THETA MARINE CONSULTING
MOORING WINCHES & MOORING LINES (WIRES & ROPES) INSPECTION / MAINTENANCE & REPLACEMENT PROCEDURES & LOG
THETA MARINE CONSULTING LTD. theta@thetamarine.net www.thetamarine.net
MOORING WINCHES & MOORING LINES (WIRES & ROPES)
M/T - M/V “ ” IMO No:
MOORING WINCHES & MOORING LINES (WIRES & ROPES)
Note: This document was developed based on "information supplied by the ship owner and / or the ship manager,
and / or the ship operator".
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RECORD OF CHANGES
No.
Date
Revised Part
Revision Detail / Description
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VESSEL PARTICULARS Ship’s Name: Ship’s Type: Flag: Port of Registry: Call Sign: IMO Number: Classification Gross Tonnage: Net Tonnage: Built by: Year Built:
Company's Name: Company's IMO : Address : Telephone / E.Mail / Fax :
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Table of Contents VESSEL PARTICULARS ........................................................................................................................ 4 SECTION 1. VERIFICATION BY SUPERINTENDENTS FOR THE CORRECT KEEPING OF THIS LOG ........ 8 SECTION 2. MOORING PLAN ............................................................................................................ 10 SECTION 3. MOORING LINES REPLACEMENT & INSPECTION PROCEDURES ......................... 12
3.0 General .................................................................................................................................... 12 SECTION 3A. MOORING WIRES REPLACEMENT & INSPECTION PROCEDURES ..................... 13
3A.0 General .................................................................................................................................... 13 3A.1 The nature and number of broken wires (a) ...................................................................... 13 3A.2 Broken Wires at Termination (b).......................................................................................... 14 3A.3 Localized Grouping of wire breaks (c) ................................................................................ 14 3A.4 Rate of Increase of Broken Wires (d) ................................................................................. 14 3A.5 The Fracture of Strands (e) .................................................................................................. 14 3A.6 Reduction of Rope Diameter Resulting from Core deterioration (f) ............................... 15 3A.7 Decreased elasticity (g) ........................................................................................................ 15 3A.8 External Wear (h) ................................................................................................................... 16 3A.9 External and internal corrosion (i) ....................................................................................... 16 3A.10 Deformation (j)...................................................................................................................... 17 3A.11 Damage due to heat or electric arcing (k) ........................................................................ 19 3A.12 Locating of Wire Breaks..................................................................................................... 20 3A.13 Removal of Wire Rope from Service ............................................................................... 22 3A.14 Wire Tails .......................................................................................................................... 22 SECTION 3B. MOORING ROPES REPLACEMENT & INSPECTION PROCEDURES ..................... 24
3B.0 Mooring Equipment ......................................................................................................... 24 3B.1 Ropes and Mooring lines care....................................................................................... 24 3B.1.1 Construction ..................................................................................................................... 26 3B.1.2 Rope Handling ................................................................................................................. 28 3B.1.3 Standards for strength and Usage ................................................................................... 31 3B.1.4 Rope Inspection and retirement ....................................................................................... 32 SECTION 4. BREAK HOLDING CAPACITY CERTIFICATE ............................................................. 40 SECTION 5. WINDLASS No.1 - PART.1 MOORING ROPES CERTIFICATES ................................ 43 SECTION 5. WINDLASS No.1 - PART.2 MAINTENANCE HISTORY ............................................... 