Oil & Gas Drilling User's Guide
Contents
1. personality trait than any other rope feature For example a rope is called stable when it spools smoothly on and off a drum or doesn t cause the ropes to twist together when a multi part reeving system is used Strand and rope construction contribute to stability for the most part Regular lay rope tends to be more stable than lang lay A rope made of seven wire strands will usually be more stable than a more complicated construction with many wires per strand There is no specific measurement of rope stability gt BENDABILITY Bendability relates to the ability of a rope to bend easily in an arc Four primary factors affect this capability 1 Diameters of wires that make up the rope 2 Rope and strand construction 3 Metal composition of wires and finish such as galvanizing 4 Type of rope core fiber core or IWRC Some rope constructions are by nature more bendable than others Small ropes are more bendable than big ones Fiber core ropes bend more easily than comparable IWRC ropes As a general rule ropes of many wires are more bendable than same size ropes made with fewer larger wires Union AWireCo WorldGroup Brand 3 SQUARED ENDS gt Typical example of breaks due to fatigue CRUSHING gt Typical example of external pressure on a wire rope CROSS SECTION OF A WORN WIRE gt Original cross section gt Worn surface oe SN CROSS SECTION O2. process provides a smooth extremely compact wire rope with greater surface area and more steel per given diameter which increases strength fatigue resistance and wear resistance When Union s Flex X products are properly matched to the application you ll get longer service life lower operating costs and less wear to sheaves and drums 6X19 6X 36 IWRC FLEX X 6 FLEX X 9 FLEX X 19 PS FLEX X 35 Minimum Minimum Breaking Breaking Minimum Minimum Minimum Minimum Force Force Breaking Breaking Breaking Breaking ON XIP XXIP Approx Force Approx Force Approx Force Approx Force Approx aan Diameter tons of tons of Weight tons of Weight tons of Weight tons of Weight Diameter tons of Weight in 2000 Ibs 2000 Ibs lbs ft 2000 Ibs lbs ft 2000 Ibs lbs ft 2000 Ibs lbs ft mm 2000 Ibs lbs ft 1 4 or 0 116 5 16 5 21 0 18 3 8 55 8 3 0 26 8 8 0 3 183 0 3 1 16 10 2 EL 0 35 11 9 0 4 11 8 0 4 1 2 13 3 14 6 0 46 15 3 0 5 15 4 0 5 9 16 16 8 18 5 0 59 19 3 0 6 19 4 0 7 5 8 20 6 2220 0 72 2280 0 8 26 2 0 9 23 8 0 8 16 30 6 0 9 3 4 29 4 32 4 1 04 32 4 1 1 37 4 173 34 12 19 42 9 1 2 7 8 39 8 43 8 1 42 43 8 1 5 50 6 1 8 46 1 6 22 Sa der 1 51 7 56 9 1 85 56 9 2 0 65 7 23 59 8 251 25A 15 8 22 1 1 8 65 15 2 34 FES 29 82 2 9 15 2 2 6 26 ors 255 1 1 4 19 9 87 9 2 89 87 9 3 1 102 Sat 87 9 Sik 28 91 6 2 6 1 3
3. When it comes to oil and gas drilling knowledge is your most important tool We know this guide Wire rope WILL FAIL if worn out overloaded misused damaged can t answer every improperly maintained or abused question you have about wire rope Wire rope failure may cause serious injury or death Protect yourself and others e ALWAYS INSPECT wire rope for WEAR DAMAGE or ABUSE BEFORE USE On UA u NEVER USE wire rope that is WORN OUT DAMAGED or informational needs ABUSED contact your Union e NEVER OVERLOAD a wire rope e INFORM YOURSELF Read and understand manufacturer s literature or Wire Rope and Wire Rope Sling Safety Bulletin sales manager e REFER TO APPLICABLE CODES STANDARDS and REGULATIONS for INSPECTION REQUIREMENTS and REMOVAL CRITERIA For additional information or the BULLETIN ask your employer or wire rope supplier distributor or district 1993 Wire Rope Technical Board Form No 193 WARRANTY Any warranty expressed or implied as to quality performance or fitness for use of wire rope products is always premised on the condition that the published strengths apply only to new unused rope that the mechanical equipment on which such products are used is properly designed and maintained that such products are properly stored handled used and maintained and properly inspected on a regular basis during the period of use Seller shall not be liable under any circumstances for c
4. 8 96 106 3 5 106 3 8 106 30 105 3 1 E 2 REVA 125 4 16 125 4 5 1125 32 119 3 4 1 5 8 132 146 4 88 146 53 1 3 4 T53 169 5677 169 6 1 1 7 8 174 192 6 5 192 T O 2 198 217 as 217 8 0 2 1 8 221 244 8 35 2 1 4 247 22 9 36 2 3 8 274 10 4 2 1 2 11302 11 6 2 578 1E3331 12 8 2 3 4 361 14 2 1 8 392 153 3 425 TIN Flex X 19 6 Union AWireCo WorldGroup Brand Guidelines for installing and operating drill lines ae a TUN INSTALLATION 1 Use a rope connector grip snake with a swivel to connect the new drill line to the old drill line This will relieve twist that may be put in the rope during spooling and handling 2 Never weld the new drill line to the old drill line 3 Try to install the new drill line ata point in the drilling operation when there is a considerable amount of weight available to help seat break in the new drill line and assist spooling 4 Remove and inspect the brass inserts on the dead line anchor for proper size and if worn replace Rope must be seated properly in the clamp to avoid damage wh
