Solutions that Optimize Machinery Moves
03/28/2024
Tight spaces and small clearances present unique challenges when it comes to moving and installing heavy machinery. Large equipment such as power transformers, turbines and pressure vessels need to be moved with precision that often cannot be done with traditional forklifts or cranes due to the sheer size and weight involved. Similarly, smaller items such as machine tools, motors, gear boxes or other items in an industrial manufacturing plant or construction environment need to be moved. Whether you need to push or pull, slide or skid, rotate or even drive into position, there are numerous technologies designed to facilitate heavy machinery moves safely and efficiently.
“When it comes to moving heavy equipment laterally, it often comes down to the basic questions of: How much? How far? And how fast? While there is a variety of equipment available for smaller capacity moves, choices become more limited when dealing with items weighing over 200 tons. Beyond that site conditions and the structure of the piece being moved often further restrict equipment that fits the project need,” explained Mike Beres, VP at Engineered Rigging.
Skidding Systems
When space limitations and costs preclude the use of a jack and slide system, a slide or skidding system is ideal for transferring a heavy machine from a trailer or rail car into final position. There are three types of slide / skidding systems to consider: heavy duty, lightweight and low height.
The Heavy Duty ER PS500 Power Slide System is comprised of skid shoes powered by hydraulic push/pull cylinders over modular high-strength track sections. With a load capacity of 250 tons per rail, it is powerful enough to move turbines, generators and much more. The unique design of the skid track means it does not have to be fully supported which leads to less setup time during a critical move. The Power Slide was the ideal solution for transporting four 220-ton transformers from their trailers to their pedestals. | Read the Case Study
Hydraulic Turntables
Often used in conjunction with a slide or skidding system, a hydraulic turntable provides a direct transfer destination for heavy loads. During a maintenance or repair project, technicians can use the platform to safely rotate a large component gaining access to install new components and safely remove old ones. The Enerpac ET400 Hydraulic Turntable is driven by two 25-ton hydraulic cylinders and has the capacity to rotate loads up to 450 tons. This innovative machine permits precision rotating before, during or after skidding/lifting operations. The compact footprint enables full functionality in confined spaces. Bricker Transport recently used the hydraulic turntable to rotate a 220-ton transformer safely and efficiently for installation at a Texas power plant. | Read the Case Study
Electric Trolley Systems
An electric trolley system like the Enerpac ETR-Series is ideal for long lateral moves of heavy equipment without the frequent start and stop which is a hallmark of a jack and slide system. It delivers synchronized movement of up to 100 tons per trolley, typically used in sets of up to eight per controller with an accuracy of 0.39 inches (10 mm). The low-profile track is a cost-effective way to guide the load while spreading it for ground bearing and keeping low to reduce safety risks. With a loaded speed of up to 164 feet/hour, an electric trolley can expedite the lateral movement of heavy loads.
Dollies & Skates
There are a variety of dollies and skates to facilitate lateral movement of heavy machinery. Options include powered, wireless, rotating and roller-chain models. The Hilman Traksporter is a fully powered self-propelled crawler that easily moves heavy machinery safely and efficiently. Powered by a “ride-along hydraulic unit” the crawler consists of two steel tracks controlled via joystick on the remote control allowing an operator to push, pull and turn an object. A turntable with an aggressive anti-slip pattern on top and bearings underneath enables the operator to rotate the crawler under the machine being moved. The Hilman Traksporter can be operated alone or used with multiple unpowered dollies and is available in capacities of 50, 75 or 100 tons in standard configuration.
Battery powered dollies offer the flexibility and capacity of a powered dolly and the freedom of wireless control without the need for a separate power source. Self-contained dollies such as the Hilman TK-EVO or Enerpac EMV E-movers range in capacity from 11-55 tons when used in combination with follower skates. Complete with cut and abrasion resistant polyurethane drive wheels and nylon load wheels, these systems provide precise movement on clean and even surfaces without risk to damaging floors. The Hilman wireless model offers speeds up to 26 feet/minute.
Rotating dollies, also known as crazy skates, are some of the most flexible dollies on the market. These multi-directional movers feature multiple poly wheels on swivel bearing mounts that allow 360-degree positioning of heavy loads on smooth surfaces. Capacity per skate generally ranges from 1-14 tons per skate depending on the size and number of wheels configured under the top plate of the dolly. GKS Skates offer 360-degree rotational movement, have a 6-ton load capacity, and a 4.6-in. loading height.
Found in many configurations and very customizable, the roller chain skate is the highest capacity skate. Consisting of a chain of ground steel rolls which link together around a steel load bearing plate, the rollers are the work horse of many machinery movers due to their relatively low cost and simple, reliable design. The Hilman ERS series of rollers offers a standard range of capacity from 15-400 tons. Typically, when using rollers the move will be a straight move due to the nature of the skate but can be using in combination with swivels to add flexibility. Care should be taken to protect floors when used indoors on painted surfaces as the track may damage the surface due to high contact loads.
Forklift Alternative: A Levered Drive
In locations where a conventional forklift is not feasible, a levered drive is a great solution. The PowerAttack Levered Drive by Hilman is an innovative load moving tool. Once attached with an adaptor to a steerable skate, the PowerAttack uses leverage and traction to position huge industrial components, weighing between 25 and 30 tons depending on floor surface, types of skates, etc. Engineered Rigging’s rental of the KPA30CC PowerAttack Levered Drive includes one charge unit, two battery packs, a load toe and two adaptors. Typical battery life is 4 hours under working conditions and the charge time is 5 hours.
SPMTs
When it comes to moving heavy equipment through small entries and tight corridors, nothing compares to the agility of Self-Propelled Modular Transporters (SPMTs). The pivoting wheel assemblies allow the trailer to move forward, backward and sideways. With a self-sufficient power source that eliminates power cords, the units can rotate 360 degrees without changing their midpoint. Depending on the model, the trailers and hydraulic power units can be arranged in endless configurations depending on the needs of the move. One hydraulic power pack can operate multiple trailers depending on the model. The SPMT’s unique hydraulic suspension means that load weight is spread across each of the connected trailers and wheels, while the cylinders absorb the unevenness of the ground and function to lift and level during travel. Engineered Rigging’s crew used an SPMT to handily transport a massive gas scrubber from a trailer into an oil refinery. | Read the Case Study
Hydraulic Gantries
Telescopic gantries are powerful systems for lifting and positioning massive loads in one pick. With load capacities from 67 to 1,178 tons and lift heights to more than 47 feet, Enerpac Hydraulic Gantries offer superior safety and stability features. The Intelli-Lift wireless control system enables encrypted bi-directional communication, remote operation using multichannel wireless (2.4 GHz) or wired (RS-485) control, automatic synchronization of lifting with an accuracy of 0.95 inch (24 mm) and automatic synchronization of travelling with an accuracy of 0.60 inch (15 mm). A hydraulic gantry easily accomplished the challenging job of lifting an 873,500-pound threaded generator at a combined cycle plant. | Read the Case Study
The machine moving tools spotlighted in this article are available to rent from Engineered Rigging. Our high quality and well-maintained rental equipment is guaranteed to arrive in optimal working order.
