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Oil & Gas Catalogue

02 BRIDON Oil and Gas

Bridon - the world’s leading specialistin the manufacture of wire and ropesolutions for the most demanding

applications, delivering reassurancethrough unrivalled experience.

Drawing from a background of long standing

experience and technology, Bridon is an acknowledged

world leader in the design, manufacture, development and

supply of specialist rope to meet the needs of the oil & gas industry.

Recognising the extreme environments in which the Offshore Oil

& Gas Industries operate, Bridon has brought together a

comprehensive range of world leading global solutions

specifically tailored to meet these demands

Specialist steel & fibre ropesolutions for the oil & gas industry

Contents

Introduction ................................................ 2-3

Product Selection ........................................4-8

Products ....................................................9-27

Synthetic Rope Technical Information ....28-29

Steel Rope Technical Information............30-69

Bridon International Services & Training ......70

Contacts........................................................71

03

All statements, technical information and recommendations contained hereinare believed to be reliable, but no guarantee is given as to their accuracyand/or completeness. The user must determine the suitability of the productfor his own particular purpose, either alone or in combination with otherproducts and shall assume all risk and liability in connection therewith.

Whilst every attempt has been made to ensure accuracy in the content of the tables, the information contained in this catalogue does not form part ofany contract.

Bridon’s products are manufactured undercontrols that conform to quality

management system ISO 9001:2000.

ISO 14001

Bridon operates environmentalmanagement systems which, where

required by legislation or risk, comply withthe requirements of EN ISO 14001:2004

and are assessed and registered byaccredited certification bodies.

BRIDON Oil and Gas

Product Selection

04

Mooring Applications

Exploration Drilling RigsHigh Strength Steel Anchor Lines

The demands of a hard working application require that Bridon’s high strength steel anchor line products are of a robustconstruction, excellent abrasion & crush resistance ensuring optimum performance on winches and sheaves. Proprietary blocking& lubrication medium assist towards the necessary corrosion resistance with additional benefit of a drawn galvanised finish.

Specialist Fibre MODU Tethers

Bridon Superline offers the highest strength to weight ratio facilitating a lightweight anchoring solution. The constructionincorporates an increased thickness braided jacket to provide a level of protection for improved handling performance

Off-take Mooring SystemsA comprehensive design package tailored to suit individual location requirements for single point moorings and tandem offloadingsystems. Packages include chafe chains, support buoys, shackles and fittings and are based on our high quality specialist fibreropes. Bridon Superline Nylon and Viking Braidline Nylon Super Hawser offer a higher strength to weight ratio than conventionalconstructions and both are fully compliant with OCIMF Guidelines for the Purchasing & Testing of SPM Hawsers.

Diamond Blue offers the highest strength to weight ratio for steel anchor linessupporting moves to ultra-deep water locations.See page 11

DYFORM® DB2K

Dyform DB2K offers the highest strength to diameter ratio enablingoptimum utilisation of limited volume winch arrangements. Furthermore, theincreased surface area of Dyformed strands improves stress distributionenabling superior crush & abrasion resistance.See page 10

Polyester (MODU)see page 25

Steelite Xcelsee page 25

Material grade can be selected for optimum application performance

Nylon Super HawserViking Braidline Nylon Super Hawser is a balanced, flexible constructionwhich distributes the weight and strength equally between the sheath andthe braided core. Viking Braidline offers a higher elongation than competingconstructions and is suitable for many shock load applications.See page 26

Nylon OCIMF 2000Bridon Superline is a torque balanced circular braided constructionconsisting of an outer protective braided jacket over a central group ofparallel low twist cores. In the as new condition Bridon Superline offers aslightly stiffer solution than the Viking Braidline Construction.See page 27

BRIDON Oil and Gas

LTM Sockets and Connection Hardware

The high tensile steel wire solutions are terminatedutilising the Long Term Mooring (LTM) Sockets whichhave been developed by Bridon over 30 years ofinvolvement in this application. Key features include:

• Carefully engineered basket dimensions to ensureefficient transfer of loads between rope and termination.

• Ultra-deepwater rated sealing to prevent water ingress.

• Bend limiter to prevent damage to the cable at thesocket neck during handling and in operation.

• Precision design interfaces to support lifetime fatigue loading.

See page 23

Product Selection

05

Floating Production Mooring SystemsBridon’s specialist fibre tethers and high strength steel cables for permanent mooring of floating production facilities offer arange of properties to ensure the suitable solution for your specific requirements - system type, location, water depth, fieldlife etc.

Bridon’s in house engineering expertise can provide custom designed connection hardware. Our dedicated projectmanagement team will oversee all aspects of your mooring system project including but not limited to design, manufacture,QA & QC requirements, shipping & handling of large package weights, on site installation and handling advice.

PolyesterBridon Superline is a torsionally balanced construction and the polyestermaterial grades offer the highest strength to weight ratio for the permanentmooring solution. The inclusion of a particle filter layer to limit the ingress ofabrasive particles and a marine finish on load bearing elements to enhanceresistance to yarn on yarn abrasion ensures long term performance forfield lives in excess of 20 yearsSee page 24

Spiral Strand

Spiral Strand comprising of either heavy galvanised or Galfan coated hightensile steel wire will enable design lives of up to 15 years. With theapplication of a continuous MDPE sheathed jacket lifetime performanceincreases beyond 20 years with no requirements for inspection ormaintenance.See page 22

For more marginal fields a high strength six strand wire rope solution withthe optional additional specification of anode inserts and heavy galvanisedwire will facilitate systems of up to 10 years.See page 11

BRIDON Oil and Gas

Product Selection

Blue Strand API 9A Standard 6x19 Class

Conventional, tried & tested lines in regular sizes and tensile grades.See page 12

DYFORM® 6Drilling lines typically utilise Dyform Bristar 6 constructions which offersprotection for the core and improved abrasion resistance on draw works,greater cross sectional stability and excellent fatigue capabilities.See page 14 & 15

Riser Tensioner LinesRiser Tensioner Lines present a tough application for wire rope, repetitive high load bending over sheaves requiring aflexible solution with exceptional bend fatigue properties and resistance to wear & abrasion.

DYFORM® 6Dyform Bristar 6 ropes for riser tensioner applications aredesigned to give characteristics which enhance fatigueperformance. The ‘compacting’ process facilitates excellentresistance to wear on the sheaves and drums.See page 14 & 15

Drilling Operations

Drilling LinesDrilling lines present a tough application for wire rope, repetitive high load bending over sheaves requiring a flexible solutionwith exceptional bend fatigue properties and resistance to wear & abrasion.

06

Handling OperationsDeck Handling

BRIDON Oil and Gas

Endurance DYFORM® 34LR

Endurance Dyform 34LR multi-strand ropes are recommended fordemanding lift operations offering high strength, low rotation construction. The Dyform construction ensures accurate diameter tolerances for multi-layer coiling and suitable for single or multi-part reeving.See page 20

Endurance DYFORM® 8PI

Dyform 8PI ropes are impregnated with plastic providing a cushion withinthe rope that increases fatigue life and internal protection, whilst maintainhigh strength, crush resistance and low stretch.See page 21

Product Selection

Knuckle Boom Crane Ropes

07

Handling OperationsBridon Hydra range of products has been developed to meet the varying demands of different offshore lifting and deployment applications.

Specialist Lifting and Deployment

Hydra 7500 DYFORM®

Hydra 7500 Dyform multi-strand ropes offer exceptional'low rotational' properties incorporating a high steel fillfactor that provides high strength, crush resistance,improved fatigue performance and low stretch.See page 16

Hydra 7300DYFORM®

Hydra 7300 Dyform ropes offer a high steel fill factor, providing highstrength, excellent resistance to crushing and abrasion. See page 17

Hydra 5500 multi strand ropes provide large diameter high strength‘rotation resistant’ ropes ensuring excellent fatigue performance with highstrength and lower weight to diameter ratio to aid in deepwater operations.Hydra 5500 is intended for use with systems incorporating a traction winchfor single layer load cases. Hydra 5500 is available in conventional andDyform construction to suit your individual requirements.See page 18 & 19

Hydra 5300DYFORM®

Increased strength, fatigue and wear resistance and greater cross sectionintegrity. A high performance steel wire rope. See page 18

Products also suitable for this application Hydra 7500 Dyform andBlue Strand 6x36. Please contact Bridon for more information.

Offshore Winch RopesHydra 5500 DYFORM®

Hydra 7500 DYFORM®

Hydra 7500 Dyform multistrand ropes offer exceptionallow rotation properties essential for specialist, deep water,single fall knuckle boom cranes. The high steel fill factorensures high strength and suitable robustness inapplications where full load is applied directly tomultilayer rope reel. See page 16

BRIDON Oil and Gas

Product Selection

08

Electromechanical & Subsea CablesThe essential building block of all cable constructions, including armour packages, is high quality steel wire. Bridon operates itsown wire mill which specialises in the production of high quality galvanised wire to the most differentiated and exactingspecifications. As a specialist wire rope manufacturer Bridon has access to the widest range of cable manufacturing equipmentand the expertise and flexibility to utilise these assets to best achieve your subsea cable requirements.

Bridon is able to supply a range of steel armoured cables to meet theindividual requirements for your application. The combination of Bridon’sexpertise in high tensile wire manufacture, cable armouring & braidingtechnology together with our partner companies’ technical leadership inmaterials, electrical & optical cable manufacture has culminated in our highperformance Thin Wall Technology armoured cables. The resulting slimprofile cables ensure minimum drag & weight alongside the logisticalbenefits of larger winch drum capacity enabling with reduced drum size orutilisation of existing equipment for more extreme locations. Please contact Bridon for your specific requirements.

Cable Armouring

Bridon’s range of torsionally balanced wire rope constructions are availablefor use within subsea cables for weight elements in critical segments.Specialist terminations and clamping arrangements can also beaccommodated. Due to the high fill factor providing the highest weight todiameter ratio, spiral strand constructions offer the most appropriate physicalproperties for this application.

Subsea Cable Weight Elements

BRIDON Oil and Gas

09

10

11

12

13

14

15

16

18

18

17

Page

Products

Dyform DB2K

Diamond Blue

Spiral Strand

Superline Polyester

Superline Polyester (MODU)

Superline Steelite Xcel

Viking Braidline Nylon Super Hawser

Superline Nylon OCIMF 2000

Endurance Dyform 8PIBlue Strand 6x19 Class to API steel core (Metric & Imperial)

Blue Strand 6x36Class steel core (Metric & Imperial)

Dyform Bristar6x19 Class for Drilling Lines

Dyform Bristar6x37 Class for Riser Tensioner Lines

Hydra 7500Dyform

Hydra 5500Dyform

Endurance Dyform34LR & 34LRPI

Hydra 7300 Dyform

Hydra 5300 Dyform

Hydra 5500

Page

19

20

21

22

24

25

25

26

27

BRIDON Oil and Gas

Products

10

Figures quoted within published tables represent our standard products.Bridon specialise in the development of products to suit your individual needs, please contact us directly and we will be pleased to develop aspecification to match your requirements.

Ropediameter

mm in kg/m lb/ft kg/m lb/ft kN Tonnes Tons(2000lbs)

MN Mlbs kN.m lbs.ft mm2 in2

In air

Approximate massMinimum breaking

force (Fmin)Submerged Ordinary lay

Axial stiffness@20% load

Torque generated @20% load Metalliccrosssection

52545657.26060.363.56466.76869.9727676.28082.6848888.99295.396100101.6

21/8

21/4

23/821/2

25/8

23/4

3

31/4

31/2

33/4

4

12.213.214.214.816.316.518.318.620.220.922.123.526.226.329.030.932.035.135.838.341.141.745.346.8

8.878.879.5410.011.011.112.312.513.514.114.915.817.617.719.520.821.523.624.125.827.628.130.431.4

11.511.512.413.014.214.315.916.117.518.219.320.422.822.925.226.927.830.531.133.435.836.339.440.7

7.727.728.308.719.539.6310.710.811.812.212.913.715.315.416.918.118.720.520.922.424.124.426.527.3

239625842778289931903222357336293942409743294593511851455670604562526861700273217856797284308702

244263283295325328364370402418441468522524578616637699714746801813859887

269290312326358362401408443460486516575578637679702771787822882896947978

146157169176194196217221240249263279311313345368380417426456490497539556

33353840444449505456596370707883859496103110112121125

1.61.82.02.22.52.53.03.03.43.63.94.35.15.15.96.56.87.98.18.89.79.91112

119513381492159018351863217522272521267129023171372937594350478850365790596964567176733580868481

140215121626169618661885209021232306239725332687299430103318353736584014409743874708477751845351

2.172.342.522.632.892.923.243.293.573.723.934.174.644.675.145.485.676.226.356.807.307.408.038.29

DYFORM® DB2K

BRIDON Oil and Gas

11

Products

Ropediameter

mm in kg/m lb/ft kg/m lb/ft kN Tonnes Tons(2000lbs)

MN Mlbs kN.m lbs.ft mm2 in2

In air

Approximate massMinimum breaking

force (Fmin)Submerged Ordinary lay



52545657.26060.363.56466.76869.9727676.28082.6848888.99295.396100101.6108114.3120.7127

21/8

21/4

23/821/2

25/8

23/4

3

31/4

31/2

33/4

441/441/243/45

11.712.613.614.215.615.717.517.719.320.021.222.425.025.127.729.530.633.534.236.639.339.943.344.750.556.663.169.8

8.878.879.5410.010.510.611.711.912.913.514.215.116.816.918.619.920.522.523.024.626.426.829.130.033.938.042.446.9

11.511.512.413.013.613.715.215.416.817.418.419.521.821.924.125.726.629.229.831.934.234.737.738.943.949.254.960.8

7.727.728.308.719.119.2010.210.411.311.712.413.114.614.716.217.317.919.620.021.423.023.325.326.129.533.136.940.8

223124062587269929703000332733793670381540314277476547905280562958216389652065607039714277508000830593021037311484

22724526427530330633934437438941143648648853857459365166566971772879081584794810571171

251270291303334337374380412429453480535538593632654718732737791802871899933104511651290

140151163170187189209213231240254269300302333354367402411440472479520536606679757838

3234373842424748525457616768758082909299106108117121136153170188

1.51.71.92.02.32.42.72.83.23.43.74.04.74.75.56.06.47.37.57.88.78.9101112141619

1113124613901481170917352026207523482489270329543474350240524460469153935561578264276570742677888616102131202714010

1338144315521619178117991995202722012288241825652858287331673376349138323911418844944560494851085771646472097981

2.072.242.412.512.762.793.093.143.413.553.753.984.434.454.915.235.415.946.066.496.977.077.677.928.9510.011.212.4

For use in floating production mooring systems the minimum breaking loads (MBL) are for cables with a drawn galvanised (Z class) finish whichgives corrosion protection for upto 6 years. For corrosion protection upto 10 years the cables are final galvanised (A class). In this case theminimum breaking loads will be reduced by approximately 2%. Contact Bridon for specific requirements.


BRIDON Oil and Gas

Products

12

Blue Strand 6x19 Class to API steel core (Metric)

Rope diameter

262832363840444852

2.703.144.105.185.786.407.749.2210.8

1.812.112.763.483.884.305.206.207.26

4264946458179101010122014501700

43.450.465.783.392.8103124148173

47.955.572.591.8102113137163191

47254771590410101120135016101890

48.155.872.992.2103114138164193

53.061.480.3102113126152181212

52060378799711101230149017702080

53.061.580.2102113125152180212

58.467.788.4112125138167199234

31.336.347.459.966.874.089.5107125

7.08.211131517202428

17221432045653762783210821376

1271582363363964626137981015

30435246058264871886910341214

0.4700.5460.7130.9021.001.111.351.601.88

In air 1770 grade 1960 grade 2160 grade Ordinary

mm kg/m lb/ft kN Tonnes 2000lbs kN Tonnes 2000

lbs kN Tonnes 2000lbs MN Mlbs N.m lbs.ft mm2 in2

Approximatemass Minimum breaking force (Fmin) Axial

stiffness@20% load

Torquegenerated@20% load

Metalliccrosssection

Blue Strand 6x19 Class to API steel core (Imperial)

Rope diameter

25.428.631.834.938.141.344.547.650.8

111/811/413/811/215/813/417/82

2.753.484.305.196.197.268.429.6611.0

1.852.342.893.494.164.885.666.497.39

3995036177438801020118013501530

40.751.362.975.789.7104120138156

44.856.569.383.598.9115133152172

46057871185410101170136015501760

46.958.972.587.1103119139158179

51.764.979.995.9113131153174198

50663678294311101300150017101930

51.664.879.796.1113133153174197

56.871.487.8106125146169192217

29.837.846.856.367.178.891.4105119

6.78.511131518212427

16423131741753967684610331252

121171233308397499624762923

29036745454765276588710171159

0.4490.5690.7040.8481.011.191.381.581.80

In air IPS EIPS EEIPS Ordinary

mmin kg/m lb/ft kN Tonnes 2000lbs kN Tonnes 2000



stiffness@20% load




BRIDON Oil and Gas

13

Products

Blue Strand 6x36 Class steel core (Metric)

Rope diameter

38404448525660

5.916.547.929.4211.112.814.7

3.974.395.326.337.478.609.88

910101012201450170019802270

92.8103124148173202231

102113137163191222255

1010112013501610189021902510

103114138164193223256

113126152181212246282

1110123014901770208024102770

113125152180212246282

125138167199234271311

697793110129150172

16172125293439

5376278321082137617172108

396462613798101512661555

6647368911060124414431656

1.031.141.381.641.932.242.57

In air 1770 grade 1960 grade 2160 grade Ordinary

Blue Strand 6x36 Class steel core (Imperial)

mm kg/m lb/ft kN Tonnes 2000lbs kN Tonnes 2000



stiffness@20% load



Rope diameter

38.141.344.547.650.857.263.566.769.976.282.688.995.3102

11/215/813/417/8221/421/225/823/4331/431/233/44

6.197.268.429.6611.013.917.319.120.824.729.033.838.744.0

4.164.885.666.497.399.3511.612.814.016.619.522.726.029.8

88010201180135015301910

89.7104120138156195

98.9115133152172215

10101170136015501760220029503240353041604830552062706340

103119139158179224301330360424493563639647

113131153174198247331364397467543620705712

111013001500171019302420

113133153174197247

125146169192217272

698295108123156193213234278326378434498

16182124283543485362738598112

53967684610331252176026233026345444385585687083659054

397499624762923129819342231254732724119506661686676

66878490910421187150218552046224826713138363541784786

1.041.211.411.621.842.332.883.173.484.144.865.646.487.42

In air IPS EIPS EEIPS Ordinary

mmin kg/m lb/ft kN Tonnes 2000lbs kN Tonnes 2000



stiffness@20% load




BRIDON Oil and Gas

Products

14

DYFORM®

6x19 Class for Drilling Lines

Ropediameter

mm in kg/m lb/ft kN Tonnes 2000lbs MN Mlbs N.m lbs.ft N.m lbs.ft mm2 in2

In air

Approximate mass Minimum breakingforce (Fmin)

EIPS/1960 grade Ordinary Lang’s



25.428.631.834.938.141.344.547.650.854.057.263.569.976.2

111/811/413/811/215/813/417/8221/821/421/223/43

2.843.604.455.366.397.518.719.9711.412.814.417.721.525.5

1.912.422.993.604.295.045.856.707.638.629.6711.914.417.2

5146528059701156135915771805205523232606321237624471

52.466.482.198.9118138161184210237266327383456

57.773.290.5109130153177203231261293361423502

344454657891106121138156175215261310

810121517202427313539485970

1802573534676087749691185144117312057281436294701

133190261345448571714874106312761517207526763467

n/an/an/an/an/an/an/an/an/an/an/an/an/an/a

n/an/an/an/an/an/an/an/an/an/an/an/an/an/a

33442452463175288410261174133815121696209025333010

0.5180.6570.8120.9791.171.371.591.822.072.342.633.243.934.67


BRIDON Oil and Gas

Products

15

DYFORM®

6x37 Class for Riser Tensioner Lines

Ropediameter

mm in kg/m lb/ft kN Tonnes 2000lbs MN Mlbs kN.m lbs.ft mm2 in2

In air

Approximate mass Minimum breakingforce (Fmin)

IPS/1770 grade Lang’s lay



4444.547.64850.852545657.260.363.56466.769.973.076.2

13/417/8

2

21/8

21/423/821/2

25/823/427/83

8.628.7910.110.311.512.013.014.014.516.217.918.219.821.723.725.8

5.795.916.786.897.728.098.729.389.7710.912.112.213.314.615.917.4

1456148617041733194120342194235923702639292629723229354638674214

148152174177198207224240242269298303329361394430

164167191195218228246265266296329334363398434473

103105121123138144156167174194215219238261285310

23242728313235383944484953596470

1.41.41.81.82.12.32.62.93.03.54.14.14.75.46.27.0

1030106213041337158517001904212421772558298730583462398445385161

1004102411741194133814021512162616931885209021232306253327623010

1.561.591.821.852.072.172.342.522.622.923.243.293.573.934.284.67


BRIDON Oil and Gas

Products

16


BRIDON Oil and Gas

7500 DYFORM®

Ropediameter

inmm kg/m lb/ft kg/m lb/ft kN Tonnes Tons(2000lbs)

MN Mlbs N.m lbs.ft mm2 in2

In air Submerged

Minimum breaking force(Fmin)

Lang’s lay


Torque generated@20% load Metallic

cross section

Approximate mass

12.913.514.616.318.019.220.221.823.124.424.525.927.428.929.029.834.134.439.540.542.645.446.148.550.052.654.357.763.467.875.278.580.187.894.494.798.6112.4

