Document Title: Fiber Rope Selection, Inspection, Use, Handling and Storage COPI Doc No.: ID-G-BU-YH0-PRO-GN-00-0019

 

Document Title:

Fiber Rope Selection, Inspection, Use, Handling and Storage

COPI Doc No.:

ID-G-BU-YH0-PRO-GN-00-0019

Originator: COPI Group Owner: Area: Location: System: Document Type: Discipline / Subdiscipline: Old COPI Document No.:

1

Rev

IFU

Status

15.02.2010

Issue Date

COPI Project - HSE General General General Procedure/Work Instruction/Job Note Project / HSE -

Issued for Use

Reason for Issue

Didik Swaradi

Prepared

Fred McFadden

Don Sample

Tony Evers

Not Reqd

Unit Owner

Snr. Manager

VP Projects

Checked

 Approvals

Printed initials in the approval boxes confirm that the document has been signed. The originals are held within Document Management.

 

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 2 of 11

Revision Sheet ConocoPhillips Indonesia Inc. Ltd

REVISION

DATE

0A

DESCRIPTION OF CHANGE Issued for Comment

1

15.02.2010

Issued for Use

Additional Approvers (If Applicable) Name

Designation

Signature

Date

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 3 of 11

Table of Contents 1.0 

SCOPE ........................................................................................................................................ .......................................................................................................................................... .. 4 

2.0 

DEFINITIONS DEFINI TIONS .................................................................... ................................................................................................................................ ............................................................4  

3.0 

LIMITATIONS LIMITA TIONS / ALLOWABLE ALLOWABLE USES ........................................................................................... ........................................................................................... 4 

4.0 

ROPE CONSTRUCTION CONSTRUCTION ....................................... ............................................................................................................. ........................................................................ .. 4  

5.0 

SIZES OF ROPE ................................................................................................... ........................................................................................................................... ........................ 5 

6.0 

ROPE MATERIALS MATERIALS ....................................................................................................................... ....................................................................................................................... 5 

7.0 

STRENGTH................................................................................................................................... ................................................................................................................................... 6 

8.0 

FORMAL FORMA L AND INFORMAL INFORMAL INSPECTIONS INSPECTIONS .......... ................................................................................ ........................................................................ .. 6 

9.0 

HANDLING, HAND LING, USE AND STORAGE ............................................................................................... 8 

TABLE 1  – COMPARISON CHART FOR NEW FIBER (AT LEAST 70 F AND 65% RH) TABLE 2 - ALLOWABLE LOADS AND WEIGHTS OF NEW FIBER ROPE TABLE 3  – EFFECTS OF HOT SURFACES/TEMPERATURE AND STRENGH LOSS ATTACHMENT 1  – EXAMPLES OF DAMAGE TO OUTSIDE ROPE

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 4 of 11

1.0

SCOPE This procedure describes the types, sizes, materials, and strengths of the most commonly used fiber rope, as well as the requirements related to their inspection, handling, storage storage and allowable allowable uses. It primarily applies to fiber fiber rope used for raising or lowering material by hand or in conjunction with well wheels or rope hoists; however, materials, strengths, inspection, inspection, handling and storage apply tto o all fiber rope regardless of of use. Fiber rope used exclusively exclusively for “warning barricades” barricades” does not not require insp inspection. However, warning barricades shall no nott be usedformal for lifting orection. securing material.fiber rope used for warning

2.0

DEFINITIONS COPI  – ConocoPhillips Indonesia Qualified Person  Person  –   –  Designated contractor employee who by extensive training, knowledge, and experience has demonstrated their ability to perform formal rope inspections and splices.

3.0

4.0

LIMITATIONS / ALLOWABLE USES 3.1

Fiber rope shall not be used in conjunction with with a crane, or other powered equipment, or mechanical lifting devices such as a chain fall, to raise or lower material or equipment. Wire rope or synthetic slings slings shall be used for this purpose.

