NAV. Cwi. ENG. LAB, me TONS aN = (eer TN NO: N-1661 TEST AND EVALUATION OF THE MT 75 TITLE: ROPE TESTER - A HAND-HELD NDT WIRE- ROPE INSPECTION DEVICE 7 WHO ( DOCUMENT \. COLLECTION a AUTHOR: L. D. Underbakke DATE: March 1983 SPONSOR: _ Naval Facilities Engineering Command PROGRAM NO: _yYo995-01-004-620 NAVAL CIVIL ENGINEERING LABORATORY PORT HUENEME, CALIFORNIA 93043 Approved for public release; distribution unlimited. “i aa “WONT OSI ae an a | = = & = a= re *98Z:01'E19 ‘ON Gojered Gs 'SZ'Z$ ad!4q ‘sainseayy pue siyBlam 40 s11UA ‘9gz “|GNd ‘OSI, = = & SN 28S ‘sage pajleyap aiow pue suoIss@NUOD JOeXA Jay 104 ~(AjIDexa) HG'Z = U! Ly re eos —. 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VayV ro) = = 4 Zz tw sa}! 9:0 S1a}9WO|I>} uw» = = = vauVv pA spied a $19}@W Ww = = ae wy $19} aWO|!} 91 Sajilu ivi) y 994} ee siajau Ww 3 ——— = ud s4a}au 6'0 spied pA ul sayoul v0 $19] @W1}Ua0 wo = = wo $49] 8U1]U99 OE yaa} y ul sayoul +00 $49} OU] [IW wu a SE wo $49}9tW!}U89 G7, Sayou! ul HLONAT a SE = HLONAT eee pee eee ee! ee ee men Rises oc Sygassk ee joquiAs puly o} Ag Ajdnjnyy MOU), NOA vay joquiAs BS) = : © joquiAs puly o} Aq Aydin ny MOU NO, Udy, joquiAs = a a 4 <==) = SaANsea|\| I14}a\J WO1J SUOISABAUOD ayeWIxXosddy LS saunseayy 21/a|A| 0} suoissanuog ayewixoiddy nN S a5 Ss Se 2 SUOLOVA NOISUAANOD OLA LAW Unclassified SECURITY CLASSIFICATION OF THIS PAGE (When Data Fntered) REPORT DOCUMENTATION PAGE Se ee 1. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER TN-1661 DN987077 4. TITLE (and Subtitle) TYPE OF REPORT & PERIOD COVERED TEST AND EVALUATION OF THE MT 75 ROPE Not final; Sep 81 — Sep 82 TESTER — A HAND-HELD NDT WIRE-ROPE 6 PERFORMING ORG. REPORT NUMBER INSPECTION DEVICE 7. AUTHOR(s; 8. CONTRACT OR GRANT NUMBER(s) L. D. Underbakke 9. PERFORMING ORGANIZATION NAME ANO ADORESS 10. PROGRAM ELEMENT. PROJECT, TASK AREA & WORK UNIT NUMSERS 63725N; Y0995-01-004-620 11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE Naval Facilities Engineering Command March 1983 Alexandria, Virginia 22332 foe i ages 14. MCNITORING AGENCY NAME & ADORESS/(if different from Controlling Office) 15. SECURITY CLASS, (of this report) NAVAL CIVIL ENGINEERING LABORATORY Port Hueneme, California 93043 Unclassified 15a, OECLASSIFICATION DOWNGRADING SCHEDULE DISTRIBUTION STATEMENT (of this Report) Approved for public release; distribution unlimited. DISTRIBUTION STATEMENT (of the abstract entered in Block 20, if different from Report) SUPPLEMENTARY NOTES KEY WORDS (Continue on reverse side if necessary and identify by block number) Wire rope, steel cable, inspection, nondestructive test, nondestructive inspection, DC wire rope test, rope tester 20. ABSTRACT (Continue on reverse side If necessary and identify by block number) The nondestructive wire rope tester, MT 75, was investigated, tested, and evaluated in order to fill the gap between the hand-held rag inspection and the large unitized AC/DC wire rope inspection device. The MT 75 can provide better information on the condition of the wire rope than can be obtained by using the “rag and visual”’ inspection method. DD jan, 1473 EDITION oF 1 Nov 551s OBSOLETE Unclassified SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered) CCU Unclassified SECURITY CLASSIFICATION OF THIS PAGE(When Data Entered) Library