BS DD CENTS 13001-3-2 Cranes. General Design. Limit States and Proof of Competence of Wire Ropes in Reeving Systems

DRAFT FOR DEVELOPMENT

DD CEN/TS 13001-3-2:2004

Licensed copy: Kit Lum, Franklin Offshore International Pte Ltd, Version correct as of 01/06/2012 09:54, (c) The British Standards Institution 2012

Incorporating Corrigendum No. 1

Cranes — General design — Part 3-2: Limit states and proof of competence of wire ropes in reeving systems

ICS 53.020.20

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DD CEN/TS 13001-3-2:2004


National foreword This Draft for Development is the official English language version of CEN/TS 13001-3-2:2004, including Corrigendum July 2006. When Parts 1, 2, 3.1, 3.2 and 3.3 of this standard are published, BS 2573 Parts 1 and 2 will be withdrawn. This publication is not to be regarded as a British Standard. It is being issued in the Draft for Development series of publications and is of a provisional nature because CEN/TS 13001-3-2:2004 is itself a provisional standard. NOTE A CEN/TS is a “Technical Specification” issued by CEN for an evolving technology, with a view to it being developed to full EN status within 3 years.

It should be applied on this provisional basis, so that information and experience of its practical application may be obtained. Comments arising from the use of this Draft for Development are requested so that UK experience can be reported to the European organization responsible for its conversion to a European Standard. A review of this publication will be initiated 2 years after its publication by the European organization so that a decision can be taken on its status at the end of its 3-year life. Notification of the start of the review period will be made in an announcement in the appropriate issue of Update Standards. According to the replies received by the end of the review period, the responsible BSI Committee will decide whether to support the conversion into a European Standard, to extend the life of the Technical Specification or to withdraw it. Comments should be sent in writing to the Secretary of BSI Subcommittee MHE/3/1, Crane design, at British Standards House, 389 Chiswick High Road, London W4 4AL, giving the document reference and clause number and proposing, where possible, an appropriate revision of the text. A list of organizations represented on this subcommittee can be obtained on request to its secretary. Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online.

This Draft for Development was published under the authority of the Standards Policy and Strategy Committee on 7 January 2005

© BSI 2006

ISBN 0 580 45306 5

Amendments issued since publication Amd. No.

Date

Comments

15623

9 March 2005

Correction to national foreword

16658

31 October 2006

Correction to Clauses 2 and 3.1

Corrigendum No. 1

TECHNICAL SPECIFICATION

CEN/TS 13001-3-2


SPÉCIFICATION TECHNIQUE TECHNISCHE SPEZIFIKATION

December 2004 Incorporating Corrigendum July 2006

ICS 53.020.20

English version

Cranes - General design - Part 3-2: Limit states and proof of competence of wire ropes in reeving systems Appareils de levage à charge suspendue - Conception générale - Partie 3-2 : États limites et vérification d'aptitude des systèmes de mouflage

Krane - Konstruktion allgemein - Teil 3-2: Grenzzustände und Sicherheitsnachweis von Drahtseilen in Seiltrieben

This Technical Specification (CEN/TS) was approved by CEN on 18 March 2004 for provisional application. The period of validity of this CEN/TS is limited initially to three years. After two years the members of CEN will be requested to submit their comments, particularly on the question whether the CEN/TS can be converted into a European Standard. CEN members are required to announce the existence of this CEN/TS in the same way as for an EN and to make the CEN/TS available promptly at national level in an appropriate form. It is permissible to keep conflicting national standards in force (in parallel to the CEN/TS) until the final decision about the possible conversion of the CEN/TS into an EN is reached. CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36

© 2004 CEN

All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.

B-1050 Brussels

Ref. No. CEN/TS 13001-3-2:2004: E


CEN/TS 13001-3-2:2004 (E)

Contents

Page

Foreword......................................................................................................................................................................4 Introduction .................................................................................................................................................................5 1

Scope ..............................................................................................................................................................5

2

Normative references ....................................................................................................................................5

3 3.1 3.2

Terms, definitions, symbols and abbreviations .........................................................................................6 Terms and definitions ...................................................................................................................................6 Symbols and abbreviations ..........................................................................................................................6

4

General............................................................................................................................................................8

5 5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.4

Proof of static strength .................................................................................................................................8 General............................................................................................................................................................8 Vertical hoisting .............................................................................................................................................8 Design rope force ..........................................................................................................................................8 Inertial and gravitational effects...................................................................................................................9 Rope reeving efficiency ..............................................................................................................................10 Non parallel falls ..........................................................................................................................................11 Horizontal forces on the hoist load............................................................................................................11 Non vertical drives.......................................................................................................................................12 Design rope force ........................................................................................................................................12 Equivalent force ...........................................................................................................................................13 Inertial effects...............................................................................................................................................14 Rope reeving efficiency ..............................................................................................................................14 Non parallel falls ..........................................................................................................................................14 Limit design rope force ...............................................................................................................................14

