Being able to detect wire rope flaws instantly, in real-time and in a portable fashion can make a significant difference for operational teams, allowing them to quickly address an issue before it escalates and requires more expensive and time-consuming maintenance.
Lubrication Engineers (LE) SA’s MD, Colin Ford, says that he has seen a number of significant technological advancements and tools entering the market that help wire rope operators detect and resolve problems faster.
“Portable inspection equipment for steel wire ropes makes it easier to see what’s happening because maintenance teams can move around to different ropes across a plant or mine and obtain a detailed read of the state of their equipment,” says Colin. In addition, teams can now track particular stress points in their machinery and conduct regular checks for issues.
Magnetic inspection techniques
LE is a regional agent for the TST FDSys.P Flaw Detection System. Tools like the TST use magnetic inductive sensing technology and magnetic flux leakage (MFL) wire rope inspection techniques. Colin is one of South Africa’s foremost experts on the use of MFL for wire ropes. He explains that the technology uses magnetic fields and complex computerised systems to determine the state of a wire rope, right from the centre of the strands to the outer layers of the rope.
Inspections can be done faster and the information will be more accurate. “These tools allow for high-speed, accurate, user-friendly inspections,” Colin adds.
100% accurate
The TST is able to perform a 100% accurate non-destructive inspection of wire ropes with diameters ranging from 6 to 70mm. Common issues that a system like the TST can detect include broken wires, corrosion, pitting, abrasion and fatigue.
The TST Portable Wire Rope Tester can inspect upwards of 5m/s (or as limited for safe operation). It offers >90% repeatability of quantitative detection for flaws, and 100% accuracy of severe flaw signals. It picks up both flaws, such as internal broken wires and fatigue, as well as external flaws, such as broken wire, abrasion and corrosion.
Pairing with correct lubrication
For the most effective approach to wire rope maintenance, regular and accurate inspections with tools like the TST need to be paired with correct lubrication. Using automated lubricant application systems and the correct type of lubricants for wire ropes are also crucial.
Products such as LE’s Wirelife Almasol Coating Grease 452 can penetrate right to the core of a rope when applied using something like a Viper lubricator. Colin explains that a Viper is a collar with seals that is strapped down and held in place so that a rope can move through it.
Environmental benefit
Inspections of wire ropes at sites with mine hoists, cranes, elevators, cableways, power grids, suspended bridges and drilling platforms also have a long-term environmental benefit as knowing about, and then dealing with, issues early on can extend the life a wire rope and reduce the need for premature replacement.
Extending the life of a wire rope has a knock-on environmental benefit, as does using the right high-quality lubricant during the rope’s lifespan. Both of these reduce waste and make sure that the maximum value is extracted from a rope; and reducing waste is key for realising environmental benefits.
