STEEL WIRE ROPE HANDLING & MAINTENANCE

Document No: 00 95 OD 77 06 0003 0

Version: 1.0
Date: 09/04/2014
Prepared By: Rohan Kudalkar, Yogesh Akolkar
Checked By: Deepak T. Balani
Approved By: Gunter Frimmel, Vishnu Parashar

ThyssenKrupp Elevator (India)

Steel Wire Rope Handling & Maintenance 0095OD770600030-Version1.0

Contents

PURPOSE 4

SAFETY GUIDELINES 4

Basic Safety Rules to be observed 4

Signs 4

INTRODUCTION 5

What is Rope? 5

HANDLING 6

Transportation 6

Tools Required 7

Storage 7

Unrolling/Unwinding of Ropes 8

Precautions while unrolling/unwinding the ropes 8

Inspections while unrolling/unwinding the ropes 9

Ropes Installation Procedure 9

Rope Tensioning 10

Rope Tension Measurement 11

When to Tension Ropes? 12

Effects of Improper Tensioning 12

MAINTENANCE 13

When to check ropes? 13

Ropes shall be checked for? 13

How to check wire rope diameter? 14

Cleaning of Ropes 15

Checking of Lubrication 16

Lubrication of Ropes 16

Lubrication Type 16

Procedure for Lubrication 16

Relubrication of Ropes 17

Criteria for Relubrication 17

Steel Wire Rope Handling & Maintenance 0095OD770600030-Version1.0

 Dispensing of Lubricant 17

Over lubrication of ropes 17

Discarding of wire ropes 18

Criteria for discarding of wire ropes 18

Disposal of Ropes 18

Wire Breaks 19

Rope Defects 19

Replacement of wire ropes 21

Rope Slip 21

Acceptable Tolerances 21

TROUBLESHOOTING 22

DOCUMENT REVISION HISTORY 23

Steel Wire Rope Handling & Maintenance 0095OD770600030-Version1.0

PURPOSE
The purpose of this document is to highlight the importance of traction rope which is a safety component and
its handling, installation and maintenance contributes to quality and life of rope.

SAFETY GUIDELINES

Basic Safety Rules to be observed

 For your safety, follow the Health, Safety & Environment guidelines established.
 Ensure that you are in possession of all PPE’s (Personal Protective Equipments) appropriate to the
work you are doing, as shown below

 Keep all PPE’s clean and in good condition. If equipment is faulty replace it immediately.
 Clear warning signs must be installed in any place where a potential hazard exists in the working
area. Labeling should be in accordance to local standards.

Signs
Following are the signs used in the document, wherever adequate.

Danger Zone
This symbol warns against imminent danger. Nonobservance can lead to physical injury
or extensive damage to property

Do Not Do

This symbol indicates not to perform or carry out the mentioned activity.

Reference

This symbol indicates reference given to a particular document.

Instructions

This symbol indicates instructions to be followed.

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INTRODUCTION

What is Rope?

Wire rope consists of several strands of metal wire

twisted about a central axis known as core. Each
individual steel thread is known as wire. Each group
of wire twisted together forms a strand. A group of
strands twisted around a central core is known as a
wire rope.

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HANDLING

Transportation
Adequate arrangements for loading and unloading the wooden reels (bobbins) containing rope shall be
provided.

 Hoist the rope in proper way, in order to avoid damage to the package
 Do not throw the rope from height

Wrong means of transportation Correct means of transportation

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Tools Required

Steel measuring tape 3m/5m,

Spanner set Tri-square (6” & 12”)
Freeman`s make

Rope diameter measuring gauge

Brush (75mmx150mm) Wire Cutter
(metric)

Storage
 The rope shall be stored in a dry environment and protected against rain, moisture and dust.
 Avoid contact with cement dust or sand, acid and alkaline materials
 Cover ropes with adequate ventilation to avoid formation of condensation.
 Do not put rope directly on the ground or under heavy object.
 Apply occasional dressing of lubricant to the top layer of rope to protect the same from corrosion, if
stored for longer period of time.
 Turning the wooden reel (bobbin) occasionally, about half a turn helps to prevent migration of the
rope lubricant.

