Handinspect Eng

8/12/2019 Handinspect Eng

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Verope special wire ropes are high-quality productswith a long useful life.

The following instructions for handling and inspect-ing verope special wire ropes have the purposeof contributing to safe use of our products whilemaintaining their value.

Three basic forms of verope special wire ropes areavailable:

verostar 8 and veropro 8Eight-strand rope constructions with a plastic-coat-ed independent wire rope core. The veropro 8 ropeconstruction has compacted outer strands.

veropower 6 and veropower 8Six- and eight-strand hammered rope constructionswith parallel lay, precompacted strands and plastic-coated central core strand.

verotop and verotop PLow-rotational rope construction with compactedstrands. The verotop P rope construction has aplastic-coated steel core.

The verope special wire ropes are available in therope grades 1960 and 2160 with bright or galva-nized wires in left hand- or right hand-Lang’s lay orordinary lay and are largely preformed, some withparticularly stabilising properties due to a plastic-coated core. The ropes are produced with the right

lubricant for each speci c application.

The wire rope construction and the rope lubricanthave to be compatible with the rope reeving sys-tem, the system elements and the impact they haveincluding environmental conditions.

On the following pages, you will nd recommenda -tions for handling and inspecting verope specialwire ropes in order to use them safely for a longuseful life.

verope | verope special wire ropes

verope special wire ropes

veropower 8veropower 6

veropro 8verostar 8

verotop verotop P



The rope supplied on reels or incoils have to be stored appropri-ately and should be protectedfrom exposure to environmental

in uences. Verope special wireropes are supplied with point-welded ends.

Storage and cutting

Always provide effective seizing at cutting (also with preformedverope special ropes).

Unspooling

d

Handling | Storage and cutting | Unspooling

L 2dL 2d

The rope supplied on reel or coil can be drawn from a turntable orwound off, in case of short length.

The reel may not be rolled!

Lifting from the reel or coil opposite the spoolingdirection will twist the rope

Protect from exposure to weather

handling



The rope should be respooled orspooled with pretension on therope. This especially applies tomulti-layer spooling.

Watch out for the eet angle(no more than 10°).

The direction of rope spoolingshould be retained because op-posite spooling directions twistthe rope. The rope should notbe dragged over the ground,drawn over edges and bent orsqueezed between edges.

Same direction of spooling

Same direction of spooling

Opposite direction of spooling

Respooling and spooling

Reel with non-tilting supporting trestleand braking equipment

Reel with non-tilting supporting trestleand braking equipment

Pay attention to spacing between

the reels to avoid too wide eet angles

Handling | Respooling and spooling

Reel with non-tilting supporting trestle

and braking equipment

Winch orintermediate reel

Winch orintermediate reel

Winch or

intermediate reel

Brakingforce

Brakingforce

Pay attention to spacing betweenthe reels to avoid too wide eet angles

Avoid any contact with the ground!



There can be wear from the slid-ing roll path w in the rope grooveat a eet angle ≤ 4° and on thegroove bottom. With reference tothe rope diameter d , the dimen-sions of the rope grooves shouldcorrespond to r ≈ 0.53 . d and

h ≈ 1.5 . d at the ank angle of ≥ 4 5°.

Before installing the rope, checkthe correct assignment of therope construction and lay direc-tion in connection with the drumwinding and rope reeving system.

Also check the state and dimen-sion of the rope grooves on thedrum and sheaves. Wherever ne-cessary, they have to be smoothed,particularly if the rope construc-tion is changed.

Providing the new rope is pulledin with an auxiliary rope of a thin-ner diameter, it is necessary touse non-rotating auxiliary ropesor ber ropes with good non-rotating properties. Providing the

new rope is pulled in with the old

New rope and old rope with the same diameter

Auxiliary rope with a smaller diameter

Chinese nger

Connecting rope with U-bolt wire rope grips EN 13411-5.

New rope with control marking forrotational effect

Old rope possibly with torque fromtorsion due to rotational effect

Rope installation

The rope should be installed in accordance with a detailedplan of procedure drawn up by the user and applying thenecessary care and occupational safety when installing a rope.

Only connect the same directions of lay

Only connect the same directions of lay

Handling | Rope installation | Wear in the sheave groove

rope, it is advisable to weld onthe rope ends pad eyes or chainlinks which are joined by wire ropestrands or thinner wire ropes. Pos-sible build up twist in the old ropecan be absorbed by the connect-ing strands or the thinner rope dur-ing the installation procedure. Anoften practised solution to connectropes is the use of the so called”Chinese ngers”.

To use the Chinese nger safelyand to avoid slippage, the ropeends covered by the Chinese n -ger should be wrapped with tapein order to increase friction be-tween the rope and the Chinesenger. Either a strand or a thinner

rope is used to join the ends.

