wire Rope Maintenance En

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FATZER AGWire Ropes Salmsacherstrasse 9 CH-8590 Romanshorn SwitzerlandPhone +41 71 466 81 11 Fax +41 71 466 81 [email protected] www.fatzer.com

Guidelines for Rope Maintenance


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Doc. 11-346: Guidelines for Rope Maintenance Rev. 04: 30.09.2008 Page 2 of 12

Content

1 Basic Lubrication by the Manufacturer ................................................................................. 3

2 Cleaning.................................................................................................................................... 3

2.1 Cleaning Stranded Ropes .................................................................................................. 4

2.2 Cleaning Full Lock Coil Track Ropes ................................................................................. 4

3 Relubricating / Maintenance................................................................................................... 5

3.1 Frequency of Relubricating................................................................................................. 53.1.1 Frequency of Relubricating Stranded Ropes (bright and galvanized) ............................ 53.1.2 Frequency of Relubricating Track Ropes........................................................................ 5

3.1.3 Frequency of Relubricating Tension / Counterweight Ropes.......................................... 5

3.2 Selection of Lubricant......................................................................................................... 6

3.3 Quantity of Lubricants......................................................................................................... 6

3.4 Applying the Lubricant ........................................................................................................ 73.4.1 Stranded Ropes.............................................................................................................. 73.4.2 Track Ropes.................................................................................................................... 93.4.3 Drying Time..................................................................................................................... 9

3.5 Special Rope Areas.......................................................................................................... 103.5.1 Splices .......................................................................................................................... 103.5.2 Area of Bollard / Reel for Track Rope Reserve............................................................. 113.5.3 Roller Chain Area.......................................................................................................... 113.5.4 Saddle Areas of Track Ropes....................................................................................... 113.5.5 Tension / Counterweight Ropes.................................................................................... 12

Special credit for support, revision and correction is given toBruno Mannsberger, P. Eng., Technical Director of the Resorts of the Canadian Rockies


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1 Basic Lubrication by the Manufacturer

Steel ropes for use in ropeways, whether they are made of either bright or galvanized wire are

lubricated during production, and are either partially or completely filled with lubricant.

This initial lubrication has the following functions:

Lubr icat ion:

reduces the internal friction created by dynamic load (between the individual wires andlayers of wire)

Protect ion:

protects ropes against corrosion

prevents water from getting into the core of the rope

Correct lubrication during manufacturing, which means lubrication suited to the use of the rope, isone of the most important steps to ensure reliable operation and a long and useful life.

2 Cleaning

During the installation of the wire rope, it may collect dirt and debris. As well, the first time the ropeis tensioned, excess lubricant will most likely come out of the rope. As a result, the rope should becleaned before being put into service.

Clean excess lubricant and other impurities resulting from the installation of track ropes.

Clean any impurities resulting from the installation of stranded ropes.

Example of wiping a track rope (left) and cleaning a stranded rope (right)

Rope must be cleaned before relubricating!Only clean ropes can be checked visually!


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Warning wh en Cleaning Ropes:

No detergents or any other aggressive cleaners shall be used.

Solvents may only be used in small quantities and for localized cleaning of the rope surface. Avoid mechanical damage to the rope by brushes.

Ensure that there is no build up of heat between the cleaning device and the surface of therope as a result of friction.

Do not use copper brushes. Remains of the bristles may increase the rate of surfacecorrosion.

2.1 Cleaning Stranded Ropes

Cleaning should be carried out with a standard cleaning device, in dry and preferably cool weather.Rope cleaning should be carried out at a slow rope speed (about 1m/s) and with empty carriers.

Cleaning device for stranded ropes

2.2 Cleaning Full Lock Coil Track Ropes

Cleaning should be carried out with a special cleaning device or using a flexible cable slingwrapped around the rope. Cleaning should be carried out at a slow operating speed (about 0.3 -1m/s) and with empty carriers.

Cleaning t rack ropes w i th mechanical ly-dr iven brush es:


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Cleaning t rack ropes w i th a f lex ib le cable sl ing:

Surface corrosion can be partly removed with a flexible cable sling, wound three times around the

track rope and loaded with a dead-weight at the trailing end.

This method is not recommended for very dirty ropes, as the dirt would only be smeared in.

