Lloyd s Register: Business unit Marine Hangt de bagger industrie aan een (zijden) draadje Door: Cor Dekker Senior Specialist Marine Equipment & Lifting Components The Group at a glance 278 offices delivering services in 100 countries Some 7,500 employees of 90 nationalities 80 companies Celebrating our 250 year anniversary this year Four business divisions: Marine Transportation (rail sector) Energy (ModuSpec, Scandpower) Management Systems (LRQA) 1
Steel wire ropes PRODUCTION SCHEME STEEL WIRE ROPE ROPE TERMINOLOGY CONSTRUCTION OF A STEEL WIRE ROPE LAY DIRECTION TYPE OF LAY AND THEIR APPLICATIONS TYPES OF STEEL WIRE ROPE IN USE ROTATING RESISTANCE REQUIREMENTS FOR ROPES USED IN LR CLASSED CRANES DISCARD OF ROPES 2
Production scheme steel wire rope MID Hangt de 4 baggerindustrie October aan een (zijden) draadje ROPE TERMINOLOGY 3
CONSTRUCTION OF A STEEL WIRE ROPE EXAMPLE 6 x 36 WS + IWRC SUMMARY Rope Strands Wires Construction Warrington Seale Core CONSTRUCTION OF A STEEL WIRE ROPE 1 SIX STRANDS 41 Wires in each strand Warrington-Seal Independent wire rope core IWRC 16 16 6 2 Warington layer Seal layer 8 1 41 5 4 3 4
LAY DIRECTION Lay direction of rope ORDINARY OR REGULAR LAY Lay direction of strands LANG S LAY LAY DIRECTION OF THE ROPE RIGHT HAND ORDINARY (OR REGULAR) LAY LEFT HAND ORDINARY (OR REGULAR) LAY 5
LAY DIRECTION ORDINARY LAY sz RHOL zs - LHOL (Strand / Rope) zz RHLL ss - RHLL (Strand / Rope) LANG S LAY ROPE LAY DIRECTION ON DRUMS RULE OF THE THUMB POINT YOUR THUMB IN THE DIRECTION OF FIXED ROPE PART ON THE DRUM POINT YOUR FINGERS IN THE UNREEVING DIRECTION THE HAND WHICH MATCH IS THE LAY DIRECTION OF THE ROPE Left hand lay rope Right hand lay rope 6
TYPE OF LAY AND THEIR APPLICATIONS TYPICAL CONSTRUCTIONS ORDINARY LAY Lifting guided loads Lifting unguided loads on several falls Lifting loads with right and left handed ropes in pairs Ordinary constructions have: High internal tensions during bending Low sheave surface contact Poor wear resistance LANG S LAY Lifting constant tensioned guided loads (boom wires) Lang s lay constructions have: Low internal tension during bending High sheave surface contact Good wear resistance Poor resistance for deterioration of the rope TYPE OF LAY AND THEIR APPLICATIONS ROTATING RESISTANCE CONSTRUCTIONS ORDINARY LAY For almost all applications Good resistance for deterioration of the rope Ordinary constructions have: High internal tension during bending Low sheave surface contact Poor wear resistance LANG S LAY For constant tensioned applications (boom wire) Poor resistance for deterioration of the rope Lang s lay constructions have: Low internal tension during bending High sheave surface contact Good wear resistance 7
TYPES OF STEEL WIRE ROPE IN USE DIE-FORMED Conventional produced rope compressed by rollers DIE-SHAPED Strands produced from shaped wires ROTATING RESISTANCE In a conventional rope, an external load creates a moment which tries to untwist the rope and to rotate the load. A rotation-resistant Wire Rope has a steel core which is an independent rope, closed in the opposite direction to the outer strands. Single fall operation: The use of non- rotating ropes is mandatory for the lifting of unguided loads with a single fall of rope. Multiple fall operation: Traditional ropes achieve a higher service life than rotation-resistant ropes when operating under identical conditions in multiple falls. Providing there are no other special conditions that require the use of rotation- resistant ropes, traditional ropes should be used in multiple fall conditions. 8
ROTATING RESISTANCE Outer strands - LH IWRC - RH 16 (1+6) 12 (1+6) 6 (1+6) 1 (1+6) Outer strands IWRC 12 (1+6) 6 (1+6) 1 (1+6) Outer strands Wire Strand Core Requirements for ropes used in LR classed cranes For ropes intend to be used in lifting appliances two important documents are involved 1. Code for Lifting Appliances in a Marine Environment 2. Rules for the manufacture, testing and certification of materials 9