5. to follow the cut off 4 Take ton miles for drag into account ARI tar NENENG may seem excessive but they are necessary to move rope through the system at the proper rate 5 Drill ships and semis using a crown motion compen sator may operate with a lower ton mile goal due to b Ton miles must be calculated and recorded additional sheaves and extra rope on the drum accurately for each operation c Inspect equipment to prevent conditions that 6 Extended drilling between round trips may necessitate making a cut to avoid exceeding maximum allowable ton miles 7 Because of the additional weight top drives accumu late more ton miles for each rig operation It has not been determined if ton mile goals should be changed to accommodate this Union offers a manual cut off program for drill lines including a Ton Mile Indicator and Calculator in a booklet Cut Off Practice for Rotary Drilling 8 Union AWireCo WorldGroup Brand adversely affect service life Equipment problems such as bearing failure in a sheave can cause unusual wear leading to long cuts A computerized system is available on CD ROM and can be obtained by contacting your wire rope supplier How to identify and correct common rope problems in the field SISIA REDUCING CRUSHING AND SCRUBBING DAMAGE ON WIRE ROPE CRUSHING When a wire rope crosses over the preceding layer on the drum it is susceptible to crushing because there i
6. 700 or info wirecoworldgroup com WIRE ROPES FOR OFFSHORE APPLICATIONS APPLICATION Anchor line Buoy pendant Riser tensioner line Guide line tensioner line WIRE ROPES FOR OFFSHORE CRANE APPLICATIONS APPLICATION Hoist Boom hoist Boom pendant RECOMMENDED WIRE ROPE 6 x 19 class RRL bright or galvanized IWRC 6 x 36 class RRL bright or galvanized IWRC 6 x 36 class RRL bright or galvanized IWRC 6 x 36 class RLL IWRC 8 x 36 class RLL IWRC Flex X 6 or Flex X 8 6 x 26WS RRL IWRC RECOMMENDED WIRE ROPE REX AS 191 PS Elek A SS 19x7 6 x 26WS Flex X 9 Flex X 6 6 x 26WS RRL IWRC Rope or strand COMMENTS Choice depends upon rope size required drum geometry and other operating characteristics The 6 x 19 ropes have larger outside wires for more abrasion resistance The 6 x 36 ropes have a greater number of outside wires for extra bendability and fatigue resistance Offers good fatigue resistance A lang lay construction is recommended because both ends of the rope are fixed and it is more resistant to fatigue than regular lay Flex X ropes increase strength and resistance to wear fatigue and crushing The 6 x 26 ropes provide a good balance between abrasion resistance and fatigue resistance COMMENTS Flex X 19 PS provides a great combination of rotation resistant properties and improved stability and resistance to crushing Provides even greater
7. F A PEENED WIRE gt Original cross section gt Peened surface The right ropes for oil and gas drilling operations AP HH TU TYPICAL WIRE ROPES FOR ROTARY DRILLING OPERATIONS The various lines for rotary drilling rigs require a complex balance of wire rope characteristics abrasion resistance crush resistance fatigue resistance strength bendability and stability Each rig is different of course but the chart below provides general guidelines for selecting the right rope For more specific recommendations consult WireCo WorldGroup Technical Support 816 270 4700 APPLICATION Rotary drilling line Sand line Mast raising line Air hoist Geronimo Tong line Derrick assist Block tie back 4 Union AWireCo WorldGroup Brand RECOMMENDED WIRE ROPE 1 8 to 1 1 8 6 x 26WS RRL IWRC ES We dL 6 x 19S RRL IWRC f 3 3 10 27 6 x 26WS RRL IWRC Above sizes and constructions available in TUF KOTE PFV and Flex X 1 4 through 5 8 6x7 RRL IPS FC 1 3 8 and smaller 6x 19 class IWRC 1 1 2 and larger 6 x 36 class IWRC 6 x 26WS RRL IWRC 6 x 36WS RRL IWRC COMMENTS This demanding application requires a rope that is abrasion resistant crush resistant fatigue resistant and relatively stable Premium ropes may be used for specific applications Tuf Kote PFV cushions the strands distributes internal stresses keeps in wire rope lubricant and keeps out d
