wire rope failure analysis price

Unfortunately, many phone calls into ITI Field Services begins this way, “We have had an incident with a wire rope and we believe the rope failed. How do we determine the cause of failure?”

Fortunately, the calls come in because wire rope users want to determine cause of failure in an effort to improve their crane, rigging and lifting activities.

A wire rope distributor received a hoist rope and sockets from a rubber-tired gantry. The rope and sockets were returned by the customer who believed the rope and sockets failed. The distributor hired ITI Field Services to conduct an analysis on the rope and sockets to determine the cause of the failure and to produce written documentation.

Based on the findings of the examination, fatigue-type breaks in the wires indicated that the wire rope lost significant strength due to vibration. There was no indication that the rope was overloaded. The poured sockets showed no evidence of abnormalities in the pouring method, wire zinc bonding length or the materials used in the speltering process. The conclusion of the inspection is that rope failed due to fatigue.

Wire rope examination is just one of the many services that is offered by ITI Field Services. ITI has some of the most highly-regarded subject-matter experts in the crane and rigging industry with experience in performance evaluations, litigation, accident investigations, manual development and critical lift planning reviews.

In 1998, a crane load line broke while lifting the south topside module of the Petronius platform, dropping the module into the Gulf of Mexico. The cost was estimated to be around 116 million US dollars. Since 1999 more than 60 people have been killed as a result of wire ropes breaking and more than 65 associated injuries.

Not many people appreciate that there are literally thousands of wire rope designs, most of which can be put into a specific category. According to BS ISO 4309 2010 there are currently more than 25 categories of crane wire rope, each with differing characteristics and also different discard criteria. Deterioration can be measured, counted or calculated and the wire rope eventually taken out of service based on sophisticated discard criteria published in chosen standards, codes of practice or users handbooks.

Unfortunately there is no simple answer to either of these questions. All wire ropes will eventually break due to corrosion, wear or fatigue even if they are maintained and used properly. Unpredictable wire rope failures will inevitably occur, quite often when you least expect it if the discard criteria is ignored, or those using the equipment are ignorant of it.

James Dawes of Topeka, Illinois, was killed in 2008 after being struck by the boom of a Link-Belt crane; the accident was caused by the boom hoist wire rope breaking. The crane rope had been inspected, but a report said that the inspector failed to reject the rope showing a high number of visible wire breaks. Premature or unexpected wire rope failures can also be attributed to poor manufacture, incorrect handling and storage, poor installation technique, poor selection or fitting of its termination, infrequent or inadequate inspection and poor maintenance. Of course there is always the possibility that mechanical damage can occur and this is usually attributed to human error.

It is necessary, particularly during offshore operations that frequent inspections are carried out over the whole length of the working part of all steel wire ropes. The frequency of inspections should be based on the severity of use and risk assessment and particular attention should be paid to the critical areas of the wire rope; areas that are frequently running over sheaves, compensating sheaves and the rope termination to name a few.

If a wire rope has not been subjected to an abnormal environmental condition such as excessive heat, chemical attack or any corrosive solution and it has not been the victim of any form of mechanical damage, then trained operatives and inspectors can reasonably predict the length of time the steel wire rope is likely to last. That prediction, of course, will be dependent on the knowledge and experience of those making it coupled with known facts about the rope, its current condition and the application it is running on. The Inspector should be aware of the previous rope’s history, capacities of loads and the reeving systems employed together with the frequency of use etc.

Various standards and codes of practice have been written by recognized bodies and institutes based on the experience of experts or representatives of corporate organizations who have a vested interest. These standards do offer guidance on when a wire rope should be removed from service based on wear, abrasion and fatigue amongst others things, but none of these standards have any legal status except when they are called up by contract. Indeed they can all be supported or overturned in a court of law by an expert.

The users handbook, or more importantly the safe use instructions do have legal status. In many parts of the world these days, suppliers of cranes or any machinery for that matter, issue safe use instructions with new equipment. Modern applications employ modern wire rope and, in some cases, sheaves and pulleys that are made with materials other than steel. Original equipment manufacturers of such applications may impose discard criteria for the wire rope that is stricter than those in chosen standards. By law the user must follow manufacturers’ instructions.

