Failed Extension Reel

We all probably own or use an Extension Reel, but how safe is it?

This Extension Reel, although showing a bit of wear, looks safe enough and in fact would pass a PAT cable test. But all not is as good as it seems.

Avoid this type of fault by following some simple tips.

Here’s the fault

After pulling out the full length of cable a break in the sleeving was easily spotted right next to the anchor point.

Clearly the cable had been pulled to get that ‘extra’ bit of reach.

Opening up the facia plate showed the full extent of the damage.

After cutting back the cable and re-wiring the Reel was re-assembled and re-tested.

The stakeholder was made aware of this fault and the extent of corrosion was also pointed out. The rusting was mainly superficial but the recommendation was to setup a more frequent review process for these types of equipment. The electrical connectors were still sound, but we have agreed that the Reel will require a re-test in 3 months time and will most likely be scrapped and replaced before then.

Tips

• Do not put the cable under any strain when it is unwound.
• Never leave the reel dangling if the cable passes over obstacles; make sure it sits flat on a firm surface.
• Always pull out the whole length of the cable before use. Under heavy loads a wound cable can induce currents across the coil and overheat.