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Unrolling/Unwinding of Ropes
The ground rules for rope mounting must be observed without fail. By removing from side via the reel
(bobbin) coupling or from the coil strap, the rope is uncoiled or coiled depending on the direction of lay. This
twisting action brings about a change in the rope structure which can no longer be corrected. In the case of
ropes with steel core, this type of forced rotation creates uneven strand lengths.

Precautions while unrolling/unwinding the ropes

 Wear protective gloves during the rope installation.
 Wipe the rope with clean cloth in case of dust or foreign materials on the surface.
 Do not clean the rope with gasoline, kerosene, water or other organic solvent.
 Protect ropes from welding sparks.
 The rope shall not be subjected to direct contact with fire.

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Inspections while unrolling/unwinding the ropes
 Inspect if the rope is free from dust or foreign materials.
 Rope shall be free from any abnormal phenomenon, such as broken rope, extruded rope core, cage
shape distortion, squashed rope etc.
 Any kind of rust observed.

Ropes Installation Procedure

Check the elevator Ensure the Release rope torsion

installation way is Unwind the rope
number correct if necessary

Wrap the other end Fasten rope & rope Make & Install the
rope socket Wrap the rope on
of the rope on the socket assembly the pulley
pulley (2:1) (counterweight side) assembly
(counterweight side)

Make & Install the

Determine the rope socket Fasten rope & rope Hang up the rope
socket assembly
rough rope length* assembly
(car side) and recheck
(car side)

Bind up the rope Cut off the extra Adjust the rope
end rope tension & rope
socket assembly

*TO DETERMINE ROUGH ROPE LENGTH, REFER THE FOLLOWING DOCUMENTS:

00 95 OD 77 00 0024 0 ‘ROPE TESTING SPECIFICATION’ &
00 95 OD 77 00 0025 0 ‘APPLICATION OF STEEL WIRE ROPE FOR ELEVATOR’

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Rope Tensioning
All hoist ropes in an elevator installation shall carry the same tension/load. Equally tensioned ropes extend
the life of the ropes/sheaves and improve ride quality.
When ropes are installed, they must be adjusted so that each rope takes its equal share of the total load.

Adjustment of Rope Tension

 Uneven rope tensions are not acceptable.

 Deviation more than ± 2 kgs is not acceptable.

Spring Adjustments for Ropes

 Difference between top end of

rods shall not be more than
20mm.
 Difference between
compression of 2 springs shall
not be more than 2mm.

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Rope Tension Measurement
Method I Manual Rope Tension Equalizer

 Keep the car and counterweight on same

level.
 Measure the rope tension at approx. 1 meter
distance above car top and counterweight
top.
 The tension should be within ±2 kg for all
ropes.

Method II Henning Mobile Rope Load Meter MSM 12

FOR DETAILED USAGE INSTRUCTIONS REFER ‘HENNINGS MOBILE ROPE LOAD METER MSM
12-OPERATING INSTRUCTIONS’ DOCUMENT

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Method III DruceGrove Rope Tensioning System

FOR DETAILED USAGE INSTRUCTIONS REFER ‘DRUCEGROVE ROPE TENSIONING SYSTEM

USER MANUAL V2’ DOCUMENT

When to Tension Ropes?

Ropes must be tensioned immediately after installation. Tensioning is especially important during the rope’s
initial constructional stretch period and during the adjustment problems when problems can still be corrected.

Effects of Improper Tensioning

 Unequal groove wear
 Unequal rope wear
 Slippage
 Vibration
 Short rope and sheave life

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MAINTENANCE

When to check ropes?

Under Installation In Operation

After 50,000 cycles of running time or 3 months After every 100,000 cycles of running or 6 months
(whichever is low) (whichever is low)

Ropes shall be checked for?

 Check for dust or foreign particles

Dust on Ropes Foreign Particles

If dust on ropes is observed, then clean it with brush Foreign particles on ropes shall be checked and cleaned

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  Broken rope wires
 Extruded wire rope
 Rusted rope
 Reduced diameter of rope

How to check wire rope diameter?

Method I

 Measure the diameter as shown.

 If the diameter is less by 6% then replace the ropes irrespective of any other defects.

Method II

 Keep the lift in stop condition.

