The Future of Rigging Safety - Synthetics June 16-17, 2016 NMSA 2016 Seattle, WA Kris Volpenhein

Transcription

1 The Future of Rigging Safety - Synthetics June 16-17, 2016 NMSA 2016 Seattle, WA Kris Volpenhein

2 Agenda High Performance Fibers Fiber Characteristics Usage Considerations & Safe Discard Elongation & Splicing Considerations Inspection & Retirement balancing Value & Risk Safety Benefits Technology / Application Case Studies Deepwater Service Winch Mining Dump Rope Vessel Mooring / ETOPS / Reduced Recoil Mobile Crane Hoist Rope Offshore Heavy Lift Summary

3 About Samson Founded in 1878 in Boston History based on innovation Largest high performance rope producer in the world Headquarters in Ferndale, WA Manufacturing locations in Ferndale & Lafayette, LA 320 employees world-wide Global distribution network Products sold in 50+ countries

4 History 1878: Company founded 1884: Registered Samson and Lion Trademark 1957: Invented/ patented double braided rope 1972: 1 st synthetic offshore SPM introduced (North Sea) 1982: 1 st HMPE ropes introduced 1993: Acquired by Wind River Holdings 1996: Introduced AmSteel-Blue 1st tanker fleet converted tohmpe (Chevron) 2006: European sales office 2008: Expanded Lafayette manufacturing facility to serve offshore oil and gas industry 2010: Singapore sales office 2012: Australian sales office 2013: Innovation and Training Center completed 2014: 1 st Synthetic hoist line for mobile cranes The biblical character, Samson, slaying the lion is the oldest active trademark in the United States.

5 Vision and Strategy Vision To be the world's leading provider of high performance synthetic strength members Strategy We bring value to customers by providing solutions. We do this through a cycle of consultation, innovation, engineering, and service. We support our strategy with Lean practices and unsurpassed quality, marketed under the Samson brand as the symbol of high performance.

6 Fiber Characteristics Tenacity Modulus Specific gravity Creep Critical temperature Chemical resistance Coefficient of Friction

7 Fiber Characteristics Tenacity The tensile stress expressed as the force per unit linear density of the unstrained specimen (CI ) Representation of fiber strength Commonly expressed in gramsforce per denier (d / denier) Modulus & Elongation The resistance to deformation; Compliance Stiffness Stretchy-ness Elasticity Elastic & Permanent Elongation

8 Fiber Characteristics Tenacity The tensile stress expressed as the force per unit linear density of the unstrained specimen (CI ) Representation of fiber strength Commonly expressed in gramsforce per denier (d / denier) Modulus & Elongation The resistance to deformation; Compliance Stiffness Stretchy-ness Elasticity Elastic & Permanent Elongation

9 Fiber Characteristics Tenacity The tensile stress expressed as the force per unit linear density of the unstrained specimen (CI ) Representation of fiber strength Commonly expressed in gramsforce per denier (d / denier) Modulus & Elongation The resistance to deformation; Compliance Stiffness Stretchy-ness Elasticity Elastic & Permanent Elongation

10 Fiber Characteristics Tenacity The tensile stress expressed as the force per unit linear density of the unstrained specimen (CI ) Representation of fiber strength Commonly expressed in gramsforce per denier (d / denier) Modulus & Elongation The resistance to deformation; Compliance Stiffness Stretchy-ness Elasticity Elastic & Permanent Elongation

11 Fiber Characteristics Specific gravity (SG) Ratio of the mass of a material to the mass of an equal volume of water SG < 1 will float in water Common representation of a fiber rope s volumetric mass density Creep Material cold flow elongation property Critical consideration for static loading applications Varies greatly by base material properties

12 Fiber Characteristics Critical/Melting Temperatures High temperatures may have adverse affects on different fiber materials Fiber specifications will commonly list two key points in regards to temperature Critical Temperature the maximum working temperature allowed Melting Point temperature at which the fiber material will melt (or char) Polyester *PBO Nylon Fiber Melting Point Chemical Resistance A fiber s ability to withstand the effects of certain chemicals Most synthetic fibers are resistant to a variety of chemicals Resistance to degradation typically dependent on exposure time, temperature, and concentration *LCP HMPE *Aramid Temperature ( F) *char temperatures listed, these fibers do not melt

13 Fiber Characteristics Coefficient of friction Numerical value characterizing a fiber s resistance to sliding across a surface Typically significantly lower coefficient of friction than steel wire Steel Polyester Approximate COF PBO Nylon LCP HMPE Aramid Friction Coefficient

14 High Performance Fiber Ropes HMPE (Dyneema, Spectra ) Positive buoyancy Floats (SG < 1) Advantages Excellent abrasion resistance Good UV resistance High strength / weight Very low elongation Excellent flex fatigue Extremely light weight Excellent chemical resistance Disadvantages Low heat resistance Creeps under static loads

