Surface Mining. World Class Products

Transcription

1 Surface Mining World Class Products

2 Demanding application? 2 Table of Contents WireCo WorldGroup Rope Selection Mining Ropes TUF-MAX XL TUF-MAX TUX-MAX C/R PowerMax PFV PowerMax MD PowerMax Strand PFV Strand Flex PFV Boom Pendants TUF-STRAND Structural Strand 15 Ara-Boom Synthetic Synthetics TufTow TufStrop Useful Tools Rope Specification Sheets Wire ropes play a vital role in a mine s production. WireCo WorldGroup is a world leader in wire and synthetic rope manufacturing. From hoisting to hauling, you can rely on our ropes to reliably meet the demands of your operation. Drawing on more than 75 years of global mining experience, we ve developed specialized products that overcome obstacles and lengthen service life. Combined with our unmatched field expertise and consultative approach, it s everything you need to maximize performance and value. Proven, quality products Global, high-volume capacity Comprehensive lineup Fast turnaround Technical mining expertise We ve got it covered. Through our Union and Phillystran brands, WireCo WorldGroup is committed to providing the broadest range of wire and synthetic ropes for all of your surface mining applications. Our comprehensive line of surface mining ropes from hoist ropes and draglines to pendants and engineered solutions ensures convenient sourcing for all your surface mining needs, including specialized applications. Union offers ropes for shovels and draglines that provide long service life and low cost of ownership backed by industryleading support and training. Special wire chemistry and superior plastic impregnation to maximize service life Tested, proven performance worldwide Phillystran offers custom stranded solutions utilizing the most advanced synthetic fibers. Expertise in engineering and materials selection to offer unique functionality Specializing in high strength to weight constructions to deliver long service life

3 Turn to a global leader. Wired for quality. From raw materials to training and testing, at WireCo WorldGroup we take quality as seriously as you do. With an ISO 9001 registered quality system for all plants producing mining products, you can have assurance in every product you order. Also, we produce ropes in accordance with many different national and international quality and safety standards. All of our manufacturing sites utilize the same corporate quality system, ensuring that the same quality processes are followed regardless of manufacturing location. By committing to quality in every product, we are able to provide consistently high performance that delivers greater value. For a complete list of our quality certifications, go to Service that adds value. Our representatives are there for more than taking orders. They are available to help you with product selection as well as proper installation, use and maintenance. Backed by an experienced engineering team, they can facilitate custom designs and provide training and information to further enhance performance and value 24 hours a day, 7 days a week. Just like your operation. Expertise. Experience. Exceptional products. That s the WireCo WorldGroup advantage helping customers find and apply the right solutions to minimize cost of ownership and maximize value. 3

4 The right rope for the job. 4 While strength, resistance to metal loss and deformation and fatigue resistance are typically the main considerations in selecting a wire rope for surface mining equipment, not all characteristics have equal importance for every application. WireCo WorldGroup offers a broad selection to help you perfectly match the requirements of your application. Case Study Commitment to Continuous Innovation To meet the challenging demands for shovel hoist ropes, our engineering experts took the mining rope standard TUF MAX and enhanced it by creating TUF MAX XL. This high performing rope delivers up to 40 percent more rope service life over other shovel ropes even under the demanding rigors of the mining environment. Shovels Hoist Ropes Require: Strength and fatigue resistance Solution: TUF MAX and TUF MAX XL 8-strand construction Designed for demanding digging conditions with proven performance Dual coated core prevents internal nicking Coated to help prevent drum corrugation Leading shovel hoist ropes Crowd and Retract Ropes Require: Minimal stretch characteristics Solution: TUF-MAX C/R Specifically designed to minimize stretch Tested and proven to provide the best performance Trip Ropes Require: Resistance to wear and fatigue Solution: 7-Flex PFV, 6-Strand PFV, 6-Strand PFV polymer distributes radial stresses, decreases abrasive wear on the rope and protects the rope from external damage caused by debris Minimal stretch characteristics Draglines Hoist Ropes Require: Strength, good resistance to both metal fatigue and abrasive wear Solution: PowerMax 8-strand construction Plastic impregnated/coated core