6 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8

Proof of fatigue strength.............................................................................................................................15 General..........................................................................................................................................................15 Design rope force ........................................................................................................................................16 Principle conditions ....................................................................................................................................16 Inertial effects...............................................................................................................................................16 Non parallel falls ..........................................................................................................................................17 Horizontal forces in vertical hoisting ........................................................................................................18 Limit design rope force ...............................................................................................................................18 Basic formula ...............................................................................................................................................18 Rope force history parameter.....................................................................................................................18 Rope force spectrum factor........................................................................................................................19 Relative total number of bendings.............................................................................................................19 Minimum rope resistance factor ................................................................................................................20 Further influences on the limit design rope force....................................................................................20 Basic formula ...............................................................................................................................................20 Diameters of drum and sheaves ................................................................................................................20 Tensile strength of wire ..............................................................................................................................21 Fleet angle ....................................................................................................................................................21 Rope lubrication...........................................................................................................................................22 Multilayer drum ............................................................................................................................................22 Groove radius...............................................................................................................................................22 Rope types....................................................................................................................................................23

Annex A (normative) Number of Relevant Bendings ............................................................................................24 Annex B (informative) Guidance for selection of design number of hoist ropes used during the useful crane life .......................................................................................................................................................27 Annex C (informative) Selection of suitable set of crane standards for a given application ............................28 Bibliography ..............................................................................................................................................................29

2

CEN/TS 13001-3-2:2004 (E)


Figures Figure 1— Example for the acting parts of hoist mass ..........................................................................................9 Figure 2 — Example for Rope Reeving Efficiency ................................................................................................10 Figure 3 — Angle βmax...............................................................................................................................................11 Figure 4— Horizontal force......................................................................................................................................12 Figure 5 — Examples for non vertical drive...........................................................................................................13 Figure 6— Example for rope tightening .................................................................................................................13 Figure 7 — Lifting positions ....................................................................................................................................18 Figure 8 — Fleet angles ...........................................................................................................................................21 Figure 9 — Groove radius........................................................................................................................................22 Table 7 — Factor ff6 ...................................................................................................................................................22 Figure A.1 — Number of relevant bendings...........................................................................................................26

Tables Table 1 — Symbols and abbreviations.....................................................................................................................6 Table 2 — Partial safety factors γp ..........................................................................................................................14 Table 3 — Minimum rope resistance factor γrb .....................................................................................................15 Table 4 — Classes SR of rope force history parameter sr .....................................................................................19 Table 5 — Reference ratio RDd .................................................................................................................................20 Table 6 — Factor ff3...................................................................................................................................................22 Table 7 — Factor ff6 ...................................................................................................................................................22 Table A.1 — Bending counts ...................................................................................................................................24 Table A.2 — Examples for the number of relevant bendings w ..........................................................................25

3


CEN/TS 13001-3-2:2004 (E)

Foreword This document (CEN/TS 13001-3.2:2004) has been prepared by Technical Committee CEN/TC 147 “Cranes — Safety”, the secretariat of which is held by BSI. The CEN/TC 147/WG 2 "Cranes — Design and Principles" is held by DIN. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to announce this Technical Specification: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. This European Technical Specification is one Part of EN 13001. The other parts are as follows: Part 1:

General principles and requirements;

Part 2:

Load effects;

Part 3.1:

Limit states and proof of competence of steel structures;

Part 3.3:

Limit states and proof of competence of wheel/rail contacts;

Part 3.4:

Limit states and proof of competence of machinery.

Annex A is normative, annexes B and C are informative.

4


CEN/TS 13001-3-2:2004 (E)

Introduction This Technical Specification has been prepared to be a harmonized standard to provide one means for the mechanical design and theoretical verification of cranes to conform with the essential health and safety requirements of the Machinery Directive, as amended. This standard also establishes interfaces between the user (purchaser) and the designer, as well as between the designer and the component manufacturer, in order to form a basis for selecting cranes and components. This Technical Specification is a type C standard as stated in EN ISO 12100-1:2003. The machinery concerned and the extent to which hazards are covered are indicated in the scope of this standard.

1

Scope

This Part 3-2 of the Technical Specification EN 13001 is to be used together with Part 1 and Part 2 and as such they specify general conditions, requirements and methods to prevent mechanical hazards of wire ropes in reeving systems of cranes by design and theoretical verification. NOTE 1 Specific requirements for particular types of crane are given in the appropriate Technical Specification for the particular crane type.

The following is a list of significant hazardous situations and hazardous events that could result in risks to persons during normal use and foreseeable misuse. Clauses 5 to 6 of this standard are necessary to reduce or eliminate the risks associated with the following hazard: Exceeding the limits of strength. This Technical Specification is applicable to cranes which are manufactured after the date of approval by CEN of this standard and serves as reference base for the Technical Specifications for particular crane types. NOTE 2

2

CEN/TS 13001-3-2 deals only with limit state method according to EN 13001-1.

Normative references

This Technical Specification incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this Technical Specification only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments). EN 1990:2002, Eurocode — Basis of structural design. EN 12385-4, Steel wire ropes — Safety — Part 4: Stranded ropes for general lifting applications. EN 13001-1, Cranes — General Design — Part 1: General principles and requirements. EN 13001-2, Cranes — General Design — Part 2: Load effects. CEN/TS 13001-3-1, Cranes — General design — Part 3-1: Limit states and proof of competence of steel structures. EN 13411-1, Terminations for steel wire ropes — Safety — Part 1: Thimbles for steel wire rope slings. EN 13411-2, Terminations for steel wire ropes — Safety — Part 2: Splicing of eyes for wire rope slings. 5

CEN/TS 13001-3-2:2004 (E)


EN 13411-3, Terminations for steel wire ropes — Safety — Part 3: Ferrules and ferrule-securing. EN 13411-4, Terminations for steel wire ropes — Safety — Part 4: Metal and resin socketing. EN 13411-6, Terminations for steel wire ropes — Safety — Part 6: Asymmetric wedge sockets. EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1:Basic terminology, methodology (ISO 12100-1:2003). ISO 4306-1:1990, Cranes vocabulary. ISO 4309, Cranes — Wire ropes — Code of practice for examination and discard.