Wire ropes will deteriorate much more quickly if they go dry and are allowed to remain in that condition. Tests have proven that a dry rope will lose up to 60 % of its expected life if it is not re-lubricated. There are differing schools of thought as to how wire rope should be lubricated. Some believe that a thin lubricant should be applied using a paintbrush. It is thought that this method allows the lubricant to penetrate. Experience has proven however, that thin penetrative lubricants will easily drain away or fly off in hot climates.

Another school of thought, and the one I stand on, is that grease should be pressure lubricated into the rope. This method, if applied properly, will ensure that the grease penetrates the rope pushing out the old lubricant with it and any possible corrosive agents such as salt water and sand. Any lubricant that is used must be compatible with the type that was applied previously and it is a good idea to consider the environment as well.

In any event, wire ropes usually announce that they are about to break. A series of individual wire breaks can be heard. These are likely to go on over several seconds and continuing for up to ten minutes before ultimate failure. Therefore, if operatives understand the warning signals, expensive incidents could be avoided.

Figure 2 shows two pieces of the same rope, the bottom portion quite clearly shows a progression of wire breaks. The operator was able to put the load down before disaster struck. The root cause of this fault was core deterioration brought about by internal corrosion.

To answer the other question on accountability, the list is extensive. Usually the first suspect is the wire rope manufacturer and that may be where the problem lies, but very often that is not the case. What if you were supplied the wrong rope for the application? Maybe you ordered the wrong rope or your buyer bought it from a cheap unapproved manufacturing source.

Perhaps your supplier is responsible, maybe he provided you with a rope that was produced to the wrong specifications. Would you know the difference? Perhaps you were sold a rope that had been stored in the suppliers or manufactures stock for a number of years and, whilst it was there, it hadn’t been properly maintained. Maybe the rope had been badly handled or installed incorrectly. The list of possibilities is endless.

In 1999 a ropeway in the French Alps snapped causing 21 deaths. In 2003, a ropeway wire rope snapped and 7 people died and a further 42 were injured. In 2007 a crane wire rope snapped at New Delhi’s metro, the entire structure tumbled down crushing workers underneath, six people were killed and 13 more were injured. In 2009 26 people were killed and 5 people were injured when a rope failed in a mine and a further 6 people were injured when a lift rope broke inside London’s Tower Bridge.

If you find yourself in the unfortunate situation after the unthinkable premature failure of a wire rope, then you might like to know that there are independent analytical services capable of determining probable cause. One of these is Doncaster Analytical Services Ltd (DAS), they have an independent metallurgical laboratory providing factual analysis and testing of wire rope for any reason (contact Mr Shui Lee, Technical Director, Tel +44(0)1302 556063, email: shui.lee@doncasteranalyticalservices. com).

You do not need a wire rope to fail in order to learn. Careful analysis of discarded ropes can also give you valuable information about your application, the way it operates, and the rope you have been using.

Based on this information, a trained, skilled and experienced inspector will be able to advise on a better crane or wire rope design, or to an improvement in maintenance procedures and safety.

Due to the wide variety of service conditions for wire ropes, they are susceptible to many types of inadequacies and failures. It is important for consumers to frequently inspect wire ropes for signs of wear and fatigue. Wire ropes will inevitably fail if not used according to manufacturing limitations or when routine inspections for fatigue and wear are not properly performed. Eventually, all wire ropes are removed from service when they meet established discard criteria.

Wire ropes are complex machines with a great many moving parts. They require attention, skilled operators, careful maintenance, inspection and lubrication.

In spite of their vital importance, wire ropes are frequently treated as and considered low-tech commodities. Failures are frequently accepted as “inevitable.”

With the appropriate inspections, wire rope failures can be predicted, and expenses and losses reduced. Consider that the price tag of rope failures can easily be in the seven or even eight digit range, and the cost of an inspection is marginal.

Much more dependable than visual inspections, magnetic rope testing (MRT) is a reliable non-destructive evaluation/examination (NDE) procedure used for the in-service inspection of wire ropes. NDE methods allow the detection and evaluation of external as well as internal rope deterioration. This allows the inspection of a rope’s entire cross-section to the core. MRT drastically increases wire rope safety. At the same time, it promises significant annual savings.

Ropes usually degrade internally with no visible indications. Internal deterioration modes include inter-strand nicking that will eventually develop into clusters of internal broken wires and corrosion including corrosion pitting.