5 Rope Selection Solution: PowerMax MD Plastic impregnated independent wire rope core Compacted outer strands for greater abrasion and fatigue resistance Solution: 6-Strand PFV 6-strand construction Plastic impregnated/coated core distributes internal stresses better Solution: 6-Strand 6-strand construction Engineered to withstand abrasion and fatigue Drag Ropes Draglines with straight-through fairlead systems Require: Maximum resistance to metal loss and deformation Solution: PowerMax 8-strand construction Better service life Solution: 6-Strand Proven performance Fatigue and abrasion resistant Draglines with reverse bend fairlead systems Require: Balance of both metal loss and metal fatigue resistance Solution: PowerMax MD Designed specifically for reverse bend fairlead systems Proven to provide the best service life Dump Ropes Require: Good resistance to bending fatigue while also maintaining high resistance to abrasion Solution: PowerMax 8-strand construction Compacted outer strands and proprietary core design minimize rope fatigue due to constant cycling over dump sheaves Boom Pendants Require: Ability to withstand the harsh conditions in mining applications Solution: TUF-STRAND Structural Strand Manufactured to the customer s exact specifications Features Unit Lay Core Design that provides optimum wire support by maximizing the surface area between wireto-wire contact Solution: Ara-Boom Synthetic For mid-boom suspension applications Synthetic rope is lighter, easier to handle during installation Can be tensioned to the same loads as pendants being replaced Comparing True Costs At WireCo WorldGroup, we know it takes more than the right size wire ropes to operate your mining equipment. It also takes the right knowledge. In addition to providing the industry s best ropes, our experts are there to help you every step of the way with the support and training you need to get top performance and service life from your investment, minimizing downtime and lowering the overall cost of ownership. Rope maintenance and operation Identifying rope damage Proper lubrication Installation tips Digging methods 5

6 Mining Ropes TUF-MAX XL Application: Hoist Ropes Designed for the most severe digging conditions Highest strength of the Tuf-Max family Dual coated core prevents internal nicking Proprietary 8-strand construction Coated to help prevent drum corrugation (in) TUF-MAX XL Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 1 3/ / / / / / / / / (mm) Weight (kg/m) (kn) Why inspect? Of course you need to inspect ropes to determine when they meet the removal criteria. But unusual wear patterns in your ropes also can offer valuable clues as to how your machinery is working, allowing you to correct problems while they re still minor

7 Mining Ropes (in) TUF-MAX Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 1 1/ / / / TUF-MAX Applications: Hoist Ropes More fatigue resistant than standard ropes PFV polymer cushions the strands and distributes internal stresses Proprietary 8-strand construction Coated to help prevent drum corrugation Dual coated core prevents internal nicking 2 1/ / / / / / / (mm) Weight (kg/m) (kn) Leading the way in shovel hoist ropes Utilizing WireCo WorldGroup s innovative engineering and optimized design process, the Tuf-Max family has become the mining world s most-specified hoist rope. 7

8 Mining Ropes TUF-MAX C/R Applications: Crowd Ropes, Retract Ropes Minimal stretch characteristics Proprietary 8-strand construction Compacted strand core reduces internal abrasion and strand-to-strand nicking Specifically manufactured to each shovel requirement End attachments and pulling loops are manufactured to required dimensions for overall fit and ease of installation (in) TUF-MAX C/R Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 1 1/ / / / / / / / / / / Tip Minimize Dampening on Drums When a slack rope is quickly tensioned, vibration is created in the rope that is dampened where the rope contacts the sheaves or drums, leading to fatigue. To minimize fatigue, operators should: Start the cut slowly and smoothly Load the rope gradually while reducing slack

9 Mining Ropes (in) PowerMax PFV Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 2 3/ / / / / PowerMax PFV Applications: Hoist Ropes, Drag Ropes Plastic polymer cushions strands, distributes internal stresses and keeps out dirt Proprietary 8-strand construction Good resistance to fatigue and abrasion wear / / / / / / (mm) Weight (kg/m) (kn) Inspection Tip Focus on Your Rope s Critical Points While you should check the entire length of the rope for any unusual or isolated damage, there are several critical points subject to greater stresses that tend to deteriorate more quickly: Pick-up point End attachments Sheaves Anywhere ropes are subjected to abnormal scuffing or scraping 9

10 Mining Ropes PowerMax MD Application: Hoist Ropes, Drag Ropes (reverse bend fairlead systems) Good resistance to both metal loss and metal fatigue Compacted outer strands for greater abrasion resistance 10 percent higher breaking strength than standard 6-strand Plastic-impregnated independent wire rope core (IWRC) (in) PowerMax MD Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 2 7/ / / / / / Keep Good Records. Good recordkeeping helps your company keep downtime and operating costs to a minimum. By keeping accurate, up-todate records, changes in service that may indicate the existence of a problem either on the machine, digging conditions, operators or the rope itself can be more quickly indentified. 3 3/ (mm) Weight (kg/m) (kn)

