OPERATORS MANUAL - Hy-Ram Engineering Co. Ltd
Contents
1. 7 ct NENI Cc Wasi and WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 e E info uisltd co uk A AA an aa NENG an Ja een re Ga ee aoe k ae reduces the scraping grating of the Inserted LS E JI Oo a poe Ll reducing the wall on or steel mains UT OI 5 Lt Ast ae ma ee Tipe IG and effects fol NA AJIN ees AS rates ne ae WINC CNIng a U tk ihe New P E ma N UTILITY INNOVATIONS SOLUTIONS LIMITED STOCK LIST SPARE amp REPLACEMENT PARTS HEAD Item Quantity 1 5 Tonne Universal Head 1 3 Tonne Universal Head 1 5 Tonne Universal Head 1 Head Reducer Bushes 4 25mm Head Attachment Pins Z 30mm Head Attachment Pins 2 35mm Head Attachment Pins 4Omm Head Attachment Pins 2 6mm Lynch Pins 2 16mm Lock Nuts 4 Retaining Washer Nylon Head Wear Shim 1 FRAME Item Quantity 12mm Hinge Pin 1 12mm Hinge Nut 1 Bottom Pin Clamp Plates Side Swivel Plate 2 10 x 30 Plate Bolts 4 SHIM SETS Item Quantity 50mm with Counter Sunk Bolts 2 63MM with Counter Sunk Bolts 2 7omm with Counter Sunk Bolts 90mm with Counter Sunk Bolts 2 110mm with Counter Sunk Bolts YA 125mm with Counter Sunk Bolts 2 140mm with Counter Sunk Bolts WA 160mm with Counter Sunk Bolts WA 180mm with Counter Sunk Bolts YA 200mm with Counter Sunk Bolts 2 213mm with Counter Sunk Bolts YA 215mm with Counter Sunk Bolts 2 229mm with Counter Sunk Bolts 2 290mm with Counter Sunk B2. WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 ek info uisltd co uk The UIS Power Push is to be removed from its storage box using the lifting handle which is provided with the product The unit is strictly a 2 person lift at all times Once removed from the storage box the product can be placed on the floor and then the lifting handle can be removed The lifting handle is simply removed by taking out the 2 retaining clips lynch pins holding it in place The unit Is now ready to be attached to the excavator UTILITY INNOVATIONS SOLUTIONS LIMITED a ih a i s gg a ak A AYCTA V IATONF arm 6 excavator dalin COlI O U A QAY Ka CQ 2 S AN mei AYCA h D gt CALC I eee KI ND IN J LOD QO YTD CALA Nas peen Orr tne Quick IDU UTILITY INNOVATIONS SOLUTIONS LIMITED LEADING THE WAY IN UTILITY INNOVATIONS EQUIPMENT OPERATION The excavator should be positioned at the edge of the excavation where the new polyethylene pipe cable is going to be inserted from Once the excavator is in the correct position with the UIS Power Push fitted the new polyethylene pipe cable can start to be inserted inside the carrier main ducting There must be a banks man in contact with the excavator operator at all times to ensure the safe Insertion of the
3. polyethylene pipe cable The UIS Power Push is used to push pull the pipe into the carrier main ducting when the excavator arm Is at the edge of the excavation and can no longer move and further back the excavator operator then pushes the dual flow hydraulic pedal button which opens up the UIS Power Push allowing the machine driver to slide the excavator arm back up the pipe cable as far as the excavator arm will reach The dual flow hydraulics on the excavator are then used again this time closing the UIS Power Push which in turn grips the pipe The same process is then repeated until the insertion length of pipe cable is achieved EMERGENCY SHUT DOWN PROCEDURE In case of any emergencies whilst using the UIS Power Push the most efficient way of shutting down all operations is to turn off the excavator using the key This operation will stop all workings of the excavator and also stop the flow of hydraulic oil to the UIS Power Push aoe a ey a ma O i a F i af i _ Wa UTILITY INNOVATIONS SOLUTIONS LIMITED WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 ek info uisltd co uk INSPECTION amp MAINTENANCE PROCEDURES The UIS Power Push should be inspected prior to every use using the following checks Hydraulic Hoses and Connections should be checked for leaks Head Bracket Pins for Head Bracket correct pins for machine Condition of Shims free fro
