Document Title: Fiber Rope Selection, Inspection, Use, Handling and Storage

COPI Doc No.: ID-G-BU-YH0-PRO-GN-00-0019

Originator: COPI
COPI Group Owner: Project - HSE
Area: General
Location: General
System: General
Document Type: Procedure/Work Instruction/Job Note
Discipline / Subdiscipline: Project / HSE
Old COPI Document No.: -

Didik Fred Don Tony Not

1 IFU 15.02.2010 Issued for Use
Swaradi McFadden Sample Evers Reqd
Snr. VP
Unit Owner
Rev Status Issue Date Reason for Issue Prepared Checked Manager Projects
Approvals

Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 2 of 11

Revision Sheet
ConocoPhillips Indonesia Inc. Ltd

REVISION DATE DESCRIPTION OF CHANGE

0A Issued for Comment

1 15.02.2010 Issued for Use

Additional Approvers (If Applicable)

Name Designation Signature Date

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 3 of 11

Table of Contents
1.0 SCOPE .......................................................................................................................................... 4
2.0 DEFINITIONS ................................................................................................................................ 4
3.0 LIMITATIONS / ALLOWABLE USES ........................................................................................... 4
4.0 ROPE CONSTRUCTION ............................................................................................................... 4
5.0 SIZES OF ROPE ........................................................................................................................... 5
6.0 ROPE MATERIALS ....................................................................................................................... 5
7.0 STRENGTH ................................................................................................................................... 6
8.0 FORMAL AND INFORMAL INSPECTIONS .................................................................................. 6
9.0 HANDLING, USE AND STORAGE ............................................................................................... 8

TABLE 1 – COMPARISON CHART FOR NEW FIBER (AT LEAST 70 F AND 65% RH)
TABLE 2 - ALLOWABLE LOADS AND WEIGHTS OF NEW FIBER ROPE
TABLE 3 – EFFECTS OF HOT SURFACES/TEMPERATURE AND STRENGH LOSS
ATTACHMENT 1 – EXAMPLES OF DAMAGE TO OUTSIDE ROPE
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 4 of 11

1.0 SCOPE
This procedure describes the types, sizes, materials, and strengths of the most
commonly used fiber rope, as well as the requirements related to their inspection,
handling, storage and allowable uses. It primarily applies to fiber rope used for
raising or lowering material by hand or in conjunction with well wheels or rope hoists;
however, materials, strengths, inspection, handling and storage apply to all fiber rope
regardless of use. Fiber rope used exclusively for “warning barricades” does not
require formal inspection. However, fiber rope used for warning barricades shall not
be used for lifting or securing material.

2.0 DEFINITIONS

COPI – ConocoPhillips Indonesia

Qualified Person – Designated contractor employee who by extensive training,

knowledge, and experience has demonstrated their ability to perform formal rope
inspections and splices.

3.0 LIMITATIONS / ALLOWABLE USES

3.1 Fiber rope shall not be used in conjunction with a crane, or other powered
equipment, or mechanical lifting devices such as a chain fall, to raise or lower
material or equipment. Wire rope or synthetic slings shall be used for this
purpose.
3.2 Fiber rope used as part of personal fall-arrest or fall-restrain systems such as
life lines, rope grabs, floats and boatswain’s chairs, shall be rated for such
use, and shall not be used for any other purpose.
3.2 Fiber rope used for lifting/hoisting shall not be used as any part of a personal
fall-arrest, fall-restraint or personnel suspension system.

4.0 ROPE CONSTRUCTION

4.1 Fiber rope is classed as plant fiber or synthetic fiber. The materials are
detailed in Section 6.
4.2 Fiber rope usually is made with 3 strands. However, in special cases, it may
be made of 4, 5, or 6 strands.
4.3 For abrasive service, a rope made of four strands laid around a small rope
core is recommended. This rope is more nearly round and smooth and
reduces the effect of abrasion.
4.4 Fiber rope is laid right-handed. The strands may be laid either tightly or
loosely and classified as:
 Hard-laid – Strands are laid tightly making the rope stiffer and more
resistant to abrasion.
 Soft-laid – Strands are laid loosely making the rope more limp but
stronger than hard-laid.
 Medium-laid – A compromise between hard- and soft-laid ropes and is
recommended for general use.
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 5 of 11

5.0 SIZES OF ROPE

5.1 Fiber rope up to 1 inch diameter generally is referred to by its diameter
dimension.
5.2 Fiber rope above 1 inch diameter generally is referred to by the circumference
dimension, which is assumed to be 3 times the diameter.
5.3 All tables and references to sizes in this procedure include both the diameter
and circumference size.