45 A) CHIPPING / PAINTING OF MACHINERY ........................................................................................... 45 B) LUBRICATION / GREASING OF THE MACHINERY ......................................................................... 46 C) RENEWAL OR REVERSAL OF THE ROPE ....................................................................................... 47 D) MECHANICAL REPAIRS (BRAKE BAND RENEWALS, FERODO LINING RENEWALS, e.t.c.) 48 SECTION 6. WINDLASS No.2 - PART.1 MOORING ROPES CERTIFICATES ................................ 51 SECTION 6. WINDLASS No.2 - PART.2 MAINTENANCE HISTORY ............................................... 53 A) CHIPPING / PAINTING OF MACHINERY ................................................................................... 53 B) LUBRICATION / GREASING OF THE MACHINERY .................................................................. 54 C) RENEWAL OR REVERSAL OF THE ROPE ............................................................................... 55 D) MECHANICAL REPAIRS (BRAKE BAND RENEWALS, FERODO LINING RENEWALS, e.t.c.) 56 SECTION 7. MOORING WINCH No.1 - PART.1 MOORING ROPES CERTIFICATES..................... 59 SECTION 7. MOORING WINCH No.1 - PART.2 MAINTENANCE HISTORY ................................... 61 A) CHIPPING / PAINTING OF MACHINERY ................................................................................... 61 B) LUBRICATION / GREASING OF THE MACHINERY .................................................................. 62 C) RENEWAL OR REVERSAL OF THE ROPE ............................................................................... 63 D) MECHANICAL REPAIRS (BRAKE BAND RENEWALS, FERODO LINING RENEWALS, e.t.c.) 64
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SECTION 8. MOORING WINCH No.2 - PART.1 MOORING ROPES CERTIFICATES..................... 67 SECTION 8. MOORING WINCH No.2 - PART.2 MAINTENANCE HISTORY ................................... 69 A) CHIPPING / PAINTING OF MACHINERY ................................................................................... 69 B) LUBRICATION / GREASING OF THE MACHINERY .................................................................. 70 C) RENEWAL OR REVERSAL OF THE ROPE ............................................................................... 71 D) MECHANICAL REPAIRS (BRAKE BAND RENEWALS, FERODO LINING RENEWALS, e.t.c.) 72 SECTION 9. MOORING WINCH No.3 - PART.1 MOORING ROPES CERTIFICATES..................... 75 SECTION 9. MOORING WINCH No.3 - PART.2 MAINTENANCE HISTORY ................................... 77 A) CHIPPING / PAINTING OF MACHINERY ................................................................................... 77 B) LUBRICATION / GREASING OF THE MACHINERY .................................................................. 78 C) RENEWAL OR REVERSAL OF THE ROPE ............................................................................... 79 D) MECHANICAL REPAIRS (BRAKE BAND RENEWALS, FERODO LINING RENEWALS, e.t.c.) 80 SECTION 10. MOORING WINCH No.4 - PART.1 MOORING ROPES CERTIFICATES.................... 82 SECTION 10. MOORING WINCH No.4 - PART.2 MAINTENANCE HISTORY ................................. 84 A) CHIPPING / PAINTING OF MACHINERY ................................................................................... 84 B) LUBRICATION / GREASING OF THE MACHINERY .................................................................. 85 C) RENEWAL OR REVERSAL OF THE ROPE ............................................................................... 86 D) MECHANICAL REPAIRS (BRAKE BAND RENEWALS, FERODO LINING RENEWALS, e.t.c.) 87
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SECTION - 1 VERIFICATION BY OFFICE SUPERINTENDENTS
SECTION - 2 MOORING PLAN
SECTION - 3 MOORING LINES REPLACEMENT & INSPECTION PROCEDURES
MOORING WINCHES & MOORING LINES (WIRES & ROPES)
SECTION 3
MOORING LINES REPLACEMENT & INPSECTION PROCEDURES
3A.6 Reduction of Rope Diameter Resulting from Core deterioration (f) Reduction of rope diameter resulting from deterioration of the core can be caused by :
Internal wear and wire indentation Internal wear caused by friction between individual strands and wires in the rope, particularly when it is subject to bending. Fracture of a steel core.
If these factors cause the actual rope diameter to decrease by 10%, the rope should be discarded even if no broken wires are visible.
Note: New ropes will normally have an actual diameter greater than the nominal diameter. Low values of deterioration might not be so apparent from normal examination. However, the condition can result in a high loss of rope strength. Any evidence of such internal deterioration should be verified by internal examination. If such deterioration is confirmed, the rope should be discarded.
Figure-2 : Reduction in Wire Rope Diameter.