8. Oil amp Gas Drilling Users Guide M Union A WireCo WorldGroup Brand CONTENTS Choosing the right wire rope Rotary drilling rigs Offshore rigs and cranes Wire rope weights and Minimum Breaking Force Installing and maintaining drill lines Cutting drill lines Identifying and correcting common wire rope problems Wire rope inspection program Inspecting equipment and protecting yourself M Union Letus show you the ropes mSS t takes more than the right I wire ropes to operate your rigs It also takes the right knowledge and experience When you know the ropes that is how to choose use and maintain each of the many types of ropes you ll know how to assure maximum service life and performance for each drilling application When it comes to showing you the ropes no one does it like Union a WireCo WorldGroup brand As the world s largest producer of wire rope and wire products we offer what you need for many different applications And we offer the right experience to help you when you have questions including how to help maximize your wire rope s service life and performance This Oil amp Gas Drilling User s Guide is only one example On the following pages you ll gain valuable information to help you CHOOSE THE RIGHT WIRE ROPES Knowing the ropes starts by under standing the wide variety of wire ropes available for the petroleum industry This guide contains practical inform
9. a tion as well as the recommended wire ropes to use for each application INSTALL WIRE ROPES Find out the proper procedures to install a drill line outlined in this useful guide INSPECT YOUR ROPES By regularly inspecting wire ropes you ll not only know when to replace them but also identify unusual wear patterns or abuse that could be caused by correctable conditions on the equipment EXTEND ROPE S SERVICE LIFE THROUGH OUR CUT OFF PROGRAM By moving your drill ine through the system so the wear is distributed more evenly you can maximize your rope s service life This guide reviews this proven practice IDENTIFY AND PREVENT COMMON PROBLEMS IN THE FIELD This guide also helps you recognize and prevent some of the more common causes of wire rope problems in the field including crushing premature wear on the drum and spooling problems TESTED TOUGH amp TRUE At Union we understand the oilfield market Our years of climbing on the rigs with you combined with the latest metallurgical practices and unique design capabilities have enabled us to continue to innovate and provide the most cost effective line of oilfield ropes in the world Union is part of the global leader in manufacturing engineering and distributing wire rope wire rope assemblies high carbon wire and electromechanical cable WireCo WorldGroup We apply thorough design and manufacturing controls including complete material trace abili
10. and may cause less service from your drill line If crushing proves to be a continual problem drum modifications may help COUNTERBALANCE GROOVING Has smaller displacement on the drum which is less damaging at each crossover point compared to helical or parallel grooving This reduces scrubbing problems at the kickover points as well as line whipping It also keeps the drum in balance by placing the kick over points halfway around the drum from each other IMPROPER TENSIONING Insufficient tensioning of the first two or three layers of rope can also cause rope wear by allowing pulling in by subse quent layers of rope Without enough tension these lower layers can be pushed apart by the upper layers The upper layers then become WS AN SA SS XS NG LAKANG NI YN n n NY SSS SN NNN N N N N N N y 4 SS N SN N SSS SS d SO SS AN WS NAN SA N lt S 44 N wedged into the lower layers which can distort the rope and or individual wires WHIPPING SS6 ASN SESS SASS eee Rope whipping or vibration is another problem that may be encountered with high line speeds and multiple layer winding Whipping is introduced by the lateral displacement or throw of the rope at the crossover points When a wave is thrown into a rope by a crossover this disturbance travels along the rope and is reflected back at the sheave ata speed relative to
11. e attention to the areas of the rope in contact with sheaves and drums when loads are picked up If there is a reason to suspect valley wire breaks such as a reduction in rope diameter or elongation of rope lay perform an inspection as outlined below for standing ropes STANDING ROPES Most wire breaks in standing ropes are internal or valley breaks that occur at the points of wire contact Inspection will reveal no surface wear and therefore nothing to cause external wire breaks The majority of broken wire problems on standing ropes occur near the end attachments or other points of restriction where vibration is dampened sheave for proper sizes as well as their smoothness Grooves that are too small or tight can cause pinching and increased abrasion while grooves that are too wide can cause flattening of the rope both of which can reduce your rope s life Also inspect for corrugation broken or chipped flanges cracks in hubs and spokes signs of rope contact with guards sheave bearings and shaft an out of round condition and alignment with other sheaves all criteria for replacement END ATTACHMENTS Rope adjacent to end attachments has its movement restricted and is subject to fatigue as rope vibrations are dampened Inspect with an awl to expose broken wires and if more than one broken wire is found replace the rope Be sure to also inspect the fitting itself OTHER IMPORTANT AREAS TO INSPECT PICK UP POINTS The s