8.79.19.811.012.112.913.514.615.516.416.517.418.419.419.520.022.923.126.627.228.630.531.032.633.635.436.538.842.645.650.652.853.959.063.463.766.375.5

11.211.812.714.215.716.717.518.920.121.321.322.623.825.125.326.029.730.034.435.237.139.540.142.244.246.548.051.156.160.066.569.570.977.783.583.887.299.5

7.57.98.59.610.511.211.812.713.514.314.315.216.016.917.017.519.920.123.123.725.026.526.928.329.731.232.234.337.740.344.746.747.652.256.156.358.666.9

236724802675294532463466363539274169435743704623488351515151524858105810666068187112765077608339866287318829981010595108891275313342135381500915784158431653019031

26627930033136538940844146848949151954957957959065365374876580085987293797398199211021190122414341499152116871774178118582138

1481561681882072212322512662812822983153323343403933964554664715235305355535806006387007508318688859701043104710901241

333538424750525660636367717575768889102105106117119120124130134143157168186195199218234235245279

433464520606701774831933102110961101119813011409141314551728173621312158235526252682300029923027309036354117429454205760589068897497754080369861

3193423834475175706136887538098128849591039104210721274128015721591173619351978221222062231227826803036316639964248434450805529556059257272

150015721695189820922234234425322687284028483013318333573375344539654004459347084761527853565415558958706060644770807581839887708950979210541105781101012545

2.32.42.62.93.23.53.63.94.24.44.44.74.95.25.25.36.26.27.17.37.48.28.38.48.79.19.410.011.011.813.013.613.915.216.316.417.119.4

24125327330033135337140042544444547149852552553559259267969572578079185088389090010001080111013001360138015301609161516851940

50.8525457.15606263.5666869.97072747676.27782.68388.9909295.396100101.6102103109114.3116125127128135139.7140143152.4

2

2 1/82 1/4

2 1/2

2 3/4

3

3 1/4

3 1/2

3 3/4

4

4 1/2

5

5 1/2

6

Products

17


BRIDON Oil and Gas

7300 DYFORM®

Ropediameter



In air Submerged


Lang’s lay



cross section

Approximate mass

2 1/8

2 1/4

2 3/82 1/2

2 5/8

2 3/4

7.38.18.99.710.611.512.213.214.214.816.316.518.318.620.220.922.123.526.2

4.95.46.06.57.17.78.98.99.510.011.011.112.312.513.514.114.915.817.6

6.57.17.88.69.410.211.511.512.413.014.214.315.916.117.518.219.320.422.8

4.44.85.35.86.36.87.77.78.38.79.59.610.710.811.812.212.913.715.3

1324146016021751190720692396258427782899319032223573362939424097432945935118

149164180197214232269290312326358362401408443460486516575

8796105115125136146157169176194196217221240249263279311

19212426283033353840444449505456596370

0.70.80.91.11.21.41.61.82.02.22.52.53.03.03.43.63.94.35.1

53962471782093110531195133814921590183518632175222725212671290231713729

84292810191113121213161402151216261696186618852090212323062397253326872994

1.31.41.61.71.92.02.22.32.52.62.92.93.23.33.63.73.94.24.6

135149163179194211244263283295325328364370402418441468522

40424446485052545657.26060.363.56466.76869.97276

Products

18


BRIDON Oil and Gas

5500

Ropediameter



In air Submerged


Lang’s lay



cross section

Approximate mass

3

3 1/4

3 1/2

3 3/4

4 4 1/44 1/24 3/45 5 1/45 1/2

26.329.030.931.935.838.341.141.746.752.859.165.973.080.688.3

17.719.520.821.524.025.727.628.031.435.539.744.349.154.159.4

22.925.226.927.831.133.335.836.340.745.951.457.463.570.176.9

15.416.918.118.720.922.424.024.427.330.934.638.642.747.151.6

45585024535655396204664471297235810391561012511291125001361414930

512564602622697746801813910102911371268140415291677

3023333543674114404724795366066797578389251014

687580829299106108121136153170188208228

3.23.74.14.35.15.66.36.47.69.110.712.514.616.719.2

235627273001315637424147460947115585670878519245107691232014149

287331673376349139114188449445605108577164647209798188059657

4.54.95.25.46.16.57.07.17.99.010.011.212.413.715.0

46551254656563267772773782693310321151127413881522

76.28082.68488.99295.396101.6108114.3120.7127133.4139.7

5300 DYFORM®

Ropediameter



In air Submerged


Lang’s lay



cross section

Approximate mass

2 1/8

2 1/4

2 3/82 1/22 5/8

2 3/43

3 1/4

3 1/2

3 3/4

4

11.512.213.214.214.816.316.518.320.220.922.126.329.030.932.035.838.341.141.746.8

7.78.98.99.510.011.011.112.313.514.114.917.719.520.821.524.125.827.628.131.4

10.211.511.512.413.014.214.315.917.518.219.322.925.226.927.831.133.435.836.340.7

6.87.77.78.38.79.59.610.711.812.212.915.416.918.118.720.922.424.124.427.3

20692396258427782899319032223573394240974329514556706045625270027321785679728702

232269290312326358362401443460486578637679702787822882896978

136146157169176194196217240249263313345368380426456490497556

30333538404444495456597078838596103110112125

1.41.61.82.02.22.52.53.03.43.63.95.15.96.56.88.18.89.79.912.0

10531195133814921590183518632175252126712902375943504788503659696456717673358481

13161402151216261696186618852090230623972533301033183537365840974387470847775351

2.02.22.32.52.62.92.93.23.63.73.94.75.15.55.76.46.87.37.48.3

211244263283295325328364402418441524578616637714746801813887

5052545657.26060.363.566.76869.976.28082.68488.99295.396101.6

Products

19


BRIDON Oil and Gas

5500 DYFORM®

Ropediameter



In air Submerged


Lang’s lay



cross section

Approximate mass

1 3/4

1 7/8

2

2 1/8

2 1/4

2 1/2

2 3/4

33 1/4

3 1/2

3 3/4

4

4 1/2

5

5 1/26

8.08.89.79.910.611.311.512.512.913.514.615.716.316.818.019.220.220.521.823.124.424.525.927.427.427.632.432.637.538.643.544.148.855.561.570.877.184.793.4111.1

5.45.96.56.67.17.67.78.48.79.19.810.511.011.312.112.913.513.814.615.516.416.517.418.418.418.521.821.925.225.929.229.632.837.341.347.651.856.962.874.7

7.07.78.48.69.29.910.010.911.211.812.713.614.214.615.716.717.517.818.920.121.321.322.623.824.324.428.728.933.234.238.439.243.349.154.462.768.375.082.798.4

4.75.25.75.86.26.66.77.37.57.98.59.29.69.810.511.211.812.012.713.514.314.315.216.016.316.419.319.422.323.025.826.329.133.036.642.145.950.455.666.2

1468161817761812194120782113229323672480267528772945303332463466363536933927416943574370462348835003500355725572618063867112745583189613102021226212900135381510718296

1651821992042182332372582662793003233313413653894084154414684894915195495625626256256947387998379351080114613781449152116972055

9210111111412213013314414815616818018819420722123223625126628128229831530230335634041342348549353261268077884893010261221

212325262729303233353841424447505253566063636771686880769395109110119138153175191209230274

0.20.20.30.30.30.40.40.40.40.50.50.60.60.60.70.80.80.90.91.01.11.11.21.23.03.13.73.74.44.65.45.76.88.49.312.013.114.416.922.3

1561802072142372632693043193423834284474675175706136276887538098128849592245225227172732324933974002422549936189689088409682106351246716477

93010251125114812301317133914531500157216951823189819552092223423442381253226872840284830133183304930653601363541704274490649785375618568757864857093991037012340

1.41.61.71.81.92.02.12.32.32.42.62.82.93.03.23.53.63.73.94.24.44.44.74.94.74.75.65.66.56.67.67.78.39.610.712.213.314.616.119.1

150165181185198212215234241253273293300309331353371376400425444445471498510510568568630670725760848980104012501315138015401865

40424444.454647.6485050.852545657.1558606263.564666869.97072747676.282.68388.99095.396101.6109114.3122127133139.7152.4

Products

20


BRIDON Oil and Gas

Diameter

mm

EIPS / 1960 grade

Minimum breaking force (Fmin)

EEIPS / 2160 grade @20% load

Axialstiffness

Torque generated @20% load Metallic

crosssectionLang’sOrdinary

mm2kg/m kN tonnes kN tonnes MN N.mN.m

Approx.nominal lengthmass

101112131415161718192021222324252627282930323435363840

4244464850

0.500.610.720.850.981.131.281.451.621.812.002.212.422.652.883.133.383.653.924.214.505.125.786.136.487.228.00

8.829.6810.611.512.5

92.111113315618120723626629833336840644648753157662367272277582993910601124118913251468

16181776194121132293

9.3911.413.515.918.421.124.027.130.433.937.641.445.449.754.158.763.568.573.679.084.595.7108115121135150

165181198215234

96.7117139163190218248279313349387426468511557604654705758813870990

9.911.914.216.719.322.225.228.531.935.639.443.547.752.156.861.666.671.977.382.988.7101

5.87.08.39.71113151719212325283033363942454852596770758392

101111122133144

1.52.02.53.24.05.06.07.28.6101214161820232629323640485863688194

109125143162183

3.34.45.77.39.111141619232731354046525865738190108130142154181211

245281321365413

58708498114131149168188210232256281307335363393424456489523595672712753839930

10251125123013391453

Dyform 34x7

Dyform 34x19

Endurance DYFORM® 34LR & 34LRPI

Products

21

DYFORM® 8PI


Ropediameter

mm in kg/m lb/ft kN Tonnes 2000lbs

kN Tonnes 2000lbs

mm2 in2

In air

Approximatemass

EIPS/1960 grade 2160 grade Ordinary Lang’s

Axialstiffness

@20% load

Torque generated@20% loadMinimum breaking force (Fmin) Metallic

crosssection

1617181919.1202222.22425.4262828.63031.8323434.9363838.1404244464850

3/4

7/8

1

11/8

11/4

13/8

11/2

1.201.361.521.701.721.882.282.322.713.043.183.693.854.234.764.825.445.736.106.796.837.538.309.119.9510.811.8

0.810.911.021.141.151.261.531.561.822.042.142.482.592.843.203.243.653.854.104.564.595.065.586.126.697.287.90

22625528631832235342743550856959669172179489290310201074114312741280141115561708186620322205

23.026.029.132.532.836.043.544.351.858.060.870.573.580.990.992.1104110117130131144159174190207225

25.428.632.135.836.139.648.048.857.163.967.077.781.089.2100101115121128143144159175192210228248

23626729933333636944645553159562372375483093394410661123119513321339147616271786195221252306

24.127.230.533.934.33845.546.354.260.763.673.776.984.695.196.3109115122136136150166182199217235

26.529.933.637.437.841.450.151.159.766.870.081.284.793.2105106120126134150150166183201219239259

1415171919212626313436424448545562656977788594103113123134

3.13.53.94.34.44.85.85.96.97.78.19.4101112121415161717192123252830

5161728586991311351712022172712893333974054855255766786837909151052120213661544

3745536263739710012614916020021324629329835838742550050458367577688610071138

657893109111127169174219260279349371429511520624675741871878101611761352154517561985

485868808294125128162192206257274316376384460498546642647749867997113912951463

1371541731931952142582633083453614194374815405476176506927717758549421034113012301335

0.2120.2390.2680.2990.3020.3310.4010.4080.4770.5340.5600.6490.6770.7450.8370.8480.9571.011.071.201.201.321.461.601.751.912.07

MN Mlbs N.m lbs.ft N.m lbs.ft

BRIDON Oil and Gas

Products

22


Spiral Strand

Stranddiameter

mm in kg/m lb/ft kg/m lb/ft kg/m lb/ft kN Tonnes Tons(2000lbs)

kN Tonnes Tons(2000lbs)

mm MN mm2

Unsheathed in air

Approximate mass

Sheathed in air Submerged SPR2plus Xtreme

Axialstiffness@20%load

Sheathingradial

thickness

Minimum breaking force (Fmin) Metalliccrosssection

65687073767982869092.595.598102105.5108111.5114118121.5124127131133137.5141144146.5147.5153

21/225/823/427/8331/831/433/831/235/833/437/8441/841/443/841/245/843/447/8551/851/453/851/255/853/457/86

21.022.624.827.329.732.735.437.340.142.945.950.453.755.659.063.166.870.374.177.781.784.688.894.799.1103108113118

14.115.216.718.320.022.023.825.127.028.830.833.936.137.439.642.444.947.249.852.254.956.859.763.666.669.572.576.079.0

22.724.426.729.331.834.937.738.943.146.149.254.057.659.462.967.271.174.678.582.286.389.393.699.6104108113119123

15.216.417.919.721.423.425.326.129.031.033.136.338.739.942.345.147.850.152.755.258.060.062.966.969.972.676.179.682.9

17.618.920.923.025.227.729.931.333.636.038.642.745.346.649.653.156.359.162.265.368.770.874.679.583.186.390.795.599.1

11.812.714.015.516.918.620.121.022.624.225.928.730.431.333.335.737.839.741.843.946.247.650.153.455.858.060.964.266.6

4072444547005120564760906550719079388394893094571026610867114271212912775135941436215073157221677517171182721918019867204692090022070

41545347952257662166873380985691196410471108116512371303138614651537160317111751186319562026208721312251

4584995285756356847368088929431004106311541221128413631436152816141694176718851930205321552233230023492480

45534869534458926416705976358095870692679917108471155812071128141367514468151771600816760176311830019204205422150922259232572425925302

4644965456016547207788258879451011110611781230130613941475154716321708179718651958209421932269237124732579

51154760066272179385890997810411114121812981356143915361625170517981883198120562157230824162500261327252842

66888888101010101111111111111111111111111111111111

41644148453758462067171276681387095410171056112011971266131313851452152815521628173618171884196920582146

2519267429353252354138784194445147875080543659636354659770037480791483098764919396701001010505111981172512154127001327513846

BRIDON Oil and Gas

Products

23


kN

40724700564765507938893010266114271277514362157221717119180204692207023835

A

1870201020602105215021952240229023402395246525302595267027352810

B

155172182191205211225235250260275285295310315325

C

136146156162176181191201216226241251261276281291

D

132141145160177182202212227237252267277292302322

E

155161166181198203223233248258273288298313323333

Tonnes

17171725252535353535353535353535

kg

2052552903354004906307909251025117013101470181019452095

Min. jaw gap

160166171186203208230240255265280295305320330340

Pin diameter

135145155161175180190200215225240250260275280290

Closed Socket

Overall termination length (mm)

Socket bore ø

Orkotbore ø

Lug width

Width inc.orkot

Pad eyeSWL

Estimated terminations weight

Required connecting steel workdimensions (mm)

Cable MBL

Closed Socket

Open Socket

Long Term Mooring Sockets

kN

40724700564765507938893010266114271277514362157221717119180204692207023835

A

1820195020052055210821612218229023482433250325722643272327902865

B

135145155161175180190200215225240250260275280290

C

155172182191205211225235250260275285295310315325

D

160166171186203208228238253263278293303318328338

E

132141145160197182202212227237252267277292302322

Tonnes

17171725252535353535353535353535

Kg

25030535040547058073090010651185136515301710209022452395

Max. link width

132141145160177182202212227237252267277292302322

Link bore dia

155172182191205211225235250260275285295310315325

Open socket

Overall termination length (mm)

Pin ø Orkotouter ø

Jawgap

Jaw gapinc. orkot

Pad eyeSWL

Estimated terminations weight

Required connecting steel workdimensions (mm)

Cable MBL

BRIDON Oil and Gas

Products


Polyester

Diameter*

in mm kN kg/m

In air Submerged

Approximate massPost installation drift

stiffnessIntermediatestiffness

Stormstiffness

lb/ft kg/m lb/ft MN 103 kips MN 103 kips MN 103 kips

MBL

415/1651/2515/1661/465/8615/1671/4715/1683/883/49 91/293/4101/8103/8109/161013/16111/16111/4117/16115/8

126139151158168177185201213223229241247257263268274281286291296

39244905618069597848882998101098712263137341471515696166771785818639196202060121582225632354424525

88211021389156517641984220524692756308633073527374839684189440946304850507152915512

10.012.114.415.918.019.921.925.828.931.833.637.239.242.444.446.448.550.752.654.756.7

6.78.19.710.712.113.414.717.319.421.422.625.026.328.529.831.232.634.135.336.838.1

2.53.03.64.04.55.05.56.57.28.08.49.39.810.611.111.612.112.713.213.714.2

1.72.02.42.73.03.43.74.34.95.45.76.36.67.17.57.88.28.58.89.29.5

51.063.880.390.5102.0114.8127.5142.8159.4178.5191.3204.0216.8232.2242.3255.1267.8280.6293.3306.1318.8

11.514.318.120.322.925.828.732.135.840.143.045.948.751.654.557.360.263.165.968.871.7

105.9132.4166.9187.9211.9238.4264.9296.6331.1370.8397.3423.8450.3482.2503.3529.7556.2582.7609.2635.7662.2

23.829.837.542.347.653.659.566.774.483.389.395.2101.2107.1113.1119.0125.0131.0136.9142.9148.8

109.9137.3173.0194.9219.7247.2274.7307.6343.4384.6412.0439.5467.0500.0521.9549.4576.8604.3631.8659.2686.7

24.730.938.943.849.455.661.769.177.286.492.698.8104.9111.1117.3123.5129.6135.8142.0148.1154.3

kips

*Diameters shown in the above table are nominal values and should be used for guidance purposes only.


Products

25

Steelite Xcel constructions shown in the above table exhibit a relative density of <1 and are therefore neutrally buoyant in seawater.*Diameters shown in the above table are nominal values and should be used for guidance purposes only.

Polyester (MODU)

Diameter*

in mm kN kg/m

in air

Approximate mass

Submerged

Post installation driftstiffness

Intermediatestiffness

Stormstiffness

lb/ft kg/m lb/ft MN 103 kips MN 103 kips MN 103 kips

MBL

55/16513/1661/465/87 75/16715/16

135147158169178186194

3924490561806965784888299810

882110213891565176419842205

11.413.615.818.120.222.124.1

7.79.110.612.213.614.916.2

2.93.44.04.55.15.56.0

1.92.32.73.13.43.74.1

51.063.880.390.5102.0114.8127.5

11.514.318.120.322.925.828.7

105.9132.4166.9188.1211.9238.4264.9

23.829.837.542.347.653.659.5

109.9137.3173.0195.0219.7247.2274.7

24.730.938.943.849.455.661.7

kips

Diameter*

in mm kN kg/m

In air

Approximate mass5% initial loading

10-30%10 cycles

20-30%300 cycles

50-50%300 cycles

lb/ft MN 103 kips MN 103 kips MN 103 kips MN 103 kips

MBL

33/1633/831/2311/16313/16315/1641/843/1643/841/245/843/4413/16415/16

8185899397100104107111114117120123125

34343924392449055396588663776867735878488339882993209810

77288299211021213132314331543165317641874198420932205

2.83.03.33.63.94.44.75.05.35.65.96.26.46.7

1.82.02.22.42.63.03.13.33.53.73.94.14.34.5

44.651.051.063.870.176.582.989.395.7102.0108.4114.8121.2127.5

10.011.512.914.315.817.218.620.121.522.924.425.827.228.7

206.0235.4235.4294.3323.8353.2382.6412.0441.5470.9500.3529.7559.2588.6

46.352.959.566.172.879.486.092.699.2105.8112.4119.0125.6132.3

291.9333.5333.5416.9458.7500.3542.0583.7625.4667.1708.8750.5792.2833.9

65.675.084.393.7103.1112.5121.8131.2140.5149.9159.3168.6177.9187.4

364.0415.9415.9519.9572.0623.9676.0727.9779.9831.9883.9935.9987.91039.9

81.893.5105.2116.8128.6140.2151.9163.6175.2187.0198.6210.3221.9233.7

kips

Steelite Xcel


BRIDON Oil and Gas

Products

26

Diameter* CircumferenceIn air

Approximate massMBL new dry MBL new wet

in mm in mm kg/m lb/ft kN kips kN kips

31/831/233/441/843/843/45 53/855/86 61/465/871/281/291/2

808896104112120128136144152160168192216240

10 11 12 13 14 15 16 17 18 19 20 21 24 27 30

251.3276.5301.6326.7351.9377.0402.1427.3452.4477.5502.7527.8603.2678.6754.0

4.04.85.76.77.88.910.211.412.814.315.817.422.828.835.6

2.73.23.84.55.26.06.97.78.69.610.611.715.319.423.9

14401750204024402820321036104110461051105660623081501030012700

3243934585486347218119241036114812721400183223152854

1370166019402310268030503420390043704850537059107730977012000

308373436519602685769876982109012071328173721962697

Nylon Super Hawser



BRIDON Oil and Gas

Products

27

Diameter* CircumferenceIn air

Approximate massMBL new dry MBL new wet

in mm in mm kg/m lb/ft kN kips kN kips

31/831/233/441/843/843/45 53/855/86 61/465/867/871/471/277/881/481/287/891/8

808896104112120128136144152160168176184192200208216224232

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

251.3276.5301.6326.7351.9377.0402.1427.3452.4477.5502.7527.8552.9578.1603.2628.3653.5678.6703.7728.8

4.25.26.17.08.39.510.411.713.214.616.217.819.822.224.126.128.630.532.535.4

2.83.54.14.75.66.47.07.98.99.810.912.013.314.916.217.519.220.521.823.8

146217762109248228843316377742674787533759256533718178488554929010055108501167412537

329399474558648745849959107611991332146816141764192320882260243826242818

1344162819422276264930413463391443954905543559946592721078588525923199571072211507

30236643751159568377888098811021221134714821620176619162075223824102586

Nylon OCIMF 2000



BRIDON Oil and Gas


A variety of Load / Extension graphs to suit your specificload case are available for the Fibre Products in thisbrochure. Please contact Bridon for further details.