6.0 ROPE MATERIALS

6.1 Number 1 manila rope is made using a plant fiber.
 Manufactures of manila rope usually identify this grade of rope by a
“trade marker,” such as colored inlaid fibers, bands, etc.
 Manila rope that has no manufacturer’s “trade marker” usually is of a
lesser grade manila and shall not be used for hoisting.
 Acids and caustics will deteriorate manila rope.
 It is susceptible to deterioration and rotting when exposure to moisture
and improperly dried.

6.2 Plant fiber such as jute (50 percent strength of manila), sisal (60 to 75 percent
strength of manila), and hemp (80 percent strength of manila) shall not be
used in hoisting operations.

6.3 Nylon rope is a strong, tough rope that:

 Handles much like manila rope.
 Is at least 2 ½ times stronger than manila and stronger than most other
common synthetic fiber rope.
 Has very good resistance to abrasion.
 Will absorb greater shock loads than most other fiber rope.
 Is ruined by acid and acid fumes.

6.4 Polyester fiber rope handles much like manila rope, but is about twice as
strong and:
 Has good resistance to abrasion.
 Is susceptible to caustic damage.
 Recommended where minimum stretch is required.

6.5 Polypropylene rope is the lightest and lowest cost of all synthetic fiber ropes.
Polypropylene rope:
 Is flexible.
 Has minimum stretch.
 Has excellent shock resistance.
 Is generally not affected by moisture, acids, alkalis, oil, grease, or other
chemicals.
 Can suffer some sunlight deterioration; black polypropylene is better for
resistance to sun damage.
 Should be stored out of sunlight.
 Must not be confused with polyethylene rope which shall not be used
for hoisting.
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 6 of 11

6.6 Glass is a special rope with poor flexibility but with excellent resistance to
chemicals and heat. Strength is comparable to Polyester rope.

6.7 For a tabular comparison of fiber rope properties, see Table 1.

7.0 STRENGTH
7.1 See Table 2 for typical allowable loads. Allowable loads are based on a
percentage of the minimum breaking strength of new and unused fiber rope
and may vary from manufacturer to manufacturer.
7.2 Allowable loads in Table 2 are calculated using a factor of safety of 5 for
manila, 6 for polypropylene, and 9 for nylon and polyester.
7.3 Allowable loads are strictly guidelines and apply only to new and unused fiber
rope.
7.4 Rope shall never be used above its allowable load rating.
7.5 Heat can dramatically affect the strength of fiber rope. See Table 3 for
examples of the relative effects of heat and temperature on some types of
fiber rope.
7.6 Knots and splices affect fiber rope strength:
 Use only approved knots. Acceptable knots include: square, bowline,
clove hitch, round turn with two half hitches, and running bowline.
 Even the most efficient knots will reduce rope strength to as much as
50%.
 Knots may be used at the ends of the rope but shall not be used to
lengthen a rope used for hoisting.
 A splice is stronger than a knot and depending on type of splice, will
provide 90 to 95% efficiency.
 Splices shall be made by a qualified person.

7.7 Breaking strength is based on direct pull along a single length of rope.
7.8 Rope loaded to over 75% of its breaking strength will be permanently
damaged.
7.9 Two “rules of thumb” – (1) never lift any object with a rope of less than ½ inch
diameter. (2) if an object is too heavy for an individual to lift it should not be
lifted with a rope by hand. “Too heavy” is considered to be 50 lbs. or greater
per person without the use of a mechanical lifting device such as a well wheel
or other rope hoist.

8.0 FORMAL AND INFORMAL INSPECTIONS

8.1 Each site/contractor shall have a rope inspection program. Inspections shall
be both formal and informal.
8.2 See Attachment 1 for examples of damage to the outside of a rope.
8.3 Formal inspections shall be:
 Performed quarterly by a qualified person,
 Documented,
 Shall include marking the rope at both ends using a quarterly-inspection
color-coded tape.
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 7 of 11

8.4 Formal inspections shall include an inspection of the outside of the rope:
 Look and feel for broken fibers or other signs of abuse. Broken fibers are
an indication of excessive abrasion or overloading. If approximately 5
percent of the fibers are broken, the rope shall be condemned.
 Reduced rope diameter is an indication of having been overloaded.
 Fiber rope will become dirty from use; however, inspect for excessive dirt
and grit penetrating between the fibers making up the strand. If
excessive to the point that it will cause internal wear in the strands, the
rope shall be condemned.
 Inspect for excessive oil on the surface of manila rope. This is an
indication of excess loading. If found, the rope shall be condemned.
 Check for strands un-laying, high-stranding, or the presence of a spiral
appearance. This will cause uneven distribution of the load on the
strands and early rope failure and is cause for condemning the rope.
 If manila rope is dry and brittle, is should be condemned as it has passed
its useful life and load capacity.
 Inspect for evidence of damage from heat, acids, or other chemicals; or
excessive moisture. If manila rope has this damage, it should be
condemned. Synthetic fiber rope should be condemned if it is not
resistant to the above exposures.

