2014 crw - best practices for wire rope installation

Best Practices for

Wire Rope Installation

© Knut Buschmann, WDI-Python/Unirope Ltd.

Brought to you in cooperation with Python America 14

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CRANE WIRE ROPE

Installation and Inspection Guide

Brought to you in cooperation with Python America

Brought to you in cooperation with Python America

If you have to field cut a rope

For regular 6 strand 6x19 / 6x36 class ropes, and for 19x7 and 19x19 rotation resistant types it is adequate to simply wire seize the rope before cutting it.

High Performance types like 34x7 non-rotating or special 8-9-10 strand boom hoist ropes you need weld the rope ends to prevent unravelling the strands.


Attach 3 hose clamps and blade cut the rope.DO NOT use a torch !


Best is to use a steel cutting blade and NOT a weld grinding wheel.


Carefully melt and fuse the ends together.


Remove hose clamps so you can install it into a wedge socket.


Selection of induction machine cut tapered rope ends.


- measure BEFORE you install- check required actual diamater tolerances- most Lebus style drums require +2% to + 4% tolerance

Measuring the rope diameter

Wrong Right

Unreeling the rope

Wrong

Right

Connecting the rope

Preferred method when installing rotation resistant ropes.

Typical length of a open ended cable grip for 7/8” rope.

Shorter grips may work themselves loose when running over sheaves.

Connecting the rope

NEVER connect ropes with different lay directions !

The result WILL be a totally destroyed wire rope !

Winding onto the drum

After installation “break-in” the ropewith 5-10% of the rope’s WLL to“set” the rope.


This is a properly tensioned spooled rope onto a multi layer drum

This is how’s looks like when the rope was not tensioned after installing.


The result of not pre-tensioning the rope onto the drum.The rope has ‘pulled-in’ to the lower layers.


The result of not pre-tensioning the rope onto the drum.The lower layers will get crushed over time.


Typical damage due to non-tensioning of lower layers.



The un-tensioned rope simply “softens up” over time by running a “hard” line over it.



The un-tensioned rope simply “softens up” over time by running a “hard” line over it.

Note the slightly angled “in-line” damage pattern which is the resultof the crossing angle on the drum.

Wedge Sockets

Wedge Sockets

Does this look right ?

Does this look right ?

Wedge Sockets

Standard to follow: EN 13411

"Torpedo” and other Crane style Buttons

We recommend to have all buttons proof tested to 40% of rope’s breaking strength.


This method employs a torpedo shaped button which sits in a special fitting pouch and can be easily removed yet can also be securely fastend during crane operation to avoid accidental release of the button.


The installation and re-reeving of hoits ropes involves that the rope endwhich is normally attached to a wedge socket has be taken out of the

socket and then pulled through all of the reevings.


This is a ‘swaged’ button which canONLY be installed by a trained andauthorized sling shop with the help of a special hydraulic SWAGER.This can NOT be field installed.After installation the button shall bePROOF TESTED.


This is a ‘spelter’ type button and can be installed ‘in the field’ by trainedstaff. In theory, YOUR staff can be trained but we highly recommend to PROOF TEST each installed button.

"Torpedo and other Crane" style Buttons

We recommend to have both types PROOF TESTED after installation. Test beds are either stationary (picture) or mobile for field testing.Special test attachments are required to prevent damage to the buttons during the proof test procedure.


Other swaged sockets

TORPEDO SPELTER BUTTON

INSTALLATION GUIDE

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"Torpedo and other Crane" style Buttons

Load Block twisting

This not what makes life easier !

Load Block twisting

This is not what makes life easier !

Load Block twisting

Block tilting can lead to torque introductionand block rotation

Load Block twisting

Solutions:

A)Disconnect rope and rotate the end in the opposite direction the same number of times as the block rotates.

B)If permitted install a swivel at the rope end.

Load Block twisting

Look for the WARNINGS your wire rope manufacturer has published !

