U.M. CE rev.8 July 2015

Transcription

1 WIRE ROPES FOR PASSENGER TRANSPORTATION USE AND MAINTENANCE HANDBOOK Page 1 of 33

2 Contents I. USE MANUAL OF COMPONENTS... 4 ROPE COMPONENTS FIELD OF APPLICATION CONDITION OF USE AND SAFETY APPLICABLE STANDARDS GENERAL INFORMATION MEASURED ROPE DIAMETER WIRE ROPE ELONGATION ( CARRY HAULING ROPE ONLY) MODULUS OF ELASTICITY HAUL ROPES, CARRY HAULING ROPES, SPLICED EVACUATION AND RECOVERY ROPES FLAR CARRYING ROPES TENSION ROPES RECOVERY ROPES SIGNAL ROPES WITH ELECTRIC CONDUCTORS OR OPTICAL FIBRES SAFETY FACTORS ROPE TENSION BENDING RADIUS GRIPS LINERS END CONNECTION FIXING DRUM FOR TRACK ROPES EVACUATION AND RECOVERY ROPES, SIGNAL ROPES, TENSIONING ROPES END FIXINGS ROPE LENGTH ROLLERS AND SHEAVES GROOVE DIMENSION AND SHAPES SHEAVES SHEAVES GROOVES DIAMETER AND ANGLE SPAN: LINE ROLLERS GROOVE DIAMETER AND ANGLE SPAN: SHEAVES AND WINCH DIMENSIONS (FOR RECOVERY & EVACUATION ROPE IF NOT SPLICED, & TENSIONING ROPE) : TRANSPORTATION AND STORAGE FACTORY PACKING ROPE IDENTIFICATION AND SHIPMENT ROPE DELIVERY AND UNLOADING STORAGE ROPE INSTALLATION WORKING AREA REEL POSITIONING AND STANDING PULLING ROPES AND ROPE INSTALLATION EVACUATION AND RECOVERY ROPES INSTALLATION: SIGNAL ROPES INSTALLATION: ROPE CUTTING STRANDED ROPES: SPIRAL STRAND ROPES AND FLAR ROPES: SIGNAL ROPES WITH OPTICAL CORE (OPTICAL FIBRES): WIRE ROPE MAINTENANCE RE-LUBRICATION INTRODUCTION LUBRICANTS USED DURING THE ROPE S PRODUCTION: TYPE AND QUALITY CARRYING ROPES (FLAR AND ERCOLE ROPES): TOWING ROPES FOR SKY TOW, FIX ROPES, TENSION ROPES: GALVANISED AND UNGALVANISED CARRY-HAULING ROPES FOR FIXED AND DETACHABLE GRIPS INSTALLATIONS, HAUL ROPES FOR AERIAL ROPEWAY AND SURFACE SYSTEM Page 2 of 33

3 SIGNAL ROPE, EVACUATION & RECOVERY ROPES ON WINCH WITH OR WITHOUT ELECTRIC CONDUCTORS & OPTICAL FIBRES RE-LUBRICATION OF IN USE ROPES: INDICATIONS AND PRODUCTS RE-LUBRICATION FREQUENCY INSTRUCTION FOR THE LUBRICANT APPLIANCE ROPE RELOCATIONS TRACK ROPE SIGNAL ROPES GRIPS FOR BICABLE AERIAL ROPEWAYS AND FUNICULARS FIXED GRIPS OF MONOCABLE AERIAL ROPEWAYS GRIP INSTALLATION RELOCATION OF GRIPS WIRE ROPE REPAIR ROPE LOOP SHORTENING FULL LOCKED COIL ROPE REPAIR STRANDED ROPES REPAIR SPLICE COMPONENTS FIELD OF APPLICATION CONDITION OF USE AND SAFETY APPLICABLE STANDARDS TENSIONING AND FIRST SPLICING (APPLICABLE FOR STRANDED ROPES ONLY) GENERAL INFORMATION ABOUT THE TENSIONING SPLICING PRELIMINARY TENSIONING SPLICING POSITION SPLICING DIMENSION WARM UP AND ELONGATION MEASUREMENTS FIRST OPERATING SERVICE AND L0 MARK SOCKET COMPONENT FIELD OF APPLICATION CONDITION OF USE AND SAFETY APPLICABLE STANDARDS SOCKETING II. WIRE ROPE INSPECTION RECOMMENDATIONS FIELD OF APPLICATION CONDITION OF USE AND SAFETY APPLICABLE STANDARDS POST INSTALLATION CHECK DAILY INSPECTION MONTHLY INSPECTION ANNUAL INSPECTION SPECIAL INSPECTION INSPECTION OF PARTICULAR ROPES: SIGNAL ROPES AND RECOVERY ROPES SIGNAL ROPES: RECOVERY ROPES (NOT SPLICED AND THAT WORKS ON WINCH): The purpose of this manual is to supply to the final user the prescription for a safe use and maintenance of the ropes supplied by Redaelli S.p.A.. All the indications shown in this manual are in references and according to the European Standards (see also Condition of use and safety Applicable Standards ). The changes of the manual are underlined: The additions, in cursive underlined The removals, through a vertical line, on the side of the page, in the point of the removal Page 3 of 33

