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    inspection, maintenance and certification of wire ropes

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    7 views12 pages

    Wire Ropes and Their Uses

    Uploaded by

    livslx
    inspection, maintenance and certification of wire ropes

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 12
    ic Se esac ear cary peo his special issue of Signal wil cover certfation and handing requirements ofeach Useful sources of erence nung inter conventions and standards, are provided on the back page SIGNALS Wire construction Source: Cortex 6x36WS.IWAC Worington Seale Wie Source:N Thompson Wire Construction Before discussing the use and maintenance of Ship's wires it is useful to understand. how Wire ope sabia from stands of ual wies. The configuration oft m selected grades of steel to predetermine Dhyscl properties and sizes. A number offnshed comer atten to form a stand, The si of suitably fabricated strands a tof the finished wire ition to properties such s material strenath ‘minimum beating load and co and the number of 8x36 construction denotes 6-strand rope, with strand having 36 wes. 1 centre of the wire may ‘rane wires on ships are commonly configued wth core (WSC) dependent wire ropecore(WRC) or wiestand sed to a fibre core ing, such a8 14/7 & 7/7, ve arrangements ofthe strand ravens andor ies arranged to sive dif known as Fille, Seale Filler (F)~ Characterized by the small spacer wires that ie inthe gaps between strands ofthe inner ayer to help positon and support the outer layer they provide crush sistance and lel, Seale (S) ~ Characterised by having eaually sized wires in the outer ayer with the some number of wifrm but sar sized wiresin the ne layer round a central core wire. The arrengement provides goad abrasion resistance but less fatigue Warrington (W) -Characterised by having one of its wite layers made up of an arrangement of altematly large and small wires. This arrangement provides good flexibly and strength but lesser abrasion esistance. The notation WS, for examal wire rope suchas 6x36 patterns are wed Continued page 2 INSIDE: puns os Peete can nih Eee coat a creme Pea WIRE CONSTRUCTION Wire rope lay Thehelicor spr ofthe wires and strands in a rope ishonas he ay and there re several asic ype. Fight hand eguerloy Aight ond Langsioy Lefthandreguorioy Lefthand ang'sioy| Regular (ordinary) ly - This denotes open which the wires are twisted in one direction, and the strands the oppsite direction to form the rope. The individual wires appear to run oughly parallel to the centre line ofthe rope. Due to the aifference indirection between the wires and strand, regular lay ropes ae ess ily to un-twistoknk Regular loy ropes ae alzo less subject to failure fom crushing and cstortion because of the shorter lenath of exposed outer wires. Lang's ly This the opposite to regularly -the wires and strands spiral inthe same erection and appear torn ata diagonal tothe centre in ofthe rope. Due ta the longer length of exposed outer wires, Lang’ lay ropes have greater flexibility and Bbrason resistance than do regular lay ropes. Greater care, however, must be exercised in handing and spooling Langs lay ropes. These ropes are more ley to twist kink nd eush than regular iy ropes. Regular lays the most common form of wire rope for cranes and usually furnished for all rope plications unless others specif. Thelay-length isthe near aatance a single stand tvtends in making one complete turnaround the rage. Lay-tength is measured in a straight line paallel to the centre line of the rope, nat by Faloning the pth ofthe stand, Strength Te responsibility for determining the minimum strength of a wte rope used in a given system ets with the manufacture ofthe machine, appliance or lifting equipment. AS art ofthis proces, they should have taken into account any relevant regulations or codes of practice governing the design of the rope ~ often refered to as the coffcient of utilisation ~ and other Factors that Wire construction (continued) ‘migtnfuence the desig, These include the design ofthe sheaves and drums, he shape ofthe groove profiles and corespending radius, the dum pitch, land the angle of fee all of which have an effect ‘nope performance ‘Once the strength (ferred to. 25. minimum breaking fore or minimum breaking oad) has been determined its then necessary to consider which type of ape wil be most suitable. Forinstance, des ited tobe rotation resistant, havea good fatigue performance, ot be able to withstand particular typescf abuse or arduous conditions? Resistance to rotation Some applications require use ofl ratation or rotation resistant rope, Examples would be ifebost fall wires, and main and aur hist crane wires ‘Suh ropes are often refered to as muti-strand ropes Sit oreight strand rope constructions are ine for ow lifting heights r those with multiple als but the mast common choice to misimise load rotation on a single part system, block ation, or ‘abling” ono multi-part eeving system, are low rotation ropes. When foade, steel wire ropes generate ‘torque It both ends of rope are Fixe, or turn if one ena Isunresrsines, The torque or turn generated wil increase asthe load applied increases, and the Aegree to which tis happens wl be influenced by the construction of the rope. The tendency for any rope to tum will be greater a5 the helt of lift increases, In 2 multi-part reeving syster, he tendency forthe rope o eal wll increase as the Spacing between the pats ofthe rope decreases Selection of the correct rope will help to prevent cabling’ and rotation of the os. Some wites have been designed to minimise problems associated th cabling and lsd rotation ‘As a general rule, however, ia rotation resistant ‘ope is ot needed then it should not be sed six ‘or eight strand rae wl always be more robust and better able to withstand excessive let angle and suse than thelemorecompex counterparts Fatigue resistance ‘The rope’ ftiqu resistances aso an