INSPECTION ~ WIRE ROPE The non-destructive inspection of wire rope to determine the proper time in which to retire a rope from service has always becn controversial. There is no completely satisfactory method yet established to positively evaluate the strength resaining in a used rope without subjecting a sample of the rope to a complete laboratory examination. This examination would necessarily include a break strength test. Fortunately, wire rope is an inherently safe machine when operated under conditions for which it was designed. Under most condi- tions, an external examination by a trained inspector will indicate when a rope has reached the end of its useful service life and is unsafe for further service. Safety is of first importance; but within the linits of safety, it is also important to obtain the best possible service life. True wire rope economy cannot be obtained unless the decision to renove a rope fron service is based on facts. Some of the more important. facts that must be known to the inspector are as follows: 1. Nature of the specific operation. This includes condition of equipment, operating practices, frequency of operation, minimum margin of safety that must be maintained at all times on the particular operation. 2. Basic knowledge of wire rope constructions and their operating characte:istics. 3. History of past rope service on specific operation. 4. Type of failure that may be expected on a specific rope application. 5. Knowledge of the care that a wire rope received and is receiving throughout its useful life. This includes proper handling, lubrication, and attach- ments. 6. Significance of diameter. Particular reférence is made to a reduction in rope diameter during service. 7. Significance of a change in the length of rope lay. 8. Significance of abrasive wear and peening of outer wire crowns. 9. Significance of broken outer wires and the pattern of wire breaks. 10. Rust and corrosion. 11, Mechanical’ damage to wires, strands, or the rope. This includes cuts, burns, crushing, scarfing, spirals, and doglegs. 12, Significance of fatigue. FD rrcess.neInspection - Wire Rope Page 2 Several specific recommendations are listed to assist wire rope inspectors in evaluating when a rope should be removed from service. 1 Broken Wires The entire rope should be examined for broken wires. This examination should be conducted both visually and by feel. Any broken wires that are found should be carefully examined to determine the cause. The appearance of the broken wire end will indicate the type of failure and, very likely, the cause. Various types of broken wire ends will be briefly described. a. Necked-down, cup and cone ~ tensile break. b. Square - fatigue. ce. Knife edge - abrasion. d. Pitted, corroded - corrosion (acid, salt, and other corrosive fluids). Shear, cut - mechanical abuse. The type of break, number of broken wires, and the location of broken wires will determine whether or not a rope should be removed from service. In any case, a tope showing broken wires should be carefully watched and reinspected at frequent intervals to determine the rate of progressive deterioration. It may be stated that a crane rope should definitely be removed from service when the following number of outer wire breaks are noted. General Broken in Wires Broken . Classification * One Rope. Lay in One Strand 6 x 19 16 to 18 4 6x19 ‘Typical 6 x 19 Seale Construction, 6x 21 F.w. 6 x 25 F.W. bx 37 28 to 30 6 ~~ ~"6 x 36 WS. 6 x 31 Seale 8x19 24 to 28 4 “8 x 19 8 x 19 Seale The experience and judgment of the inspector {s very important. The hazard of the operation might rake it advisable to remove a specific rope from service long before the above mentioncd number of broken wires is FD racers. neInspection - Wire Rope 1 Page 3 Broken Wires (cont'd) noted. Also, in the case of broken wires from corrosion, internal corrosion may be suspected and the rope should be retired as soon as the condition ts noted. Conversely, a few scattered outside wire breaks, caused by mechanical abuse, would affect the safety and service life of the rope but slightly. Abrasive Wear The entire rope should be examined for abrasive wear. A field inspection of this type should be essentially visual. It is necessary to estimate the percentage of the cutside wire crowns that have been worn away. Care must be taken to observe if the wear is uniform or spotty. A rope that has been set into a spiral, dogleg, or bend, may show heavy abrasive wear along the outside curvature. Other sections of the rope nay show little or no wear. Since a rope is no stronger than its weakest section, always consider the worst section in determining if a rope should be removed froa service. Uniform abrasive wear indicates that a rope is performing satisfactorily. Within limits, pure abrasive wear should not be cause for undue alarm. In general, a rope should not be removed fron service for reasons of abrasive wear alone until approximately 35% of the diane:er of the outside wire crown has been worn avay. An experienced inspector can determine the percentage of abrasion rather accurately by comparing the width of the worn oval with the diameter of the wire. As you can readily visualize, a wire crown that has worn more than 50% will present 2 dumbbell shape. This is true because the cord measured across the minor axis of a Wire, at a worn section worn more than 50%, is less than the original diameter of the wire. Hence, a wasp-vaisted or dumbbell shape is evident. By using 0% and 50% abrasive wear as visual bench marks, an estimate can be made of the actual abrasive wear. Without going into great detail, it should be pointed out why a wire rope may be safely operated when the wear of outer wires is 35% or even greater. Each construction of wire rope has a theoretical reserve strength. This figure is