15 High Performance Fiber Ropes LCP (Vectran ) Negative buoyancy Sinks (SG > 1) Advantages Excellent dimensional stability High strength / weight Very low elongation Light weight High critical temperature Disadvantages UV Chemical exposure

16 High Performance Fiber Ropes Aramid (Technora, Kevlar ) Negative buoyancy Sinks (SG > 1) Advantages Excellent dimensional stability High strength / weight Very low elongation Light weight High critical temperature Disadvantages UV resistance Axial Compression fatigue Abrasion resistance

17 Fiber Characteristics Summary Wide variety of fiber types results in range of possible solutions Lost in Samson Catalog High performance fiber ropes replacing steel wire rope Safety and speed Performance requirements will dictate the optimal solution Consult the Experts

18 Usage Considerations & Safe Discard The practical considerations Rope change-in-length behavior Twist in braided ropes Making the rope work: eyes terminations splicing Inspections & Safe Discard Pros & Cons Tools for decision making

19 Rope Length Behavior Elongation is a nuanced phenomena! Permanent Elongation i.e. Constructional Stretch Elastic Elongation Hysteresis Users should consider the implications

20 Rope Length Behavior

21 Induced Twist Induced Twist Can decrease strength in a braided rope Caused by uneven load sharing between strands

22 Termination Efficiency Splicing When properly executed, splices translate 100% of the published rope strength* It is important to use the proper method for rope construction and fiber Alternative Options Knot Reduces strength Potted termination Can achieve up to 90% efficiency, but sensitive to conditions *Note: All Samson published specs are based on spliced values unless otherwise noted. Samson splicing instructions are available in the Samson Splicing Manual, on DVD, and on the web at

23 Inspection & Retirement Single Braid vs Jacketed Single Braid provides the ability to inspect & repair Jacketed provides resistance to cutting

24 Inspection & Retirement AmSteel Blue K-100

25 Inspection & Retirement

26 Safety High Performance Fiber Ropes Driving Safety Improvements Unpredictable recoil Heavy Strain injuries Fish Hooks Hand injuries Lower stored energy recoil Lightweight Easy handling Faster Rigging / Deployment Soft Hand Reduced cutting injuries

27 Case Studies High Performance Fiber Ropes Driving Safety Improvements

28 Shell s Perdido Spar Synthetic Rope Traction Winch World s deepest oil production facility 2,800 m. (9,200 ft.) water depth Onboard winch to reduce reliance on support vessels Steel wire not viable Quantum-12 solution 85% less weight Neutral buoyancy Patented DPX fiber technology Traction Bend fatigue Complete rope and winch package

29 Mining Dump Rope

30 Mining Dump Rope Productivity Improvement 3 4 diameter wire rope replacement Reduces weight by 83% 1/6th the change-out time Increases machine capacity time and load Safety Reduces back injuries Reduces time in pit and exposure to other equipment

31 Vessel Mooring Key Benefits Reduces; Risk of injury from handling weight and fish hooks Mooring deployment time Maintenance costs Long Term Value 3 year ROI year life span Environmentally friendly Onboard service & repair

32 High Performance Mooring Lines Technologies ETOPS / Fire Wire Fiber replacement for ETOPS reducing hand and back injuries Reduced Recoil Risk Sequential break

33 High Performance Mooring Lines Technologies ETOPS / Fire Wire Fiber replacement for ETOPS reducing hand and back injuries Reduced Recoil Risk Sequential break

34 Offshore HeavyLift Slings Monopile installation in North Sea 80% weight savings vs wire Monopile weights of MT Rigging time savings Durability Installed 140 turbine foundations Recertified by Lloyds

35 K-100 TM Hoist Rope Application Development Partners Manitowoc Crane technology Samson Rope and coating technology DSM Dyneema Fiber technology Rope Construction & Fibers 12- strands Blend of Dyneema Six twisted each direction (torque neutral) Control core Maintains cross-sectional stiffness to improve winding Proprietary coating to improve abrasion and bend fatigue

36 K-100 TM Hoist Rope Direct replacement for steel wire rope Same drums / sheaves utilized for both Minor retrofit required to sheaves/blocks Advantages over existing technology 1/7 th weight (vs R.R. Steel Wire); 16mm conversion saves 74 lbs. / 100 ft. 19mm conversion saves 108 lbs. / 100 ft. Resistance to common mechanical damage; Birdcaging Kinking Diving Cabling No lubrication required Non-corrosive material High chemical resistance

37 Summary High Performance fiber ropes provide a proven option for replacing steel wire rope technically challenging applications Value added to market served, via; Reduced Weight Improved handling speed & safety Increased service life Maximizing service life & product value; Periodic inspection & care needed to prolong the life Structured programs for line maintenance & retirement