Examples:

Wire Rope Inspection

Abrasion, Bending and Crushing represent the ABC’s of wire rope inspection.


When any degradation indicates a loss of original rope strength, a decision must be made

quickly to allow the rope to remain in service. Such a decision can only be made by an

trained inspector. His determination will be based on:

1) Details of the equipment’s operation

2) Frequency of inspection

3) Maintenance history

4) Consequences of failure

5) Historical records of similar equipment


Shortly after installation

The occasional premature failure of a single wire may be found early in the rope life and in

most cases it should not constitute a basis for rope removal.

TENSILE breaks are characterized by their typical ‘cup and cone’

appearance.

FATIGUE breaks are typically squared off straight across the

wire ........

Under normal operating conditions FATIGUE wire

breaks shall be visible and be located at the CROWN

of the strands.

Look for broken wires

These are FATIGUE wire breaks

..... or in the case of Tension-Tension type Fatigue they often have a Z-shape apprearance.



And this is how bending fatigue wire breaks actually look like ….

…pretty clear and obvious…

(by the way: this is how wire rope SUPPOSED to break up !)


…. on a good quality rotation resistant rope …..

… clearly visible outside breaks give ample warning !


Flexing the rope exposes broken wires which are hidden in the strand valleys.IMMEDIATELY Remove the rope if you detect this break pattern; most likely this indicates a broken up- or failed rope core

Location of ‘Valley Breaks’

These are VALLEY wire breaks


This is how VALLEY breaks actually look like ….

…. in this example on a 8 x 36 overhead crane rope ….


Close up detail of the core and strands.


Valley breaks on a 19 x 7 wire rope ….

… where you have to look very closely to detect the SINGLE wire break …


…. which was hiding a much more serious condition …

… which caused the rope to fail in service !


Core Inspection

I don’t recommend thisto be done unless youare trained and qualified !


Pay particular attention to your boom hoist lines.

Photos provided by Pellow Engineering


Because if NOT, THIS could happen ....



.... or this ....


Wire Rope Inspection.... or this. He does not have happy boating weekend anymore !


Wear, Abrasion and Peening - Examples


We understand that not all is perfect !


Wear, Abrasion and Peening - Examples

Cross section of peened wire at 50x magnification

Transverse section of of peened wire showing severe wear and subsequentbreaking and snaaging of the surface


-Inspections-

Check sheave groove for fitness to accept a NEW replacement rope

Sheave Inspection

The black dot is approximately

at the location of the original

groove bottom.

Sheave Inspection

-Groove Dimension-

5/8” + 1/64 (=+2.5%)

5/8” + 1/32 (=+5%)

Sheave measured with ‘No-Go’ gauge having only 1/2 rope oversize tolerance.

New rope having full 5% oversize tolerance may not fit. Sheave must be

replaced.

Same sheave measured with gauge having the full oversize tolerance of the rope. New rope would get pinched and develops damages like ‘Bird-Cages’ or

‘High-Stranding’.

Sheave Inspection

Rope Lubrication - OSHA Rule

FactSheet

Shift Inspection

Subpart CC – Cranes and Derricks in Construction: Wire Rope – Inspection This fact sheet describes the inspection requirements of subpart CC – Cranes and Derricks in Construction, as specified in 29 CFR 1926.1413. These provisions are effective November 8, 2010. This document is intended to assist wire rope inspectors and supervisors.

Inspection Trigger Inspection Details Performed by Documentation

Apparent Deficiencies – Category I Removal from Service Criteria

FactSheet

Shift Inspection

Subpart CC – Cranes and Derricks in Construction: Wire Rope – Inspection This fact sheet describes the inspection requirements of subpart CC – Cranes and Derricks in Construction, as specified in 29 CFR 1926.1413. These provisions are effective November 8, 2010. This document is intended to assist wire rope inspectors and supervisors.