Tensile Strength

Strengths are determined on new ropes under laboratoryconditions according to Bridons’ QA25 quality procedures.Ropes can be supplied and tested to a number ofinternational quality standards including EN 919, US MilSpecifications and Cordage Institute specifications.

Weight

Rope mass is determined by weighing a rope sample thathas been measured at a reference load.

For most ropes this is calculated as:

Reference Load (kg) = D²/8

Where D = Rope diameter (mm)

Care in useStorage

Ropes should be stored, where possible under suitablecover. The area should be clean, dry and cool out of directsunlight. Rope should be stored off the ground, to allowadequate ventilation, and away from metal walls or steampipes. Never store rope on concrete or dirty floors, or dragover rough ground - dirt and grit picked up by the rope canwork into the strands cutting the inside fibres. Keep awayfrom chemicals of all types. In the case of long termstorage used ropes should be hosed down with fresh waterto reduce salt crystals that can affect the life and efficiencyof the ropes.

Physical Properties

Extension Properties of Synthetic Ropes

Rope extension and elasticity are important characteristicsbecause they will determine rope behaviour in terms of peakloads and mooring excursions. Synthetic fibre ropes differfrom steel because the load-extension characteristics ofsynthetic fibre ropes are non-linear and time dependent.

The overall extension of a synthetic rope is made up fromseveral different components:

Elastic Extension

Elastic extension is the extension that is immediatelyrecoverable upon the release of the load. In a continuouslyworking environment elastic extension will dominate therope behaviour.

Visco-elastic Extension

Visco-elastic extension is only recoverable with time afterthe release of the load. The behaviour of ropes subjected tooccasional high loads will be significantly influenced by thisvisco-elastic component.

Permanent Extension

Permanent extension is non-recoverable. It will occur when anew rope is first used or when a rope is subject to an unusuallyhigh load. It occurs as a result of the individual fibrecomponents of the rope “bedding in” to their preferredpositions. Continuous loading of some ropes can also lead tofurther permanent extension due to creep at the molecular level.

Components of Rope Extension

Synthetic Rope Technical Information

Nylon (Polyamide) 1.14 0.1 – 0.12 218Polyester 1.38 0.12 – 0.15 256HMPE (Steelite) 0.97 0.07 147

Material Properties

Material SpecificGravity

DynamicCo-efficientof FrictionagainstSteel

MeltingTemp.oC

Permanent Visco-elastic Elastic Extension

Total Extension


"V" shaped grooves should not be used as they tend topinch and damage the rope by increasing friction andcrushing the fibres. Sheave surfaces should be smooth andfree from burs. Sheaves should be maintained regularly sothat they are free to rotate at all times.

Sharp Bends

Sharp bends around any piece of equipment should beavoided. Where a static rope passes around any surfacewith a deflection of 10 degrees or more then the diameterof the surface should be a minimum of three times the ropediameter. Any sharp bend in a rope under load willsubstantially decrease its strength and may causepremature damage or failure.

Eye Splices

The length of an eye in a rope should be a minimum ofthree times, and preferably five times, the diameter of theitem around which it is to be passed. This will ensure thatthe angle between the two legs of the eye will not cause atearing action at the throat of the eye. For instance if theeye of a mooring line is passing around a 600mm diameterbollard then the eye should be a minimum of 1.8 metresand preferably 3 metres.

Retiring Ropes

Apart from rejecting your rope when obviously damaged, itis wise to establish lifetimes of your rope within theparameters of the use for which it was selected. This willallow you to retire your rope on a regular scheduled basis,provided of course, that your conditions of usage remainunchanged. Remember to re-establish your discard criteriaif changing rope type, rope material or rope breaking load.Safety of life and property is the prime consideration. If indoubt ask Bridon for recommendations.

Handling

If a rope is supplied on a reel this must be allowed to freelyrotate on a central pin or pipe so that the rope can bedrawn off the top layer. Never take rope from a reel lying onits side.

Braided ropes can not be kinked or hockled, however, twistcan be imparted into the ropes in service. Excessive twistcan cause an imbalance between the right and left handstrands and should therefore be removed as soon aspossible by counter-rotating the rope when it is relaxed.

Rope Safety

Never stand in line with a rope under tension. If a rope failsit can recoil with sufficient force to cause serious injury oreven death. Ensure all end terminations are adequate totake shock loads. Use correct safety factors.

Rope Inspection

In use, rope should be inspected regularly for evidence ofsurface abrasion (chafe) including major yarn or strandcuts.

Ropes should be examined along their entire length forareas of stiffening or inconsistent diameter, where the ropehas either flattened (necking) or has an unusual lump orsurface hernia. This can indicate internal damage or corefailure due to overloading or severe shock loads. If limitedto one small section the damaged area may be cut out andre-spliced, otherwise the rope should be discarded.

Check splices and tucks for evidence of movement ormisalignment. If in doubt cut off and re-splice.

Rope installation and handling equipment

Full guidelines for rope installation and operation areavailable on request from Bridon.

Pulleys and Sheaves

The ratio between rope diameter and sheave diameter iscritical to the safe usage of a rope. As a general guide aratio of 8:1 minimum should be used for 8-strand, 12-strandand Braidline (Double Braid) ropes and 12:1 minimumshould be used for Superline ropes. The groove of thepulley should be "U" shaped and the groove width 10%greater than the rope diameter. The depth of the grooveshould be approximately half the rope diameter.

Synthetic Rope Technical Information

Steel Rope Technical Information


Recommended Handling Procedures

This section provides recommendations and information on thecorrect installation and handling of Drilling Lines, to ensureoptimum working lives are achieved.

In general all reputable Wire rope producers now manufactureDrilling-Lines to very precise regulations and within high qualitycontrol procedures.

As a result of this, it is a proven fact that the majority ofunnecessary drilling line wear, damage and premature discardproblems arise from incorrect handling and treatment of therope in service.

With the Drilling Lines now becoming much larger in diameterand often longer in length, making them significantly heavier,the potential for damage is proportionally greater. Therefore itbecomes increasingly essential that these ropes are handledcorrectly in order to operate safely and optimise the ropeworking life.

Rope Storage

Unwrap and examine the rope immediately after delivery to site,(whether it’s at the on-shore base warehouse, or out on the rig)to confirm everything is in order.

Check its diameter, it’sidentification and conditionand to verify that it is fully inaccordance with yourrequirement, as per thepurchase order andspecification and importantlythe details shown on theCertificates and documents.

Select a clean and well ventilated, dry location for storage,where it is not likely to be affected by chemical fumes, steam ofcorrosive agents.

Mount the reel on timbers or suitable frame to ensure that the ropedoes not make direct contact with the ground and if stored forextended periods of time ensure the reel in rotated periodically toprevent the migration of lubricants from the rope.

Installation

Prior to installation of the rope (drill-line), ensure that:

A. The drill-line storage reel is properly mounted and free torotate.

B. The reel is correctly positioned, so that the drill-line willspool off correctly, in the same direction the fast-line willspool onto the draw-work’s drum, i.e. Over-wind to over-wind, or under-wind to under-wind.

C. Prior to reeving the drill-line, the following components andequipment must be inspected, to ensure they arecompatible with and won’t damage the new drill-line that isto be installed.

i), All sheave groove root profiles are to be gauged, to ensurethat they are within acceptable tolerances (as per picturesleft). Ideally the groove profile should measure 7.5% abovethe nominal diameter of the rope.

ii), All sheave grooves areto be checked thoroughly,to ensure that there are norope (drill-line) tread wearpatterns, indentations orscoring in them.

iii), All sheave bearingsmust be checked foradjustment, so they arefree to rotate efficientlyand with the minimum oftractive effort.

Check to ensure that there is no excessive side-movement,(wobble) which would cause sheave groove enlargementand the accompanying premature sheave bearing failure,and undoubtedly contribute to premature drill-line discard.

D. The Travelling Block should be positioned so it is aligned aswell as possible with the Crown Cluster Block’s sheaves. Itshould also be “hung off” and secured to preventmovement, which is essential to ensure that no turn isinduced in the rope during installation. On most operationalrigs, the travelling-block is hung-off in the derrick , stillattached to its guide dolly, so the sheave alignment of bothblocks will be good.

E. The Draw-works drum and it’s flanges need to be inspectedto make sure all grooves are in good condition and that theyare still compatible with the drill-line size.

(Note: The groove radius and pitch should be checked andmeasured prior to ordering the new line and the detailsadvised to the rope supplier, to ensure the rope supplied issuitable for the system).

F. The drum flanges, wear and kick-plates should be checked toensure they are in good condition. (As damage and adversewear to them can damage the drill-line).

G. The Travelling block must be hung off and secured to preventmovement whilst the new Drill line is being reeved.

If any component in the reeving configuration is worn, ordamaged, to the extent where it might damage the drill-line,then it should be repaired in situ or changed out prior to reevingthe new drill-line.

To leave it in this condition and continue operating, will not onlycause premature drill-line discard, but also constitute an unsafeworking operation.

Drilling Lines

P

O

BBRRIIDDOONN

WRONG

Sheave groove toonarrow

Sheave groove toowide

Sheave groovecorrectlysupporting therope for 33% ofits circumference

WRONG

RIGHT


31BRIDON Oil and Gas

Rope Installation

Installation of the new drilling Line is usually undertaken bypulling it through the reeve-up system with the old rope. API9B, recommends that the two ropes be connected by means ofwhat they call a “swivel stringing grip”, (which is also known asa snake, a Chinese finger, or a sock). This can be a satisfactoryprocedure with the smaller drill-lines with minimum number offalls. But preferably without a swivel in the reeving hook-up.

(A swivel should never ever be used with Flattened Strand or anyother Langs Lay rope.)

In the case of the much larger diameter drilling lines and multi-fallsystems, where the tensions in reeving are much higher, then the useof a stringing grip, or similar, is not a practical or safe way toproceed. The common practice is to directly connect one line to theother. (Splicing is the preferred and safest method).

The prime objective during reeving of the new line is to ensurethat no turn is introduced into the new line, either from the oldline or by the system.

The possible imposition of rope turn can be checked byattaching a flag or marker at the connection point of the newdrill-line and then observed during installation. If any twist isseen to be induced into the rope, then this should be let outbefore the rope is attached to the drawworks.

Ideally the rope should then be wound onto the Draw-work’sdrum at the recommended minimum required fast-line tension ,possibly by using a pinch-roller type drill-line tensioner. Thisrope tension should be applied until the drill-line has the weightof the travelling assembly on it.

The manufacturers recommended minimum number of deadwraps on the Drawworks drum, should where possible becomplied with, as any additional or an excessive number ofdead wraps, especially any wraps without sufficient tension onthem, could lead to rope slackness on the drum with probablerope crushing damage.

On Rigs with Crown Mounted Compensators, it is recommendedthat the cylinders be extended, prior to winding the line on to thedraw-work’s drum. This ensures that the excessive amount ofdrill-line that is required for CMC operation when the cylinders areextended, is taken up in the falls between the crown and travellingblocks as the drill-line is wound onto the drum under tension.

On some draw-works the fast-line’s exit-hole through the drumflange to the clamp may not allow the rope to enter if it has beenserved (seized). In such a case it is essential to fuse all the wiresand strands at the rope end, by weld, to ensure that nothingmoves when the serving (seizings) are removed.

Once installed, the rope system should then be lifted andlowered under average working tensions for several cycles,until the rope has bedded in.

Slipping and Cutting

It is essential that before the rope is cut it is securely bound, onboth sides of the cut. Failure to properly bind the rope will allowrelative movement of the components of the rope – wires andstrand – which can cause constructional unbalance andsubsequent distortion of the rope in the working rope system.

Distortions or disturbance of the strands within the rope, will resultin uneven distribution of the load applied and also surface wear.

A condition, that will effect the working life of the rope.

The binding/seizing itself should be of soft or annealed wire orstrand (of approximately 0.125” in diameter), wound tightlyaround the rope at both sides of the cutting position, using a‘Serving Mallet’ or a ‘Marlin Spike’.

Alternatively a clamp of suitable design, such as a spare draw-work’s drum anchor clamp is ideal for serving (seizing) the drill-line prior to cutting and fusing it

For conventional 6 strand preformed ropes the serving (seizing)length, should be no less than twice the diameter of the ropebeing cut. However in Triangular (Flattened) Strand or otherLangs Lay ropes, then two servings (seizings) on either side ofthe cut would be preferred.

The calculated length of rope to be slipped is critical to ensurethat the rope is subject to even wear as the rope progressesthrough the reeving system. Therefore this length must bemeasured as accurately as possible, to avoid the rope beingpositioned at repeat critical wear positions in the system.

An inaccurate measurement and cut of say half of a singledrum wrap, could cause a slip and cut to be inaccurate enoughto cause critical wear-spots to move to repeat positions duringthe slip and cut.

It is of course of paramount importance, after the slip and cut iscompleted, that the drill-line is wound onto the drawworks at therecommended tension using a pinch-roller type drill-line tensioneruntil the weight of the travelling assembly is on the drill-line.

One Important Thing To Remember

The main issue that normally dictates/necessitates the need fordrill-line handling, whether it’s to do a slip and cut, or to changeout a complete drill-line, is the actual rope condition in terms ofwear and damage.

Ton.Miles is a conventional method, based upon experience, ofcalculating the amount of work done by the rope and to thendetermine the service life of the rope through a slip and cutprogramme. However it must be emphasised that Ton.Miles is ageneral guide only and should not be used as the sole criteriafor assessing the rope condition, as continual visual monitoringis also essential.

If the visual condition of the drill-line, indicates that the drill-lineis showing excess wear and/or damage, or is encroaching on,equal to, or exceeding that described as discard criteriaaccording to ISO 4309, then it should take precedence overTon.Mileage as the discard criteria.

Failure to slip and cut, if this sort of excessive drill-line wearoccurs, ahead of the scheduled ton-mileage slip and cut,normally results in extremely long slip and cuts in the future andprobably an unsafe working condition.

It should be noted, If the rope regularly appears in goodcondition at the programmed time for slip and cut, and that thisgood condition can be further confirmed by the Manufacturer,then the Ton.Mile Slip and Cut programme may be extended toincrease the rope’s service life.

The above recommendations are offered as a guidance to thehandling of Drilling Lines during installation and service. It isessential that the Drilling Line is at all times correctly handled,inspected and slipped through the system, to ensure a safeworking operation and an optimum working rope life

For further information please contact Bridon direct.


32

Any assembly of steel wires spun into a helical formationeither as a strand or wire rope, when subjected to a tensileload, can extend in three separate phases, depending onthe magnitude of the applied load.

There are also other factors which produce rope extensionwhich are very small and can normally be ignored.

Phase 1 - Initial or Permanent Constructional Extension

At the commencement of loading a new rope, extension iscreated by the bedding down of the assembled wires with acorresponding reduction in overall diameter. This reductionin diameter creates an excess length of wire which isaccommodated by a lengthening of the helical lay. Whensufficiently large bearing areas have been generated onadjacent wires to withstand the circumferential compressiveloads, this mechanically created extension ceases and theextension in Phase 2 commences. The Initial Extension ofany rope cannot be accurately determined by calculationand has no elastic properties.

The practical value of this characteristic depends uponmany factors, the most important being the type andconstruction of rope, the range of loads and the numberand frequency of the cycles of operation. It is not possibleto quote exact values for the various constructions of ropein use, but the following approximate values may beemployed to give reasonably accurate results.

The above figures are for guidance purposes. More precisefigures are available upon request.

Phase 2 - Elastic Extension

Following Phase 1, the rope extends in a manner whichcomplies approximately with Hookes Law (stress isproportional to strain) until the Limit of Proportionality orElastic Limit is reached.

It is important to note that wire ropes do not possess aYoung’s Modulus of Elasticity, but an ‘apparent’ Modulus ofElasticity can be determined between two fixed loads.

The Modulus of Elasticity also varies with different ropeconstructions, but generally increases as the cross-sectional area of steel increases. By using the valuesgiven, it is possible to make a reasonable estimate ofelastic extension, but if greater accuracy is required it isadvisable to carry out a modulus test on an actual sampleof the rope.

Elastic Extension =

W = load applied (kN)

L = rope length (m)

EA = axial stiffness MN

Phase 3 - Permanent Extension

The permanent, non-elastic extension of the steel causedby tensile loads exceeding the yield point of the material.

If the load exceeds the Limit of Proportionality, the rate ofextension will accelerate as the load is increased, until aloading is reached at which continuous extension willcommence, causing the wire rope to fracture without anyfurther increase of load.

Thermal Expansion and Contraction

The coefficient of linear expansion (∝) of steel wire rope is0.0000125 = (12.5 x10-6) per oC and therefore the changein length of 1 metre of rope produced by a temperaturechange of t oC would be;

Change in length ∆| = ∝ |o t

where:

∝ = coefficient of linear expansion

|o = original length of rope (m)

t = temperature change (oC)

The change will be an increase in length if the temperaturerises and a decrease in length if the temperature falls.

Extension due to Rotation

The elongation caused by a free rope end being allowed to rotate.

Extension due to Wear

The elongation due to inter-wire wear which reduces thecross-sectional area of steel and produces extraconstructional extension.

Example: What will be the total elongation of a 200 metre length of 38mm diameter Blue Strand 6x36 wire rope with an axial stiffness of 69MN, at a tension of 202 kNand with an increase in temperature of 20oC.

Permanent Constructional Extension = 0.25% of

rope length = 500mm

Elastic Extension = = = 585mm

Thermal Expansion = ∆| = ∝ |o t = 0.0000125 x 200,000 x 20 = 50mm

Therefore total extension = 500 + 585 + 50 = 1135mm

Properties of Extension of Steel Wire Ropes

WL (mm)EA

WLEA

202 x 20069

% of rope length

Fibre Core Steel CoreLightly loaded 0.25 0.125Factor of safety about 8:1Normally loaded 0.50 0.25Factor of safety about 5:1Heavily loaded 0.75 0.50Factor of safety about 3:1Heavily loaded Up to 2.00 Up to 1.00with many bends and/or deflections

BRIDON Oil and Gas


33

In addition to bending stresses experienced by wire ropesoperating over sheaves or pulleys, ropes are also subjectedto radial pressure as they make contact with the sheave.This pressure sets up shearing stresses in the wires,distorts the rope’s structure and affects the rate of wear ofthe sheave grooves. When a rope passes over a sheave,the load on the sheave results from the tension in the ropeand the angle of rope contact. It is independent of thediameter of the sheave.

Load on bearing =

Assuming that the rope is supported in a well fitting groove,then the pressure between the rope and the groove isdependent upon the rope tension and diameter but isindependent of the arc of contact.

Pressure, P =

P = pressure (kg/cm2)

T = rope tension (kg)

D = diameter of sheave or drum (cm)

d = diameter of rope (cm)

Maximum Permissible Pressures

It should be emphasised that this method of estimation ofpressure assumes that the area of contact of the rope inthe groove is on the full rope diameter, whereas in fact onlythe crowns of the outer wires are actually in contact with thegroove. The local pressures at these contact points may beas high as 5 times those calculated and therefore thevalues given above cannot be related to the compressivestrength of the groove material.

If the pressure is high, the compressive strength of thematerial in the groove may be insufficient to preventexcessive wear and indentation and this in turn will damagethe outer wires of the rope and effect its working life. Aswith bending stresses, stresses due to radial pressureincrease as the diameter of the sheave decreases.Although high bending stresses generally call for the use offlexible rope constructions having relatively small diameterouter wires, these have less ability to withstand heavypressures than do the larger wires in the less flexibleconstructions. If the calculated pressures are too high forthe particular material chosen for the sheaves or drums orindentations are being experienced, consideration shouldbe given to an increase in sheave or drum diameter. Sucha modification would not only reduce the groove pressure,but would also improve the fatigue life of the rope.

The pressure of the rope against the sheave also causedistortion and flattening of the rope structure. This can becontrolled by using sheaves with the correct groove profilewhich, for general purposes, suggests an optimum grooveradius of nominal rope radius +7.5%. The profile at thebottom of the groove should be circular over an angle ofapproximately 120o, and the angle of flare between thesides of the sheave should be approximately 52o.

Hardness of Rope Wire

Suggested pulley hardness: 250-300 Brinell for Mn steel orequivalent alloy steel.

If the calculated pressure is too high for the particularmaterial chosen for the pulley or drum, considerationshould be given to increase in pulley or drum diameter.Such a modification would not only reduce the groovepressure, but would also improve the fatigue life of the ropeby reducing the bending stresses imposed.

Pressures between Ropes and Sheaves or Drums

2T sin θ2

2TDd

Min. TensileStrength

2160N / mm2

1960N / mm2

1770N / mm2

1570N / mm2

API 9AGrade

EEIPS

EIPS

IPS

PS

Brinel

480 / 500

470 / 480

445 / 470

405 / 425

Rockwell‘C’

52

51

49

45

Ropegrade

ApproximateEquivalent

ApproximateHardness

5 - 8 Ordinary lay5 - 8 Lang’s lay9 - 13 Ordinary lay9 - 13 Lang’s lay14 - 18 Ordinary lay14 - 18 Lang’s layTriangular strand

20253540424755

404560707585100

105120175200210240280

Number of outer wiresin strands

Groove material

Castiron

kgf/cm2

Lowcarboncast steel

kgf/cm2

11 to 13%Mn steel

orequivalentalloysteelskgf/cm2

BRIDON Oil and Gas


34

Bend fatigue testing of ropes usually consists of cycling alength of rope over a sheave while the rope is under aconstant tension and as part of its ongoing developmentprogramme Bridon has tested literally thousands of ropesin this manner over the years on its in-house own designbend testing equipment.

