Special Features: High-Risk & Extreme Environment Hoist Applications

Date: 1/29/2025

Previous Blog: Special Features for Better Performance

 

Special Features: High-Risk & Extreme Environments

Extreme industry environments often involve harsh conditions that pose inherent dangers. These environments also present unique challenges that can severely impact the performance and lifespan of equipment. They require specialized features to ensure safety, efficiency and compliance with regulatory standards. As industries continue to push the boundaries of where and how they operate, the need for equipment capable of withstanding high-risk and extreme environments becomes increasingly vital. Examples of industries operating in these environments include:

  • Petroleum & Gas
  • Paper & Pulp
  • Textiles
  • Railyards
  • Precast Concrete
  • Mining Operations
  • Steel and Metal Processing
  • Aerospace

 

High-Risk & Extreme Environments

 

Critical Lifts

Smart controls and safety features are added to hoist and crane components when operators must come in close contact with the load as a part of the standard operating procedure. Depending on the application, these features may include true vertical lift, anti-sway, micro-speeds and additional redundant limits and/or brakes.

 

Industries and examples:

 

Aerospace: Constructing items like airplanes, satellites and space shuttles requires extremely precise handling, along with additional safety features to protect the workers maneuvering around large, suspended loads.

 

Steel and Metal Processing: Moving large metal sheets and components requires precision to ensure correct positioning during the manufacturing process, to minimize the risk of damage and ensure worker safety.

 

Redundant Braking

 

For additional safety, a secondary brake, that acts as back-up brake, can be added to the SX2, SX3, SX4 or SX5 hoists. Both brakes open simultaneously, but the second brake’s closing is momentarily delayed. This delay ensures the secondary brake remains in “ like-new" condition, reducing the risk of dropped loads should the primary brake fail to engage.

 

A hoist drum brake can be added for additional safety for larger hoists (SX5-7, SXL and PDW). The hoist drum brake can be a holding brake and an over-speed brake. The hoist can be outfitted with either or both options. The holding brake secures the hoist drum in place after lifting or lowering has stopped. It is for indoors only. The over-speed brake engages if the drum rotation exceeds 25% of the rated speed, bringing the load to a smooth stop. This brake can be used indoors or outdoors.

 

Industries and examples:

 

Petroleum & Gas: Drilling components require safe handling, and their large capacities and outdoor exposure makes redundant safety features a key part of the material handling design.

 

Steel & Metal Processing: High-duty cycles, prevalent in the steel industry, make secondary braking a smart choice to improve safety.

 

Explosion-Proof and Non-Sparking

 

R&M’s Spacemaster® EX hoist is available with a Class I, Division 1 or Class I, Division 2 rating. Non-sparking options include bronze-coated hooks, brass wheels, brass drop lugs on the trolley and stainless steel wire rope. Additional control options, like an explosion-proof radio control unit, improve crane safety and productivity by allowing operators better range and visibility.

 

Industries and examples:

 

Petroleum & Gas: Refineries handle volatile substances that can ignite when in a gas or vapor form.

Mining Operations: Underground mining operations often encounter flammable gases like methane or natural gas.

Steel & Metal Processing: Paint booths in an assembly line may have explosive vapors and gases present.

 

Dust and Moisture Resistance

 

IP66 protection is added to the motors and electrical panels to prevent dust and moisture from entering the components. The bottom side drum cover provides additional protection from dust and moisture coming from below the hoist. Rail sweeps are added if the trolley or runway rail may be covered with dust or debris, even indoors, like in a paper mill or steel fabrication facility. Heaters on motors also help to burn off condensation, even when ambient temperature ranges are normal.

 

Industries and examples:

 

The following industries generate or operate in dusty and moist environments, even though they are often indoors. IP66 protection and other features keep the equipment running smoothly by preventing dust and moisture ingress, ensuring longevity and reliability and reducing costly downtime.

 

  • Paper & Pulp
  • Steel & Metal Processing
  • Mining Operations
  • Precast Concrete

 

Weather Resistance

 

Rain covers protect the hoist and traveling machinery from overhead precipitation. IP66 protection includes specially sealed motors, brakes and electrical panels for humid or dusty conditions. Rail sweeps are added if the trolley or runway rail can be covered with snow, dust or debris, and special paint thicknesses can be added to protect the hoist body from corrosive atmospheres, like in offshore applications. Anti-jump catches can be added to the top running double girder trolley or top running end carriages to prevent the trolley or bridge from leaving the rail in cases of high winds. R&M can provide heating and/or air conditioning of electrical panels to protect electronic equipment in extreme temperatures.

 

Industries and examples:

 

Petroleum & Gas: Offshore rigs face harsh weather conditions, including rain, wind and saltwater.

Railyards: Railyards operate outdoors and face various weather conditions.

Mining Operations: Open-pit mining and other outdoor mining activities are exposed to the elements.

 

High Altitude

 

At altitudes over 3,300 ft (1000 m), hoist cooling efficiency decreases. Upsized motors accommodate reduced air density and prevent overheating by increasing the effective electrical duty cycle (ED%). R&M’s wide range of available motor and gear pairs can often accommodate this need without unnecessarily upsizing the frame size of the hoist.

 

Corrosive Environments / Galvanizing

 

Special paint and special paint thicknesses protect against corrosive vapors, like hydrochloric acid, sulfuric acid or sulfur dioxide, rising from preparation pools. Specialty cast-iron motor housings are also available for galvanizing applications. Special coatings and housings protect the equipment from corrosion, ensuring reliable operation and longevity.

 

Industries and examples:

 

The following industries often use corrosive chemicals that can damage equipment.

  • Petroleum & Gas
  • Paper & Pulp
  • Galvanizing Facilities
  • Precast Concrete

 

Extreme Temperature Protection

 

Standby heating for hoist, bridge and trolley motors prevents damage to electrical components in extremely low temperatures (below -40° F (-40° C)) and is left on, even when equipment is not being used. Special metal types for some structural components, the elimination of plastic parts and synthetic lubricants are also applied in extremely low-temperature applications Fan and air-conditioned cooling types ensure reliable operation in warm climates or facilities with high-heat processes.

 

Industries and examples:

 

Petroleum & Gas: Oil and gas operations often occur in extreme temperatures, such as arctic or desert regions. Hoists and cranes with extreme temperature protection ensure dependable performance in both.

Railyards / Precast Concrete Manufacturing: These industries operate in various weather conditions, including extreme temperatures. Equipment with extreme temperature protection ensures reliable operation.

Paper & Pulp Industry: Paper and pulp production requires large amounts of water and heat. Protection for equipment is crucial for maintaining productivity, safety and cost-effectiveness.

 

Benefits of R&M’s Special Features for High-Risk & Extreme Environments

Maintains Performance

 

Ensures that equipment can handle its designated loads and perform required tasks without degradation in performance even under challenging conditions. This consistency in performance is crucial for maintaining production targets and ensuring that the equipment does not become a bottleneck in the operation.

 

Enhances Safety

 

Advanced features and robust design reduce the risk of equipment failures, creating a safer work environment and preventing costly incidents.

 

Reduces Downtime

 

These special features ensure consistent performance to minimize operational delays, especially in remote or extreme environments where access and maintenance can be challenging. This allows operations to continue without significant interruptions and reduces the cost and logistical challenges associated with downtime.

 

Contact us online or call 800-955-9967 to talk with an expert about your application needs in high-risk and extreme environments.