important facta. Stel wire ropes wil suffer from fatigue ven working around a sheave or drum. Therate of eteroratonsintuenced by te umber of sheaves inthe sytem, the tareteraf the sesves and um nd the lating conditions. fatigue resistance is an sau, then its wise to select a rope containing Sirall wires, sch a5 6 x 26 0S (14/78 7/711), 28 opposed toa rope containing larger wires suchas 2 6 19 (/0/1, whichis more resstan to wear. Additonal resistance to atgue canbe achieved by selecting 9 wire rope with a smoother surface than standard rope. Thisimproves roe 1oSheave contact leasing to reduced wear on both rope an sheave ‘An increased cross-sectional steel area. and improved interne contact also ensures that the rope wil operate with omer internal tres evel ‘Thisultmately resus in greaterbendingfatioe life ‘nd long-term lower operating costs Wire pe on aocent rum fpscon couse pointcontactondacelerated wear Compoctedouterstandswilleduce abrasion | troughimproved contactconditions. Resistance fo weor ‘Source Certex Resistance to abrasive wear ‘Aarasive wear cn take pace beteen ir rope and sheave, and betwen wite ope and drum, ut the greatest cause of abrasion Is often through ‘ntererenc’ atthe drum. abrasions determined to bea major factor in rope deteriaration then a wire ope with relatively large outer wires should beseecte, ‘tan’ oy structure, hen the ditecton of lay of the wires inthe tr sans he sane as that of the outer stands inthe ope, aso has better wear characterises than a regular ay rape ~ when the {irecton ofa ofthe wires in the outer stands in theoppsite Breton tthe af the outerstrands intherope Crush resistance ropes In multi-layer coling applications, where there is more than one layer of rope on the érum, itis tssentl to instal she rope with some back tension. This should be between 295 and 108 of the minimum breaking force of the wite rope. this is hot achieved, rin applications where high peessure ‘on the underlying rope i inevitable - such as a boom hast rpe ralsng 2 oom from the horizontal Dostion ~ then severe crushing damage can be ‘caused to the underlying layers Use of steel core as opposed to fibre core wll hep this situation, land for this reason stel core ropes are always recommended for crane use. ditional resstance’s offered by wies which have high steel fil-fector and these rapes are also recommended fr multi- layer coling operations where crushing on lower layersis ineitabe It should also be noted tata Lana's ay ope resists interference atthe dum beter than a regular ay. Corrosion resistance ropes When the wire rope is tobe used in 2 comosive envionment = which applies broacly acass the maine environment thena galvanized coating my ‘be recommended and where moisturecan penetrate ‘the rope and attack the core, plastic impregnation ‘could be considered. In order o minimise the eects of eosin itis important to slecta wie ope with = suitable manufacturing lbrcat This should bee plied regulary while the ropes inser: a ~» SRP TT ROUTINE INSPECTION ’ Routine Inspection The time interval and extent of inspection and intenance for wites will vary. depending documented by the manufacturer an incorporate repent office rt ofa continuous races of inspection for age, the wire rope shouldbe signs of genera general condition of al monitored on a daly bass when in use. All wires ian by a resposile person before work commences and on completion Jer nvoranc if socksosding is thought to Rave ire ropes are stored on drums, considera the timescale and logistics that wil be involved cludes vith planning ‘Although wies of si or eght strand constuction ands, ts the super provided by the ore whi maintains the wires efficiency and performance of any inspection regime and may be cared out bya The sagram exibited a minimum amount ofcorsion, with ao GP broken wires and limited wear, The rope pated Periodic Examination By cond of therope incu iting heavier nada oad, ates the rate of fatigue damage tothe must be including the fequency of inspection, rie to rect this Rate ofeceurence of broken onition of wre. These are commonly refered to Period examination shouldbe carried out by @ m « er50n and will involve the complete nd the ves 150 43 eile ag Stat rework for an examination and many determining how often they shouldbe caved ou. how often it suse, referred to a the number of Internal Examination Some specialized tols are required to carr out an ternal examination, These nelude + AT neele(e Nat spike wit rounded edges) ora fed scremdrver for displacing outer + Tape measure for measuring lay length + Chatkelectricians tape for marking any areas that equi further examination + Cleaning materials solvent fr removing debris ‘The examination should concentrate on evidence of ake wits internal abrasion ction, the degree of eonesion ad intra vrei ‘lamps approximately 100mm ~ 200mm apart of causing permanent damage. The stands can tbe manipulated with the probe to facitate ‘nce the examination complete, desing can be ont the cre. At 2 pint of termination one clan will usualy be suc must be recorded and compares tothe discard ‘Source: Certex Examining ropes running over sheaves he lengths of rope running aver sheaves are the most heavily worked pats of the ope and the " The rope MUST NOT Discard Stress, abrasion, bending, crushing and coresion tae the most common Sources of damage to wires. Henever rotation, vibration cabling and elongation may also oceur under certain circumstances. These can in extreme cases lead to catastrophic ire au A detalied external examination should compare ‘the wire agains the dscord criteria foreach typeof ‘ite. These eriteria are determined in consultation ‘sith the manufacturer and include + Number of broken wires ~ The number of permissible broken wires til depend on the funtion of the wire and wl include the ate of breakage occurence and grouping of broken wires For example single ayer 67 ice core wireropeused fora carga wie snow be diced 12 or more wires ae visibly broken ina length