NCCCO Wire Rope Inspection and Replacement 4 — Questions and Answers
Question 1: When inspecting wire rope on a crane hoist drum, what condition requires immediate removal from service?
- Minor surface rust that brushes off easily
- Two broken wires in one lay on a standing rope (Correct answer)
- Slight waviness along the rope length
- Visible lubrication between strands
Correct answer: Two broken wires in one lay on a standing rope
ASME B30.2 requires removal from service if two or more broken wires are found in one rope lay on a standing rope.
Question 2: What is 'bird caging' in a wire rope and what does it indicate?
- A systematic lubrication pattern applied by the manufacturer
- Outer strands separating and opening up, indicating torsional damage (Correct answer)
- A weaving pattern used in rotation-resistant ropes
- Color-coded inspection markings applied by the rigger
Correct answer: Outer strands separating and opening up, indicating torsional damage
Bird caging occurs when outer strands flare outward due to sudden release of tension or shock load, indicating internal structural damage.
Question 3: What is the minimum discard criterion for broken wires in a running rope (reeved over sheaves) per ASME B30 standards?
- 6 broken wires in one rope lay or 3 broken wires in one strand in one lay (Correct answer)
- 2 broken wires in any location
- 10 broken wires distributed across the full rope length
- 1 broken wire in a load-bearing strand
Correct answer: 6 broken wires in one rope lay or 3 broken wires in one strand in one lay
ASME B30 requires removal when a running rope has 6 or more broken wires in one rope lay, or 3 or more broken wires in one strand within one lay.
Question 4: Which internal wire rope condition is most difficult to detect during a visual inspection?
- External broken wires at the termination
- Valley breaks between outer strands
- Internal corrosion and broken core wires (Correct answer)
- Kinks caused by improper spooling
Correct answer: Internal corrosion and broken core wires
Internal corrosion and broken core wires cannot be detected visually from the outside, making them a hidden hazard that requires periodic disassembly or electromagnetic inspection.
Question 5: A crane operator notices a 'kink' in the wire rope. What is the correct action?
- Apply extra lubrication to the kinked section and continue operations
- Straighten the kink by hand and document it in the inspection log
- Remove the rope from service immediately; kinks are a permanent discard criterion (Correct answer)
- Monitor the kink over the next 30 days before deciding
Correct answer: Remove the rope from service immediately; kinks are a permanent discard criterion
A kink permanently distorts the wire rope's geometry and weakens it; ASME B30 standards list kinking as an immediate removal-from-service criterion.
Question 6: What does a reduction in rope diameter of 3% or more from the nominal diameter indicate?
- Normal break-in stretch that requires no action
- Excessive external wear, internal wear, or core failure requiring removal from service (Correct answer)
- The rope has been properly pre-stretched for use
- The rope grade is lower than specified and should be re-lubricated
Correct answer: Excessive external wear, internal wear, or core failure requiring removal from service
A 3% or greater reduction in nominal diameter is a discard criterion under ASME B30, indicating significant loss of metallic cross-sectional area.
Question 7: During a wire rope inspection, you find severe heat damage with fused or annealed wires near the drum. What should you do?
- Allow the rope to cool and re-inspect after 24 hours
- Apply water to the affected area and continue lift operations
- Remove the rope from service immediately; heat damage is a discard criterion (Correct answer)
- Increase the rope's maintenance lubrication interval
Correct answer: Remove the rope from service immediately; heat damage is a discard criterion
Heat damage including fused, annealed, or discolored wires permanently reduces tensile strength and is an immediate removal-from-service condition.
NCCCO Wire Rope Inspection and Replacement 4
When inspecting wire rope on a crane hoist drum, what condition requires immediate removal from service?