Card Naval Civil Engineering Laboratory TEST AND EVALUATION OF THE MT 75 ROPE TESTER — I1AND-HELD NDT WIRE-ROPE INSPECTION DEVICE, by L. D. Underbakke TN-1661 35 pp illus March 1983 Unclassified 1. Wire rope 2. Nondestructive testing I. YO995-01-004-620 The nondestructive wire rope tester, MT 75, was investigated, tested, and evaluated in order to fill the gap between the hand-held rag inspection and the large unitized AC/DC wire rope inspection device. The MT 75 can provide better information on the condition of the wire rope than can be obtained by using the “‘rag and visual’’ inspection method. Unclassified —$—$—$—————— EEE SECURITY CLASSIFICATION OF THIS PAGE/When Data Entered) CONTENTS Page TIN DRO DU CTO Nie se ee er cep sak cites Sluice eee Oo ieee kT each Se ee eR 1 Mime SRORE ESTERS = nce se ke Se ae we RO Se ee ss 1 PABORATORVSSTE SITTING **.. Stee we cs net. Wet one ieee, tele. Memeo, HEN em. BAER 2 Test Procedures 2 Gap Configuration 2 Gap Orientation 2 Gap Space 3 Rope Speed . 3 Rope Guides 4 RAED) SEE SWUNG Hs er ee ete sre tt ea ta, eae hor er ee eat cht, Sa ey MPP 4 CONCUSSIONS IS firs ce war cs eet ens es rout. Gat ewe ek SO yoann Nae ieiae. Gn mama cin 4 RE COMMENDATHONS cate arr toete. Maret aun eee Meme Sic val tay enema eee oo Las Ny 5 Appendix - MT 75 Rope Tester, Operation and Maintenance Manual .. 15 + 1 = i - hi . rar Mee | 2] > ‘ 4 r : aay iD i i a1 at : ot Fi : ; Tees aAt a H 4 gry ly oat recs se, es | rn ee kk, Mee ) i ite, ie il Bll ‘aie, he ht PE Mm i Aa A ahbascd he OE Veen bid pe am Ay Wate. , We bie no an 1 ay cae aeaeesabaiiiate. 2 hence ‘il ibn J Figure 2. MT 75 wire rope inspection device. * a. => ogy el x = clear air gap space in longitudinal direction of wire rope Figure 3. Gap configuration for wire rope. bebstatese t =e 33! E egece: t pegs saceosas + = Hest re es tTEH Y T aga: £ 185 - Break B #4 + + E t + thy et H iz flaw La location i (a) d=0 Break A tt wea = Bssqg ceaes 2s tt SST HH + ; EE + : H ies Poa Sees cs See et EE 4 Break A = Tt age Eb f agg 9 gese se HoE pareeentts + (b) 0 = 45° A ot SEES E = = Fe gira : S58 soanz cress sees cede crest nen] 22502 c¢770 302 TEER : £ SS ad He HE et + T t = : ; = pit 3 + > + t aos + + i ioai > zs = + a aged : + + E 3 I E EEE + E Seas Seis peebd basta coats roses vaned tate f Asia 4 Ht = 5 Hert 1g +t = as! + : Hi seas ees rae: seeg eat £ Break B gee : H Break A i t = fz i HH 1 yard (c) 6 = 90° Figure 4. The effect of sensor head rotated on signal strength using a 1/2-inch diameter wire rope. ‘Ul p/T ‘spoads adoi jenba iv sisay, -adoi DIM JOIIUILIP YUI-Z/T 10} 9zIs de3 Jo uo dun] v sv dZIS [RUSIS aIIM UdyoIg “¢ oinsIy “Ul OT/E ttt @ LYUVHONIIV “Ul 8/T “Ul OT/T : yeog “Ul 8ZT/T towne o ' @ LYVHONIIV + att yeorg ‘adod a11M J9I9WeIP YOUI-Z/T ¥ Jo UoTadsut pjary e WoIyZ vIVq "9 Inst 8uni1d worsos109 jo staiy = g SOIIM UsYOIg = VV ‘ou] pinod @ LYVHINIDV ++ 10 (‘paeds 1xeyd UR SUOD &B 1B Papiosay) ‘“sasvosoul paads aul] sv JueIsUOD suTeUTaI apnatjduie [eusIg -Z oinsIy widj OOE wid} 00Z widj OOT uidj ¢ SSS 11 ‘(adou aiM JaiaweIp yout-z/T) apnayjduie yeusis ay2 soonpar [}09 Ydievas pazisioao uy -g aInsIy [109 yo1vas JoaWeIp [109 Yoavas 1939 uIEIpP youl p/€ Yam apnaryjdure jeusis You! Z/T YIM apniijdure jeusis @LYVHINIDY JVHINIDV > Salm Uax01q 12 Figure 10. Inspector using the MT 75 rope tester. 