12. ections of a rope that contact sheaves or drums when the initial load is applied HEAT EXPOSURE lf an electric arc contacts the rope remove the entire rope from service immediately Although the problem may not be visible electric arcs can affect the rope s properties and the rope needs to be replaced ABUSE POINTS Look for bright spots where ropes are subjected to abnormal scuffing and scraping Union AWireCo WorldGroup Brand 11 Inspect your equipment e 2 Check the lagging on the drum for size IN ADDITION TO CAREFUL ROPE a INSPECTION PERFORM THESE and smoothness If excessively worn EQUIPMENT INSPECTIONS ON A or corrugated repair or replace it INSPECT YOUR REGULAR BASIS EQUIPMENT AND 3 The kick back plates kick back rollers WIRE ROPE and line guide roller assembly should REGULARLY 1 Check the traveling block and crown be inspected periodically gt Inspection should sheaves If the depth or size of the NG NAN bir groove shows excessive wear the 4 Rope should be removed from service ee ren sheaves must be replaced or repaired if it meets the retirement criteria training or practical especially the fast line sheave specified by API RP54 experience Protect yourself Bji E the real world accidents do happen wire rope in your applications always and that s why you need to take read and follow the warning label NEED MORE special precautions Before installing attached to each product INFORMATION gt
13. ed to matching and advancing wire wire rope and electro mechanical cables to your dynamic applications throughout the world With a global manufacturing and distribution base along with our unmatched technical expertise the world is our worksite 816 270 4700 infoewirecoworldgroup com O N e zZ E 9 LL 12200 NW Ambassador Dr Kansas City MO 64163 1244 fax 816 270 4707 www wirecoworldgroup com 2008 WireCo WorldGroup A WireCo WorldGroup Brand
14. en torqued down Torque the nuts on the dead line anchor clamp to the manufacture s specifications Torque should be rechecked after one to two hours of operation Refer to page 10 for inspection information 5 Special care should be taken during rig moves to prevent damage of the drill line such as kinks and doglegs OPERATION SETTING CASING 1 The optimum service is received when the drill line operates witha design factor ranging from b to 7 A high design factor over 7 wears the drill line out from bending fatigue because ton miles do not accumulate as fast as at lower design factors 2 The upper layer of the drill line can pull down through lower layers on the drum when setting heavy loads This occurs because the block goes up empty with very little load The drill line is not spooled tightly on the drum The load is then applied to the drill line on the top layer which If the design factor for setting the forces the wraps on the next lower layer apart allowing the top wrap to pull down Using a heavier block or by adding cheek plates to the block will lessen the problem Rope service increases with fewer parts of lines The fewer the number the less rope is spooled on the drum so less rope is subjected to the crossover points on the drum It also allows more rope available to cut As an example on a 7500 reel if 12 lines are strung there is approxi mately 2200 of rope in the strin
15. es Every rope is subject to metal fatigue from bending stress while in operation and therefore the rope s strength gradually diminishes as it is used gt ABRASION RESISTANCE Resistance to metal loss and deformation Metal loss refers to the actual wearing away of metal from the outer wires of a rope and metal deformation is the changing of the shape of outer wires of a rope In general resistance to metal loss by abrasion usually called abrasion resistance refers to a rope s ability to withstand metal being worn away along its exterior This wear reduces the strength of a rope The most common form of metal deformation is usually referred to as peening since outside wires of a peened rope appear to have been hammered along their exposed surface Peening usually occurs on drums caused by rope to rope contact during spooling It may also occur on sheaves Peening causes metal fatigue which in turn may cause wire failure The hammering which causes the metal of the wire to flow into a new shape realigns the grain structure of the metal thereby affecting its fatigue resistance The out of round shape also impairs wire movement when the rope bends gt STRENGTH Wire rope strength is usually measured in tons of 2 000 lbs In published material wire rope strength is shown as minimum breaking force MBF referring to calculated strength figures that are accepted by the wire rope indus