Through this work, Bridon has been able to compare theeffects of rope construction, tensile strength, lay direction,sheave size, groove profile and tensile loading on bendfatigue performance under ideal operating conditions. Atthe same time it has been possible to compare rope life todiscard criteria (e.g. as laid down in ISO 4309) with that tocomplete failure of the rope, i.e. to the point where the ropehas been unable to sustain the load any longer. As part ofthe exercise, it has also been possible to establish theresidual breaking strength of the rope at discard level ofdeterioration.

Effects of D:d Ratio and loading on fatigue life -Typical example Dyform 6

What needs to be recognised, however, is that very fewropes operate under these controlled operating conditions,making it very difficult to use this base information whenattempting to predict rope life under other conditions. Otherinfluencing factors, such as dynamic loading, differentialloads in the cycle, fleet angle, reeving arrangement, type ofcoiling on the drum, change in rope direction, sheavealignment, sheave size and groove profile, can have anequally dramatic effect on rope performance.

However, the benefit of such testing can be particularlyhelpful to the rope manufacturer when developing new orimproving existing products.

If designers or operators of equipment are seeking optimumrope performance or regard bending fatigue life as a keyfactor in the operation of equipment, such information canbe provided by Bridon for guidance purposes.

Service life curve for various D:d ratios

When considering the use of a steel wire rope around aminimum D:d ratio, it is generally accepted that at below4:1 the effect on the strength of the rope needs to beconsidered. Permanent distortions within the rope will occurwhen using ratios of 10:1 and less and that a minimum ratioof 16:1 be used for a rope operating around sheaves.

Approximate loss in breaking strength due to bending

Bend FatigueNumber of bends to rope failure

30 29 28 27 26

5% MBL

10% MBL

20% MBL

25 24 23 22 21 20 19 18 17 16

D:d ratio0

100

60

40

20

0

5 10 15 20 25 30 35 40 45 50 55 60 65

80

Relative Rope Service Life

Efficiency % MBF

1.0000 10 20 30 40

0.900

0.800

0.700

0.600

0.500

0.400

0.300

0.200

0.100

0.000

D:d rat io

EB = 1 -0.5

D/d

Sheave D:d rat io

BRIDON Oil and Gas


35

Rotaing loads can put at risk the safety of those personswithin a lifting zone during a lifting operation.

In order to reduce the risk of rotation the machinerydesigner or user may find it may be necessary toincorporate a swivel in the reeving system; however, itshould be recognised that excessive rotation could have anadverse effect on rope performance depending on therope’s rotational characteristics.

To assist the machinery designer or user in determiningwhether or not a swivel should be used in a lifting system,the following guidance, taking into account the rope type,

construction and lay type and direction, is given. For simplicity, the ropes are grouped according to theirrotational characteristics.

Note 1: A swivel should not be used when installing a rope.

Note 2: Further guidance on the use of swivels with six strand

and rotation-resistant ropes is given in ISO 4308 ‘Cranes

and lifting appliances - selection of wire ropes - part 1

General’.

Note 3: Swivels have varying degrees of efficiency and may be

either an independent accessory or an integral part of a

lifting accessory such as a crane hook.

Swivels

Group 1

Both sets of ropes in this group have high values of rotation when loaded and must not be used unless both ends of the rope are fixed and prevented from rotating however they must NOT be used with a swivel, under any circumstances.

Blue Strand 6x19 Lang’s layBlue Strand 6x36 Lang’s layEndurance Bristar 6 Lang’s lay

Endurance Dyform Bristar 6 Lang’s layEndurance 8 Lang’s layEndurance 8PI Lang’s lay

Endurance Dyform 8 Lang’s layEndurance Dyform 8PI Lang’s layEndurance Dyform 6 Lang’s layEndurance Dyform 6PI Lang’s lay

Endurance DSC 8 Endurance Dyform DSC 8

DO NOT USE A SWIVEL

Group 1a: Single layer ropesLang’s lay

Group 1b: Parallel-closed ropesLang’s and Ordinary (Regular) lay

Group 2

With one end free to rotate, all of the ropes in this group will generate less rotation when loaded than those listed inGroup 1. However, such ropes are still likely to unlay and distort under this condition.

When used in single part reeving they may require a swivel to prevent rotation in certain operating conditions but thisshould only apply when employee safety is an issue.

Blue Strand 6x19 Ordinary layBlue Strand 6x36 Ordinary lay

Diamond BlueDyform DB2K Ordinary lay

Hydra 5300 Dyform Ordinary layHydra 7300 Dyform Ordinary lay

Endurance 8 Ordinary layEndurance Dyform 6 Ordinary layEndurance Dyform 6PI Ordinary lay

Endurance Dyform 8 Ordinary layEndurance 8PI Ordinary lay

Endurance Dyform 8PI Ordinary layEndurance Bristar 6 Ordinary lay

Endurance Dyform Bristar 6 Ordinary lay

Group 2: Single layer ropesOrdinary (Regular) lay

BRIDON Oil and GasBRIDON Oil and Gas


36

Group 3

The ropes in this group incorporate a centre which is laid in the opposite direction to that of the outer strands andare specifically designed to have a medium amount of resistance to rotation.

If it is necessary to use a swivel with any of these ropes in single part reeving to prevent rotation of the load, therope should operate within the normal design factor of 5, not be subject to any shock loading and be checked dailyfor any evidence of distortion.

Where any of these ropes are used in multi-part reeving, the use of an anti-friction swivel at the outboard anchorpoint is not recommended. However, a swivel which can be locked may be useful when optimising the reeving,following rope installation or after subsequent changes to the reeving arrangement.

It should be noted that if a swivel is used in conjunction with these ropes, the bending fatigue life may be reduceddue to increased internal deterioration between the outer strands and the underlying layer.

Endurance 18 Endurance Dyform 18 Endurance 18PI

Group 3: Rotation-resistant ropesLang’s and Ordinary (Regular) lay

Group 4

The ropes in this group are designed to have extremely low levels of rotation when loaded and, if necessary, mayoperate with a swivel in both single and multi-part reeving systems.

Any induced rotation which might normally result from any fleet angle or loads cycle effect would be expected to berelieved when the rope is used with a swivel.

Testing has also shown that when used with a swivel at normal design factor of 5 and zero fleet angle, no reduction ineither rope breaking force or bending fatigue life would be expected.

Endurance 35LSEndurance Dyform 34LREndurance Dyform 34LR PI

Hydra 5500Hydra 5500 Dyform

Hydra 7500 Dyform

Group 4: Low rotation ropes

Swivels

BRIDON Oil and Gas


37

Of all the factors which have some influence on the windingof a rope on a smooth drum, the fleet angle, arguably, hasthe greatest effect.

Fleet angle is usually defined as the included anglebetween two lines, one which extends from a fixed sheaveto the flange of a drum and the other which extends fromthe same fixed sheave to the drum in a line perpendicularto the axis of the drum. (See illustration).

Illustration of Fleet Angle

If the drum incorporates helical grooving, the helix angle ofthe groove needs to be added or subtracted from the fleetangle as described above to determine the actual fleetangle experienced by the rope.

At the drum

When spooling rope onto a drum it is generallyrecommended that the fleet angle is limited to between 0.5O

and 2.5O. If the fleet angle is too small, i.e. less than 0.5O,the rope will tend to pile up at the drum flange and fail toreturn across the drum. In this situation, the problem maybe alleviated by introducing a ‘kicker’ device or byincreasing the fleet angle through the introduction of asheave or spooling mechanism.

If the rope is allowed to pile up it will eventually roll awayfrom the flange creating a shock load in both the rope andthe structure of the mechanism, an undesirable and unsafeoperating condition.

Excessively high fleet angles will return the rope across thedrum prematurely, creating gaps between wraps of ropeclose to the flanges as well as increasing the pressure onthe rope at the cross-over positions.

Even where helical grooving is provided, large fleet angleswill inevitably result in localised areas of mechanicaldamage as the wires ‘pluck’ against each other. This isoften referred to as ‘interference’ but the amount can bereduced by selecting a Lang’s lay rope if the reeving allows.The “interference” effect can also be reduced by employinga Dyform rope which offers a much smoother exteriorsurface than conventional rope constructions.

Floating sheaves or specially designed fleet anglecompensating devices may also be employed to reducethe fleet angle effect.

At the sheave

Where a fleet angle exists as the rope enters a sheave, itinitially makes contact with the sheave flange. As the ropecontinues to pass through the sheave it moves down theflange until it sits in the bottom of the groove. In doing so,even when under tension, the rope will actually roll as wellas slide. As a result of the rolling action the rope is twisted,i.e. turn is induced into or out of the rope, either shorteningor lengthening the lay length of the outer layer of strands.As the fleet angle increases so does the amount of twist.

To reduce the amount of twist to an acceptable level the fleetangle should be limited to 2.5O for grooved drums and 1.5O forplain drums and when using rotation-resistant low rotation andparallel-closed ropes the fleet angle should be limited to 1.5O.

However, for some applications it is recognised that forpractical reasons it is not always possible to comply withthese general recommendations, in which case the rope lifecould be affected.

Rope TorqueThe problem of torsional instability in hoist ropes would notexist if the ropes could be perfectly torque balanced underload. The torque generated in a wire rope under load isusually directly related to the applied load by a constant‘torque factor’. For a given rope construction the torquefactor can be expressed as a proportion of the ropediameter and this has been done below..

Variation with rope construction is relatively small andhence the scope for dramatically changing the stability of ahoisting system is limited. Nevertheless the choice of thecorrect rope can have a deciding influence, especially insystems which are operating close to the critical limit. Itshould be noted that the rope torque referred to here ispurely that due to tensile loading. No account is taken ofthe possible residual torque due, for example, to ropemanufacture or installation procedures.

Torsional Stability

The torque factors quoted on page 39 are approximatemaximum values for the particular constructions. To calculate the torque value for a particular rope sizemultiply by the nominal rope diameter. Example: for 52mm dia. Hydra 7500 Dyform Lang’s Lay at20% of minimum breaking force:-

Torque value = torque factor x rope dia.= 1.8% x 52mm= 0.936mm

To calculate the torque generated in a particular rope whensubjected to a tensile load, multiply the load by the torquevalue and conbine the units. Example:- For 20mm dia. Hydra 7500 Dyform Lang’s Lay at 496kN:

Torque generated = torque value x load.= 0.936 x 496= 464Nm

Fleet Angle

Fleet angle

Drum

Sheave

Fleet angle

Drum

Sheave



38

The torsional characteristics of wire rope will have the effectof causing angular displacement of a sheave block whenused in multi-fall reeving arrangements. The formula below gives a good approximation under such arrangements.

S2 = 4000L. Tv

sin θ�

Where S is the rope spacing in mm

L is the length of each part in the reeving

Tv is the torque value of the rope

θ is the angular displacement of the sheave block

When the angular displacement of the sheave blockexceeds 90O (sin θ = 1) torsional instability results and‘cabling’ of the reeving will occur. Therefore the test forstability of any particular reeving can be expressed as:

S > 4 000 L. Tv

Where S is the rope spacing in mm

L is length of each part in metres

Tv is torque value in mm

The preceding equations are all relative to a simple twopart reeving. For more complex systems a similar approachmay be used if account is taken of the different spacings ofthe ropes.

Even Number of Falls

Note: For hoisting arrangements in which the rope falls arenot parallel an average rope spacing should be used.

Uneven Number of Falls

(Rope Termination at Bottom Block)

Rope Plan

Effective Rope Spacing and modified formula for stablecondition

Effective Rope Spacing S

Stable condition if

S > 6 000 . L. Tv

Angular displacement of block

To predict the amount of angular displacement by which asheave block may turn under the influence of rope torque:

sin θ = (4 000 L. Tv)

S2

(for even number of falls)

The equations assume that rope is torque-free in the no-load condition, therefore, induced torque during orimmediately after installation will adversely influence thecalculated effect.

The above data assumes a constant torque value which isa valid assumption for a new rope. Wear and usage canhave a significant effect on the torque value but practicalwork shows that under such circumstances the torquevalue will diminish, thus improving the stability of thearrangement. Some arrangements may be of suchcomplexity that the evaluation demands a computer study.

Examples:

Assuming a pedestal crane working on two falls is ropedwith 52mm diameter Hydra 7500 Dyform and the bottomblock carries a sheave of 936mm diameter with the fallsparallel:

Torque value = 1.8% x 52

= 0.936mm

If the rope is new (worst condition) and no account is takenof block weight and friction then angular displacement for aheight of lift of 30 metres is given by

sin θ = (4 000 . 30 . 0.936)

9362

= 0.128 i.e. 7O 35’

The reeving would be expected to ‘cable’ at a height of liftcalculated as:

L = S2

4 000 . Tv

= 9362

4 000 . 0.936

= 234 metres

From the crane designer’s viewpoint a safety factor against‘cabling’ should be recognised (angular displacementlimited at 30O) hence the practical height of lift isapproximately 45 metres.

Rope Torque

Effective RopeSpacing

Rope Plan

2-Fall

4-Fall

3-Fall

S

BRIDON Oil and Gas


39

Bridon supply a range of ‘Endurance’ High Performance steel wire ropes specifically designed and manufactured to meetthe needs of today’s cranes and the demanding applications to which they are exposed. High performance ropes arenormally selected by customers when they require the specific characteristics of improved performance, high strength, low extension or low rotation.

Summary Technical Information(For guidance purposes only)

Rope ConstructionFill

Factorf ’%

NominalMetallicAreaFactorC ’

Ropemodulusat 20%of

breakingforce

kN/mm2

Initialpermanentextension

%

Torque factor at20% of breaking

force %

Ordinary Lang’s

Turn valueat 20% ofbreakingforce

degrees/rope lay

Nominal Rope Lay length

mm

6 & 8 Strand High PerformanceDyform 6 & 6-PIDyform Bristar 6Endurance 8 & 8-PIDyform 8 & 8-PIDyform DSC 8ConstructexDyform ZebraBrifil 6x36 iwrc class

Rotation ResistantDyform 18 & 18-PIEndurance 50DB

Low RotationDyform 34LR & 34LR-PIEndurance 35LS

Conventional ConstructionsBlue Strand 6 x 19 iwrc classBlue Strand 6 x 36 iwrc class

6.5 x Nom. rope dia.6.5 x Nom. rope dia.6.5 x Nom. rope dia.6.5 x Nom. rope dia.6.5 x Nom. rope dia.6.0 x Nom. rope dia.6.5 x Nom. rope dia.6.5 x Nom. rope dia.

6.25 x Nom. rope dia.6.5 x Nom. rope dia.



67.066.063.068.075.072.159.158.6

71.063.0

74.063.9

57.258.6

0.5260.5180.4950.5340.5890.5660.4640.460

0.5580.495

0.5810.502

0.4490.460

10310396100107108103102

9597

99102

103104

0.10.10.20.150.090.050.10.15

0.10.24

0.050.1

0.150.17

6.96.97.07.08.1777

3n/a

0.80.8

77

10.910.99.09.011.0n/a1111

4.53.6

1.81.8

99

6060909070606060

43

0.70.7

5060

Rotationalcharacteristics

Extensioncharacteristics

The figures shown in the above table are nominal values given for the product range and are for guidance purposes only,for specific values please contact Bridon.

The above modulus vales are based on the nominal rope metallic area


DYFORM® outer strands provide controlled diameter with increased surface area facilitation even load distributionresulting in excellent crush resistance and wear performance.

Typical mode of failure for heavily worked ropes used in drilling line and riser tensioner lines is a combination of internal wirepressures and bending fatigue combined with corrosion, particularly on the smaller wires of the core. To address this modeof failure Bridon has designed a solution incorporating the patented Bristar core. The core of the rope is fully impregnatedwith high density polymer and is precisely manufactured to replicate its fluted shape within the rope construction supportingthe outer strands. Specialist design and carefully controlled manufacture ensures optimum & consistent strand gapenabling the necessary stability of construction and high bend fatigue performance.


40

Some of the More Common Types of Wire Fractures Can Include:

Factors Affecting RopePerformanceMulti-coiling of the rope on the drum can result in severedistortion in the underlying layers.

Bad coiling (due to excessive fleet angles or slackwinding) can result in mechanical damage, shown as severe crushing, and may cause shock loading during operation.

Small diameter sheaves can result in permanent set ofthe rope, and will certainly lead to early wire breaks due to fatigue.

Oversize grooves offer insufficient support to the ropeleading to increased localised pressure, flattening of therope and premature wire fractures. Grooves are deemed tobe oversize when the groove diameter exceeds the nominal rope diameter by more than 15% steel, 20%polyurethane liners.

Undersize grooves in sheaves will crush and deform therope, often leading to two clear patterns of wear andassociated wire breaks.

Excessive angle of fleet can result in severe wear of therope due to scrubbing against adjacent laps on the drum.Rope deterioration at the Termination may be exhibited inthe form of broken wires. An excessive angle of fleet canalso induce rotation causing torsional imbalance.

The continued safe operation of lifting equipment, liftingaccessories (e.g. slings) and other systems employing wirerope depends to a large extent on the operation of wellprogrammed periodic rope examinations and theassessment by the competent person of the fitness of therope for further service.

Examination and discard of ropes by the competent personshould be in accordance with the instructions given in theoriginal equipment manufacturer’s handbook. In addition,account should be taken of any local or application specificRegulations.

The competent person should also be familiar, asappropriate, with the latest versions of related International,European or National standards such as ISO 4309 “Cranes- Wire ropes - code of practice for examination.

Particular attention must be paid to those sections ofrope which experience has shown to be liable todeterioration. Excessive wear, broken wires,distortions and corrosion are the more commonvisible signs of deterioration.

Note: This publication has been prepared as an aid for rope

examination and should not be regarded as a substitute for the

competent person.

Wear is a normal feature of rope service and the use of thecorrect rope construction ensures that it remains asecondary aspect of deterioration. Lubrication may help toreduce wear.

Broken wires are a normal feature of rope service towardsthe end of the rope’s life, resulting from bending fatigueand wear. The local break up of wires may indicate somemechanical fault in the equipment. Correct lubrication inservice will increase fatigue performance.

Distortions are usually as a result of mechanical damage,and if severe, can considerably affect rope strength.

Visible rusting indicates a lack of suitable lubrication,resulting in corrosion. Pitting of external wire surfacesbecomes evident in some circumstances. Broken wiresultimately result.

Internal corrosion occurs in some environments whenlubrication is inadequate or of an unsuitable type.Reduction in rope diameter will frequently guide theobserver to this condition. Confirmation can only be madeby opening the rope with clamps or the correct use of spikeand needle to facilitate internal inspection.

Note: Non-destructive testing (NDT) using electromagnetic means

may also be used to detect broken wires and/or loss in metallic area.

This method complements the visual examination but does not

replace it.

Pictures courtesy of S.M.R.E. Crown Copyright 1966

Guide to Examination

A Severedby wear

B Tension C Fatigue D Corrosionfatigue

E Plasticwear

F Martensite G Shearedend

BRIDON Oil and Gas


41

Troubleshooting Guide

Mechanical damagedue to rope movementover sharp edgeprojection whilst underload.

1 Typical wire fracturesas a result of bendfatigue.

9

Localised wear due toabrasion on supportingstructure.

2 Wire fractures at thestrand, or coreinterface, as distinctfrom ‘crown’ fractures.

10

Narrow path of wearresulting in fatiguefractures, caused byworking in a grosslyoversize groove, orover small supportrollers.

3 Break up of IWRCresulting from highstress application.

11

Two parallel paths ofbroken wires indicativeof bending through anundersize groove in thesheave.

4 Looped wires as aresult of torsionalimbalance and/or shockloading.

12

Severe wear,associated with hightread pressure.

5 Typical example oflocalised wear anddeformation.

13

Severe wear in Lang’sLay, caused byabrasion.

6 Multi strand rope ‘birdcaged’ due to torsionalimbalance.

14

Severe corrosion.7 Protrusion of ropecentre resulting frombuild up of turn.

15

Internal corrosionwhilst external surfaceshows little evidence ofdeterioration.

8 Substantial wear andsevere internalcorrosion.

16

Typical examples of Wire Rope deterioration



42


Mechanical damage caused by the rope contacting thestructure of the installation on which it is operating or anexternal structure - usually of a localised nature.

•Generally results from operational conditions.

•Check sheave guards and support/guide sheaves toensure that the rope has not “jumped out” of theintended reeving system.

•Review operating conditions.

Opening of strands in rotation resistant, low rotation andparallel closed ropes - in extreme circumstances the ropemay develop a “birdcage distortion” or protrusion of innerstrands.

Note - rotation resistant and low rotation ropes are designed

with a specific strand gap which may be apparent on

delivery in an off tension condition. These gaps will close

under load and will have no effect on the operational

performance of the rope.

•Check sheave and drum groove radii using sheavegauge to ensure that they are no smaller than nominalrope radius +5% - Bridon recommends that the sheaveand drum groove radii are checked prior to any ropeinstallation.

•Repair or replace drum/sheaves if necessary.

•Check fleet angles in the reeving system - a fleet anglein excess of 1.5 degrees may cause distortion(see page 37).

•Check installation method - turn induced duringinstallation can cause excessive rope rotation resultingin distortion (See pages 46 - 53).

•Check if the rope has been cut “on site “ prior toinstallation or cut to remove a damaged portion fromthe end of the rope. If so, was the correct cuttingprocedure used? Incorrect cutting of rotation resistant,low rotation and parallel closed ropes can causedistortion in operation (See page 50).