4. MI i B y o IA I INI Lo Historically there have been a number of serious personal injuries near misses associated with the handling and manipulation of coiled pipe during Insertion activities One of the major difficulties encountered whilst pushing pk and winching pipe is when the new main comes into an open service connection excavation pit Di ue to oi PE pipe being coiled this die natural energised pressure resulting in the pipe naturally springing pwards T ne UIS Level Head resolves this problem with ease and is simple to install plastic that is ie all diameter ranges that t enables a safer more comp sustainable produc a more fluent inse operation FIT RO ENV ME NT TIME COST eCan be inst as onto lead end within 2 minute e cosi Very effective pr oduct 1 of coiled pipe Simple e design simple to install no special training required e Manufactured from recycled plastics e Sustainable ae duct reducing overall P E wastage and associated time SAFETY ENGINEERING e Significantly reduces stored energy contained in lead end of coiled pipes e Eliminates o operatives ente 2 e xcavations to manipulate pipe through the next host section of main due to the pipes natur ale energy c
5. PP 058 UIS PP 059 UIS PP 060 Order Code UIS PP 061 UIS PP 062 UIS PP 063 UIS PP 064 UIS PP 065 UIS PP 066 UIS PP 067 UIS PP 068 UIS PP 069 UIS PP 070 UIS PP 071 UIS PP 072 Order Code UIS PP 073 UIS PP 074 UIS PP 075 UIS PP 076 UIS PP 077 UIS PP 078 UIS PP 079 UIS PP 080 UIS PP 081 UIS PP 082 UIS PP 083 Notes Notes Made to order Made to order Made to order Made to order Notes Made to order Made to order Made to order Made to order Made to order Made to order Made to order Made to order Notes Made to order UTILITY INNOVATIONS SOLUTIONS LIMITED i UVDB empowered by Achilles Institgition of as Engineers amp Managers UTILITY INNOVATIONS SOLUTIONS LIMITED Utility Innovations Solutions Limited Unit 2 Hargreaves Court Hargreaves Road Northwich Cheshire CW9 7BL Telephone 0161 428 7959 e Fax 0161 428 7933 e Email info uisltd co uk e Web uisltd co uk Ei facebook com uisltd e twitter com uisltd 6
6. UTILITY INNOVATIONS SOLUTIONS LIMITED WELCOME ABOUT US Utility Innovations Solutions Limited UIS Ltd are specialists in manufacturing new innovations equipment for the utilities SECIOr Within the staff employed at UIS Ltd we have a wealth of experience In gas water and electricity replacement rehabilitation and reinforcement projects Our experience has enabled us to target key areas and functions within utilities we feel we can improve upon with new Innovations created and manufactured in house Although we are a relatively new company our progression over the short time has been rapid with interest and demand for our products being very high The concept of UIS Ltd is to develop and advance Innovation products that aid the process of replacing renewing pipe utility work A main aim is that all of our products should eradicate the inherent safety and technical faults encountered by existing methods Aligned to safety quality and engineering compliances there are also productivity benefits that allows our products to be compliant versatile and proven speedier than alternative approved methods of works within utilities As our products nave been developed through extensive trials a detailed technical assessment has been made in which includes a detailed analysis of its performance against alternatives The use of this equipment may be adapted to water gas and cabling activities or any other use for the process of
7. contact damage CO NTROL M EASU RES e Machinery to be adequately maintained e Operator to perform pre start checks of all connectors e No excessive pressure to be applied e Spill kits to be readily available e Training given in the correct handling and use of hand tools e Correct maintenance of hand tools Replace or maintain as necessary e Use the correct tool for the job and appropriate PPE e g gloves eye protection etc as instructed e Full compliance with NRSWA New Roads and Streetworks Act e Site barriered off signed and guarded with appropriate signs care for the pedestrian e The product not to be used as a lifting aid at any time e The driver operator must have a valid CITB CPCS card e Speed of operations dictated by specific site conditions e The excavator must be sited on good firm ground e Drivers to be aware of Permit to Work controls and restrictions e Live gas pipelines to be protected against impact damage e Banksman to control close working e Underground services to be protected e Site set out to restrict public access barriers herras fencing e All works to be contained within the site area no working over live footpaths or traffic e Mechanical excavators to work within demarcated site no swinging buckets across or into live carriageway UTILITY INNOVATIONS SOLUTIONS LIMITED WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 ek info uisltd co uk f p g N A
