1、June 2013 Translation by DIN-Sprachendienst.English price group 22No part of this translation may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 5
2、3.020.30!%NO“2024344www.din.deDDIN ISO 4309Cranes Wire ropes Care and maintenance, inspection and discard (ISO 4309:2010),English translation of DIN ISO 4309:2013-06Krane Drahtseile Wartung und Instandhaltung, Inspektion und Ablage (ISO 4309:2010),Englische bersetzung von DIN ISO 4309:2013-06Apparei
3、ls de levage charge suspendue Cbles Entretien et maintenance, inspection et dpose (ISO 4309:2010),Traduction anglaise de DIN ISO 4309:2013-06SupersedesDIN 15020-2:1974-04www.beuth.deDocument comprises 57 pagesIn case of doubt, the German-language original shall be considered authoritative.06.13 Cont
4、ents Page Introduction .4 1 Scope . 5 2 Normative references . 6 3 Terms and definitions. 6 4 Care and maintenance 7 4.1 General. 7 4.2 Rope replacement. 7 4.3 Offloading and storing the rope 9 4.4 Condition of the rope prior to installation 9 4.5 Installing the rope. 9 4.6 Running-in the new rope 1
5、2 4.7 Maintaining the rope. 13 4.8 Maintenance of rope-related parts of the crane 13 5 Inspection 14 5.1 General. 14 5.2 Daily visual inspection . 14 5.3 Periodic inspection. 14 5.4 Inspection following an incident . 17 5.5 Inspection following period with crane out of operation 17 5.6 Non-destructi
6、ve testing 17 6 Discard criteria 18 6.1 General. 18 6.2 Visible broken wires . 18 6.3 Decrease in rope diameter. 21 6.4 Fracture of strands . 21 6.5 Corrosion. 23 6.6 Deformation and damage. 24 Annex A (informative) Key areas requiring particular close inspection. 27 Annex B (informative) Typical mo
7、des of deterioration. 29 Annex C (informative) Internal examination of rope. 38 Annex D (informative) Typical examples of inspection record 41 Annex E (informative) Useful information on rope deterioration and discard criteria 43 Annex F (informative) Combined effect assessment of rope condition and
8、 severity rating One method . 46 Annex G (informative) Examples of cross-sections of ropes and corresponding rope category number (RCN) 49 Annex H (informative) Guidance on assessment and rating of external corrosion 55 Bibliography . 57 A comma is used as the decimal marker. DIN ISO 4309:2013-06 2N
9、ationale foreword. 3National foreword General Discard of wire ropes Wire ropes used today in cranes and lifting appliances such as hoists are carefully selected by the manufacturer based on their application (e.g. as hoist wires or guy wires). Wire ropes for cranes are subjected to high stresses and
10、 must therefore be deemed as “wear parts”. Wire rope must be discarded when certain types of wear or damage are found during an inspection of the rope, in which case the rope is said to have “reached discard”. Wire ropes on cranes and lifting appliances are regarded as expendable components, requiri
11、ng replacement when the results of inspection indicate that their condition has diminished to the point where further use would be unwise from a safety standpoint. In Germany, the national standards DIN 15020-1, Lifting appliances Principles relating to rope drives Calculation and construction and D
12、IN 15020-2, Lifting appliances Principles relating to rope drives Supervision during operation are still used to determine the discard of steel wire rope, although the informative Annex to DIN EN 12385-3, Steel wire ropes Safety Part 3: Information for use and maintenance refers to ISO 4309 in this
13、regard. The following German regulation governs occupational health and safety in the provision of work equipment at national level: Betriebssicherheitsverordnung (BetrSichV) (German Ordinance on Industrial Safety and Health) History International Standard ISO 4309:2010, Cranes Wire ropes Care and m
14、aintenance, inspection and discard, Edition: 4 has been prepared by Technical Committee ISO/TC 96 “Cranes”, Subcommittee SC 3 “Selection of wire ropes”. The Normenausschuss Maschinenbau (Mechanical Engineering Standards Committee), Section “Cranes”, Steering Committee CEN/TC 147 ISO/TC 96 Krane (NA
15、060-22-10 AA) and Working Committee NA 060-22-15-03 AK Seile were responsible for the German translation of the ISO Standard and thus, its adoption into the collection of German Standards. The Standards Committee and the German wire rope trade association Drahtseilvereinigung e.V. herewith document
16、the conformity of the German translation with the ISO Standard. Because Steering Committee CEN/TC 147 ISO/TC 96 Krane (NA 060-22-10 AA) deems the ISO Standard to be a helpful document for manufacturers, expert appraisers, crane operators and others involved in the care and maintenance, and the inspe
17、ction and discard of wire rope, it has adopted the standard at national level as a DIN ISO Standard. The first edition of the German version is a translation of the 4th edition of ISO 4309 published in 2010 and fills a gap in the German body of standards. Amendments The current edition of the Englis
18、h version of ISO 4309:2010 (Fourth edition dated 2010-08-01) takes account of all operating conditions for steel wire rope, which have considerably changed over the past years, and thus replaces DIN 15020-2:1974-04. Previous editions DIN 4130: 1940x-10 DIN 15020-2: 1954-11, 1974-04 DIN ISO 4309:2013