 Put a scale on ropes.
 Difference between any 2 ropes shall not be more
than 1mm.

Method III

Check the diameter of rope using the diameter checking

gauge as shown in the adjacent image.

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Cleaning of Ropes
Method I Manual Cleaning of Ropes

 Put the lift in Inspection mode.

 Make use of wire brushes for cleaning the ropes.
 Move the lift up/ down till all dust is removed.

Method II Using Rope Oiling and Cleaning Unit

Item Code Item Description UOM

0096OP029901030 ASSY_ROPE OILING AND CLEANING UNIT EA

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Checking of Lubrication

 Check the lubrication on car top or machine

room.
 Rub the fingertip slightly on rope.
 If you don’t find lubrication, then lubricate the
ropes with appropriate lubricant.

Lubrication of Ropes
Wires, strands and cores are important components of the rope, which are only able to interact with each
other in presence of lubrication.
Lubrication is necessary to:

 Minimize wear between ropes and sheave.

 Reduce friction between the wires.
 Minimize corrosion due to atmospheric and/or operating conditions.
 Help reducing the bending fatigue by allowing movement between the wires and strands.

Lubrication Type
Item Code Item Description Make of the lubricant Oil Type

0095OP080102030 LUBRICANT OIL_WIRE ROPE_ENKLO HLP T 32_HP Hindustan Petroleum Mineral

Procedure for Lubrication

 Put the car in maintenance mode.
 Keep the car on lowermost floor.
 Start applying oil by brush just above counterweight from machine room.
 Allow the lift to move up slowly section by section.

DO NOT TOUCH ANY OF THE MOVING PARTS OF THE LIFT

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Relubrication of Ropes
Elevator ropes are lubricated during manufacture in order to prevent corrosion and abrasion. However, the
quantity of lubricant applied shall only be good enough to ensure that elevators operate with sufficient
traction and without slippage. The initial lubrication is hardly ever sufficient to be effective over the entire
service life of the rope. It is consequently advisable to occasionally re lubricate elevator ropes. As long as
wiping a finger over the rope shows faint smudge, there is no need for lubrication.

Criteria for Relubrication

It is not possible to provide any definitive statement in respect of re lubrication intervals, as they depend on.

 The frequency of elevator use.

 The environment (temperature, incidence of dust).
 The sheave material and sheave wear (hardened traction sheaves require more relubrication, as no
graphite is released from the sheave as a result of wear).
 Slip between the rope and sheave.

OVERSPEED GOVERNOR ROPE SHALL NEVER BE LUBRICATED

Dispensing of Lubricant
As the life of an elevator rope is closely linked to its effective rope diameter, it is essential for the fibre core to
maintain its volume for as long a period as possible. Consequently relubrication shall be performed from the
outside in such a way that lubricant also penetrates the fibre core.

Over lubrication of ropes

One of the possible causes of excessive slippage of ropes on the sheave can be over lubrication of ropes.
Under no circumstances should an attempt be made to wash down ropes using cleaning agents or solvents.

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Discarding of wire ropes
Elevator ropes are normally discarded due to wire breakage, wear and diameter reduction. However, other
discarding criteria such as corrosion or excessive elongation can also take effect.

Criteria for discarding of wire ropes

The number and distribution of externally visible wire breaks are the most important criteria when it comes to detecting
when an elevator rope shall be discarded. This is quantified by a count of maximum number of visible wire breaks over
a reference length of the rope. According to ISO 4344, the criteria for discarding ropes are:

 Broken wires

Replace ropes or examine within a

specified period as stated by the Discard ropes immediately
competent person
Condition
Rope Construction

Class 6 X 19 FC Class 8 X 19 FC Class 6 X 19 FC Class 8 X 19 FC

Broken wires
randomly distributed More than 12 per More than 15 per More than 24 per More than 30 per
# # # #
among the outer rope lay rope lay rope lay rope lay
strands

Broken wires
predominating in More than 6 per rope More than 8 per rope More than 8 per rope More than 10 per
# # # #
one or two outer lay lay lay rope lay
strands

Adjacent broken
wires in one outer 4 4 More than 4 More than 4
strand

# #
More than 1 per rope More than 1 per rope
Valley breaks 1 per rope lay 1 per rope lay # #
lay lay

#
The length of one rope lay is approximately equivalent to 6 x d (where d is the nominal rope diameter)

 Reduction in diameter (If rope diameter is less than 6% the desired diameter of the rope, then
replace the rope).

