Company Case Studies

Hydraulically Stressed Out!

Special high pressure stressing cylinders were sent into our hydraulic workshop for detailed examination, quotation for full hydraulic overhaul and the request of specific testing criteria following hydraulic repair.Worlifts engineers fully stripped the hydraulic stressing cylinders checking for minor or major defects, a report was issued of our findings detailing all components that would be required to return the hydraulic cylinders to working condition. On receiving the official purchase order service kits were manufactured to samples, some piston rods were ground and replated, cylinder bores were polishedand all high pressure couplers were replaced. The final testing critera was so specific that pressure testing following repair was carried out at our premises and the hydraulic stressing cylinders were then subject to further witness tests as attended by the client and a third party on a specially designed test bed. Satisfactory results were acheived and the appropriate certification issued to our client.

An exisiting customer to Worlifts needed a quick solution to a new problem. Our customer had the requirement to finally adjust a small component for fixing to a secondary component from the underside. A concept was put to the customer which included all dimensions making sure our concept did not interfere with exisiting obstructions. The design was agreed and manufacture commenced on the bespoke material handling device, a fabricated top plate was manufacturedin our in-house fabrication department, a ball typetransfer top was also manufactured in-house which incorporated mechanical end stop devices. Maximum safe working load load testes were carried out, proof load tests werecarried out and the hydraulic relief valve then set on the table to match that of thesafe working load of the product. All this modification was carried out in10 working days, this was acheived by utilising all standard components where possible and a lot of hard work from our fabrication guys!

On a recent project four rail car lifting jacks were in need of a new lease of life. The units had been standing redundant for a while and certification and basic service was required to get the units back into action. Engineers from our specificrail division staff were tasked with a basic back to service repair and test. The units were individuallyexamined checking all load nuts and safety nuts, electrical controls and hydraulic transport devices, from here the units werelinked into series and checked from the master panel.  All that was required was to fit a number of bulbs and re-gland a number of electrical cables. The units were then subject to a dynamic proof load test using calibrated test weights. With all this work now complete the units were issued with the approriate certification, loaded onto a vehicle for transportation and successfully commissioned at the new place of work.

Following a sucesful site visit Worlifts were to instructed to carry out independant on site examination and testing of mutliple concealed lifting points at a top UK hotel. The project required careful planning as to not to interupt planned events and paying guests. Utilising calibrated hand test weights, calibrated load measuring and defelection measuring equipment loads were applied increments as per the customers test plan. Following successful test results on random points as per the customers request, noncritical and disused points were subject toadditional proof load testing of up toworking load limit + 200 %. The customerfor who this was the first time he had used Worlifts commented 'the engineers who attended site were punctual, approachable and flexible'. Documents such as risk assessments and method statements were produced in advance for review and accompanying certificates followed.

Worlifts were contacted by a power generation contractor who were having regular problems with a hydraulic unit currently used to perform critical maintenance tasks during planned shutdowns. Worlifts attended site and carried out a basic functional assessment, many connections and fittings were incorrectly rated and the unit was clearly in need of an overhaul, the unit was subsequently collected from the site and taken back to Worlifts hydraulic repair workshop. The unit underwent a complete overhaul consisting of: telescopic cylinder stages were honed, polished and re-sealed, the power unit was flushed and replenished with the correct grade of hydraulic oil, new hydraulic hoses were fitted andnew basic visual operational stickers were fitted.

Special Spreader Beams

Following successful prototype developmentin conjunction with a nationwide cable contractor Worlifts fabricated four identical 7500 KG rated adjustable spreader beams to specification. The process included on-site case studyof how the application was currently being carried out, the possible health and safety risks and howbypurchasing beams exactly to specification we could shownot onlya health and safety benefitbut a reduction in the loading and unloading timeover the current method. The project also included the supply of heavy duty polyester round slings with heavy duty wear sleeves, us federal alloy pinbow shacklesand on-site familiarisation training. The beams were also proof load tested and issued with the appropriate certification on delivery.

Little Lifter, BIG IMPACT!

