Being able to get instant, real-time and portable detection of wire rope flaws can make a significant difference for operational teams as it allows th
Being able to get instant, real-time and portable detection of wire rope flaws can make a significant difference for operational teams as it allows them to quickly address an issue before it escalates and requires more expensive and time-consuming maintenance.
Lubrication Engineers (LE) South Africa’s Managing Director 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 them around to different ropes across a plant or mine and get a detailed read of the state of their equipment,” says Ford. In addition, this allows teams to track particular stress points in their machinery and do regular checks for issues.
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. Ford 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,” says Ford.
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 5 m/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 inspection 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. Ford 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 hoisters, 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 them to be prematurely replaced. 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.
Lubrication Engineers (LE) South Africa represents the LE brand in South Africa, Botswana, Namibia, Mozambique, Zimbabwe and Zambia. We hold the rights to Southern Africa on the LE brand, recognised internationally as a specialist in lubrication.
Through LE Incorporated, we are a member of a worldwide network of companies spanning Europe, South America, Asia and Africa, while LE Incorporated operates in the USA and covers North America including Canada, Mexico and the USA.
We provide high performance, heavy-duty, quality lubricants for virtually every industry and application, as well as expert technical back-up and support.