External deterioration includes winding-on-drum damage. Urgently needed, suitable inspection equipment and procedures are now available – especially for the quantitative characterization of internal rope deterioration.

But on one particular day in early May of 2009, it wasn’t a boom reaching toward the big Texas sky that was causing people to stop and stare; it was one that was lying in a heap just beside the water, lattice sections bent and lacings twisted into mess of mangled steel and frayed wire rope. “I got the call to investigate the cause of loss on a Manitowoc 888 that was being used to drive underwater pilings at a dock in Port Isabel,” says JR Bristow, of Bristow Truck and Equipment Specialists, an organization based in Ridgewood, NJ that provides failure analysis and appraisals, among other things, for heavy equipment. “The operator was hoisting the boom when it just sort of gave out and crashed to the ground. No one was hurt, but the boom was in bad shape. The initial reserve was set at $500,000.”

Though a half million dollars wasn’t a total loss – the crane was valued at $1.5 million – it was a pretty hefty price to pay for something that, as it turned out, could have been avoided. On lattice-type cranes, booms are raised and lowered using boom hoist wire rope, and when that wire rope shows surface wear or corrosion, or worse, has broken wires within the rope strand, it can fail. It’s usually just a matter of time.

The subsequent investigation that followed revealed that the wire rope used to hoist the boom of the Model 888 had been in an out-of-service condition for quite some time, due to lack of proper lubrication.

“An examination of the failed boom hoist wire rope revealed that the wire rope had gone without the proper lubrication, which was the responsibility of the insured per the attached lease agreement,” Bristow remembers. “I also noted significant broken wires within the rope strands at an average of six to 12 per strand lay. Clearly, if the insured had performed a daily inspection of the boom hoist wire rope as required, that incident would not have happened.”

The broken strand condition that Bristow observed was caused by load cycles that occurred during boom up and boom down functions that were part of the daily operation of the crane. Simultaneous compression and expansion of the wire rope usually occurs as it travels over the hoist sheaves, and that causes the gradual deterioration of the strand wires.

Like many other segments of the crane and rigging industry, the nuances of wire rope are complicated and varied. Considerable time, money and resources have been invested in new technology, new inspection suggestions and new manufacturers. And rightly so. As was the case in Bristow’s example earlier, there’s quite a bit at stake in terms of both human capital and equipment cost.

Python High Performance wire rope, a wire rope manufacturer that has produced a number of resources to assist people in understanding and ultimately purchasing wire rope, clarifies the structure of wire rope on its website www.pythonrope.com.

Python’s site explains that a typical wire rope can contain hundreds of individual wires. These wires are fabricated and formed to operate at close bearing tolerances to one another. When a wire rope bends, each of its many wires slides and adjusts in the bend to accommodate the difference in length between the inside and the outside bend. The sharper the bend, the greater the movement, and the greater capacity for stress on the wire rope.

While manufacturers of wire rope are many and varied, each of the wire ropes they produce have three basic components:The wires, which form the strands and collectively provide the rope strength

According to Python’s site, the greatest differences in wire ropes are found in the number of strands, the construction of strands, the size of the core and the lay direction of the strand versus the core. But what does that mean for the layperson? What should he or she look for when purchasing wire rope?

Tony Fastuca, vice president Python America & High Performance Products, says that most people buy rope based on four ideal standards. “Abrasion resistance, fatigue resistance, flexibility and strength. Those four typical standards often weigh into a purchase decision: he says. “A buyer sometimes has to give a little in one area to get a bit more in another, but a lot of buyers are looking for a good balance of those four standards.”

Whereas other products usually come with an expected lifespan, wire ropes don’t really have an average operational life. “There are records that exist of wire ropes getting two to three years of use, sometimes longer,” says Fastuca. ”But it’s about the level of wear on the rope, not the length of time it’s been in service.”

Just as the crane itself needs to undergo frequent and period inspections, the wire rope does, too. Fastuca talks of the so called “A,B,Cs” of wire rope abuse – abrasion, bending, crushing.

The principle goal of a wire rope inspection is to find potential problems before they manifest into incidents or serious accidents. Inspections should be performed slowly and methodically, with a keen eye for corrosion or broken wires or sections of rope that look questionable. Because the reality of wire rope is that it will fail if it becomes worn out, overloaded, damaged, misused or improperly maintained. It can lead to huge headaches for companies that try to take shortcuts or don’t properly maintain it – a risk that just isn’t worth taking.

