LIFTING EQUIPMENT, WIRE ROPE & BELOW QP-036/002 Rev.

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TABLE OF CONTENTS

1.0 SCOPE
2.0 REFERENCES DOCUMENTS
3.0 RESPONSIBILITIES
4.0 ROPE CLASSES
5.0 CERTIFIED WIRE ROPE INSPECTORS
6.0 TRAINING
7.0 WIRE ROPE RECORDS
8.0 PROCUREMENT AND RECEIPT OF WIRE ROPE
9.0 STORAGE, HANDLING AND MAINTENANCE
10.0 ROPE INSTALLATION
11.0 LUBRICATION
12.0 VISUAL INSPECTION
13.0 NON DESTRUCTIVE EXAMINATION (NDE) OF WIRE ROPE
14.0 TRENDING ANALYSIS
15.0 CONSIDERATIONS FOR THE APPLICATION OF WIRE ROPE
16.0 LIST OF ATTACHMENTS
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1.0 SCOPE
This procedure outlines the system and responsibilities for the entire life-cycle of
the wire rope, including procurement, receiving, storage, handling, use,
maintenance, inspection and retirement in the Batam Fabrication Yard to ensure
compliance with E&M Guidelines.
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2.0 REFERENCES DOCUMENTS

This procedure shall be read in conjunction with the following referenced
documents:
• JRM 2204-001b Corporate Wire Rope Guidelines Manual
• O.S.H.A. for the Construction Industry (29 CFR Part 1926), with Amendments
as of February 1, 1998
• API RP 2D - 2003, Operation and Maintenance of Offshore Crane
• API 9A - 2004, Specification for Wire Rope
• ASTM E1571 - 2006, Standard Practice for Electromagnetic Examination of
Ferromagnetic Steel Wire Rope
• ASME B30.2 - 2005, Overhead and Gantry Crane (Top Running Bridge,
Single or Multiple Girder, Top Running Trolley Hoist)
• ASME B30.4 - 2003, Portal, Tower and Pedestal Crane
• ASME B30.5 - 2004, Mobile and Locomotive Crane
• Wire Rope Users Manual, by Wire Rope Technical Board.
• QP-036/001 – Lifting Equipment, Wire Rope & Below the Hook Lifting
Devices – Volume 1: Lifting Equipment
• QP-036/003 – Lifting Equipment, Wire Rope & Below the Hook Lifting
Devices – Volume 3: Below the Hook Lifting Devices and Hand Operated
Lifting Devices
• QP-041 Critical Lifts
• Permenaker No. 05/MEN/1985
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3.0 RESPONSIBILITIES
3.1 OPERATION MANAGER
• Responsible for submitting the proposed training details, list of appointed
person & provider to the JRM Group E&M Department.

3.2 YARD GENERAL SUPERINTENDENT

• Shall ensure that the yard lift schedule allows sufficient time for the
appointed persons to perform the necessary crane & wire ropes
inspections.

3.3 DESIGN ENGINEER ONSHORE

• The Design Engineer Onshore shall attend to witness all tests and to record
the results and observations made during the test.
• The Design Engineer Onshore shall maintain the backup files of personnel
basket design calculation, drawing and register.

3.4 RIGGING SUPERINTENDENT

• The Rigging Superintendent shall appoint in written all “appointed persons”
involved in wire rope monthly and annual inspections.
• The Rigging Superintendent shall ensure that all activities identified within
this procedure are complied with.
• Shall ensure that all record related to the wire rope shall be documented
and maintained.

3.5 MAINTENANCE MANAGER

• The Maintenance Manager shall appoint in written all “appointed persons”
involved in crane monthly and annual inspections.
• Shall ensure that the record of crane monthly inspections are maintained
and updated.
• Shall ensure that the annual certifications of the cranes are performed
consistently and follow the Indonesian Regulation No. 05/MEN/1985.

3.6 TRAINING MANAGER

• Shall ensure the training providers and syllabus are approved by the
Corporate E&M Group.
• Shall maintain a current register of crane inspector personnel on a quarterly
base.
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4.0 ROPE CLASSES

4.1 All wire ropes fall into one of three categories as follows:
4.1.1 CLASS A: This includes only critical ropes. These ropes are manufactured to
a tight procurement specification written and issued by JRM. Examples include
ropes for:
• Lampson cranes

4.1.2 CLASS B: This includes important ropes that are typically involved in
overhead lifting and/or movement of personnel. Examples include ropes for:
• Crawler cranes
• Hydraulic Crane
• Overhead cranes
• Tower Cranes
• Tuggers involved in overhead lifting (including man-rider tuggers)

4.1.3 CLASS C: These ropes are less critical and examples include:
• Tuggers (not used for overhead lifting)
• Deck mooring winches

4.2 PTMI will submit a list of all wire ropes grouped by class to the JRM Group E &
M Department for approval.
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5.0 CERTIFIED WIRE ROPE INSPECTORS

5.1 Training Managers, in conjunction with the Rigging Superintendent who
responsible for wire rope, will ensure that wire rope inspectors are appropriately
qualified and that certification is maintained.
5.2 The only individuals who are authorized to perform inspections and determine
when wire rope replacement is necessary are Wire Rope Inspectors who have
the appropriate certification for the tasks that are being performed and Qualified
3rd Party Inspectors.
5.3 Wire rope certifications will be awarded by Rigging Superintendent based on an
individual’s level training and experience. Certifications can be invalidated at the
discretion by Rigging Superintendent.
5.4 There are three levels of wire rope certifications as shown in the following table.
Each requires increased levels of knowledge and competence.

