INSTRUCTIONS FOR HANDLING & USE OF SYNTHETIC ROPES

Transcription

1 INSTRUCTIONS FOR HANDLING & USE OF SYNTHETIC ROPES FOR THE TROUBLEFREE & LONGER SERVICE LIFE OF THE SYNTHETIC ROPES THE BELOW MENTIONED CONDITIONS / INSTRUCTIONS MUST BE FOLLOWED:. MAIMUM WORKING LOAD (WLL): THE MAIMUM LOAD THAT THE ROPE MUST OPERATE, DEPENDING ON THE CONDITIONS OF USE, MUST NOT ECEED THE 20% OF THE MINIMUM BREAKING LOAD OF THE ROPE FOR A DESIGN FACTOR OF 1:5. FOR CRITICAL APPLICATIONS, THE DESIGN FACTOR CAN REACH 1:12 AND THE WLL WILL BE REDUCED ACCORDINGLY. AVOID OVERLOADING OVER THE ABOVE MAIMUM WORKING LOAD INSPECT FULL LENGTH REGULARLY AND OPERATING LENGTH BEFORE AND AFTER EACH USE DO NOT SUSPEND LOADS OR SUBJECT THE ROPE TO PRESSURE (CRUSHING FORCES) FOR A LONG PERIOD OF TIME, IT WILL CAUSE PERMANENT DEFORMATION (CREEP) CARE MUST BE TAKEN SO THAT TWIST IS NOT INDUCED IN THE ROPE DURING ITS SERVICE LIFE AS THERE IS A REDUCTION IN THE STRENGTH OF 5-10% (DEPENDING ON CONSTRUCTION & MATERIAL) PER TURN PER METER KEEP ROPE CLEAN- IMBEDDED DIRT IS ABRASIVE ON FIBERS ( SANDPAPER EFFECT) AND WILL SPEED UP THE WEAR DISTRIBUTE THE WEAR - REVERSE OCCASIONALLY FROM TIME TO TIME SO THAT THE OUTER SPLICED PART COMES IN AND VICE VERSA IF A ROPE PART GETS DAMAGED, CUT OUT THIS SECTION AND SPLICE THE REST GOOD (UNINJURED) PART AVOID KINKS - SHARP ANGLES, SHOCK AND DYNAMIC LOADS AND THE COMBINATION OF FRICTION AND HIGH LOADS AVOID UNNECESSARY WEAR WINCH DRUMS, PULLEY SHEAVES ETC. SHOULD BE SMOOTH; DON T DRAG ROPE OVER ROUGH SURFACES KNOW THE WORKING LIMIT (WLL) OF YOUR ROPE USE ONLY ROPE IN GOOD CONDITION, WITHOUT CUTS, KINKS, KNOTS, OR PULLED OUT STRANDS KNOTS REDUCE ROPES STRENGTH BY UP TO 50%. MAKE A SPLICE INSTEAD OF A KNOT THE MAIMUM WORKING LOAD OF THE ROPE IS VOIDED IF SHOCK AND DYNAMIC LOADS ARE APPLIED ON THE ROPE DO NOT BEND OVER ANGLED PARTS, CORNERS & SHARP EDGES OR USE OVER ROUGH SURFACES WITHOUT SHEAVES OR CHAFE PROTECTION DO NOT STAND WITHIN RECOIL (SNAPBACK) AREA SHOULD ROPE OR ATTACHMENT BREAK- DEATH OR LIMB CAN OCCUR DO NOT USE OVER SHEAVES OR AROUND SURFACES WITH LESS THAN A 5:1 D/d (BEND) RATIO FOR HOISTING OPERATIONS, WHERE PROTECTION OF LIFE IS PARAMOUNT, A FACTOR OF SAFETY OF AT LEAST 1:12 FOR A NEW ROPE MUST BE USED NEVER USE A SWIVEL IN A SYNTHETIC LINE UNDER HEAVY LOAD, LOSS OF TURN WILL CAUSE PERMANENT DAMAGE/DEFORMATION TO THE ROPE TRAIN THE PERSONNEL THAT WORKS WITH THE ROPES NORMAL WORKING CONDITIONS ARE THE USE UNDER THE CONDITIONS OF MODERATE DYNAMIC LOADING, NOT OVER THE MAIMUM WORKING LOAD. THAT MEANS THAT THE LOAD HAS TO BE HANDLED SLOWLY AND STEADILY FOR THE MINIMIZATION OF THE DYNAMIC EFFECTS. THE LOADS OVER THE WLL WILL HAVE TO BE CONSIDERED AS SHOCK LOADS, WHICH CAN OVERSTRESS AND DESTROY THE YARNS, AND CONTRIBUTE IN THE EARLY DAMAGE OF THE ROPE EVEN WHEN HANDLING LOADS UNDER THE WLL. THE LOADS APPLIED TO THE ROPE MUST NEVER BE OVER THE WORKING LOAD LIMIT (WLL OR SWL).. Page 1 of 5