To solve a manual handling solution for a long established customer of Worlifts we manufactured a cost effective fabricated fully adjustable counter balance lifting device. The project including the deisgn and manufacture of a cost effective solution which would enable our client to pick up and handle in excess of 7 differing sizes of pressed steel blanks. The unit was fully certified to 1000 KGs safe working load. Worlifts also carried out familiarisation training on the new lifter when delivered and demonstated for the first time. Just a project to show no matter the size of the job Worlifts will give the same ammount of time and effort to deliver the project on time and find a solution for your lifting problems. The customers phrase 'we would never have belived such a small investment could result in so much time being saved'

Modified Enerpac Workshop Press

The standard Enerpac workshop press would not quite carry out all the pressing applications that our customer required? What did we do? Worlifts engineer attended our customers premises and followed the process through looking at all the pressing sequences and decided that with a small amount of modification the whole job could be carried out with a modified VLP 100 series Enerpac workshop press. The modifications included new traversing cylinder top plate allowing the movement of the pressing cylinder along the full width of the press and a manual hand winch customised and bolted to the frame work allowing easy movement and positioning of the press bed height. All this work was designed and carried out at Worlifts premises andthe unit was delivered within 4 weeks from order placement. Utilising a standard quality product like Enerpac also allowed us stay well within the customers budget.

Power, Power, Power Units!!!!

We were contactedby a fluid power contractor who had won a project to upgrade an exisiting bulk product handling factory. When coming close to the final commisioning it was noticed that the exisiting plant had outdated and foreign hydraulic power units fitted to the material handling equipment. We were called in to assess the possibility of a quick overhaul to 8 power units, on examination it was clear that the exisiting units had never been maintained and that spare parts would be difficult now and in the future to obtain. We sat down with the end user and presented our findings and put together a package to offer 8 new UK specification power units with standard industry parts, the order was placed for 9 in total units, 1 unit being kept as an emergency spare just in case! the units also provided a challenge due to the location and restricted size of the powerpack location, for this we manufactured a bespoke hydraulic reservoir, the units also incorporated pressure gauges, pressure switches, sight level gauges etc.

Enerpac Hydraulic High Tonnage Project

A project to upgrade a pressing facility allowed Worlifts to win a prestigious order for a new complete design, manufacture, install and commissioning of a 300 tonne pressing assembly. The entire project included the manufacture of a 1500 mm diameter pressing table complete with an adaptor plate to incorporate a new Enerpac cylinder, design and manufacture an ergonomic pressing plate stand, supply a new Enerpac high pressure power pack and all the neccessary high pressure fittings. The unit upon completion underwent factory inspection and sign off by the customer, following this our engineers placed in the final location, installed the unit and the customers electrician wired into the mains supply incorporating our emergency stop. This project required careful planning and regular updates to both customer and sub-contract machinists ensuringthe delivery deadline was achieved.

Post Mounted Jib Project

Time was of the essence when Worlifts were called to a pressing company who had been let down by another supplier. The project included the supply and installation of a post mounted jib, electric hoist and slings to handle and rotate a finished assembly. When on site we spotted an exisiting jib that was destined for the scrap yard, our quick thinking sales engineer advised the customer we could re-use the main beam assembly and modify to the customers requirement, we would need to manufacture a new post mounted bracket but this solution would allow us to not only provide a solution on time but well under the exisiitng quotation. This job from the phone call to the office was installed and commissioned in less than 14 days.

Enerpac Modified Workshop Press

Worlifts were contacted to offer a basic hydraulic solution for a pressing application. The requirement from the customer was to be able to control the force manually while pushing pressed steel products on to varying adaptor plates. Our solution was to fit a standard manual relief valve and large calibrated pressure gaugeinto a Enerpac basic press mountedpanel. The customers operting range was between 10 tonne and 40 tonne. The final modification was to machine and colour code 'quick fix' rod extension pieces allowing easy pressing of avariety of tools sizes.

Twin Runway Project

As part of a continuos improvement plan Worlifts were contacted to attenda site visit to asses the probability of increasing productivity on a new production line.  The project involved restricted access and exisiting supporting steelwork, our offer included the design, manufacture, installation, commissioning and training of a twin runway supporting structure which also incorporated a cantilever one end for finished product off loading, the unit would also include 2 x electric hoists, electrical festoon systemand associated ancillary slings.

Lifting Appliance Upgrade & Makeover

Worlifts undertook a project in the power generation sector to carry out thorough examination, make anassessment of the suitability for a possible safe working load upgrade, carrry out proof load test andissue the appropraite certification to an important item of lifting plant. The existing unit manufactured many years ago carried a safe working load that now was not sufficient for the new lift plan which incorporated additional sub assemblies. Worlifts initially carried out NDT to all exisiting welds, with satisfactory results proof load testing was carried out to attain the new safe working load and post NDT was then carried out to ensure no defects were present. The unit was deemed safe for use and thenwas ready for an overhaul, which included strip, paint, affix new stickers and last but not least apolish of the brass sight level indicators!

© Worlifts Limited 2012