Nept

une®
N2Hyrope® OF
FSHOREROPES

Wi
reRopeManagementGui
de
 Qual
i
tyAs
sur
anc
e

I
SO 9001DetNor
skeVer
itasManagementSys
tem

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icat
eforManuf
act
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oces
s

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icat
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act
uri
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ses
sment

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tif
icat
eofDes
ignAs
ses
sment

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icat
eofTypeAppr
oval(
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itasAppr
ovalofManuf
act
urerCer
tif
icat
e

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tif
icat
eofWor
ksAppr
oval

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ovalofaWor
ksf
ort
heManuf
act
urerofSt
eelWi
reRop

KISWIREi
scommitt
edtosuppl
yingt
hehi
ghestpos
sibl
equal
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ros
sit
sful
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oductrange.
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evedbyst
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encet
oISO9001towhicht
hewhol
eofKISWI
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ted.

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SWI REmaint
ainsit
sQAprogr
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tsoper
ationst
oensurethatpr
oduc
tsar
emanuf
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ured
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yst
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andar
d.

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 CONTENTS Page

Qual
it
yAs
sur
anc
e 1

1.ManagementGuide 3
1.
1 RightRopef ortheappl
icat
ion 3
1.
2 Det er
miningwireropeSpecif
icat
ion 3
1.
3 Verifi
cat
ionofPOVSPr oduc t
ionorder 3
1.
4 Qual i
tycert
if
ied 3

1.
5 Howt ostor
et hewi
rer
ope 4
1.
6 Safetyfi
rst 4
1.
7 Preventropeturni
ngduri
ngi
nst
all
ati
on 4
1.
8 Cutti
ngwi reropes 4

1.
9 Remov ingbrok
enwires 5
1.
10 Spl
it& Cut 5
1.
11 Spool
ingofacraner
ope 5

1.
12 Reevi
ngofacraner
ope 6
1.
13 Trai
ningofac
raner
ope 6

1.
14 Wi
rer
opequal
i
tymoni
tor
ing 7

1.
15 Wir
eRopedi
ameter
s 8
1.
16 NDEorNDTmagneti
cfl
uxt
est
ing 8

1.
17 L
ubr
icat
ionofwi
rer
ope 9

1.
18 L
ifet
imeofac
raner
ope 10

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 Page3.

Awireropemanagementsyst
em coveri
ngthepurchas
e
oft
herighttypeandqual
it
ywi r
eropeaswellasthe
opt
imiz
ationofit
sperf
ormanceands er
vic
eli
fe.

1.
1 Ri
ghtr
opef
ort
heappl
icat
ion

Asurv
eyoft hedevicetheropes hal
lbedepl
oyedoncantel
lus
whatspec
if
icat
ionsthewi r
er opeshal
lcompl
ywi t
h.
Weareatc ust
omer sdisposaltoass
ists
peci
fyi
ngther
ightwi
re
r
opefortheapplicati
on.

1.
2 Det
ermi
ningwi
rer
opes
pec
ifi
cat
ion

Thent hedet ai
ledwireropespecif
icat
ionsc anbec omposed
(seeattachedPr oductDataSheetforguidanc e)
ThisProduc tDataSheetcanbeus edasac hec kl
is
ttosetout
thec orr
ectwi r
er opespeci
fi
cati
onsaswel l
. Itmakessurethat
noi t
emsar emi ssedout.

1.
3 Ver
ifi
cat
ionofPO ver
susPr
oduc
tionOr
der

I
nconsentwi
ththewi
reropeproducert
hepr oduceroft
he
r
opeconfi
rmstomanufact
uret
her opei
nc omplianc
ewitht
he
s
peci
fi
cati
onsuponwhi
c haPOc anbeexchanged.

1.
4 Qual
it
ycer
tif
ied

Oftenat hir
dpar t
yCl ass
ifi
cat
ionBureauCert
ifi
c ateisagr
eed
tobes uppliedwithther ope,al
ongwi t
hthepr oduc er
sown
MILLc ert
ifi
cat
e,containi
ngalldetai
l
sofallcomponentmat er
ial
usedfort hemanuf actur
ingoftherope,guarant eei
ngamongs t
othersthetraceabi
lit
yoft hemateri
al.

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 Page4.

1.
5 How t
ost
oret
her
ope

Oncet hes peci

fi
edwi r
er opeisdeli
ver
edones hal
lstor
ethe
r
opei nsideawar ehouseandpr efer
ablynotexposetherope
t
os un, r
ain,snowandf rost.
Besttostorethewir
eropeata
const
antt emper atureof,saybetween5t o20degreesCels
ius
.