2 FOR APPLICATIONS WHERE THE WLL HAS NOT BEEN DETERMINED OR A SUCCESSFUL EPERIENCE RECORD IS NOT AVAILABLE FOR THE TYPE AND SIZE OF ROPE USED, THE FOLLOWING VARIABLES SHOULD BE CONSIDERED IN DETERMINING THE DESIGN FACTOR (1:5 UP TO 1:12) Loading conditions and/or exposure to Dynamic Loading: Downsizing of larger diameter ropes to a smaller rope Loads are not accurately known High-level shock loads, extreme dynamic or high cyclic loads are likely to occur Tension is on the rope for long periods Knots are used, reducing strength up to 50% Experience of or guidance available to users: Operators are poorly trained Operation/use procedures are not well defined and/or controlled Conditions of use: Inspection of rope/attachments is infrequent Abrasion, cutting surfaces and dirt is present Ropes kept in service for long periods may develop fatigue Ropes will be subject to sharp bends, or used over pulleys or surfaces with too small a radius Environmental considerations: Temperatures higher than fiber limits are present Hazardous chemicals are present Fiber resistance to chemicals must be considered Death, injury or loss of valuable property may result if rope fails BELOW YOU WILL FIND SOME OF THE REASONS FOR WHICH THE CONDITION OF THE ROPE WILL HAVE TO BE RE-EVALUATED BEFORE USING IT AGAIN AND YOU MUST EITHER CUT & SPLICE THE PART THAT SHOWS THE LARGE LOCALISED WEAR (INTERNALLY OR ETERNALLY) OR THE PULLED-OUT STRAND OR THE MELTING DUE TO INCREASED TEMPERATURE CAUSED FROM FRICTION AGAINST A METAL SURFACE UNDER LOAD OR THE ROPE TO BE DEGRADED AND USED AFTERWARDS IN A LESS DEMANDING APPLICATION OR TO BE RETIRED AND WITHDRAWN FROM FURTHER USE AND BE DESTROYED / RECYCLED ACCORDING TO THE LOCAL LEGISLATION OR THE CORPORATE OR OTHER REGULATIONS ON HANDLING END OF LIFE PRODUCTS. Page 2 of 5