3.2

Fiber rope used as part of personal fall-arrest or fall-restrain systems such as life lines, rope grabs, floats and boatswain’s chairs, shall be rated for such use, and shall not be used for any other purpose.

3.2

Fiber rope used for lifting/h lifting/hoisting oisting shall not be used as any part of a personal fall-arrest, fall-restraint or personnel suspension system.

ROPE CONSTRUCTION 4.1

Fiber rope is classed as plant fiber or synthetic fiber. detailed in Section 6.

4.2

Fiber rope usually is made with 3 strands. However, in special cases, it may be made of 4, 5, or 6 strands.

4.3

For abrasive service, a rope made of four strands laid around a small rope core is recommended. This rope is more nearly round and smooth and reduces the effect of abrasion.

4.4

Fiber rope is laid right-handed. right-han ded. The strands may be laid either tightly or loosely and classified as:   Hard-laid  –   –  Strands are laid tightly making the rope stiffer and more resistant to abrasion. Soft-laid  –   –  Strands are laid loosely making the rope more limp but   stronger than hard-laid. Medium-laid  –   –  A compromise between hard- and soft-laid ropes and is   recommended for general use. 

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The materials are

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 5 of 11

5.0

SIZES OF ROPE 5.1

Fiber rope up to 1 inch diameter generally is referred to by its diameter dimension.

5.2

Fiber rope above 1 inch diameter generally is referred to by the circumference circumference dimension, which is assumed to be 3 times the diameter.

5.3

All tables and references to sizes in this procedure include both the diameter and circumference size.

6.0

ROPE MATERIALS 6.1

Number 1 manila rope manila rope is made using a plant fiber.  

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6.2

Manufactures of manila rope usually identify this grade of rope by a “trade marker,” such as colored inlaid fibers, bands, etc.  etc.  Manila rope that has no manufacturer ’s ’s “trade marker” usually is of a lesser grade manila and shall not be used for hoisting.  Acids and caustics caustics will deteriorate deteriorate manila rope. rope. It is susceptible to deterioration and rotting when exposure to moisture and improperly dried.

Plant fiber such as jute as jute (50  (50 percent strength of manila), sisal  (60  (60 to 75 percent strength of manila), and hemp hemp (80  (80 percent strength of manila) shall not  not  be used in hoisting operations.

6.3

Nylon rope Nylon  rope is a strong, tough rope that:    

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6.4

Polyester   fiber rope handles much like manila rope, but is about twice as strong and:  

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6.5

Handles much like manila manila rope.  rope. Is at least 2 ½ times stronger than manila and stronger than most other common synthetic fiber rope. Has very good resistance to abrasion. Will absorb greater shock loads than most other fiber rope. Is ruined by acid and acid fumes.

Has good resistance to abrasion. Is susceptible to caustic damage. Recommended where minimum stretch is required.

Polypropylene  rope is the lightest and lowest cost of all synthetic fiber ropes. Polypropylene rope Polypropylene Polypropy lene rope:        

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Is flexible. Has minimum stretch. Has excellent shock resistance. Is generally not affected by moisture, acids, alkalis, oil, grease, or other chemicals. Can suffer some sunlight deterioration; black  polypropyl  polypropylene ene is  is better for resistance to sun damage. Should be stored out of sunlight. Must not be confused with  polyethylene   rope which shall not not   be used for hoisting.

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 6 of 11

7.0

6.6

Glass  is a special rope with poor flexibility but with excellent resistance to Glass  chemicals and and heat. Strength is comparable to Polyester  rope.   rope.

6.7

For a tabular comparison of fiber rope properties, see Table 1. 1. 

STRENGTH 7.1

See Table 2  2  for typical allowable loads. Allowable loads are based on a percentage of the minimum breaking strength of new and unused fiber rope  rope  and may vary from manufacturer to manufacturer.

7.2

Allowable loads in Table 2 are calculated using a factor of safety of 5 for manila, 6 for polypropylene, and 9 for nylon and polyester.