19、-06 3 Introduction A wire rope on a crane is regarded as an expendable component, requiring replacement when the results of inspection indicate that its condition has diminished to the point where further use would be unwise from a safety standpoint. By following well-established principles, such as
20、 those detailed in this International Standard, along with any additional specific instructions provided by the manufacturer of the crane or hoist and/or by the manufacturer of the rope, this point should never be exceeded. In addition to encompassing the guidance on storage, handling, installation
21、and maintenance, which was first introduced in the last revision, this International Standard also provides discard criteria for those running ropes which are subjected to multi-layer spooling, where both field experience and testing demonstrate that deterioration is significantly greater at the cro
22、ss-over zones on the drum, than at any other section of rope in the system. It also provides more realistic discard criteria covering decrease in rope diameter and corrosion, and gives one method for assessing the combined effect of deterioration at any position in the rope. When correctly applied,
23、the discard criteria given in this International Standard are aimed at retaining an adequate safety margin. Failure to recognize them can be extremely harmful, dangerous and damaging. To assist those who are responsible for “care and maintenance” as distinct from those who are responsible for “inspe
24、ction and discard”, the procedures are conveniently separated. DIN ISO 4309:2013-06 4Cranes Wire ropes Care and maintenance, inspection and discard 1 Scope This International Standard establishes general principles for the care and maintenance, and inspection and discard of steel wire ropes used on
25、cranes and hoists. This International Standard is applicable to those ropes used on the following types of cranes, the majority of which are defined in ISO 4306-1: a) cable and portal cable cranes; b) cantilever cranes (pillar jib, wall or walking); c) deck cranes; d) derrick and guy derrick cranes;
26、 e) derrick cranes with rigid bracing; f) floating cranes; g) mobile cranes; h) overhead travelling cranes; i) portal or semi-portal bridge cranes; j) portal or semi-portal cranes; k) railway cranes; l) tower cranes; m) offshore cranes, i.e. cranes mounted on a fixed structure supported by the sea b
27、ed or on a floating unit supported by buoyancy forces. This International Standard applies to rope on cranes used for hook, grabbing, magnet, ladle, excavator or stacking duties, whether operated manually, electrically or hydraulically. This International Standard also applies to rope used on hoists
28、 and hoist blocks. In view of the fact that the exclusive use of synthetic sheaves or metal sheaves incorporating synthetic linings is not recommended when single-layer spooling at the drum, due to the inevitability of wire breaks occurring internally in large numbers before there is any visible evi
29、dence of any wire breaks or signs of substantial wear on the periphery of the rope, no discard criteria are given for this combination. DIN ISO 4309:2013-06 5 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only
30、the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 17893, Steel wire ropes Vocabulary, designation and classification 3 Terms and definitions For the purposes of this document, the terms and definitions given in IS
31、O 17893 and the following apply. 3.1 nominal diameter d diameter by which the rope is designated 3.2 measured diameter actual diameter dmaverage of two measurements, taken at right angles to one another, of the diameter that circumscribes the rope cross-section 3.3 reference diameter drefmeasured di
32、ameter of a section of rope that is not subject to bending, taken directly after the rope has been broken in NOTE This diameter is used as the baseline for uniform decrease in diameter. 3.4 cross-over zone that portion of rope coincident with a crossing over of one wrap by another as the rope traver
33、ses the drum or rises from one layer to the next at the drum flange 3.5 wrap one revolution of rope around a drum 3.6 reel flanged spool on which rope is wound for shipment or storage 3.7 wire rope periodic inspection in-depth visual inspection of the rope plus measurement of the rope and, if practi
34、cable, an assessment of its internal condition NOTE This is sometimes referred to as a “thorough examination”. 3.8 competent person wire rope inspection person having such knowledge and experience of wire ropes on cranes and hoists as is necessary for that person to assess the condition of the rope,
35、 make a judgement as to whether it may remain in service and stipulate the maximum time interval between inspections DIN ISO 4309:2013-06 63.9 valley wire break wire break that occurs at the inter-strand contact point or valley area between two outer strands NOTE Outer wire breaks that also occur wi
36、thin the rope anywhere between one valley area and the next, including any strand-core breaks, may also be regarded as valley wire breaks. 3.10 severity rating amount of deterioration expressed as a per cent towards discard NOTE The rating may relate to either an individual mode of deterioration, e.