4 I. USE MANUAL OF COMPONENTS 1. FIELD OF APPLICATION ROPE COMPONENTS Haul ropes, carrying hauling ropes, locked coil carrying ropes, towing and fix ropes, recovery and evacuation ropes, tension ropes and signal ropes for cableways installations designed to carry persons. Hercules ropes are not included in the EN CE marking does not apply on Hercules ropes. Hercules ropes shall only be selected to replace similar ropes on existing installations. 2. CONDITION OF USE AND SAFETY Applicable standards If not otherwise specified in this document the applicable standards are: Preservative compounds for Keope friction drive winding ropes mining Safety requirements DIN 21258:1986 and testing DIN DM 1175 EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN Determination of behaviour of rubber and elastomers when exposed to fluids and vapours Disposizioni per le verifiche e prove per l accettazione delle funi metalliche destinate ai pubblici servizi di trasporto effettuati mediante impianti funicolari aeree e terrestri (N.B. this standard is applicable for Ercole ropes only) Steel wire and wire products Steel wire for ropes Part 1: General requirements Steel wire and wire products Steel wire for ropes Part 2: Cold drawn non-alloyed steel wire for ropes for general applications Steel wire and wire products Steel wire for ropes Part 3: Cold drawn and cold shaped nonalloyed steel wire for heavy duty applications Steel wire ropes Safety Part 1: General requirements Steel wire ropes Safety Part 2: Definitions, designation and classification Steel wire ropes Safety Part 3: Information for use and maintenance Steel wire ropes Safety Part 4: Stranded ropes for general lifting applications Steel wire ropes Safety Part 8: Stranded Hauling and carrying-hauling ropes for cableway installation designed to carry persons Steel wire ropes Safety Part 9: Locked coil carrying ropes for cableway installation designed to carry persons Safety requirements for cableway installations designed to carry persons Operation Safety requirements for cableway installations designed to carry persons Quality assurance Safety requirements for cableway installations designed to carry persons Ropes Part 1: Selection criteria for ropes their end fixings Safety requirements for cableway installations designed to carry persons Ropes Part 2: Safety factors Safety requirements for cableway installations designed to carry persons Ropes Part 3: Long splicing of 6 strand hauling, carrying-hauling and towing ropes Safety requirements for cableway installations designed to carry persons Ropes Part 4: End fixings Safety requirements for cableway installations designed to carry persons Ropes Part 5: Storage, transportation, installation and tensioning EN Safety requirements for cableway installations designed to carry persons Ropes Part 6: Page 4 of 33

5 EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN 1709 EN 1907 EN 1909 EN 444 ISO 2592 EN 1908 ISO :2003 DIN teil 1 DIN 1501 teil 2 Discard criteria Safety requirements for cableway installations designed to carry persons Ropes Part 7: Inspection, repair and maintenance Safety requirements for cableway installations designed to carry persons Ropes Part 8: Magnetic rope testing (MRT) Safety requirements for cableway installations designed to carry persons - General requirements - Part 1: Requirements for all installations Safety requirements for cableway installations designed to carry persons - General requirements - Part 2: Additional requirements for reversible bicable aerial ropeways without carrier truck brakes Safety requirements for cableway installations designed to carry persons Calculations Safety requirements for cableway installations designed to carry persons Operation Safety requirements for cableway installations designed to carry persons Civil engineering works Safety requirements for cableway installations designed to carry persons Drive system and other mechanical equipment Safety requirements for cableway installations designed to carry persons Electrical equipment other than for drive system Terminations for steel wire ropes Safety Part 1: General purpose steel thimbles Terminations for steel wire ropes Safety Part 2: Spliced eyes Terminations for steel wire ropes Safety Part 3: Ferrule secured eyes Terminations for steel wire ropes Safety Part 4: Metal and resin socketing Terminations for steel wire ropes Safety Part 5: U-Bolt wire rope gripped terminations Terminations for steel wire ropes Safety Part 6: Asymmetric wedge socket clevis Terminations for steel wire ropes Safety Part 7: Symmetric wedge socket clevis Safety requirements for cableway installations designed to carry persons Carriers Part 1: Grips, carrier trucks, on-board brakes, cabins, chairs, carriages, maintenance carriers, tow-hangers Safety requirements for cableway installations designed to carry persons Carriers Part 2: Slipping resistance tests for grips Safety requirements for cableway installations designed to carry persons Carriers Part 3: Fatigue testing Safety requirements for cableway installations designed to carry persons Precommissioning inspection, maintenance, operational inspection and checks Safety requirements for cableway installations designed to carry persons Terminology Safety requirements for cableway installations designed to carry persons Recovery and evacuation Non-destructive testing General principles for radiographic examination of metallic material by X and gamma rays Determination of flash and fire points Cleveland open cup method Safety requirements for cableway installations designed to carry persons Tensioning device Cranes and lifting appliances Selection of wire ropes - General Rillenprofile fur seilrollen Rillenprofile fur Seiltrommeln Page 5 of 33