7.3

Allowable Allowable loads are strictly guidelines guidelines and apply only to new and unused fiber rope.

7.4

Rope shall never be used above its allowable load rating.

7.5

Heat can dramatically dramatically affect the strength of fiber rope. See Table 3 for examples of the relative effects of heat and temperature on some types of fiber rope.

7.6

Knots and splices affect fiber rope strength:  

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Use only approved knots. Acceptable knots include: square, bowline, clove hitch, round turn with two t wo half hitches, and running bowline. Even the most efficient knots will reduce rope strength to as much as 50%. Knots may be used at the ends of the rope but shall not be used to lengthen a rope used for hoisting.  A splice is stronger than a knot and depending depending on type of splice, will provide 90 to 95% efficiency eff iciency.. Splices shall be made by a qualified person.

7.7

Breaking strength is based on direct pull along a single length of rope.

7.8

Rope loaded to over 75% of its breaking strength will be permanently damaged.

7.9

Two “rules of thumb” – (1) – (1) never lift any object with a rope of less than ½ inch diameter. (2) if an object is too heavy for an individual individual to lift it should not be lifted with a rope by hand. “Too heavy” is considered considered to be 50 lbs. or gre greater ater per person without the use of a mechanical lifting device such as a well wheel or other rope hoist.

8.0

FORMAL AND INFORMAL INSPECTIONS 8.1

Each site/contractor shall have a rope inspection program. Inspections shall be both formal and informal.

8.2

See Attachment 1 for examples of damage to the outside of a rope.

8.3

Formal inspections inspections shall be:   Performed quarterly by a qualified person,   Documented, 

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Shall include marking the rope at both ends using a quarterly-inspection color-coded tape.

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 7 of 11

8.4

Formal inspections shall include an inspection of the outside of the rope:  

Look and feel for broken fibers or other signs o off abuse. Broken fibers are an indication indication of excessive excessive abrasion abrasion or overloading. overloading. If approximately approximately 5 percent of the fibers are broken, the rope shall be condemned.

 

Reduced rope diameter is an indication of having been overloaded.

 

Fiber rope will become dirty from use; however, inspect for excessive dirt

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and grit grit penetrating penetrating between between the fibers fibers making making up the strand. strand. If excessive to the point that it will cause internal wear in the strands, the rope shall be condemned.  

Inspect for excessive oil on the surface of manila rope. This is an indication of excess loading. If found, the rope shall be condemned.

 

Check for strands un-laying, high-stranding, or the presence of a spiral appearance. This will cause uneven uneven distribution distribution of the load on the strands and early rope failure and is cause for condemning the rope.

 

If manila rope is dry and brittle, is should be condemned as it has passed its useful life and load capacity.

 

Inspect for evidence of damage from heat, acids, or other chemicals; or excessive moisture. If manila rope has this damage, damage, it should should be condemned. Synthetic fiber rope should be condemned condemned if it is is not

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resistant to the above exposures. 8.5

Formal inspections shall include an inspection of the inside of the rope:  

Open up the strands by twisting rope in the opposite direction of the lay in several places. places. Do not open open to the extent of kinking the fibers or damaging the rope lay.

 

If excessive broken fibers are found, this is an indication that the rope has been overloaded and it shall be condemned.

 

Interior of the rope should should be as bright bright as a new rope. rope. If discolored or dirty and there are indications of chemical or excessive dirt penetration, the rope should be condemned. condemned.

 

The presence of powder-like sawdust indicates there has been severe internal wear and the rope shall be condemned.

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8.6

Formal inspections should include, if possible, an inspection of the inside of the strands and can usually be accomplished accomplished as follows:  

Pull on several several fibers near near the center of the strand. If they come out in in short pieces, the rope has been overloaded and shall be condemned.

 

Pull out some long fibers near the center of the strand and check for strength. If the fibers break break easily, easily, the rope probably probably has been been chemically attacked and shall be condemned.