•Rope may have experienced a shock load.

Broken wires or crushed or flattened rope on lower layersat crossover points in multi - layer coiling situations.

Wire breaks usually resulting from crushing or abrasion.

•Check tension on underlying layers. Bridonrecommends an installation tension of between 2% and10% of the minimum breaking force of the wire rope.Care should be taken to ensure that tension is retainedin service. Insufficient tension will result in these lowerlayers being more prone to crushing damage.

•Review wire rope construction. Dyform wire ropes aremore resistant to crushing on underlying layers thanconventional rope constructions.

•Do not use more rope than necessary.

•Check drum diameter. Insufficient bending ratioincreases tread pressure.

The following is a simplified guide to common wire rope problems. More detailed advice can be obtained from any Bridondistributor. In the event of no other standard being applicable, Bridon recommends that ropes are inspected/examined inaccordance with ISO 4309.

Problem Cause/Action

Wires looping from strands. • Insufficient service dressing.

•Consider alternative rope construction.

• If wires are looping out of the rope underneath acrossover point, there may be insufficient tension on thelower wraps on the drum.

•Check for areas of rope crushing or distortion.

BRIDON Oil and Gas


43


“Pigtail” or severe spiralling in rope. •Check that the sheave and drum diameter is largeenough - Bridon recommends a minimum ratio of thedrum/sheave to nominal rope diameter of 18:1.

• Indicates that the rope has run over a small radius orsharp edge.

•Check to see if the rope has “jumped off” a sheave andhas run over a shaft.

Two single axial lines of broken wires running along thelength of the rope approximately 120 degrees apartindicating that the rope is being “nipped” in a tightsheave.

•Check sheave and drum groove radii using sheavegauge to ensure that they are no smaller than nominalrope radius + 5% - Bridon would recommend that thesheave/drum groove radii are checked prior to any rope installation.


One line of broken wires running along the length of therope indicating insufficient support for the rope, generallycaused by oversize sheave or drum grooving.

•Check to see if the groove diameter is no greater than15% greater than the nominal rope diameter.


•Check for contact damage.

Short rope life resulting from evenly/randomly distributedbend fatigue wire breaks caused by bending through thereeving system.

Fatique induced wire breaks are characterised by flatends on the broken wires.

•Bending fatigue is accelerated as the load increasesand as the bending radius decreases (see page 34).Consider whether either factor can be improved.

•Check wire rope construction - Dyform ropes arecapable of doubling the bending fatigue life of aconventional steel wire rope.


Continued on next page

Short rope life resulting from localised bend fatigue wirebreaks.

Fatique induced wire breaks are characterised by flatends on the broken wires.

•Bending fatigue is accelerated as the load increasesand as the bending radius decreases (see page 34).Consider whether either factor can be improved.

•Check wire rope construction - Dyform ropes arecapable of doubling the bending fatigue life of aconventional steel wire rope.

•Localised fatigue breaks indicate continuous repetitivebends over a short length. Consider whether it iseconomic to periodically shorten the rope in order tomove the rope through the system and progressivelyexpose fresh rope to the severe bending zone. In orderto facilitate this procedure it may be necessary to beginoperating with a slightly longer length of rope.



44


Wave or corkscrew deformations normally associatedwith multistrand ropes.

•Check sheave and drum groove radii using sheavegauge to ensure that they are no smaller than nominalrope radius +5% - Bridon recommends that thesheave/drum groove radii are checked prior to any rope installation.


•Check fleet angles in the reeving system - a fleet anglein excess of 1.5 degrees may cause distortion (see page 37).

•Check that rope end has been secured in accordancewith manufacturers instructions (see page 50).

•Check operating conditions for induced turn.

Rotation of the load in a single fall system. •Review rope selection.

•Consider use of rotation resistant or low rotation rope.

Rotation of the load in amulti - fall systemresulting in “cabling” ofthe rope falls.

Possibly due to inducedturn during installation oroperation.

•Review rope selection.

•Consider use of rotation resistant or low rotation rope.

•Review installation procedure (See pages 46 - 53)or operating procedures.

Broken rope - ropes are likely to break when subjected tosubstantial overload or misuse particularly when a ropehas already been subjected to mechanical damage.

Corrosion of the rope both internally and/or externally canalso result in a significant loss in metallic area. The ropestrength is reduced to a level where it is unable to sustainthe normal working load.

•Review operating conditions.


Anchored

Free toRotate

ForceCreates

Turn

Remedy(Release3 turns)

1.5 turnsL.H. cable

RIGHT HAND LAY ROPE

BRIDON Oil and Gas


45



External corrosion. •Consider selection of galvanised rope.

•Review level and type of service dressing.

Internal corrosion. •Consider selection of galvanised rope.

•Review frequency amount and type of service dressing.

•Consider selection of plastic impregnated (PI) wire rope.

Short rope life induced by excessive wear and abrasion. •Check fleet angle to drum.

•Check general alignment of sheaves in the reevingsystem.

•Check that all sheaves are free to rotate.

•Review rope selection. The smooth surface of Dyformwire ropes gives better contact with drum and sheavesand offers improved resistance to “interference”betweeen adjacent laps of rope.

Sunken wraps of rope on the drum normally associatedwith insufficient support from lower layers of rope orgrooving.

•Check correct rope diameter.

•If grooved drum check groove pitch.

•Check tension on underlying layers - Bridon recommendan installation tension of between 2% and 10% of theminimum breaking force of the wire rope - Care shouldbe taken to ensure that tension is retained in service.Insufficient tension will result in these lower layers beingmore prone to crushing damage.

•Make sure that the correct rope length is being used.Too much rope (which may not be necessary) mayaggravate the problem.

Rope accumulating or “stacking” at drum flange - due toinsufficient fleet angle.

•Review drum design with original equipmentmanufacturer - consider adding rope kicker, fleetingsheave etc.

Core protrusion or broken core in single layer six or eightstrand rope.

•Caused by repetitive shock loading - review operating conditions.



46

Ensure that the rope does not make any direct contact with the floor and that there is a flow of airunder the reel.

WARNING

Failure to do so may result in the rope becomingcontaminated with foreign matter and start the onsetof corrosion before the rope is even put to work.

Support the reel on a simple A-frame or cradle,located on ground which is capable of supporting thetotal mass of rope and reel. (See Fig. 2) Ensure thatthe rope is stored where it is not likely to be affectedby chemical fumes, steam or other corrosive agents.

WARNING

Failure to do so may seriously affect its conditionrendering it unfit for safe use.

1.3 Examine ropes in storage periodically and, whennecessary, apply a suitable dressing which iscompatible with the manufacturing lubricant. Contactthe rope supplier, Bridon or original equipmentmanufacturer’s (OEM) manual for guidance on typesof dressings available, methods of application andequipment for the various types of ropes and applications.

Re-wrap the rope unless it is obvious that this will bedetrimental to rope preservation. (Refer to the relevantProduct Data sheets on rope dressings for moredetailed information.)

WARNING

Failure to apply the correct dressing may renderthe original manufacturing lubricant ineffective andrope performance may be significantly affected.

Ensure that the rope is stored and protected in such amanner that it will not be exposed to any accidentaldamage either during the storage period or whenplacing the rope in, or taking it out of storage.

The following Instructions and Warnings combine toprovide guidance on Product Safety and are intended foruse by those already having a working knowledge of wireropes, as well as the new user. They should be read,followed and passed on to others.

Failure to read, understand and follow these instructionscould result in harmful and damaging consequences.

A ‘Warning’ statement indicates a potential hazardoussituation which could result in a significant reduction in ropeperformance and/or put at risk, either directly or indirectly,the safety or health of those persons within the dangerzone of the rope and its associated equipment.

Note: As a result of the creation of the single European market and

the ‘New Approach’ Directives which set out ‘essential requirements’

(e.g. for safety) designers, manufacturers, suppliers, specifiers and

users need to keep themselves abreast of any changes to the

appropriate Regulations and national standards.

1. Storage

1.1 Unwrap the rope and examine the rope immediatelyafter delivery to check its identification and conditionand verify that it is in accordance with the details onthe Certificates and/or other relevant documents.

Note: The rope should not be used for lifting purposes without the

user having a valid Certificate in his possession.

Check the rope diameter and examine any ropeterminations to ensure that they are compatible withthe equipment or machinery to which they are to befitted. (See Fig. 1)

1.2 Select a clean, well ventilated, dry, undercoverlocation. Cover with waterproof material if the deliverysite conditions preclude inside storage.

Rotate the reel periodically during long periods ofstorage, particularly in warm environments, to preventmigration of the lubricant from the rope.

WARNING

Never store wire rope in areas subject to elevatedtemperatures as this may seriously affect its futureperformance. In extreme cases its original as-manufactured strength may be severely reducedrendering it unfit for safe use.

Product Safety: Instructions & Warnings on the use of steel wire rope

Fig 1

Fig 2

BRIDON Oil and Gas


47BRIDON Oil and GasBRIDON Oil and Gas

WARNING

Failure to carry out or pay attention to any of theabove could result in a loss of strength and/or areduction in performance. In extreme cases therope may be unfit for safe use.

2. Certification and Marking

Make sure that the relevant Certificate has beenobtained before taking the rope into use for a liftingoperation. (Refer to statutory requirements)

Check to verify that the marking on the rope or itspackage matches the relevant Certificate.

Note: The rating of a component part of a machine or lifting

accessory is the responsibility of the designer of the machine or

accessory. Any re-rating of a lifting accessory must be approved by a

competent person.

Retain the Certificate in a safe place for identificationof the rope when carrying out subsequent periodicstatutory examinations in service. (Refer to statutoryrequirements)

3. Handling and Installation

3.1 Handling and installation of the rope should becarried out in accordance with a detailed plan andshould be supervised by a competent person.

WARNING

Incorrectly supervised handling and installationprocedures may result in serious injury to persons in the vicinity of the operation as well asthose persons directly involved in the handling andinstallation.

3.2 Wear suitable protective clothing such as overalls,industrial gloves, helmet, eye protectors and safetyfootwear (and respirator, particularly where theemission of fumes due to heat is likely).

WARNING

Failure to wear suitable protective clothing andequipment may result in skin problems from overexposure to certain types of rope lubricants anddressings; burns from sparks, rope ends, moltenlubricants and metals when cutting ropes orpreparing sockets for re-use; respiratory or otherinternal problems from the inhalation of fumeswhen cutting ropes or preparing sockets for re-use; eye injuries from sparks when cutting ropes;lacerations to the body from wire and rope ends;bruising of the body and damage to limbs due torope recoil, backlash and any sudden deviationfrom the line of path of rope.

3.3 Ensure that the correct rope has been supplied bychecking to see that the description on the Certificateis in accordance with that specified in the purchaser’sorder.

3.4 Check by measurement that the nominal diameter ofthe new rope conforms to the nominal size stated onthe Certificate.

For verification purposes, measure the diameter byusing a suitable rope vernier fitted with jaws broadenough to cover not less than two adjacent strands.Take two sets of measurements spaced at least 1metre apart, ensuring that they are taken at thelargest cross-sectional dimension of the rope. Ateach point take measurements at right angles to each other.

The average of these four measurements should bewithin the tolerances specified in the appropriateStandard or Specification.

For a more general assessment of rope diameter usea rope calliper. (See Fig 1)

3.5 Examine the rope visually to ensure that no damageor obvious signs of deterioration have taken placeduring storage or transportation to the installation site.

3.6 Check the working area around the equipment for anypotential hazards which may affect the safeinstallation of the rope.

3.7 Check the condition of the rope-related equipment inaccordance with the OEM’s instructions. Include the following -

Drum

Check the general condition of the drum.

If the drum is grooved, check the radius and pitchand ensure that the grooves will satisfactorilyaccommodate the size of the new rope (see Fig 3)

Check the condition and position of the kicker platesor wear plates, if fitted, to ensure that the new ropewill spool correctly on the drum.


Fig 3

PITCH

RADIU

S


48


Sheaves

Ensure that the grooving is of the correct shape andsize for the new rope

Check that all sheaves are free to rotate and in good condition.

Rope guards

Check that any rope guards are correctly fitted andare in good condition.

Check the condition of any wear plates or rollerswhich are protecting structural members.

WARNING

Failure to carry out any of the above could result inunsatisfactory and unsafe rope performance.

Note: Grooves must have clearance for the rope and provide

adequate circumferential support to allow for free movement of the

strands and facilitate bending. When grooves become worn and the

rope is pinched at the sides, strand and wire movement is restricted

and the ability of the rope to bend is reduced. (See Fig. 4)

When a new rope is fitted a variation in sizecompared with the old worn rope will be apparent.The new rope may not fit correctly into the previouslyworn groove profile and unnecessary wear and ropedistortion is likely to occur. This may be remedied bymachining out the grooves before the new rope isinstalled. Before carrying out such action the sheavesor drum should be examined to ensure that there willbe sufficient strength remaining in the underlyingmaterial to safely support the rope.

The competent person should be familiar with therequirements of the appropriateapplication/machinery standard.

Note: General guidance to users is given in ISO 4309 Code of

practice for the selection, care and maintenance of steel wire rope.

Transfer the wire rope carefully from the storage areato the installation site.

Coils

Place the coil on the ground and roll it out straightensuring that it does not become contaminated withdust/grit, moisture or any other harmful material.(See Fig. 5)

If the coil is too large to physically handle it may beplaced on a ‘swift’ turntable and the outside end ofthe rope pulled out allowing the coil to rotate. (See Fig. 5)

WARNING

Never pull a rope away from a stationary coil asthis will induce turn into the rope and kinks willform. These will adversely affect ropeperformance. (See Fig. 6)

Fig 4

WRONG

Sheave groovetoo narrow

Sheave groove too wide

Sheave groove correctlysupporting the rope for33% of its circumference

WRONG

RIGHT

Fig 5

Fig 6

WRONG

Note the kinks

forming

BRIDON Oil and Gas



Ensure that the reel stand is mounted so as not tocreate a reverse bend during reeving (i.e. for a winchdrum with an overlap rope, take the rope off the top ofthe reel). (See Fig. 7)

3.9 Ensure that any equipment or machinery to be ropedis correctly and safely positioned and isolated fromnormal usage before installation commences. Referto the OEM’s instruction manual and the relevant‘Code of Practice’.

3.10 When releasing the outboard end of the rope from areel or coil, ensure that this is done in a controlledmanner. On release of the bindings and servingsused for packaging, the rope will want to straightenitself from its previously bent position. Unlesscontrolled, this could be a violent action. Stand clear.

WARNING

Failure to control could result in injury.

Ensure that the as-manufacturedcondition of the rope is maintainedduring installation.

If installing the new rope with the aidof an old one, one method is to fit awire rope sock (or stocking) to eachof the rope ends. Always ensure thatthe open end of the sock (orstocking) is securely attached to therope by a serving or alternatively by aclip (See Fig. 9). Connect the two endsvia a length of fibre rope of adequatestrength in order to avoid turn beingtransmitted from the old rope into thenew rope. Alternatively a length offibre or steel rope of adequatestrength may be reeved into thesystem for use as a pilot/messengerline. Do not use a swivel during theinstallation of the rope.

Reels

Pass a shaft through the reel and place the reel in asuitable stand which allows it to rotate and be brakedto avoid overrun during installation. Where multi-layercoiling is involved it may be necessary for the reel tobe placed in equipment which has the capability ofproviding a back tension in the rope as it is beingtransferred from reel to drum. This is to ensure thatthe underlying (and subsequent) laps are woundtightly on the drum. (See Fig. 7)

Position the reel and stand such that the fleet angleduring installation is limited to 1.5 degrees.(See Fig. 8)

If a loop forms in the rope ensure that it does nottighten to form a kink.

WARNING

A kink can severely affect the strength of a sixstrand rope and can result in distortion of arotation- resistant or low rotation rope leading toits immediate discard.

Fig 7

Fig 8

ANGLE OFFLEET

CENTRE LINEOF REEL

CENTRE LINEOF SHEAVE

Fig 9



50

A minimum of two servings either side of the cut (seefig 10) is normally sufficient for ropes up to 76mmdiameter and for larger ropes a minimum of fourservings either side of the cut should be applied. It isessential that the correct size serving wire or strand(see fig 10a) is used and that adequate tension isapplied during the serving process to ensure theintegrity of the rope is maintained. It is particularlyimportant to maintain the integrity of non-preformedropes, multistrand rotational resistant ropes andparallel closed ropes as failure to do so could affectthe ropes breaking strength and performance inservice. During the serving procedure, servingmallets and hand operated serving machines can beused to generate tight servings.

Bridon ‘On-site serving instructions’

Arrange and position the rope in such a manner thatat the completion of the cutting operation the ropeends will remain in position, thus avoiding anybacklash or any other undesirable movement.

Cut the rope with a high speed abrasive disc cutter.Other suitable mechanical or hydraulic shearingequipment may be used although not recommendedwhen a rope end is required to be welded or brazed.

For serving instructions for FL and HL ropes refer toBridon.

Fig 10


3.11 Monitor the rope carefully as it is being pulled into thesystem and make sure that it is not obstructed by anypart of the structure or mechanism which may causethe rope to come free.

WARNING

Failure to monitor during this operation couldresult in injury.

This entire operation should be carried out carefully andslowly under the supervision of a competent person.

3.12 Take particular care and note the manufacturer’sinstructions when the rope is required to be cut.Apply secure servings on both sides of the cut mark.(See Fig. 10 for typical method of applying a servingto a multi-layer rope.)

Ensure that the length of serving is at least equal to tworope diameters. (Note: Special servings are required forspiral ropes, i.e. spiral strand and locked coil.)

<24mm

24mm to 38mm

40mm to 76mm

76mm to 100mm

>100mm

1.32mm

1.57mm

1.83mm

2.03mm

n/a

1.70mm

1.70mm

2.60mm

3.00mm

3.60mm

Rope Diameter

Diameter of Serving Wire or Strand

Single Wire 1x7 WireStrand

Fig 10a

BRIDON Oil and Gas



When terminating a rope end with a wedge socket,ensure that the rope tail cannot withdraw through thesocket by securing a clamp to the tail or by followingthe manufacturer’s instructions.

(See Fig. 11 for two recommended methods ofsecuring the rope tail of a wedge socket termination).

The loop back method uses a rope grip and the loopshould be lashed to the live part of rope by a soft wireserving or tape to prevent flexing of the rope in service.

The method of looping back should not be used ifthere is a possibility of interference of the loop withthe mechanism or structure.

WARNING

Failure to secure in accordance with instructionscould lead to loss of the rope and/or injury.

3.14 When coiling a rope on a plain (or smooth) barreldrum ensure that each lap lies tightly against thepreceding lap. The application of tension in the ropegreatly assists in the coiling of the rope.

WARNING

When using a disc cutter be aware of the dangerfrom sparks, disc fragmentation and fumes.(Refer 3.2.)

Ensure adequate ventilation to avoid any build-up offumes from the rope and its constituent partsincluding any fibre core (natural or synthetic) any ropelubricant(s) and any synthetic filling and/or coveringmaterial.

WARNING

Some special ropes contain synthetic materialwhich, when heated to a temperature higher thannormal production processing temperatures, willdecompose and may give off toxic fumes.

WARNING

Rope produced from carbon steel wires in the formshipped is not considered a health hazard. Duringsubsequent processing (e.g. cutting, welding,grinding, cleaning) dust and fumes may beproduced which contain elements which mayaffect exposed workers.

The products used in the manufacture of steel wireropes for lubrication and protection present minimalhazard to the user in the form shipped. The user musthowever, take reasonable care to minimise skin andeye contact and also avoid breathing their vapour and mist.

After cutting, the rope cross-sections of non-preformed ropes, multi-layer ropes and parallelclosed ropes must be welded, brazed or fused andtapered such that all wires and strands in the rope arecompletely secured.

WARNING

Failure to correctly secure the rope end is likely tolead to slackness, distortions, premature removalfrom service and a reduction in the breaking forceof the rope.

3.13 Ensure that any fittings such as clamps or fixtures areclean and undamaged before securing rope ends.

Make sure that all fittings are secure in accordancewith the OEM’s instruction manual or manufacturer’sinstructions and take particular note of any specificsafety requirements e.g. torque values (andfrequency of any re-application of torque).

Fig 11



52

the termination is fitted in accordance with the OEM’sinstruction manual or manufacturer’s instructions.

When re-using a socket and depending on its typeand dimensions, the existing cone should be pressedout. Otherwise, heat may be necessary.

WARNING

When melting out sockets which have previouslybeen filled with hot metal, the emission of toxicfumes is likely. Note that white metal contains ahigh proportion of lead.

Correctly locate and secure any connection pins andfittings when assembling end terminations to fixtures.Refer to manufacturer’s instructions.

WARNING

Failure to pay attention to any of the above couldresult in unsafe operation and potential injury.

3.16 Limit switches, if fitted, must be checked and re-adjusted, if necessary, after the rope has been installed.

3.17 Record the following details on the Certificate afterinstallation has been completed: type of equipment,location, plant reference number, duty and date ofinstallation and any re-rating information/signature ofcompetent person. Then safely file the Certificate.

3.18 ‘Run in’ the new rope by operating the equipmentslowly, preferably with a low load, for several cycles.This permits the new rope to adjust itself gradually toworking conditions.

Note: Unless otherwise required by a certifying authority, the rope

should be in this condition before any proof test of the equipment or

machinery is carried out.

Check that the new rope is spooling correctly on thedrum and that no slack or cross laps develop.

If necessary, apply as much tension as possible to ensure tight and even coiling, especially on the first layer.

