Draglines

Wire Rope Reference Guide

CONTENTS
Choosing the right wire rope.. . . . . . . . . . . . . . . . . . . . 2 Wire rope product options.. . . . . . . . . . . . . . . . . . . . . . 4 Wire rope inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Maximizing wire rope service life.. . . . . . . . . . . . . . . . 8 Digging practices for draglines.. . . . . . . . . . . . . . . . . 11

WEVE BEEN MAKING WIRE ROPE FOR DRAGLINES AND SHOVELS FOR OVER 75 YEARS Union, a WireCo WorldGroup brand, is committed to providing the broadest range of wire ropes for all of your mining applications. Our complete line of surface mining ropes, including dragline and shovel ropes, and structural strand boom pendants, offer service and reliability synonymous with the Union name. Buy from the besta company, and products, that are tested, tough and true.

Mining ropes for draglines

t takes more than the right wire ropes to operate your mining equipment. It also takes the right knowledge and experience. When you know the ropes that is, how to choose, use and maintain each of the many types of ropes youll know how to achieve maximum service life and performance for dragline applications. When it comes to showing you the ropes, no one does it like Union, a WireCo WorldGroup brand. As the worlds largest producer of wire rope and wire products, we offer what you need for many different applications. And we offer the right experience to help you when you have questions, including how to help maximize your wire ropes service life and performance. This Wire Rope Reference Guide is only one example. On the following pages, youll gain valuable information to help you: CHOOSE THE RigHT wiRE ROPES Of course, knowing the ropes starts by understanding the wide variety of wire ropes and structural strand available for your many needs. This guide contains practical information to aid you. INSPEcT YOuR ROPES By regularly inspecting wire ropes on draglines, youll not only know when to replace them, but also find unusual wear patterns or abuse that could shorten rope service life. MAXimiZE wiRE ROPE SERVicE LiFE Union can help you get top performance and service life from your wire ropes through proper care and maintenance. This guide offers helpful suggestions in rope maintenance and operation such as moving wear points, identifying and reducing rope damage, lubrication, installation tips and digging methods. TESTEd, TOugh & TruE At Union, we understand the mining market. Our years of climbing on the draglines with you, combined with the latest metallurgical practices and unique design capabilities, have enabled us to continue to innovate and provide the most cost-effective line of mining ropes in the world. Union is one brand of the global leader in manufacturing, engineering and distributing wire rope, wire rope assemblies, high carbon wire, and electromechanical cable: WireCo WorldGroup. We apply thorough design and manufacturing controls including complete material traceability. And WireCo WorldGroup is the only wire rope manufacturer in the world that is QPL qualified, API certified, and registered to both ISO 9001:2000 and AS-9100 Quality Systems.
Buy ThE bEST wirE rOpE: UNiON Tested, Tough & True

Union A WireCo WorldGroup Brand

Choose the right wire rope for your application

ith each application, your choices of wire ropes can be many. How do you know which one will work best for you? All wire ropes have a combination of characteristics that give them specific performance abilities. Before you choose, it pays to match the requirements of an application with the characteristics of the rope.

The two major rope characteristics in mining

crOSS-SEcTiON Of a wOrN wirE > Original cross-section > Worn surface

In the operating ropes of large surface mining equipment, not all characteristics have equal importance. There are two characteristics resistance to metal loss and deformation and fatigue resistance that are usually the main considerations. Most applications require a balance of these two characteristics. METal lOSS aNd dEfOrmaTiON METAL LOSS refers to the actual wearing away of metal from the outer wires of a rope. Metal deformation is the changing of the shape of a ropes outer wire. Both frequently occur at the same time, although one usually predominates. In general, resistance to metal loss by abrasion (also called abrasion resistance) refers to a ropes ability to withstand metal being worn away along its exterior. This is due to the rope having sliding

contact with another hard object. The resulting loss of steel reduces the wire ropes strength and can accelerate the occurrence of broken wires. In most cases, metal loss has three main causes: 1. An improper rope fleet angle. As the rope enters or leaves a sheave, it contacts the sheave flange, causing wear to both the rope and sheave. This can occur on drum grooves, too. 2. Grooves that are too small in a sheave. The rope slides between the flanges as it seats in the groove, causing rope wear. 3. Pulling drag rope through the roll of rock at the edge of the pit can also result in rope surface wear.

