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PROVENCE GRAND LARGE WIND FARM N2SSM-SBM-PGL-001
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Document title PROVENCE GRAND LARGE WIND FARM Sheathed Spiral Strand
Revision 0
Document establishment
Function Name Designation Team Date
Drafted by Mohd Qalid Sen. Manager Sales 09-07-2020
Document history
Date Rev. Summary Drafter
Establishment of PROVENCE GRAND LARGE WIND FARM
09-07-2020 0 Qalid
Sheathed Spiral Strand
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Table of Contents
1. Company Introduction 5
2. Scope of Supply 7
5.2 Drawing 19
5.4.2 Winding 21
5.4.3 Stranding. 21
5.5 Extrusion 23
5.7 Socketing 24
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6.1 Testing 26
6.1.1 The following test on individual wires and the finished spiral strand 26
6.1.2.1 Rods 26
6.1.2.2 Wires 27
6.2 Inspection 27
6.2.1.1 Jacket 27
6.3 Traceability 28
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1. Company Introduction
Kiswire is the World’s largest manufacturer of steel wire rope. The company has grown into a major
international operation with global sales and marketing presence and manufacturing facilities in KOREA,
MALAYSIA, CHINA, VIETNAM, INDONESIA, EUROPE and USA.
In 1997 KISWIRE established a dedicated manufacturing operation in Johor, Malaysia. This factory
offers a complete range of wire ropes for the oil and gas industry, with unit weights for 6 strand rope reaching
up to 120 tonnes. Through continuous improvement, product development and expansion, Neptune Wire Rope
(6 & 8 strand) has grown into one of the leading products for the offshore industry.
In the 3rd Quarter of 2011, KISWIRE established a new specialized factory for offshore rope at a
strategic location in Tanjung Langsat, Johor, Malaysia in order to meet with various customers’ demands.
Currently, the market requires longer, heavier, and stronger wire rope. Now, unit weights for our 6 and 8
strand wire rope can reach 320 and 405 tonnes, respectively. This new plant is dedicated to produce
offshore wire rope; N2 Hyrope this new plant will design and produce 6 and 8 strands ropes, multi strand and
Spiral Strand Wire Rope (SSW) in diameters ranging 50 to 170mm.
KISWIRE has begun Sheathed Spiral Strand Wire Rope production known as N2 Spiral. This N2 Spiral
is for use on deep water permanent mooring for offshore industry N2 Spiral offers a torsional balanced
construction and high strength permanent mooring solution. Corrosion protected using galvanized wire, a
dedicated lubricant package, and with the presence of robust sheathing is ideal for systems with design lives
of up to 15 ~ 30 years’ service.
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Address : PLO475C, Jalan Ipil, PO Box 101, Pasir Gudang, 81707, Johor, Malaysia.
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2 Scope of Work
Kiswire will supply SSW complete package with wire rope sockets, sacrificial anodes, and bend
stiffeners as required and together steel reel & cradles, spreader beam, and related accessories as specified.
2.1.1 Sheathed Spiral Strand Wire Rope (SSW) Characteristics and Properties
REF GENERAL DATA UNITS ROPE DATA
1 Steel Wire rope name - Sheathed Spiral Strand Wire Rope
2 Wire material specification - API Spec 9A
3 Line number ea 18
4 Rope construction - 1 x 483
5 Rope length & tolerance m 55 (-0% +0.1%)
6 Rope steel diameter & tolerance mm 122 (-0.0% / + 5.0%)
7 Design life year 20.5
CLASSIFICATION SOCIETY
8 Classification Society Name - Bureau Veritas
ROPE PROPERTIES
9 Minimum Breaking Load kN 16,000
10 Axial Stiffness (EA) MN 1,394
11 Tolerance on axial stiffness - +/- 3%
12 Permanent stretch after repeated cycling at 55% of MBL % 0.15 ~ 0.35
13 Bending ratio (D/d) vs laying tension curve - D/d 25
14 Maximum twist allowance @ 55% MBL o
/m 0.05
SOCKET TERMINATION
15 TYPE: Closed or Open type - Open
16 Fatigue safety factor of socket - TBA
17 Padeye capacity - TWO 20 tons padeye per socket
18 Manufacturing method - Forging
Required dimension, tolerances and surface roughness of
19 - -
shackle pin connected to socket
CORROSION PROTECTION
20 Corrosion protection for rope, including details of galvanising - Yes
21 Corrosion protection for socket termination (anodes & coating) - Yes
SHEATHING (PROTECTIVE JACKET, OPTION)
22 Type of sheathing (single or double) - Single
23 Material (HDPE, MDPE…) - HDPE
24 Sheathing thickness mm 11
25 Sheathing thickness tolerances mm Min. 9 / Max. 13
26 Max. allowable pressure on sheathing N/mm² 21
FINISHED SHEATHED ROPE WEIGHT PROPERTIES
27 Rope weight in air kg/m 82.9
28 Rope weight in seawater kg/m 72.1
REEL DESIGN
29 Reel design (single or dual) - dual
30 Back tension for reel design kN 50
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2.1.1.1 Technical Data Sheet of Sheathed Spiral Strand Wire Rope (SSW)
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SSW construction is 1 x 483 wires; consist of SeWS55 core and 9 layers of wires helically spun in
opposite direction. The SSW will be designed to provide the high strength and torque balance properties as
specified spiral strand design prepared to have torque values of zero and develop 0 Nm torque at 25% of the
mbl for the 122mm spiral strands. These designs have been produced using Kiswire’s computerized design
software.