6 3. GENERAL INFORMATION 3.1. Measured Rope diameter The measured diameter of ropes shall be in accordance with the standard, EN (for towing, signal ropes, recovering rescue ropes, tension rope), EN for haul and carry hauling ropes, The Redaelli general diameter production tolerance shall be +1% / +5% of the nominal diameter of the wire rope. The measured diameter of the Full Locked Coil Ropes and Ercole shall be in accordance with the standard EN (± 2% of the rope nominal diameter). Different tolerances can be agreed with the customer during the commercial and technical discussion before the issue of the order confirmation IMPORTANT: the diameter measurements shall be taken in accordance of EN Wire Rope Elongation ( carry hauling rope only) The indicative elongation values of the non pre-tensioned stranded wire ropes are indicated below: 0,20 % in the first 500 hours of use 0,30 % in the first 1500 hours of use 0,60 % in the life of the cable The experiences confirm that the pre-tensioned ropes show a reduced elongation values than the ones above indicated for the non pre-tensioned ropes (close to 50% less than the standard values indicated). The real values depend by different factors and mainly by: correct rope installation and its over tensioning before the splicing operation (see chapter Splice Component paragraph 10), number of bending cycles, tensioning, working temperature, etc. THE GALVANISED ROPES SHOW MORE ELONGATION DURING ITS SERVICE LIFE DUE TO THE DEFORMABILITY OF THE ZINC COATING. FOR THIS MATTER THE VALUES LISTED ABOVE SHALL BE INCREMENTED OF 0.05% AT LEAST. FOR MORE DETAILS ABOUT THE WIRE ROPE ELONGATION CONTACT THE TECHNICIANS OF REDAELLI S.P.A Modulus of Elasticity The modulus of elasticity indicated below are refereed to values determinate after the initial trial stage. During the rope lifetime these values will increase significantly Haul ropes, Carry hauling ropes, spliced evacuation and recovery ropes For six strands wire ropes with fibre core, the value of the modulus of elasticity (after a certain period of use) is: E = 125 kn/mm 2 ± 4% For seven strands wire ropes with fibre core, the value of modulus of elasticity (after a certain period of use) is: E = 114 kn/mm 2 ± 4% FLAR carrying ropes For the track rope the indicative value of the modulus of elasticity is: E = 140 kn/mm 2 ± 4% for Ercole rope type E = 155 kn/mm 2 ± 5% for Full Locked Coil rope type Page 6 of 33

7 Tension Ropes For the tension ropes the indicative value of the modulus of elasticity is: E = 110 kn/mm 2 ± 4% Recovery Ropes For the recovery ropes with metallic core the indicative value of the modulus of elasticity is: E = 120 kn/mm 2 ± 4% Signal ropes with electric conductors or optical fibres For the signal ropes the indicative value of the modulus of elasticity is: E = 170 kn/mm 2 ± 4% for Spiral Strand ropes E = 120 kn/mm 2 ± 4% for stranded ropes If the actual measured value of E is to be known, it should be determined experimentally on an appropriate wire rope specimen Safety factors They shall comply with the EN standards if not otherwise specified. A lower safety factor could be adopted only for rope s installation purpose. For this specific situation refer to specific instruction of the rope manufacturer if available 3.5. Rope tension It shall comply with the EN standards if not otherwise specified. If the rope needs to be spliced, the installation s manufacturer shall notify in advance the value of the minimum rope tension (or the value of maximum safety factor) to the rope manufacturer and the organization in charge for the splice so to evaluate the right splice length ad design following the EN standards 3.6. Bending radius The minimum bending radius depends by the rope type and construction. The allowable values shall comply with the EN or specific standards and / or rope s manufacturer indications (see par. 3.11) In same cases, using special rope constructions (7 strands rope for example), the minimum bending radius may be lower allowing to use smaller rollers, sheaves etc. The minimum bending radius selection can be addressed by the rope manufacturer. A sharp bending may permanently damage the rope Grips They shall comply with the EN standards if not otherwise specified. Their grooves must comply with the rope diameter. The closing force must be as specified by the manufacturer. The max admissible transversal pressure on the rope is 35 N/mm 2 (referred to the nominal rope diameter); see SS1 Technical Documentation released by Redaelli. After the releasing of the clamping force, the rope shall not stay permanently deformed Liners They shall comply with the EN standards if not otherwise specified End connection They shall comply with the EN standards (En , EN for example) if not otherwise specified Fixing drum for track ropes The storage of the spare cable and the winding of the suspension cables on drums shall be carried out by running out the end of the cable along the route and placing it in the correct position as the operation proceeds. Page 7 of 33

8 It is important that the cables are placed in position without having been rotated, as this may create anomalies. To do this, the pitch should be checked in the section immediately in front of the departure and arrival stations, extending the check to the intermediate zones if any difference in the lay length is noted. The excess lengths of cable (storage rope) must be coiled or wound on drums having a diameter equal or larger than 30 times the rope nominal diameter. The direction and the diameter of the coiling must be the same of those of the anchor drum Evacuation and recovery ropes, signal ropes, tensioning ropes End fixings The connection of the evacuation and recovery ropes, signal ropes and tensioning ropes shall be performed accordingly with the EN and EN13411 or specific National standards where applicable and request. The end fixing in the main cases is an EC component and as indicated before each possible or chosen type of end fixing shall be comply and respect the proper EN or local (if request by the local authority) standards and subjected to an EC conformity evaluation by an authorized notify body. The indicated standards give the minimum indication and parameters for the end fixing characteristics, dimensioning and safety strictly parameters can be adopted. Possible main end fixings that can be use and take in consideration during a people transportation installation design are (see EN also): Filled and Clamp Socket: Splice Drum Wedge socket Spliced eyes Ferrule secured eye etc The end fixing efficiency indicated in the EN standard shall be take in account during the installation design and calculation. All the developed end fixing or in line connection shall not damage the rope and its components (for example optical fibres, cupper electric wires etc, metallic core etc.) Special connection could be design but shall be communicate to the rope manufacture in order to verify that the rope will be not subjected to any damage or important reduction in safety and if requested must be subjected to the EC conformity procedure. FOR SIGNAL ROPES WITH OPTICAL FIBRES THE FINAL CONNECTION AT THE FINAL ELECTRICAL BOARD SHALL BE PERFORMED BY COMPETENT / SPECIALIZED PERSONS AND ADEQUATE AND PROPER TOOLS MUST BE USE SO TO AVOID ANY COMPONENT DAMAGE AND FAILURE THAT CAN RESULT IN A SAFETY REDUCTION Rope length The length of each rope depends by : The rope tension (depending by the force, the rope metallic area and the E modulus) The rope stretch (depending by the type of rope, its core, rope pre-stretching) The environmental temperature [depending by the factor 12 mm/(km x C)] Rollers and sheaves groove dimension and shapes In order to reduce and avoid any rope rotation that could compromise the rope in service life time and then ensure its best behaviours during the service, all the systems where the rope pass through shall have the correct dimension and shape to avoids its lateral and transversal compression that are one of the causes of its rotation. The sheave and groove of the line rollers and the drive and bull sheaves shall be meet at least the dimension indicated in the next sub paragraphs Sheaves They shall be comply with the EN standards if not otherwise specified. The lining material shall be compatible with the rope lubricant and the lubricant used for the rope relubrication Page 8 of 33