crOSS-SEcTiON Of a pEENEd wirE > Original cross-section > Peened surface

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METAL DEFORmATiON (also called peening see illustration at left) is the flattening of the wires external surface caused by slapping against a hard object such as a rock, sheave or a roller. The steel is not worn away, but pushed to the side. The distorted shape of the wires affects and shortens the ropes fatigue life. FaTiguE rESiSTaNcE FATiguE RESiSTANcE involves metal fatigue of the wires that make up a wire rope. Fatigue is normal and will occur in areas of the rope that: 1. Repeatedly bend over sheaves and drums. 2. Dampen vibrations (near end attachments or other points of rope restriction). 3. Are subjected to changes in load.

In general, a rope made of many wires will have greater fatigue resistance than a rope made of fewer, larger wires because smaller wires have greater ability to bend as the rope passes over sheaves or around drums. Lang lay ropes are more fatigue-resistant than regular lay rope. PFV ropes are also more fatigue resistant than standard ropes. Every rope is subject to metal fatigue from bending stress while in operation, and therefore the ropes strength gradually diminishes as the rope is used.
NOTE When a decision is made to try a different rope construction, it is normally best to use several sets of the selected rope construction to determine its average service. This way, you can compare the cost per hour (ton or yard) to the other constructions cost to determine the best rope construction for your application.

If yOu NEEd abraSiON rESiSTaNcE > Abrasion resistance increases with fewer, larger outside wires per strand.

If yOu NEEd faTiguE rESiSTaNcE > Fatigue resistance increases with more, smaller outside wires per strand.

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Wire rope product options

6-STraNd hOiST rOpES Backed by a service-proven reputation, these ropes are built tough to withstand abrasion and fatigue. Available in right lang lay (RL) and left lang lay (LL) with a standard independent wire rope core. POwErMaX An 8-strand wire rope created to provide operating characteristics essential to drag ropes and hoist ropes, and only available from Union. Our proprietary metallurgy was utilized in developing special rod chemistry requirements to provide optimum wire characteristics for mining ropes. The technology combines all aspects of rope manufacturing in one cohesive process that assures a product thats second to none. With eight outer strands, PowerMax is more fatigue resistant than 6-strand ropes of the same diameter, plus, its greater surface area puts more steel in touch with contact surfaces, reducing wear and abrasion.

Just as importantly, no other mining rope is subjected to more rigorous standards of manufacturing than PowerMax. The industrys highest manufacturing standards, continuous tracking and testing, and the use of enhanced plastics in core impregnation give PowerMax a clear-cut edge in drag rope performance. POwErMaX MD Also only available from Union. This unique drag rope was designed specifically for exceptional performance and extended service life on draglines with reverse bend fairlead systems. (See illustration at right.) With unique metallurgy, 8-strand construction and Unions exclusive compaction process, PowerMax MD ropes have set industry standards for drag rope performance and service life. (See chart below.) Built around a plastic-impregnated independent wire rope core (IWRC) are eight compacted strands of cold-drawn,

6 x 49 SwS

pOwErmaX

pOwErmaX md

Union A WireCo WorldGroup Brand

high-carbon steel wires, a construction that delivers the optimal combination of strength and resistance to bending fatigue and abrasion. With eight outer strands fortifying the compacted-strand design of PowerMaxMD, this rope delivers approximately 10% higher minimum breaking strength than standard 6-strand drag ropes and also supplies the fatigue resistance to handle the bending stresses at the fairleads. The strand compaction puts a wider, smoother outer rope surface in contact with the sheaves and drums for much greater abrasion resistance, as well. The specific combination of rope characteristics found in PowerMax MD delivers more hours and more yards with fewer rope changes. PFV plaSTic-imprEgNaTEd rOpES Designed and manufactured to the same exacting standards as our 6- and 8-strand ropes, these ropes are plastic-

