power supply to the winch (7) via the

main switch. X Decommission the service lift immediately. X Attach a corresponding sign at the main switch of the

service lift. X Inform the operator and manufacturer of the service lift. X Have the gripper (6) inspected and repaired by

authorised and qualified specialist personnel.

X Stop lift movement. à The brake grips and holds the service lift on the sus-

pension cable. X Move the service lift downward. X Stop lift movement.

à The brake grips and holds the service lift on the sus-pension cable.

The brake does not grip and does not hold the service lift on the suspension cable:

X Press the EMERGENCY STOP button (2) immediately. à The hand lever (1) jumps from position A to position

B. à The gripper (6) closes, and lift movement stops.

X Disconnect the power supply to the winch (7) via the main switch.

X Decommission the service lift immediately. X Attach a corresponding sign at the main switch of the

service lift. X Inform the operator and manufacturer of the service lift. X Have the winch (7) inspected and repaired by authorised

and qualified specialist personnel.

The inspections and results must be documented in the inspection record immediately after the inspection. X Tick the "Drive," "Motor brake" and "Centrifugal force weight" fields after the inspection has been carried out. X If the inspection failed, tick the "Out of service" field. X If all inspections have been completed successfully, tick the "Ready for operation" field. X Enter any special items of note in the "Notes" field.

A

B

2.

1.

A

B

11

What to do in case of emergency lowering

9 What to do in case of emergency lowering

DANGERRisk of falling!The winch may only be lowered manually in an emergency.

X Do not carry out emergency lowering with an overload. X After each emergency lowering, have the winch checked by Tractel Greifzug GmbH or a hoist

service centre authorized by Tractel Greifzug GmbH. X Replace damaged or worn parts.

Exceptions: à Emergency lowering from the emergency limit switch. à Emergency lowering over a distance of less than 20 cm.

WARNiNGRisk of crushing.Emergency lowering is impermissible as a substitute for electrical lowering and leads to increased wear on the centrifugal brake and potential failure of the brake.

X Observe the path of movement carefully, as the electrical safety functions are not active. X It is impermissible for anyone to remain under the service lift in the area of danger or on the lad-

der.

à Emergency lowering must be interrupted for at least 5 minutes after a downward movement of approx. 30 m.

X Each movement with emergency lowering must be documented in the inspection record! X Once emergency lowering has been carried out, tick the "Emergency lowering" field and the "Out of service"

field. X Send the winch to be checked by the manufacturer. X Inform the operator and manufacturer of the service lift.

Daily inspection recordWPS No.

Service lift serial number

Gripper type

Winch type

Date

Inspection Event

Out of service

Company/name of the inspector (block letters)

Signature of inspector Notes

Seals Stickers

Gripper WinchReady for

opera-tion

Emer-gency

loweringCatch

TriggerCentrifugal

force weight

Drive Motor brake

ZARGES GmbHZargesstraße 782362 Weilheim, Germany

Tel.: +49 881 / 687-100Fax: +49 881 / 687-500E-mail: [email protected]: www.zarges.de

March 2016

en ZARGES Service Lift with winch and gripper from … · X Open the gripper manually or through a...

Documents

Transcript of en ZARGES Service Lift with winch and gripper from … · X Open the gripper manually or through a...