3A.7 Decreased elasticity (g) Upon certain circumstances usually associated with the working environment, a rope can sustain a substantial decrease in elasticity and be unsafe for further use. Decreased elasticity is difficult to detect. If the examiner has any doubt, advice should be obtained from a specialist in wire ropes. However, it is usually associated with the following:
Reduction in rope diameter Elongation of the rope lay length Lack of clearance between individual wires and between strands caused by the compression of the component parts against each other. Appearance of fine, brown powder between or within the strands. Increased stiffness. While no wire breaks may be visible, the wire rope will be noticeably stiffer to handle and will certainly have a reduction in diameter greater than that related purely to wear of individual wires. This condition can lead to abrupt failure under dynamic loading and is sufficient justification for immediate discard. Issue No.01 / Date: 01.06.2015
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Figure-3 : Rope Stretch Leading to Decreased Elasticity
3A.8 External Wear (h) Abrasion of the outer strands of the rope results from rubbing contact, especially under load, with fittings such as chocks and fairleads. Wear is promoted by lack of incorrect lubrication and also by the presence of dust and grit. Wear reduces the strength of ropes by reducing the cross-sectional area of the steel strands. If the actual rope diameter has decreased due to external wear by 7% or more of the nominal rope diameter even if no wire breaks are visible, the rope should be discarded. 3A.9 External and internal corrosion (i) Corrosion is a particular problem in marine and polluted industrial atmospheres. It will diminish the breaking strength of the rope by reducing the metallic cross-sectional area. It will accelerate fatigue by causing surface irregularities, which lead to stress cracking. Severe corrosion can cause decreased elasticity of the rope.
External Corrosion
Corrosion of the outer surface of the wire can be detected visually. Wire slackness due to corrosion attack / steel loss is justification for immediate rope discard.
Internal Corrosion
This condition is more difficult to detect than the external corrosion that frequently accompanies it, but the following indications can be recognized:
Variation in rope diameter
Loss of clearance between the strands in the outer layer of the rope frequently combined with wire breaks between or within the strands. If there is any indication of internal corrosion, the rope should be subjected to internal examination carried out by a competent person. Confirmation of severe internal corrosion is justification for immediate rope discard.
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cause will be corrosion and the rope should be immediately discarded.
Figure-8: Loose Wires
ďƒ˜ Nodes A node is a local increase in rope diameter with the core easily visible between several covering strands. It can be caused by shock loading or, in the case of fiber main core ropes, by the absorption of moisture. A node is a justification for discard.
Figure-9: Nodes
ďƒ˜ Flat areas Flattering can be caused by bending the rope severely over the rim of a sheave or any sharp object with the wires on the inside of the bend being forced out of position. Ropes with flat areas should be discarded.
Figure-10: Flat Areas
3A.11 Damage due to heat or electric arcing (k) Ropes that have been subjected to exceptional thermal effects, externally recognized by the colors produced in the rope, should be immediately discarded. Heating rope wires to approximately 3000C and over will lead to considerable reduction in tensile strength of the wires.
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3A.13 Removal of Wire Rope from Service Mooring wire stowed on winches should wherever practical be protected from the elements by a plastic cove. Vessels exempt from this requirement on voyages less than 48 hours in duration. Mooring wires should be kept greased / lubricated. The majority of wear and tear to wires is likely to occur at the working end. Wires should thus be end for ended during shipyard repair periods. Wires must be inspected by the C/O at intervals not exceeding 6 months and recorded in the form CMS/045. “Inventory of Ship’s wires and ropes”. Mooring wires should be renewed at intervals not exceeding 5 years from the date of fitting, unless thorough inspection ascertains that they are fit for further use. Only qualified and experienced personnel, taking the appropriate safety precautions and wearing the appropriate protective clothing, should be responsible for removing wire rope from service. Care should be taken when removing the condemned rope from drums as it may be grossly distorted, lively and tightly coiled. Discarded rope should be stored in a safe and secure location suitably marked to identify it as rope that has been removed from service and is not to be used again. The date and reason for discard should be recorded on the rope’s certificate before it is filed for future reference. Attention should be paid to any regulations affecting the safe disposal of steel wire rope.
