Industrial Cable Assemblies factory

How to detect wear and tear in industrial cable

Industrial cables are the lifelines of manufacturing plants, power stations, and heavy machinery, transmitting electricity and data to keep operations running smoothly. However, constant exposure to harsh environments—such as extreme temperatures, chemical spills, mechanical stress, and UV radiation—inevitably causes wear and tear over time. Undetected damage can lead to costly downtime, equipment failure, or even safety hazards like short circuits and fires. To mitigate these risks, regular and effective wear detection is critical. This article outlines practical, actionable methods to identify signs of deterioration in industrial cables, helping maintenance teams address issues before they escalate.

1. Visual Inspection: The First Line of Defense

Visual inspection is the most accessible and initial step in detecting cable wear, requiring no specialized equipment—only a trained eye. Start by examining the cable’s outer sheath, as it is the first barrier against external damage. Look for the following red flags:

• Cracks and Fractures: Small cracks on the sheath, especially around bends or joints, indicate material degradation due to age, temperature fluctuations, or repeated flexing. These cracks can widen over time, exposing the inner conductors to moisture and contaminants.
• Discoloration: Yellowing, darkening, or fading of the sheath often signals UV damage (if the cable is used outdoors) or heat exposure from nearby machinery. Discoloration may also accompany chemical erosion if the cable is in contact with oils, solvents, or corrosive substances.
• Bulging or Swelling: Unusual bulges suggest internal damage, such as insulation breakdown or the accumulation of moisture. This is particularly common in cables subjected to high pressure or frequent vibration.
• Abrasion Marks: Scratches, scrapes, or thinning of the sheath along areas where the cable rubs against metal surfaces, conveyor belts, or other equipment. Severe abrasion can quickly wear through the sheath, risking conductor exposure.

For thoroughness, inspect the entire length of the cable, including connection points, cable trays, and areas where the cable is routed around sharp edges. Use a flashlight for dark or hard-to-reach spots, and clean the cable surface if dirt or grease obscures visibility.

2. Physical Inspection: Assessing Tactile and Dimensional Changes

Beyond visual cues, physical inspection involves touching and measuring the cable to identify subtle wear. Begin by running your hand along the sheath—any roughness, stiffness, or softness (compared to a new cable of the same type) indicates degradation. A brittle sheath that crumbles when pressed is a clear sign of aging or thermal damage.

Dimensional checks are equally important. Use a caliper to measure the cable’s diameter at multiple points. If the diameter is significantly reduced (more than 10% compared to the manufacturer’s specifications), it may indicate internal conductor damage or sheath erosion. Additionally, check for any stretching or elongation, which can occur if the cable is subjected to excessive tension, leading to conductor breakage.

3. Electrical Testing: Uncovering Hidden Damage

Visual and physical inspections may miss internal issues like insulation breakdown or conductor corrosion. Electrical testing uses specialized tools to evaluate the cable’s performance and integrity:

• Insulation Resistance Test: Using a megohmmeter (megger), this test measures the resistance of the cable’s insulation to electrical current. A sudden drop in insulation resistance (below the manufacturer’s recommended value) indicates moisture absorption, aging, or damage to the insulation layer. Test at regular intervals (e.g., quarterly) and compare results to establish a baseline for normal wear.
• Conductivity Test: This checks if the conductors are intact and transmitting current efficiently. A higher-than-normal resistance reading suggests corrosion, loose connections, or partial conductor breakage. For three-phase cables, balance testing ensures current is evenly distributed across all phases—imbalances may point to internal damage.
• Partial Discharge (PD) Test: PD occurs when electrical energy leaks from the conductor through small defects in the insulation. Using a PD detector, maintenance teams can detect these tiny discharges, which are early warning signs of insulation failure. PD testing is especially critical for high-voltage industrial cables, as insulation breakdown can lead to catastrophic failures.

4. Advanced Non-Destructive Testing (NDT) Methods

For complex or critical cables, advanced NDT techniques provide deeper insights into internal wear without damaging the cable:

• Infrared Thermography: An infrared camera detects heat patterns along the cable. Hotspots indicate poor connections, overloaded conductors, or insulation degradation, as these issues cause excessive heat buildup. This method is ideal for scanning large cable runs or inaccessible areas quickly.
• Ultrasonic Testing: High-frequency sound waves are transmitted through the cable, and the reflected waves are analyzed to identify internal defects like conductor corrosion, insulation voids, or water ingress. Ultrasonic testing is particularly effective for detecting damage in thick or armored cables.

5. Establish a Preventive Maintenance Schedule

Detection is most effective when integrated into a regular preventive maintenance plan. Document all inspection results, including dates, findings, and test readings, to track wear patterns over time. Schedule more frequent inspections for cables in high-stress environments (e.g., near furnaces, chemical tanks, or heavy machinery) and replace cables that show irreversible damage or are approaching the end of their service life.

Choose FRS for Reliable, Wear-Resistant Industrial Cables

While thorough detection is key to minimizing downtime, starting with high-quality, durable cables reduces wear in the first place. FRS brand factory specializes in manufacturing industrial cables engineered to withstand harsh conditions—from extreme temperatures and chemical exposure to mechanical stress and vibration. Our cables undergo rigorous pre-production testing and quality checks, ensuring superior insulation integrity, abrasion resistance, and long-term performance. Backed by expert technical support, FRS helps you select the right cables for your application and provides guidance on maintenance best practices. Trust FRS to keep your operations powered safely and efficiently, with cables that stand the test of time.