11 Mining Ropes (in) PowerMax Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 2 3/ / / / / / / / / / / / / / / / / / / (mm) Weight (kg/m) (kn) PowerMax Applications: Hoist Ropes, Drag Ropes, Dump Ropes Good resistance to metal fatigue, metal loss, deformation and abrasive wear 8-strand construction PFV-coated core distributes radial stresses when bending over sheaves and protects the rope from internal nicking Strength The published minimum breaking force (MBF) or nominal (catalog) strength applies to new, unused rope and is the calculated strength figure that has been accepted by the wire rope industry. During its useful life, a rope gradually loses strength due to factors such as surface wear and metal fatigue. 11

12 Mining Ropes 12 6-Strand PFV Applications: Hoist Ropes, Drag Ropes, Dump Ropes PFV Polymer cushions strands and distributes internal stresses traps lubricant in, allowing internal movement between wires and strands reduces internal abrasion due to debris intrusion 6-strand construction PFV Plastic-Impregnated Ropes Plastic polymer cushions the strands, distributes internal stresses, keeps in wire rope lubricant and keeps out dirt and debris. Polymer won t melt or soften from heat of normal operating temperatures and is virtually unaffected by sunlight and cold weather. Deep penetration of the polymer into the rope delivers uniform support throughout the length of the rope. (in) 6-Strand PFV Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) XIP 1 3/ / / / / / / / / / / / / / / (mm) Weight (kg/m) (kn)

13 Mining Ropes (in) 6-Strand Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) XIP 1 3/ / / / / / / / / / / / / / / / / / / / / / / (mm) Weight (kg/m) (kn) Strand Applications: Hoist Ropes, Drag Ropes, Dump Ropes Engineered to withstand abrasion and fatigue 6-strand construction Independent wire rope core Available in right lang lay (ZZ) and left lang lay (SS) Metal deformation Metal deformation, or peening, is the changing of the shape of a rope s outer wires. It is caused by slapping against a hard object such as a rock, sheave or a roller. The steel is not worn away, but pushed to the side. Cross section of a worn wire Original shape Worn surface 13

14 Mining Ropes 7-Flex PFV Applications: Trip Ropes PFV Polymer cushions strands, reducing wire-contact stress keeps lubricant in, allowing internal movement between wires and strands reduces internal abrasion due to debris provides greater wear area for greater resistance to bending fatigue 7-strand construction (in) 7-Flex PFV Strength and Weights Approx Weight (lb/ft) (tons of 2000 lb) 3/ / / / / / / / / / / / / / / / Don t overlook boom pendants Boom pendants are subject to vibratory fatigue at end attachments and at points where they run through the dampeners between the pendants. Broken wires at the socket or dampener are an indication of deterioration. When it comes time to replace your pendants, it s best to replace the complete set of pendants because of the differences in operating characteristics of a new and used pendant.

15 Boom Pendants Nominal (in) TUF-STRAND Strength and Weights MINIMUM BREAKING STRENGTH IN TONS OF 2000 LB GRADE 1 (ASTM A586) GRADE 2 Class A Coating Throughout Class A Coating Inner Wires/ Class B Coating Outer Wires Class A Coating Inner Wires/ Class C Coating Outer Wires Class A Coating Throughout Approx. Gross Metallic Area (in 2 ) Approx. Weight (lb/ft) / / / / / / / / / / / / / / MINIMUM BREAKING STRENGTH IN METRIC TONS GRADE 1 (ASTM A586) GRADE 2 Nominal (mm) Class A Coating Throughout Class A Coating Inner Wires/ Class B Coating Outer Wires Class A Coating Inner Wires/ Class C Coating Outer Wires Class A Coating Throughout Approx. Gross Metallic Area (mm 2 ) Approx. Weight (kg/m) TUF-STRAND Structural Strand Application: Boom Pendants Custom designed and fabricated to customer requirements Designed to withstand severe conditions of the mining environment Unit Lay Core Design utilizes a multilayer, single operation strand core that provides optimum wire support by maximizing the surface area between wire-towire contact 15