equialentto diameters ‘Fractured strands ~Astrandthathas completely feactted will quite the wire tobe discard + Decrease in elasticity ~ This can be quite aifficlt to detect and it may be necessary to consult 2 wite specislist if i is suspected Warning sign can include a reduetion inthe diameter of the rope, elongation of the ly length, signs of compression between strands ‘long with the appearance offne brown ponder, and an inereas inthe stiffness ofthe wie Although broken strands maybe absent fom 2 wie that has a reduction in elasticity this ‘The lifespan of any wire will depend to gre! featent on the way that it is maintained on board. The technical nature of wire manufacture ‘demanes that planned maintenance programmes bbe developes in collaboration with che manufacturer before the wite is supplied to the vessel, Where lubrication or drssing of the wire is required this shoulé be applied prior to the wires installation on board and reapplied at pre-determined intenals. determined by the ‘manufacture. Lubricants may need tobe workes | into the core of the rope during application if they | areto sere thee intended purpose If cleaning of the wie is required before lubrication care mus be taken to ensure substances used are ‘compatible with the components ofthe wire and lubricants tobe used Changes to operating practices and environmental conditions will requite planned mainterance programmes tobe fll and aticipatory to ensure the continued safe operation of wires an board DISCARD CRITERIA J MAINTENANCE AND RECORDS Criteria condition cam lea to catastophic wire allure ‘and should result in the immediate removal of ‘the wire from servi. + External and internal corrosion ~ External corrosion is easier to detect than internal Diseolovration will be accompanied by an apparent slakness between wires, whic is result of reduction nthe cross-sectional area ‘of the wire. Coresion can rapidly accelerate fatigue damage by causing surface deformation hich canleadtostescracking the discard criteria may nh: 1 Heat damage + ate of permancr elongation ‘+ Reduction in tensile strength + Length of sevice + Number offe-cyeles, + Broken wiresat termination pins + Redution’n ameter. In addition to these considerations 2 detailed ‘examination ofthe wire will be required here has been a prolonged pei f inactivity ora change to the characteristics ofthe loading and discharge pattern ofthe ese Evidence of broken wites should vigger a more aggressive inspection regime, grouping of broken strands may indicate inherent wean the work procedure for the particular wire affected and should be monitored closely if not removed Maintenance and Examination records Detaled records of examinations must be ‘maintained, this wil allow those responsible to identity patterns of Information can then be ued in conjuntion with eamage occurence. This the anticipated cycles of work to determine expected deterioration prior tothe nest scheduled inspection. On detecting damage which exceeds that predicted inthe maintenance record, a re- evaluation ofthe life expectancy ofthe ire will bbe requited and this should be followed by an inspection ofall other associated machinery inorder to establish the source of the accel crated damage. International standard 150 4309 contains examples of rope examination records for both individual inspections and_ running records. Details should include: + Number f visible broken wires + Measurement of reduction in diameter from service. Once broken wites nave been identified i important that they be removed without further damage being done to the wit or injury to crew Pliers may be used to work the broken wire back and forward until it beaks close tothe stand. Nondestructive testing Wil greatly assist wice Inspection in applications Where there is an increases isk of internal wire damage. destructive testing is employed, initial eeference In circumstances where non- ra must be determined as soon as posible after the wires installation to allow subsequent comparisons tobe made Records” + Degree of abasion + Degree ofcorosion. + Degree ofdamage and deformation + Location of Damage and an overal assssmen of wire condition ‘The degre of deterioration may be asseseed on 3 percentage basis: igh 40% = medium 20% ane = high r= very igh 1008 = isc Storage en not in use, wires shouldbe stored in ey conditions or there protected fram chemicals and sibstanes that may harm their protective eesing read corsion ACCOMMODATION LADDERS “Accommodation Ladders r Accommodation lacers are the mast commonly Used means of acces to ships. On vessels that have iarge freeboard, they may fll the rleof genera access when in port and facilitate pilot boerdng and disembarking at the beginning and end of passage, They are generally located en the main feck, constructed in a composite fashion wich collapsible hand cils and platform. Ths allows space when the veselisonpasage The complex nature ofthis semi-permanent design may eause problems. Removable stanchions and hinged components are often damaged by excessive wear uring therigging and dsmanting proces. 5 of International Labour Organization (io) Convention adequate, sae, propery installed and secure However, the leek of specific guidance making reference to periodic inspection of accommodation laders inthe existing regulations contained in chapter 1 ofthe International Convention forthe Safety of Life at Sea SOLAS) equations 7 and & detailed planned maintenance regime Construction of accommodation ladder wire The stowage location of ladders on high freeboard ure them tobe lowered significant distance ta the vesse’s shell dor acces. Tis ean require large amounts of wire tobe spooled on winen drums, Wire used fortis purpose must be compact, have a small diameter and be flexible ough to rotate around the multiple sheave configurations associated with these ladders Strands constructed of 36 wires give good Melty ile maintaining shape and geometry with an independent wire rope core. This reduces the