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June 2001
SCHEME OF TESTING AND INSPECTION FOR
CERTIFICATION OF
LOCKED COIL WINDING ROPES
ACCORDING TO IS 3626:2001
1.0 LABORATORY - An inspection department shall be maintained which shall be
suitably equipped and staffed to carry out the different tests and various inspections given
in the specification.
1.1 All the testing apparatus shall be periodically checked and calibrated and records of
such checks checks shall be maintained. Pressure gauges shall be calibrated at an interval
of one month.
2.0
TEST RECORDS - All records of tests and inspection shall be kept in suitable
forms approved by the Bureau.
2.1
Copies of any records and other connected papers that may be required by the
Bureau shall be made available at any time on request.
2.2
It is recommended that, as far as possible, Statistical Quality Control (SQC)
methods may be used for controlling the quality during production as envisaged in this
scheme [ See. IS 397 (Part 1):1972, IS 397(Part 2):1985 and IS 397 (Part 3):1980 ].
In addition the provision of quality system specified in IS 14003:1988 "Quality
Systems Model for the Quality Assurance in final Inspection and Test" may be complied with as
far as possible.
2.3
3.0
STANDARD MARK – The standard Mark, as given in Column (1) of
the First Schedule of the licence shall be stamped on a metal tag attached to each reel or
drum on which ropes are coiled, provided always that the wire rope coiled on the reel or
drum to which this Mark is thus applied conforms to every requirement of the
specification.
3.1 The standard mark shall be applied in such a manner that it gets
destroyed when the reels are opened for use, as otherwise this might be
misused.
3.2 The manufacturer shall furnished to the purchaser a Certificate of test
with each reel of completed rope in the proforma given in Annexure -I.
4.0 OTHER MARKING - In addition, the following information shall
be legibly stamped upon a metal tag securely attached, when wire ropes are
supplied in coils. In case, wire ropes are supplied in reels, the information
may be stenciled on both sides, of the reels or stencilled on one side of the
reel & metallic tag giving the information may be attached on the other side
of the reel.
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June 2001
a)
b)
c)
d)
e)
f)
g)
h)
i)
Name of the manufacturer or his recognised trade mark, if any;
Type of construction ;
Identification in code or otherwise, to enable the date and lot of
manufacture to be traced back to the factory records ;
Nominal diameter of ropes;
Tensile designation of round and shapes wires;
Length of rope;
Order number of purchaser;
Type of external lubricant recommended for application in
service; and
Licence number (CM/L………..).
5.0
LEVELS OF CONTROL : The tests as indicated in Table 1 attached and at the
levels of control specified therein, shall be carried out on the whole production covered
under this scheme and appropriate records and charts maintained in accordance with
paragraph 2 above. On the basis of test results decision regarding conformity or
otherwise of the control unit shall be taken. All the production which conforms to the
Indian Standard and covered by the licence shall be marked with Certification Mark of
the Bureau.
5.1
The rope shall not be less than the length specified by the purchaser nor shall it
exceed the specified length by more than 2.5%.
5.2
All ropes shall be lubricated as per cl.7.1 of the specification.
6.0
In respect of all other clauses of the specification and at all stages of manufacture,
the factory shall maintain appropriate controls and checks to ensure that their production
conforms to the various requirements of the specification.
7.0
The rope shall be suitably protected to avoid damage in transit and corrosion.
8.0
In view of the fact that steel wire ropes are an item involving safety, extreme care
should be exercised in the selection of raw materials and during the process of
manufacture. Annexure II gives the requirements of the Director General of Mines
Safety in this regard which should also be satisfied.
9.0
REJECTIONS -A separate record shall be maintained giving information
relating to the rejection of production not conforming to the requirements of the
specification and the method of its disposal. Such material shall in no case be stored
together with that conforming to the specification.
10.0 SAMPLES - The licensee shall supply, free of charge, the samples required in
accordance with the Bureau of Indian Standards (Certification) Regulations 1988, as
subsequently amended, from his factory or godowns. The Bureau shall pay for the
samples taken by it from the open market.
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June 2001
11.0 REPLACEMENT - Whenever a complaint is received soon after the
goods with Standards Mark have
been purchased and used , and if there is
adequate evidence that the goods have not been misused, defective goods are
replaced free of cost by the licensee in case the complaint is proved to be genuine and the
warranty period ( where applicable ) has not expired. The final authority to judge
conformity of the product to the Indian standards shall be with the Bureau.