16 Boom Pendants Ara-Boom Synthetic Application: Boom Pendants times the service life of wire rope or strand Able to withstand tension-tension fatigue Maintenance-free Lighter, easier to handle during installation Customized to your requirements and tensioned to the same loads as the pendants being replaced Part No. ARA-BOOM 600 ARA-BOOM 685 Ara-Boom Strength and Weights Rope Outside in (mm) Rated Breaking Force lb (kn) Jacketed Rope Weight lb/ft (kg/m) 2 5/8 600, /8 (66.7) (2,669) (3.2) 2 3/4 685, /4 (69.9) (3,047) (4.1) End Termination Resin-filled spelter sockets(3) with molded bend restrictors Resin-filled spelter sockets(3) with molded bend restrictors ARA-BOOM /8 732, /4 (85.73) (3,256) (4.84) Resin-filled spelter sockets(3) with molded bend restrictors 16 Synthetic ropes offer the strength and low stretch of steel wire ropes at a a fraction of the weight. These products are ideal replacements for steel wire rope or chain for towing. ARA-BOOM 1000 ARA-BOOM /8 1,000, /2 (98.43) (4,448) (6.7) 4 3/8 1,560,000 6 (111.13) (6,939) (8.9) Resin-filled spelter sockets(3) with molded bend restrictors Resin-filled spelter sockets(3) with molded bend restrictors (1) Cycles are 10-40% RBS. (2) Creep rate based on 5-year continuous 10% RBS. Example: Creep Rate for 80 ft. (24.4 m) assembly for 5 10%=1.54 (39 mm). (3) Phillystran recommends new sockets. NOTE: Rope data and dimensions are approximated and may vary at time of manufacturing

17 Synthetic Ropes TufTow Application: Towing Lines Fabricated from high strength aramid fiber for maximum strength to diameter ratio and low stretch for safety Double protective jacketing Inner braided polyester jacket Outer urethane coating Spliced eyes furnished as soft eyes reinforced with high tenacity fiber or with optional wire rope thimbles ( hard eyes ) Standard colors are black or orange. Other colors available upon request. TufStrop Applications: Safety support assemblies designed for the demands of ultra-class off-highway haul trucks Made from high strength low stretch aramid fiber grommet Double layered ultra-tough jacketing Primary jacket composed of heavy polyester braid tightly secured to the core Tough outer urethane coating protects sling from abrasion, eliminates UV damage and prevents dirt and other foreign material from penetrating 23-ton safe working load. Other sizes available upon request. Made to customer length specifications Available in high-visibility safety yellow TufTow Strength and Weights Part Number (Dia.) Approx Weight RBS 17 in mm lb/ft kg/m lb kn , / , / ,000 1, / ,000 2, ,000 3,692

18 Useful Tools ROPE Specifications 18

19 Useful Tools STRUCTURAL STRAND BOOM PENDANT Specifications QUANTITY DIAMETER LENGTH MEASURING POINTS (Example: C-Pin to C-Pin) GALVANIZED CLASS (Check one.) A (Throughout) B (B outer/a inner) C (C outer/a inner) LENGTH TOLERANCE Prestretch? Yes No Stripe? Yes No Measure length under load? Yes No BEFORE YOU ORDER We can assist you in every stage of your project from design to completion. To make a purchase or to request technical expertise, contact us at: or info@wirecoworldgroup.com Select your configuration: SOCKET SPECIFICATIONS Lube tubes? Yes No Strand Socket (on one end) Strand Socket (on one end) Pin diameter (D) Pin diameter (D) Jaw opening (O) Jaw opening (O) Ear thickness (V) Ear thickness (V) C-pin to basket (M) C-pin to basket (M) Bail: Thickness (K) Bail: Thickness (K) Bail: Inside width (W) Bail: Inside width (W) 19 Bail: Inside length (L) Bail: Inside length (L) Special dimensions not noted: Special packaging required: Closed Strand Socket (css) open Strand Socket (OSS)

20 12200 N.W. Ambassador Drive Kansas City, Missouri Tel: Fax: wirecoworldgroup.com unionrope.com phillystran.com Any warranty, expressed or implied as to quality, performance or fitness for use of WireCo WorldGroup products is always premised on the condition that the published strengths apply only to new, unused products, that the mechanical equipment on which such products are used is properly designed and maintained and properly inspected on a regular basis during the period of use. Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including but not limited to personal injury, labor costs, a loss of profits resulting from the use of said products or from said products being incorporated in or becoming a component of any other product Wireco WorldGroup Form No. 1123