The results in Section 2 showed that corrosion reduced the ultimate strain and elongation of bridge cable, however, these two factors have great influence on steel wire fatigue performance. The steel wire mechanical properties undergo some changes due to corrosion, so characteristic fatigue damage AE signals are different with non-corroded steel wires. Currently, there is a dearth of studies on the corroded bridge cable using AE techniques. The research on corroded bridge cable fatigue damage evolution using AE signals is helpful to explain failure mechanism(s) and provide an effective method to determine its safety state. It is necessary to do fatigue testing for corroded bridge cable and offer a research base to assess the safety and predict the remaining life for the bridge cable.

A total of 69 wires were chosen from dismantled stay cables of the 18-year-old TianJin YongHe Bridge. In order to judge damage state according to AE signals, the selected steel wires should have different corrosion degree through the surface detection. In the re-manufactured new stay cable process, from outside to inside, the wires were ranged according to corrosion degree from serious to slight. This would ensure failure occurred first in the outside wires during the fatigue testing. The outside wires" fatigue crack initiation and propagation can be easily observed through visual inspection. The length of the steel wires is 1,750 mm. These steel wires were re-manufactured into new stay cables in Liuzhou OVM Co., Ltd. (China). The cable specimen was fixed on the MTS fatigue testing machine. Force was used to control the fatigue test. All specimens were tested under sinusoidal cyclic loading at a frequency of 5.0 Hz. The initial stress amplitude is 360 MPa, and the stress ratio is 0.5.

Before cable fatigue testing, the cable was tensioned in advance with a 500 kN static loading to investigate the strain difference of the different wires. The mean wire strain was 1,896.18 με and the maximum strain difference of the wire was less than the 3% of the average strain. Therefore, each wire stress was uniform based on these data. The fatigue experiment ignored the effect of nonuniform stress on the fatigue life of the wires. The load-displacement curve of the fatigue performance experiment is presented in Figure 3. Energy released from the wire fracture is clearly reflected on the load-displacement curve. After fracture, the tensile rigidity was reduced and the displacement increased because of the unchanged loading. Wire failure indicates the mutation of the displacement.

This report describes the work performed by the Pacific Northwest Laboratory and its subcontractor Battelle Columbus Laboratories on the Wire Rope Improvement Program during FY-1979 and the first half of FY80. The program, begun in 1975 by the US Bureau of Mines, was transferred to the US Department of Energy (DOE) on October 1, 1978. Since that time, the DOE"s Division of Solid Fuels Mining and Preparation has sponsored the program. To address identified problems and provide information from which behavior of large-diameter wire rope could be better understood, efforts in the following areas were undertaken: large-diameter rope testing, small-diameter rope testing, data analysis and evaluation, wear and failure analysis, load sensor development, and technology transfer. Wire ropes 3/4 in., 1-1/2 in., and 3 in. in diameter were tested in bend-over sheave fatigue. Attempts were made to correlate fatigue life of these ropes. Limited field rope data were available to compare with test results. The modes of failure and wear in laboratory ropes were compared with those seen previously in field ropes. A load sensor was designed and ordered in FY79. It will be connected to the drag rope and jewelry of working draglines during the summer of FY80. Technology transfer was achieved through disseminating written materials, conducting seminars, holding a national symposium, and filming of selected field operations.

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Present work describes the failure analysis of AISI 304 stainless steel consisting of 7x19 construction lanyard wire rope which has failed during service. The microstructures and properties of failed wire rope have been investigated and compared with unused wire rope. Both the periphery and fracture surface of the wire rope display the presence of corrosion debris enriched with O and Cl. The fracture surfaces of the failed and unused wire ropes display intergranular and dimples, respectively…Expand

Significant innovation in science inevitably caused significant breakthrough in technology. The weight of portable wire rope tester is less than 2 kgs, it is 1/6-1/25 of traditional testing equipment. The highest sensitivity of TCK sensor can reach 5v/mT, is beyond 700 times than traditional sensor’s sensitivity. The gap between sensors and rope are 10-30 mm, non-contact wide width inspection is realized, which is not affected by oil sludge, warped wires and rope speed. The device has a high pass capability, unique self open-lock function, ensuring safe testing operation. Humanized interfacial design makes testing operation very convenient. Instant random viewing inspection data, curve, analysis report and digital inspection result can be viewed as soon as inspection is finished. Connecting portable wire rope tester with computer the formal test reported can be printed. It provides users with scientific basis of safe wire rope operation and reasonable wire rope replacement.