POLYMER PENETRATION With one strand and part of the polymer removed, you can see how deep the polymer penetrates into the rope, giving you uniform and continuous support for all strands throughout the length of the rope. 6-STraNd pfv

impregnated. The plastic polymer is applied at high pressure, cushions the strands, distributes internal stresses, keeps in wire rope lubricant and keeps out dirt and debris. This polymer doesnt melt or soften from the heat of normal operating temperatures. Its also virtually unaffected by sunlight and cold weather.

pOwErmaX pfv

RECOMMENDED WIRE ROPES FOR YOUR APPLICATIONS

HOiST ROpES Hoist ropes on draglines require good resistance to both metal fatigue and abrasive wear. PowerMax offers the best overall characteristics for use as hoist ropes on draglines as a result of the 8-strand construction and plastic impregnated/coated core. PowerMax is also available with full PFV coating through 3 - 3/4 diameter. Drag ROpES Draglines with straight-through fairlead systems need drag ropes with maximum resistance to metal loss and deformation. PowerMax is an 8-strand rope with the ideal strand construction to provide the best service life for straight through fairlead systems. Draglines with reverse bend fairlead systems need a balance of resistance to both metal loss and metal fatigue. PowerMax MD is designed specically for reverse bend fairlead systems and has been proven to provide the best service life. Dump rOpES Dump ropes require good resistance to bending fatigue while also maintaining high resistance to abrasion. PowerMax typically offers the best rope properties for this application.

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Why inspection is practical to your long-term success

espite their durability and strength, wire ropes used on draglines will eventually wear out and need to be retired from service. Thats why you need to regularly inspect your ropes not only to determine when they meet the removal criteria, but also to establish normal wear patterns so you can detect and correct unusual wear patterns. This section offers you general guidelines on wire rope inspection. For more detailed information, please consult our Tech Report 107.

iNSpEcT yOur wirE rOpE rEgularly > Inspection should be performed by a person with special training or practical experience.

HOw OfTEN TO iNSpEcT Obviously the more you use a wire rope, the more often you need to inspect it. It makes good sense to visually inspect all working wire ropes on a frequent basis. Any areas of wear, damage or broken wires should be marked and observed while the rope is in service. When or if a problem is found, you can better identify the locations the area contacts and whether the problem is caused by the rope itself, the equipment or simply operator technique. There are no established industry standards to determine the exact time to replace surface mining ropes because so many variables are involved. Its also important to remember there are minor sometimes major differences among installations, even on machines with similar designs. Both are excellent reasons to use the best judgment of a trained, qualified person to conduct proper rope inspection. Information from the inspection should be recorded so that you have a basis for judging the rate of change in the condition of a wire rope. A sudden change is more critical than a gradual change.

FOcuS ON yOur rOpES criTical pOiNTS While you should check the entire length of each rope for any unusual or isolated damage, there are several critical points in a rope subject to greater internal stresses, greater external forces or that are more susceptible to damage. These points tend to deteriorate more quickly, so it pays to focus on these important areas: PicK-uP POiNTS These are sections of ropes contacting the sheaves or the drum when you apply the initial load of each lift. Accelerated internal and external wear occurs at these points for two reasons: higher loads from acceleration and the ropes radial transfer or load to the sheave or drum. Look for diameter reduction, broken wires, wire wear and wire deformation at these locations. END ATTAcHmENTS End attachments on wire ropes restrict the free movement of wires, normally leading to the broken wires adjacent to the end attachment. If broken wires are seen, cutting off the affected area and resocketing can extend the ropes service life. Corrosion can be more prevalent in this area. Be sure to also inspect the fitting itself. SHEAVES The grooves on sheaves normally wear smaller over time. With a groove gauge, check each sheave for