Where multi-layer coiling is unavoidable, succeeding layers should coil evenly on thepreceding layers of rope.

WARNING

Any looseness or uneven winding will result inexcessive wear, crushing and distortion of the rope.

With plain barrel drums it is difficult to achievesatisfactory multi-layer coiling beyond three layers.

The direction of coiling of the rope on the drum isimportant, particularly when using plain barrel drums,and should be related to the direction of lay of therope in order to induce close coiling.

(See Fig. 12 for proper method of locating ropeanchorage point on a plain drum.)

When multi layer coiling has to be used it should berealised that after the first layer is wound on a drum,the rope has to cross the underlying rope in order toadvance across the drum in the second layer. Thepoints at which the turns in the upper layer crossthose of the lower layer are known as the cross-overpoints and the rope in these areas is susceptible toincreased abrasion and crushing. Care should betaken when installing a rope on a drum and whenoperating a machine to ensure that the rope is coiledand layered correctly.

3.15 Check the state of re-usable rope end terminationsfor size, strength, defects and cleanliness before use.Non-destructive testing may be required dependingon the material and circumstances of use. Ensure that

Proper method of locating rope anchorage pointon a plain drum

RIGHT HAND

LAY ROPE-UNDERWIND

RIGHT HAND

LAY ROPE-OVERWIND

LEFT HAND

LAY ROPE-UNDERWIND

LEFT HAND

LAY ROPE-OVERWIND

LEFT

HAND

LEFT

HAND

START ROPE

AT LEFT

FLANGE

RIGHT

HAND

Note: Thumb indicates side of rope anchorage

Fig 12


BRIDON Oil and Gas



Note: Shortening the rope re-positions the areas of maximum

deterioration in the system. Where conditions permit, begin operating

with a rope which has a slightly longer length than necessary in order

to allow for periodic shortening.

When a non-preformed rope, multi-layer rope orparallel closed rope ie (DSC) is used with a wedgesocket and is required to be shortened, it is essentialthat the end of the rope is secured by welding orbrazing before the rope is pulled through the mainbody of the socket to its new position. Slacken thewedge in the socket. Pass the rope through thesocket by an amount equivalent to the crop length orsample required. Note that the original bent portion ofthe rope must not be retained within the wedgesocket. Replace the wedge and pull up the socket.Prepare and cut in accordance with section 3.12.Ensure that the rope tail cannot withdraw through thesocket, see section 3.13.

WARNING

Failure to observe this instruction will result in asignificant deterioration in the performance of therope and could render the rope completely unfit forfurther service.

In cases where severe rope wear takes place at oneend of a wire rope, the life of the rope may beextended by changing round the drum end with theload end, i.e. turning the rope ‘end for end’ beforedeterioration becomes excessive.

4.2 Remove broken wires as they occur by bendingbackwards and forwards using a pair of pliers untilthey break deep in the valley between two outerstrands (see Fig. 15). Wear protective clothing suchas overalls, industrial gloves, helmet, eye protectorsand safety footwear during this operation.

WARNING

Do not shear off the ends of broken wires withpliers as this will leave an exposed jagged edgewhich is likely to damage other wires in the ropeand lead to premature removal of the rope fromservice. Failure to wear adequate protectiveclothing could result in injury.

WARNING

Irregular coiling usually results in severe surfacewear and rope malformation, which in turn is likelyto cause premature rope failure.

3.19 Ensure that the as-manufactured condition of therope is maintained throughout the whole of thehandling and installation operation.

3.20 If samples are required to be taken from the rope forsubsequent testing and/or evaluation, it is essentialthat the condition of the rope is not disturbed. Referto the instructions given in 3.12 and, depending onthe rope type and construction, any other specialmanufacturer’s instructions.

4. In Service

4.1 Inspect the rope and related equipment at thebeginning of every work period and particularlyfollowing any incident which could have damaged therope or installation.

The entire length of rope should be inspected andparticular attention paid to those sections thatexperience has proven to be the main areas ofdeterioration. Excessive wear, broken wires, distortionand corrosion are the usual signs of deterioration. Fora more detailed examination special tools arenecessary (see Fig. 13) which will also facilitateinternal inspection (see Fig. 14.)

In the case of ropes working over drums or sheaves itis particularly necessary to examine those areasentering or leaving the grooves when maximum loads(i.e. shock loads) are experienced, or those areaswhich remain for long periods in exposed placessuch as over a Jib Head sheave.

On some running ropes, but particularly relevant tostanding ropes (e.g. pendant ropes) the areasadjacent to terminations should be given specialattention. (see Fig. 14).

Fig 13

Fig 14

Fig 15



54

WARNING

Failure to take adequate precaution could result ininjury or damage to health.

Only use compatible cleaning fluids which will notimpair the original rope lubricant nor affect the ropeassociated equipment.

WARNING

The use of cleaning fluids (particularly solventbased) is likely to ‘cut back’ the existing ropelubricant leading to a greater quantity of lubricantaccumulating on the surface of the rope. This maycreate a hazard in appliances and machinery whichrely on friction between the rope and the drivesheave (e.g. lifts, friction winders and cableways).

4.8 Lubricants selected for in-service dressing must becompatible with the rope manufacturing lubricant andshould be referenced in the OEM’s instruction manualor other documents approved by the owner of theappliance.

If in doubt contact Bridon or your rope supplier.

4.9 Take particular care when applying any in-servicelubricant/dressing. Application systems which involvepressure should only be operated by trained andauthorised persons and the operation carried out strictlyin accordance with the manufacturer’s instructions.

Most wire ropes should be lubricated as soon as theyare put into service and at regular intervals thereafter(including cleaning) in order to extend safe performance.

WARNING

A ‘dry’ rope unaffected by corrosion but subject tobend fatigue, is likely to achieve only 30% of thatnormally attained by a ‘lubricated’ rope.

Do not dress/lubricate the rope if the applicationrequired it to remain dry. (Refer OEM’s instruction manual.)

Reduce the period between examinations when ropesare not subjected to any in-service dressing andwhen they must remain dry.

Note: The authorised person carrying out a rope inspection must be

capable of recognising the potential loss of safe performance of

such a rope in comparison with lubricated rope.

Clean the rope before applying a freshdressing/lubricant if it is heavily loaded with foreignmatter e.g. sand, dust.

Note: Broken wires are a normal feature of service, more so towards

the end of the rope’s life, resulting from bending fatigue and wear.

The local break up of wires may indicate some mechanical fault in

the equipment.

Record the number and position in the rope of anyremoved broken wires.

4.3 Do not operate an appliance if for any reason (e.g.rope diameter, certified breaking force, ropeconstruction, length or strength and type of ropetermination) the wire rope and its termination isconsidered unsuitable for the required duty.

4.4 Do not operate an appliance if the wire rope fitted hasbecome distorted, been damaged or has deterioratedto a level such that discard criteria has been reachedor is likely to be reached prior to normal expected lifebased on historical performance data.

WARNING

Rope distortion is usually a result of mechanicaldamage and can significantly reduce rope stren gth.

4.5 An authorised competent person must examine therope in accordance with the appropriate Regulations.

4.6 Do not carry out any inspection, examination,dressing/lubrication, adjustment or any othermaintenance of the rope whilst it is suspending aload, unless otherwise stated in the OEM’s instructionmanual or other relevant documents.

Do not carry out any inspection or maintenance of therope if the appliance controls are unattended unless thesurrounding area has been isolated or sufficient warningsigns have been posted within the immediate vicinity.

If the appliance controls are attended, the authorisedperson must be able to communicate effectively withthe driver or controller of the appliance during theinspection process.

4.7 Never clean the wire rope without recognising thepotential hazards associated with working on amoving rope.

WARNING

Failure to pay attention or take adequateprecaution could result in injury.

If cleaning by cloth/waste, the material can besnagged on damaged surfaces and/or broken wires.If cleaning by brush, eye protectors must be worn. Ifusing fluids it should be recognised that someproducts are highly inflammable. A respirator shouldbe worn if cleaning by a pressurised spray system.


BRIDON Oil and Gas



Ensure that the sample is kept straight throughout thewhole procedure and ensure that the minimumsample length is 4 metres for ropes up to andincluding 76mm diameter and 8 metres for largerdiameter ropes.

The rope should be cut with a high speed abrasivedisc cutter or an oxyacetylene torch. Weld the ropeends of the sample as described in section 3.12, afterwhich the clamp or grip can be removed.

The identification of the rope must be established andthe sample suitably marked and packed. It isrecommended that the 3 metre sample is retainedstraight and secured to a wood batten fortransportation. For a 12 metre sample, coil to adiameter as large as practically possible and neverless than 2 metres.

Note: Samples taken for destruction testing are required to be

terminated in accordance with a recognised resin socketing

standard (e.g. BS EN 13411-4).

WARNING

Failure to comply with these procedures will result inmeasured breaking force values which are not trulyrepresentative of the actual strength of the rope.

5. Wire Rope Discard

5.1 Discard the wire rope in accordance with currentRegulations and in accordance with the OEM’sinstruction manual.

Note: The authorised competent person should also be familiar with

the latest versions of International Standard ISO 4309 ‘Cranes

- wire ropes - Code of practice for examination and discard’

and B.S. 6570 ‘ The selection, care and maintenance of steel

wire ropes’ which provide greater detail than that given in the

relevant Regulations. Other standards and instructions

covering rope discard may also be applicable. In the case of

synthetic sheaves (or synthetic linings) refer to the OEM’s

instruction manual or contact the sheave (or lining)

manufacturer for specific discard criteria.

5.2 If a wire rope is removed from service at a level ofperformance substantially different to historicallyestablished performance data and without anyobvious reason(s), contact Bridon or Bridon’sdistributor for further guidance.

5.3 Only qualified and experienced personnel, taking theappropriate safety precautions and wearing theappropriate protective clothing, should beresponsible for removing the wire rope.

WARNING

Take particular care when removing ropes withmechanical damage as they may fail abruptlyduring the change-out procedure.

4.10 The authorised person responsible for carrying outwire rope maintenance must ensure that the ends ofthe rope are secure. At the drum end this will involvechecking the integrity of the anchorage and ensuringthat there are at least two and a half dead laps tightlycoiled. At the outboard end the integrity of thetermination must be checked to ensure that it is inaccordance with the OEM’s manual or otherdocuments approved by the owner of the appliance.

Adjust the lengths of ropes in multi-rope systems inorder that equal forces (within approved limits) are evident.

If a wire rope needs cutting refer to 3.12.

When securing rope ends refer to 3.13.

When re-usable end terminations are used refer to 3.15.

When re-connecting any end terminations to fixturesrefer to 3.15.

4.11

WARNING

Damage to, or removal of component parts(mechanical or structural) caused by abnormalcontact with wire rope can be hazardous to thesafety of the appliance and/or the performanceof the rope (e.g. damage to the drum grooving,such that coiling is erratic and/or the rope is‘pulled down’ into underlying layers, whichmight cause a dangerous condition or,alternatively, cause localised rope damage at‘cross-over’ positions, which might thenradically affect performance; loss/removal ofwear plates protecting the structure leading tomajor structural damage by cutting and/or failureof the wire rope due to mechanical severance).

4.12 Following any periodic statutory examination orroutine or special inspection where any correctiveaction is taken the Certificate should be updated anda record made of the defects found, the extent of thechanges and the condition of the rope.

4.13 Apply the following procedures for the selection andpreparation of samples, from new and used lengthsof rope, for the purpose of examination and testing todestruction.

Check that the rope end, from which the sample willbe taken, is secured by welding or brazing. If not,select the sample length further away from the ropeend and prepare new servings (see 3.12).

Handle the rope in accordance with the instructionsgiven in section 3. Serve the rope, using the buriedwire technique (see Fig. 10) and apply a rope clampor grip as close to the cut mark as practicallypossible. Do not use solder to secure the servings.



56

WARNING

Wire rope which bends around sheaves, rollers ordrums will deteriorate through ‘bending fatigue’.Reverse bending and high speed will acceleratethe process. Therefore, under such conditionsselect a rope with high bending fatigue resistance.Refer to Product Data Information, and if in doubtask for advice.

6.3 Abrasion

Wire rope which is subject to abrasion will becomeprogressively weaker as a result of:

Externally - dragging it through overburden, sand orother abrasive materials and passing around asheave, roller or drum.

Internally - being loaded or bent.

WARNING

Abrasion weakens the rope by removing metalfrom both the inner and outer wires. Therefore, a rope with large outer wires should normally be selected.

6.4 Vibration

Vibration in wire rope will cause deterioration. Thismay become apparent in the form of wire fractureswhere the vibration is absorbed.

WARNING

These fractures may be internal only and will notbe visually identified.

6.5 Distortion

Wire rope can be distorted due to high pressureagainst a sheave, improperly sized grooves or as aresult of multi-layer coiling on a drum.

Rope with a steel core is more resistant to crushingand distortion.

6.6 Corrosion

Rope with a large number of small wires is moresusceptible to corrosion than rope with a smallnumber of large wires. Therefore, if corrosion isexpected to have a significant effect on ropeperformance select a galvanised rope with as largean outer wire size as possible bearing in mind theother conditions (e.g. bending and abrasion) underwhich the rope will be operating.

Take the utmost care when removing ‘exhausted/failed’ropes from drums and sheaves as they may be grosslydistorted, lively and tightly coiled.

WARNING

Failure to take adequate precautions could resultin injury.

5.4 Store discarded rope in a safe and secure location orcompound and ensure that it is suitably marked toidentify it as rope which has been removed fromservice and not to be used again.

WARNING

Discarded rope can be a danger (e.g. protrudingbroken wires, excessive grease/lubricant and ropemass) to personnel and equipment if not handledcorrectly and safely during disposal.

5.5 Record the date and reason for discard on theCertificate before filing for future reference.

5.6 Pay attention to any Regulations affecting the safedisposal of steel wire rope.

6. Rope Selection Criteria

Ensure that the correct type of wire rope is selectedfor the equipment by referring to the OEM’sinstruction manual or other relevant documents. If indoubt contact Bridon or Bridon’s distributor for guidance.

6.1 Rope Strength

If necessary, refer to the appropriate Regulationsand/or application standards and calculate themaximum force to which the rope will be subjected.

The calculation may take into account the mass to belifted or moved, any shock loading, effects of highspeed, acceleration, any sudden starts or stops,frequency of operation and sheave bearing friction.

By applying the relevant coefficient of utilisation(safety factor) and, where applicable, the efficiency ofthe rope termination, the required minimum breakingload or force of the rope will be determined, thevalues of which are available from the relevantNational, European or International standards or fromspecific Product Data literature. If in doubt ask for advice from Bridon or Bridon’s distributor.

6.2 Bending fatigue

The size and number of sheaves in the system willinfluence the performance of the rope.


BRIDON Oil and Gas



6.10 Rope Length

Rope length and /or difference in length between twoor more ropes used in a set may be a critical factorand must be considered along with rope selection.

WARNING

Wire rope will elongate under load. Other factors such as temperature, rope rotation andinternal wear will also have an effect. These factors should also be considered during rope selection.

6.11 Preformed and Non-preformed Ropes

Single layer round strand rope is normally suppliedpreformed. However, if a non-preformed rope is selectedthen personnel responsible for its installation and/ormaintenance need to take particular care when handlingsuch rope, especially when cutting. For the purposes ofthis instruction, multi-layer, parallel closed and spiralropes should be regarded as non-preformed ropes.

6.12 Operating Temperatures

Wire rope with a steel core should be selected if thereis any evidence to suggest that a fibre core will notprovide adequate support to the outer strands and/orif the temperature of the working environment may beexpected to exceed 100˚C.

For operating temperatures above 100˚C de-rating ofthe minimum breaking force of the rope is necessary(e.g. between 100˚C and 200˚C reduce by 10%;between 200˚C and 300˚C reduce by 25%; between300˚C and 400˚C reduce by 35%).

Do not use ropes with high carbon wires above 400˚C.

WARNING

Failure to observe this general guidance couldresult in failure of the ropes to support the load.

For temperatures over 400˚C, other materials such asstainless steel or other special alloys should beconsidered.

WARNING

Rope lubricants and any synthetic filling and/orcovering materials may become ineffective atcertain low or high operating temperature levels.

Certain types of rope end terminations also havelimiting operating temperatures and the manufactureror Bridon should be consulted where there is anydoubt. Ropes with aluminium ferrules must not beused at temperatures in excess of 150˚C.

6.7 Cabling

‘Cabling’ of rope reeving due to block rotation canoccur if the rope is incorrectly selected (see Fig.16).Applications involving high lifts are particularlyvulnerable to this condition therefore, ropes specificallydesigned to resist rotation need to be selected.

Corrective procedurefor cabling, where therope length involved isrelatively short, may besimply to disconnectboth ends of the ropeand pull the rope outstraight along theground. This will allowany build up of turn inthe rope to bereleased before therope is re-installed onthe crane. If cablingpersists, or the ropelength involved isrelatively long, it maybe necessary tocorrect by releasing orcorrect by releasing orinducing turn at the

outboard anchorage. If left hand cabling is producedin the reeving system, correction is usually achieved(on the right hand lay ropes, see Fig. 16) by releasingturn at the anchorage. Effort must be made to workreleased or induced turn throughout the workinglength of rope, by operating the crane at maximumheight of lift with a light load. It may be necessary torepeat the process until the cabling has beencorrected. For right hand cable it will normally benecessary to induce turn at the anchorage.

6.8 Fixing of Rope Ends

Ropes which have high rotation characteristics (such assingle layer Lang’s lay rope and parallel closed ropee.g. DSC) must not be selected unless both ends of therope are fixed or the load is guided and unable to rotate.

6.9 Connecting Ropes

In the event that it is necessary to connect one rope toanother (in series) it is essential that they have therequired strength, are of the same type and both have thesame lay direction (i.e. connect ‘right’ lay to ‘right’ lay).

WARNING

Failure to heed this warning could result incatastrophic failure particularly at a terminationwhich is capable of being pulled apart (i.e.splice) due to unlaying.


Remedy(Release3 turns)

1.5 turnsL.H. cable

RIGHT HAND LAY ROPE

Fig 16


58

2.0 The productsBridon Hydra 3500, Hydra 5500 and Hydra 7500 are 'LowRotational' multi-strand constructed wire rope products,typically of construction 34LR, 31LS, 28LR, 31LR. Wire ropesare produced by helically twisting wires into strands andstrands into a rope. When an axial tension is applied, allropes will rotate or generate a torque if prevented fromrotating. Degree of rotation or torque will depend upon therope construction and the loading profile to which the rope issubjected. These rope constructions having 16 strands in theouter most layer, helically spun in the opposite direction to thecore, produce excellent rotational balance; the outer strandswanting to rotate in the opposite direction to the core.

As ropes are helically spun, they will elongate (stretch) whensubjected to an axial load; the extension can beconsidered in two parts. Firstly, the permanent constructionalextension which results from the individual wires 'beddingdown' within the rope, a significant amount of whichtakes place during the rope’s first few loading cycles.Secondly, once bedded with constructional extensionstabilised, the rope behaves elastically with the stretch beingcalculated using the rope modulus (E), as shown in the table,based on the metallic cross section of the rope.

USER MANUAL FOR LARGE DIAMETER ‘LOW ROTATIONAL’ MULTI-STRAND ROPES FOR SPECIALISTOFFSHORE LIFTING, DEPLOYMENT &RECOVERY ACTIVITIES

Products: Hydra 3500, Hydra 5500, Hydra 7500Constructions: 34LR, 31LS, 28LR, 31LR

1.0 General SafetyBefore use carefully read and understand all instructions related to this product, whilst every effort has been made to ensure accuracy of informationcontained within this manual, the Bridon policy is one of continuous improvement to our products and as such we reserve the right to change the product specificationwithout prior notice.

Any information provided can be clarified with Bridon toprevent injury to personnel or damage to the productduring handling, installation and use. If required, Bridoncan supply experienced service engineers to provideassistance or undertake specialist service work.

Additional Information for Hydra Users

BRIDON Oil and Gas

The reel should be supported to allow easy rotation and aprovision made for a braking system to prevent over run ofthe rope. It is preferable that the support stand be motorisedto allow the rope to be re-spooled on to the supply reel, ifrequired.

The cradle should be removed from the reel before beingplaced in the installation stand or spooler. The direction ofspooling should be considered prior to loading into thespooler; to ensure safe control of the rope, it isrecommended that the rope comes off from the bottom ofthe supply reel. Once positioned in the spooler, the driveand/or brake system must be engaged before removal oflifting accessories to prevent uncontrolled or unexpectedrotation of the reel.

5.0 Rope InstallationBefore installation, all sheaves over which the rope is intendedto pass should be checked to ensure the groove profile fullysupports the ropes cross section. The groove diameter shouldbe between +7% to +10% larger than the nominal ropediameter, and the diameter of the sheave should not be lessthan 24 times the nominal rope diameter.

All ropes must be installed on the winch drum under tension, thelevel of tension depending upon the winching system, method of

3.0 Lifting and handling of reelsBridon Hydra range of ropes are supplied on steel reelssuitable for transportation and handling purposes. The reelswill generally be supplied with a cradle to provide stabilityand to distribute floor loadings. Cradles will either attach tothe lower half of each flange or supplied as a separateitem. Reels can be supplied with dedicated lifting points oralternatively can be handled by placing a shaft of suitabledimensions through the centre of the reel and lifted usingslings and a spreader beam to prevent excessive pressureon the reel flanges.

Critical reel dimensions, height, width, shaft size and drivearrangement should be agreed when ordering as these canvary depending on rope diameter, length required andresulting gross weight.