Disposal of Ropes
PLEASE FOLLOW THE TKEI GUIDELINES FOR DISPOSAL OF ROPES.

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Wire Breaks
For all other elevator ropes, reference is made to the specifications of the relevant rope manufacturer. Taking
the number of wire breaks at discard as a reference, it is then possible to determine whether

 The rope shall be discarded immediately

 Shall be more intensively monitored in the future or
 Shall continue to be monitored normally

Rope Defects
Sr. No. Defects View Remark

If the number of broken wires is

1 more than 5 or 6 or exceeds,
replace the ropes

Broken wires on surface

If more than 5 wires are broken

2 remove the broken wire sticking out
and replace the rope

3 Broken Strands Replace the rope

Try to remove the twist if it cannot

4 Deformed rope
be removed, then replace the ropes

5 Extruded rope core Replace the rope

If rope diameter is less than 6% the

6 Reduced rope diameter desired diameter of the rope, then
replace the rope

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Sr. No. Defects View Remark

7 Squashed rope section Replace the rope

Air gap between rope

8 Replace the rope if gaps are more
strands

9 Backward distortion Replace the ropes

Replace the rope if knot cannot be

10 Knot on the rope
removed

11 Nose distortion on ropes Replace the ropes

Replacement of rope depends on its

density. For small rust it shall be
12 Rusted ropes
cleaned, for more rust replace the
ropes

If rope diameter is less than 6% the

13 Abrasion desired diameter of the rope, then
replace the rope

Increase in diameter of
14 Replace the ropes
ropes

15 Forward distortion Replace the ropes

Extended interior rope

16 Replace the ropes
strands

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Replacement of wire ropes
When replacing suspension ropes, all ropes in a set shall be replaced. All ropes in the set
shall be from the same manufacturer and of the same material, grade, construction and
diameter and preferably be cut from the same reel (bobbin).

Rope Slip
Keep the elevator in normal mode on top most floors

Allow the lift to travel 1 full round from top to bottom and
Mark the ropes and machine at same point by chalk again bottom to top in non-stop mode, ideally the original
marks shall match, but these markings will never match

Acceptable Tolerances
 For G+7 rope slip = 15 to 20mm
If the same is not observed then possible causes are

 Rope tensioning not proper

 Dust on ropes
 Rusted ropes
 Rope twist
 Other defects
 Defective sheave.
 Over lubrication.

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TROUBLESHOOTING
Rope Trouble Cause Solution

Severe impact/jerk Avoid overloading and jerk loads

Formation of twist during Avoid formation of twist during

Snapping of Rope (Breakage) installation/handling
installation

Severe rusting/ corrosion Store in dry environment

Overload Avoid loading beyond capacity

Prevent twisting of rope through proper

Twist
Breakage of one or more strands method of unwinding, handling at site

Prevent rusting/corrosion through proper

Rusting/Corrosion & fatigue
storage and lubrication during use

Increase in lay length and Avoid overloading by keeping load as per

Overloading
reduction in diameter capacity

Damage due to improperly Fix hoisting suspension bolts in correct

Distortion of rope.
attached hoisting suspension bolts manner.

Worn out sheaves & grooves Rectify or replace worn-out sheaves &
grooves
Abrasion wear. Misalignment Correct the alignment

Lack of lubrication Apply regular lubrication during use

Use bigger sheaves and maintain groove dia.

Undersized sheaves or grooves between 6 to 10% more than the nominal
rope diameter in case of standard rope
Wire breakage due to fatigue.

Improper selection of rope Always use rope of specification

construction recommended by OEM or rope manufacturer

Allowing rope to drag over objects Remove external objects in rope path during
during installation / operation installation / use
Spiraling.

Wrong method of handling Follow the recommended method of handling

Excessive flattening. Overload Prevent overloading beyond capacity

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DOCUMENT REVISION HISTORY
Sr. No. Version Description Revised By Revision Date Released Date

1 1.0 New Document Released Rohan Kudalkar --- 09th April 2014

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