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proper groove size and contour, as well as smoothness. Grooves that are too small or tight can cause pinching and increased wear while grooves that are too wide can cause flattening of the rope both of which can reduce your ropes life. Also check each sheave to make sure it turns freely, is properly aligned, has no broken or cracked flanges and has bearings that work properly. On sheaves that have grooves for two ropes (found in most 4-rope draglines), groove depth is critical. If the depth is not the same, one or both ropes will have to slide in the grooves as the sheave rotates. This will cause accelerated wear and damage to the rope. DrumS aNd hOw TO prEvENT cOrrugaTiON Drum surfaces may develop a wavy pattern with the lay of ropes over time, leading to worn grooves that can cause premature wire breaks due to the corrugation. You can help prevent corrugation by alternating right lay and left lay rope with standard uncoated wire ropes. Or use our PFV ropes because the coating on these ropes distributes the radial pressure on the drum, effectively preventing drum corrugation.

OThEr pOTENTial arEaS Of cONcErN ThaT yOu ShOuld iNSpEcT OfTEN ABuSE POiNTS Check for bright spots where ropes are subjected to abnormal scuffing and scraping. HEAT EXPOSuRE Watch for evidence of heat exposure which can damage the rope and its lubricant. Contact with an electrical arc such as welding can cause localized wire breaks. Never use the rope as the ground for an arc welder. MuLTi-LiNE DETERiORATiON Because many machines use two ropes at the same time, check to see if damage occurs in one or both ropes to help you identify the cause of the wear. DONT OvErlOOk bOOm pENdaNTS Often composed of structural strand, boom pendants are subject to vibratory fatigue at end attachments and at points where they run through the dampeners between the pendants. Regular inspection is critical. Broken wires at the socket or dampener are an indication of deterioration. When it comes time to replace your pendants, we recommend you replace the complete set of pendants all the uppers or all the back stays, for example because of the differences in operating characteristics of a new and used pendant.

KEEp rEcOrdS ON all machiNES > Good recordkeeping helps your companys maintenance program do what its supposed to do: keep downtime and operating costs to a minimum and promote good operating practices. By keeping accurate, up-to-date records, you have a complete history of your wire ropes performance. Changes in service can indicate the existence of a problem either on the machine, digging conditions, operators or the rope itself. Be sure to record any unusual events that occur in your ropes service life.

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How to maximize rope service life for draglines

T
rESOckETS arE NEcESSary > For best results, resocket at around 20% increments of a drag ropes expected service life.

o help you get the most service life from your Union drag ropes at the lowest cost, weve developed the following recommendations for use with your draglines.

REcyclE uSEd rOpES You can extend the service life of selected ropes through recycling. If your dragline uses the same diameter hoist and drags, frequently a set of drags can be cut from a retired set of hoists. You can also use old drag or hoist ropes for dump ropes if theyre the right size and still have useful service life. Whens the best time for that? Your experience is your best guide. RESOckET ROpES REgularly It is important to have an established resocketing program that is adhered to on a consistent basis. Too often a drag rope failure occurs because the rope was not resocketed in time causing it to be prematurely removed from service. Regular resockets are necessary because of the metal fatigue and wear that occurs near the socket. Resocketing also moves the wear points of the ropes through the fairlead sheaves helping to distribute wear over a greater length of rope.

A typical resocket program requires the drag ropes to be resocketed at intervals no greater than 20% of the ropes expected service life. Drag ropes typically are resocketed two to three times during their service life, and they should never be run more than 50% of the expected service life before being resocketed. TurN Drag ROpES ENd-fOr-ENd Drag rope wear normally occurs in the area that operates through the fairleads and contacts the overburden. This usually affects about one-third to one-half of the ropes overall length. The best drag rope life is attained by turning the ropes endfor-end after 35%-45% of the expected service life. To maximize service life it is important to turn the drag ropes end-forend before too many wire breaks occur in the area running through the fairleads.

Metal fatigue and wear occurs near the socket.