3 3.1

Terms, definitions, symbols and abbreviations Terms and definitions

For the purposes of this Technical Specification, the terms and definitions given in EN ISO 12100-1:2003, EN 1990:2002 and clause 6 of ISO 4306-1:1990 apply.

3.2

Symbols and abbreviations

For the purposes of this Technical Specification, the symbols and abbreviations given in Table 1 apply. Table 1 — Symbols and abbreviations Symbols, abbreviations a C D Ddrum Dsheave Dcomp d dbearing Fequ Fgd Fgl Fo FRd,s FRd,f FSd,s Fr FSd,f Ft Fu Fw ff ff1 ff2 ff3 ff4 ff5 ff6 ff7

6

Description Acceleration Total number of working cycles (see EN 13001-1) during useful life of crane Relevant diameter Minimum pitch diameter of drum Minimum pitch diameter of sheave Minimum pitch diameter of compensating sheave Rope diameter Diameter of bearing or shaft Equivalent force Part of Fequ induced by gravity, exclusive mass of payload, amplified by γp Part of Fequ induced by gravity forces of mass of payload, amplified by γp Part of Fequ induced by any other forces, amplified by γp Limit design rope force for the proof of static strength Limit design rope force for the proof of fatigue strength Design rope force for the proof of static strength Part of Fequ induced by resistances, amplified by γp Design rope force for the proof of fatigue strength Part of Fequ induced by rope tightening forces, amplified by γp Minimum rope breaking force Part of Fequ induced by wind forces, amplified by γp Factor of further influences Factor of diameter ratio influence Factor tensile strength of wire influence Factor of fleet angle influence Factor of lubrication influence Factor of multilayer drum influence Factor of groove radius influence Factor of rope type influence


CEN/TS 13001-3-2:2004 (E)

Table 1 (concluded) Symbols, abbreviations fS1 fS2 fS3 f*Si g i kr lr q mH mHr mred mtrans n nf nfs nm R0 RDd rg SR sr t w wc wD wtot z, zi, zmin, zmax

α β, βmax γ γn γp γrb γrf δ

ε ηs ηtot νr φ φ* φ2 φ5 φ6 ω

Description Rope force increasing factor from rope reeving efficiency Rope force increasing factor from non parallel falls Rope force increasing factor from horizontal acceleration Rope force increasing factors in fatigue Gravity constant Index for cycles of lifting and lowering Rope force spectrum factor Number of ropes used during useful life of the crane Height distribution Mass of hoist load (see EN13001-2) Mass of hoist load that is acting on the rope falls under consideration Rotatory rope driven mass Translational rope driven mass Number of contact points passed by rope Number of falls or reeving lines Number of fixed sheave between drum and moving part Mechanical advantage Minimum tensile strength of the wire used in the rope Reference ratio of rope bending diameter to rope diameter Groove radius Class of rope force history Rope force history parameter Rope type factor Number of relevant bendings per lifting movement Bending count Number of bendings at reference point Total number of bendings Height coordinates Angle of slope Angles between falls and line of acting force Angle between gravity and projected rope in plane of Fh and g Risk coefficient Partial safety factor Minimum rope resistance factor (static) Minimum rope resistance factor (fatigue) Design fleet angle Angle between sheave planes Efficiency of single sheave Total efficiency of rope drive Relative total number of bendings Dynamic factor for inertial or gravity effects Dynamic factor for inertial or gravity effects in fatigue Dynamic factor for hoisting an unrestrained grounded load Dynamic factor for loads caused by acceleration Dynamic factor for testload Angle between the sheave groove sides

7

CEN/TS 13001-3-2:2004 (E)


4

General

In all cranes running wire ropes are stressed by loads (described by a load spectrum) and by bendings. Both constitute the rope force history, classified in classes SR (see 6.3.2). Classes SR are used for the selection of the wire rope and diameters of drums and/or sheaves. They are independent of time. The proof of competence for static strength and the proof of competence for fatigue strength shall be fulfilled for the selection of ropes and components. This standard is for design purposes only and should not be seen as a guarantee of actual performance. To ensure safe use of the rope the discard criteria according to ISO 4309 shall be applied. The wire rope should be in accordance with EN 12385-4. Rope terminations shall meet the requirements of EN 13411-1, EN 13411-2, EN 13411-3, EN 13411-4 and EN 13411-6.

5

Proof of static strength

5.1

General

For the proof of static strength it shall be proven that for all relevant load combinations of EN 13001-2

FSd , s ≤ FRd , s

(1)

where: FSd,s

is the design rope force

FRd,s

is the limit design rope force.