Level Training Experience Renewal

Will have performed at least
3rd Party basic
one full barge main crane Retraining and re-
training, plus an
1 inspection under the direction assessment required
on-the-job
of a certified inspector (or a after 3 years
assessment.
qualified 3rd Party)
3rd Party basic Retraining and re-
2 training (for a 3 years at level 1 certification assessment required
second time) after 3 years
3rd Party
Reassessment
3 advanced 3 years at level 2 certification
required after 5 yrs.
training.

5.5 Rigging Department will maintain up to date a register of certified wire rope
inspectors that includes the certification level and renewal date for each
individual.
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6.0 TRAINING
6.1 Wire Rope Certification Training
6.1.1 Training managers, in conjunction with the Rigging Superintendent who
responsible for wire rope, will ensure that 3rd party wire rope certification training
courses are identified and pre-approved by the JRM Group E & M Department.
6.1.2 All wire rope inspectors are required to have successfully completed 3rd party
approved training.
6.1.3 Wire Rope Rigging Consultants (Woodland, WA) and Evita Training Services
(Doncaster, UK) have been evaluated and are pre-approved to provide
certification training for wire rope inspectors. Use of any other 3rd party training
service requires the approval of the JRM Group E & M Department.
6.1.4 Third party wire rope inspector training as a minimum will include instruction in:
• Wire rope characteristics and construction
• Wire rope damage modes, inspection and retirement criteria
• Wire rope handling and storage
• Wire rope slings
• Alloy chain slings
• Synthetic web slings
• Below the hook lifting devices
6.1.5 Successful completion of the 3rd party training requires inspectors to have
passed written and practical examinations based on the relevant API and
ASME/ANSI standards.
6.1.6 Those personnel who are responsible for material handling and storage will
undergo training in the handling and storage requirements for wire rope. This
training will include as a minimum:
• Correct procedures for lifting, moving and storing of reels.
• Correct procedures for transferring, handling and storing of rope.
• The type of damage that will render rope unfit for use, and the potential cost
impact.
6.1.7 Records of training will be maintained in file.
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7.0 WIRE ROPE RECORDS

7.1 Equipment Manufacturer’s Specifications
7.1.1 Records of wire rope will be maintained for the life of the wire rope. Rigging
Superintendent will make every effort to ensure that a copy of the Original
Equipment Manufacturer’s (OEM) specification for every rope in service is
maintained in file. Allowable exceptions are noted below:
7.1.1.1 Manufacturer’s Part Numbers used in place of Equipment Manufacturer’s
Specifications: In some circumstances the original equipment manufacturer will
prefer to act as the sole supplier of rope to be used on their equipment. Under
these circumstances, the equipment manufacturer may be reluctant to provide
the operating unit with rope specifications and will insist that the rope be bought
from them using a part number. PTMI may buy the rope using a part number
providing that they have on file correspondence showing that the manufacturer
refused to provide a rope specification and insisted that it is being bought by
using a part number.
7.1.1.2 Equipment Manufacturer’s Specification is not available: There may be a
number of reasons for an equipment manufacturer’s specification to be
unavailable such as:
• The equipment manufacturer may have gone out of business.
• The manufacturer insists that the rope is bought with a part number (see
7.1.1.1)
Under these circumstances the operating unit may develop a rope specification
in accordance with the procedure outlined in section 15.
7.1.2.3 Equipment is designed and built in-house: Where equipment is designed and
built by PTMI (e.g. Overhead Crane), Design Onshore Engineer is responsible
for developing and maintaining a rope specification for use on the equipment.
The specification will be developed in accordance with the procedure outlined in
section 15.

7.2 Alternative to Equipment Manufacturer’s Specified Rope

7.2.1 If anything other than the equipment manufacturer’s specified rope is used (e.g.
due to an emergency), a record of the manufacturer’s approval will be obtained
and maintained in file.

7.3 Reel Files

7.3.1 Reel files will be maintained for all Class A ropes. While it is mandatory for Class
A, it would be advisable to maintain them for all ropes. Dedicated reel files for
each rope will contain the total history and all relevant information of the rope
from procurement to retirement. Reel files will be maintained for the life of the
rope as a minimum.
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7.3.2 The minimum documentation that will be included in the reel files for Class A
ropes will be:
• The procurement specification used to buy the rope *
• The material requisition *
• The purchase order *
• Shipping documentation *
• Receipt inspection report *
• Mill certificate and supporting documentation *
• ABS or Lloyd certification
• Results of inspection prior to first use (see section 12.5) *
• Results of monthly inspections *
• Results of visual inspection by qualified 3rd party
• Results of electromagnetic inspection by qualified 3rd party
• Results of annual inspection (for class B & C ropes see section 12.9) *
• Documentation of lubrication history *

7.4 Class B & C Ropes Minimum Documentation

7.4.1 For Class B & C ropes, it is mandatory to retain on file the items indicated with an
asterisk in 7.3.2
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8.0 PROCUREMENT AND RECEIPT OF WIRE ROPE