3A.14 Wire Tails In order to introduce an element of elasticity into wire moorings, wire lines should generally be used in conjunction with 11 meter tails. Tails must have a minimum breaking load at least 25% greater than that of the wire to which they are attached. Α record of all tails together with their date of fitting and 6 monthly inspection must be maintained in the form CMS/045. “Inventory of Ship’s wires and ropes”. Each tail must be provided with a test Certificate. Mooring wire tails must be renewed at intervals not exceeding 18 months from date of fitting, unless observed in very good condition; in this case renewal may be brought ahead for time interval defined on case-by-case basis by the technical department. Tails should be replaced prior to their residual strength falling to 60% of their original MBL. All vessels are supplied and fitted with Tongsberg or Mandal mooring shackles. In order to avoid confusion and possible incorrect installation, the simple rule is:
a. Tongsberg - Fibre rope on bolt. Wire rope around the body.
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3B.1.1 Construction
The below figure shows the common structures used in synthetic ropes. The four and six-strand with core structures are twisted ropes similar to conventional wire rope and are sometimes used for mooring lines. They may be prone to hock ling. The eight- strand (sometimes called square braid or plaited) and twelve-strand braided ropes are constructed of left and right-hand laid strands to give a torque-free rope. They are easily splice able and provide a good rope structure for mooring lines. Double braid ropes, sometimes called braid-on-braid, are constructed of a core braided of many small strands and surrounded by a cover that is also braided of many small strands. The cover provided an integral component to the line’s strength and neither the core nor the cover should provide more than 55% of the overall weight. They are commonly used for mooring hawsers at single point moorings (SPMs) and for tails on wire ropes. Parallel strand ropes have the core ropes protected by a non-load bearing protective jacket. They are commonly used for regular mooring ropes and as SPM mooring hawsers.
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Figure-a: Construction of Conventional and High Modulus Synthetic Fiber Ropes
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The ratio of the length of an eye splice to the diameter of the object over which the eye is to be placed (bollard bitt clear etc) should be a minimum three to one relationship and preferably five to one. In other words, if there is a bollard two feet in diameter the eye splice should be six or ten feet in length. By issuing this ratio the angle of the two legs of the eye splice at its throat will not be so severe as to cause a parting or tearing action at this point (thimbles are normally designed with three to one ratio). Winch and Sheave Winding Rope – Tug assist lines A minimum of the first 3-4 wrap layers of rope around the winch storage drum should be installed so the rope has a close and tight fit on the drum. The installation tension on the rope should be approximately 10% of the rope's minimum breaking strength. For ne rope installations, the greater the number of warp layers installed under the suggested tension will minimize or prevent subsequent wraps for diving or buying down into lower wraps. As the rope is used, the wrap tensions may loosen, it is suggested the total rope be -tensioned at original installation loads and thereby prevent potential downward wrap slippage. A single drum or split drum winch, should always keep minimum of eight wraps of rope on the drum at all times. This is to insure that the connecting point of the rope to the winch does not undergo load.
Winding Rope – Mooring Lines The mooring line should be installed on the winch storage drum under tension that can be created by running the rope around a capstan, bollard, or pin. There are two key factors, it is important the rope be installed with tension and in a close tight fit on the drum to prevent rope diving or burying into the lower wrap layers. It is also important that the surface of the device used to create the tension is not abrasive to the rope and the installation speed or tension applied does not generate excessive heat build up on the rope. A single drum or split drum winch, should always keep a minimum of eight wraps of rope on the drum at all times. This is to ensure that the connecting point of the rope to the winch does not undergo load.
In connecting the rope to the winch drum flange, it is suggested that the end of the rope either be back spliced or whipped to create better rope firmness for the flange connection bracket to compress upon. Sheave Recommendations To assure maximum efficiency and safety, the sheave diameter should not be less than recommended by type of rope construction. The sheave groove diameter should be no less than 10% greater than the rope diameter and the groove should be round in shape. Sheaves with "V" shaped grooves should be avoided, as they tend to pinch and damage the rope through friction and crushing of the fibers. Sheave surfaces should be kept smooth and free of burs and gouges. Bearing should be maintained to ensure smooth rotation of sheaves.
