Installation Guide

ASME Standards for wire rope (cable) inspection and replacement
Reprinted with permission from ASME B30.19 Cableways
The following is intended as a helpful guide to the general topic of inspection and replacement
of wire rope (cable). It is not intended to be an exhaustive treatment of the topic.
Frequent inspection (at least daily) by a competent person and prompt replacement of any cable that shows any sign of
wear is the responsibility of the owner and the operator of the PANELLIFT
®
Drywall Lift.
With reference to the chart below at 19-2.4.3(b)(6) the Panellift® Drywall Lift cable is a nominal 1/8” high tensile cable (rope).
(3) Care shall be taken when inspecting sections of rapid deterioration,
such as the following:
(a) sections in contact with saddles, equalizer sheaves, or other sheaves,
including track cable sheaves, where rope travel is limited;
(b) sections of the rope at or near terminal ends where corroded or broken
wires may develop.
19-2.4.3 Rope Replacement
(a) No precise rules can be given for determination of the exact time for
rope replacement, since many variable factors are involved. Once a rope
reaches any one of the specified removal criteria, it may be allowed to operate
to the end of the work shift, based on the judgment of a qualified person. The
rope shall be replaced after that work shift, at the end of the day, or at the
latest time prior to the equipment being used by the next work shift.
(b) Removal criteria for rope replacement shall be as follows:
(1) In running ropes, six randomly distributed broken wires in one lay,
or three broken wires in one strand in one lay.
(2) One outer wire, broken at the contact point with the core of the rope,
that has worked its way out of the rope structure and protrudes and loops out
from the rope structure. Additional inspection of this section is required.
(3) Wear of one-third the original diameter of outside individual wires.
(4) Kinking, crushing, birdcaging, or any other damage resulting in
distortion of the rope structure.
(5) Evidence of heat damage from any cause.
(6) Reductions from nominal diameter greater than those shown below:
(7) In standing ropes, more than two broken wires in one lay in sections
beyond end connections, or more than one broken wire at an end connection.
(c) Broken wire removal criteria cited in this Volume apply to wire rope
operating on steel sheaves and drums. The user shall contact the sheave,
drum, or cableway manufacturer, or a qualified person for broken wire removal
criteria for wire ropes operating on sheaves and drums made of material other
than steel.
(d) Replacement rope shall have a nominal strength rating at least equal
to the original rope furnished or recommended by the cableway manufacturer
or designer, or a qualified person. Any deviation from the original size, grade,
or construction shall be specified by the rope manufacturer, the cableway
manufacturer or designer, or a qualified person.
(e) Ropes Not in Regular Use. All rope that has been idle for a period of
a month or more due to shutdown or storage of a cableway on which it is
installed shall be given an inspection in accordance with para. 19-2.4.2(b)
before it is placed in service. This inspection shall be for all types of
deterioration and shall be performed by an appointed or authorized person.
(f) Inspection Records
(1) Frequent inspection-no records required.
(2) Periodic inspection - in order to establish data as a basis for judging
the proper time for replacement, a dated report of rope condition at each
periodic inspection shall be kept on file. This report shall cover points of
deterioration listed in para. 19-2.4.2(b)(2).
(g) A long-range inspection program should be established and should include
records on examination of rope removed from service so a relationship can
be established between visual observation and actual condition of the internal
structure.
(00) General
…
The use of cableways, cranes, derricks, hoists, hooks, jacks, and slings
is subject to certain hazards that cannot be met by mechanical means but
only by the exercise of intelligence, care, and common sense. It is therefore
essential to have personnel involved in the use and operation of equipment
who are competent, careful, physically and mentally qualified, and trained in
the safe operation of the equipment and the handling of the loads. Serious
hazards are overloading, dropping or slipping of the load caused by improper
hitching or slinging, obstructing the free passage of the load, and using
equipment for a purpose for which it was not intended or designed.
…
Section 19-2.4: Rope Inspection, Replacement, and Maintenance
19-2.4.1 General. Sheave diameters, drum diameters, and rope design
factors are limited because of cableway design configuration. Due to
these parameters, inspection in accordance with para. 19-2.4.2 to detect
deterioration and timely replacement in accordance with para. 19-2.4.3 are
essential.
19-2.4.2 Inspection
(a) Frequent Inspection
(1) All running ropes in service should be visually inspected once each
working day. A visual inspection shall consist of observation of all rope that
can reasonably be expected to be in use during the day’s operations. These
visual observations should be concerned with discovering gross damage that
may be an immediate hazard, such as listed below:
(a) distortion of the rope such as kinking, crushing, unstranding, birdcaging,
main strand displacement, or core protrusion. Loss of rope diameter in a short
rope length or unevenness of outer strands should provide evidence that the
rope or ropes are to be replaced.
(b) general corrosion;
(c) broken or cut strands;
(d) number, distribution, and type of visible broken wires [see paras.
19-2.4.3(b)(1), (2), and (7) for further guidance];
(e) core failure in rotation-resistant ropes; when damage is suspected, the
rope shall either be removed from service or given an inspection as detailed in
para. 19-2.4.2(b).
(2) Care shall be taken when inspecting sections of rapid deterioration,
such as flange points, crossover points, and repetitive pickup points on drums.
(3) Care shall be taken when inspecting certain ropes, such as
rotation-resistant ropes, because of their higher susceptibility to damage
and increased deterioration when working on equipment with limited design
parameters. The internal deterioration of rotation-resistant ropes may not be
readily observable.
(b) Periodic Inspection
(1) The inspection frequency shall be determined by a qualified person
and shall be based on such factors as expected rope life (determined by
experience on the particular installation or similar installations), severity of
environment, percentage of capacity lifts, frequency rates of operation, and
exposure to shock loads. Inspections need not be at equal calendar intervals
and should be more frequent as the rope approaches the end of its useful life.
The inspection shall be made at least every 1000 hr of cableway operation or
annually, whichever comes first.
(2) Periodic inspections shall be performed by an appointed or
authorized person. This inspection shall cover the entire length of rope. Only
the surface wires of the rope need be inspected. No attempt should be made
to open the rope. Any deterioration resulting in appreciable loss of original
strength, such as described below, shall be noted, and a determination shall
be made as to whether further use of the rope would constitute a hazard:
(a) points listed in para. 19-2.4.2(a):
(b) reduction of rope diameter below nominal diameter due to loss of core
support, corrosion, or wear of outside wires;
(c) severely corroded or broken wires at end connections;
(d) severely corroded, cracked, bent, worn, or improperly applied end
connections.
Max. Allowable
Reduction From
Rope Diam. Nominal Diam.
Up to 5/16 in. (8 mm) 1/64 in. (0.4 mm)
Over 3/8 in. up to 1/2 in. (13 mm) 1/32 in. (0.8 mm)
Over 9/16 in. up to 3/4 in. (19 mm) 3/64 in. (1.2 mm)
Over 7/8 in. up to 1 1/8 in. (29 mm) 1/16 in. (1.6 mm)
Over 1 1/4 in. up to 1 1/2’ in. (38 mm) 3/32 in. (2.4 mm)