8.1 Equipment Manufacturer’s Specifications
8.1.1 The Operation Manager and Rigging Superintendent are responsible for ensuring
wire rope is procured in accordance with the requirements of this procedure and
the procurement procedures. Rigging Department will develop and maintain in
file a procurement specification for every rope. These specifications will be used
in the procurement process to communicate details of the required rope to the
Purchasing Department. All requisitions will provide a complete description of the
rope to be purchased.
8.1.2 All rope procurement specifications will as a minimum accurately reflect all
information contained in the equipment manufacturer’s rope specification (or an
otherwise JRM generated approved specification – see 7.1). Additional
information may also be included (in particular for Class A ropes).
8.1.3 All units of measure contained in specifications will remain in the original units of
measure (i.e. either U.S. Customary or Metric) unless other wise approved in
writing by the equipment manufacturer.
8.1.4 Class A rope specifications will follow a standard format, the operating units may
use the same format for class B & C ropes but it is not mandatory. The specific
information that will be contained as a minimum in Class A rope specifications
will be:
• Application – Identify the intended application for the rope (e.g. Boom Load
Line, Main Load Line etc.)
• Fabrication specification – Specify that the rope is to be manufactured to
API 9A as a minimum. This specification provides the default tolerances on
diameter, length and breaking strength.
• Provide a description of the rope, to include:

Item Description

Length See API 9A for details on length tolerances

Diameter Nominal diameter. Refer to API 9A for standard rope

diameter tolerance. If rope diameter is critical for the
intended application, the maximum and minimum limits
will be specified.

Construction e.g. 6x36 Warrington Seale

Preformed or Under normal circumstances, the rope should be

Not Preformed specified as “preformed”. This will ensure that the rope
will tend to hold its’ shape.

Lay Typical choices: right regular lay, left regular lay, right
lang’s lay, or left lang’s lay

Finish Typical choices: galvanized, drawn galvanized, or

“bright”, i.e. not galvanized.
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Core Under normal circumstances, an independent wire rope

core (IWRC) should be specified.

Breaking Wire rope manufacturers normally provide nominal

Strength breaking strengths in their catalogs. The actual breaking
strength may be above or below the nominal strength
within manufacturing tolerances. The breaking strength
will be specified as the absolute minimum required when
is ordered

Lubrication This lubrication refers to the lubricant that is applied by

the rope manufacturer during manufacture. Typically, the
requirement is “Fuchs 10RZ or equivalent to be approved
by JRM”.

Tests required Specific tests which are to be performed to qualify the

rope. Typically, Class A ropes are purpose-built rather
than drawn from stock. It is required that a breaking load
test be performed and a report on a length cut from the
actual rope is to be supplied.

Test` All wire rope will be supplied with a test certificate which
certificates will describe the rope and its unique identification, details
of qualification tests, and the results. The certification will
be signed and approved by a competent person. The
purchase order will specify the tests required on the
rope.

Terminations Details of any required end terminations will be specified

Marking and Details of any spooling, reel packing and identification

Packing will be included (See API 9A, paragraphs 12.1 and 12.2.)

8.1.5 The following special procurement requirements will be included in specifications

for ropes used in multi-rope systems and these in turn will be incorporated into
the procurement documents:
• Both ropes of a pair installed in multi-rope systems will be from the same
manufacturer, and matched in terms of specification of outside diameter, lay
length, wire strength, construction, type of lubricant, etc.
• If possible, ropes intended for use in a multi-rope system will be made
during the same production run. However, if due to production limitations
this is not possible, then it is permissible that the ropes will be built in
consecutive production runs using the same production set-up.
• In some cases, both ropes in a set cannot be made in the same production
run due to the fact that one of the ropes is a right lay rope and the other is a
left lay rope. In these cases, the two ropes can be made using the same
production set-up with only the lay direction having been changed.
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8.2 Requisitioning and Procurement of Wire Rope

8.2.1 Rigging Superintendent will ensure that material requisitions and purchase
orders accurately include all the requirements contained in the wire rope
specification. The preferred way to communicate the information is to attach a
copy of the specification to the requisition and ultimately to the purchase order.
The alternative is to retype the requirements on the requisition and purchase
order.
8.2.2 For class A ropes the presence of a McDermott or a McDermott nominated 3rd
party on-site inspector is required during the rope manufacture. Details of all
inspection requirements will be included on the requisition and in the subsequent
purchase order. The inspection requirements will vary according to whether the
vendor is pre-qualified for the rope(s) being purchased (see paragraph 8.2.4). In
all instances the inspector is required to complete and sign an inspection report
confirming that he has verified that the rope has been correctly manufactured
and meets the requirements of the order. The rope will not be released for
shipment until this document is available.
8.2.3 It is preferred that class A ropes are purchased from pre-qualified manufacturers.
Pre-qualification will involve an on-site audit of the manufacturer’s facility, an
extensive review of their capabilities and quality system plus detailed discussions
of the class A Procurement specification. As in September 2005, the following
vendors have been pre-qualified to provide class A ropes:
• Haggie Rand
• Bridon International (U.K.)
• Williamsport Wire Rope
Any questions regarding pre-qualification should be addressed to the JRM Group
E & M Department.
8.2.4 When Class A ropes are being purchased from a pre-qualified manufacturer, the
on-site inspector is required to review the mill manufacturing plan and/or shop
travelers to verify that the rope was made to the material, construction,
dimensions and other requirements of the procurement specification. The
inspector will witness the manufacturing process at the agreed hold points and
throughout the rope closing operation. Dimensions will be checked during hold
points. The appropriate application and good condition of the lay-up lubricant will
be verified. Wire dimensions, tensile and torsion tests will be witnessed for
lot/diameter combinations. The rope breaking strength will also be witnessed.
8.2.5 Class A ropes should only be bought from a manufacturer who is not pre-
qualified where it is not possible or practical to procure from a pre-qualified
source. In addition to the inspection requirements detailed in 8.2.4 the on-site
inspector will also be required to witness the manufacturing process, the
application of factory lubricant and all API 9A requirements. The inspector will be
required to witness and confirm the correct application and condition of the lay-up
lubricant before the rope is released.

