2015 CRW - Crucial Calls When Evaluating Wire Rope

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Crucial Calls When Evaluating Wire Rope

John F. Groce, P.E.Sr. Technical Service EngineerWireCo WorldGroup

TOPICS

BendsDefinitions Angle versus curveASME B30, ISO 4309SourcesWaveDefinitionISO 4309, ASME B30, WRTBSourcesHelical DeformationsDefinitionSourcesKinksDefinitionStages of a kinkSourcesCurrent B30 replacement criteria (and OSHA)

All contents 2015 WireCo WorldGroup Inc. All rights reserved.

DefinitionsBend An angular shape or a curve causing a directional change from a straight line.ASME B30.5 5-2.4.4(d) Rope Maintenance During installation, care should be exercised to avoid dragging of the rope in dirt or around objects that will scrape, nick, crush, or induce sharp bends in it.ISO 4309 3.5.11.9 Bends Angular deformations of rope caused by external influence.BENDS

CurveAngle


BENDS CURVE


BENDS CURVE

Bending in service A 1 (25.4mm) wire rope operates over a 30 (762mm) sheave. The length of the rope side in contact with the sheave will be approximately 3-1/8 (79.4mm) shorter than the side away from the sheave. This is accounted for by the movement and adjustment of the wire ropes individual components as the rope is bent around the sheave.Length of contact w/ sheaveOutside length of wire rope


BENDS CURVEThings to considerNo written standard lists curves as a criteria for removal from service.Tensile tests have shown that wire rope samples with curves of varying degrees still met or exceeded their associated MBFs.All wire ropes operating over sheaves or on-and-off a drum can potentially develop curves.The severity of a curve is directly related to load and the D/d ratio in play.Does the curve disappear under load?Are there other types of retirement criteria associated with the area?

Curve


Definitions (cont.)WRTB, Wire Rope Users Manual 4th Edition, Appendix DDogleg Permanent bend or deformation, in a wire rope, caused by improper use or handling.BENDS ANGLE

If no strand distortion is exhibited and the dogleg cannot be observed when the rope is under tension, the rope can remain in service.


BENDS ANGLE


BENDS ANGLE


BENDS ANGLE


Definitions (cont.)The following is currently being considered for inclusion by ASME B30Dogleg (severe) A permanent, localized, irreparable angular bend or deformation in a wire rope that restricts the natural adjustment of the rope's components during operation. It is caused by improper use or handling and results in an indeterminate loss of strength in the rope. This condition cannot be corrected and is cause for removal from service.

Dogleg (minor) Bend or deformation exhibiting no associated strand distortion and cannot be observed while the rope is under tension. Should be noted and the wire rope may remain in service.

BENDS ANGLE


Things to considerThe condition can accelerate wire rope degradation in area of dogleg.Was rope bent over sharp edge while under tension (perpendicular loading)?Any associated localized mechanical damage or strand distortion?Are rope components natural adjustment restricted?Does condition disappear under load?Severe doglegs are cause for removal from service.BENDS ANGLE

Angle


Definition & Industry Standards for Rope RetirementWave Distortion in a wire ropes structure that occurs when one or more outer strands have moved from their original, natural position along the ropes axis.ISO 4309 3.5.11.2 Waviness A deformation in which the longitudinal axis of the wire rope takes the shape of a helix under either a loaded or unloaded condition.ISO 4309 & WRTBs Wire Rope Users Manual Both provide the same condition limits for removal.ASME B30 Currently does not address wave distortion.

WAVE


Waviness Rope, under any load condition, must be removed from service if, in a straight portion that does not bend around a sheave or drum, the following condition is met: dw > 1.33d (33% increase over nominal)Or, in a portion of rope that bends around a sheave or drum, the following condition is met:dw > 1.1d (10% increase over nominal)Where :d = nominal diameter of the ropedw = diameter corresponding to the wave

ddwWAVE


ddwCurrently under consideration by ASME B30Any portion of a wire rope operating in a system.dw > 1.1d (10% increase over nominal)Where :d = nominal diameter of the ropedw = diameter corresponding to the waveWAVE


Possible sources to waveManufacturing issues with the wire ropes outer stands preforming.Tight sheaves (small grooving, rope over max. diameter specified).Buildup of twist (improper handling, poor installation practices, excessive fleet angles, poor operating practices use of an in-line swivel / load induced torque).WAVE


Things to considerDoes the affected section operate over a sheave or drum?Has the diameter of the wave reached appropriate maximum?Check system grooving.Check rope diameter on unaffected sections on both sides of wave section.Check fleet angles (component alignment).Load induced torque occurring (load rotation, swivel usage)?Suggest reviewing installation procedures.