Inspection Trigger Inspection Details Performed by Documentation

Apparent Deficiencies – Category I Removal from Service Criteria


Background:

Intend is great by OSHA because they want you tolocate individual wire breaks which are causefor time sensitive rope removal.


Background:

And their concern is that that thick lubricated wireropes can not be properly inspected.


And that is CORRECT !

Very good lubrication, effective, and will protect from corrosion and will extend rope life ........

but ...rejected by OSHA.



How about lubrication like this ?

We were told:Rejected by OSHA.


How about lubrication like this ?

This is acceptable.


Difference betweenlubricated and non-lubricated rope fatigue tests is about 80% !


SEILLEB 2

Rope Drive, five dimensioning limits (Number of working cycles, discardingnumb. of wire breaks, opt. rope diameter, Donandt-force, rope safety factor) Lit.: Feyrer, K.: Wire Ropes. Berlin, New York: Springer 2007, ISBN 3-540-33821-7, p. 265.....Feyrer, K.: The endurance of running ropes under the influence of size effect. Lift-Report 37(2011)1

The signs in the yellow underlaid column of the application area can be changed.For the first five lines the signs given in parentheses have to be used. The rope has to be defined by the blue or the red signs.

Application areaNumber of working cycles (ZA10; ZAm; Z10; Zm) ZamRope construction (S; F; W; WS) (Spiral) FRope core; resp. torsion (6; 8) (18; 34) 6Number of strands (FC; IWRC; PWRC; ESWRC) (FC; WSC) IWRCLay direction (sZ; zZ) sZTensile force S = (Q*g/n*fS1*fS2*fS3*fS4) S in kN 96Diameter sheave, drum and traction sheave D in mm 330Nominal rope diameter (not for d < 6 mm) d in mm 22Nominal strength R0 in N/mm2 1960Bending length (not for l < 10d) l in mm 30000Rel. tensile force difference deltaS /S = (S - Su) /S 0Simple bendings per working cycle w ein 16Reverse bendings per working cycle w geg 1Comb. fluctuating tension and bendings per working cycle w zug 0Product of endurancs factors (without fN2 for rope constr.) fNges = fN1*fN3*fN4 1

Results:S/d_ in N/mm_= 198.3 Number of simple bendings Nein 7,300D/d = 15.00 Number of reverse bendings Ngeg 5,500l/d = 1363.6 Numb. of fluctuating tension and bendings Nzug 7,300fS5 = 1.000 Number of working cycles Z 400Sequ in N 96000 Discarding number of wire breaks *) BA30 1Fmin in kN 337.72 Rope safety factor Fmin/S nü 3.5

Opt. rope diameter dopt = d(Zmax) dopt in mm 22.2Donandt-force (Q = 1%) SD1 in kN 118.20

*)Visual a. tactual inspection: The discarding number of wire breaks BA30 is valid for ordin. lay ropes sZ. For lang lay ropes zZ, spiral-strand-ropes and all ropes running over plastic sheaves, it is only valid, if the considered rope shows - assured by tests - its discarding condition by visible wire breaks.Magnetic inspection: The discarding number of wire breaks BA30 for sZ-ropes is also valid for zZ-ropes and ropes running over plastic sheaves. Special cases: see Lit. above

Signs Number of bending cycles N resp. working cycles ZNA10; ZA10 resp. NA10; ZA10 no more than 10% of the ropes .. discardedNAm; ZAm NAm; ZAm 50% of the ropes have to be discardedN10; Z10 N10; Z10 no more than 10% of the ropes are broken Nm; Zm Nm; Zm 50% of the ropes are broken

Ropes S Seale FC fibre core sZ ordinary layF Filler IWRC steel core indep. zZ lang layW Warrington PWRC parallel steel core with strandsWS Warr.-Seale ESWRC wire rope core enveloped with solid polymerSPIRAL Spiral-round-strand-rope