1.
6 Saf
etyf
irs
t

Ifawi r
eropehasbeeni nst
oragelongerthan12months
afterproduct
ion,iti
srec
ommendedt ocutasampl
eandtest
i
t sbreaki
ngstrengthpri
ort
ous e.Steelmaylos
esomeofit
s
strengthoverti
me.

1.
7 Pr
eventr
opet
urni
ngdur
ingi
nst
all
ati
on

Alt
houghawi r
er opes hallbe,andc ommonl yis,spool edon
thest
or agedr um byt hepr oduc erfreeoft wist,whic henabl es
theri
gger stoinstallther opetwi stfreeont hec ranewi nch,
oneshal lbeawar eandmakec ert
aint hatther opei sspool ed
onthec ranewi nchf reeoft wist(torque/turn).
Inver
yc r i
ti
calsi
tuationsonec anl ayoutt heropet wistfreeon
thefl
oorandpai ntthet ops i
de. Thepai ntmar kont her ope
enabl
esust ospoolt her opeont hewi nchwi thoutt urningi t
byaccident .

1.
8 Cut
tingwi
rer
opes

Cuttingofs t
eelwirer
opess hal
lbedonewi t
hahi ghspeed
discc ut
ter
. I
tisver
yimportanttoseizeboths i
desnexttothe
i
ntendedc utoft hewir
eropet i
ghtlywithsteelwir
epriort
o
cutti
ngt herope.Theti
ghts ei
zingpreventstheropetounlay
.
Preformedr opesdonotunl ay,
howev ercertai
nropesmay
havebeenl i
ghtl
ypref
ormedf orgoodr easonsandmayunl ay
sl
ight l
yifcutwit
houtseiz
ings.

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 Page5.

1.
9 Removi
ngbr
okenwi
res

Wi thi
nt heav ai
labledis
c ar
dc r
it
eriaofwireropeduet obr
ok enwires
(seewww. neptunehyrope.com )thesewireendss hallber
emov ed
carefull
y.Bes tt
obendt hebrokenwi reendf or
war dandback war
d
untilitbreaks.Thenmak esurethatthewi r
eendshi deasdeepas
pos si
bleint hegapbet weent heout ers
trands.Brokenwiresthat
stic
koutoft her opes’s
ur f
acedes t
roybotht heropeandt hedrum
ors heavegr ooveswhenr unni
ngov ersheavesanddr um.

1.
10 Sl
ip& Cut

Veryoft
enwi r
eropess hal
lbedi s
cardedwhil
eonlyoneortwos hor
t
sect
ionsoftheropehav ebeendamagedorwor n.
Ifthesy
stem
all
owsitandthelengthofther opeissuf
fi
ci
entl
ylong,onecan
short
ent hewi
reropebyc utti
ngof fthemostdamagedsecti
onsand
re-i
nst
allthes
hortenedrope.

1.
11 Spool
ingofac
raner
ope

Thespool i
ngf rom t hes t
orager eelont othec ranewinchs hal
lbe
donewi thac ertainamountofbac kt ensi
oninor dertogett hewire
ropetightinthegr oov esofthewi nchdr um. Theamountofbac k
tensi
ondependsont hes iz
eoft her opeandi tsstrength(MBL–
Minimum Br eakingL oad).Commonl yabac kt ensionof1to2%
ofther ope’
sMBLi sappl i
ed.Uponor deri
ngawi reropeones hal
l
agreeont hes pec soft hestorager eelwiththepr oducer,
i.e.t
he
amountofbac kt ens i
ont hereelshallbec ompat iblewi
th.

Remembertowindther
opefr
om t
hestorager
eelontot
hecr
ane
winc
hdrum i
nthesamebendi
ngdir
ect
ion.So,
from t
opt
otopor
fr
om bot
tom t
obottom.

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 Page6.

1.
12 Reevi
ngofac
raner
ope

Toinst
allawi
rer
opeonanewc r
aneoneusual
lyr
igsfi
rsta
smallr
opeint
othereevi
ngsys
tem wi
thwhicht
hec r
aner opei
s
connect
edandpull
edintot
hereevi
ngsys
tem.

I
nthecaseofrepl
acementofacraner
opeoneconnec
tsthenew
r
opewiththeoldrope.
Bypull
ingouttheol
drope,
thenewrope
i
spul
ledin.

Oft
enus edconnect
ionsar
eawel
dedli
nkorreev
ingeyepadoraso
cal
ledChines
eF i
nger,whi
chc
ont
rac
tsar
oundtheropesf
ir
mlywhen
i
tispull
edon.