16. g up or 5300 of rope available to cut For 10 lines there is 1900 of rope in the string up or 5600 of rope available to cut This would increase rope service by over 5 BRASS INSERTS ON DEAD LINE ANCHOR gt Remove and inspect the brass inserts on the dead line anchor for proper size and if worn replace Always make a cut based on ton miles accumulated prior to and after setting casing Rope must be seated properly in the clamp to avoid damage when casing is approximately 3 0 cuta torqued down minimum of 200 from the string up Inspect the remaining rope and make another cut if necessary If the design factor is down to 2 0 the lowest allowed by API cuta minimum of 600 from the string up After inspection make another cut if necessary For design factors between 2 0 and 3 0 cut between 200 and 600 Make another cut if needed after inspection Try not to install a new drill line or slip all new rope into the system just before setting a heavy load of casing New or unused rope is more susceptible to crushing than a rope that has been in service Union AWireCo WorldGroup Brand 7 Guidelines for making drill line cuts end when it has reached the end of its useful service life As the rope is cut off the drum end new rope is fed into the system on the dead line side extending ervice life of drilling lines can be increased dramatically by following a pla
17. irt and debris extending the service life Flex X ropes provide additional strength more wear resistance more fatigue resistance and more crush resistance These ropes have larger outside wires to resist wear and help reduce costs Construction selected for balance of wear resistance and durability Right regular lay or right lang lay is commonly used Never mix right and left lay mast raising lines Better crushing and abrasion resistance than a 6 x 25 rope Increased bendability and fatigue resistance TYPICAL WIRE ROPES FOR OFFSHORE OPERATIONS Offshore rigs and cranes need wire ropes that rely on a different set of performance characteristics Maintaining a stable platform in deep water subject to constant battering by wind and waves requires a system of powerful anchoring lines and tensioner cables with excellent bendability fatigue and abrasion resistance On deck wire ropes are needed to operate cranes moving heavy loads to and from the rig with a minimum of maintenance and downtime A variety of wire ropes are available for offshore cranes The chart at the right describes some of the typical ropes their usages and traits WireCo WorldGroup manufactures a full line of crane ropes and also fabricates custom boom pendants A more detailed look at cranes and crane ropes is covered in Union s Crane User s Guide The guide and technical support can be requested by contacting us at 816 270 4
18. itional choices in design can modify these characteristics You may choose a rope with more wires in each strand for increased fatigue resistance and with compacted strands which will also provide increased abrasion resistance Choose the rope you need based on the type of operation to be performed Different tasks demand different characteristics and the right rope for each task can be critical to the overall success of operations The primary characteristics you will need to evaluate include several rope design characteristics gt FATIGUE RESISTANCE Fatigue resistance involves metal fatigue of the wires that make up a rope To have high fatigue resistance wires must be capable of bending repeatedly under stress for example a rope passing over a sheave 2 Union A WireCo WorldGroup Brand Increased fatigue resistance is achieved in a rope design by using a large number of wires It involves both the basic metallurgy and the diameters of wires In general a rope made of many wires will have greater fatigue resistance than a same size rope made of fewer larger wires because smaller wires have greater ability to bend as the rope passes over sheaves or around drums To overcome the effects of fatigue ropes must never bend over sheaves or drums with a diameter so small as to permanently bend the wires or rope There are precise recommendations for sheave and drum sizes to properly accommodate all sizes and types of rop