5.2

Vertical hoisting

5.2.1

Design rope force

The design rope force FSd,s in vertical hoisting shall be calculated as follows:

FSd , s =

m Hr ⋅ g ⋅ φ ⋅ f S1 ⋅ f S 2 ⋅ f S 3 ⋅ γ p ⋅ γ n nf

(2)

where: mHr

is the mass of the hoist load (mH) or that part of the mass of the hoist load that is acting on the rope falls under consideration (see Figure 1). The mass of the hoist load includes the masses of the payload, lifting attachments and a portion of the suspended hoist ropes. In statically undetermined systems, the unequal load distribution between ropes depends on elasticities and shall be taken into account.

g

is the gravity constant

nf

is the number of falls carrying mHr

φ

is the dynamic factor for inertial and gravity effects as shown in 5.2.2

fS1 to fS3 are the rope force increasing factors as shown in 5.2.3 to 5.2.5 γp

8

is the partial safety factor (see EN 13001-2) γp = 1,34 for regular loads (load combinations A)


CEN/TS 13001-3-2:2004 (E)

γp = 1,22 for occasional loads (load combinations B) γp = 1,10 or exceptional loads (load combinations C) is the risk coefficient (see EN 13001-2)

γn

Figure 1— Example for the acting parts of hoist mass 5.2.2 5.2.2.1

Inertial and gravitational effects Dynamic factors

For vertical hoisting the maximum inertial effects from either hoisting an unrestrained grounded load or from acceleration or deceleration shall be taken into account by the dynamic factor φ. 5.2.2.2

Hoisting an unrestrained grounded load

φ = φ2

(3)

where:

φ2 5.2.2.3

is the dynamic factor for inertial and gravity effects when hoisting an unrestrained grounded load (see EN 13001-2) Acceleration or deceleration of the hoistload

φ = 1 + φ5 ⋅

a g

(4)

where: 9


CEN/TS 13001-3-2:2004 (E)

φ5

is the dynamic factor for loads caused by acceleration (see EN 13001-2)

a

is the vertical acceleration or deceleration

g


5.2.2.4

Testload

φ = φ6

(5)

where:

φ6 5.2.3

is the dynamic factor for testload (see EN 13001-2) Rope reeving efficiency

The increase of the design rope force by the rope reeving efficiency is given by

f S1 =

1

(6)

η tot

The total efficiency of the rope drive ηtot shall be calculated as follows:

η tot =

(η S ) nm

n fs

⋅

1 − (η S ) nm 1 −ηS

(7)

where:

ηS

is the efficiency of a single sheave: ηS = 0,985 for sheave with roller bearing ηS = 0,985 × (1 - 0,15 × dbearing / DSheave ) for sheave with plain bearing Other values for ηS may be used if verified by test results for the applied rope, sheave or bearing.

nm

is the mechanical advantage (see example in Figure 2)

nfs

is the number of fixed sheaves between drum and moving part

Figure 2 — Example for Rope Reeving Efficiency 10

CEN/TS 13001-3-2:2004 (E)


5.2.4

Non parallel falls

When the rope falls are not parallel the rope force is increased. The rope force increasing factor fS2 shall be determined for the most unfavourable position. For simplification fS2 may be calculated by

fS2 =

1 cos β max

(8)

where:

βmax

is the maximum angle between the falls and the direction of load (see Figure 3)

Figure 3 — Angle βmax 5.2.5

Horizontal forces on the hoist load

The rope force increasing effect of the horizontal forces (e. g. by crab or crane accelerations, wind) may be neglected in applications with free swinging loads. However in applications with several non parallel ropes (rope pyramid, see Figure 4) the horizontal forces increase the rope force considerably. This effect shall be taken into account. For simplification the rope force increasing factor fS3 may be calculated by

f S3 = 1 +

Fh ≤2 m H ⋅ g ⋅ tan γ

(9)

where: Fh

is the horizontal force on the hoist load

mH

is the mass of the hoist load

g


γ

is the angle between gravity and the rope projected in the plane of Fh and g

11


CEN/TS 13001-3-2:2004 (E)

Figure 4— Horizontal force

5.3

Non vertical drives

5.3.1

Design rope force

The design rope force FSd,s in non vertical drives (see examples in Figure 5 and Figure 6) shall be calculated as follows:

FSd,s =

Fequ nf

⋅ φ ⋅ f S1 ⋅ f S 2 ⋅ γ n

(10)

where:

12

Fequ

is the equivalent force acting on the rope falls under consideration as shown in 5.3.2. In statically undetermined systems, the unequal load distribution between ropes depends on elasticities and shall be taken into account.

nf

is the number of falls or reeving lines

φ

is the dynamic factor for inertial effects as shown in 5.3.3

fS1 , fS2

are the rope force increasing factors as shown in 5.3.4 and 5.3.5

γn

is the risk coefficient (see EN 13001-2)


CEN/TS 13001-3-2:2004 (E)

Figure 5 — Examples for non vertical drive

Figure 6— Example for rope tightening 5.3.2

Equivalent force

In general the load actions of gravity forces, resistances (e. g. rolling or gliding, wheels, bearings), rope tightening forces, wind forces and any other forces (e. g. buffer forces, forces from climatic effects) contribute to the equivalent force Fequ as illustrated in equation 11. Those load actions shall be amplified by partial safety factors γp (see EN 13001-2) for the load combination under consideration, as given in Table 2.