8.3 Receipt Inspection

8.3.1 Upon receipt, the Certified Wire Rope Inspector at the receiving location will
undertake the following checks to verify that the rope complies with the
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requirements of the purchase order (and the procurement specification), and that
full certification has been received. A receipt inspection report will be raised and
maintained in file for the life of the rope. See appendices 3 & 4 :
• Confirm that the rope complies with the requirements of the procurement
specification. This will typically require removal of packing materials to
facilitate visual inspection and rope diameter measurements. Note: any
measurements shall be taken using the same units of measure as were
used in the procurement specification.
• Confirm that the reel markings agree with the identification markings on
shipping and certification documents.
• Confirm the condition of the rope, reel, and lubricant.
• Confirm that certification documents have been received and that they
include the details required in the purchase order (and procurement
specification).
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9.0 STORAGE, HANDLING AND MAINTENANCE

9.1 Care of rope in Storage
9.1.1 The General Superintendent or Rigging Superintendent is responsible for
ensuring that all requirements for the storage, maintenance and handling of wire
rope detailed in this procedure are met. Rope in storage will be maintained in a
well lubricated condition and will be stored and handled to prevent damage and
deterioration. The following actions will be taken while wire rope is in storage:
• Whenever possible the rope should be stored in a covered, well-ventilated
area, away from excessive heat.
• The reel will be elevated to prevent standing water from having a
detrimental effect on the rope and to prevent contact with dirt, debris, plant
life, etc.
• Where covered storage is not available, the rope and reel will be covered
with waterproof material. This will be fitted to protect the rope from rain, etc.,
but will allow it to breathe so that the moisture is not entrapped.

9.2 Wire Rope Inspection in Storage

9.2.1 Wire rope in storage will be inspected by a certified wire rope inspector on a
quarterly basis to confirm preservation is adequate and condition acceptable for
use when required. Records of these inspections will be issued and maintained
in file for the life of the rope. See appendix 5.
9.2.2 The inspection frequency for wire rope in storage will be:
• Class A Ropes – will be inspected quarterly
• Class B Ropes – if stored indoors will be inspected once every 6 months,
otherwise will be inspected quarterly
• Class C Ropes – Ropes for tugger/anchor lines have the same
requirements for inspection during storage as for Class B ropes.
9.2.3 The quarterly inspection during storage will include an evaluation of the condition
of the lubricant to confirm that it is adequate to provide protection.
9.2.4 While in storage the reel will be rotated one quarter turn at each quarterly
inspection while in storage. Quadrants of the rope reels will be marked so that it
can be demonstrated that the reel has the correct orientation. Arrows may be
applied to the reel to show the direction of rotation.
9.2.5 Where more than one reel is held in stock of a specific wire rope, usage will be
planned to utilize the older stock first.

9.3 Out of Service Equipment

9.3.1 All lifting equipment that is to be out of service for long periods of time (typically 3
months) the preferred approach for preservation is to pressure lubricate the wire
rope, reel it back onto the drum, then lubricate the outer layer of the rope on the
drum.
9.3.2 If for any reason this is not possible, an alternative as a minimum is that the
lubricant should be applied to the outside layer of the rope on the drum, and
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additional lubricant should be applied to the accessible exposed rope in the hoist
system.
9.3.3 Records will be maintained to document that rope on out of service has been
correctly cared for.
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10.0 ROPE INSTALLATION

