The ability to instantly detect flaws in wire ropes in real-time, in a portable and efficient manner, can have a major impact on operational teams. This technology allows maintenance teams to address issues promptly before they escalate, avoiding costly and time-consuming repairs.
According to Colin Ford, Managing Director of Lubrication Engineers (LE) SA, several technological advancements have emerged, helping wire rope operators detect and resolve issues more quickly.
“Portable inspection equipment for steel wire ropes offers significant advantages because it allows maintenance teams to move between ropes across a facility, providing detailed insights into the condition of their equipment,” says Colin. “Additionally, teams can now track specific stress points in machinery and conduct regular inspections to identify potential problems.”
Magnetic Inspection Technology
LE represents the TST FDSys.P Flaw Detection System in the region. This tool utilizes magnetic inductive sensing technology and magnetic flux leakage (MFL) inspection techniques for wire ropes. As one of South Africa’s leading experts in MFL, Colin explains that this technology uses magnetic fields and advanced computer systems to assess the condition of a wire rope, from the inner strands to the outer layers.
With tools like the TST, inspections are faster, more accurate, and more efficient. “These tools provide high-speed, precise, and user-friendly inspections,” Colin adds.
100% Accuracy in Wire Rope Inspections
The TST system delivers 100% accurate, non-destructive inspections for wire ropes ranging from 6 to 70mm in diameter. The system can detect a range of common issues, such as broken wires, corrosion, pitting, abrasion, and fatigue.
The TST Portable Wire Rope Tester can inspect ropes moving at speeds of up to 5m/s (subject to safety limitations). It offers more than 90% repeatability in detecting flaws and guarantees 100% accuracy in identifying severe flaws. The tool detects both internal flaws like broken wires and fatigue, as well as external issues such as corrosion, abrasion, and broken wires.
Integrating Proper Lubrication
For optimal wire rope maintenance, regular and precise inspections using tools like the TST should be combined with the correct lubrication. Automated lubrication systems and the right lubricants are essential for maintaining the longevity of wire ropes.
Products like LE’s Wirelife Almasol Coating Grease 452 are designed to penetrate deep into the core of the rope when applied using equipment such as the Viper lubricator. The Viper is a collar with seals that holds the rope in place, allowing it to move through while the lubricant is applied.
Environmental Benefits
Regular inspections of wire ropes used in mine hoists, cranes, elevators, cableways, power grids, suspended bridges, and drilling platforms not only extend the life of the ropes but also contribute to long-term environmental sustainability. By identifying and addressing issues early, the lifespan of wire ropes can be significantly extended, reducing the need for premature replacements.
Extending the lifespan of wire ropes, coupled with the use of high-quality lubricants, also offers environmental benefits. Both practices help reduce waste and maximize the value extracted from the ropes—essential for minimizing environmental impact and promoting sustainability in the industry.