Fequ = Fgd + Fgl + Fr + Fw + Ft + Fo

(11)

where: Fgd

is that part of Fequ that is induced by gravity forces of the rope driven masses, exclusive the mass of the payload, amplified by the relevant partial safety factor.

Fgl

is that part of Fequ that is induced by gravity forces of the rope driven mass of the payload, amplified by the relevant partial safety factor.

Fr

is that part of Fequ that is induced by resistances, amplified by the relevant partial safety factor.

Fw

is that part of Fequ that is induced by wind forces, amplified by the relevant partial safety factor.

Ft

is that part of Fequ that is induced by rope tightening forces (see example in Figure 6), amplified by the relevant partial safety factor.

Fo

is that part of Fequ that is induced by any other forces, amplified by the relevant partial safety factor.

13

CEN/TS 13001-3-2:2004 (E)


Table 2 — Partial safety factors γp Regular loads

Occasional loads

Exceptional loads

Load combinations A

Load combinations B

Load combinations C

exclusive mass of payload

1,22

1,16

1,1

Fgl

Gravitation on payload

1,34

1,22

1,1

φ

Inertia

1,34

1,22

1,1

Fr

Resistances

1,34

1,22

1,1

Ft

Rope tightening

1,22

1,16

1,1

Fw

Wind forces: In service

—

1,22

1,16

Wind forces: Out of service

—

—

1,1

Snow and ice

—

1,22

1,1

Temperature

—

1,16

1,05

Buffer forces

—

—

1,1

Description Gravitation on masses,

Fgd

Fo

5.3.3

Inertial effects

In non vertical drives the inertial effects from accelerations shall be taken into account by the dynamic factor φ calculated as follows:

φ = 1+

(∑ m

trans

+ ∑ mred ) ⋅ a ⋅ φ5 ⋅ γ p Fequ

(12)

where: Σmtrans

is the sum of translational rope driven masses, referred to the coordinate of acceleration

Σmred

is the sum of rotatory rope driven masses (see examples in Figure 5 and Figure 6), referred to the coordinate of acceleration

a

is the acceleration or deceleration

φ5

is the dynamic factor for loads caused by acceleration (see EN 13001-2)

γp

is the partial safety factor, as given in Table 2, line inertia

Fequ

is the equivalent force

5.3.4

Rope reeving efficiency

The increase of the design rope force by the rope reeving efficiency is given by the rope force increasing factor fS1, calculated as shown in 5.2.3, equations 6 and 7. 5.3.5

Non parallel falls

The increase of the design rope force by non parallel falls is given by the rope force increasing factor fS2, calculated as shown in 5.2.4 and equation 8.

5.4

Limit design rope force

The limit design rope force FRd,s is given by

14


CEN/TS 13001-3-2:2004 (E)

FRd,s =

Fu γrb

(13)

where: Fu

is the minimum breaking force of the rope as specified by the manufacturer

γrb

is the minimum rope resistance factor.

The minimum rope resistance factor γrb is dependent on the geometry of the reeving system and is given by

γ rb = 1,34 +

5,0 D   d

(14)

0 ,8

−4

where: D

is the minimum relevant diameter: D = Min(Dsheave ; 1,125*Ddrum ; 1,125*Dcomp)

d

is the rope diameter.

Table 3 gives minimum rope resistance factors for selected ratios of D/d. Table 3 — Minimum rope resistance factor γrb

6 6.1

D/d

11,2

12,5

14,0

16,0

18,0

20,0

γrb

3,06

2,75

2,52

2,30

2,16

2,05

Proof of fatigue strength General

According to test results the fatigue strength of ropes in terms of number of bendings is approximately inversely proportional to the second power of the applied rope tension force. With the additional requirement that the ratio of the rope bending diameter D to the rope diameter d increases with the number of bendings wtot according to

D ~ 1,125 log 2 (wtot ) d

(15)

(i. e. D/d increases by 1,125 for increasing wtot by 2), the rope force to number of bendings relationship follows closely the power -3. Therefore this additional requirement is used in the classification of the rope force history. When calculating the number of bendings, one lifting movement is considered to comprise both a lifting and lowering action. In non vertical drives to and from movements are treated respectively. For the proof of fatigue strength it shall be proven that

FSd,f ≤ FRd,f

(16)

where: FSd,f

is the design rope force for fatigue

FRd,f

is the limit design rope force for fatigue.

15

CEN/TS 13001-3-2:2004 (E)


6.2

Design rope force

6.2.1

Principle conditions

The design rope force FSd,f shall be calculated for regular loads (load combinations A) only, with partial safety factors γp, risk coefficient γn and rope efficiency set to 1. For vertical hoisting:

FSd ,f =

m Hr ⋅ g * * ⋅ φ ⋅ f S 2 ⋅ f S*3 nf

(17)

where: mHr

is the mass of the hoist load (mH) or that part of the mass of the hoist load that is acting on the rope (see Figure 1).

g


nf

is the number of falls carrying mHr

φ

*

is the dynamic factor for inertial and gravity effects as shown in 6.2.2

f S*2 , f S*3

are the rope force increasing factors as shown in 6.2.3 to 6.2.4

For non-vertical drives:

FSd,f =

Fequ nf

⋅ φ * ⋅ f S*2

(18)

where: Fequ

is the equivalent force acting on the rope according to the principles of 5.3.2.

nf

is the number of falls or reeving lines

φ*

is the dynamic factor for inertial effects as shown in 6.2.2

f S*2

is the rope force increasing factor as shown in 6.2.3

Instead of the rope force increasing factors f*si the factors fsi as given in clause 5 may be used. Instead of the dynamic factor φ* the factor φ as given in clause 5 may be used. 6.2.2

Inertial effects

As the inertial effects act for short time only, they do not affect all bendings. Therefore the dynamic factors φ* may be calculated by

φ* = φ φ* = 3

for w = 1 or

(w − 1) + φ 3 w

for w ≥ 2

where: w 16

is the relevant number of bendings per lifting movement (see annex A).