10.1 The Rigging Superintendent and Certified Wire Rope Inspector are responsible
for ensuring that wire rope is installed correctly. All wire rope will be installed in
accordance with the equipment manufacturer’s specifications and under the
direction of either a qualified 3rd party crane inspector or an in-house certified
wire rope inspector level 3.
10.2 Unreeling or uncoiling of rope will be done as recommended by the rope
manufacturer, and particular attention will be given to avoid introduction of kinks
or twists, as this is cause for rope retirement.
10.3 Rotation resistant ropes may be particularly susceptible to kinking or twisting,
thus, special care may be required during installation.
10.4 The following criteria will be used in all multi –rope systems to include equalizer
components if fitted:
• Both ropes of a pair installed in multi-rope systems will be from the same
manufacturer and are matched in terms of specification of outside diameter,
lay length, wire strength, construction, type of lubrication, etc. If possible,
the above will be from the same production run.
• If due to production limitations it is not possible to have both ropes made
during the same production run, then it is permissible that they will be built
in consecutive production runs using the same production set-up.
• In some cases, both ropes in a set cannot be made in the same production
run due to the fact that one rope of a pair is a right lay rope, and the other is
a left lay rope. In these cases, the two ropes can be made using the
production set-up with only the lay direction having been changed.
• Both ropes will be replaced at the same time when one rope in the system
is found to be unserviceable. This does not apply when only one equalizer
rope is found to be in the need of replacement.
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11.0 LUBRICATION
11.1 General
11.1.1 The Rigging Superintendent and Rigging Engineer are responsible for ensuring
that lubrication of all ropes is correctly maintained. Ropes are considered to be
“machinery”, and as such, they require a lubricant to minimize internal friction
and to provide corrosion protection. Most ropes have a factory-applied “lay-up”
lubricant applied during manufacture. The protection provided by the lay-up
lubricant is normally only adequate to prevent corrosion during shipment and
storage, and to provide lubrication during the early part of the rope’s life. “Field”
lubricants are applied by the rope used in order to maintain lubrication as the lay-
up lubricant looses its effectiveness, and for the remainder of the ropes life.

11.2 Lubricant Compatibility

11.2.1 In order to ensure that the lubricants perform as intended, it is important to
ensure that the lay-up lubricant and the field lubricant are compatible with one
another. In particular, it should be understood, that if the lubricants are not
compatible, it may result that their corrosion protection capabilities are
compromised. Thus, it is not permissible to use a field lubricant before
confirmation has been obtained that the perspective field lubricant is compatible
with the lay-up lubricant that was applied by the manufacturer.
11.1.2.1 Pre-approved Lubrication Combinations : Fuchs 10RZ and Brilube 8 are the
asphalt-based lay-up lubricant that typically is applied during manufacture of
Class A ropes. It has previously been verified (through discussions with the
lubricant manufacturer) that this lay-up lubricant is compatible with either
Centiguard 200 or 300 field lubricants (which are available from Fuchs as well). It
also has been verified that Fuchs 10RZ and Brilube 8 are compatible with Brilube
70; however, due to its high viscosity, special precautions must be taken to
ensure that this field lubricant penetrates to the core of the rope.
11.1.2.2 Alternative Field Lubricants May Be Acceptable Provided That Compatibility is
Confirmed: Rigging Department may choose to use a field lubricant other than
those that have been pre-approved. In this case, the lubricant manufacturers
(and/or rope manufacturer) should be contacted to confirm that the lubricants are
compatible. The manufacturer’s approval shall be maintained in file.

11.3 Identification, Application and Record of Field Lubricants

11.3.1 Field lubrication will as a minimum be applied in accordance with the wire rope
and lubricant manufacturer’s recommendation. It is very important that the
method of application is physically able to force the lubricant into and through the
core of the rope.
• Pressure lubrication systems have, in the past, been tested and proven to
be successful at lubricating the core of the rope provided that the field
lubricant has a sufficiently low viscosity. These systems function by flooding
the rope with a relatively high volume of lubricant.
• Misting lubrication systems have, in the past, been tested and proven to be
successful provided that the crevices and valleys of the rope are clear of
excess lubricant and debris, and provided that the lubricant is applied as the
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rope is being bent to expose rope internals (such as when it passes through
a sheave).
• Manual lubricant applications should only be employed in cases where it is
not possible or practical to use either a pressure or misting system. The
concern with manual applications has to do with difficulties in supplying
enough lubricant is to ensure that the rope internals have been thoroughly
lubricated.
11.3.2 In general, it is intended that the need for field lubrication will be identified during
monthly rope inspections, and that field lubricant will be applied before the next
inspection cycle. A “red rust” surface appearance shall be taken to mean that the
rope needs to be lubricated as soon as possible (but definitely within 30 days).
11.3.3 The application of lubricant will be documented (in Reel Files). This
documentation will be maintained for the life of the rope and will be available for
audit.
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12.0 VISUAL INSPECTION

12.1 General
12.1.1 Visual inspection is the key to ensuring that wire rope is suitable for continued
use, and for maximizing its service life expectancy. It is McDermott policy that
these inspections will be carried out by trained, skilled and certified personnel,
and that the inspections will take place at suitable time intervals and at a
sufficient level of detail that a serviceable rope condition always will be assured.
This section provides the requirements for inspection methods, reference
standards, frequencies, and the documentation of results.

12.2 Documentation of Inspections

12.2.1 For all of the inspections described herein, reports will be raised and maintained
in file. The retention period for these reports shall, as a minimum, extend for the
full life of the rope. At the discretion of the Operating Unit, these inspection
records can be discarded when the rope is retired from service. It is
recommended to archive these records to support rope trending analysis that is
required by this procedure.

12.3 Inspection Checklists

12.3.1 Inspection checklists have been developed to provide guidance during the
inspection process, and to ensure that the inspections are documented in a
consistent manner.

