Corrosion is a huge problem in refineries and chemical plants, so how can you ensure safe lifting in such environments?

In industries like oil refineries or petrochemical plants, lifting operations may have unforeseen risks due to substandard lifting points. Imagine this scenario - A tank needs to be lifted for maintenance. The operations team fixes the lifting chains to the welded eyelets on the tank. As the tank is lifted, one eyelet breaks because of a swivel movement. The tank sways to one side, and as the remaining chain cannot handle the load, the other eyelet also breaks, causing the multi-tonne tank to crash. Production is halted, and the unplanned downtime is estimated to cost hundreds of thousands of dollars. Seem familiar? Probably not if you are using RUD lifting points and lifting chains.

The Risk of Standard DIY Lifting Points

Even in everyday lifting operations that involve setup, dismantling, repairs or maintenance, manufacturers and operators of chemical and petrochemical refineries often use substandard lifting points. They can be simple, welded attachments that do not match the requirements of the weight to be lifted and do not have clearly defined nominal load capacities, safety factors, or certifications. Even if the cranes use specified lifting chains, it highlights the weakest link: the actual connection points.

Relying on such substandard lifting points is a critical safety risk. Many operators are not aware that such lifting points fail to meet safety requirements, and their functionality is assumed, even after years of exposure to operational stresses. Visible deformations on many lifting points, even after a single lifting, clearly indicate their inadequate safety.

Corrosion and Environmental Factors

The harsh operating environments of chemical and petrochemical refineries can accelerate the risks of substandard lifting points. High process temperatures, hot steam, noxious gases, dust, and outdoor elements can significantly impact components and their welded lifting points. While simple lifting points made of inferior structural steel can corrode easily and may be visible, they will not be so easily detectable with stainless steel. Stainless steel is used to prevent embrittlement and flaking of coatings, but the lifting point may not be rated for lifting or load bearing, which may lead to catastrophic failures.

RUD Stainless Steel Anchor Points

RUD's INOX-ABA, launched a few years ago, is a significant development suited for industries that face corrosion. It is manufactured in Germany and has been tested by DGUV. INOX-ABA is the first lifting point made from duplex steel 1.4462, offering superior corrosion resistance (PREN value 30.9 to 38.0).

High Performance and Broad Applicability

INOX-ABA lifting points are currently available with nominal working load limits of 0.8, 1.6, and 2.7 tonnes and are certified for maritime environments. They are part of the ABA family and were developed from the popular W-ABA weld-on lifting point for safe lifting in harsh environments.

• Full WLL in any direction with 4:1 design factor
• Clear marking of the WLL
• Patented wear markings on the inside and outside

INOX-ABA can tolerate a broad temperature range from -40°C to +250°C with no reduction in WLL. It can withstand superheated steam and liquids with high chloride content and is long-term resistant to pitting and surface corrosion. A closed and circumferential fillet weld further protects it against rusting.

The high corrosion resistance of INOX-ABA ensures safe lifting over long periods. It is also safe for food processing because coatings or material particles cannot contaminate it. Patented wear indicators act as a safety visual aid and the magnetic properties of duplex steel 1.4462 aid in electromagnetic crack detection.

In addition, INOX-ABA lifting points allow for highly stable "black-and-white connections," enabling integration beyond stainless steel surfaces to structural steel components without compromising safety or corrosion resistance, offering broad utilisation across plants and refineries.

For more technical details, you can refer to the product page - INOX-ABA Lifting Point for Welding.

Investing in Safety and Future Operations

The introduction of duplex stainless-steel lifting points from RUD marks a new chapter in lifting technology for refineries. There is no justification to use unsafe and substandard lifting points that compromise safety. RUD’s corrosion-resistant lifting points guarantee safe lifting even after years of use and prevent contamination - benefits that substandard welded points cannot provide.

DIY points are not designed and rated for lifting. They are unsafe, potentially risky and may be illegal under safety standards. By contrast, investing in high-quality, rated lifting points with defined load capacities and safety factors effectively minimises risks to personnel and materials. In such cases, the responsibility of the load capacity rests on the manufacturer, ensuring user compliance. Investing in secure stainless steel anchor solutions for harsh environments should be the only long-term investment for safety.

Original article by Fabian Bihlmaier, RUD Germany, published in the German magazine Edelstahl Aktuell - https://edelstahlaktuell.de/sicheres-heben-und-positionieren-im-rauen-umfeld/

Further Reading:

Also read our blog article on the application and industries where INOX-ABA can be used - https://www.rud.com.au/event-and-entertainment-solutions/

Copyright to RUD: This information is accurate at the time of publication, and RUD Australia takes no responsibility for any errors, inadvertent or otherwise.