Inspection of Rust and Broken Wire Hazards & Maintenance Replacement Skills for Steel Wire Ropes

I. Common Causes of Rust and Broken Wires

1. Environmental corrosion: High-salt sea fog, rainwater and humid underground surroundings erode surface coating, forming rust spots and weakening structural strength.
2. Mechanical wear: Bending, pulley friction and heavy impact cause surface abrasion, resulting in fatigue broken wires under continuous stress.
3. Insufficient maintenance: Lack of regular lubrication and dirt adhesion accelerate aging and damage.
4. Overload operation: Working beyond rated load intensifies tensile fracture of internal steel wires.

II. Key Points for Rust and Broken Wire Inspection

1. Visual appearance check
   Examine the rope surface for rust spots, peeling rust layers, single or multiple broken wires, loose strands, distortion and flattening.
2. Partial wear inspection
   Focus on pulley contact areas, fixed ends and frequent bending sections, where wire breakage occurs most frequently.
3. Internal structure verification
   Check obvious diameter reduction and abnormal strand gaps, which indicate internal rust and hidden broken wires that weaken load capacity.
4. Safety judgment standard
   The rope is regarded as high-risk when broken wires exceed limited quantity, rust penetrates coating or severe distortion appears.

III. Practical Daily Maintenance Skills

1. Regular dirt cleaning
   Remove sediment, dust and corrosive attachments to avoid persistent surface abrasion.
2. Even protective grease coating
   Apply anti-corrosion and wear-resistant grease evenly to isolate air and moisture, reduce friction and slow down rusting.
3. Standard storage
   Store idle ropes in dry and ventilated warehouse. Avoid outdoor exposure, water soaking and contact with acid and alkali substances.
4. Standard operation
   Operate within rated load. Forbid overload, sudden pulling and sharp twisting to reduce fatigue damage.

IV. Replacement Time and Precautions

1. Replacement criteria
   Stop using and replace immediately in case of concentrated broken wires, large-area deep rust, excessive diameter wear, loose strands and decreased elasticity.
2. Reasonable model selection
   Select wire ropes with proper structure, material and diameter according to working load and environment. Galvanized and anti-rotating compact strand ropes are preferred for port and offshore drilling use.
3. Trial operation after replacement
   Carry out no-load and light-load test run after installation. Ensure smooth operation without jamming and abnormal vibration before formal work.

V. Conclusion