11.1 In the event of any damage caused by the goods bearing the Standard Mark, or
claim being filed by the consumers against BIS Standards Mark and not "conforming to"
the relevant Indian Standard, entire liability arising out of such non conforming product
shall be of the licensee and BIS shall not in any way be responsible in such cases.
12.0 PRODUCTION DATA - The licensee shall send to BIS as per the enclosed
proforma-1 to be authenticated by a Chartered Accountant or by the manufacturer by
giving an affidavit/undertaking, a statement of quantity produced, marked and exported
by him and the trade value thereof at the end of each operative year of the licence.
Table 1.…..
3626:2001
LOCKED COILD WINDING ROPES
TABLE 1 LEVELS OF CONTROL
(Para 5 Of Scheme of Testing and Inspection)
Test Details
Clause.
No.
Requirement
Levels of Control
Test Methods
Clause
Reference
5.3
Chemical Composition
5.1
IS 1835
Each heat
In case a test certificate is obtained
of steel wire
ensuring conformity to the specification
No. of Samples
Lot Size
One
One heat
Two
One coil
no further analysis is required.
5.5
Galvanising Test
5.5
IS 3626:2001
Each fifth coil of 1. Only required in case of galvanised
galvanized wire
rope.
Frequency
4.
Dimensions
Each continuous
4.1 &
-do-
Two
-do-
One
4.2
length of finished rope
6.
7.1
Mass of rope,
-doBreaking Force
-do-
Table 1
Two
One from each end of rope.
Construction
-do-
7.1
-do-
One
IS 3626:2001
LOCKED COILD WINDING ROPES
TABLE 1 LEVELS OF CONTROL
(Para 5 Of Scheme of Testing and Inspection)
Test Details
Clause
No.
9
Requirement
Individual wires before
stranding
Levels of Control
Test Methods
Clause
Reference
No. of Samples
Lot Size
Frequency
Round Wires
a) Diameter
coil
b) Tensile strength
c) Torsion Test
d) Reverse bend test
10.1
IS 1835
If a sample fails in any of the
12.2
-dorequirement, the particular coil shall
12.3
-dobe rejected for the purpose of marking
12.4
-doISI certified ropes
Two
Each
one
-do-
one
-do-
one
-do-
Shaped Wires
a) Dimensions
Fig. 1
IS 3626:2001
Two
-do-
b) Tensile Strength
9.1.1
-do9.1.2
9.1.3
-do-
One
-do-
-do-do-
One
One
-do-do-
c) Torsion Test
d) Reverse bend test
IS 3626:2001
LOCKED COILD WINDING ROPES
TABLE 1 LEVELS OF CONTROL
(Para 5 Of Scheme of Testing and Inspection)
Test Details
Clause
No.
10 *
Levels of Control
Requirement
Test Methods
Clause
Reference
No. of Samples
Lot size
Test on wires from completed
wire rope
Round Wires
a) Diameter
10.1
IS 1835
Nine
continuous
If two or more wires fail to pass the tensile,
b) Tensile test
12.2
-do-doproduction of wire
torsion and reverse bend tests specified,
c) Torsion Test
12.3
-do-doretests limited to the type of test under which
d) Reverse Bend test
12.4
-do-dothe failure occurred, shall be carried out.
Each
rope
If under the retest, two or more wires fail in
Shaped Wires
any test, the rope represented by the
Sample shall be considered not to comply
Fig. 1 IS 3626:2001
with this specification.
b) Tensile Test
9.1.1
-doc) Torsion Test
9.1.2
-dod) Reverse bend test
9.1.3
-doa) Dimension
Nine
-do-do-do-
-do-
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------* If required by the purchaser.
Frequency
IS 3626:2001
LOCKED COILD WINDING ROPES
TABLE 1 LEVELS OF CONTROL
(Para 5 Of Scheme of Testing and Inspection)
Test Details
Sl.
No.
Requirement
Round Wires
Each continuous
a) Diameter
production of wire
b) Tensile Test
rope
c) Torsion Test
d) Reverse bend test
Levels of Control
Test Methods
Clause
Reference
No. of Samples
IS 1835:1976
If two or more wires fail to pass the
10.1
tensile, torsion and reverse bend
12.2
-dotests specified, retests limited to the
12.3
-dotype of test under which the failure
12.4
-dooccurred, shall be carried out. If
Lot Size
Nine
-do-do-do-
If under the retest, two or more wires
Shaped Wires
fail in any type of test, the rope
represented by the sample shall be
Fig. 1
IS 3626:2001
considered not to comply with this
b) Tensile Test
9.1.1
-do-dospecification.
c) Torsion Test
9.1.2
-doa) Dimension
d) Reverse bend test
9.1.3.