13 an Efe ~~ a ' ? be RS 999 _ NDT technologies, ine. og o°ega- =a) e @” 125 mohegan trail 080 e2%o south windsor, ct.06074 $3%85°0° (203) 644-8507 =) Appendix MY 75 ROPE TESTER Operation and Maintenance Vianual = i = DEE St OAR PSEA OR APPLICATION The DC Rope Tester MT-75 is used in the field to test for and detect external and internal broken wires, broken cores, defor- mations, abrasion and corrosion in steel wire ropes. It was developed particularly for routine testing of wire ropes in Mining, industrial and military applications where safety and hence the detection of anomalies is of paramount importance. OPERATION A section of the steel rope is magnetically saturated in the longitudinal direction by a strong permanent magnet. Where there is an inhomogeneity in the rope such as a broken wire, a broken core, corrosion or abrasion, the magnetic flux is dis- torted and leakage flux radiates from the rope into the sur- rounding air space. Test coils are positioned close to the rope to sense the leakage flux. The rope is moved which causes the leakage flux to intersect the coils. The changing intersecting flux induces signals in the coils. The signals are conditioned by electronic circuitry and aurally and/or visually displayed by headphones or a recorder. The Rope Tester MT-75 consists of the following items: 1 ea. Tester Assembly comprising 1 ea. Magnet Assembly 1 ea. Signal Conditioning Circuitry 1 ea. Instrument Case 2 Cae Hinged Sensors 8 ea. Rope Guides 1 ea. Headphone Set 1 ea. Carrying Case 1 ea. Operation and Maintenance Manual 16 ID) SG Ee ae) Fig.1 shows the MT-75 DC Rope Tester with Headphones attached. The tester assembly including headphones is stored in a compact Carrying Case (not shown). In operation, the Tester Assembly attaches to the rope by means of guide shoes to detect flaws as the rope moves at rates from 5 fpm to high speeds of 500 fpm. Rope flaws are indicated by clicking sounds in the Headphones. The fault signal can also be recorded by a strip chart recorder or a cassette recorder. Differ- ent rope flaws can then be identified from their characteristic chart patterns. The Rope Tester operates from replaceable or rechargeable 9 V batteries. FUNCTION OF SIGNAL CONDITIONING CIRCUITS Fig.2 shows a Functional Block Diagram of the instrument. The Signal conditioning circuitry comprises the following components: 1. PREAMPLIFIER AND SPEED COMPENSATION CIRCUIT - This circuit amplifies the sense coil signal. At the same time, it equa- lizes the signal to make its amplitude independent of rope test speed (at speeds greater than 5 fpm). 2. DETECTION LEVEL CIRCUIT - This circuit controls the threshold level at which fault signals are detected. 3. SIGNAL ENHANCER CIRCUIT - This circuit controls the extent to which that part of the test signal above the detection level is enhanced and that part below the detection level is Suppressed. 17 18 Figure 1. MT-75 rope tester. ‘WeIseIp YOOTq [eUoNOUNY *Z 2IN3I.y souoydpeeH dwWw “umd Tapiocssy asuoudpeey tetzttduy ieyzsnd JajzoUoTIUSzOd 4tnoatod [oOr4UOD Zeoueyug_ oun TOA Teubts Ie}zSwoTzUSz 0d Jeoueyuy Teubts tetyt i duy ALIN IACTES) [eaeT uot 399e3eqG Je zewoTIUSeyzo0g TeAeT uoT39e30ed Jepi0se4 atosjjnd esuas edoy OITM eptnd edou AT quessy qZeubew 19 DUETS. Gane Own 4, BUFFER AMPLIFIERS - The buffer amplifiers amplify the test Signals to a level necessary for driving headphones or a recorder. 