(19)

CEN/TS 13001-3-2:2004 (E)


φ

is the dynamic factor (see 5.2.2 or 5.3.3)

6.2.3

Non parallel falls

For the proof of fatigue strength the distribution of height and angle within the working range can be taken into account by

f

* S2

=3

zmax

∫ z

min

q( z ) dz cos 3 β ( z )

(20)

where: z

are height coordinates as shown in Figure 7. zref is the reference height The whole working range is from zmin to zmax. The most frequent working range is from z1 to z2.

β(z)

is the angle between rope and line of the acting force

q(z)

is the height density of the crane use in the working range

Z max

∫ q( z )dz = 1 zmin

(21)

When the crane operates approximately equal on all heights of the most frequent working range, the density function is constant

q( z ) =

1 z 2 − z1

(22)

and f*S2 may be calculated as

f

* S2

   z ref − z 2  1  = 1+  − 1 ⋅     cos β ( z 2 )   z ref − z1 

0,9

(23)

17


CEN/TS 13001-3-2:2004 (E)

Figure 7 — Lifting positions 6.2.4

Horizontal forces in vertical hoisting

If horizontal acceleration and lifting acceleration act together regularly, f*S3 shall be calculated by

f S*3 = f S 3

(24)

where: is the rope force increasing factor calculated from an average angle γ (see 5.2.5)

fS3

When horizontal forces and lifting acceleration do not act together regularly, f*S3 may be set to 1.

6.3

Limit design rope force

6.3.1

Basic formula

The limit design rope force FRd,f shall be calculated by

FRd,f =

Fu 3

s r ⋅ γ rf

⋅ ff

(25)

where: Fu

is the minimum breaking force of the rope as specified by the manufacturer

sr

is the rope force history parameter

γrf

is the minimum rope resistance factor

ff

is the factor of further influences.

6.3.2

Rope force history parameter

In analogy to stress history parameter (see EN 13001-1), the rope force history parameter is given by

sr = k r ⋅ νr 18

(26)

CEN/TS 13001-3-2:2004 (E)


where: kr

is the rope force spectrum factor

νr

is the relative total number of bendings.

The rope force history parameter shall be determined either by direct use of equations (26), (27), (28) and (29) or simplified by selection of a class SR from Table 4. Table 4 — Classes SR of rope force history parameter sr

6.3.3

Class

SR0

SR1

SR2

SR3

SR4

SR5

SR6

SR7

SR8

SR9

sr

0,008

0,016

0,032

0,063

0,125

0,25

0,5

1,0

2,0

4,0

Rope force spectrum factor

The rope force spectrum factor kr is calculated by

 FSd,f,i kr = ∑   i =1  FSd,f imax

3

 wi  ⋅  w tot 

(27)

where: i

is the index of one lifting movement with FSd,f,i

imax

is the total number of lifting movements per rope, considering all the working cycles, numbers of which per rope equals to C/lr

FSd,f,i

is the design rope force in lifting movement i

FSd,f

is the maximum design rope force

wi

is the relevant number of bendings in one lifting movement i (see annex A).

wtot

is the total number of bendings during the useful life of a rope.

C

is the total number of working cycles during the useful life of the crane (see EN 13001-1)

lr

is the design number of ropes used during the useful crane life (Guidance for lr is given in the annex B)

The total number of bendings wtot is calculated by imax

wtot = ∑ wi

(28)

i =1

where: wi

is the relevant number of bendings per lifting movement (see annex A).

imax

is the total number of lifting movements per rope

6.3.4

Relative total number of bendings

The relative total number of bendings is calculated by

νr =

wtot wD

(29) 19

CEN/TS 13001-3-2:2004 (E)


where: is the total number of bendings during the useful life of a rope

wtot

5

is the number of bendings at reference point: wD = 5 ⋅ 10 .

wD 6.3.5

Minimum rope resistance factor

The minimum rope resistance factor γrf shall be

γrf = 7

6.4

(30)

Further influences on the limit design rope force

6.4.1

Basic formula

The factor ff takes into account further influences on the limit design rope force:

ff = f f 1 ⋅ f f 2 ⋅ f f 3 ⋅ f f 4 ⋅ f f 5 ⋅ f f 6 ⋅ f f 7

(31)

where: are the factors of influences as given in 6.4.2 to 6.4.7.

ff1 to ff7 6.4.2

Diameters of drum and sheaves

As explained in 6.1 the additional requirement that the ratio D/d of the rope bending diameter D to the rope diameter d increases with the number of bendings wtot according to equation 15 is incorporated in equation 24. D is the minimum relevant diameter

D = Min ( Dsheave ;

1,125 ⋅ Ddrum ;

1,125 ⋅ Dcomp )

(32)

The reference ratio value of D/d is calculated by

RDd = 10 ⋅ 1,125

 s  log 2  r   0,004 

(33)

Table 5 gives standardized values of RDd in terms of classes SR: Table 5 — Reference ratio RDd Class

SR0

SR1

SR2

SR3

SR4

SR5

SR6

SR7

SR8

SR9

RDd

11,2

12,5

14,0

16,0

18,0

20,0

22,4

25,0

28,0

31,5

The factor ff1 is calculated by

f f1 =

D

d R Dd

The chosen ratio D/d shall not be less than 11.2 and shall be selected such that ff1 becomes greater than 0,75.