19. its weight and tension To reduce whipping problems a line guide can be used between the drum and the crown sheaves Union A WireCo WorldGroup Brand 9 Make the most of your wire rope through regular inspections espite their durability and strength wire ropes will eventually wear out and must be removed after a period of use That s why regular inspection is crucial HOW OFTEN TO INSPECT All hoisting lines should be visually inspected at least once each day when in use as is suggested by American Petroleum Institute API RP54 guide lines Hoisting lines should be thoroughly inspected once each month and a record made of the monthly inspection Any wire ropes that have met the following criteria for removal must be immediately replaced When in doubt replace The cost is minimal compared to what could happen if your rope breaks WHEN TO REPLACE RUNNING ROPES DUE TO BROKEN WIRES Wire ropes used as running ropes other than sand lines should be removed from service when broken wires meet any of the following criteria gt For six and eight strand constructions replace when you see six randomly distributed broken wires within one lay length or three broken wires in one strand within one lay length FOLLOW THESE STEPS TO INSPECT FOR VALLEY BREAKS 1 The first step is to relax your rope to a stationary position and move the pick up points off the sheaves Clean the surface of the rope with a cloth a wi
20. nned cut off program based on work performed This moves the rope through the system so wear can be spread uniformly along the entire length of the rope enabling the line to be removed from the drum A 10 STEP GUIDE TO A DRILLLINE CUT OFF PROGRAM service life When exercising a cut off program follow the guidelines below closely 1 For the first few cuts wrap the drill line at the point 8 Short frequent cuts will shift critical wear points being cut with duct tape prior to making the cut to Caused by excessive jarring prevent unlaying 9 Long cuts are necessary when the amount of rope 2 When making a cut and slipping new rope into the string up all of the wraps should be removed from the deadline anchor The rope should never be pulled through a loosened clamp which can put a twist in the rope The clamp should be completely removed and inspected If worn or damaged replace 3 After making a cut the dead wraps should be spooled to be cut doesn t remove all the rope that meets removal criteria This can be caused by failure to follow the ton mile goal improper calculation or recording of ton miles Damage at any point may require a long cut 10 To prevent long cuts n l a Find the optimal ton mile goal for your drill line on the drum with sufficient tension to prevent excessive et drum crushing or milking of the bottom layer experience may indicate you have to change your ton mile goal It s important
21. ons for removal of wire rope from service are gt Corrosion that pits the wires gt Corroded wires at end connections ST zz a anna e E E a Te EZ E Typical valley above and crown below wire breaks in outer wires gt API RP 9B Recommended Practice on Application Care and Use of Wire Rope for Oilfield Service gt API RP 54 Recommended Practices for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations gt ASME B30 5 Mobile and Locomotive Cranes crane rope removal criteria gt End connections that are corroded cracked bent worn or improperly applied gt Evidence of kinking crushing cutting bird caging or a popped core gt Wear that exceeds one third of a wire s original diameter gt Severe reduction of the rope s diameter gt Evidence of heat damage gt A significant increase in lay length HOW TO FIND BROKEN WIRES One of the most common signs of rope deterioration is broken wires normally the outside wires on the crowns of the strands RUNNING ROPES Because of their contact with sheaves and drums running ropes typically receive heavier external wear than standing ropes This can result in surface wire breaks the easiest kind ROPE INSPECTION CRITERIA FOR DRILLING OPERATIONS All portions of wire rope must be inspected thoroughly for possible deterioration on a regular basis This starts with a close examination of the ro