12.4 Inspection Scheduling and Frequency

12.4.1 The frequency of wire rope inspection will conform to the requirements of the
equipment on which it is used but will as a minimum comply with the
requirements outlined in this section of the procedure.
12.4.2 Operating Units will maintain an equipment inspection schedule that includes a
plan and schedule for rope inspection and maintenance. This should be within
the local computerized menu-driven Preventive Maintenance System.
12.4.3 All visual inspections, rope inspection and retirement criteria shall be in
accordance with the relevant standard, as follows:
• For Class A Rope: API RP 2D
• While API RP 2D includes rope crushing as a reason for removing a rope
from service JRM recognizes that crushing to the bottom layer of rope on
the drum can not be avoided and in most cases is not cause for removal of
a rope from service. Crushing which is limited to bottom layer on the drum
which does not make its way into rope off of the drum is acceptable. Final
judgment on wire rope acceptance for continued use is up to the certified
internal wire rope inspector.
• For Class B Rope: The corresponding standard within the ASME/ANSI B30
series.
• For Class C Rope: API RP 2I for mooring lines (as reference only), and
ASME/ANSI B30 series for all others.
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12.5 Inspection Prior to First Use

12.5.1 After installation, and prior to first use, checks will be made to ensure that the
wire rope is of the correct type for the application. The inspection will be
performed by a certified rope inspector. The results of the inspection will remain
on file for the life of the rope as a minimum, see attachment-2. The following
steps will be included in this inspection.
• Identify the rope construction and verify that it is correct
• Verify the correct breaking strength by reference to certificates
• Verify the code for retirement criteria and design factors
• Inspect the rope

12.6 Pre-shift Inspection

12.6.1 The operator is responsible for the continued safe operation of his equipment.
These responsibilities require that he always be alert and aware of changes in
the wire rope and rigging that could negatively impact on safety. When damage
is discovered, a certified wire rope inspector will examine the rope and make a
decision on continued service. The equipment operator will ensure that full
details of any such damage and inspection are reported on the operator’s daily
checklist.
12.6.2 The qualified equipment operator will inspect the wire rope prior to the start of
operations for every shift. This inspection will include a visual check of the wire
rope for any obvious signs of damage, deterioration or improper reeving, etc
results will be recorded in the operators daily checklist.
12.6.3 Prior to making a lift, a visual check will also be made by a designated person of
all rigging appliances such as slings, shackles, etc.

12.7 Monthly Inspection During Service

12.7.1 Monthly inspections will be performed and documented by a certified wire rope
inspector for all Class A and Class B wire ropes. At this time a certified wire rope
inspector will examine the rope to assess the condition of the wire rope and
lubrication. While the certified rope inspector may require assistance during
these examinations, only a certified rope inspector is authorized to evaluate the
rope and verify that it is suitable for continued service on the crane (or any other
device). It is important that the full accessible length of the rope be examined.
12.7.2 The detailed monthly inspections will be recorded on the checklists included in
attachment-3. Space is provided on the checklist to document the location and
the type of damage. The certified wire rope inspector will make a
recommendation as to the continued serviceability of the rope. He will also make
a recommendation regarding the need for field lubrication maintenance. The
certified rope inspector will sign and date the inspection report. The
superintendent will also sign and date the report to show his awareness of the
results and his concurrence with the recommendation. Copies of these reports
will be forwarded to the Maintenance Department.
12.7.3 When damage is found, if the rope is acceptable for further use, in addition to
documenting the damaged location on the checklist, the damaged region of the
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rope will be spray painted so that the damaged region can easily be found during
subsequent inspections.
12.7.4 Prior to each inspection, the certified wire rope inspector will review previous
inspection checklists to determine the location and type of any damage which is
previously found. During this review, the inspector will also take note of the
previous rope diameter and lay length measurement as any changes in these
from month to month indicates a potential problem.
12.7.5 During monthly inspections, rope diameter measurements will be taken and
documented at strategic locations along the length of the rope. Such locations
include cross-over points and regions where the rope is highly worked. The
lengthwise position of these measurements will be documented. The
measurements will be taken using a device that is calibrated to be accurate to
three decimal places if the measurement is in U.S. customary units, (i.e. x.xxx
inches), and two decimal places if the measurement is in metric, (i.e. x.xx mm).
12.7.6 All measurements taken from wire rope during inspections will be in the same
units as used for the manufacture of the rope,( i.e. U.S. Customary or Metric).
Comparison of inspection measurements to rope retirement criteria will be done
in comparable system units.
12.7.7 The inspection checklists provide suggested wording to describe the condition of
the rope lubricant, e.g. “continuous and tacky”, “drying and discontinuous”, and
“red rust visible”. When rust is visible, or when there is any doubt as to whether
rust will form before the next inspection period, it is imperative that the inspector
make the recommendation that the rope receive lubrication maintenance at the
earliest possible opportunity.
12.7.8 Pendant lines: will be included in the monthly rope inspections, and will be retired
if their condition meets the retirement criteria of the code. However, these ropes
are very difficult to inspect in the vicinity of end connections. Based on this,
pendant lines will be retired after seven (7) years of service based solely on age,
and in spite of good inspection results. Business units will maintain on file a table
of all pendant lines showing rope installation and retirement dates.