5. HEADPHONE POWER AMPLIFIER - This amplifier, built into the headphones, amplifies the test signal to a power level necessary for driving the headphone speakers. 20 ee Sib eCuulieie he Ce ALTO NGS Input Limits Rope Speed: Faults Sensed: Wire Ropes: 5 50) 5\O(@) ae iobu External and internal broken wires. Broken core. Corrosion. Abrasion. Various changes in rope structure. Up to 0.75 inch diameter Power Batteries: Low Voltage Indicator: Battery Life: 9 V Rectangular Batteries (replaceable or rechargeable) Eveready CH22 or equivalent. LED indicator turns on at end of battery life. 4-5 hours of continuous operation. Readout and Recording Headphones: Built-in power amplifier including battery. Broken wires indicated by clicking sounds. Other rope deterio- rations indicated by "thundering” or "crackling" sounds. Indication inde- pendent of speed. 21 -5- Sib i Cale ee Genel O mens Strip Chart Recorder: One or two channel recorder. Rope flaws indicated by characteristic chart patterns. Signal amplitudes independent of rope speed. Dimensions Length: 6 inches Width: 1.5 inches Depth: 8.5 inches Weight: 5 lb. (Test instrument including electronic and battery) Environmental Conditions Dust proof, splash proof (oil and water) Humidity to 95% Operating temperature: 0° to 55° C Storage temperature: ao? 6 5° 22 OPE ra haAgr ae OM FUNCTION OF CONTROLS AND CONNECTORS 1. ON-Off Switch - The ON-OFF Switch turns on battery power. 2. BATTERY INDICATOR - Turn-on of the red LED indicator light indicates the end of useful battery life. No light indicates adequate battery voltage for operation of the instrument. 3. BATTERY CHARGE CONNECTOR - This connector allows charging of the rechargeable batteries from the battery charger. 4, AUDIO PLUG - A modified test signal is available at this jack intended for audio detection by headphones. The modi- fied signal can also be recorded by a strip chart recorder or a cassette recorder. 5. RECORD PLUG - The unmodified test signal is available at this jack. It can be recorded by a strip chart recorder or a cassette recorder. The unmodified signal can also be monitored by earphones. 6. VOLUME POTENTIOMETER - This potentiometer controls the volume at the Audio Plug. 7, Detection Level Potentiometer - This potentiometer controls the signal level at the Audio Plug at which fault signals are detected. 8. SIGNAL ENHANCE POTENTIOMETER - This potentiometer controls the degree to which that part of the signal at the Audio Plug above the detection level is enhanced, and that part of the signal below the detection level is suppressed. 23 OREM E a Rene tae eOnN CALIBRATION 1. Mount proper size Guide Shoes and Pick-up Head on the in- strument (see page 11 of this manual). 2. Plug Headphones into Audio Plug. 3. Turn Detection Level Potentiometer to the "0" setting (Extreme counterclockwise position). 4, Turn the Signal Enhance Potentiometer to the "10.0" setting (Extreme clockwise position). 5. Turn the Volume Potentiometer to the "10.0" setting (Ex- treme clockwise position). 6. Turn on Power Switch. 7. LED indicator above power switch should not turn on. (A turned on LED indicates weak batteries. Charge or replace batteries. See page 11 of this manual.) 