based on the strength of the remaining wires in a rope after all of the outside wires have been removed. The following table gives reserve strengths for a few of the constructions in common use: Construction Reserve Strength 6x19 37% 6 x 25 FW, 44% 6 x 36 WS. 54% 6x 41 WS. 55% Assume a 6 x 41 W.S. rope of x diameter with a breaking strength of 1,000 Ibs. and with 35% abrasive wear on outer wire crowns. Lf all of the outer wires vere removed, the rope would have a theoretical breaking strength of 550 Ibs. Since only 35% of the diameter of the outer wires has been removed, 65% of the outer wires remain. Therefore, the theoretical breaking strength of this rope is .55 + (.65 x .45) x 1000 = 842.5 lbs. Since this rope was originally designed to operate at a factor FD esceco ne.Inspection - Wire Rope Page 4 Abrasive Wear (cont'd) of safety of 5, the loads lifted would not materially exceed 200 lbs. On this basis, the rope with 35% abrasive wear would operate at a factor of safety of 4.2, This example is theoretical and involves deterioration from abrasive wear only, However, it serves to illustrate the fact that considerable reserve strength remains in a rope that appears to be heavily worn. It should be pointed out that a new rope will appear to wear rather rapidly during the initial part of its service life. This is due to the fact that only a small area of the outside wires of a rope is in contact with the sheaves or drug, As the outside wire crowns continue to wear, the area in contact with the sheaves and drum increases and the rate of wear decreases. Diameter It ds suggested that the rope inspector check the rope diameter at several different spots throughout the length of the rope during his inspection. The use of an accurate pair of Vernier calipers is suggested. Valuable information concerning the service remaining in a wire rope can be gained from gauging the rope diameter. All wire ropes are manufactured within permissible tolerances which are specified within U. S. Federal Specifications as shown below: Nominal Wire Rope Diameter Undersize Oversize 1- 9/16" - 2-1/4" 2- 5/16" and larger 0 - 3/6" o 13/16" ~ 1-1/8" 0 1 3/16" = 1-1/2" 0 0 0 It 4s common practice to manufacture near the top side of the permissible tolerance. This insures a rope that will meet or exceed the published breaking strengths. Even more important, it will operate throughout the Greater portion of its useful life near its nominal dianeter and maintain a satisfactory factor of safety. When a new rope is first put to work, there is a short period of rapid stretch. This is due to compacting of strands on the core and compacting of wires in the strands. A diameter decrease will be noted. This is normal and is no cause for concern. During the effective rope life, a very slight stretch will occur. Diameter readings will decrease slightly, but will stay at nominal or near nominal. For the most part, the slight decrease in diameter during this period will be caused by the increasing wear on outer wires. Finally, a point is reached in the life of the rope where the stretch again becomes rapid. This is a danger point, and the rope should be removed from service. A rather rapid decrease in diameter suggests core deterioration, internal wire breakage, and abrasive wear. FD racers.Inspection - Wire Rope 3. 5. Page 5 Diameter (cont'd) It is suggested that the inspector gauge the dianeter of a rope at each regular inspection. He should note the following: a. Actual diameter - nominal, above nominal, or below nominal. b. Roundness of rope. c. Uniformity of gauging. An unexplained reduction in diameter might well indicate internal deterioration. d. Rapid decrease in diameter below nominal. This condition indicates that the rope has served its useful life and removal is indicated. Rust & Corrosion Corrosion is controlled by proper lubrication. However, should it be Present, it deteriorates all of the wires in the rope. Ia addition, rust and corrosion impede the movement of wires in the strands and strands in the rope. Since the internal parts of the rope are locked and can no longer move one against the other, the rope’acts more like a steel rod than a flexible uenber, and early failure due to fatigue results. When corrosion is present, there is no reasonable way to determine the safety of the rope. The inspector's experience is the only possible way to determine whether a rope should remain in service. With the exception of light surface rust, it is recommended that any rope showing evidence of corrosion (pitting) should be removed from service. Mechanical Damage The significance of various types of mechanical damage depends upon the type of damage and the severity of the damage. It is important to determine the cause of the damage to prevent recurrence. It is also advisable to remove a dauaged section from the rope if it is possible. The most frequent types of mechanical damage are as follows: 4. Cuts - Treat as broken wires, and base decision to remove rope from Service on the number of damaged wires. Remove damaged section from rope if possible. b. Burns ~ Remove damaged section from rope if possible, or retiré rope if necessary. €- Crushing - Drum crushing greatly reduces service life. The severity of crushing and ultimate wire failure due to fatigue determine whether rope should be removed from service or not. 4. Scarfing - Regard as abrasive wear. e. Kinks - Remove kinked section from rope if possible, or retire rope from service. . TD rrcicoineInspection - Wire Rope Page 6 Mechanical Damage (cont'd) Spirals - Check outside curvatures for excessive wear, and base decision for removal on abrasive wear or broken wires at worst section. f. Doglegs or Bends - Check outside curvature for excessive wear, and base decision for removal on wear or broken wires. (ay 15, 1979) oO : PACECO nc