12.8 Inspection Before a Critical Lift

12.8.1 Non-routine inspection may be required prior to certain critical lifts. Typically, a
“critical lift” would involve lifting an item whose weight equals at least 95% of the
rated lifting capacity of the lifting device at lift radius. However, depending on the
circumstances, it may be prudent to perform a critical lift inspection before lifting
items having a weight lower than 95% of the lifting capacity. Also, depending on
circumstances, it may be allowable to forego a critical lift inspection for an item
whose weight exceeds 95% of the rated lifting capacity. The responsibility for
deciding the need for a critical lift inspection rests on the Rigging Superintendent
and General Superintendent.
12.8.2 All critical lift inspections shall be identified as a “critical lift inspection” and fully
documented. This would include sign-off by the inspector and the Rigging
Superintendent that the rope is acceptable for the intended lift.
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12.9 Annual Full Length Inspection

12.9.1 Once per year, a detailed visual inspection and review will be performed for
every rope. Special requirements for Class A Ropes are provided below. For all
ropes the annual inspection should follow the same sequence of steps as for the
“prior to first use” inspection described in section 12.5. However, the step should
be added that a review of the inspection history is required, and should take into
consideration the results of inspections over the past twelve months, if possible.
The results of this inspection should be documented and maintained on file for
the life of the rope as a minimum.
12.9.2 An Annual Full Length Visual Inspections will be performed for all Class A
Ropes by a Qualified 3rd Party: Inspector who has been approved by the JRM
Group E&M Department.
12.9.3 Documentation of the results of this inspection shall be reviewed by Rigging
Engineer and maintained in the Reel File for the life of the rope.
12.9.4 The annual inspection shall encompass the full-length of the rope. It is
permissible that this inspection occur concurrently with an electromagnetic
inspection provided that the visual inspection is thorough and detailed, and that
the inspection does not interfere with the accuracy of the electromagnetic test.
12.9.5 Annual Inspection for all Class B & C Ropes must be performed by a Certified
Wire Rope Inspector. The following steps will be included in the inspection:
• Identify the rope construction.
• Verify correct breaking Strength by reference to certificates.
• Verify code for retirement criteria and design factors.
• Review inspection history.
• Inspect the rope.
12.9.6 Wire rope designated as unfit for use by a certified wire rope inspector, or by a
qualified 3rd Party, will immediately be removed from use on that equipment.
Undamaged portions of the rope may possibly be used for other purposes
provided that inspection by a certified wire rope inspector shows that it meets the
criteria for intended use.
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13.0 NON DESTRUCTIVE EXAMINATION (NDE) OF WIRE ROPE

13.1 General
13.1.1 Electromagnetic testing provides a means of non-destructively examining a rope.
The technique can be used to establish the extent of rope cross-sectional
metallic area loss and to find localized rope faults, pockets of corrosion, etc. It is
particularly valuable in that this technique makes it possible to examine the
internal core of the rope.
13.1.2 The General Superintendent and Rigging Superintendent will ensure that the
NDE for class A applications is undertaken in a timely manner as required by this
procedure.

13.2 Ropes requiring NDE

13.2.1 Electromagnetic Testing is required for All Boom and Main Load Lines in Class
A Applications: This inspection is required after 18 months in use, and every 12
months thereafter. This testing is permitted but not required for any other
application.

13.3 NDE Testing Services

13.3.1 Electromagnetic testing will be performed by a skilled and experienced 3rd Party
provider of this service. While many inspection companies may have the
necessary equipment, every effort should be made to employ a 3rd Party whose
primary business is electromagnetic testing of ropes. All 3rd party NDE providers
require prior approval of the JRM E&M Group. At present, Kim Teck Leong and
Longview are approved to provide NDE services for these ropes.
13.3.2 The qualifications of 3rd Party testing personnel will be reviewed by Rigging
Engineer in order to ensure that they are qualified and experienced. The
accuracy of this test technique is highly dependent on the ability of the test
personnel to interpret the output of the device.
13.3.3 Whenever possible, It is highly recommended that an in-house certified wire rope
inspector accompany the 3rd party inspector throughout the investigation. It is
particularly important that the in-house inspector be aware of the location of any
damage, and take action on any final recommendations when the inspection is
completed.

13.4 NDE Testing Criteria

13.4.1 Electromagnetic Testing Shall be in Accordance with ASTM E1571, Standard
Practice for Electromagnetic Examination of Ferromagnetic Steel Wire Rope: It is
important that purchasing agreements with the 3rd Party testing service require
that the testing be performed in accordance with the ASTM E1571 Standard
Practice. Compliance with this specification ensures that the equipment has been
properly set up and calibrated.
13.4.2 Electromagnetic Test Retirement Criteria Must Clearly Be Communicated to the
3rd Party Testing Provider: It is important to communicate to the 3rd Party test
vendor the codes and retirement criteria that are applicable. It also is important
that the 3rd Party base their recommendations on the retirement criteria that
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have been chosen by McDermott, and that the rope shall immediately be
removed from service when any of these criteria are met. For Class A Ropes, the
broken wire retirement criteria are provided in API RP2D. See paragraph
13.4.2.1 for additional detail. McDermott also has decided on a retirement
criterion based on loss of cross sectional area, see paragraph 13.4.2.2 below.
13.4.2.1 Broken Wire Retirement Criterion: If the electromagnetic test shows that the rope
has a sufficient number of broken wires to merit retirement, then, this should be
confirmed by visual inspection of rope internals, if necessary.
13.4.2.2 Cross-Sectional Area Retirement Criterion: If electromagnetic testing shows that
the rope has lost 10% of its estimated breaking strength, it must be retired
immediately. If testing indicates that corrosion is the cause of this loss of cross
section, then, this condition should be confirmed by visual inspection of rope
internals.
13.4.2.3 Inspection of Rope Internals: Consistent with paragraphs 13.4 and 13.4.2.1,
above, it is permissible to open the rope in order to verify the presence of
damage indicated by the electromagnetic test. This inspection shall be
undertaken by Certified Wire Rope Inspector (level 2 or above), or a qualified 3rd
Party. Care must be taken not to damage the rope during this inspection. If the
decision is made that the electromagnetic test was inaccurate, this section of the
rope should be spray painted and subject to close scrutiny in subsequent
monthly rope inspections.
13.4.3 Electromagnetic Test Reports : It is important that, immediately upon completion
of the test, the 3rd Party testing vendor should provide verbal feedback as to the
status of the rope. The 3rd Party testing vendor should also provide a preliminary
written report that summarizes the test results. It is anticipated that a more
detailed report will be needed and provided at a later date. The preliminary report
and the more detailed report shall be maintained in the Reel File for the life of the
rope as a minimum.
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14.0 TRENDING ANALYSIS

