Operation of the Pipe Lifter DOW CONFIDENTIAL - Do not share without permission

Operation of the Pipe Lifter

DOW CONFIDENTIAL - Do not share without permission

Beam Clamp Pipe Lifter

Wall/Pier Pipe Lifter

Pipe Lifter

Introduction

• The ThyssenKrupp Xervon Pipe Lifter was developed for Dow as a result of a Six Sigma project (MFG390 – Reduce Costs of Lifting Pipes for Maintenance and Inspection Activities at Stada)

• The advantages of the pipe lifter include:

– Ensures safe work in areas with limited space.

– Reduces the risk of injury.

– Improves existing best practices.

– Reduces set-up time.

– Saves money.

• The pipe lifter will be available for check-out from the

RSC Tool Room.

Terminal Objective

• Become familiar with the pipe lifter and its application.

• Know when the use of the pipe lifter is appropriate.

• Know how to safely assemble and use pipe lifter.

Upon completion of this training, the user will:

Enabling Objectives

1. The user can determine the need for the pipe lifter according to the job scope.

2. The user can determine if the pipe lifter can be used for the job.

3. The user can list current equipment that the pipe lifter can be substituted for.

Enabling Objectives

4. Field Planner and WACs can identify the most appropriate application of the pipe lifter according to job scope.

5. The user can inspect all parts to identify corrosion, excessive wear, defective steel components, deformities in the chain, etc.

6. The user will be able to properly assemble the pipe lifter.

7. The user will be able to properly use the protection plates.

Is the pipe lifter needed?

Some examples of where the pipe lifter can be used effectively:

– To inspect piping– To repair piping– To paint piping– NDT of piping

Enabling Objective #1

Determining when the Pipe Lifter can be Used

Factors to consider:• The size, metallurgy, schedule of the pipe, and

the density of the material in pipe.• Maximum load (3800 lbs.) table calculation

basis:– Pipe size must be between 2” and 12”– Carbon steel piping– Standard wall piping– Density of material (salt solution)- 0.685871 oz/in3


What Tools can the Pipe Lifter Replace?

Examples of equipment that the pipe lifter can be used in place of:

– Mobile cranes– Hydraulic jacks– Chain falls

Enabling Objective #3/4

Pre-Use Inspection

Inspection is required before assembling the pipe lifter

– Inspect the chains and hooks for corrosion, wear, pits, deformation, cracks

– Inspect pipe lifter components for defects:• Corrosion, bent iron, cracks, distortion, etc.• Support rollers turn freely.

Do not use a defective pipe lifter!


Pipe Lifter Parts

1. Protection Plates (2)2. Lifting Arms (2)3. Support Roller (2)4. Beam Clamp5. Cross beams (2)6. Pins & Keepers (2)7. Safety Chain 8. Come-A-Long1

2 3

4

5

7

8

6


Assembly

Assembly/use of the beam clamp pipe lifter:


2. Tighten the screw on the beam clamp to firmly secure the clamp to the beam, making sure that the jaws are tight against the edge of the beam flange.


1. Attach the beam clamp to the bottom flange of the beam directly below the pipe to be lifted.

Note: The first three steps of assembly are different for the beam clamp pipe lifter and the wall/pier pipe lifter.

Assembly (Continued)

Assembly/use of the beam clamp pipe lifter:


3. Attach the narrow end of the two lifting arms to both sides of the beam clamp by lining up the holes in each and inserting the pins and keepers.



Assembly/use of the pipe lifter:


4. Remove the cross beams from the lifting arms by removing the keepers and pulling out the pins.

Beam Clamp and Wall/Pier Pipe Lifter

5. Swing the lifting arms up high enough to reattach the cross beams above the pipe.

6. Reattach the cross beams to the lifting arms.

NOTE: From this point on, the steps for both styles of pipe lifter are the same.




7. Attach the come-a-long to the center holes on the cross beams.





8. Ratchet the come-a-long to begin lifting the support rollers toward the bottom of the pipe. Lift the support rollers leaving approximately ½” between the bottom of the pipe and the top of the support rollers.





9. Insert the protection plates between the bottom of the pipe and the top of the support rollers.





10. Continue ratcheting the come-a-long to lift the pipe to the desired height.

Warning: Continue to ensure the protection plates stay in position.





11. When the pipe has been lifted to the desired height, attach the safety chain as tightly as possible to the remaining hole on each of the cross beams.

Warning: Safety chains must be used to support the load!


Pipe Lifter Parts

• Pipe Lifter Parts:

1

23

4

56

87

9

1. Protection Plates (2)2. Lifting Arms (2)3. Holding Pipe (2)4. Support Roller (2)5. Pipe Lifter Holders (2)6. Cross beams (2)7. Come-A-Long8. Safety Chain 9. Securing Brackets (2)



Assembly/use of the wall/pier pipe lifter:



1. Place the two pipe lifter holders over the support on each side of the pipe to be lifted.

2. Select the two appropriate length holding pipes and place them in the hooks at the bottom of the two pipe lifter holders so that they cross under the pipe to be lifted.




3. Attach the two lifting arms to the holding pipes and latch the securing brackets around the holding pipes.





Go to Step 4.

Steps 4 through 11 are the same for the wall/pier pipe lifter as the beam clamp pipe lifter.


Video - Assembly of the Wall/Pier Pipe Lifter (6 minutes)

Safety Precautions

• Follow M64, Barricades and Guards, when determining where to barricade the hazard zone.

• Multiple opportunities for pinch points – watch your line of fire. Awareness of your body position is the first line of defense.

• Always wear your safety equipment – gloves – safety glasses – there could be additional PPE required.

• Be sure to inspect all parts of the pipe lifter before use. Never use equipment with defective parts.

• Do not drop the pipe lifter.

Resources

• The procedure is located in the Site Maintenance file share

• Equipment information will be available in the Site Maintenance file share

• During roll out – training simulator will be available at the Machine Shop

• After roll out – training simulator will be available at the RSC tool room for practice

Contacts

• Site contacts for questions on the pipe lifter:- Steve Rouse – 979 238 5130- Jack Christy – 979 238 1330

Documents

Operation of the Pipe Lifter DOW CONFIDENTIAL - Do not share without permission