9 FOR FURTHER INFORMATION READ CHAPTER 1 PARAGRAPH N 6 WIRE ROPE MAINTENANCE OF THIS USE AND MAINTENANCE MANUAL. The groove diameter must be higher than the rope diameter (see and also) For the recovery and evacuation rope if are not spliced and are install on winch, particular attention to the installation design (sheaves and drum) need to be take in account.(see also) Sheaves grooves diameter and angle span: Bicable installation (reversible aerial ropeway, 2S,3S, Funifor etc.): the groove angle span (α) shall be: α 60. The new groove diameter shall be at least: 1.05d d 1.10d where d =nominal rope diameter. In presence of wear groove its diameter shall be at least d wear groove d actual rope diameter Gondola lifts, chairlifts, ski-tow: the groove angle span (α) shall be a least 80 α 140 with optimal angle span of 120. The groove diameter after 200 working hours shall be at least d groove 200h d actual rope diameter In presence of lining material with M.E N/mm 2 small groove diameter than the ones above mentioned could be allowed but shall be respect the actual dimension after 200 working hours 200h: d groove 200h d actual rope diameter Line Rollers groove diameter and angle span: the groove angle span (α) shall be α 120 with optimal angle span of 120. The new groove diameter shall be at least: 1.05d d 1.10d where d =nominal rope diameter. In presence of wear groove its diameter shall be at least d wear groove dactual rope diameter.. In presence of lining material with M.E N/mm 2 small groove diameter than the ones above mentioned could be allowed but shall be respected the actual dimension after 200 working hours 200h: d groove 200h d actual rope diameter The following sketch put in evidence the difference between the angle span and the envelope angle. The span angle shall be calculated taking as reference the angle between to two lines starting from the roller / sheave centre, and tangent to the circle that simulate the rope diameter + 10% (figure below on the left) For flat rollers the span angle is due to the roller / sheave side flanges inclination Page 9 of 33

10 Redaelli suggest as optimal dimension of the groove: Where: D = groove diameter [mm] dn = nominal rope diameter [mm] D = dn x 1.10 A REGULAR CONTROL OF THE GROOVES DIMENSION AND THEIR REGULAR MAINTENANCE AVOID POSSIBILE DAMAGE ON THE ROPE. DIAMETERS AND SHAPES LESS THAN THE MINIMUM TOLERANCES INDICATED ARE NOT ALLOWED AND REDUCE DRASTICALLY THE IN SERVICE ROPE LIFE Sheaves and winch dimensions (for recovery & evacuation rope if not spliced, & tensioning rope) : Sheaves: The groove dimension for the sheaves shall be at least 1.05d and not more than 1.10d ( where d = nominal rope diameter), with optimal dimension of 1.108d when new (see ISO :2003 also). The construction material shall be choose in order to support the rope pressure on it under working condition so to avoid fast and dangerous groove wear. For the pressure calculation see table below. The sheave diameter must be 25d (where d= nominal rope diameter) and the open span angle must be not less than 30 and not more than 60 included (see ISO :2003 also). The maximum allowed fleet angle is 1.5%. Different value not included in the above indication shall be communicate to the rope manufacturer for evaluation and in use admissibility; Winch: the winch must be design to allow a perfect rope wind on it. The drum diameter shall be at least 30d (where d = nominal rope diameter), while the drum width must be design in order if will work in a single or multi layer and if the drum will be smooth or grooved. The dimensions shall be develop to avoid any wrap cutting and or incorrect rope winding. For grooved winch the groove s pitch shall be 1.06 d and the groove diameter equal to 1.05d (where d = rope nominal diameter) and in any case respect how indicated in the ISO :2003 or DIN The max allowed fleet angle is 1.5. During the first installation the rope shall be wind on the drum with appropriate back tension (see par 5.4). INCORRECT SYSTEM DESIGN OR SMALLER DIMENSION THAN THE ONES INDICATED ABOVE CAN RESULT IN RAPID AND UNEXPECTED ROPE DETERIORATION WITH A SAFETY DRASTICAL REDUCTION Page 10 of 33

11 Maximum acceptable specific pressure P table for different sheave construction material Sheaves material construction Cast Iron Fe410 C45 36NiCrMo4 Sheaves material hardness [HB] >100 >160 >235 >465 Max admissible rope pressure [N/mm 2 ] Note values for 6 strand ropes only Formula for rope / sheaves pressure calculation Where: P 2F Dxdx P = effective pressure on the sheave s groove [N/mm 2 ] (P due to the rope slide and contact) F = force applied on the rope [N] D = sheave diameter [mm] d = rope nominal diameter [mm] λ = shape coefficient - depends by the rope type, sheave and groove conditions, etc. λ values for a 6 strands ropes with IWRC New groove, without fleet angle and right groove diameter 0.50 Wear sheave with max 1.5 of fleet angle 0.25 smooth drum or sheave with groove diameter higher (more than 1.10d) than rope diameter 0.25 Rope on the cross over point in the multi layer drum / winch 0.10 Page 11 of 33