8.5 Formal inspections shall include an inspection of the inside of the rope:
 Open up the strands by twisting rope in the opposite direction of the lay in
several places. Do not open to the extent of kinking the fibers or
damaging the rope lay.
 If excessive broken fibers are found, this is an indication that the rope
has been overloaded and it shall be condemned.
 Interior of the rope should be as bright as a new rope. If discolored or
dirty and there are indications of chemical or excessive dirt penetration,
the rope should be condemned.
 The presence of powder-like sawdust indicates there has been severe
internal wear and the rope shall be condemned.

8.6 Formal inspections should include, if possible, an inspection of the inside of

the strands and can usually be accomplished as follows:
 Pull on several fibers near the center of the strand. If they come out in
short pieces, the rope has been overloaded and shall be condemned.
 Pull out some long fibers near the center of the strand and check for
strength. If the fibers break easily, the rope probably has been
chemically attacked and shall be condemned.

8.7 In addition to the above formal inspection requirements, for fiber rope having
a center core rope, an inspection of the core shall also be conducted. If the
rope has been overloaded, the core will be the first to fail.

8.8 New rope shall be formally inspected throughout its entire length before it is
placed in service.
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 8 of 11

8.9 Contractor shall maintain records of all formal inspections on site and shall
make them available to COMPANY PMT personnel on request.

8.10 COMPANY PMT personnel shall periodically inspect contractor’s formal

inspection records as well as checking rope condition during field audits.

8.11 Informal inspections shall be performed by the user before each use.
Adequate and effective before-use inspections are critical to the safe use of
fiber rope since it is possible that damage can occur immediately after a
formal inspection.
 The user shall inspect the rope for obvious defects and the presence of
the current quarterly-inspection color-coded tape.
 Contractors shall ensure each user of fiber ropes has sufficient training to
conduct an adequate before-use inspection.

8.12 Rope that fails a formal or informal inspection shall be cut into short pieces
and discarded.

9.0 HANDLING, USE AND STORAGE

9.1 When opening a coil of rope, read the attached manufacturer’s instructions
and follow their uncoiling procedure. In general:
 Uncoiling of rope should start with the loose end inside the coil. The coil
can be laid flat and the rope uncoiled by pulling the loose end up and
away from the coil to obtain the desired length.
 As rope comes out of the coil, it should unwind in a counterclockwise
direction and may form loops. Loops should be removed carefully to
avoid damage-causing kinks.

9.2 Before cutting rope, whipping shall be applied on both sides of the intended
cut to prevent un-lay of the strands, or upsetting the fibers in the strands.
Keep rope ends seized.

9.3 DO NOT:
 Drag rope over dirty or gritty surfaces. Abrasion to the outside of the
rope will occur, and picking up of gritty particles will cause later internal
damage.
 Wrap or pull rope over sharp edges or hot surfaces. Use padding or
softeners to protect the rope.
 Bend or flex frozen rope.
 Use fiber rope in areas where excessive heat, acids, chemicals, or
chemical fumes/vapors are present unless the rope will resist those
atmospheres.
 Use in the vicinity of welding or burning operations.
 Use rope that shows signs of cutting, unraveling, or breaking.

9.4 Synthetic fiber ropes are subject to melt at high temperatures and shall not be
used in “high-friction” applications.

9.5 Avoid sudden strains, jerking, etc., since this may cause failure of a rope
normally strong enough to handle the load. Use a steady, even pull.
Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 9 of 11

9.6 Fiber rope must be stored in a clean, well-ventilated area.

 Excessive temperatures (below 20 degrees F or above 180 degrees F) or
extremely dry storage conditions (less than 10 percent relative humidity)
should be avoided.
 The ideal storage area should have a temperature of from 50 to 70
degrees F and a relative humidity of 40 to 60 percent.
 If stored on shelving, shelves should be of a “wood grating design” a
minimum of 6 inches above the floor.
 If hung, hang loosely on large-diameter pegs.
 If necessary to store on metal or concrete floors, planks shall be used to
prevent rope contact with the floor.