effet of compression and cush damage Crossecton of 361/7AC Source: Cert ‘occommodation adder wie Principal causes of damage + Corrosion - Storage onthe main deck exposes contamination. The smal diameter of wite require its the effectiveness of internal core lubrication and weakens the wires esitance to Abrasion - Damage often occurs a a esl of pulley and sheave seizure, wires canbe damaged ad kinked during rigging and dismantling, Poor supervision of adders landed on the quay may result bights of wire being expose to quay and cush damage, + Cutting in = This occurs when rope buries itself under tension ina wire that hasbeen spools poorly underneath. I nt monitored clase this an la 0 jamming causing counter rotation, Crushing ~ Uneven spooling can result in crossed wires onthe drum ~ under load this can result crush damage. This may also accu to exposed ire whien have become snagged or sipped onthe quaside * Fatigue ~ The rate of fatigue damage is accelerated by frequent bending ofthe wire while under load ~ tight nips round smal diameter pulleys and kinking damage during rigging ace examples. The rate of fatigue is accelerates by por lubrication and exposure to ‘orosion damage Care and handling The complex nature of ladder contruction requ that the rigging process be supervised by a responsible officer. During ths process 2 careful inspection should be conductes to ensute each component ofthe adr free from damage fit for purpose, secure and sultably lubricated. The supervising affcer shoud inspec the wie fr signs ae shouldbe taken to of damage and fatigue ensure» suitable amount of ack tension is applied during spooling. This wll reduce te kelihoed of the wich Most adders are designed to ret on the quayside and pivot atthe point of attachment tothe ship's hull Ths can resultina significant concentration of leasing ste, often compounded by movement of the vstel onthe berth, Supervision ofthe vessel's access can monitor the extent ofthis movement and prevent the ladder becoming overoaded when arge groups reassembled waiting to board or disembark This is particulary important when the vessel is at anchor and the adders entirely suspended from the wire and davitarcngement. Tere have been 2 number of fatal accidents under these circumstances with suspension wires. parting, rapping ladders into the water Sigs ingesting ‘maximum loading should be attached to the ladder both atthe top an bottom toads on the capacity oftheladder atany onetime. Maintenance and inspection Aan inspection bya responsible person should take Blac rior tothe preparation ofthe ladder for use and subsequent to dismanting. This shoul include vies ll moving parts nd printsfstachment The ‘out ata time interval which hasbeen determined appropriate bythe Flag State séminisration and shoud rete the Frequency of use If no guidance sprovied by te Flag State it may be prudent to adopt. 2s a minimum, te Frequency (of examination for the pilot hoist and Equipmen Cerificate Storage onthe main deck exposes the each survey for the ship's Safe wire and winching mechanism to the extremes of enranments damage possible, wire shouldbe removed from winch drums before the vessel embarks on a long ocean voyage, If this is impractical, maintenance procedures should incorporate particularly aggressive lubrication regimes to compensate and suitable protective coverings should be used when the ladder i no Discard eriteri should take account of the high levels of corrosion associated with this application LIFEBOAT WIRES Lifeoat systems have been subject 0 seat del Of scrutiny an investigation recently following cident during statutory dls nd maintenance procedures Several independent investigations have been Carried out by Fag State administrations another organisations, including the UX Maritime and Coastguard Agency (MCA) and Marine Accident Investigation Branch IMAIB). Ther conclusions orcut rat although casaton may not be direct linked to fall wire fatigue its integral role in the overall function ofthe system demands that those involved withthe maintenance, inspection and operation of ifeboat systems fully understand the complet of the design and the contribution of each component Tricing pennants, gripe wires and hanging-off pendants are subject to similar sources of fatigue and misuse sal wires and must nate overooked during inspection and maintenance programmes Tein penrants in particular have been deified by several esearch projects asbeng subjected to increasing levels of misuse by orl supervised ‘ren members who overioad nem during dis by lowering boats ta point where the weight ofthe bets mosty transfered fom the fal wire to he ttcing pennant. This dangerous practice ca ea to slack fll wires, trcing neat failure and the potential forthe consequential failure ofthe entire davit structure. These risks highlight the importance ofa resporsbe officer supervising lactis thet involve movement af the boat ana maintenance activity conducted by ship's crew. Robust rk procedures must precede all ‘examination ane maintenance work. Construction Fall wires ae required tobe both eb arstabie in order to withstand the shocking ane rotation that can be present during lowering and recovery, this equites larger sumber of smal! ameter wires within he structure of the rpe Fall ives maybe certificated to remain in sence for up {ove yeas Lubrication and the corosio estat ‘quay ofits orsruction ae therefore very important. ‘ras section af 2x7 RC low rotaionsteleore Ieboat fot wire Lifeboat Wires Principal causes of damage + Conrosion~Fersstentexpsue ie eiarmental extremes attach the constuction ofl wires. “Wisi compounded by rested access tong lenaths of wire spooled on winch drums protittng penetrating dressing and lbricaton + Abrasion ~ Seized davit sheaves and poor ope teas wil aceerate the extent of damage to the lager numberof exsese wires associated ith thistyp of ope. + Crushing High freeboar esses with laroe amount of fll wire can suter from eutingin™ uring bad