4.0 Positioning reel for installationThe supply reel, on which the rope is delivered, should bepositioned to limit any rope fleet angle during installation to1.5 degrees or less. Greater fleet angles can inducesignificant rotation of the rope, impacting upon the torsionalcharacteristics of the rope resulting in rope deformationsand/or ‘cabling’ of the rope reeving during use.

Turn (degrees/rope lay)Torque factor (%)Permanent extension (%)Rope modulus (kN/sq.mm)Diameter Reduction Factor (%)

0.82.30.051151.2%

1.13.50.151102.0%

0.93.00.11151.3%

Hydra 3500, Hydra 5500, Hydra 7500 (34LR construction)

Hydra 5500(31LS construction)

Hydra 7500(28LR/31LR construction)

Lang’s Lay Rope Properties at 20% MBF

Characteristics are not linear and vary with loading history. Properties shown in the above table are for fully bedded ropes.

59




6.0 Cutting of rope or preparing of rope endsCutting of the rope can be necessary for socketing, re-socketingand / or removal of samples for inspection or testing. Special careis required to maintain the integrity of the rope construction toensure its properties are retained.

These ropes are torque balanced, typically utilising three layers ofstrand, the two inner layers being spun in one direction and theouter layer of strands being spun in the opposite direction. Thisbalance is secured after manufacture by welding of the rope end.It is therefore essential that before cutting the rope, that the ropeis securely wire served correctly to maintain the integrity of therope during cutting and afterwards welded unless an appropriatefitting is to be attached.

After cutting, movement of the rope should be limited until therope end is welded or an attachment fitted. Samples removed fortesting should be strapped to a steel I-beam or similar supportingstructure to prevent bending or other movement duringtransportation and handling.

Simple hand held serving device should be used to ensureserving strand is tightly applied to ropes before cutting. Theminimum level of wire serving are given in the table below;

It is recommended, to maintain the integrity of the rope andminimise delays during rope installation that the rope ends arefactory prepared / fitted and therefore it is essential that themethod of attachment to the winch drum is confirmed /supplied when ordering.

Fitting of terminations to complex ropes should be completedby qualified personnel only. Bridon can supply trainingcourses or Site Services Engineers to complete theseactivities. Fitting of sockets should be completed inaccordance with suitable International Standards (EN 13411pt.4 / ISO 17558) with special attention to specificrequirements for complex rope which can be advised byBridon as necessary.

7.0 Training or bedding-down of the rope after installationBridon strongly recommends that all ropes are fully trained,after installation onto equipment and prior to first use.Failure to effectively train the rope may result in the ropefailing to achieve optimum performance, includingincreased potential for subsequent damage in use.

operation and expected rope loadings in service. A normal drumwinch system will require a higher installation tension, than a twincapstan winch used together with a storage winch. An operationalalternative may be to spool the rope whilst applying a nominaltension, followed by the rope being run off at sea and re-tensionedat a level suitable to provide good spooling. In this instance,consideration must be given to the self weight of the rope, and thetension /crushing forces this may apply to the lower layers of ropeand the tendency to induce rotation of the rope if dragged alongthe sea-bed.

Wire rope supply reels are normally designed for transportationpurposes only and are not designed to sustain rope tensionsgreater than 20kN. It will therefore be necessary to introduce atensioning device between the supply reel and the winch drum,the preferred method being a twin capstan traction winch.

The level of tension to be applied during spooling for ropesoperating at a design factor of 5 should be a minimum of 2.5%of the ropes breaking force. Where the rope is to operate ondrums of 20 times the rope diameter or less, and or subjectedto higher loads, then a higher installation tension of at least 4%of the ropes breaking force should be applied.

For ropes spooling onto storage winches a minimum tensionof 2% of the ropes breaking force is recommended to achieveacceptable spooling on the winch.

The installation tension is required for two reasons:

Firstly, to ensure a good fit between the diameter of the ropeand the pitch of the drum grooving, critical to achieve correctmultilayer spooling. Generally, the relationship indicates thatthe measured rope diameter should be slightly smaller thanthe pitch dimension; it must be recognised that aftermanufacture ropes will relax during transportation andhandling, resulting in the actual diameter of the ropeincreasing. The tension applied during spooling is thereforenecessary to return the rope diameter to that which wasmeasured during manufacture or testing and required for therope to correctly spool.

Secondly, the rope must be installed on the winch under tensionto prevent crushing and deformation of the rope as subsequentlayers are spooled on the winch and to prevent the cuttingthrough of subsequent layers in to the lower layers. Cuttingthrough of rope will not only result in damage to the rope, but alsoin extreme cases could result in rope failure.

Before disconnecting the end of the rope from the supply reel,ensure that the reel is secure and prevented from rotatingwhilst undertaking this operation. Care must be taken as asudden and unexpected movement of the rope may take placewhen the rope end is released. With the end free, it can beconnected securely to the ‘pull in’ rope in a chosen mannerthat is capable of sustaining the installation tensions as therope moves through the system. This connection must becarefully observed as it moves towards the drum, ensuring itdoes not become caught or obstructed whilst passing throughthe system.

It is Bridon’s recommendation that the rope be fully trainedprior to being subjected to a service or test load (see item 7),particularly when the rope is new, as the rope will always bemost vulnerable to damage from high loads when in its newcondition. Failure to fully train the rope may result insubsequent damage in use.

40mm to 76mm

76mm to 100mm

> 100mm

2.60mm

3.00mm

3.60mm

Rope Diameter

Diameterof ServingStrand(1x7)

Number of Servings

2 servings, each 2rope diameters inlength, placed 1 ropediameter apart, eitherside of the cut mark

4 servings, each 2rope diameters inlength, placed 1 ropediameters apart, eitherside of the cut mark




During the training process and subsequent use, the ropewill have rotated and elongated, therefore whilst the rope isunder tension it will contain a build up of torque; this is ofno concern whilst the rope remains under tension. If thetension in the rope is released, either during a re-spoolingoperation or as part of the operation, the torque in the ropewill be released resulting in twisting and screwing up of therope. For this reason it is particularly important to maintainrope tension between a traction winch and storage drum atall times.

8.0 Rope maintenance during serviceDuring normal deployment operation it is typicallyunavoidable that tension in the lower layers of rope will bereduced, resulting in these layers of rope becoming softerand more susceptible to crushing damage. It is thereforeadvisable that when an opportunity arises and particularlybefore the rope is subjected to significantly high loadings,that the rope is all run off the winch drum as per the trainingexercise mentioned earlier to re-tension the rope.

During service, a record should be maintained of theoperations conducted, confirming the length of ropedeployed, load applied, etc and if any changes in the ropescondition, lay extension, rotation, spooling pattern, etc occurs.

During service the rope may be sprayed with a light oil tomaintain the rope in good condition, but having beenoperating sub-sea it is considered almost impossible toremove all the salt water from the rope during operation. Ifthe rope is to be stored during use for a long period,additional efforts of washing the rope with fresh waterduring retrieval and the coating with a thin oil to penetratethe rope and displace moisture is recommended.

It is recommended that all Bridon Hydra range ropes areproduced from drawn galvanised wires to resist corrosionduring service. The centre of the multi-strand ropecontributes to approximately 50% of the ropes strength anddue to the difficulty of visual inspection every effort must bemade to ensure the core remains in good condition.

If during use, slackness or disturbance of the outer strandsoccurs towards the outer end of the rope as a result ofrotation and elongation in service, the rope should be re-socketed. It is important, before commencing re-terminationof the rope that a written procedure is referred to whichclearly outlines how this work will be conducted, ensuringthat the integrity of the rope is maintained at all times.

9.0 Further reference documents

IMCA M194 Guidance on Wire Rope IntegrityManagement for Vessels in theOffshore Industry.

IMCA M 197 Non-Destructive Examination (NDE) byMeans of Magnetic Rope Testing.

ISO 4309:2004 Cranes – Wire ropes – Care,maintenance, installation, examination and discard.

EN12385-3:2004 Steel wire ropes – Safety – Informationfor use and maintenance.

Guidance will also be available from third party authoritiesand the equipment manufacturers. Bridon Services offshorecertified engineers & technicians are available to superviseand support all installation, training and maintenanceactivities to enable optimised rope life in service.

The rope has been produced from many individual wires whichare firstly spun in to strands and then the strands spun into therope, these individual wires therefore have one or more helixeswithin them. Although these wires are positioned in the ropeduring manufacturing whilst applying tension, furtherequalisation and balancing is necessary during the trainingprocess to optimise load sharing throughout the rope. Onmultilayer winch drums the training process will prevent ropecrushing, cutting through of the lower layers during operationand will minimise spooling contact damage during use.

Where possible, the total length of rope, with the exceptionof the dead wraps (normally a minimum of 3) should be runoff the system, to allow the wires and strands within therope to position themselves as the rope rotates andextends due to its self weight and free movement. If all therope cannot be spooled off the winch during the aboveexercise, the remaining layers of rope will be subjected tocrushing forces that could easily result in permanentdamage to the rope and possible removal from service.

By repeating this exercise 10 times with an increasingadditional load ensures the rope is conditioned to anapproximation of its working state, hence improving its in-service performance. The recommended 10 deploymentsare based on the number of cyclic loads normally requiredduring a pre-stressing operation to fully bed a wire rope,removing all the permanent constructional extension at agiven load case. The hysteresis graphs of load againstextension indicate that approximately 65% of the anticipatedconstructional extension is removed after 4 cycles.

The recommended loading cycle is defined in the tablebelow, increasing the additional load in an incrementalmanner ensures lower layers are adequately bedded towithstand crushing forces as higher layers are added:

It is acknowledged that operational time constraints may notpermit the full recommended training cycle. In theseinstances, the minimum number of deploymentsrecommended is 4, following cycles 1-4 in the above table.In this case special attention should be paid during spoolingafter the 4th deployment to ensure there are no significantgaps between the individual wraps of rope or at the drumflanges. The minimum number of cycles is based on theunderstanding of hysteresis graphs of load against extensionthat indicate approximately 65% of the anticipatedconstructional extension is removed after 4 cycles. The full10 cycles will better equip the rope for long termperformance and operators should aim to achieve themaximum number of cycle possible given time constraintsallowable. Variation from the above advice and selection ofthe most appropriate training cycle is the responsibility of therope user considering Bridon’s advice for the rope and thelifting equipment’s anticipated maximum operational loads.

1 Self weight only

2 Self weight plus 8% of the maximumoperational load.

3 Self weight plus 17% of themaximum operational load.

4-10 Self weight plus 25% of themaximum operational load.

Cycle Number Load Case

61

WARNING

CAUTIONARY NOTICE – RESTRICTIONS ON THEUSE OF LARGE DIAMETER MULTISTRAND ROPES.

All wire ropes are prone to damage if they are notproperly supported when used at high loads.Larger Multistrand ropes are particularlysusceptible to this form of abuse, due to their rigidconstruction and the relatively fine wire sizesinvolved in their manufacture/construction.Instances have been recorded of ropes beingheavily worked over plain drums and failing"prematurely", despite the nominal tension being

Type of contact Close-fitting U-groove Oversize U-groove Plain drumLevel of support Good Fair PoorTread path width 100% of rope dia. 50% of rope dia. 20% of rope dia.Tread pressure = 2T/Dd 4T/Dd 10T/DdContact stress = 20T/Dd 40T/Dd 100T/Dd

being in the region of half the breaking strength of the rope.

The best way of preventing difficulties of this sortis to avoid conditions that are likely to generatedamagingly high contact stresses. A simplemethod of assessing the severity of the contactconditions is to firstly calculate the tread pressurebased on the projected nominal area and thenapply a factor (of say 10*) to allow for the highlylocalised and intermittent nature of the actual wirecontacts, as indicated below :-

WARNING

Wire rope will fail if worn-out, shock loaded, overloaded, misused, damaged, improperly maintained or abused.

• Always inspect wire rope for wear, damage or abuse before use

• Never use wire rope which is worn-out, damaged or abused

• Never overload or shock load a wire rope

• Inform yourself: Read and understand the guidance on product safety given in this catalogue; also read and understand the machinery manufacturer’s handbook

• Refer to applicable directives, regulations, standards and codes concerning inspection, examination and rope removal criteria

Protect yourself and others - failure of wire rope may cause serious injury or death!

Note: Contact stresses which exceed 10% of the wire UTS

should be considered a cause for concern, especially if the

rope is operating at a low factor of safety.

[* This is because the true contact area is very much less than the

projected nominal area.]

Worked example:

Consider case of a 50mm Multistrand rope (MBL=2100kN)operating at a 3:1 factor of safety. Then, for the Contactstress < 200 Mpa say, the following minimum bendingdiameters are indicated:

Close-fitting groove – 1400mm

Oversize U-groove - 2800mm

Un-grooved drum - 7000mm






external covering. No Occupational Exposure Limits(OEL’s) exist for steel wire rope and the values provided inthis publication relate to component elements andcompounds. The actual figures quoted in relation to thecomponent parts are taken from the latest edition of EH40.

Rope produced from carbon, coated or stainless steelwires in the as-supplied condition is not considered ahealth hazard. However during any subsequent processingsuch as cutting, welding, grinding and cleaning, dust andfumes may be produced which contain elements that mayaffect exposed workers.

The following indicates the order in which specificinformation is provided:-

Carbon steel wire, Coated steel wire, Stainless steel wire,Manufacturing rope lubricants, Fibre cores, Filling and covering materials, General information

Introduction

Steel wire rope is a composite material and dependentupon its type may contain a number of discrete materials.The following provides full details of all the individualmaterials which may form part of the finished wire rope.

The description and/or designation of the wire rope stated onthe delivery note and/or invoice (or certificate, whenapplicable) will enable identification of the component parts.

The main component of a steel wire rope is the wire, whichmay be carbon steel, coated (zinc or Zn95/A15) steel orstainless steel.

The other three components are (i) the core, which may beof steel of the same type as used in the main strands oralternatively fibre (either natural or synthetic), (ii) the ropelubricant and, where applicable, (iii) any internal filling or

Material Safety Data

BASE METALAluminiumCarbonChromiumCobaltCopperIronManganeseMolybdenumNickelPhosphorusSiliconSulphurVanadiumBoronTitaniumNitrogenLeadArsenicZirconiumCOATEDSodiumCalciumBoronPhosphorusIronZincOil may be applied

0.31.00.40.30.5

Balance1.00.10.50.10.50.50.250.10.10.010.10.010.05

0.50.51.01.01.01.05.0

10None Listed

0.50.10.255510.110

None Listed0.5101050.150.25

None Listed2100.1555

20

10510

0.3

20

9

10

200.3101010

Specific Gravity: 7.5 - 8.5Melting Point: 1350 - 1500 oCAppearance & Odour: Solid. Odourless MetalSolubility in water: InsolubleFlash Point: None

Vapour Pressure: N/AVapour Density: N/AEvaporation: N/A% Volatiles: N/ABoiling Point: > 2800 oC

Component % Weight (Max)Long term exposure limit(8-hour TWA reference

period) mg/m3

Short term exposure limit(10-minute reference

period) mg/m3

Carbon Steel Wire - Hazardous Ingredients

Physical Data

63


BASE METALAluminiumCarbonChromiumCobaltCopperIronManganeseMolybdenumNickelPhosphorusSiliconSulphurVanadiumBoronTitaniumNitrogenLeadArsenicZirconiumCOATEDZincAluminiumIronSodiumCalciumBoronPhosphorusSulphurOil may be appliedWax may be applied

0.31.00.40.30.5

Balance1.00.10.50.10.50.50.250.10.10.010.10.010.05

10.01.55.00.50.51.01.00.55.05.0

10None Listed

0.50.10.255510.110

None Listed0.5101050.150.25

5105

None Listed21000.1

None Listed52

20

10510

0.3

20

9

10

102010

200.3

106

Specific Gravity: 7.5 - 8.5Melting Point: 1350 - 1500 oCAppearance & Odour: Solid. Odourless MetalSolubility in water: InsolubleFlash Point: None

Vapour Pressure: N/AVapour Density: N/AEvaporation: N/A% Volatiles: N/ABoiling Point: > 2800 oC

Component % Weight (Max)Long term exposure limit(8-hour TWA reference

period) mg/m3

Short term exposure limit(10-minute reference

period) mg/m3

Coated (Zinc and Zn95/A 15) Steel Wire - Hazardous Ingredients

Physical Data





The worker should:1) use oil impermeable gloves, or if not available, suitable

oil repellent type barrier creams,2) avoid unnecessary contact with oil using protective clothing,3) obtain first aid treatment for any injury, however slight,4) wash hands thoroughly before meals, before using the

toilet and after work,5) use conditioning creams after washing, where provided.

The worker should not:1) put oily rags or tools into pockets, especially trousers,2) use dirty or spoiled rags for wiping oil from the skin,3) wear oil soaked clothing,4) use solvents such as parafin, petrol etc., to remove oil

from the skin.

Concentrations of oil mists, fumes and vapours in the workingatmosphere must be kept as low as is reasonably practicable.Levels quoted in the current edition of HSE Guidance NoteEH40 ‘Occupational Exposure Limits’ must not be exceeded.

Health Hazards

Inhalation of oil mists or fumes from heated rope lubricantsin high concentrations may result in dizziness, headache,respiratory irritation or unconsciousness. Eye contact mayproduce mild transient irritation to some users.

Fumes from heated rope lubricants in high concentrationsmay cause eye irritation.

If heated rope lubricants contacts skin, severe burns may result.

Prolonged or repeated skin contact may cause irritation,dermatitis or more serious skin disorders.

Fibre Cores

Being in the centre of a steel wire rope, the materials(natural or synthetic) from which fibre cores are produceddo not present a health hazard during normal ropehandling. Even when the outer core strands are removed(for example when the rope is required to be socketed) thecore materials present virtually no hazard to the users,except, maybe, in the case of a used rope where, in theabsence of any service dressing or as a result of heavyworking causing internal abrasive wear of the core, the coremay have decomposed into a fibre dust which might beinhaled, although this is considered extremely unlikely.

The principal area of hazard is through the inhalation offumes generated by heat, for example when the rope isbeing cut by a disc cutter.

Manufacturing Rope Lubricants

The products used in the manufacture of steel wire ropesfor lubrication and protection present minimal hazard to theuser in the as-supplied condition. The user must, however,take reasonable care to minimise skin and eye contact andalso avoid breathing their vapours and mists.

A wide range of compounds is used as lubricants in themanufacture of steel wire rope. These products, in themain, consist of mixtures of oils, waxes, bitumens, resins, gelling agents and fillers with minor concentrationsof corrosion inhibitors, oxidation stabilizers and tackiness additives.

Most of them are solid at ambient temperatures andprovided skin contact with the fluid types is avoided, nonepresent a hazard in normal rope usage.

However, to assist in the assessment of the hazard causedby these products, the following table contains all thecomponents which may be incorporated into a wire ropelubricant and which may be considered hazardous to health.

Hazardous Ingredients:

There are no other known constituents of any wire ropelubricant used that are classified as hazardous in thecurrent edition of EH40.

General advice on handling ropes with lubricants

To avoid the possibility of skin disorders, repeated orprolonged contact with mineral or synthetic hydrocarbonsmust be avoided and it is essential that all persons whocome into contact with such products maintain highstandards of personal hygiene.

Oil mistParaffin wax fumeBitumenSilica, fused

Total inhalable dustRespirable dust

Aluminium flakeZinc oxide, fumeButane

525

0.30.1105

1430

Component

Long termexposure limit(8-hour TWAreference

period) mg/m3

Short termexposure limit(10-minutereference

period) mg/m3


10610

20101780



Under these conditions, natural fibres are likely to yieldcarbon dioxide, water and ash, whereas synthetic materialsare likely to yield toxic fumes.

The treatment of natural fibres, such as rotproofing, mayalso produce toxic fumes on burning.

The concentrations of toxic fumes from the cores, however,will be almost negligible compared with the productsgenerated by heating from the other primary materials, e.g.wire and manufacturing lubricant in the rope.

The most common synthetic core material is polypropylene,although other polymers such as polyethylene and nylonmay occasionally be used.

Filling and Covering Materials

Filling and covering materials do not present a health hazardduring handling of the rope in its as-supplied condition.

The principal area of hazard is by the inhalation of fumesgenerated by heat, for example when the rope is being cutby a disc cutter.

Under these conditions, fillings and coverings, which aregenerally polypropylene, polyethylene and polyamid (but insome cases may be of natural fibre) are likely to producetoxic fumes.

General InformationOccupational protective measures

1) Respiratory protection - Use general and localexhaust ventilation to keep airborne dust or fumesbelow established occupational exposure standards(OES’s). Operators should wear approved dust andfume respirators if OES’s are exceeded. (The OES for total dust is 10mg/m3 and for respirabledust is 5mg/m3).

2) Protective equipment - Protective equipment shouldbe worn during operations creating eye hazards. Awelding hood should be worn when welding or burning.Use gloves and other protective equipment when required.

3) Other - Principles of good personal hygiene should be followed prior to changing into street clothing oreating. Food should not be consumed in the working environment.

Emergency medical procedures

1) Inhalation - Remove to fresh air; get medical attention.2) Skin - Wash areas well with soap and water.3) Eyes - Flush well with running water to remove

particulate; get medical attention.4) Ingestion - In the unlikely event that quantities of rope or

any of its components are ingested, get medical attention.

Safety Information

1) Fire and explosion - In the solid state, steel componentsof the rope present no fire or explosion hazard. the organicelements present, i.e. lubricants, natural and syntheticfibres and other natural or synthetic filling and coveringmaterials are capable of supporting fire.

2) Reactivity - Stable under normal conditions.

Spill or leak procedures

1) Spill or leak - Not applicable to steel in the solid form.2) Disposal - Dispose of in accordance with

local Regulations.