12 4. TRANSPORTATION AND STORAGE 4.1. Factory Packing The Redaelli S.p.A. Wire Ropes supplies all Haul ropes, carrying hauling ropes, locked coil carrying ropes, towing and fix ropes, recovery and evacuation ropes, tension ropes and signal ropes for cableways installations designed to carry persons; in reels packed according to the Client s specification, if any.. Only short lengths of tensioning rope can be packed in coils. The rope identification tag is firmly fixed to the reel in a readable position Rope Identification and Shipment The wire rope shall be recognized and identified by means of the identification s tag applied to the reel and on the rope. Normally the tag (Redaelli one) is filled with the following details : CE Marking followed by the last two numbers of the rope production year and the notified body number that released the CE certification; Rope Manufacture name and address Customer; Installation name; Rope Identification; Customer Order Number; Reel number; Rope Designation; Rope Length; Gross weight; Net weight; Tare; Year of manufacture; The order number confirmation is written in the rope CE declaration also. For the FLAR ropes the reel number is write in the rope CE declaration too. If the reel is shipped via sea, it will be suitably protected or placed in a container to prevent damage during handling, transportation and storage phases. Specific agreement about the transportation and tags can be discussed and required with the customer Rope Delivery and Unloading At the beginning of the shipment all the delivery documents are sign by the carrier and at the arrival by the person in charge to the delivery receiving. Copy of the rope s identification tag must be keep with all the delivery documents by the customer job site representative. During transportation the reel shall be placed in a horizontal position and suitably anchored by restrains. The reel shall be handled using suitable and certified lifting devices inserting a proper shaft throughout the centre hole s shaft of the reel. The reel must be unloaded using the appropriate equipment avoiding: no direct contact between the lifting slings and the wire rope happens; Shocks. Jerks, falls etc The reel shall not be dropped or subjected to any shock, jerk, knock etc. which may cause damage to the rope or the structure of the reel itself. This may adversely affect the uncoiling operation and any braking action; Reel roller. The reel should not be rolled over the floor. If this cannot be avoided, ensure that the flanges are not damaged and that the outer layer of the rope does not touch the ground. If inclined plane is used a continuously and correct control of the reel must be adopt Page 12 of 33

13 4.4. Storage If not otherwise agreed, the supplied protection of the reels is only provided for the duration of the transport (maximum 2 months). If the rope needs to be stored for a longer period, an adequate protection shall be adopted in relation to the storage site also. It s better to store the reel in a safe well covered place and avoid that the rope is expose and goes in contact with rain, humidity, dust, dirt, chemical agents or chemical vapour, corrosive environments. Under good storage conditions, a reel of rope could be stored for an unlimited period of time. Preferably, the reel should be stored with horizontal axis. In case of hot climates or hot environments the lubricant on the rope may leak out. In this case, the reel must be rotated half a revolution (at least every six months) in order to prevent migration and dripping of the original lubricant. Care should also be taken to preserve intact the protection applied by the manufacturer. The condition of the cable-reel assembly must be assessed at the start and at the end of the storage period, and the results written on the identification tag. For rescue rope and signal rope with electric conductors and / or optical fibres if long storage is required attention shall be take for the rope s ends also. A proper and adequate seal must be adopt so to avoid water or humidity penetration, damages due to incorrect handling etc. of the optical core. IMPORTANT: for further information refers to the European standards EN and EN Page 13 of 33

14 5. ROPE INSTALLATION 5.1. Working Area Whatever techniques are adopted, which may vary according to the availability of equipments or factors linked to the site layout, the company responsible for the preparation and erection works must provide for: - A horizontal platform with the necessary anchors points for fixing the reel on the pay-off system; - The installation of the pay-off equipment, winches or pulling devices, shall comply with all safety requirements and shall be designed to ensure the regular and uniform tensioning of the rope; - Supplementary supports for running-out the rope (supports, guide rollers, pulleys, etc.) shall be installed according to the ground configuration, to prevent the rope from coming into contact with the ground or any other obstacles. It is discouraged to use wooden timbers to prevent contact with the ground (to prevent rope rotation, lubricant removal and possible accidents). The deviation rollers shall be laid-out in such a way to prevent fleet angle, sharp bending or bends on not allowed reduced diameter. The installation company shall use the necessary site equipment in accordance with the procedures previously accepted by the cableway constructor and by the rope manufacturer. FAIL IN THE ABOVE INDICATIONS CAN RESULT IN A PERMANENT AND IRREPARABLE ROPE DAMAGE 5.2. Reel Positioning and Standing The reel shall be placed on a suitable stand, which allows the reel control and its freely rotation, the uncoiling speed control to allow the keep the designated tension in the cable by of an appropriate braking system. The stand shall be secured to ensure its stability during all the uncoiling phases. Prior to start each run-out, the installation company shall ensure that it has obtained all the necessary authorisations. THE REELS WHERE THE ROPES ARE WOUND ARE DESIGNED ONLY FOR THE TRANSPORTATION PURPOSE. THEY CAN NOT ACCEPT A DIRECT PULLING OF THE ROPE UNDER A TENSION HIGHER THAN 1t FOR REEL MADE IN STEEL. FOR HIGHER PULLING FORCE, THE ROPE SHALL BE SPOOL USING A SUITABLE TENSIONING DEVICE (capstan for example). WOODEN REEL ARE NOT ABLE TO SUPPORT DIRECT PULL 5.3. Pulling Ropes and Rope Installation The dimensioning of the messenger wire and pulling ropes shall be carried out considering the proper safety coefficients. Before pulling, it is advisable to run-out metres of rope to check any tendency to twist and measure the rope lay length. Some ropes are provided with a painted longitudinal strip. The stripe helps in detecting any rope rotation which may occur during installation. The connection between the ropes shall be made using a suitable connection system (short splice or Chinese fingers for six strands rope, socket terminal or clamps for multi-strand, Spiral Strand Ropes, FLAR etc). In case of connection by short splice, the diameter ratio between the messenger wire and the rope, shall be > 0.5. To prevent rope rotation, the lay direction of the ropes used shall be the same. Page 14 of 33