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4 STORAGE CONDITIONS BEFORE AND AFTER USE: THE ROPES MUST BE STORED IN A COOL ( C), DRY (SO THAT THERE WON T BE ANY MOISTURE ABSORPTION), CLEAN & FREE FROM DIRT & OTHER PARTICLES PLACE, AWAY FROM DIRECT SUNLIGHT, HEAT SOURCES AND ACID/ALKALINE ENVIRONMENT. THE COILS MUST BE STORED ABOVE THE GROUND SO THAT THEY WILL BE WELL VENTILATED. ROPES, AFTER BEING USED IN SEA WATER, MUST BE LEFT TO DRY BEFORE RECOILED & STORED. DURING INSPECTION OF THE ROPES, PLEASE PAY ATTENTION TO THE SALT ACCUMULATION (WHICH IMPREGNATES THEM AFTER USE IN SEA WATER). THE ROPES MUST NOT BE USED AFTER THEY HAVE DRIED OUT AS THE INNER FIBER TO FIBER FRICTION WILL INTENSIFY (CAUSING PREMATURE WEAR). ROPES MUST BE WASHED WITH FRESH WATER SO THAT THE SALT ACCUMULATION IS REMOVED. OPERATING TEMPERATURES: ETREME AMBIENT WORKING TEMPERATURES (INCLUDING BELOW ZERO ONES) MUST BE AVOIDED. LOW TEMPERATURES & BELOW ZERO TEMPERATURES CAN HAVE THE SAME DETRIMENTAL EFFECT AS THE HIGH TEMPERATURES. HEREBELOW YOU WILL FIND INDICATIVE MONITORING LOGS FOR THE USE OF THE ROPES SO THAT THEIR CONDITION MAY BE PROMPTLY IDENTIFIED / EVALUATED. SAMPLE MOORING LINE LOG VESSEL:. I.D. NUMBER:. SIZE: FIBER: CONSTRUCTION:.. LENGTH:.NUMBER OF EYES:..SIZE EYES:./. MAKER OR NSN:.... SPLICED BY.: DATE:.. INSPECTION SCHEDULE:... HISTORY DATE PUT IN SERVICE:.. MOORING STATION:.. DATE INSPECTION OR INCIDENT COMMENTS SAMPLE TOWING LINE LOG VESSEL:. I.D. NUMBER:. SIZE: FIBER: CONSTRUCTION:.. LENGTH:...TYPE END FITTING:./. MAKER OR NSN:.... SPLICED BY.: DATE:.. INSPECTION SCHEDULE:... HISTORY DATE PUT IN SERVICE:.. MOORING STATION:.. Page 4 of 5

5 DATE INSPECTION OR INCIDENT COMMENTS CRITERIA TO RESPLICE OR TO RETIRE THE ROPES ACC EN ISO 9554:2005 Rope type and condition All ropes -Bulk of surface yarns or strands reduced by 50% or more for a linear distance equal to the rope diameter -Rope suspected of being shock loaded -Exposure to excess temperature as specified for type of fibre Resplice (if localized) -Burns or melting visible for a length of over four rope diameters -Abrasion on inside radius of eye, with bulk of surface yarns or strands reduced by 50% or more -Rust on nylon (might indicate chemical damage) -Oil and grease Wash in mild detergent -Heavy surface fuzz-progressive Remove source of abrasion -UV degradation, splinters on yarn surface For braided cover and core ropes -More than four consecutive pulled cover stands (which cannot be reincorporated into cover braid) -More than 3 cut cover strands -Multiple cut yarns of filaments within distance of one pitch length -Core visible through cover, because of cover damage -Core damage-pulled, cut, abraded, powdered, or melted strands -Herniation-core pokes through cover (sheath) For 3-& 4-strand and 8- &12/24-strand(braided) ropes -5% of yarns cut or badly abraded in score between strands -Cover yarns cut or abraded more than 50% on one or more crowns of rope -Strand cut to 5% of diameter within one lay length -Powdering between adjacent strand contact surfaces -Hockle or backturn -10% abrasion of one strand within one lay length Thermal damage -Hard, melted, flattened areas of the rope which can indicate serious damage to the rope -Melting or fusing affecting 20% or more of rope yarns --If within one lay length --If over more than one lay length Short-term exposure to temperature above fibre working temperature -Polyolefins (PP, PE, PP/PE), over 65 C -Polyamide, over 100 C -Polyester, over 100 C -Manila, over 100 C -Sisal, over 100 C -Hemp, over 150 C Retire Page 5 of 5