spooling with low back texsion resistance increasing the lieihood of crush damage + Jamming - Uneven movement f devi and fl ‘wires ca eed to slack wire ad bight forming between sheaves, unchecked this can result in salient and sppage of tefl wre the sheave blocks jamming fall wites between ‘heave and dit seuctue Care and handling The accident investigations refered to earer {stablised that many ofthe inedents associated sit feboats ive alls, sheaves, blocks cing pennants and rie arrangements Davit alignment relies on the precise tensioning of fal wie. During lowering and recovery operations fue diligence must be exercised to ensure even spooling on winch des. Smooth opertion of the wine controls necessary to avoid sharp juddering ‘movement ofthe dts ana boat. Sheoves ae aften seat anges the than vertical Sippage of wire off sheave blocks may resut in the wire jamming bese the sheave and chet late Crew members should be made aware of the angers associated with lonering the boat to embarkation level beyand the pont of weight transfer from fall wie toting pennant, Larger apc ifeoats that are bowsed-in alongside the vest close tothe davit head produce fal wie angles that are increasingly removed from the vera. This produces nereasing large horizontal Suspended iteboat With he iteboatin ths position thereisnoloedon the fli so he tricingpennontsond doit ams apport the ene meant the ifebootunaiged ‘moments and transfers unacceptable loads on to both the dai arm and cing pennant. Maintenance and inspection AL ifeboat wes are requied ob ispectes rely ons iesiate eadiness and monthly toesut they ae maintained in gos order SOLAS chapter eulatin 2 ques wires tobe tue tod frend atintenal no exceeding 30 months and replaced at nteraenot exceeding years "ubjet tothe conto ofthe we An akeratve arrangement eaves the need for end-or-nding if wires are inspect requnty and renewed at intena not exceesing four yer, subec to wire condition Moret miotenance nd servicing guidlines than reo velable have een prompted by {helnternationl Martie Organization (10) i the annex to IMO crear MSCICre 206. This ince: + Rekae ga ncn esting proces for on leadmetanm + Davittinitsnitehes sheaves ition of roving pars. + Winch power suply, convols and braking arrangement (On vessels that are exempt fom the Iauneing reirement seid innterationalCrwenton forthe Setey of Life at Sea (SOLA) ene regulation 19, planned maintenance schedules Should tate acount of periods of inactivity. Discussion wth manufacturers should determine sual dressings and labia to reflec hese Reports and records Detailed records of inspection and maintenance work must be maintained and signed by the maintenance companys representative, ship's raster and those involved in conducting the maintenance programme. When repairs and Servicing have been completed a. statement confirming that ifebost arangements remain fi for purpose sould be issued by the manufacturer’ representative oinviual cette by them ELEVATOR WIRES "Elevator Wires Elevators orl havebeen used on merchant veses for many years. The wires used to operate them are refered to as ‘host rope’ and commonly have Numer of Visible Broken Wires Single Layer Ropes with ibe Core Operating in Cast kon or Stee Sheaves Ciera flere cor an af Sorta Tapas psec caine vin s Construction. Wies are nomal“p-frmed Skekeopetovesanoyihe | Okcadopesinmeitey ‘theres hat nnn wea prt ompetepenon not adversely change the geometry ofthe rope. Conation Gass6x19FC | Casexi9FC | Casexi9RC | Cisaxi9FC Aroenwiesrndomiy| Moretan 2 | warethan1s | Morethan2# | Moe than20 Germataronae | propel” | perpely | pereecoy” | peronciey | {oo | Bren ies Moetané | wort | Moret 5 | oe than io | beaming inone | peropeay? | peropeloy | pevopelny” | peopel | Srwouterstons | | Cossreionetxisdeet —— Sowce Cotes apcentwatenuies | 4 4 | woretana | Moreton aaron inane outer sand | Ap teseorie Both regu ay and Lang iy are sed in oit_—_| Vey beats Spa pest || eum | Masties 10) Mert rope construction. Each has quite different Lehane eon avantages. Regularly is easier to handle and wl luemor resilient to rshing damage Lanta th ‘enteral wires being expsed toa longer sy length reduces wear more effectively than ordinary lay thus improving the wires fatigue life. Whichever construction method is selected, i is important that it be mainaineéthraughout the operation of the elevate Te fibre core, which may be natural sisal or synthetic polypropylene, is impregnated with lubricant during manutacture to ensure a gradual felease during the operation of the wire. Tis facitatee mechanical movement between inaivual vires during bending anda offers some protection Against corrosion. Rate of lubricant release is critical, too quick and the wire wl slip on the sheaves, too iw and abrasion damage will eu. Combination wir constuction ules high tensile wite inthe inner strands where thei harder mare brittle construction cn be protected by softer more raleable low tensile strands on the exterior. Wihicrever wires selected its construction must be ‘compatible withthe materi used to manufsture the sheave configuration, Ses lifting ropes must share identical properties throughout thei length particularly ther stretch characterises under loa, Manufacturers must therefore ensure that pairs of rope are taken rom the same production ngth Principal causes of damage ‘+ Fatigue ~ Felt is avitl component ina hoist rope, continual bending and compression coversheave blacks wil pemeate throughout the lifespan of the rope, which, depending on ‘warking condition rama between 3 and 8 years. Weta fatigue wil produce spontaneous {racks that spread along the ength ofthe wire unt fracture Abrasion ~ rsufcen ubriant wil sult n cacessive internal wear inown 35 feting corrosion. Individual wires rub. together producing an appearance iia to rust damage. Thiscan lead to premature ise ofthe rope + Steteh- tight sscrepancesin diameter and etastic properties ofa particular wie can result “Thelength of one rope lays approximately