14.1 General
14.1.1 The Wire Rope Inspector level 3 and Rigging Engineer are responsible for
reviewing the trend analysis derived from the Rigging Department wire rope
records. Rigging Department will review rope records to determine rope usage
trends that can be used to increase rope life and otherwise improve rope usage.
Typically, this will include evaluation of:
• Condition of ropes in service at their retirement.
• The total history of the rope correlated with their condition.
• Problems with in-service rope applications.
14.1.2 This trending analysis review will be performed and documented at least once
per year

14.2 Rope Retirement Classification

14.2.1 When a rope is retired from service a certified wire rope inspector will classify the
rope problem or reason for retirement into one of these three areas:
• Rope Service Related - Examples of rope service-related problems include
broken wires, crushing, abrasion, or corrosion. Actions that might be taken if
the data shows that corrosion is a consistent problem is that the type of
lubricant used and the frequency of application should be reviewed.
• Equipment Related - If the reason for retirement is equipment-related,
inspection reports usually show a downward trend in rope life as well as
notable wear to the sheaves and/or hoist drum.
• Operator Related - Operator-related causes such as popped rope core due
to shock loading require action to be taken with operator awareness or
training.
14.2.2 Using information gathered from a review of inspection reports, the
manufacturers of the equipment and wire rope will be consulted for
recommendations to improve rope service life.
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15.0 CONSIDERATIONS FOR THE APPLICATION OF WIRE ROPE

15.1 In some cases it is necessary for PTMI to develop in-house rope specifications
and the E&M Department are responsible for the approval of these
specifications.
15.2 For some applications, such as for abandonment and recovery equipment, PTMI
acts as the equipment designer and/or integrator. This section provides a
procedure for developing a rope specification for PTMI-designed equipment. This
same procedure can be used to develop a rope procedure for the case where the
original equipment manufacturer is no longer in business (such as for the
Russian-built cranes on the PLBG) or is not willing to provide rope specifications,
but would prefer to provide the rope according to a part number (e.g. Manitowoc).
15.3 Competent persons with the appropriate training, knowledge, experience and
certification will perform the design, selection, and application of wire rope in
mechanical systems. In some cases, a design team will be required in order to
adequately cover the required range of technical expertise.
15.4 Input from in-house experts, equipment/component manufacturers and makers of
wire rope will be included in the design and approval process. The result of this
effort will be a specification that can be used to procure the rope.
15.5 The rope design and selection process will be fully documented and the
documentation will be maintained on file to:
• Identify the in-house individuals that were involved in the design review
process and what their role was.
• Identify external contacts such as rope manufacturers, etc.
• Demonstrate that these key individuals have reviewed and approved the
rope specification.
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16.0 LIST OF ATTACHMENTS

Attachment – 1 : Wire Rope Receipt Inspection
Attachment – 2 (a - d) : Prior to First Use Inspection Report
Attachment – 3 (a - d) : Monthly Wire Rope Inspection Report
Attachment – 4 (a - d) : Annual Wire Rope Inspection Report
Attachment – 5 : Wire Rope in Storage Inspection Report
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Attachment – 1: Wire Rope Receipt Inspection

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Attachment – 2a: Prior to First Use Inspection Report: Overhead Crane

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Attachment – 2b: Prior to First Use Inspection Report: Tower Crane

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Attachment – 2c: Prior to First Use Inspection Report: Mobile Crane

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Attachment – 2d: Prior to First Use Inspection Report: Boom Pendant

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Attachment – 3a: Monthly Wire Rope Inspection Report: Overhead Crane

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Attachment – 3b: Monthly Wire Rope Inspection Report: Tower Crane

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Attachment – 3c: Monthly Wire Rope Inspection Report: Mobile Crane

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Attachment – 3d: Monthly Wire Rope Inspection Report: Boom Pendant

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Attachment – 4a: Annual Wire Rope Inspection Report: Overhead Crane

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Attachment – 4b: Annual Wire Rope Inspection Report: Tower Crane

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Attachment – 4c: Annual Wire Rope Inspection Report: Mobile Crane

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Attachment – 4d: Annual Wire Rope Inspection Report: Boom Pendant

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Attachment – 5: Wire Rope in Storage Inspection Report