1.
13 Tr
aini
ngofac
raner
ope

Beforeawireropei sdepl oyedfullswing,i

ti srecommendedt o
trai
ntherope. Thatistoc ycl
ether opet woort hr
eet i
meswi t
h
max i
mum 5% t ension/loadofitsMBLont her ope. Bytrai
ningthe
ropeoneallowst hec omponentwi r
est ofindt hei
roptimalpos i
ti
on
beforet
heac tualjobs tart
s.Thi
swayc onstructi
onalinconveniences
areavoi
ded. Thet r
ainingofac raner opeisak i
ndofwar mi
ngupor
may bebett
erc ompar edwi thnews hoes: bes ttoweart hem afew
ti
mesbeforer unningamar athonwi thit.

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 Page7.

1.
14 Wi
reRopequal
it
ymoni
tor
ing

Ani
nst
all
edc
raner
opes
hal
lbei
nspec
tedper
iodi
cal
l
y

a.vis
uall
y,ev
eryti
meoneusest
herope.Corr
osion,damageand
wirebreakscanbedi
agnos
edbytheeye.Seetheattac
heddis
car
d
cri
teri
adiagr
am.

b.tec
hni
call
y,bymeasuri
ngtherope’
sact
ualdi
amet
er,
eit
her4
ti
mesperyearoraf
terev
ery25li
fti
ngcyc
les.

Awireropeinus
es howsacons
truct
ionalandanelast
icext
ensi
on
ors
tret
ch.Bothr
esulti
nareduc
tionofdiameteroftherope.

Thecons t
ruc t
ionalextensi
onhappensdur i
ngt hef i
rstl
ift
ing
cycl
es.Thec onstruct
ionalset
ti
ngofthec omponentwi resint he
roperesultintoaper manentreduc
edr opedi amet er(s
eealso
theabovei t
em under10) .Ac ommonc onstr
uct i
onalextension
ofacraner opei s0,
50t o0.80%.Prec
iselythes ameper centage
diameterreduc t
ionoc cur
s.

Ela
sticex tensionha ppenswhent her opeisputunderl oada ndis
gonea ss oont heloadistakenof ftherope. Atl eastaslonga sthe
wireropei singoodc ondi
ti
on. Byt heti
met her opea pproaches
theendofi t
sl i
fet
ime, t
heelasti
ci
ty
ofthec omponents t
eelwiresinther oper educ es ,
result
inginto
theelas ticstretchbecomingl essandl essel as
t i
candmor eand
mor eper manent .Atthesamephas eseveralc omponentwi res
canbr eakont heout s
ideandi nsideofther ope. Bothabov e
fact
or sc auseper manentdi ameterr educti
onoft herope, whic
h
mak est hec losemoni tori
ngofdi amet erreduc tionar eli
abletool
towat cht hequal i
tyofawi rerope.

All
owabledi amet erreduc t
ionforac raner ope, both
constr
uctionalandper manentelasti
c, shallnotex ceed2%. As
soonast heper manentr opediameterr educ ti
onappr oaches
the2%, ones hallmeas uretheropeev eryweekorev ery5lift
ing
cycl
es.Onc ethedi amet erreduct
ioninc reasesins hortt i
mef rom
2til
l3orahi gher%, ther opeshallber eplaced.Noneedt os ay
thatt
her opes hallal
way sbemeas uredatt hesames potsand
underthes amel oad. Sincetheropei sass trongasi tsweakes t
spot,t
heweakes tspot sshallbemoni toredi nthef i
rstplace.

I
tisi
mpor
tantt
ous
eal
argej
aws
,el
ect
roni
cdi
amet
erc
ali
bre.
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 Page8.

1.
15   Wi
reRopedi
amet
ers

Awi
rer
opehast
hef
oll
owi
ngdi
amet
erpar
amet
ers:

•
Thenomi naldi
ameter,
i.
e.t
hediameterasitisor
dered–100( index)
•
Thedes igndiameter-103.
5
•
Thedi ametertheropehasunder3% tensi
onofthemac hinewith
whichitiscl
osed-103.0
•
Thedi ametertheropehasonthestoragedrum wit
hwhi c
hi tis
suppl
ied-103.5
•
Thedi ameterat10% l
oadoftherope’sminimum break
ings tr
ength-
102.
4
•
Thedi ameterat20% l
oadoftherope’sminimum break
ings tr
ength-
101.
5

1.
16 NDEorNDTmagnet
icf
luxt
est
ing

I
nor dertoas s
esst
hequal i
tyofawireropeinter
nally
,beyond
vi
si
bili
ty,wenowadaysav ai
lofamet hodtos eei
nsideawirerope
bymaki ngaMagnet i
cFluxtrac
koft herope.Thi
sNDEorNDTs c
an
det
ec t
sbr okenwir
es,l
ossofmet al
li
carea,andotherint
ernalr
ope
di
storti
on.