20

(34)

CEN/TS 13001-3-2:2004 (E)


6.4.3

Tensile strength of wire

A non-linear relationship between the tensile strength level Rr of the wire and the limit design rope force shall be taken into account by

ff2

 1770   =   Rr 

0, 4

, for Rr > 1770

(35)

for Rr ≤ 1770

ff2 = 1, where:

is the level of requirement of breaking force (tensile strength) which is designated by a number (e. g. 1770, 1960 etc.), see EN 12385-4.

Rr

6.4.4

Fleet angle

Fleet angles at sheaves or drums are illustrated in Figure 8. Fleet angles shall always be counted positive. For a selected point of the rope, the design fleet angle δ being associated with the most frequent working range shall be taken into account by factor ff3 according to Table 6. The design fleet angle is calculated by n

δ =

3

∑δ j =1

3 j

(36)

n

where: δj

is the fleet angle at the tangential contact point j of rope at drum or sheave (see Figure 8)

n

is the number of contact points passed by the most bent part of the rope (See Figure 8 for an example with n = 6)

Figure 8 — Fleet angles

21

CEN/TS 13001-3-2:2004 (E)


Table 6 — Factor ff3 design fleet angle

δ

non rotation

rotation

resistant rope

resistant rope

≤0,5°

1,0

1,0

1,0°

0,9

0,9

2,0°

0,75

0,7

3,0°

0,7

4,0°

0,67

not covered

Intermediate values may be interpolated

6.4.5

Rope lubrication

For lubricated ropes the factor ff4 is set to one. For ropes without lubrication (e. g. clean room) the factor ff4 shall be ff4 = 0,5. 6.4.6

Multilayer drum

Multilayer drums reduce the limit design rope force. A factor ff5 < 0,8 shall be applied. 6.4.7

Groove radius

The ratio of groove radius rg to rope diameter d and the requirements for angle ω between the sides of a sheave (see Figure 9) shall be taken into account by ff6 according to Table 7.

Figure 9 — Groove radius Table 7 — Factor ff6 rg/d 0,53 0,55

ω ≤60°

0,6 0,7 0,8 ≥ 1,0

ff6 1 0,84 0,75

No requirement

0,63 0,58 0,54

Intermediate values may be interpolated

22

CEN/TS 13001-3-2:2004 (E)


6.4.8

Rope types

Differing bending fatigue performance of the various rope types shall be taken into account by the factor f f 7 , given by

ff7 =

1 t

(38)

where t

is the rope type factor.

In general for non-rotation resistant ropes with 6 to 10 outer strands, t = 1 is valid. For other rope types values of t in the range of 0,95 to 1,25 may be specified by the rope manufacturer.

23


CEN/TS 13001-3-2:2004 (E)

Annex A (normative) Number of Relevant Bendings

One lifting movement comprises both a lifting and lowering action. The number of relevant bendings w of a rope during one lifting movement shall be established for the most unfavourable part of the rope by counting the sum of bending counts wc according to Table A.1 and A.2. When the loads in lifting and lowering are different (e. g. when loads are deposited at upper level), w/2 for the lifted load and w/2 for the lowered load shall be used. In these cases, both lifting and lowering are each considered as one lifting movement for the calculation of the rope force spectrum factor. Table A.1 — Bending counts Type of bending Any bending with a deflection angle α less than 5°

Illustration

Bending count

wc = 0

Rope termination

wc = 0

Compensating sheave/whip

wc = 0

Drum

wc = 1

Sheave with same sense bending (angle ε between planes

wc = 2

less than 120°)

Sheave with reverse sense bending (angle ε ≥ 120°)

24

wc = 4


CEN/TS 13001-3-2:2004 (E)

Table A2 shows examples assuming movements where the most unfavourable part of the rope runs from the drum over all sheaves. Table A.2 — Examples for the number of relevant bendings w

w=1

w=7

w=3

w=5

w=7

w=5

w=7

If during the cycle the rope runs only over a part of the sheaves, w depends on the length of the stroke. Figure A.1 gives an example:

25


CEN/TS 13001-3-2:2004 (E)

Key length between sheaves a1, a2, a3 c1, c2, c3 circumferential length 1 rope travel distance w = 11 2 rope travel distance w = 10 3 rope travel distance w = 6

Figure A.1 — Number of relevant bendings

26


CEN/TS 13001-3-2:2004 (E)

Annex B (informative) Guidance for selection of design number of hoist ropes used during the useful crane life

Item no. Type of crane

Operation method

S-class (see EN 13001-3-1)