15 Special care must be taken to: Prevent injuries during the rope cutting. Generally the ropes are not fully preformed : the wires or the strands may unwind during cutting operations (see par. 5.4 also) Prevent the cables from touching sharp edges. Support rollers must be placed at the points where the cable could come into contact with the ground or other; Prevent the cable from rotating. The connection point must be ballasted using a lever system to prevent twisting in the cable. Where the cable is run-out over snow, suitable measures must be taken to prevent the cable from burying itself in the snow; If the run-out is performed under tension, pulling forces up to approximately one ton (for steel reel) could be applied directly to the reel. Forces greater than one ton require the use of special equipment designed specifically for the purpose (see point 5.2); Ensure that communications between the operators during the running-out operations is safe and secure (visual, direct, voice connection, etc.); Ensure that the appropriate precautions are taken during storms and in the presence of lightning or unconformable environments conditions; Ensure that, if there are any interruptions in the running-out operations, the cables is safely immobilised, taking into account any forces and live loads which may intervene during the stoppage; Never heat the cable (fire, torch, welding, etc.) and never use the cable as an earth wire or earth connection during welding; FOR FURTHER INFORMATION REFERS TO THE EUROPEAN STANDARD EN AND DQ19 02 REV_1 WIRE ROPES FOR PEOPLE TRANSPORTATION ROPE INSTALLATIONS RECOMMENDATIONS EDIT BY REDAELLI Evacuation and recovery ropes installation: This rope, if not spliced and will be used on specific winch, shall be installed following some specific rules: Rope back tension: the rope shall be wind on the drum (first installation) with a back tension equal to 2% of the rope Fmin or 10% of the SWL (safety working load). Smaller values of back tension could be accepted, but during the first working operation the rope behaviour shall be constantly verified in order to avoid dangerous localized rope squeezing or deformation due to the inadequate initial rope back tension. The original reel used for the rope delivery is not able to support the installation back tension, so appropriate capstan or device able to ensure the right back tension without damage the rope must be used; During the rope installation attention shall be adopt to avoid any rope rotation and rope damage; Particular attention must be carry out during the rope s winding on the drum in order to verify that each wrap is close to the previous one. In case of multi layer winch attention must be carry out in the layer change points also, so to verify the proper rope winding. IF THE ABOVE INDICATIONS ARE NOT FOLLOWED THE ROPE PERFORMANCE AND SAFETY CAN BE REDUCED Signal ropes installation: For this specific ropes the same attentions indicated above for the other ropes shall be take in account and observed so to avoid any rope damage and failure. In addition particular attention shall be adopted in order to avoid the optical core damage: Not allow to bend the rope on sheaves, roller etc with a diameter smaller than 20d; During the rope s installation operations not apply a tension over 15% - 20% of the rope Fmin; No pre-stretch the rope Avoid any rope rotation / twisting Apply all the attention and precautions against the rope and optical core failure Page 15 of 33

16 5.4. Rope cutting The rope cutting is a dangerous and delicate operation that require to follow some basic attentions and must be carry out by competent person so to avoid operators injuries and ropes / thing damages MISTAKES OR SUPERFICIAL ATTENTION DURING THE CUTTING CAN RESULT IN A OPERATORS INJURIES AND ROPE DAMAGE Generally the ropes are not fully preformed : the wires or the strands may unwind during cutting operations. For this a proper rope s extremity seizing / blocking to avoid uncontrolled wires / strand unwind shall be carry out. The distance between the two seizing on both sides of the cutting point must be equal 2d Stranded ropes: Normally two seizing equal 2d in length and 10d distant (where d = nominal rope diameter) on each end are enough to ensure the rope stability and avoid any wires / strands loosening. The following sketches is an example of the correct way as carry out rope seizing and cutting. For further information see ISO 4309:2004 also Page 16 of 33

17 Spiral Strand Ropes and FLAR ropes: For the Spiral Strand ropes and FLAR ropes longer servings than ones indicated in the par are requested to ensure the rope s elements stability and avoid any wires loosening and unhook. Redaelli suggest at least 3 servings >3d in length distant at least 2d each one Signal ropes with optical core (optical fibres): For the signal ropes with optical core particular attention shall be take during the cutting to avoid damage and failure of the optical core itself Normally the optical fibres are located in the rope core (centre) and are contained inside to an aluminium tube. As for the previous ropes before to proceed to the rope s cutting a proper seizing shall be perform. On depending to the type of rope (stranded, Spiral Strand ropes or FLAR etc.) the corresponding serving shall be carry out (see par , 5.4.2, 5.4.3), then is possible to proceed to cut the rope following the next indications: With a grinder cut the external and inner steel wires layers doing attention to not cut the aluminium core hose; After cut the steel wires and the aluminium hose is visible proceed to cut it on its circumferences by with hand saw. Attention shall be take so to avoid to cut the optical fibres inside the aluminium hose; When the aluminium hose is cut and take out is possible to proceed to cut the optical fibres with the specific fibres cutter or if not available with a scissor. At this step and the previous one tools with flame or tools that generate heat cannot be used. IF THE ABOVE INDICATIONS ARE NOT FOLLOWED DAMAGE ON THE OPTICAL CORE CAN HAPPEN AND THE OPTIMAL AND CORRECT ROPE PERFORMANCE IS NOT ENSURED IF NECESSARY FOR FURTHER INFORMATION ABOUT ROPE CUT CONTACT THE ROPE MANUFACTURER Page 17 of 33