equivalent to 6x4 (whered's the nominsl ope dzmeter] Tobie ofaiscorderiteraforsuspensionropes, ‘ovemor ropes and compensating ropes inone ofa pir of hast ropes stretching lightly ‘more than theater, of traveling more quickly ‘though the rope cycle. Without a compensation ‘mechanism inthe lit operation this an lead to slippage onthe sheave during use and affect the rection properties of the sheave and wite combination. Elastic stetch could commonly amount to about ém for every 10 metres of trove, permanent stretch ean aecount for as much as 40mm pee 10 metres of length when 2 wireisnew this isa symptom of bedg in and wil occur very quik further stretch by a5 much as GOmm per 10 metre length isnot Uncommon avers number of years Maintenance and inspection Inspection intenals for hoist wires wil be dependant on ca administration and Fg State teguatin. Subject ta the numberof rope cles, industry best practice recommends 8 cael cxamination aS monhy tena The extensive benging hich ost ropes experience demands careful assessment of fatigue rack on india wire stands. ispectons shoul ako leude termination points and the means fatachent 0 thecarand eunterneght Sheaves re designed to be softer than the wie and wil she slivers 8 resultofropesippage reset the case mustbe invested rug High operating temperatures, traction, fst ne speeds and small bending rats al reduce the efficiency of tubicatin,Adtoal biation during the operational ite ofthe wie wllcean and iaitain traction, penetrate nto the wie tng to repel mostue and recuce abrasion damage. Small amounts applies fequenty ll radce the best results. Lbatng compounds must be approved by the manufactures. Shave groves Should exhibit a sigh sponge ite texture tthe Source: Utond scolator Industry Assocation LEA) {ouch when the wires wel ubrieated. the ger remains ry, the ope requires bration. Governor ropes should nat be lubricated afterinstallaton. Inadition to sscard criteria applicable tal wie ropes the following require particular attention: + Surface eardamage to exterior wires caused by sheave action and slippage. ‘Inequality in tension between pied ropes. ‘+ Excessive stretching, tis canbe monitored by the countereight bottom overnun dimensions ‘Inequality in wire diameter throughout the length ofthe rope. ‘+ xtealevdenc of nteralreting orosion tn the absence of any national regulations or instrvetions fom the equipment manufacture the lpove table provides a general guide to broken wire ddscard citer A propery qualified competent person inspecting the wire must le aware ofthe posible increase in internal damage f operating sheaves ar construed ‘om mater other than cast ron orstee Care and handling Theres it handing of hoist apes once instal homeve they arewlnerable to gamage fom sharp edges and corners ring transportation and shiping Ropes must be protected fom wet damage, uit and heat. ubiarts ean soften in strong sunlight ard ep from the wires. The ‘ethos of urreeing must ensure there 0 kink damage and na contamination ofthe wire, pling ‘the rope ove sharp edges during installation cn praace ore which can de-stabiieits stir Some manufactrers mark the op a maior he amount of twisting ding instalation, excessive {wsting can apy reduce the fe expectancy of ist ire an ma require conection. ito HOIST WIRES Mechanical Pilot Hoists Pilot hosts were orginally introduced to assist lt to board shins with lage freeboard as an alternative to the ace modation and pit ade combination. Although pilots nave sometimes ions about their effectiveness, they ate stil in use and their safe operation is. describes in detail in Intemational Maritime (Organization (IMO) Resolution A889(2)- Pl raster Arengements adopted bythe MO in Flot host are sometimes semi-pertabe, in which ase they requite careful assembly under else slowing suficient time for rigging and testing before the vessel is due to arive at the Construction Hoist wires are required tobe made from flexibe steel wire rope whichis resistan to the corrosive joperties in the marine environment. The construction wil be very similar to that o Similar sources of damage and fatigue. = Sure: Certer WC pot hit wie Care and handling Fiat hoists consist of a moveable plot ladder section hosted or lowered from 2 su embarkation position, The necesity for two fentof one of the wires parting, however wires ‘must be spooled carefully to maintain horizontal aration on the winch drums Thi ensures » iaximum resistance to twisting and improves the concem of pilots Great care must be exerised during Ii lowering to ensure freedom of ovement ofa ies, saves and winch drums. Confined spaces at conventional plo ladder be placed adjacent and accesible ot is immetiatty available should the Maintenance and inspection Te International Convention forthe Safety of ie at Sea (SOLAS) chapter 1, regulations 7 and 8 tr intermediate survey and at each ot the shin’ Sofety Equipment Certieate. shouldbe supe by obo spe responsible officer before and after each use and ‘xamined atime intervals that both manufactures sider appropriate. Analysis te installation st of te averoad required the the dint wastage and trimming of the hoist wires uring the life-span othe wie arst care must be ‘aximum freeboard extension of the hoi hile maintaining a minimum o thee turns onthe vine drum, ofthe roles tobe ited othe platform section fhe hist f hese llr seize ican increase the fatigue damage Power failure safety mechanisms and brake stranger lowering from the vesses access. In the event of power $s. should be tested during @ (eof the hoist ta distance of metres failure a manual method of recovery should avilable and must be ited in such a fashion that hen itis engaged the power Supply to the imtarzed winch is cisengage. MOORING WIRES “Mooring Wires Wire failure continues to feature a 2 causative ‘actor in acident investigations int incidents that ‘occur during mooring operations. These ar almost alwaysserious ad sometimes atl, Each mooring operation requires careful