Rope TerminologyWiresOuter wires: All wires positioned in the outer layer of wiresin a spiral rope or in the outer layer of wires in the outerstrands of a stranded rope.

Inner wires: All wires of intermediate layers positionedbetween the centre wire and outer layer of wires in a spiralrope or all other wires except centre, filler, core and outerwires of a stranded rope.

Core wires: All wires of the core of a stranded rope.

Centre wires: Wires positioned either at the centre of aspiral rope or at the centres of strands of a stranded rope.

Layer of wires: An assembly of wires having one pitchcircle diameter. The exception is Warrington layercomprising alternately laid large and small wires where thesmaller wires are positioned on a larger pitch circlediameter than the larger wires. The first layer is that which islaid immediately over the strand centre.

Note: Filler wires do not constitute a separate layer.

Tensile strength grade of wires: A level of requirement oftensile strength of a wire and its corresponding tensilestrength range. It is designated by the value according tothe lower limit of tensile strength and is used whenspecifying wire and when determining the calculatedminimum breaking force or calculated minimum aggregatebreaking force of a rope.

Wire finish: The condition of the surface finish of a wire,e.g. bright, zinc coated.




Multiple operation lay strand: Strand constructioncontaining at least two layers of wires, at least one of whichis laid in a separate operation. All of the wires are laid in thesame direction.

Cross-lay: Multiple operation strand construction in whichthe wires of superimposed wire layers cross over oneanother and make point contact, e.g. 12/6-1.

Compound lay: Multiple operation strand which contains aminimum of three layers of wires, the outer layer of which islaid over a parallel lay centre, e.g. 16/6+6-6-1.

RopesSpiral Rope: An assembly of two or more layers of shapedand/or round wires laid helically over a centre, usually asingle round wire. There are three categories of spiral rope,viz. spiral strand, half-locked coil and full-locked coil.

Spiral Strand: An assembly of two or more layers of roundwires laid helically over a centre, usually a single round wire.

Half-locked Coil Rope: A spiral rope type having an outer layer of wires containing alternate half lock and round wires.

Full-locked Coil Rope: A spiral rope type having an outerlayer of full lock wires.

Stranded Rope: An assembly of several strands laidhelically in one or more layers around a core or centre.There are three categories of stranded rope, viz. singlelayer, multi-layer and parallel-closed.

Single Layer Rope: Stranded rope consisting of one layerof strands laid helically over a core.

Note: Stranded ropes consisting of three or four outer strands may,

or may not, have a core. Some three and four strand single layer

ropes are designed to generate torque levels equivalent to those

generated by rotation-resistant and low rotation ropes.

Rotation-resistant Rope: Stranded rope having no lessthan ten outer strands and comprising an assembly of atleast two layers of strands laid over a centre, the directionof lay of the outer strands being opposite (i.e. contra - lay)to that of the underlying layer of strands.

Low Rotation Rope: Rotation resistant rope having atleast fifteen outer strands and comprising an assembly ofat least three layers of strands laid over a centre in two operations.

Note: this category of rotation resistant rope is constructed in such a

manner that it displays little or no tendency to rotate, or if guided,

generates little or no torque when loaded.

Compacted Strand Rope: Rope in which the outerstrands, prior to closing of the rope, are subjected to acompacting process such as drawing, rolling or swaging.

Note: Bridon’s products containing compacted strands are identified

by “Dyform”.

StrandsStrand: An element of rope usually consisting of anassembly of wires of appropriate shape and dimensionslaid helically in the same direction in one or more layersaround a centre.

Note: Strands containing three or four wires in the first layer or certain

shaped (e.g. ribbon) strands may not have a centre.

Round strand: A strand with a cross-section which isapproximately the shape of a circle.

Triangular strand: A strand with a cross-section which isapproximately the shape of a triangle.

Note: Triangular strands may have built-up centres (i.e. more than

one wire forming a triangle).

Oval strand: A strand with a cross-section which isapproximately the shape of an oval

Flat ribbon strand: A strand without a centre wire with across-section which is approximately the shape of a rectangle.

Compacted strand: A strand which has been subjected toa compacting process such as drawing, rolling or swagingwhereby the metallic cross-sectional area of the wiresremains unaltered and the shape of the wires and thedimensions of the strand are modified.

Note: Bridon’s brands of Dyform rope contain strands which have

been compacted.

Single lay strand: Strand which contains only one layer ofwires, e.g. 6-1.

Parallel lay strand: Strand which contains at least two layersof wires, all of which are laid in one operation (in the samedirection), e.g. 9-9-1; 12-6F-6-1; 14-7+7-7-1. Each layer ofwires lies in the interstices of the underlying layer such thatthey are parallel to one another, resulting in linear contact.

Note: This is also referred to as equal lay. The lay length of all the

wire layers are equal.

Seale: Parallel lay strand construction with the samenumber of wires in each wire layer, each wire layercontaining wires of the same size, e.g. 7-7-1; 8-8-1; 9-9-1.

Warrington: Parallel lay strand construction having anouter layer of wires containing alternately large and smallwires, the number of wires in the outer layer being twicethat in the underlying layer of wires, e.g. 6+6-6-1; 7+7-7-1.

Filler: Parallel lay strand construction having an outer layerof wires containing twice the number of wires than in theinner layer with filler wires laid in the intersticeswires of theunderlying layer of wires, e.g. 12-6F-6-1; 14-7F-7-1.

Combined parallel lay: Parallel lay strand constructionhaving three or more layers of wires, e.g. 14-7+7-7-1; 16-8+8-8-1; 14-14-7F-7-1; 16-16-8F+8-1.

Note: The first two examples above are also referred to as

Warrington-Seale construction. The latter two examples are also

referred to as Seale-Filler contruction.

Rope Terminology



BRIDON Oil and Gas

Compacted Rope: Rope which is subjected to acompacting process after closing, thus reducing its diameter.

Solid Polymer Filled Rope: Rope in which the freeinternal spaces are filled with a solid polymer. The polymerextends to, or slightly beyond, the outer circumference ofthe rope.

Cushioned Rope: Stranded rope in which the inner layers,inner strands or core strands are covered with solidpolymers or fibres to form a cushion between adjacentstrands or layers of strands.

Cushion Core Rope: Stranded rope in which the core iscovered (coated) or filled and covered (coated) with a solid polymer.

Solid Polymer Covered Rope: Rope which is covered(coated) with a solid ploymer.

Solid Polymer Covered and Filled Rope: Rope which iscovered (coated) and filled with a solid polymer.

Rope Grade (Rr): A number corresponding to a wiretensile strength grade on which the minimum breakingforce of a rope is calculated.

Note: It does not imply that the actual tensile strength grades of the

wires in a rope are necessarily the same as the rope grade.

Preformed Rope: Stranded rope in which the wires in thestrands and the strands in the rope have their internalstresses reduced resulting in a rope in which, after removalof any serving, the wires and the strands will not spring outof the rope formation.

Note: Multi-layer stranded ropes should be regarded as non-

preformed rope even though the strands may have been partially

(lightly) preformed during the closing process.

Rope Class: A grouping of rope constructions where thenumber of outer strands and the number of wires and howthey are laid up are within defined limits, resulting in ropeswithin the class having similar strength and rotationalproperties.

Rope Construction: System which denotes thearrangement of the strands and wires within a rope, e.g.6x36WS, 6x19S, 18x7, 34xK7.

Note: K denotes compacted strands.

Cable-laid Rope: An assembly of several (usually six)single layer stranded ropes (referred to as unit ropes) laidhelically over a core (usually a seventh single layerstranded rope).

Braided Rope: An assembly of several round strandsbraided in pairs.

Electro-mechanical Rope: A stranded or spiral ropecontaining electrical conductors.

Strand and Rope LaysLay direction of strand: The direction right (z) or left (s)corresponding to the direction of lay of the outer layer ofwires in relation to the longitudinal axis of the strand.

Lay direction of rope: The direction right (Z) or left (S)corresponding to the direction of lay of the outer strands inrelation to the longitudinal axis of a stranded rope or thedirection of lay of the outer wires in relation to thelongitudinal axis of a spiral rope.

Ordinary lay: Stranded rope in which the direction of lay ofthe wires in the outer strands is in the opposite direction tothe lay of the outer strands in the rope. Right hand ordinarylay is designated sZ and left hand ordinary lay isdesignated zS.

Note: This type of lay is sometimes referred to as ‘regular’ lay.

Lang’s lay: Stranded rope in which the direction of lay ofthe wires in the outer strands is the same as that of theouter strands in the rope. Right hand Lang’s lay isdesignated zZ and left hand Lang’s lay is designated sS.

Alternate lay: Stranded rope in which the lay of the outerstrands is alternatively Lang’s lay and ordinary lay. Righthand alternate lay is designated AZ and left hand alternatelay is designated AS.

Contra-lay: Rope in which at least one inner layer of wiresin a spiral rope or one layer of strands in a stranded rope islaid in the opposite direction to the other layer(s) of wires orstrands respectively.

Note: Contra-lay is only possible in spiral ropes having more than

one layer of wires and in multi-layer stranded ropes.

Rope lay length (Stranded Rope): That distance parallelto the axis of the rope in which the outer strands make onecomplete turn (or helix) about the axis of the rope.

CoresCore: Central element, usually of fibre or steel, of a singlelayer stranded rope, around which are laid helically theouter strands of a stranded rope or the outer unit ropes of acable-laid rope.

Fibre core: Core made from natural fibres(e.g. hemp,sisal) and designated by its diameter and runnage.

Synthetic Core: Core made from synthetic fibres (e.g.polypropylene) and designated by its diameter andrunnage.

Steel core: Core produced either as an independent wirerope (IWRC)(e.g. 7x7) or wire strand (WSC)(e.g. 1x7).

Solid polymer core: Core produced as a single elementof solid polymer having a round or grooved shape. It mayalso contain internal elements of wire or fibre.

Insert: Element of fibre or solid polymer so positioned asto separate adjacent strands or wires in the same oroverlying layers and fill, or partly fill, some of the intersticesin the rope. (see Zebra)

Rope Terminology



Rope Characteristics and PropertiesCalculated Minimum aggregate Breaking Force: Valueof minimum aggregate breaking force is obtained bycalculation from the sum of the products of the cross-sectional area (based on nominal wire diameter) and tensilestrength grade of each wire in the rope, as given in themanufacturer’s rope design.

Calculated Minimum breaking Force: Value of minimumbreaking force based on the nominal wire sizes, wire tensilestrength grades and spinning loss factor for the rope classor construction as given in the manufacturer’s rope design.

Fill factor: The ratio between the sum of the nominalcross-sectional areas of all the load bearing wires in therope and the circumscribed area of the rope based on itsnominal diameter.

Spinning loss factor (k): The ratio between the calculatedminimum breaking force of the rope and the calculatedminimum aggregate breaking force of the rope.

Breaking force factor (K): An empirical factor used in thedetermination of minimum breaking force of a rope andobtained from the product of fill factor for the rope class orconstruction, spinning loss factor for the rope class orconstruction and the constant π/4.

Minimum breaking force (Fmin): Specified value, in kN,below which the measured breaking force is not allowed to fallin a prescribed test and, for ropes having a grade, obtainedby calculation from the product of the square of the nominaldiameter, the rope grade and the breaking force factor.

Minimum aggregate breaking force (Fe,min): Specifiedvalue, in kN, below which the measured aggregatebreaking force is not allowed to fall in a prescribed test and,for ropes having a grade, obtained from the product of thesquare of the nominal rope diameter (d), the metallic cross-sectional area factor (C) and the rope grade (Rr).

Norminal length mass: The nominal mass values are forthe fully lubricated ropes.

Rope torque: Value, usually expressed in N.m, resultingfrom either test or calculation, relating to the torquegenerated when both ends of the rope are fixed and therope is subjected to tensile loading.

Rope turn: Value, usually expressed in degrees per metre,resulting from either test or calculation, relating to theamount of rotation when one end of the rope is free torotate and the rope is subjected to tensile loading.

Initial extension: Amount of extension which is attributedto the initial bedding down of the wires within the strandsand the strands within the rope due to tensile loading.

Note: This is sometimes referred to as constructional stretch.

Elastic extension: Amount of extension which followsHooke’s Law within certain limits due to application of atensile load.

Permanent rope extension: Non-elastic extension.

Rope Terminology

Conversion Factors S.I. UnitsForce Mass

Pressure/Stress Area

Volume

Length

1 kN = 0.101 972 Mp 1 UK tonf = 9964.02N

1 N = 0.101 972 kgf 1 lbf = 4.448 22N

1 kgf = 9.806 65 N 1 lbf = 0.453 592 kgf

1 kgf = 1 kp 1 UK tonf = 1.01605 tonne

1 N = 1.003 61 x 104 UK tonf 1 UK tonf = 9.964 02 kN

1 N = 0.2244 809 lbf 1 UK tonf = 2240 lbf

1 kgf = 2.204 62 lbf 1 short tonf

1 t = 0.984 207 UK tonf (USA) = 2000 lbf

1 kN = 0.100 361 UK tonf 1 kip (USA) = 1000 lbf

1 kN = 0.101 972 tonne (t) 1 kip = 453.592 37 kgf

1 kg = 2.204 62 lb 1 lb = 0.453 592 kg

1 tonne (t) = 0.984 207 UK ton 1 UK ton = 1.01605 tonnes (t)

1 kg/m = 0.671 970 lb/ft 1 lb/ft = 1.488 kg/m

1 kg = 1000 g 1 kip (USA) = 1000 lb

1 Mp = 1 x 106 g

1 tonne (t) = 9.80665 kN

1 m = 3.280 84 ft 1 ft = 0.304 8 m

1 km = 0.621 371 miles 1 mile = 1.609 344 km

1 N/mm2 = 0.101972 kgf/mm2

1 kgf/mm2= 9.806 65 N/mm2

1 N/mm2 = 1 MPa

1 kgf/mm2= 1 422.33 lbf/in2 1 lbf/in2 = 7.030 x 10-4

kgf/mm2

1 kgf/mm2= 0.634 969 tonf/in2 1 tonf/in2 = 1.57488 kgf/mm2

1 N/m2 = 1.450 38 x 10-4lbf/in2 1 lbf/in2 = 6894.76 N/m2

1 N/m2 = 1 x 10-6N/mm2 1 tonf/in2 = 1.544 43 x 108

dyn/cm2

1 bar = 14.503 8 lbf/in2

1 hectobar= 10N/mm2

1 hectobar= 107N/m2

1 mm2 = 0.001 55 in2 1 in2 = 645.16 mm2

1 m2 = 10.763 9ft2 1 ft2 = 0.092 903 0 m2

1 cm3 = 0.061 023 7 in3 1 in3 =16.387 1 cm3

1 litre (1) = 61.025 5 in3 1 in3 = 16.386 6 ml

1 m3 = 6.102 37 x 104 in3 1 yd3 = 0.764 555 m3



BRIDON Oil and Gas

Good Practice When Ordering a Rope

Basic information to be supplied;

Application or intended use: Boom / luffing rope

Nominal rope diameter: 22mm

Diameter tolerance (if applicable): +2% to +4%

Nominal rope length: 245 metres

Length tolerance (if applicable): -0% to +2%

Construction (Brand or Name): Dyform 6x36ws

Type of core: IWRC (Independent wire rope core)

Rope grade: 1960N/mm2

Wire finish: B (Drawn galvanised)

Rope Lay: zZ (Right hand Lang’s)

Level of lubrication: Lubricated internally, externally dry

Minimum breaking force: 398kN (40.6tonnes)

Rope standard: BS EN 12385-4:2004

Supply package: Wood compartment reel

Rope terminations - Inner end: DIN 3091 solid thimble with 43mm pin hole

Outer end: Fused and tapered

Third party authority (if required): Lloyd’s Register

Identification / markings: Part number XL709 – 4567

Useful additional information;

Equipment manufacturer: J Bloggs, Model XYZ crawler crane

Drum details - Grooved: Yes or No

If Yes: Helical or Lebus

Pitch of grooving: 23.10mm

20. Spooling – Number of wraps per layer: 32

Number of layers: Approximately 3 1/2

Services & Training


Non destructive examination (NDE)

The primary cause of wire rope failure is internal degradationthrough corrosion and fatigue. We provide acomprehensives non-destructive examination service,operating to the most meticulous standards. This detects thepresence of defects such as broken wires, both on thesurface and within the rope, loss of metallic cross-sectionalarea and distortions. Results from this examination arerecorded progressively, in digital format, from the surveyhead of the specialist equipment to a notebook or laptop, asthe wire rope passes through the head. The resulting trace isthen analysed and a comprehensive report produced.

Splicing

In addition to any basic splicing requirements, BRIDON areable to offer a variety of specialist splicing abilities, such aslong splicing, to meet our client’s needs.

Such requirements, which are carried out in-situ, mayentail; rope driven conveyors, aerial haulages, funiculars,tile conveyors etc. and may be long splices or eye splices,including multi-strand and bordeaux connection. All splices,including passenger carrying ropes, are carried out tointernationally recognised standards. Where required allsplicing materials, including liquid rubber for injection to thesplice area, can be provided.

TrainingBridon has established a deserved reputation for runninghigh quality training courses, which is no less than would beexpected from a world leader in the design, manufacture andsubsequent use of wire and fibre ropes. Our courses neverstand still and are directly relevant to current legislation,improved technology, and the competitive trading conditionsof today’s markets. In an increasingly competitive world,costs must be continually reduced without compromisingsafety. There is no better way to prepare for this challengethan through a Bridon training course.

For further information on training courses, includingpractical workshop based wire rope splicing and socketingcourses, any of which can be fine tuned to suit yourindividual needs, please contact BRIDON.

Bridon International Services employ some of the mosthighly trained professionals in the industry. Ourunderstanding of, and expertise in dealing with, all mannerof issues related to wire and fibre ropes has enabled us todevelop a wide portfolio of cost effective services which areenjoyed by Bridon customers world-wide.

24 hours a day, 365 days a year, our engineers andtechnicians are dispatched across the globe to provideexpert assistance and solutions, no matter what theproblem, or wherever the location. With resources andsupport services based at key hubs on every continent,BRIDON really does provide a truly International specialistafter sales service in wire and fibre rope.

Repair and Maintenance

Repair and maintenance can be carried out in many forms.All types of ropes including haulage, multi-strand rope,Locked Coil and Spiral Strand are catered for, from abroken wire to a total re-splice.

Installation & Replacement Services

The service life and safety of a wire rope can depend as muchupon the quality of the installation as upon the quality of theproduct itself. To protect your investment, take advantage ofour installation and replacement service - expert internationalsupport covering virtually all types of equipment which uses orincorporates wire rope. Typical installations include: miningapplications, elevators, excavators, cranes and aerialropeways. Bridon Services has a range of specialisedinstallation equipment, such as back tension winches,spoolers and hydraulic tensioners, that can be employed inconjunction with our skilled engineers to ensure installations ofwire rope are carried out correctly, professionally, and aboveall, safely.

Inspection & Statutory Examination Services

We are also able to provide customers with statutoryexamination services, as required under law, whichsubjects wire rope and lifting equipment (“below the hook”)to stringent testing and examination procedures.


Contacts

BRIDONSales Offices

BRIDON Oil and Gas

UNITED KINGDOMDoncaster

Balby Carr Bank, DoncasterSouth YorkshireDN4 5JQUnited [email protected]: +44(0) 1302 565100Fax: +44(0) 1302 565190

UNITED STATESBridon American

C280 New Commerce Blvd.Wilkes BarrePA [email protected]: +1 800 521 5555Fax: +1 800 233 8362

GERMANYBridon International GmbH

Magdeburger Straße 14a D-45881 [email protected]: +49(0) 209 8001 0 Fax: +49(0) 209 8001 275

RUSSIABridon International Moscow

Ivovaya Street 2/8Building 1, Office 215129329 [email protected]: +7 495 1808001Fax: + 7 495 1809231

INDONESIAPT Bridon

Graha Inti Fauzi2nd FloorJl. Buncit Raya No.22Jakarta [email protected]: +62 (021) 791 81919Fax: +62 (021) 799 2640

AFRICAAngola

Sonils [email protected]: + 244 923 726890Fax: + 244 923 854180

Kwanda [email protected]: + 244 935 939761Fax: + 244 937 638565

SOUTH [email protected]: +27 (0) 11 867 3987Cell: +27 (0) 79 887 2747Fax: +27 (0) 11 867 3987

MIDDLE EASTBridon Middle East

PO Box 16931Dubai United Arab [email protected]: +971 488 35 129 Fax: +971 488 35 689

[email protected]: +55 15 3232 8012Fax: +55 15 3232 8012

SINGAPOREBridon Singapore (Pte) Ltd.

Loyang Offshore Supply Base(SOPS Way)Box No: 5064Loyang CrescentSingapore [email protected]: +65 654 64 611Fax: +65 654 64 622

CHINABridon Hong Kong Ltd.

Unit B G/F Roxy Industrial Centre 58-66 Tai Lin Pai Road Kwai Chung Northern Territory Hong Kong [email protected]: +852 240 11 166Fax: +852 240 11 232

Bridon Hangzhou

57 Yonghua StreetXiacheng DistrictHangzhou CityZhejiang [email protected]: +86 571 8581 8780Fax: +86 571 8813 3310

[email protected]: +61 429 999 756

NEW ZEALAND6-10 Greenmount DriveEast TamakiPO Box 14 422 [email protected]: +64 9 2744299Fax: +64 9 2747982

Ground Floor, Icon Building, First Point, Balby Carr Bank,Doncaster, South YorkshireDN4 5JQ United Kingdom

Phone: +44(0) 1302 565100Fax: +44(0) 1302 565190Email: [email protected]

www.bridon.com 08/201

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