8. Find a rope section without flaws to be tested. 9. Open Sense Head. Attach instrument to the rope. The instru- ment is held against the rope by magnetic attraction. Close Sense Head. 10. Put on Headphones. Turn on Headphones. 11. Move instrument by hand up and down along the flawless part of the rope. Crackling or clicking sounds are usually audible. 12. Keep moving the instrument. Increase the detection level by turning the Detection Level Potentiometer in the clockwise direction until crackling or clicking sounds disappear. 24 0) TE AR A eI so) 13. Make a note of all potentiometer settings for later refer- ence. Lock potentiometers. The instrument is now ready for testing. 14, Note: If during testing, clicking or crackling sounds are audible for rope sections which have definitely no flaws that warrent attention, the detection level can be raised even further. Ideally, the detection level should be set such that for marginally acceptable ropes no sounds are audible. TESTING INSTALLED ROPES Audio Inspection 1. Mount proper size Guide shoes (3/8", 1/2", 5/8" or 3/4") on instrument. (Refer to page 11) 2. Mount proper sized Pick-Up Head on instrument. (Refer to page i1) 3. Set all potentiometers to calibrated setting. (Refer to page 7 for calibration procedure.) Lock potentiometers. 4, Plug Headphones into Audio Plug. 5. Open Sense Head. Attach instrument to the rope. The instru- ment is held against the rope by magnetic attraction. Close Sense Head. 6. Turn on Power Switch. 7. A turned on LED indicates weak batteries. In that case, charge or replace batteries. (Refer to page 11) 25 OP BeRV AGE ALAOaN 8. Put on Headphones. Turn on Headphones. 9. Holding instrument so that it cannot move, run rope at in- spection speed. 10. If crackling or clicking sounds are audible, stop rope and visually search for flaws. Flaws can be located by moving instrument manually up and down along the rope and listen- ing to sounds in the headphones. 11. Mark position of flaw for later reference. Permanent Record: If a permanent record of the rope condition is desired, a two channel strip chart recorder can be used as follows: 1. Connect first channel of Strip Chart Recorder to Audio Jack. 2. Connect second channel of Strip Chart Recorder to Record Jack. 3. Turn Detection Level Potentiometer to calibrated setting. 4, Turn Volume Potentiometer to 10.0 setting. 5. Turn Signal Enhance Potentiometer to 10.0 setting. 6. Lock Potentiometers. 7. Turn on Instrument Power Switch. 8. Open Sense Head. Attach instrument to rope. Close Sense Head. 26 11. 12. 13.6 13. Olas O Pipi A we it Ok Signals will be in the 0.1 to 5V range. Adjust Strip Chart Recorder sensitivity accordingly. Start Strip Chart Recorder. Holding instrument so that it cannot move, run rope at in- Spection speed and record signals. The amplitude and shape of the "Audio" signal can be adjusted by the Volume and Enhancement controls. Inspect strip chart recording. In general, flaws will be in- dicated by pronounced pulses in the "Audio" recording. The nature of the flaw can usually be better identified from the DRecorad wee cloxadina es Reinspect rope visually making use of the headphones to pre- cisely locate the flaw and compare results with strip chart recording. 