Flank angle

Point of striking against the groove ank

S l i d i n g r o l l p a t h w

r

h d

Contact width on the groove bottom

0,5 . d

!

!

Wear in the sheave groove

Serving with at least 2 x d length per side

!

Welding seam or shacklewith anti-rotation device

New rope with control markingfor rotational effect

Auxiliary rope with lower torque resul-ting from torsion due to loading


http://slidepdf.com/reader/full/handinspect-eng 6/12Inspection | Strain conditions | Critical zones

Wire ropes are wear parts thathave to be inspected regularly.

System elements and essentialin uences

- environmental conditions andhigh or low temperatures

- properties, load-bearing beha-viour and rotational behaviourof the ropes with a rotationaleffect on the load- lifting heights, number of ropefalls and eet angle

- winding drums and sheaveswith their dimensions and with

the material, condition anddimensions of the rope grooves

- one- and multi-layer spooling- rope torque and eet angle

with a rotational effect on therunning rope

Strain conditions

Critical zones

The critical zones of multi-layerspooling are the rst rope layers,especially the climbing zonesinto the next layer and the crossover points. Pendular rotationand/or spread angle variationcan quickly damage the rope innon visible sections on compen-

sating sheaves. Locally concen-trated compression of wires alsolead to premature wire breakson line rollers. Compensating sheave ( D/d ≥10) ; line roller ( D/d ≤10)

RS >D

S S

Locally concentratedcompression of wires

An example of a simple rope reeving system

High position

Partial lifting heigth

Sheave with rope groove

L i f t i n g

h e

i g h t f r e q u e n c y

Winding drum withsingle-layer ormulti-layer spooling

h0

F*F Low position

F l e e t

a n g l e

Mean valueof the partiallifting heights

Rope forces S resultingfrom the maximum loadF and the load range withmean value F*

Rope terminationor compensatingsheave

H

h

Sections of damage

Spread angle variation

Torque and rotationof the rope

pendular rotation

Inspektion


http://slidepdf.com/reader/full/handinspect-eng 7/12Inspection | Inspection | Maintenance

Inspection

Daily inspection of visible ropelength to control outer damagesto the rope such as clearly visiblechanges in:- the rope diameter d - the lay lengthH or if there is occurrence of:- deformation- wire breaks- force being applied

Periodical inspection in com-pliance with the statutory regula-tions of the country where it isused, in conformity with the cra-ne classi cation and taking thecritical zones and rope sectionsin the rope reeving system intoconsideration.

Periodical inspection in connection with the load range,the sum of the bending load

cycles in the rope section undermaximum stress and other criti-cal zones due to lifting frequency,work cycles, useful life and envi-ronmental conditions.

Rope sections have to beespecially observed- in case of synthetic sheave

grooves- in the striking zones of compensating sheaves- in the zone of rope terminations- on reels with multi-layer spooling

The different positions in therope, the critical zones or otherrope sections under greateststress in the rope reeving sys-tem should also be de ned forinspection in keeping with theoperational experience.

Maintenance

Maintenance should be carriedout according to the recommen-dations of the rope manufacturerand the manufacturer of the ap-plied lubricant, considering tem-perature-, maritime and sea waterimpacts and /or use of syntheticsheaves.

For relubrication use only lubri-cants compatible with the origi-nally applied lubricant

iThe load range with the exponential mean value F* and thelifting height frequency with the number of work cycles dur-ing the useful life of the rope should be known or recordedfor inspection.

!


http://slidepdf.com/reader/full/handinspect-eng 8/12Inspection | Damage to the rope | Discard criteria following the allowed number of broken wires | ISO 4309 and DIN 15020

Wire break numbers according to ISO 4309 and DIN 15020, p.2

Professionally dimensioned wire ropes can be safelydiscarded by applying the standard discard criterias

iDamage to the rope

Outer damage to the ropeand visible wire break numberscan be generally identi ed andevaluated.

Visible broken wires or wire me-shings in the strand gaps andreduction in the rope diameterd under load are an indication ofinner damage to the rope.

Inner damage to the rope andwire break development cannotgenerally be identi ed. Profession -ally dimensioned wire ropes canbe safely discarded by applyingthe standard discard criterias.

Ropes should be discarded not later than at reaching thenumber of allowed broken wiresas mentioned in the table below.

In cranes and hoisting equipmentthe two generally recognised rulesof technology for discard criteriacan be applied for verope specialwire ropes. Also the operator`s ex-perience and product knowledgeand the national regulations haveto be taken into consideration.

In some hoisting systems otherissues are to be considered, suchas: dimensioning rules, operatingconditions and speci c regulations.