Caut ion:

Special safety precautions have to be taken for this method of cleaning (for example,special precautions must be taken to prevent fouling on structural features such as towersaddles, or tearing off of the cable sling).

3 Relubricating / Maintenance

Correct relubrication at proper intervals will maintain the initial lubrication of the rope and prolongits serviceable life considerably. The lubricant used must be compatible with the initial lubricantapplied by the rope manufacturer, and with all materials in contact with the rope or used in thesplice. The lubricant must not negatively affect the operating conditions of these components.

Failure to relubricate regularly and appropriately will reduce the useful life of the rope.

3.1 Frequency of Relubricating

3.1.1 Frequency of Relubricating Stranded Ropes (bright and galvanized)

We recommend dressing strand ropes for the first time after about 30,000 bending cycles1or at thevery latest, after 3 years of operation, whichever occurs first.Yearly relubrication is recommended from then on.

3.1.2 Frequency of Relubricating Track Ropes

In the case of full lock coil track ropes, relubrication has the purpose of protecting the bare ropesurface against increased corrosion.We recommend relubricating track ropes regularly until a protective coating has built-up. After that,yearly relubrication is generally sufficient. Relubrication should be carried out after a visualinspection.

3.1.3 Frequency of Relubricating Tension / Counterweight Ropes

In the case of tension ropes, relubrication has the purpose of ensuring that the wires can move.Tension and counterweight ropes have to be relubricated at least every three months. During therequired visual or non-destructive inspections, the type of lubrication and the frequency ofrelubrication may need to be adjusted.

1Bending cycles: one turn around a drive or deflection bullwheel


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Caut ion:

In special rope areas (see point 3.5) or in the case of special environmental conditions, for

example high humidity, the lubricant type and frequency of relubrication may need to bereviewed and adjusted.

3.2 Selection of Lubricant

For every initial lubricant (see rope certificates) there is a corresponding lubricant for re-lubrication.Most lubricants are the same as the initial lubricants, but do contain solvents. The compatibility ofthe relubricant with the initial lubricant cannot be guaranteed if it is from a different manufacturerand therefore needs to be checked.

Requi rements fo r lubr icant of st randed rop es:

The relubricant must comply with the requirements of EN 12385-8, appendix A.

Friction coefficient at 20C: > 0.22 (DIN 21258)

Flash point: > 55 C (ISO 2592)

Acidity: < 0.5 mg KOH/g (DIN 21258)

Reduction of liner hardness: < 10 Shore A

Modification in volume filler material: < 20% (DIN 23521)

Adhesive strength and plasticity in compliance with DIN 21258

The compatibility must be confirmed by the lubricant supplier and by the rope manufacturer. Datasheets for the initial lubricants used by FATZER are available on request.Lubricants with excessive solvents can affect the initial lubricant or can wash it out. Excessivedilution should therefore be avoided.

Requi rements for lubr icant of Track Rop es:

Lubricants must be compatible with the basic lubricant.The compatibility must be confirmed by the lubricant supplier and by the rope manufacturer. Datasheets for the initial lubricants used by FATZER are available on request.

Warning:

For ropeways equipped with track rope brakes, relubricants must be chosen in accordancewith the ropeway manufacturers requirements for the minimum friction coefficient betweenthe track rope and the braking surfaces.

3.3 Quantity of Lubricants

When applying the lubricant, irrespective of the method of application, the correct amount must beapplied. Too little lubricant has no effect and too much of it will cause problems such as soiling ofthe station, line equipment and carriers as well as damaging the bullwheel liners, interfering withthe friction coefficient on the drive bullwheel, or polluting the environment, etc.Depending on requirements and frequency, the quantity of lubricant for stranded ropes should notexceed 30 g/m2of rope surface for track ropes and it should never be more than 15 g/m2of ropesurface (lubricant not counting solvent content).

The following diagram shows the approximate quantity of lubricant to be applied (not counting

solvent content) for each 1,000m of rope, depending on the rope diameter, and for differentquantities per square meter of rope.


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The basic principle is: apply smaller quantities of lubricant, but lubricate more frequently.Where there is a lack of experience with a particular installation, it is recommended that atrial be conducted on a 100 m section of the rope before the actual relubrication, in order todetermine the right quantity and the drying time, therefore avoiding the danger of excessivelubrication and any problems arising from this.