planning to ensure that 2 safe working environment for the crew can be ‘maintained while reducing the mately sources offatique and stress damage tthe wire. Environmental exposure, abrasion damage and shock-loading al pla a part in accelerating wire fatigue. Significant loads can be experienced unexpectedly during any berthing manoeuste Incidents of this type wil frequently expose weakness within the structure ofthe rope and accelerate fatigue to the point of wie failure Designing a mooring wire with sufficiently robust ‘qualities to withstand these external fores con be particularly challenging often a technical solution ‘one source of fatigue may nate compatible with ‘the requirements demanded by the application Maintenance regimes must therefore be designed to maintain the lexbilty and subsequent fe span of the wire, while inspection programmes should erable ships crew to identity symptoms of Fatigue early in order tO protect the crew from the consequences of wie flue Construction Ropes that are constructed with wires of larger diameter will be less vulnerable to coresion damage, This chractristic i also desirable for abrasion resistance properties However to large 8 Aiameter of wice wil produce a less flexible ope and reduce resistance to fatigue damage Compromise i therefore equted to produce a wire thatcan satisfy the demands of mooring operations and also be suitably lubricated to protect it from corrosion. Wires that may be exposed to crushing damage benefit fom a wire core and equal ay construction, this wll produce a mare robust shape ‘hats ssl to deform unde peessut. typical rooting wire construction consists of ixstrand of 36 wires with an independent wire core (6x36 IWRC). Mocrng wires canbe supplied from ast 35 10mm to ove 1mm diameter Resistance to shock-oading can be difficult for 8 ‘manufacturer to include inthe design ofa rope Sometimes lengthof nylon mltilaitraneifites 2 the working end ofthe mooring wit to absoro ‘most ofthis shock Fiting a aylon tal which as 2 lower breaking strain than the wire, alo ensures that the cheaper and easier to replace tal parts before the wire when seeidental overoading takes place Principal causes of damage ' Conosion -Thisis common cause of wire rope failure. Mooring wires located on drums a the fentremities of the vessel can be subject to extensive environmental exposure + Cutting in This occurs when wire ope buries itself under tension in a wire that has been spooled poory underneath it causing counter rotation during terthing and kink damage. If undetected by erew members tis wl not only seriously damage the wire and wine, but could result in serious injury othe cre Crushing - This can seriously damage the structure of the rope by separating strands hich will change the geometry of the rope reducing te breaking strain sgnifcant, Abrasion ~ Some sources of abrasion damage are unavoidable - stevedores repeatedly fragging the wite over quaysde knuces will produce progressive wearin every mooring Wie Preventable abrasion damage accuts when wire is led through poorly maintained leads which have become seizeé or have uneven comoded surfaces, Fatigue —The extent ofa wire’ lesilty shouls be discussed with the manufacturer prior to purchase Frequent excessive bending o the wie while under load wll produce fatigue eamage, Which wil be acelerated i the wie is being used beyond its design specification. Careful consideration should be given to. the characterises of the wie when od wire being replaced by nem Before ordering new wie those responsible nee to ensure thatthe diameter of the lle leads and pedestal alles on board are ‘ompatbiewith he construction af the wie and ‘the manufactur’ recommendation. Care and handling Haneling of mooring wire ropes is 2 hazardous activity and all those involved should receive propriate instruction on the dangers and precautions requ oeduce thers of ij. ‘raining should include the limitations of use and posible causes and consequences of poor handing and insufficient maintenance. Topics could include ‘butrot be limited te ‘+ voiding sharp angles in mooring srangements. * Correct use of leads and pedestal ler ‘voiding snap-back ones. + Danger ofboken strands. ‘Hazards of lubricansin contact with skin, + Precautions required when working with single srr, spit drum and dum ends. Wires tres on rus. Mooring operations are no different to anyother hazardous activity onboard the vessel and requiea risk assessment to be cari out as pat of the ‘iting and preparation process. The raring plan should be discussed with all those who will be Involved to establish the most appropriate leads and roles tobe used foreach wie Maintenance and inspection Because af the exposed location of mooring wires and their vulnerability to fatigue damage, strict maintenance and lubrication senedues must be maintained to prevent carrion Wires should be removed from winch drums for detailed ‘examination at a time interval based on the manufacturers recommendations andthe wire’s siscard criteria. The wire should be cleaned with products compatible with the wire, intended lubricant and approves ty the wite's manufacture. During cleaning crew members must be aware of ‘the possiblity of broken wire and wear appropriate hand protection. very broken wie detected should be brought to the attention ofthe supervising officer. Wire manufacturers will stipulate the Permissible maximum numberof broken standsin given wire enath ‘Ageneral rule of thumb for mooring wires would be breakage in 108 of te vse strands in any length of wireequal to lamers this number is exceeded then the wite should be condemned and removed from service. Once ‘leaned and examined, damage to the wire must be recorded in planned maintenance records and compared tothe manufacturers discard rtera and previous damage notes, This is also an ideo! opportunity to inspect the end fiting ofthe wire to the drum and check method of attachment. When the responsibeoficer is satisfied with the wire’s condition it