Discard criteria applied on verope special wire ropes

i

Two methods enable you to es-timate the bending load cyclenumbers by calculation up tovisible and non-visible wire breaknumbers on the rope construc-tion in the critical zones or therope sections under greateststress of the rope reeving systems.

The wire break numbers estima-ted by calculation have to becompared with the acceptablevisible wire break numbers fromISO 4309 (Tables 1 and 2) orDIN 15020, page 2 and the da-mage behaviour in accordancewith your application experienceduring the useful life.

Discard criteria following the allowed number of broken wires

1) ISO 4309 – The assignment to the ISO-RCN number is only approximate2) ISO 4309 – The wire break numbers may apply to steel grooves or plastic rope grooves and multi-layer spooling (for

the rope section under greatest stress); they donot apply to plastic rope grooves and one-layer spooling. In this caseit is particularly important to watch out for inner damage and non-visible inner wire breaks.

3) The higher wire break numbers only apply if the ropes are used in work or on mechanisms with a known classi cationaccording to M5-M8.

Number of visible wire breaks which must not be exceeded.






http://slidepdf.com/reader/full/handinspect-eng 11/12Inspection | Discard criteria for wave development

Loosening of the outer strands

”Corkscrew”, primarily in wire ropes with bre core

dm0 1 2 3 4 5 6 1 2 3 4 5 607 8 7 8 d 1

Lay length H Lay length H

Wave length not necessarily in conformity with the lay length H

Wave development may be causedby the rotational effect in the ropereeving system.

”Corkscrew” can develop if thereis no longer radial support for thestrands of one-layer strand ropesafter damage to the core. Therope force is largely shifted to thewithdrawn strands.= discard criteria

Birdcage deformation can developduring handling & installation,caused by concentrated buildup

twist in sections of the rope sys-tem which did little work. The loadis shifted to the strands of thecore. Wave height d 1 > 4d/3 without rolling-over andd 1 > 1.1d with rolling-over= discard criteria ISO 4309

Compressed steel core can occurby twisting in connection withthe ”birdcage”, primarily in strand

ropes with parallel lay.= discard criteria

Discard criteria for wave development

- Parallel wire rope core (PWRC)or low-rotational rope

- Outer strands completely loose= Discard criteria reached

- Independent wire rope steel core (IWRC)- Outer strands completely loose= Discard criteria reached

Upsetting of the steel core

”Birdcage” might happen in wire ropes with a parallel wirerope core (PWRC) or in low-rotational ropes, also with an in-

dependent wire rope steel core (IWRC)

!

!

Corkscrew changes the load-bearing behaviour

The rope force is only carried by the steel core

0 1 2 3 4 5 6 1 2 3 4 5 60 dm

Lay length H Lay length H

Wave length ≈ lay length HWave length ≈ lay length H

- Strand partiallywithdrawn

= Begin of reaching discard

criteria

- Strand mostlywithdrawn

- Fibre core damaged= Discard criteria

reached

- Strand totally withdrawn- Fibre core no longer

available= Discard criteria

reached



St. Antons-Gasse 4aCH-6300 Zug / Switzerland

Tel: +41 41 72 80 880Fax: +41 41 72 80 888

[email protected]

Disclaimer of liability: The descriptions in these instructions are a summary of longstanding experience in conformity with the state-of-the-art and do not claim to be complete. The authors herewith declarethe exclusion of all liability for any damage that may arise from applying said descriptions. The user has to decide whether said descriptions are suitable to his purpose. The descrip-tions and data may only be used with the required circumspection critically comparing them with each framework of experience and considering the application-speci c developmentof each product, standard and regulation for wire ropes and rope systems.

Abbreviated reference to basicstandards:

EN 12385-1 to -4; ”Steel wire ropes;Safety; ...”

EN 13411-5; „Terminations for steelwire ropes; Safety; Part 5: U-bolt wirerope grips”

DIN 15020 page 1 and page 2;”Lifting appliances; basic principles forrope reeving components; ...”

FEM 9.661:06; ”Berechnungsgrundla-gen für Serienhebezeuge; Baugrößenund Ausführung von Seiltrieben.”

ISO 4309; ”Cranes; wire ropes; care,maintenance, installation, examinationand discard.”

Basic literature:

Jehmlich, G.: ”Anwendung und Über-wachung von Drahtseilen. VEB Verlag

Technik Berlin 1985.”

Feyrer, K.: ”Drahtseile. Bemessung, Be-trieb, Sicherheit. Springer - Verlag Berlin

Heidelberg 1994 and second revisedand enlarged edition 2000.”

Personal experience from work and pu-blications as well as descriptions in com-pany publications of the competition.

Imprint:

Compilation and technical consultation:Dipl.-Ing. G. Steinbach VDI

Layout:Wickert Medien DesignCh. Friesch / B. Lüdiger

®

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