Portable wire rope tester can evaluate correctly residual bearing capacity and service life of tested wire rope by inspecting quantitatively percentage loss of metal effective bearing cross-section area caused by internal and external flaws of rope such as broken wires, abrasion, corrosion, fatigue etc, and providing users with scientific basis of safe wire rope operation and reasonable wire rope replacement which conforms to related standard and code. It is a high-tech safeguard which can prevent from wire rope failure, decrease reasonably cost of wire rope and improve operating efficiency.

Weak magnetic inspection technology is an important innovative achievement in the field of wire rope inspection, based on successful discovery made by our country’ scientist on the changes and movement rules of Space Magnetic Field Vector Status. This leading weak magnetic flaws detection technology focuses on 3 innovations and 2 breakthroughs.

Our company takes an active part in drafting China’s Coal Industry Professional Standard (MT/T970-2005): Non destructive and fix quantity detecting method and determinant rule for tight wire on-line, which was issued by the National Development and Reform Commission of China. This is not only China’s first wire rope inspection standard, but also the world’s first standard with assessment rules. The base of this standard is W® weak magnetic inspection technology; therefore,the technical grade of it is much higher than wire rope inspection standard issued by countries such as USA and Europe. The standard’s publication marked that the Chinese wire rope inspection technology is at leading level in the world.

1. instrument can detect quantitatively all kinds of internal and external wire rope flaws such as broken wires, abrasion, corrosion, fatigue, deformation, evaluating residual bearing capacity, safety coefficient and service of tested wire rope.

6. The gap between the internal shell and surface of wire rope is 20-30mm.The relative movement design mode between the guide wheels and wire rope tested is adopted. The pass capacity of rope is not affected generally by deformation of rope, oil sludge, dirt, warped wires etc. It is applicable to inspections under all kinds of severe operation environment.

7. The gap between the internal shell and surface of wire rope is 20-30mm.The relative movement design mode between the guide wheels and wire rope tested is adopted. The pass capacity of rope is not affected generally by deformation of rope, oil sludge, dirt, warped wires etc. It is applicable to inspections under all kinds of severe operation environment.

9. Instant random viewing inspection data, curve, analysis report and digital inspection result can be viewed as soon as inspection is finished. Connecting portable wire rope tester with computer, a formal test reported can be printed

“Weak magnetism sensor” technology: uniquely created by the scientists in our company, its sensitivity is 700 times higher than traditional tester. The sensor has strong resolution, and can inspect quantitatively actual wire rope flaws under various working status.

Quantitative uncertainty for measuring the percentage loss of effective bearing metallic cross-sectional area (LMA) and other flaws such as broken wires, corrosion and abrasion (LF) : ±1%.

By analyzing the original data extracted by TCK•W® testers from the wire rope, TCK•W® patented software is capable of evaluating the working condition of the rope in use. It will not only display the testing result and print out the test report in real time, but also exchange data between the tester and a PC at fast speed;

Applicable to wire rope inspections under complex working conditions and not be affected by the inspectors’ experience or skills, rope speed, noise, water spraying, warped wires, oil dirt and other factors;

Capable of quantitatively measuring the percentage loss of effective bearing metallic cross-sectional area (LMA), caused by internal and/or external broken wires, abrasion, corrosion, fatigue and other defects and thereby evaluate the residual bearing capacity and service life of the inspected wire rope.

1. TCK.W-BX Wire Rope Flaws Quantitative Inspection (Lower computer) built-in professional software inside the wire rope tester, assist to realize the calibration of test benchmark, real-time signal collection, data storage, pretreatment, info retrieval, memory management and instrument self-checking during wire rope online inspection.

Used for handle of testing data, assist to realize data transferring, curve analysis, tabulation management, display & print, storage & filing. Computer terminal: Fig(2), Fig.(3)

Manual analysis for each wire rope inspection made by portable wire rope tester is not necessary; only need connecting with PC and printer, can a test report with analysis result be printed any time.