22. onsequential or incidental damages or secondary charges including but not limited to personal injury labor costs a loss of profits resulting from the use of said products or from said products being incorporated in or becoming a component of any other product 12 Union A WireCo WorldGroup Brand WireCo WorldGroup Engineering wire rope for your application is a highly specialized field with exacting standards that we gladly live by Across the entire WireCo WorldGroup organization we draw from our global pool of talented engineers to drive results for your application Eight WireCo WorldGroup manufact uring operations and seven distribution centers in North America plus manu facturing facilities in Germany and China give our customers unparalleled support and global reach Our manufacturing standards typically exceed the minimum design standards for a wire rope We take an active role in industry associations that develop wire rope specifications and standards such as ASTM A1023 We apply thorough design and manu facturing controls including complete material traceability And we are the only manufacturer in the world that is OPL qualified API certified and registered to both ISO 9001 2000 and AS 9100 Quality Systems ED ell WireCo WorldGroup world headquarters located in Kansas City Missouri So look to the best The Union brand backed by the WireCo WorldGroup organization We re dedicat
23. pe s critical points The critical points of an application are those that subject the rope to greater internal stresses or greater external forces Rope wear is more likely in the following critical areas so it pays to closely inspect these areas DRUMS When the rope spools properly normal wear occurs at the crossover kickover and change of layer points Look for scrubbing on the side of the rope in other words rope that rubs against the preceding wrap on the drum Crushing may result on rope s top and bottom sides If severe remove the rope from service Both the scrubbing and the crushing normally occur twice with each drum revolution Inspection of drums is also critical Check for signs of wear that could damage wire rope All drums should be smooth not corrugated Check for minimum number of dead wraps remaining on the drum the spooling characteristics of rope and the condition of flanges SHEAVES It s very important to check for broken wires in the wire ropes traveling over the sheaves in your system See section on broken wires on facing page Grooves tend to wear smaller over time especially under heavy loading conditions With a groove gauge check each to locate during your inspection The challenge is to find valley wire breaks These may occur when ropes are used with small diameter sheaves sheave grooves that are too small heavy loads and other poor operating conditions During your inspection pay clos
24. re brush if necessary so you can see any breaks 2 Flex the rope to expose any broken wires hidden in the valleys between the strands 3 Visually check for any broken wires One way to check for crown breaks is to run a cloth along the rope to check for possible snags 4 With an awl probe between wires and strands and lift any wires that appear loose Evidence of internal broken wires may require a more extensive rope examination For additional information and requirements please refer to the latest edition of gt API RP 2D Recommended Practice for Operation and Maintenance of Offshore Cranes 10 Union AWireCo WorldGroup Brand gt For rotation resistant constructions replace when you see two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters sand lines should be removed from service when you see three broken wires within one lay length WHEN TO REPLACE STANDING ROPES DUE TO BROKEN WIRES Wire ropes used as standing ropes such as guy lines escape lines and pendant lines should be removed from service when any of the following conditions exist gt Three broken wires are found within one lay length gt More than one broken wire is found at the end connection gt Broken wires are found in the valleys between the rope s strands OTHER REASONS TO REPLACE ROPES Broken wires are only one way wire ropes wear out Other conditi
25. rotation resistance more lifting capacity and fatigue resistance Lower strength and less wear resistance than Flex X 19 PS but does provide rotation resistance May be used if block rotation iS not a problem Flex X 9 is designed to provide the resistance to drum crushing that is critical in many boom hoist applications Flex X 6 provides resistance to bending fatigue as well as stability Crane manufacturers specify a number of boom hoist ropes but these are the most common Check your owner s manual to assure ropes meet strength requirements Custom fabricated to your requirements Union AWireCo WorldGroup Brand 5 FLEK K AND INCREASED SURFACE AREA gt Flex X ropes provide greater surface area and more steel per given diameter increasing rope stability strength and service life Wire rope weights and minimum breaking force he 6 x 19 classification of wire ropes includes standard six round strand ropes with 16 through 26 wires per strand The 6 x 36 classification includes standard six round strand ropes with 27 to 49 wires per strand Although the physical characteristics of these two can vary widely both have the same weight per foot and the same minimum breaking force size for size While 6 x 19 ropes have more abrasion resistance the 6 x 36 ropes WIRE ROPE MINIMUM BREAKING FORCES AND WEIGHTS have more fatigue resistance because they have more wires per strand The Flex X