-do-
Nine
-do-do-do-
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Frequency
ANNEX URE(Clause 3.2 of Scheme of Testing & Inspection)
CERTIFICATE OF TEST
Certificate No. ……………………………….
Reel/Coil No…………………………
1)
Name and address of maker or supplier of rope ………………………………………………
2)
Particulars of Rope
3)
a)
Diameter of rope ………………………………..
b)
Number of strands ……………………………...
c)
Number of wires per strands …………………….
d)
Lay ………………………………………………
e)
Coating …………………………………………
Tensile strength grade ……………………………………
a)
Date of test of sample of rope ………………….
b)
Breaking load of rope (Aggregate/Actual)………………………
4)
Name and address of test house making test and examination …………………………….
5)
Name and designation of signatory of test house conducting the test and examination………….
6)
Any other details ………………………………
I certify that the above particulars are correct and that the wire rope conforms to IS 3626:2001.
………..…………………………..
Signature of competent person
Date ………………………………
A N N E X U R E - II
Requirements of the Director General of Mines
Safety (formerly Chief Inspector of Mines)
Regarding Raw Materials and Process Control
(Para 8 of the Scheme of Testing & Inspection )
1.
Raw Material i.e. Wire Rods
1.1
Only coils of the same heat or cast number and having the same carbon range shall be selected for
making a winding rope.
Provided that in the case of Flattened strand locked coil and other special construction ropes all
wires symmetrically placed about the axes of the strand of a winding rope shall be made from coil
of wire rod of the same heat or cast number and of the same carbon range.
1.1.1
If coils of different heat or cast number are found mixed together such coils shall not be used for
making winding ropes, unless each coil is chemically tested and carbon range of steel is again
stamped on a tag and fixed on the coil.
1.2
Not less than 20 percent of the coils against each heat or cast number shall be analysed on drillings
taken from both ends for carbon content. These samples shall also be macro - examined to detect
segregation of carbon and sulphur. If the carbon content is not as per the suppliers' certificate or if
segregation is detected in the coil of a particular 'heat', then all coils drawn for winding rope from
that 'heat' shall be analysed on 100 per cent basis, and only those coils which are found to conform
to the declared carbon content and found free from segregation shall be used for making a winding
rope.
1.3
Each coil of wire rods shall be coloured to indicate its carbon range as per colour code, and bear a
metal tag giving its heat or cast number, carbon content and size. The coils of wire rod shall be
stacked systemically according to their heat or cast number and carbon content.
2.0
Heat Treatment (Patenting)
2.1
Temperature in the patenting furnace shall the thermostatically controlled and be recorded at
regular intervals for each charge.
2.2
Graphs shall be used to record the temperature of patenting as well as hourly speed of wire rods
or wire taken through the furnace. If the hourly speed record cannot be made directly on the same
graph, a separate speed record may be maintained in a register alongwith the corresponding
temperature record as ascertained from the temperature graph.
2.3
The first length of each patented coil shall be tested for tensile strength and /or macro-structure.The
tensile value or the photograph shall be compared against standardized reference value or charts,
as the case may be.
2.4
Pyrometers shall be calibrated at least once in every six months and the calibration charts
maintained for the scrutiny of Inspecting Officers.
2.5
Every patended coil shall carry a metal tag carrying its heat or cast number, carbon content and size.
Each such coil selected for making winding rope shall also have the words "WINDING ROPE'
stamped on it or be capable of being so distrnguished in any other approved manner.
3.0
Pickling
3.1
Every coil shall be properly pickled and cleaned.
4.0
Wire drawing
4.1
No wire which carries a brazed or welded joint shall be used in the making of a winding rope.
Provided that such joining of rods or wires may be done, if necessary, only before the final
patenting stage.
4.2
A wire rope which has a brazed or welded joint in a wire made after the final patenting of rods or
wires shall not be supplied as a winding rope.
4.3
All wires to be used in the manufacture of winding ropes shall be hand picked to ensure that they
have compatible tensile, torsion and reverse bend values, and are of uniform surface hardness.