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We have completed the fatigue life calculations with provided data from document
PESDHYFS885111C1 “LONG TERM DISTRIBUTION TENSION for Wire Rope” and, as expected, the
predicted life is very long - 455 to 845 years, depending on the mooring line leg. The corrosion resistance is
the more important consideration on the critical path to achieving a minimum of 20.5 years’ service life. In
this regard Kiswire can offer an excellent and quality assured product.
An analysis on theoretical fatigue life of spiral strand has been compiled using the calculations
provided in API RP 2SK.
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Steel reel is designed to carry load net weight 11.74t (55m x2ea + 4 socket set) withstand minimum
5.0t of back tension and be able to sustain normal sea transportation and be able to carry spare segment for
long term storage.
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Where required, rods will be patented on a modern heat treatment line. The patenting process is in
two stages; heating to produce a homogeneous austenite and then quenching to produce a fine pearlitic
microstructure.
During heating, the rod temperature is controlled to ensure a fine grained austenitic structure is retained and
the furnace atmosphere is carefully controlled to prevent surface decarburisation and to minimise scale
formation.
The lead quench temperature is selected to produce the optimum combination of strength and ductility in the
rod. This allows successful drawing for high tensile wire.
All rod coils are tested to ensure the tensile strength lies within the expected range and that the ductility
(constriction) is satisfactory.
The patented rod will have a grain size of 6 or lower according to ASTM E112 and show less than 10%
resolvable pearlite at a magnification of 1000 with a numerical aperture of 0.85. (Nital – nitric acid in ethyl
alcohol – is preferred to picral for etching. Nital is similar to picral for microstructural examination but does
not have the health and safety issues of picric acid). No welds are used in the patenting process.
All cleaning processes are carried out in hydrochloric acid of controlled concentration, temperature and iron
content to ensure total removal of surface scale in the minimum immersion time.
Special inhibitors are routinely added to the baths to minimise acid attack of the underlying steel and
hydrogen absorption in the steel. All coils are visually inspected by the operator before processing further.
The rod coils are chemically coated to aid subsequent wiredrawing. A reactive coating (phosphate) is bonded
to the steel surface followed by a non-reactive outer coat. This combination of coatings provides protection to
the steel surface during wiredrawing and ensures that adequate lubricating soap adheres to the surface to
prevent die/steel contact in the tungsten carbide die.
The composition and temperature of the coating baths are controlled within specified limits to ensure
consistent coating. Coating weights are regularly monitored
5.2 Drawing
Wiredrawing is planned to ensure a minimum storage time of the cleaned and coated rods to prevent
deterioration of the coating.
Wiredrawing is carried out on modern state-of-the art machines with excellent block cooling. Selected dry
soap lubricants are employed to ensure satisfactory lubrication and to aid subsequent cleaning. The die
geometry and aperture sizes are selected according to starting rod and finished wire diameters.
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Wire drawing conditions are controlled to ensure that the wire temperature does not exceed proven control
limits. Excessive wire temperatures lead to ‘ageing’ in the wire, which is accompanied by reduced ductility
and variable tensile strength.
Wire temperatures are routinely measured, together with the wire diameter after each of the drawing dies.
Coil to coil welds identified and removed after drawing. Each wire coil is tested to confirm the strength and
ductility are satisfactory.
Kiswire provide wire coating with zinc. The drawn wire is stress relieved before acid cleaning. This
stage prevents embrittlement of the wire and burns any residual drawing coat, which aids cleaning. The stress
relieving temperature is controlled to prevent tensile and ductility changes beyond those resulting from the
zinc coating baths.
The wire is cleaned, fluxed and dried to provide a steel surface which readily reacts with the molten metal and
provide an adherent coat.
The coat weight is controlled to meet the requirements of ASTM A586 Class A or ASTM A856 Class A
through selection of processing conditions. These also ensure a smooth, uniform and continuous coat. Ingots
of 99.95% pure zinc are used for galvanizing.
The mechanical properties, adherence and coat weight are measured on one end of each coil. The zinc coat
weight is measured by a gravimetric test.
Coil to coil welds may be used through the coating process but can be identified and removed after drawing.
The delivery note should be checked for quantity and correct wire coil identification. A visual inspection for
damage must be carried out on 100% of the wire coils. Delivery note must be signed for. The goods shall be
unloaded and stored in the correct area. Certification should be forwarded to the appropriate QC person.