Copyright: K. Feyrer, Institut für Fördertechnik, Holzgartenstr. 15 B, 70174 Stuttgart 9-11Proposals for improvement or correction please to address or e-mail [email protected]


SEILLEB 2

Rope Drive, five dimensioning limits (Number of working cycles, discardingnumb. of wire breaks, opt. rope diameter, Donandt-force, rope safety factor) Lit.: Feyrer, K.: Wire Ropes. Berlin, New York: Springer 2007, ISBN 3-540-33821-7, p. 265.....Feyrer, K.: The endurance of running ropes under the influence of size effect. Lift-Report 37(2011)1

The signs in the yellow underlaid column of the application area can be changed.For the first five lines the signs given in parentheses have to be used. The rope has to be defined by the blue or the red signs.

Application areaNumber of working cycles (ZA10; ZAm; Z10; Zm) ZamRope construction (S; F; W; WS) (Spiral) FRope core; resp. torsion (6; 8) (18; 34) 6Number of strands (FC; IWRC; PWRC; ESWRC) (FC; WSC) IWRCLay direction (sZ; zZ) sZTensile force S = (Q*g/n*fS1*fS2*fS3*fS4) S in kN 96Diameter sheave, drum and traction sheave D in mm 330Nominal rope diameter (not for d < 6 mm) d in mm 22Nominal strength R0 in N/mm2 1960Bending length (not for l < 10d) l in mm 30000Rel. tensile force difference deltaS /S = (S - Su) /S 0Simple bendings per working cycle w ein 16Reverse bendings per working cycle w geg 1Comb. fluctuating tension and bendings per working cycle w zug 0Product of endurancs factors (without fN2 for rope constr.) fNges = fN1*fN3*fN4 0.2

Results:S/d_ in N/mm_= 198.3 Number of simple bendings Nein 1,500D/d = 15.00 Number of reverse bendings Ngeg 1,900l/d = 1363.6 Numb. of fluctuating tension and bendings Nzug 1,500fS5 = 1.000 Number of working cycles Z 100Sequ in N 96000 Discarding number of wire breaks *) BA30 1Fmin in kN 337.72 Rope safety factor Fmin/S nü 3.5

Opt. rope diameter dopt = d(Zmax) dopt in mm 22.2Donandt-force (Q = 1%) SD1 in kN 118.20

*)Visual a. tactual inspection: The discarding number of wire breaks BA30 is valid for ordin. lay ropes sZ. For lang lay ropes zZ, spiral-strand-ropes and all ropes running over plastic sheaves, it is only valid, if the considered rope shows - assured by tests - its discarding condition by visible wire breaks.Magnetic inspection: The discarding number of wire breaks BA30 for sZ-ropes is also valid for zZ-ropes and ropes running over plastic sheaves. Special cases: see Lit. above

Signs Number of bending cycles N resp. working cycles ZNA10; ZA10 resp. NA10; ZA10 no more than 10% of the ropes .. discardedNAm; ZAm NAm; ZAm 50% of the ropes have to be discardedN10; Z10 N10; Z10 no more than 10% of the ropes are broken Nm; Zm Nm; Zm 50% of the ropes are broken

Ropes S Seale FC fibre core sZ ordinary layF Filler IWRC steel core indep. zZ lang layW Warrington PWRC parallel steel core with strandsWS Warr.-Seale ESWRC wire rope core enveloped with solid polymerSPIRAL Spiral-round-strand-rope

Copyright: K. Feyrer, Institut für Fördertechnik, Holzgartenstr. 15 B, 70174 Stuttgart 9-11Proposals for improvement or correction please to address or e-mail [email protected]


Difference between tests were ropes have been re-lubed during the tests and not re-lubed is about 60%.

In this cases about240,000 vs 390,000 cycles

2014 crw - best practices for wire rope installation

Education

rope wrong right

untensioned rope

tensioned spooled rope

tapered rope ends

rope preferred method

crane wire rope installation

rope diameter wrong

drum typical damage