18 6. WIRE ROPE MAINTENANCE 6.1. Re-lubrication Introduction The internal lubrication of steel wire ropes should be carried out during fabrication with the correct lubricants / greases selected to suit the rope s final application. The lubricants meet the in force standards for the final rope s application (EN for example). Benefits of lubricating a rope internally include: lubrication helps the wires slipping during rope bending, Lubrication helps to preserve the potential degrading of the natural fibre core and reduces the possibility of the internal rope being oxidised. (PP core does not degrade when subjected to humidity, chemical elements etc. and so core lubrication is not strictly required) Actually during the stranding operation specific developed (in collaboration with Kluber) lubricant, Redaelli 9R100, is used. Redaelli 9R100, has great lubricant performances, no effect on the lining materials (in conformity to EN ). After the lubrication with this lubricant, the rope surface appears dry and clean, and doesn t drop off in huge quantity from the rope during the first working hours avoiding problems to the in line grips controls and other automatic control devices present in the stations and in line. If solid and sticky lubricant / grease is used is important to know that the quantity of lubricant used during the stranding operations is normally more than the effective quantity that the rope could keep after its initial period of adjustment. It is possible that during the first working hours some lubricant will leak from the rope. The lubricant that leaks will rest on the outer rope s surface and protects the rope from the external oxidation during the first few hours of the ropes operation Lubricants used during the rope s production: type and quality Carrying ropes (FLAR and Ercole ropes): The rope lubrication, starting from the second last round wire s layer of the spiral strand core is carried out using ELASKON SK-V MOS2. These lubricants are applied using a special pump which allows application without heating Towing ropes for sky tow, fix ropes, tension ropes: For the core, made by PP fibres, the lubrication is limited at 2 fibres each strand that compose the core itself. The lubricant utilised is ELASKON 30. In case of metallic core the lubrication is carry out during the stranding operation with the same lubricant utilised for the outer strands Towing ropes (following UNI 7169), fix ropes, tension ropes: the lubrication is carry out during the stranding operation with ELASKON 20 BB or with NYROSTEN T BS or with Redaelli 9R100 Towing ropes (following EN ): the lubrication is carry out during the stranding operation with Redaelli 9R galvanised and ungalvanised carry-hauling ropes for fixed and detachable grips installations, haul ropes for aerial ropeway and surface system For the core, made by PP fibres, the lubrication is limited at 2 fibres each strand that compose the core itself. The lubricant utilised is ELASKON 30. The rope lubrication is carry out during the stranding operation with Redaelli 9R signal rope, evacuation & recovery ropes on winch with or without electric conductors & optical fibres For this type of ropes the lubrication is carry out during the standing operation with Redaelli 9R100. The conductors and optical fibres are sealed and are not directly in contact with the rope s lubricant. Page 18 of 33

19 IT IS POSSIBLE USE DIFFERENT LUBRICANTS THAN THOSE MENTIONED ABOVE, HOWEVER THIS MUST BE AGREED PRIOR TO CONTRACT AWARD WITH OUR COMMERCIAL OFFICE AND TECHNICAL DEPARTMENT. COMPATIBILITY TEST BY LUBRICANT - RUBBER LINING OF THE ROLLS SHALL BE CARRY OUT BEFORE THE ROPE PRODUCTION IN CONFORMITY TO EN Re-lubrication of in use ropes: indications and products The greases used for rope re-lubrication shall be select in order to ensure their compatibility with the lubricant that has been used in rope production (original lubricant), and the rubber lining of the rollers and sheaves present in the installation. The lubricant shall meet the requirements indicated in the used standards (EN for example). There are many different lubricants on the market, with different characteristics for the same application. Before using new products, in particular if they contain solvent, specific test should be carried out to shows the compatibility of the lubricant with the rollers and sheaves lining material and with the original lubricant also, or this information needs to be asked and confirmed by the lubricant / grease manufacturers. As general information the re-lubricants, apart what above, needs to ensure the following: Stranded ropes: good fluidity so to ensure a better penetration in the rope components (strands, wires), absence of mineral oils, good anti oxidation / corrosion properties, no effect against the steel and or its surface protection (galvanization for example) Track ropes (FLAR): o External / surface re-lubrication: absence of mineral oils, good oxidation / corrosion properties, no effect against the steel and or its surface protection (galvanization for example) o On saddles / shoes: specific lubricant that allow reduce / limit the rope wear and corrosion under particular condition. This lubricant normally contains special compounds (MoS 2, graphite etc.) that enable the lubricant to maintain its specific characteristics and properties under heavy cyclic pressure conditions FOR ANY SPECIFIC APPLICATION OR IN CASE OF DOUBTS TO THE IN USE RE-LUBRICANT ALWAYS CONTACT THE LUBRICANT MANUFACTURER OR THE ROPE MANUFACTURER BEFORE TO USE / APPLY IT ON THE ROPE Re-lubrication frequency The frequency of rope re-lubrication will depend by many factors including local climate, bending cycles, owner preferences, etc. The main aim of the re-lubrication is to protect the rope surface from the external oxidation, mainly during the installation shutdown (after the winter season), and reduce the internal strands wires friction. If one rope is constantly in use, then re-lubrication is not essential to protect it from the external oxidation because continuous contact with the rolls inhibits possible oxidation, but is recommendable so to reduce the internal strands wires friction and so ensure a longer rope lifespan. Nevertheless, to the installation and service characteristics, we suggest the following re-lubrication frequencies: 1. Stranded ropes (carrying-hauling, hauling, tensioning ropes): a. Whole rope i. At least every working hours or single bending cycles (choosing the restricted one) ii. At least every working hours or single bending cycles (choosing the restricted one), in presence of critical aggressive environmental conditions b. Specific rope areas: i. Splice: Only the tucks and the tucked tail ends of a long splice, should be intensively re-lubricated at least monthly after each regular visual inspection. The specific area Page 19 of 33

