Reeling Cable Repair Programme at a Container Terminal

Client Background

A container terminal operator was replacing crane reeling cable far more often than the cable's rated flex life suggested. Inspection showed most replacements were triggered by localised jacket damage rather than by conductor or insulation failure.

Project Challenge

Give the terminal's own electrical team a way to repair jacket damage between shifts using flame retardant materials appropriate to a marine environment.

Customer Pain Points

• Reeling cable replaced whole because of localised jacket damage
• Salt environment defeating repairs made with general purpose materials
• No repair capability on site so damaged cable stayed damaged until replacement
• Repairs having to happen between shifts with no workshop

Our Solution

An on site repair kit built around R1 wraparound sleeves in three sizes covering the terminal's cable range plus S3(h) heavy wall flame retardant tubing for the free end positions and T1 tape for irregular geometry.

Manufacturing Process

Flame retardant grades formulated for wet and salt laden service. Heavy wall for the mechanically hostile positions on a reeling drum.

Supply Chain Coordination

Initial kit plus a quarterly replenishment sized against actual consumption after the first three months.

Quality Control

Per lot testing including low temperature flexibility at -40 °C and water absorption. CCS ABS and DNV approval documentation supplied for the terminal's records.

Final Result

Cable replacement frequency dropped substantially in the first year. The most valuable single change was a written instruction to wash salt off the jacket before cleaning with solvent which had been the cause of the terminal's earlier repair failures.

Customer Benefit

A terminal that repairs its own cable between shifts instead of replacing whole reeling cables because of a metre of jacket damage.