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8.7

In addition to the above formal inspection requirements, requirements, for fiber rope having a center core rope, rope, an inspection of the core shall also be conducted. conducted. If the rope has been overloaded, overloaded, the core will be the ffirst irst to fail.

8.8

New rope shall be formally inspected throughout its entire length before it is placed in service.

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 8 of 11

8.9

Contractor shall maintain records of all formal inspections on site and shall make them available to COMPANY PMT personnel on request.

8.10

COMPANY PMT personnel shall periodically inspect contractor’s formal inspection records as well as checking rope condition during field audits.

8.11

Informal inspections inspections shall be performed performed by the user before each each use.  Adequate and effective before-use inspections are critical to the safe use of fiber rope since it is possible that damage can occur immediately after a formal inspection.  

The user shall inspect the rope for obvious defects and the presence of the current quarterly-inspection quarterly-inspection color-coded tape.

 

Contractors shall ensure each user of fiber ropes has sufficient suff icient training to conduct an adequate before-use inspection.

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8.12

9.0

Rope that fails a formal formal or informal inspection shall be cut into short short pieces and discarded.

HANDLING, USE AND STORAGE 9.1

When opening a coil of rope, read the attached manufacturer’s instructions and follow their uncoiling procedure. In general:  

Uncoiling of rope should start wi with th the loose end inside inside the coil. The coil can be laid flat and the rope uncoiled by pulling the loose end up and away from the coil to obtain the desired length.

 

 As rope comes out of the coil, it should unwind in a counterclockwise counterclockwise direction and and may form loops. Loops should should be removed removed carefully carefully to avoid damage-causing kinks.

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9.2

Before cutting rope, whipping shall be applied on both sides of the intended cut to prevent un-lay of the strands, or upsetting the fibers in the strands. Keep rope ends seized.

9.3   9.3

DO NOT: NOT:  

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Drag rope over over dirty or gritty surfaces. surfaces. Abrasion to the outside of the rope will occur, and picking up of gritty particles will cause later internal damage.

 

Wrap or pull pull rope over over sharp edges edges or hot surfaces. surfaces. Use padding padding or softeners to protect the rope.

 

Bend or flex frozen rope.

 

Use fiber rope in areas where excessive heat, acids, chemicals, or chemical fumes/vapors are present unless the rope will resist those atmospheres.

 

Use in the vicinity of welding or burning operations.

 

Use rope that shows signs of cutting, unraveling, or breaking.

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9.4

Synthetic fiber ropes are subject to melt at high temperatures and shall not be used in “high“high-friction” applications. applications.  

9.5

Avoid sudden strains, jerking, etc., since this may cause failure of a rope normally strong enough to handle the load. Use a steady, even pull.

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 9 of 11

9.6

Fiber rope must be stored in a clean, well-ventilated well-ventilat ed area.  

Excessive temperatures (below 20 degrees F or above 180 degrees F) or extremely dry storage conditions (less than 10 percent relative humidity) should be avoided.

 

The ideal storage area should have a temperature of from 50 to 70 degrees F and a relative humidity of 40 to 60 percent.

 

If stored on shelving, shelves should be of a “wood grating design” a minimum of 6 inches above the floor.

 

If hung, hang loosely on large-diameter pegs.

 

If necessary to store on metal or concrete floors, planks shall be used to prevent rope contact with the floor. f loor.

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9.7

Rope that becomes muddy or dirty may be washed with cold water and moderate hose pressure, but never steam.

9.8

If rope has become damp or wet during use, it must be dried before storing.