37、g. broken wires or decrease in diameter, or the combined effect of more than one mode of deterioration, e.g. broken wires and decrease in diameter. 4 Care and maintenance 4.1 General In the absence of any instructions provided by the manufacturer of the crane in his manual and/or any provided by the
38、 manufacturer or supplier of the rope, the general principles given in 4.2 to 4.7 shall be followed. 4.2 Rope replacement Unless an alternative rope has been approved of by the crane manufacturer, rope manufacturer or other competent person, only one of the correct length, diameter, construction, ty
39、pe and direction of lay and strength (i.e. minimum breaking force), as specified by the crane manufacturer, shall be installed on the crane. A record of the rope change shall be placed on file. In the case of larger diameter rotation-resistant ropes, it may be necessary to apply additional means of
40、securing the rope ends, e.g. through the use of steel straps, particularly when preparing samples for test. If the length of rope required for use is to be cut from a longer length, such as a bulk manufactured reel of rope, servings shall be applied at both sides of the intended cutting point to pre
41、vent the rope from unlaying (i.e. unravelling) after the cut has been made. Figure 1 is an example of how a single-layer rope should be served before cutting. For rotation-resistant and parallel-closed ropes, multiple length servings may be necessary. Ropes that are only lightly preformed are more l
42、ikely to unlay (i.e. unravel) after cutting, if inadequate or insufficient servings are applied. NOTE Serving is sometimes referred to as “seizing”. Unless an alternative rope termination has been approved of by the crane manufacturer, rope manufacturer or other competent person, only one of a type,
43、 as specified by the crane manufacturer in his manual, shall be used to attach a rope to a drum, hook block or anchor point on the machinery structure. DIN ISO 4309:2013-06 7 L = 2d minimum Figure 1 Application of serving prior to cutting of single-layer type rope DIN ISO 4309:2013-06 84.3 Offloadin
44、g and storing the rope To avoid accidents and/or damage to the rope itself, ropes should be offloaded with care. Reels or coils of rope shall not be dropped, neither shall they be struck by a metal hook or fork of a lift truck or any other external force that could damage or deform the rope. Ropes s
45、hould be stored in a cool, dry building and should not be allowed to be in contact with the floor. They should not be stored where they are likely to be affected by chemicals, chemical fumes, steam or other corrosive agents. If outdoor storage cannot be avoided, ropes should be covered so that moist
46、ure cannot induce corrosion. Ropes in storage shall be checked periodically for any signs of deterioration such as surface corrosion and, if deemed necessary by a competent person, dressed with a suitable preservative or lubricant which is compatible with the rope manufacturing lubricant. In warm en
47、vironments, the reel shall be periodically rotated one half-turn to prevent drainage of lubricant from the rope. 4.4 Condition of the rope prior to installation Before installing the rope, and preferably on receipt, the rope and its certificate should be checked to ensure that the rope is in accorda
48、nce with that ordered. The strength of the rope to be installed shall not be lower than that specified by the crane manufacturer. The diameter of the new rope shall be measured with the rope under no tension and the value recorded. Check the condition of all sheave and drum grooves to ensure that th
49、ey are capable of accepting the size of the new rope, do not contain any irregularities, such as corrugations, and have sufficient remaining thickness to safely support the rope. For optimal performance, the effective sheave groove diameter should be larger than the nominal rope diameter by about 5 % t