Requirements for ropes used in LR classed cranes Surveyors have to deal with another important document 3. Marine Survey Procedure Manual Which can be found on surveyors laptop and/or on the hub Requirements for ropes used in LR classed cranes CODE LAME Ch.6 - Section 6 6.3 Construction and application 6.3.4 Wire ropes for running rigging are to be constructed of not less than six strands over a main core. Each strand is, generally, to consist of not less than 19 wires and may have a fiber or a wire core. Where the strand has a fiber core, the wires are to be laid round it in not less than two layers. 6.3.5 Wire ropes for standing rigging, guy pendants and similar applications are generally to be constructed of six strands over a wire core. 6.3.6 Lang's lay rope will not normally be accepted for any part of a ship's cargo handling gear. 6.3.8 Consideration will be given to the use of other constructions and nominal strengths and to the requirements for particular applications 10
REQUIREMENTS FOR ROPES USED IN LR CLASSED CRANES Equipment for Mooring and Anchoring Chapter 10 Section 6 Steel wire ropes 6.1 Scope 6.1.1 Provision is made in this Section for the requirements for the manufacture, testing and certification of steel wire ropes intended to be used for general marine purposes, as well as permanent anchoring, mooring and marine lifting applications. 6.2 General requirements 6.2.1 For general marine purposes, such as stream wires, towlines and ship mooring lines, the construction is to be in accordance with Table 10.6.1. The construction, diameter and strength of steel wire ropes for permanent offshore applications, such as mooring, anchoring and lifting, are covered by other LR Rules. Alternative applications of wire ropes may be accepted, subject to special consideration. Requirements for ropes used in LR classed cranes MSPM 4.3 Deck cranes d) The crane is to be reeved with certified hoist and luffing ropes from an approved manufacturer. The surveyor is to ensure that ropes of the correct diameter, construction and minimum breaking load, as stated on the approved plans, are fitted e) Running wire ropes will normally be of a 6-strand or multistrand non-rotating construction with either independent wire rope or fibre cores. They should be galvanised 11
REQUIREMENTS FOR ROPES USED IN LR CLASSED CRANES WHY? Code LAME 6.3.8 Consideration will be given to the use of other constructions and nominal strengths and to the requirements for particular applications Rules for materials: 6.2.1 Alternative applications of wire ropes may be accepted, subject to special consideration. MSPM: 4.3 Deck cranes As stated on the approved plans Question: YES YES YES Are these constructions allowed? Requirements for ropes used in LR classed cranes 12
Requirements for ropes used in LR classed cranes DISCARD OF ROPES ISO 4309:2004 (E) 3.5 Discard criteria 3.5.1 General a) The nature and number of broken wires b) Broken wires at the termination b) Localized grouping of wire breaks c) The rate of increase of wire breaks d) The fracture of strands e) Reduction of rope diameter, including that resulting from core deterioration f) Decreased elasticity g) External and internal wear h) External and internal corrosion i) Deformation j) Damage due to heat or electric arcing k) Rate of increase of permanent elongation 13
DISCARD OF ROPES ISO 4309:2004 (E) Parallel-closed ropes DISCARD OF ROPES ISO 4309:2004 (E) Rotating resistant ropes 14
QUESTIONS INSPECTION OF ROPES Is a serious business Don t take things for granted Don t take a risk THINK SAFETY REMEMBER there is no redundancy in a crane!! STOP THINK OBSERVE PLAN Where you are in a position of safety About where you are and what you are about to do What is going on around you Your safe way in to your task site LIFE MATTERS 15
LIFTING APPLIANCES For more information, please contact: Cor Dekker Lloyd s Register EMEA Weena zuid 170 3012 NC Rotterdam T +31 (0)10 4145 088 F +31 (0)10 2140 190 E cor.dekker@lr.org 16