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3B.1.3 Standards for strength and Usage Working Loads Working loads are for rope in good condition with appropriate splices, in noncritical applications and under normal service conditions. Working loads are based on a percentage of the approximate breaking strength of new and unused rope of current manufacture. For the threestrand, eight strand, twelve-strand, twenty four - strand and double braid rope products depicted in this manual, when used under normal conditions, the working load percentage is 20% of published strengths. Normal working loads do not cover dynamic conditions such as shock loads or sustained loads, nor do they cover where life, limb or valuable property are involved. In these cases a lower working load must be used. A higher working load may be selected only with expert knowledge of conditions and professional estimates of risk, if the rope has been inspected and found to be in good condition, and if the rope has not been subject to dynamic loading (such as sudden drops, snubs or pickups), excessive use, elevated temperatures, or extended periods under load. Normal Working Loads Normal working loads are not applicable when rope has been subject to dynamic loading. Whenever a load is picked up, stopped, moved or swung there is an increased force due to dynamic loading. The more rapidly or suddenly such actions occur, the greater the increase will be. In extreme cases, the force put on the rope may be two, three, or even more times the normal load involved. Examples could be ropes used as a tow line, picking up a load on a slack line, or using rope to stop a falling object. Dynamic effects are greater on a low elongation rope such as polyester than on a high elongation rope such as nylon, and greater on a short rope than on a long one. Therefore, in all such applications normal working loads as given do not apply. Dynamic loading For dynamic loading applications involving severe exposure conditions, or for recommendations on special applications, consult the manufacturer. Danger to Personnel Persons should be warned against the serious danger of standing in line with a rope under tension. Should the rope part, it may recoil with considerable force and speed. In all cases where any such risks are present, or where there is any question about the load involved or the condition of use, the working load should be substantially reduced and the rope properly inspected before every use. Splicing & Knots Splices should be used instead of knots whenever possible because knots can decrease rope strength up to 50%. When splices are used, always use the manufacturer's recommended splicing procedures. When knots are used, be sure to take into consideration the knot's corresponding reduction to the rope strength and adjust your working load accordingly. Rope Inspection Avoid using rope that shows signs of aging and wear. If in doubt, destroy the used rope. No type of visual inspection can be guaranteed to accurately and precisely determine the actual residual strength. When the fibers show wear in any given area, the rope should be re-spliced, downgraded, or replaced. Check the line regularly for frayed strands and broken yarns. Pulled strands should be re-threaded into the rope if possible. A pulled strand can snag on a foreign object during rope operation. Both outer and inner rope fibers contribute to the strength of the rope. When either is worn, the rope is naturally weakened. Open the strands of the rope and look for powdered fiber, which is one sign of internal wear. A heavily used rope will often become Issue No.01 / Date: 01.06.2015
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MOORING LINES REPLACEMENT & INPSECTION PROCEDURES
R e c o m m e n d e d
W o r k
Load
L i m i t s
Constructions
Working Load (% of break strength)
3 strand
20%
8 strand
20%
12 strand
20%
Double braid
20%
Bending: Any sharp bend in a rope under load decreases its strength substantially and may cause premature damage and failure. Sheave diameters on rotating sheave blocks should be 10 times the rope diameter for twisted ropes and eight times the rope diameter for braided ropes. The diameter on fixed pin terminations should be at least three times the rope diameter (i.e. the bending radius for 1/2" ropes should be 1-1/2"). Knots: While it is true that a knot reduces rope strength, it is also true that a knot is a convenient way to accomplish rope attachment. The strength loss is a result of the tight bends that occur in the knot. With some knots, ropes can lose up to 50% of their strength. It is vital that the reduction in strength by the use of knots be taken into account when determining the size and strength of a rope to be used in an application. To avoid knot strength reduction, it is recommended that a rope be spliced according to the manufacturer's instructions. Splice terminations are used in all our ropes to determine new and unused tensile strengths. Therefore, whenever possible, spliced terminations should be used to maximize the rope strength for new and used ropes. Rope Storage: Keep your ropes as clean and dry as possible and store them in a coil away from heat sources.