26. s only a single point of contact This increases pressure and can result in damage by distorting the cross section shape of the rope its strands or core or all three Ropes that are new or not spooled onto the drum under tension are also more susceptible to crushing In addition crushing may occur at the change of layer point where the rope is wedged against the flange of the drum SCRUBBING As the rope spools on the drum it rubs against the preceding wrap at the kickover points making the sides of the rope vulnerable to scrubbing damage Scrubbing occurs most commonly when the rope runs into its preceding wrap in the same valley between two ropes on the lower layer It can also occur as the adjacent rope comes into contact as a result of fleet angle FACTORS AFFECTING ROPE WEAR The degree of scrubbing and crushing damage depends on a variety of factors such as rope construction previous usage of the rope the load on the rope the drum diameter the number of layers and the pitch of the grooving Single layer winding on a plain faced drum is more likely to produce an increased rate of wear to both the rope and drum compared to a grooved drum Grooved drums control the position of the base rope layer thereby reducing some types of spooling problems FIELD SOLUTIONS If crushing is a problem on drill lines one solution is to go to more parts of line to reduce the load in the wire rope This will result in longer string up
27. try When placed under tension on a test device a new rope will break ata figure equal to or higher than the MBF shown for that rope Minimum breaking force applies to new unused rope A rope should never operate at or near its MBF During its useful life a rope loses strength gradually due to natural causes such as surface wear and metal fatigue Sudden loss of strength can be caused by abusive situations gt CRUSHING RESISTANCE Crushing is the result of external pressure ona rope which damages it by distorting the cross section shape of the rope its strands or core or all three Crushing resistance therefore is a rope s ability to withstand or resist external forces and is a term generally used to express comparison between ropes When a rope is damaged by crushing the wires strands and core are prevented from moving and adjusting normally during operation In general IWRC ropes are more crush resistant than fiber core ropes Regular lay ropes are more crush resistant than lang lay ropes Six strand ropes have greater crush resistance than eight strand ropes or 19 strand ropes Flex X ropes are more crush resistant than standard round strand ropes gt STABILITY The word stability is most often used to describe handling and working characteristics of a rope It is not a precise term since the idea expressed is to some degree a matter of opinion and is more nearly a
28. ty And we are the only wire rope manufacturer in the world that is OPL qualified API certified and registered to both ISO 9001 2000 and AS 9100 Quality Systems Buy the best Union Tested Tough amp True Union AWireCo WorldGroup Brand 1 IF YOU NEED ABRASION RESISTANCE Abrasion resistance increases with fewer larger outside wires per strand IF YOU NEED FATIGUE RESISTANCE Fatigue resistance increases with more smaller outside wires per strand Choose the right wire rope for your application ll wire ropes include a combi nation of characteristics that give them specific performance traits depending on design engineering materials and composition With the many specialized procedures required for efficient well drilling it is important to select ropes that are best suited for each application No single rope can do it all DESIGN CHARACTERISTICS OF WIRE ROPE Consider how the composition of a rope can affect its performance character istics A rope with fewer but larger outside wires per strand will deliver more abrasion resistance because of the greater rope surface area exposed to drums and sheaves However this most often results in a reduction of fatigue resistance A greater number of smaller outside wires per strand allows the rope to bend more freely which will increase fatigue life but at the same time the smaller wires are more susceptible to abrasion Add
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