can be treated with the approved lubrednt and greased if requires. Care must be taken to ensure that the lubricant penetrates between the surface wies and int the central core ofthe rope. During re-spooing crew must ensure sufficient back tension is maintained this wil not only protec the wie fom crushing damage but wil help prevent cutting in and kink damage during future se Routine external examination shoud be incorporated inte pre-artival and departure checks in acordance with the vessels safety management system: ‘Ai feads, rollers and contact surfaces must be ‘maintained to ensure they ae kept smooth and ‘ree rom signs of cortsion this will reduce likey Sources fabasion damage Pedestal and fiend roler bearing surfaces shoul be kept lbrcated. Maintenance of back tension during operation and poling fo inspection must be maintained + ‘Amore detailed examination should take place after any shoetloading or unusual event. Those involved should compare the condition of the wire to the manufacturer's recommended Aiseard criteria and should check for signs of elongation and bid-caing CARGO WIRES Cargo wires are used in cranes, gantres and othe cargo ling ap sed for other lifting operations such as stores ce, Similar wires wl so be anes and engine room ganties. The spy tall such wires used n cargo and other iting Sirens the tensile forces imposed on them bythe design of appropriate factor of safety, Applicable safety factors forthe re ropes are se outin the design requirement for vanes and other lifting appliances by various ‘sasifiation societies andar primarily based on 3 safe working load (SW of the equipment. For ship's cranes ot other lifting appliances rated between 20 and 60 tonnes (SIL), the required braking strength ofthe wie ofthe order of four Fo five times the maximum signed duty load in servic. Thisaplies to iting aa ling Wrst forcesin which alter depending upon te cietation ofthe crane, ban the dymamic influences during operation Construction The most common wire construction for nite ropes on ship's anes iting appliances isthe single ayer wire rope corresponding, 3s the name suggests, single ayer of strands helieally wound srounda cove. Other typesare manufactured suchas rotation resistant’ or ‘muli-strang” in which @ number of layers of strands are contra-helclly the rotational tendency and torgue inthe rope under terslon These ope canals compacted strands in whieh the inividual wires are not round but shaped to provide @ greater rece the contac pressure Defects and damage ntemational_ standard 150.4909 provides 2 | comprehensive isting of, and photographs, showing ‘number of defects that ean oceur on crane or iting appliance wire ropes, Obvious defects such kinks and basket deformation n which the external shape af the wire rope changes shouldbe able to be identified relatively quick External corosi Should alsa be obvious during inspection. Wire ropes shouldbe frequently checked closely f other damage and defects, suchas indication of wear (fitting of wires) ane broken wires in the strands. Te extent of broken wires na give eng ‘and grouping of wire beaks real factors tha ees tobe considered when judg criteria for allowing the rope to continue in sevice. Tables in standards set out the eelevantcfteria although there are differences between the and standards under the regulatory inthis regard ee Cargo Wir Probably the most common defect within wire ope inwhich eursory examination of greased rope can often ovrooks wear. This is shown by fiateing of the round wie elements learcan be acelerted ty defective (non-otatng) sheaves with the rope abreding around it orf the wie ope diameter i larger than, an not matched, othe sheaves. Too small diameter sheaves can als result in excessve bending ofthe rope. Eventually, Patening ofthe wires reduces the load beating ctoss-secton of individual wires, which can lead to wire fractures. Wear can also initiate fatigue From a maintenance and safety perspective of wire rope, regular inspection and ubrication of sheaves in accordance with the manuf res instructions. should be flowed Wire facture caused Source:WThompson byexcessive wear Fatigue crocs Source:NThampson oO far are shown inthe two figures on et In one ican be sen by the naked eye that excessive wear. The scanning electron microscope photograph in the other shows two rack fronts propagating frm the fltteneé portion ofthe wire hough fatigue that ordinarily may not be vibe to he raked ye According to 80 4209, 2795 reduction in nominal rope ameter warrants discard ofthe rope evenfno Whichever guideline document is used to judge conton ofa wire open use onboard a esses wire ropes should be consieredconsumabe ems, Care and handling There iso set pei forthe expected lifetime o rapes. Homever in practice 2 survey cycle period of five years would bea typical maximum ifetime fo crane or lifting appliance wire ropes. OF course, depending on the duty of the crane o lifting appliance ad sil of operators, particualy prone to external abrasion o crushing ‘damage Such damage can occur ina single even and possibly resulting in relatively new wie to ‘wie, similar toa chai, sonly strong sits weakest pint. Inspection and maintenance Regular bua inspection, ideally before and after ‘operations handling cargo, should be ered ut on bord to check For damage and defects Measurement of the rope diameter (scribed from the surrounding the entire rope) shoulé be made and recorded regulary to monitor wear partulary Crane and other iting apolances and ther loose 9 nludng wie ropes ae subjet to annual and diate yearly surveys. at which hey are also prooflad tested bythe clasfiation society Details ‘ofthe surveysare recorded the vessels Reisterof Ling Appliances and Cargo Handling Gear ‘Adocumentary record af wie ropes in us onthe ‘rane or lifting appliances, their identification, appropriate est cetficates ang dates of renewal (> should be maintained onboard. When wires are

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