3.4 Applying the Lubricant

3.4.1 Stranded Ropes

Ropes should only be relubricated when they are dry and under warm weather conditions.

Warning:

While it is a requirement that the lubricant must be applied while operating the ropeway toensure that the lubricant properly penetrates between the wires, all necessary precautionsfor worker safety and equipment safety must be taken into account.

Deposits of lubricant and a reduction of friction in the drive (slipping) must be avoided. Thebest place to apply the lubricant is, on the outgoing side of the drive bullwheel or on the

incoming side of the return or deflection bullwheel.


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Example: Position of lubrication device for hauling ropes in cable cars

Example: Position of relubrication device for hauling rope on revolving ropeways

Example: Inefficient point of lubrication in direction of free rope area

Point of relubrication:

Before deflection

Point of relubrication:Before last deflection inreturn terminal or in drive

terminal


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Relubrication device for stranded ropes

3.4.2 Track Ropes

Ropes should only be lubricated when they are dry and under warm weather conditions with littlewind. The most important area of a track rope to lubricate is the section of the rope that is notdirectly contacted by a sheave, saddle or roller chain.

Warning:

It is important to avoid deposits of lubricant on carriage sheaves. This can be achieved bycareful positioning of the spray nozzles.

Depending on the model of the lubrication device, the spray nozzles can be closedindividually.

Relubrication device for track ropes

3.4.3 Drying Time

After relubrication, the rope should not be used right away - the drying time of the lubricant must bechecked and verified before returning the installation into service.

Warning:

At least 95% of the solvent content should have evaporated before resuming operation.


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3.5.2 Area of Bollard / Reel for Track Rope Reserve

Ropes on and in the area of the bollard and on the reserve reel must be protected againstcorrosion. Independent of the general relubrication of the rope, these areas require regular

application of external lubrication to ensure that no moisture damages the rope. The interval forrelubrication should be based on regular inspections of these areas and the lubricant used shouldtake into account any special environmental conditions.

Warning:

Should this delicate area of the rope be exposed to the elements, we recommend diligentsurveillance and maintenance of the area.

3.5.3 Roller Chain Area

The rope area on the roller chain is under particular stress. Normally, it is equipped with apermanent lubrication device. The lubricants used in this case have a good viscosity and containsolid lubricants.

Product Requi rements for Lubr icants:

Lubricants must be compatible with initial lubricant used during the manufacture of the rope.Please have the compatibility of the relubricant confirmed by the lubricant supplier and by the ropemanufacturer. Data sheets for the initial lubricants used by FATZER are available on request.

Warning:

These viscous lubricants should only be applied in the roller chain rope area. The position

and layout of the permanent lubrication device has to cover all of the deflection area of thetrack rope. Once the lubrication process is started, it must never be stopped.

Example: Permanent lubrication

3.5.4 Saddle Areas of Track Ropes

The section of the rope which rest on the saddles are also exposed to higher strain than the opensections of the rope. Adequate lubrication between the saddle point and the rope ensures bothsmooth movement of the track ropes in the saddles as well as ensures proper maintenance of thecorresponding bottom of the track rope (danger of accumulation of moisture). As an example,

lubrication of the saddles can be carried out through lubrication grooves at the saddle point, thusguaranteeing a constant film of lubricant between the rope and the saddle.


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Warning:

The sliding and adhesion coefficient of the lubricant should be as similar as possible to

allow smooth movement of the rope. To prevent water from entering the saddles as it runs down the track rope, a special device

can be fitted (for example drip edge).

Example: Drip edge

Warning:

Solid particles between the saddle and the rope can severely damage the rope.

Care must be taken if pneumatic/hydraulic grease pumps are used, as the steel balls of the

lubricating nipples can be pressed out.

3.5.5 Tension / Counterweight Ropes

The lubricant must be applied to the whole length of the rope. In particular, the areas of the ropewhich are bent by the deflection sheave must be relubricated (total length of deflection plus 1metre along the rope on both sides).

Ropes should be dry when being relubricated.The transition area between the tension rope and the end sockets must be inspected regularly forcorrosion or damage and maintained accordingly.

Documents

wire Rope Maintenance En