Shock Loads: Shock loads are simply a sudden change in tension from a state of relaxation or low load to one of high load. Any sudden load that exceeds the work load by more than 10% is considered a shock load. The further an object falls, the greater the impact. Synthetic fibers have a memory and retain the effects of being overloaded or shock loaded and can fail at a later time even though loaded within the work load range.
STEP 3. Retirement Retire rope from use when it has reached its discard point. One of the most frequently asked a question is "When should I retire my rope?" The most obvious answer is before it breaks. But, without a thorough understanding of how to inspect it and knowing the load history, you are left making an educated guess. Unfortunately, there are neither definitive rules nor industry guidelines to establish when a rope should be retired because there are so many variables that affect rope strength. Factors like load history, bending radius, abrasion, chemical exposure or some combination of those factors make retirement decisions difficult. Inspecting your rope should be a continuous process of observation before, during and after each use. In synthetic fiber ropes the amount of strength loss due to abrasion and/or flexing is directly related to the amount of broken fiber in the rope's cross section. After each use, look and feel along every inch of the rope length inspecting for abrasion, glossy or glazed areas, inconsistent diameter, discoloration and inconsistencies in texture and stiffness. Understanding the Rope Design / Construction: It is first important to understand the design of the specific rope in use. Most ropes are designed to have features specifically tailored to their Issue No.01 / Date: 01.06.2015
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application. These features can lead to misconceptions during visual inspections. When a rope has a braided cover, it is only possible to visually inspect the cover (which, at best, carries only 50% of the load). Rope designs utilizing HMPE (High Modulus Polyethylene) fibers will show initial rapid abrasion until the rope has a fuzzy appearance — this appearance actually acts as a protective layer. Determining The Average Condition Of The Rope: The average condition of a rope can be an important factor in determining the rope's retirement. To determine the average condition, walk the entire length of the rope and document its overall condition. Many ropes can be classified by the total amount of overall wear and cleanliness.
Fig 1: New Rope
Fig 2: Used Rope
Fig. 3 Severely abraided rope Abrasion When the rope is first put into service the outer filaments of the rope will quickly fuzz up (fig. 2). This is the result of these filaments breaking and this roughened surface actually forms a protective cushion and shield for the fibers underneath. This condition should stabilize, not progress. If the surface roughness increases (fig. 3), excessive abrasion is taking place and strength is being lost. As a general rule for single braid ropes, when there is 25% or more wear from abrasion the rope should be retired from service. In other words, if 25% or more of the fiber is Issue No.01 / Date: 01.06.2015
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SECTION - 4 BREAK HOLDING CAPACITY CERTIFICATE
SECTION - 5 WINDLASS No.1 TWO DRUMS
SECTION - 5 WINDLASS No.1 PART-1 MOORING ROPES CERTIFICATES
SECTION - 5 WINDLASS No.1 PART-2 MAINTENANCE HISTORY
SECTION - 6 WINDLASS No.2 TWO DRUMS
SECTION - 6 WINDLASS No.2 PART-1 MOORING ROPES CERTIFICATES
SECTION - 6 WINDLASS No.2 PART-2 MAINTENANCE HISTORY
SECTION - 7 MOORING WINCH No.1 TWO DRUMS
SECTION - 7 MOORING WINCH No.1 PART-1 MOORING ROPES CERTIFICATES
SECTION - 7 MOORING WINCH No.1 PART-2 MAINTENANCE HISTORY
SECTION - 8 MOORING WINCH No.2 TWO DRUMS
SECTION - 8 MOORING WINCH No.2 PART-1 MOORING ROPES CERTIFICATES
SECTION - 8 MOORING WINCH No.2 PART-2 MAINTENANCE HISTORY
SECTION - 9 MOORING WINCH No.3 TWO DRUMS
SECTION - 9 MOORING WINCH No.3 PART-1 MOORING ROPES CERTIFICATES
SECTION - 9 MOORING WINCH No.3 PART-2 MAINTENANCE HISTORY
SECTION - 10 MOORING WINCH No.4 PART-1 MOORING ROPES CERTIFICATES
SECTION - 10 MOORING WINCH No.4 PART-2 MAINTENANCE HISTORY