Themos tef
fecti
vewayofus i
ngthist
echnologyi
st ohaveaNDE
scanmadeoft henewlyproducedwir
er ope,whi
cht henlat
ercanbe
comparedwi t
hthes c
ansmadeaf t
eruseinthefi
eld.Thisway,qual
i
ty
dif
fer
encescanbenot i
ced.Ki
swir
eoffer
sNDE /NDTs cansbothofnew
ropesaswellasropesinuseonsit
e.

Sayi
ngallt
his,NDEs canstomoni
tortheinter
nalquali
tyofwi
rer
opes
arehar
dlypracti
cedduet oext
ensi
ve,
c os
tlyoperat
ionsinv
olv
edwit
h
i
t,whil
ebri
ngingr el
ati
vepoorass
essi
ngres ul
ts
.

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 Page9.

17. Lubr
icat
ionofwi
rer
ope

Duri
ngthema nufac
turingofwirerope, i
.
e.duri
ngthecl
osingofthe
wir
esint
oas tr
and,lubric
antisappli
edt oprov
idethei
nsi
dea nd
outs
ideofthestr
andwi thalubri
cant.Thesameproces
sgoesf orthe
I
WRCoft herope.Awi reropethereforeisl
ubri
cat
edenti
rely
,ins
ide
andoutsi
de,whendel i
vered.

Thema infuncti
onofwirer
opelubri
canti
storeducei
nter
nalf
ri
cti
on
ofthewireropeinuse.Theac
hieva
blenumberofbendingcyc
les
bet
weenal ubri
cat
edropeandanotlubri
cat
edr opei
s100vers
us
40,res
pectivel
y.

Anotherfri
cti
onreduci
ngfactoristhezinccoat
ingonwi r
es.
Gal
vanizedwireropesgeneratelowerinter
nalf
ric
tionthan
notgalvani
zedwireropes.
Thez inclay
erac t
sasalubricant.
Thesecondaryfunct
ionoflubric
antistoprotec
tther opef r
om
cor
rosion.

Oper ati
ngt emper at
uresofthebestavai
lablewireropelubr
icants
var
yf rom mi nus50t oplus120degreesCelsius.
Re-l
ubr i
c at
ingawi reropeinthefi
eldisadelicat
emat t
er.
Reali
s t
icall
y,aproperre-l
ubri
cati
onishardlypossibl
eandtherefor
e
l
imitedef fi
cient
.Wek nowt hefol
lowingavail
ablemethodsof
re-
lubricati
ngi nthefi
eld.

• Tobrushthelubric
antont heropewhil
espooli
ngit.
• Tosprayl
iqui
dl ubric
antonther opewhi
lespool
ingit
.
• Toruntheropet hroughadev i
ceinwhic
hthelubri
canti
s
pr
essedonandpar tl
yintherope.

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 Page10.

1.
18 Li
fet
imeofac
raner
ope

I
ntheendi tisallaboutt helifetimeoft hewi rerope.Howl ongwil
l
t
heropes ervic
ei ngoodc ondition?Thes erv
iceli
fedetermining
f
act
orsofawi r
er opear e:
• Thel oad/tensi
onappl i
edont her ope
• Drum ands heavedi amet ers(D/dr atios)
• Thenumberofs heav esandt hei
rpos i
ti
on( D/Ddistanceand
possibleRev er
seBendi ngs)
• Veloc i
tyofoper ati
ons( accelerat
ion/ deceler
ation)
• Tensileoft hewires
• Weat herc ondit
ionsandac c
identst hatimpac tthequali
tyof
therope.

Quit
eof t
entheproduc eroft hewireropeisaskedinthisrespect
howmanybendi ngc yclesapar t
icul
arwireropecouldac hi
eve.
Indi
cat
ionsareabout300. 000c y
clesforaHYROPE35x K7or40x K7
or55xK7at10% tensionofi t
sMBLi nt helabor
ator
y.Since,the
aver
ageof f
shor
ec ranedoespr obablynotmor ethan100c y
c l
es
peryear,
thetheoreti
cbendi ngc ycl
elif
eti
meofaHYROPEi s3.000
year
s.

Obv i
ously,t
heabov elabor
atorybendingfat
igueres
ult
sareone
t
hing, t
hepr act
icalf
iel
dwireropesarebeingusedinhasadynami
c
content,whicheffec
tsthebehavi
orandt heevent
ualbendi
ng
f
atiguelif
e.

Li
nks: www.
nept
unehyr
ope.
com

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