Sockets and fittings must be examined visually. They must be clearly identified with the contract name or
number. They should be stored in a secure area (fittings include Pins, Bend Limiters, Anodes etc.)
Lubricants should be clearly identified and should be stored upright with the lids fully sealed.
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5.4.2 Winding
The coil identification conforms to the bobbin labels. A satisfactory condition of 100% of the wire. Set the
length clock. Set the traverse to achieve the required standard.
Before removal of the bobbin from the machine the bobbin identification label should be fastened to each
corresponding strander bobbin.
5.4.3 Stranding
Ensure that all operations are done in accordance with the job card.
Welds are only performed where allowed by the specification.
A wire break report is completed for each break.
Verify that the correct bobbins are at the machine and that all bobbin labels are attached.
Unload and load the machine.
Check that correct core is loaded.
Correctly position the pulling away strap.
Retain the bobbin label and thread wires to the forming point.
Form up and fit equipment. (For outer cover use nylon dies and clamps to avoid strand surface
damage)
Check lubricant type and temperature.
Check strand is aligned correctly in the forming point.
Set bobbin tensions.
Form approximately 3 meters of strand.
Check strand for die or roller marking.
Apply serving (500mm for intermediate covers below 86 mm:1 meter above 86 mm:14 x strand
diameter for final cover)
Call for full inspection by QC.
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Strand diameter
Lay
Lubricant cover
Wire size
Strand or wire distortion
Visual damage to the cover.
Set length clock.
Check bobbin tensions.
During manufacture of the Seale, a datum mark should be applied at the start of the manufacture.
The Seale should then be “hand taped” using a calibrated tape, to the correct length and verified with
the clock length.
This operation will require three men – one operating and two hand taping.
For final cover, run end over to the take up reel, cut down and weld pad eye to the strand.
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Run rope end over to the take up reel cut and remove test piece (this may have to be witnessed by a
third party) and weld pad eye to strand end.
Place test piece on a length of steel girder to prevent damage to the test sample.
Length Measurement.
Two operators are required for this operation
Check the condition of the calibrated tape.
Run a length of the sheathed strand down the measuring line.
Check the length required from the master sheet.
Mark the sheathing with datum mark [point A]
First operator measures 30 meters from [Point A] and marks the sheathing [Point B] and signs the
master sheet.
The second operator them measures from [Point B] to [Point A] and verifies the measurement, and
counter signs the master sheet.
This procedure continues until the length is completed.
5.5 Extrusion
Extrusion Process
Load extruder hopper with HDPE, and load the auxiliary with black HDPE
Switch on dryer, load take up reel.
Fit die and pin to cross head
Thread pilot rope back to pay off reel.
Release rope end.
Straighten rope end and remove serving.
Fasten pilot rope to pulling eye on the strand
Pull strand to cross head and align strand in cross head.
Purge the extruder.
Start extrusion.
Start applying the black line.
Start non-destructive test machines –
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Use X-ray to check for sheathing thickness and any lifted wires
Check for concentricity, size and surface finish using automatic gauges for eccentricity and for
pin holes.
As strand leaves pay off, remove serving.
Confirm water quench bath temperatures
Straighten strand.
Run completed strand onto take up reel.
Remove full take up reel.
5.7 Socketing
Socketing procedure
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Select appropriate sites and warehouse, the place should be in the clean, no harmful gases or dust.
Stored in a warehouse where NO alkali’s, acids, alkali, salts, and other corrosive materials are
stored.
It will be necessary to store the goods in controlled atmosphere with low humidity. This is
probably best achieved by storing the goods inside a container or any kind of well covered area
with service to control the relative humidity.
The goods may be supplied with standard plastic covering but the plastic cover should be
removed when the goods are place inside the container or any kind of well covered area. This will
allow air circulation and avoid moisture entrapment.
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6.1 Testing
6.1.1 The following tests on the individual wires and the finished spiral strand product:
a) Individual galvanized wire tests, according to ASTM A 586 or ASTM A 856 class A minimum, on
each round wires of the spiral strand, according to our standard sampling method, to be agreed with
local inspector, and proposed in our final Quality Plan, prior to the start of manufacture.
b) Wire rope test samples: 2 load/break test samples are proposed, for each wire rope diameter, as
follows:
Proof loading of the supply package will be fully tested in a mock up arrangement prior to shipment and be
available to the client and external inspectors for witnessing.
The breaking strength of the strand will be tested using the specified sockets to be used the mooring line
supply.
6.1.2.1 Rods
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6.1.2.2 Wires
Qualifying Test Sample (QTS) locations shall be per DNV-OS-E304, Ch.2, Sec.5. will be commenced by
socket manufacturer.
6.2 Inspection
6.2.1.1 Jacket
Spark arrestor, X-ray (to detect sheathing thickness & pin hole), diameter measurement.
1) Continuous wall thickness by using x-ray measuring device at overall circumference of jacket.
2) Length marks at every agreed interval by using permanent ink with inkjet printer.
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6.3 Traceability
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