9.7 Rope that becomes muddy or dirty may be washed with cold water and
moderate hose pressure, but never steam.

9.8 If rope has become damp or wet during use, it must be dried before storing.

Table 1 – Comparison Chart for New Fiber Rope (at 70 degrees F and 65 % RH)a

b
3/4 – inch dia. Resistance to
Use
rope Elongation
with
Minimum at 20% of
Material block Abrasion
breaking break Aci
Ft/lb and Alka Water Sunlight Rot
strength strength d
fall Wet Dry
Lb

F-
Manila 5,400 6.00 5-8% E F-G P P F F P
G
Nylon 14,200 7.25 14-23% G E G P E E G E
Polyester 12,500 5.7 7-9% G G G G P E G E
Polypropylene 8,200 9.52 -- E F F E E E G E

a
Tensile strengths listed are for conditions of 70 degrees F and 65 percent relative humidity.
Strength of rope is changed when conditions other than these are encountered.
b
Most chemical solutions and solvents affect rope to varying degrees; therefore, care must be
taken to prevent contact with them.

Key: E-Excellent G-Good F-Fair P-Poor

 Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 10 of 11

Table 2 – Allowable Loads and Weights of New Fiber Ropea

Manila Nylon Polyester Polypropylene

Size
Safety factor – 5 Safety factor – 9 Safety factor - 9 Safety factor - 6
Weight Weight
Dia Allowable Allowable Allowable Weight Allowable Weight
Circ (in.) lb/100 lb/100
(in.) load (lb) load (lb) load (lb) lb/100 ft. load (lb) lb/100 ft.
ft. ft.
1/2 1-1/2 450 7.5 675 6.5 675 7.9 840 4.6
9/16 1-3/4 690 10.4 845 8.3 845 10.3 1,020 6.0
5/8 2 880 13.3 1,100 10.3 1,055 13.3 1,160 7.5
3/4 2-1/4 1,080 16.7 1,500 13.8 1,320 17.5 1,640 10.5
7/8 2-3/4 1,540 22.5 2,100 19.5 1,900 25.0 2,300 14.4
1 3 1,800 27.9 2,640 25.0 2,320 29.4 2,800 17.5
1-1/8 3-1/2 2,400 36.0 3,480 34.0 3,110 39.0 3,600 23.0
1-1/4 3-3/4 2,700 41.8 3,960 38.5 3,500 45.0 4,200 26.5
1-5/16 4 3,000 48.0 4,540 44.0 3,960 51.0 4,800 30.0
1-1/2 4-1/2 3,700 60.0 5,595 54.5 4,940 65.5 6,000 37.5
1-5/8 5 4,500 74.4 6,860 67.0 6,015 79.0 7,300 47.0
1-3/4 5-1/2 5,300 89.5 8,230 81.0 7,155 96.0 8,800 56.5
2 6 6,200 108.0 9,710 95.0 8,445 115.0 10,600 69.0
2-1/8 6-1/2 7,200 125.0 11,185 111.0 9,710 130.0 12,400 81.0
2-1/4 7 8,200 146.0 13,195 129.0 11,295 150.0 14,000 92.5
2-1/2 7-1/2 9,300 167.0 14,775 148.0 12,875 175.0 16,000 106.0
2-5/8 8 10,400 191.0 17,100 165.0 14,460 197.0 18,000 122.0
a
Tensile strengths listed are for conditions of 70 degrees F and 65 percent relative humidity.
Strength of rope is changed when conditions other than these are encountered.

Table 3 – Effects of Hot Surfaces/Temperature and Strength Loss

Effects of Hot Surfaces ( 287 degrees F)

% Loss of Original
Type of Rope
Strength
Polyester 13.2%
Nylon 16.5%
Manila 24.6%
Polypropylene 100.0% (distorted)

Strength Loss vs. Temperature

Temperature (degrees F)
Type of Rope
68 105 140 175 212
Manila 0 -3% -8% -20% -30%

Nylon 0 -2% -7% -14% -20%

Polypropylene 0 -7% -18% -30% -40%

Procedure/Work Instruction/Job Note: ID-G-BU-YH0-PRO-GN-00-0019 Rev. 1
Fiber Rope Selection, Inspection, Use, Handling and Storage
ConocoPhillips Indonesia Page 11 of 11

Attachment 1
Examples of Damage to Outside Rope

New Rope

Slightly Used Rope

Severely Abraded Rope

Damaged/Distorted Rope

Birdcage

Flattened Area