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GUARD AGAINST MARTENSITE ThE #1 CauSE Of PrEmaTurE WirE BrEakS Wire ropes are made of high carbon steel wires that have been cold drawn, producing very ductile, fatigue resistant properties, as well as very high strength. Martensite is a very hard, non-ductile phase of steel that can be formed along the ropes surface if friction and heat occur from fairlead sheaves spinning against the rope, or if the rope comes into contact with a hard surface. This problem is more common with straight-through fairlead arrangements and once the martensite is formed, the wires are permanently damaged. Martensite may also develop as a result of rock damage if the drag rope is continually pulled through the roll at the front of the dragline. Friction with the rock and dirt can form martensite. Cracks can develop in the martensitic layer formed at the wire surface and quickly spread through the wire resulting in complete wire breaks as the rope continues to operate.
CONTrOlliNg fairlEad ShEavE OvErSpiN iS kEy TO miNimiZiNg ThE chaNcES Of dEvElOpiNg marTENSiTE. EvEry dragliNE OpEraTOr ShOuld bE cONSciOuS Of ThiS cONdiTiON.

LubricaTE ROpES OfTEN Regular lubrication is crucial to reduce friction between the ropes components as well as the friction between rope and sheaves or drums. Wire ropes are thoroughly lubricated at the factory, but rope service life is increased with field lubrication. For hoist and drag ropes, automatic drip or spray systems used to apply lubricant at preselected intervals have been found to be effective methods of keeping the ropes well lubricated to help maximize rope life. Trim BrOkEN WirES If damage or other conditions lead to a small number of broken wires early in a ropes life, the best practice is to use a wire cutter or bolt cutter to trim broken wires. If left untrimmed, broken wires can lay across adjacent unbroken wires. When this section of rope runs through a sheave, the broken wires will be pressed into the wires it lays over, nicking them and leading to a nest of broken wires and reduced rope life.

ThrEE mEThOdS Of applyiNg lubricaTiON: > Drip

> Spray

> Brush

marTENSiTE

brOkEN wirES

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How to maximize rope service life for draglines (continued)

FacTS abOuT rEvErSE bENd > Compared with straight-through fairlead sheaves, reverse bend systems offer the advantage of maintaining constant contact between the sheaves and the drag ropes.

ChEck fOr prOpEr fairlEad OpEraTiON To help assure maximum service from your straight-through or reverse-bend fairlead systems, you need to check these critical areas: GROOVE cONTOuR Grooves that are too small or tight can cause pinching and increased wear while grooves that are too wide can cause flattening of the rope both of which can reduce your ropes life. PROPER SHEAVE ALigNmENT Fairlead systems have three different kinds of alignment: between the vertical and horizontal, between vertical and the bucket, and the alignment of the sheaves themselves vertical to vertical, or horizontal to horizontal. The grooves of each of these fairleads can wear down over time as a result of continual rope contact, leading to reduced rope service life. You can help maximize rope service life by aligning the sheaves properly with the bucket. The small space between the sheaves, however, may cause the rope to jump back and forth, so you need to be aware of possible impact fatigue or martensite and take steps to prevent them. One way is to shim up the sheave to restore proper alignment. Check with your equipment manufacturer for proper alignment procedures. SHEAVE mOVEmENT All sheaves must rotate freely. Make sure that sheave housings that are required to pivot can move freely. ROLLER OPERATiON Guide rollers in front of vertical sheaves should move freely to maximize rope life. If rollers become grooved or flat on one side, they need to be replaced.

OVERSPiNNiNg A proven remedy is to put a heavy, tacky lubricant in the throat of the vertical fairleads. This helps the rope start and stop the sheave, and keeps the sheave from grinding against the rope. To reduce rope damage, do not begin the digging cycle until the vertical fairleads stop spinning. MONiTOr drag TrOughS Covering the area between the fairleads and the drag drums, the drag trough frequently has sheaves, idlers and other members to support the drag rope when it is slack and protect it from possible damage. If sheaves are used, the grooves in drag trough sheaves are affected by extended wire rope usage. Ropes will cut the groove smaller and deeper over time, causing accelerated wear and shorter service life from future ropes you install. If other materials are used to support the drag rope, make sure theyre in proper repair. EXamiNE fOr uNEvEN wEar ON TwiN ShEavES The depth of both grooves of twin sheaves should always be equal. If one wears deeper than the other, the rope is forced to slide. If this wear extends beyond the hardened surface of the sheave, youll frequently see a rapid change in the sheave, causing more serious problems later. This results in decreased rope performance and service life as well as accelerated sheave wear. You can prevent this problem by making sure both grooves of twin sheaves are the same depth. If not, always replace or repair the sheave.

