Maintaining critical equipment across a large industrial processing facility requires lifting systems tailored to the specific demands of each application area. For a UK dockside seed-crush and refinery plant, Hoist & Winch Ltd delivered a turnkey package of eight high-quality electric chain and wire rope hoists to support vital site-wide maintenance operations. Installed as part of a multi-year plant improvement programme, the high-performance hoists serve a variety of maintenance functions across indoor and outdoor process areas, including a quayside pump station, an ATEX-rated mineral oil extraction zone and several general production locations.
Following close customer consultation, Hoist & Winch specified and supplied equipment from three renowned European manufacturers, selecting individual hoist designs according to each location’s operational requirements.
One of the most demanding applications involved the maintenance of process water pumps situated below sea level at the dockside. To support lifting operations, Hoist & Winch supplied two GIS electric chain hoists, each offering 6-ton safe working load (Swl). Capacity, reliability, travel performance and hook coverage were all key considerations during equipment selection.
The GIS hoists feature two-speed motion, cross-travel limit switches and remote radio control. Given their exposed quayside location, the hoists were also supplied with weather-resistant canvas covers and galvanised steel parking enclosures for protection when not in use.
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Elsewhere on site, maintenance activities within the mineral oil extraction area required a lifting solution suitable for operation in a potentially explosive atmosphere. Hoist & Winch specified an Italkrane YY series 2-ton Swl electric chain hoist certified for ATEX applications up to Zone 1 II B T4.
The hoist incorporates flameproof electrical protection, anti-corrosion finishes and anti-sparking components, including brass trolley wheels, load hook and anti-tip devices. A low-headroom design, two-speed operation, cross-travel limit switches and radio control functionality further enhance its suitability for lifting vessel hoods and other equipment during maintenance procedures. A Hoist & Winch CompEx-certified engineer undertook the installation of all ATEX electrical connections.
For the indoor and outdoor process plant locations, Hoist & Winch supplied Stahl ST series electric chain hoists with 3.2-ton Swl. These units provide maintenance teams with a reliable means of lifting equipment between ground level and elevated work areas.
A separate maintenance location required significantly higher lifting capacity, leading Hoist & Winch to specify a Stahl SH series wire rope hoist with 9-ton Swl. Here, low-headroom configuration was essential to maximise available lifting height while accommodating larger process plant components. Across locations, the hoists were again supplied with two-speed operation, cross-travel limit switches and radio control systems to improve operational control and positioning accuracy.
Electrical power distribution was tailored to suit the constraints of each installation area. In general process locations, festoon cable C-track systems were mounted alongside runway beams. For the dockside and ATEX installations, however, specialised festoon trolley arrangements running along the bottom flange of the hoist runway beams were employed to accommodate beam configurations and site clearance/access requirements.
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Following installation, Hoist & Winch conducted comprehensive testing and certification of every lifting system. All hoist and runway beam installations underwent LOLER inspection, dynamic load testing and 125% proof-load testing before entering service. The company issued LOLER Thorough Examination reports for all installed systems.
“Every area of this facility presented its own technical challenges, from dockside lifting operations and ATEX requirements to low-headroom maintenance applications,” says Hoist & Winch Director Andy Allen. “By selecting the most appropriate hoist technology for each location, we were able to provide the customer with a safe, reliable and long-term lifting solution that supports efficient maintenance across the entire plant.”
Hoist & Winch completed its work on site by delivering operator training, covering safe use of the equipment, operating controls, limit switches, emergency stop functions, routine inspections, lubrication requirements and annual certification obligations.
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