4.4
Every coil of wire selected for making a winding rope shall be marked with 'WINDING ROPE'
stamped on the tag (bearing other particulars, such as coil number, tensile range, and size) by a
competent person after he has satisfied himself that the coils have compatible value mentioned in
clause 4.3.
4.5
When the wires are drawn at separate works, the manufacturer shall obtain a certificate of
compliance with the requirements of 4.2 above and IS 1835:1976 from the supplier of wires, and
shall also carry out at his own works independent test on the samples cut from both ends of each
coil to verify that the wires satisfy the requirements of IS 1835:1976.
5.0
CORE
5.1
Each coil of the core shall be weighed just before the closing operation to check if it is fully
impregnated with the lubricant. It is recommended that in no case the amount of lubricant in the
core should be less than 18 per cent by weight.
5.2
The temperature of lubricant in the impregnation tank shall be thermostatiscally maintained at
900 + 50 C.
5.3
Where pre-lubricated core is used, care shall be taken before use in the winding rope that it is free
from moisture, and if necessary, the core shall be re-lubricated to satisfy the requirements of 5.1 to
5.2.
6.0
TYPE OF LUBRICANT
6.1
All lubricants used in the manufacture of winding rope shall be miscible. The lubricants used
shall be selected in consultation with reputed lubricant manufacturers to meet the service
requirements of the winding shafts.
NOTE : To meet the service requirements in winding shafts, the lubricant, should be water repellant, acid
free, and have close affinity to the steel used. Unless otherwise specified by the purchaser, the lubricant
should also be capable of standing a temperature range of 00C to 950C (320 F to 2030 F), that is to say it
should not drain out in service leaving the core or rope dry.
6.2
The lubricants used in the manufacture of winding rope shall be checked for their required
properties laid down in clause 8.1 of IS 6594:1977. A record of the results of such checks shall be
maintained.
6.3
The manufacturer shall advise the user about the type of lubricant that should be applied by him to
the rope while in service. The type of lubricant recommended (in consultation with reputed
lubricant manufacturers) shall be suitable for the working conditions in the shaft.
NOTE - Generally speaking, the recommended lubricant should be acid free; it should not harden
so that it will crack, chip, or peel off in a cold weather nor soften and drip in hot weather, that is to
say, unless otherwise specified by the purchaser, it should be capable of with standing a
temperature range of 00C to 950C. The lubricant should not dry out rapidly in service, but should
be sufficiently adhesive and cohesive so that it will not be thrown off by vibration and high speed;
nor should it come off the rope and build up in the grooves of the sheaves. The lubricant should
also be water repellant.
7.0
Additionnal Treatment
7.1
Wire shall be lubricated immediately before the stranding etc.
7.2
The core shall be throughly lubricanted again at the closing mochine.
7.3
A rust preventing wire rope dressing compund shall be applied on the rope either during closing
operation or immediately before the rope is coiled on a reel.
8.0
Length of Lay
8.1
The length of lay, that is the pitch of winding rope shall be between seven and eight times the
diameter of the rope.
9.0
Quality Control
9.1
A continuous check on the quality of the winding ropes manufactured in the works shall be
maintained as follows :
a)
b)
c)
During stranding and closing operation, it shall be ensured, that size, lays, wire tension,
stranding tension, strand tension, lubrication, die pressure etc. are rightly controlled.
Surprise checks shall be carried out by test house staff to verify compliance with these
requirement. They shall countersign the relevant records during every such checks.
Special attention is invided to strict compliance with the manner of carrying out various
tests specified in the relevant IS specification
9.2
The officer Incharge of Testing and Inspection Department shall be directly responsible to the
head of the work, and be independent of the production Deptt.
9.3
The officer Incharge of the Test House shall be a qualified metallurgist or a qualified graduate
engineer competent in metallurgy and he shall be assisted by competent staff in the Test House.
9.4
Adequate number of competent staff shall be appointed for floor inspection.
10.0
Service Facilities
10.1
The manufacture shall appoint a competent service engineer who shall be present at the
time of installation of the rope, as far as possible, regularly visit the mines where indigenous ropes
are installed, keep a check on the condition of the winding rope, and generally advise the mine
management on proper maintenance and installation of the winding rope. He shall bring to the
notice of the management and the Director General of Mines Safety any defects noticed by him in
the winding rope at any time.