While the reverse bend fairlead arrangement helps minimize fairlead sheave overspin and the problems that occur with the straightthrough fairlead sheave arrangements, the reverse bend fairleads place much more demand on the ropes ability to withstand metal fatigue due to bending, while also maintaining muchneeded resistance to wear and abrasion.

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Suggested digging practices for draglines

irst, follow a proven method of drilling and blasting. If you leave the breakup of a rock formation to the bucket, the ropes life will suffer. When digging, the fundamental rule is the same as shovels. Always dig as near the optimum position as possible. Position the bucket directly in line with the axis of the boom and as near the boom point as possible. This position places less load on your hoist and drag ropes, and makes the most of their service life. Your wire ropes service life will suffer, however, when you dig at less optimal angles. A wide angle, for example, that

involves overcasting of the bucket will cause undue stress on the bucket, rope and rigging. A narrow angle can put more stress on your rope, requiring more power to lift the same load. Up to 42% more power for the poor digging position as shown here. Operator technique is also very important to your ropes service life. By overloading the bucket or increasing the stall amperage or clutch pressure to allow larger-thanrecommended loads, you can overload the rope and increase downtime for rope replacement. Ideally, the bucket should fill in a relatively short distance approximately two bucket lengths.

ShEavE grOOvE SiZE, cONTOur aNd SmOOThNESS ShOuld bE mONiTOrEd

dig aS NEar ThE OpTimum pOSiTiON aS pOSSiblE

As the angle of digging moves closer to the dragline, you need more power to lift the same load. 1. Avoid casting of the bucket. Undue stress and unequal load is put on the rope. 2. The best digging zone requires 3.5% more power than needed to lift the same load vertically. 3. Good digging zone requires 15% more power to lift. 4. Poor digging zone requires 42% more power to lift. 1. 2. 3. 4.

> When a minimum for worn sheave gauge does not reach the bottom of the groove, the sheave should be replaced for maximum rope life.

> Grooves that are too small or tight can cause pinching and increased rope wear.

> Grooves that are too wide can cause attening of the rope.

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Warning

n a perfect world, nothing ever goes wrong with wire rope. No injuries. No damages. No problems, period. But we all know theres no such place. In the real world, accidents do happen, and

thats why you need to take special precautions. Before installing wire rope in your surface mining applications, always read and follow the warning label attached to each product.

WARRANTY
Any warranty, expressed or implied as to quality, performance or tness for use of wire rope products is always premised on the condition that the published strengths apply only to new, unused rope, that the mechanical equipment on which such products are used is properly designed and maintained, that such products are properly stored, handled, used and maintained, and properly inspected on a regular basis during the period of use. Seller shall not be liable under any circumstances for consequential or incidental damages or secondary charges including but not limited to personal injury, labor costs, a loss of prots resulting from the use of said products or from said products being incorporated in or becoming a component of any other product.

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WirECO WOrldGrOup hEadQuarTErS, lOcaTEd iN KaNSaS CiTy, MiSSOuri WireCo WorldGroup is dedicated to being number one in customer service and support. We understand the daily challenges you face and are fully prepared to provide the best products and support to meet those challenges. We are a company deep in resources and global services. As the only manufacturer in the world that is QPL qualied, API certified, and registered to both ISO 9001:2000 and AS-9100 Quality Systems, WireCo WorldGroup is the global leader in manufacturing and distributing wire, wire rope, wire rope assemblies and electromechanical cable. With a trusted team of support staff and with inventories at locations around the world, Union is here for you, 24 hours a day, 7 days a week.

816.270.4700 info @wirecoworldgroup.com 12200 NW Ambassador Dr Kansas City, MO 64163 -1244 fax: 816.270.4707 Unionrope.com

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