20 lubrication shall be done after the splicing, shortening or repair activities also and limited to the involved area only ii. Filled socket area: only the specific area close to the socket neck were the rope goes into the socket should be re-lubricated at least monthly after each regular visual inspection iii. Clamp socket, chapeau de gendarme, bolted clamp, drum, grips, any other end connection: following the specific end connection s designer indications and remarks. iv. Tensioning rope: It is recommended that the flexed rope area be re-lubricated at least monthly after the regular inspection 2. Carrying ropes For this ropes the in line periodical re-lubrication is not strictly necessary, but can be implemented in case of specific situations, like environmental working conditions for example. The re-lubrication is recommendable for specific areas: a. Saddles / shoes: i. Metallic saddles / shoes (steel, stainless steel, brass etc): at least every six months, or less in depends by the installation working time, environmental conditions etc, restricted to the contact and slide point so to maintain and ensure the correct friction and allow the proper sliding ropes movement, and also to avoid any direct contact between the rope and the saddle material that can result in a premature rope damage and failure (fretting problems for example) ii. Specific self-lubricant materials (like Ultra High Molecular Weight Polyethylene type Polizene 1000, Cestilite or similar): the periodical rope re-lubrication is not strictly necessary due to the specific material characteristics. For the saddle maintenance refers to the manufacturer indications also b. Roller-chain: It is recommended that the rope area flexed over a roller chain be lubricated on a frequent basis, preferably continuously. If no continuous lubrication device has been installed, it is recommended that the flexed rope area is re-lubricated during operation at least monthly after the regular inspection. c. Bollards: Care should be taken to ensure that the rope part wrapped around the bollard remains inspectable and is always covered with lubricant in order to avoid corrosion mainly if the environmental conditions are Instruction for the lubricant appliance The rope s re-lubrication shall be carried out following the next general rules: The re-lubrication shall be carry out when the weather is dry and sunny. The rope shall be perfectly and completely dry (inside also). For example if the weather conditions are not satisfactory (i.e.: rain, wet weather etc.) the re-lubrication of a rope is not recommended. Clean the rope surface from the old and dry grease, powder, rubber particles etc, with special spatulas or special devices that are not able to damage the rope. For the cleaning operation is not allowable use products that contain chemical and solvent elements. THE LUBRICANT MUST STICK TO THE CLEANED SURFACE OF THE ROPE. THE LUBRICANT WILL NOT STICK TO THE ROPE IF IT IS APPLY ON DIRTY SURFACE. If the lubricant contains solvent, it must be mixed continuously during application on the rope. This avoids the possibility that the solvent only goes in contact with the rope and therefore the mixing will prevent any damage that may otherwise occur. After its application is better not move the rope to give time to the solvent to evaporate.. The lubricant must be apply on the rope in small quantities and uniformly to create a thin layer on the rope. Application using this method will ensure that the rope will be perfectly lubricated allowing visual inspection of the rope to take place without the need for re-cleaning. After applying the lubricant, it is Page 20 of 33

21 recommended that the rope is not used for a few hours to ensure that the lubricant is fully dry. The formula below provides an indication of the quantities of lubricant that should be used for re-lubrication: P = 0.2 d L where: P = lubricant quantity [kg] d = rope nominal diameter [mm] L = rope total length [km]. The result takes into account loss that will occur to a lesser or greater extent. These loss depends on the devices used and application method. If oil lubricant (Redaelli 9R100 for example) is used for the re-lubrication the lubricant quantity must be 50% of the quantity resulted by the above formula. If is necessary or is planned already to change the rollers / shave rubber lining material, it is better to carry out this operation after the re-lubrication IF THE ABOVE RE-LUBRICATION INDICATIONS ARE NOT FOLLOWED, THE LUBRICANT WILL NOT WORK PROPERLY AND THIS COULD BE DANGEROUS FOR THE ROPE. FOR FURTHER INFORMATION READ EN and OITAF Book 28 General recommendations for the manufacturer s lubrication and the re-lubrication of steel wire ropes used in ropeway installation for passengers - edition 2014 ALSO 6.2. Rope relocations The support points and contact points of the cables must be moved periodically as follows: Track rope Relocation of the track ropes has a great influence on the safety. Redaelli Tecna SpA recommends carrying out periodical rope relocations. If applicable the minimum relocation time is listed in the standard EN or National standards where applicable and request, tacking in account the restrictive one. The rope manufacturer can supply more information for setting the proper relocation time depending by the plant configuration. The plant designer should be contacted on this matter also. This is particularly true for modern plant lay out (2S, 3S etc.type), where Redaelli suggest to relocate the rope at least every 3 years Signal ropes. Redaelli recommends to carry out periodical rope relocations of the signal ropes, if this is possible and spare cable length is available. Suggested relocation time: at least every 5-10 years if no rope damages are detached during the normal rope inspections (see chapter 2 also) in case wires break are found close to the fixed points (clamp, drum etc) and is necessary to move the damaged section in a dead/ waiting position so to avoid more breaks in the involved area avoiding in this way the necessity of rope change; RELOCATION OF THE ROPES HAS GREAT INFLUENCE ON THEIR SAFETY AND LIFETIME Page 21 of 33