Number of ropes lr

1

Hand-operated cranes

S0 – S2

1-2

2

Assembly cranes

S0 – S2

1-2

3

Powerhouse cranes

S1 – S3

1-3

4

Warehouse cranes

Intermittent operation

S4 – S5

3-6

5

Warehouse cranes, lifting beam cranes, scrapyard cranes

Continuous operation

S6 – S8

6-14

6

Workshop cranes

S3 – S5

2-6

7

Bridge cranes, skull cracker cranes

S6 – S8

6-14

8

Ladle cranes

S6 – S8

6-14

9

Pit cranes

S7 – S9

8-20

10

Stripper cranes, charging cranes

S8 – S9

10-20

11

Forging cranes

S6 – S8

6-14

12

Unloaders, stocking and reclaiming bridges, semi-portal cranes, portal cranes with trolley or slewing crane

Hook service

S4 – S6

3-8

Grab, magnet, spreader

S6 – S9

6-20

S3 – S5

2-6

Hook service

S3 – S5

2-6

Hook service

S4 – S6

3-8


S6 – S8

6-14

S1 – S3

1-3

Hook service

S3 – S5

2-6


S4 – S6

3-8

S1 – S4

1-4

Hook service

S1 – S3

1-3

Hook service

S3 – S5

2-6


S4 – S6

3-8

S4 – S5

3-6

Hook service

S2 – S5

2-6


S4 – S6

3-8

S1 – S3

1-3

13 14

Travelling conveyor gantries with fixed or sliding conveyor(s)

15

Shipbuilding cranes, slipway cranes, fitting-out cranes

16 17 18 19 20

Wharf cranes, slewing cranes, floating cranes, level-luffing slewing cranes High-capacity floating cranes, high capacity gantry cranes Shipdeck cranes

21

Revolving tower cranes for construction service

22

Erection cranes, derricks

23 24 25 26 27 28


Rail-mounted slewing cranes Locomotive cranes, licensed for in-train Haulage Loader cranes, mobile cranes High capacity loader and mobile cranes

27


CEN/TS 13001-3-2:2004 (E)

Annex C (informative) Selection of suitable set of crane standards for a given application

Is there a product standard in the following list that suits the application? EN 13000: 2004

Cranes — Mobile cranes

prEN 14439:20002

Cranes — Tower cranes

PrEN14985:2004

Cranes — Slewing jib cranes

WI 00147032

Cranes — Bridge and gantry cranes

EN 13852-1:2004

Cranes — Offshore cranes — Part 1: General purpose offshore cranes

EN 13852-2:2004

Cranes — Offshore cranes — Part 2: Floating cranes

prEN 14492-1:2004

Cranes — Power driven winches and hoists — Part 1: Power driven winches

prEN 14492-2:2002

Cranes — Power driven winches and hoists — Part 2: Power driven hoists

EN 12999:2002

Cranes — Loader cranes

EN 13157:2002

Cranes — Hand powered cranes

prEN 13155:1998

Cranes — Non-fixed load lifting attachments

EN 14238:2004

Cranes — Manually controlled load manipulating devices YES

Use it directly, plus the standards that are referred to

NO

Use the following: EN 13001-1:2004

Cranes — General design — Part 1: General principles and requirements

EN 13001-2:2004

Cranes — General design — Part 2: Load actions

CEN/TS 13001-3-1:2003

Cranes — General design — Part 3.1: Limit states and proof of competence of steel structures

CEN/TS 13001-3-2:2003

Cranes — General design — Part 3.2: Limit states and proof of competence of wire ropes

WI 00147 050

Cranes — General design — Part 3.3: Limit states and proof of competence of wheel / rail contacts

EN 13135-1:2003

Cranes — Equipment — Part 1: Electrotechnical equipment

prEN 13135-2:2000

Cranes — Equipment — Part 2: Non-electrotechnical equipment

EN 13557:2003

Cranes — Controls and control stations

EN 12077-2:1998

Cranes safety — Requirements for health and safety — Part 2: Limiting and indicating devices

EN 13586:2003

Cranes — Access

prEN 14502-1:2002

Cranes — Equipment for the lifting of persons — Part 1: Suspended baskets

prEN 14502-2:2002

Cranes — Equipment for the lifting of persons — Part 2: Moveable cabins

EN 12644-1:2001

Cranes — Information for use and testing — Part 1: Instructions

EN 12644-2:2000

Cranes — Information for use and testing — Part 1: Marking

28

CEN/TS 13001-3-2:2004 (E)


Bibliography

[1]

Feyrer, Klaus: Drahtseile — Bemessung, Betrieb, Sicherheit. Berlin, Heidelberg: Springer-Verlag 2000. ISBN 3-540-67829-8

[2]

Feyrer, Klaus: Laufende Drahtseile — Bemessung und Überwachung. Renningen-Malsheim: Expert-Verlag 1998. ISBN 3-8169-1481-0

[3]

Feyrer, Klaus: Biegewechselzahl und Ablegereife von Spiral-Rundlitzenseilen. Fördern und Heben 5/1997 Vereinigte Fachverlage GmbH. ISDN 0441-2636

[4]

EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2: Technical principles and specifications (ISO 12100-2:2003).

29


DD CEN/TS 13001-3-2:2004

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BS DD CENTS 13001-3-2 Cranes. General Design. Limit States and Proof of Competence of Wire Ropes in Reeving Systems

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