Table 1  – Comparison Chart for New Fiber Rope (at 70 degrees F and 65 % RH) a 

Material   Material

3/4  – inch dia. rope Minimum breaking Ft/lb strength Lb Lb  

Resistance to

Elongation at 20% of break strength

Use with block and fall

Wet

Dry

Abrasion

 

Aci d

Alka

Water

Sunlight

Rot

Manila

5,400

6.00

5-8%

E

F-G

FG

P

P

F

F

P

Nylon

14,200

7.25

14-23%

G

E

G

P

E

E

G

E

Polyester

12,500

5.7

7-9%

G

G

G

G

P

E

G

E

8,200

9.52

--

E

F

F

E

E

E

G

E

Polypropylene a

 

b

 

Tensile strengths listed are for conditions of 70 degrees F and 65 percent relative humidity. Strength of rope is changed when conditions other than these are encountered. Most chemical solution solutions s and solvents affect rope to varying varying degrees; therefore, care must be taken to prevent contact with them.

Key: E-Excellent

G-Good F-Fair

P-Poor

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 10 of 11

Table 2  – Allowable Loads and Weights of New Fiber Ropea 

Size

Manila

Nylon

Polyester

Polypropylene

Safety factor  – 5 Weight Allowable lb/100 load (lb) ft. 450 7.5

Safety factor  – 9 Weight Allowable lb/100 load (lb) ft. 675 6.5

Safety factor - 9

Safety factor - 6

Dia (in.)

Circ (in.)

1/2

1-1/2

9/16

1-3/4

690

10.4

845

5/8

2

880

13.3

3/4

2-1/4

1,080

7/8

2-3/4

1

Allowable load (lb)

Weight lb/100 ft.

Allowable load (lb)

Weight lb/100 ft.

675

7.9

840

4.6

8.3

845

10.3

1,020

6.0

1,100

10.3

1,055

13.3 13.3

1,160

7.5

16.7

1,500

13.8

1,320

17.5

1,640

10.5

1,540

22.5

2,100

19.5

1,900

25.0

2,300

14.4

3

1,800

27.9

2,640

25.0

2,320

29.4

2,800

17.5

1-1/8

3-1/2

2,400

36.0

3,480

34.0

3,110

39.0

3,600

23.0

1-1/4

3-3/4

2,700

41.8

3,960

38.5

3,500

45.0

4,200

26.5

1-5/16

4

3,000

48.0

4,540

44.0

3,960

51.0

4,800

30.0

1-1/2

4-1/2

3,700

60.0

5,595

54.5

4,940

65.5

6,000

37.5

1-5/8

5

4,500

74.4

6,860

67.0

6,015

79.0

7,300

47.0

1-3/4

5-1/2

5,300

89.5

8,230

81.0

7,155

96.0

8,800

56.5

2 2-1/8

6 6-1/2

6,200 7,200

108.0 125.0

9,710 11,185

95.0 111.0

8,445 9,710

115.0 130.0

10,600 12,400

69.0 81.0

2-1/4

7

8,200

146.0

13,195

129.0

11,295

150.0

14,000

92.5

2-1/2

7-1/2

9,300

167.0

14,775

148.0

12,875

175.0

16,000

106.0

2-5/8

8

10,400

191.0

17,100

165.0

14,460

197.0

18,000

122.0

a

 Tensile strengths listed are for conditions of 70 degrees F and 65 percent relative humidity. Strength of rope is changed when conditions other than these are encountered.

Table 3  – Effects of Hot Surfaces/Temperature Surfaces/Temperature and Strength Loss

Effects of Hot Surfaces ( 287 degrees F) % Loss of Original Strength 13.2% 16.5% 24.6% 100.0% (distorted)

Type of Rope Polyester Nylon Manila Polypropylene

Strength Loss vs. Temperature Type of Rope

68

Temperature (degrees F) 105 140 175

212

Manila

0

-3%

-8%

-20%

-30%

Nylon

0

-2%

-7%

-14%

-20%

Polypropylene

0

-7%

-18%

-30%

-40%

 

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1 Fiber Rope Selection, Inspection, Use, Handling and Storage ConocoPhillips Indonesia Page 11 of 11

Attachment 1 Examples of Damage to Outside Rope

New Rope

Slightly Used Rope

Severely Abraded Rope

Damaged/Distorted Rope

Birdcage

Flattened Area  Area