Rotary Drilling Rig Wire Rope Use & Maintenance Guide

1. Uncoiling and Installation

When uncoiling and installing wire rope, always use the correct method to prevent twisting and kinking. Also avoid getting sand or soil on the rope surface, as abrasive contaminants can accelerate wear and reduce service life.

2. Cutting a Full Coil of Wire Rope

If a full coil must be cut during use, the rope end should be secured by binding or fused (heat-sealed) as shown in the figure, to prevent the strands from loosening and the rope from unraveling.

3. Installing Wire Rope Clips

If wire rope clips must be used, install them according to the method shown in the figure. The recommended spacing between clips is 5–6 times the wire rope diameter.

4. Selecting Rope Lay Direction

Choose the wire rope lay direction so that the wrapping direction of the bottom layer on the drum matches the method shown in the figure. Correct lay selection helps reduce twisting and improves winding stability.

5. Proper Winding on the Drum

When winding wire rope onto the drum, the rope must be laid neatly in order—never randomly. Poor winding can cause severe pinching, crushing, and deformation during operation, which significantly shortens wire rope service life.

6. Break-In Period for New Wire Rope

A new wire rope must be “broken in” under light load during the initial stage of use. This helps improve service life. During operation, avoid excessive shock loads that may damage the rope.

7. Prevent Over-Paying During Drilling

During drilling, carefully calculate the required payout distance and do not over-release the wire rope. Excessive payout can cause the rope to become slack and cross-wrap, leading to structural damage and complete rope failure, as shown in the figure.

8. Managing “Rope Biting” in Multi-Layer Winding

For equipment with multi-layer winding, “rope biting” is unavoidable during service. It is recommended to:

• frequently inspect the rope-biting area,

• improve lubrication at that location, and/or

• periodically reposition the rope (cut and re-terminate if necessary) to shift the rope-biting point.

  
  

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9. Routine Inspection of High-Risk Areas

Wire rope performance gradually decreases after it is put into service. Therefore, after a period of use, inspect high-risk areas frequently, including:

• rope-biting locations,

• lower drum layers,

• sections passing over sheaves after heavy impact events, and

• areas where the rope enters and exits the drum.
  Regular inspection provides the basis for safe and reasonable wire rope use.

10. Handling Broken Wires

If broken wires appear and the rope must continue to be used, the broken wire ends should be treated immediately as shown in the figure. You can grip the broken end with wire pliers and repeatedly bend it back and forth until it breaks off. After this treatment, the broken end will be clamped between strands and will not create a hazard during use.
Replacement rule: If the number of broken outer wires within one lay length reaches 10% of the total outer wires, the wire rope must be replaced.

11. Recommendation: Use Rotation-Resistant Wire Rope

Because rotary drilling rig wire rope operation is typically a single-line lifting system (meaning the rope has a free-rotating end during operation), for safety and ease of handling it is strongly recommended to prioritize rotation-resistant wire rope when purchasing.