27 Sines SS EN Ca ah BATTERY CHARGING 1. Plug Battery Charger into wall outlet. Turn off instrument Power Switch. 2. Plug Charger Cord into "Battery Charge" connector of instru- ment. 3. Charge for approximately 14 hours. CAUTION: Charge Nickel-Cadmium batteries only! Other types of batteries may rupture causing severe damage to instrument. BATTERY REPLACEMENT If battery recharging is not feasible, used batteries can be replaced by charged Nickel-Cadmium batteries or by replaceable batteries. 1. Remove 9 screws from instrument lid. ao Inalstias Ostit suasimeuimeiong IbiGl, 3. Remove old batteries from battery holders. 4, Install new batteries (9V Rectangular replaceable or recharge- able batteries). 5. Replace instrument lid. EXCHANGE OF GUIDE SHOES AND SENSE HEAD 1. Loosen two brass srews on bottom of instrument. 2. Remove sense head by gently pulling it in a foreward directior. 28 S 15 RW 3. Lift guide shoes and slide them out of the instrument in opposite longitudinal directions. The guide shoes are mag- netically retained and moderate force is required. Note: Guide Shoes cannot be removed with sense head in place. 4, Insert new guide shoes by reversing the above procedure. 5. Insert sense head by gently pushing it into the magnet assem- bly. 6. Secure sense head by tightening two brass srewS on bottom of instrument. CAUTION: Keep connectors absolutely clean! Sense head, guide shoes and magnet assembly can be cleaned with most cleaning compounds. Iron filings can be removed from magnet assembly by using self- adhesive tape. 29 DISTRIBUTION LIST AF HQ LEEH (J Stanton) Washington, DC AFB AF Tech Office (Mgt & Ops), Tyndall, FL; CESCH, Wright-Patterson; HQ MAC/DEEE, Scott, I; SAMSO/MNND, Norton AFB CA; Stinfo Library, Offutt NE NATL ACADEMY OF ENG. Alexandria, VA ARCTICSUBLAB Code 54, San Diego, CA ARMY ARRADCOM, Dover, NJ; BMDSC-RE (H. McClellan) Huntsville AL; DAEN-MPE-D Washington DC; ERADCOM Tech Supp Dir. (DELSD-L) Ft. Monmouth, NJ; Tech. Ref. Div., Fort Huachuca, AZ ARMY COASTAL ENGR RSCH CEN Fort Belvoir VA; R. Jachowski, Fort Belvoir VA ARMY COE Philadelphia Dist. (LIBRARY) Philadelphia, PA ARMY CORPS OF ENGINEERS Fac Engr Supp Agency, Ft. Belvoir, VA; MRD-Eng. Div., Omaha NE; Seattle Dist. Library, Seattle WA ARMY CRREL A. Kovacs, Hanover NH; Library, Hanover NH ARMY DARCOM Code DRCMM-CS Alexandria VA ARMY ENG DIV HNDED-CS, Huntsville AL; HNDED-FD, Huntsville, AL ARMY ENG WATERWAYS EXP STA Library, Vicksburg MS ARMY ENGR DIST. Library, Portland OR ARMY ENVIRON. HYGIENE AGCY HSE-EW Water Qual Eng Div Aberdeen Proy Grnd MD ARMY MATERIALS & MECHANICS RESEARCH CENTER Dr. Lenoe, Watertown MA ARMY MOBIL EQUIP R&D COM DRDME-GS Fuel Tech Br, Ft Belvoir, VA ARMY MTMC Trans Engr Agency MTT-CE, Newport News, VA ARMY TRANSPORTATION SCHOOL Code ATSPO CD-TE Fort Eustis, VA ASST SECRETARY OF THE NAVY Spec. Assist Submarines, Washington DC BUREAU OF RECLAMATION Code 1512 (C. Selander) Denver CO CINCPAC Fac Engrng Div (J44) Makalapa, HI CNM MAT-0718, Washington, DC; NMAT - 044, Washington DC CNO Code NOP-964, Washington DC; Code OP 323, Washington DC; Code OPNAV 09B24 (H); Code OPNAV 22, Wash DC; Code OPNAV 23, Wash DC; OP-098, Washington, DC; OP-23 (Capt J.H. 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