WAVE


DefinitionHelix A shape formed by a line that curves around and along a central line.

HELICAL DEFORMATION


DefinitionHelix A shape formed by a line that curves around and along a central line.

HELICAL DEFORMATION


HELICAL DEFORMATION


DemonstrationHELICAL DEFORMATION


Things to considerSeverity of the helix.Does it disappear under load?Any other removal criteria present?Do sheaves have proper D/d ratios?Are sheaves turning properly loaded and unloaded?Damage to guards, sheaves, shafts, or other components?HELICAL DEFORMATION


DefinitionKink - A unique deformation of a wire rope caused by a loop of rope being pulled down tight. It represents irreparable damage and an indeterminate loss of strength in the rope. This condition cannot be corrected and is cause for removal from service.

Above definition currently being considered for inclusion by ASME B30KINKS


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Incorrect

KINKS STAGES & SOURCES


Permanent irreparable damageKINKS FINAL RESULT

Incorrect


KINKS FINAL RESULT

Incorrect

Permanent irreparable damage


KINKS FINAL RESULTPermanent irreparable damage

Incorrect


Possible sourcesImproper handlingBuildup of twist (poor installation practices, excessive fleet angles, poor operating practices, load induced torque use of an in-line swivel or allowing the load to rotate).

KINKS


Load induced torque

KINKS


Load induced torque

DemonstrationKINKS


Rotation Resistant(Category 1)Non-Rotation Resistant(Standard)SWIVELS TWIST TEST VIDEOS


SWIVELS EFFECTS ON STRENGTH


SWIVELS


Wire rope is a consumable itemInspection is necessary to determine remaining useful service lifeAll ropes should be visually inspected each dayA thorough inspection should be performed at least monthlyInspection records should be keptInspections need to be performed while the rope is unloaded and relaxedInspections need to be performed by a competent personRope retirement criteria is based on local governing standards

INSPECTION A MATTER OF SAFETY


B30.2 Overhead and Gantry CranesB30.3 Tower CranesB30.4 Portal and Pedestal CranesB30.5 Mobile and Locomotive CranesB30.6 DerricksB30.7 WinchesB30.8 Floating Cranes and Floating DerricksB30.13 Storage & Retrieval (SR) Machines and Associated EquipmentB30.16 Overhead Hoists (Underhung)B30.24 Container Cranes

ASME B30 Safety Standards for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and SlingsINSPECTION A MATTER OF SAFETY


* Or 1 Valley BreakASMEStandardTitle# of Broken Wires Away from End Connections *At End ConnectionsIn one rope layIn one strand in one rope layB30.2Overhead & Gantry CranesAll running ropes124Not StatedB30.3Tower CranesStandard124> 2Rotation Resistant2 over 6 Dia4 over 30 DiaB30.4Portal & Pedestal CranesStandard63> 2 Rotation Resistant42B30.5Mobile & Locomotive CranesStandard63Not stated(> 2 recommended)Rotation Resistant2 over 6 Dia4 over 30 DiaB30.24Container CranesStandard63>2

INSPECTION A MATTER OF SAFETYASME B30 Safety Standards for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings


Broken wires Running wire ropes6, 3, or 1 valley Non-rotation-resistant (standard) wire ropes2 over 6 dia or 4 over 30 dia or 1 valley Rotation-resistant wire ropesCore protruding between outer strandsKinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structureApparent damage from any heat sourceReduction from nominal of more than 5%Broken wires Standing wire ropes3 in one lay or 2 or more at end connectionsInspections (5-2.4.2)Frequent Daily visual, no records required, rope reasonably expected to be usedPeriodic At least annually, frequency determined by qualified person, records required, entire length of ropeINSPECTION A MATTER OF SAFETYASME B30.5 Mobile and Locomotivie Cranes


INSPECTION A MATTER OF SAFETY


Re-lubing is an essential part of maintenance

LUBRICATION MAINTENANCE


THANK YOU. QUESTIONS?


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2015 CRW - Crucial Calls When Evaluating Wire Rope