8. f the UIS Power Push UTILITY INNOVATIONS SOLUTIONS LIMITED a LEADING THE WAY IN UTILITY INNOVATIONS OPERATING VARIABLES AND CONTROLS The operations of the UIS Power Pusn are all done through the operations of the excavator which the unit is attached to These are the same controls that the excavator operator would use to operate the excavator in the same manner as digging an excavation or using an excavator mounted hydraulic breaker The open and close function on the UIS Power Push is done through the use of the dual flow hydraulics on the excavator which is either through a foot pedal on the excavator or through a button on the operating levers This is dependent on the make and model of the excavator which the UIS Power Pusn is attached to as this may vary START UP amp SHUT DOWN PROCEDURE The UIS Power Push fits onto an excavator in the Same way as an excavator bucket hydraulic breaker or other attachments are fitted which is via pins or a quick hitch system The universal head bracket which Is fitted to the UlS Power Push allows It to fit the majority of mini excavators This UIS Power Push can also be fitted to different size excavators such as a 31 or ST Should the UIS Power Push be used on a 31 or ST excavator then UIS would need to be Informed of the excavator type before operation begins to enable UIS to fit the correct head bracket to the excavator if not already done SC
9. h 590mm Jaw Opening Width 180mm Clamping Force SOOOKGF Recommended Working Pressure 200 Bar Max Recommended Excavator Size Excavator Size 31 amp oT SOLUTIONS LIMITED WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 E info uisltd co uk PRODUCT STORAGE The UIS Power Push comes stored in its own storage box which is where the product should be stored at all times when it is not in use The lifting handle which is also supplied with the unit should be connected back to the head bracket to aid the process of lifting of the unit in and out of the storage box Please remember that the UIS Power Push always equates to a two person lift The product will also come with a holdall bag or another storage box which is for the storage of shim sets These shims should always be stored in the bag box when they are not being used by the UIS Power Pus SHIM SYSTEM The UIS Power Push uses an interchangeable Using the incorrect sized shims for the diameter shim system which is made from recycled plastics pipe being inserted may cause damage to the pipe These shims are made internally to fit each size of wall and effect efficiency of the operation pipe which will be inserted using the UIS Power Push The shims are fixed In using 5 countersunk bolts The correct size of shims must be inserted for the pipe diameter being inserted to ensure the TM safe and correct use o
10. insertion and a best practice information is provided LEADING THE WAY IN UTILITY INNOVATIONS UTILITY INNOVATIONS SOLUTIONS LIMITED H PIPE PUSHER POWER PUS UIS SCOPE The purpose of this operators manual is to demonstrate the safe working process and procedure of the UIS Power Push Pipe Pusher In this operators manual you will find all of the safe working practices which are required for using the product for its designed purpose ESEE Ar nad S E ims both for small 63mm gt 180mm model GENERAL ABBREVIATIONS The UIS Power Push is an attachment which fits onto an excavator and is used for inserting new polyethylene pipe on predominantly gas and water Sites The UlS Power Push may also used for inserting cables through ducting and can be used as an alignment clamp UIS Utility Innovations Solutions PP Power Push PPE Personal Protective Equipment 1 5T 1 5 onne Excavator 3T 3 Tonne Excavator 51 5 Tonne Excavator SDR Range Standard Dimension Ratio PE Polyethylene UTILITY INNOVATIONS SOLUTIONS WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 ek info uisltd co uk LIMITED ga CONTENTS e Chapter 1 Design Basis amp Specification e Chapter 2 Product Storage e Chapter 3 Shim System e Chapter 4 Operating Variables amp Controls e Chapter 5 Start up amp Shut down Procedure e Chapter 6 Eq
11. m Pin Grub Screws Ram Guard Ram Guard Bolts UIS LEVEL HEAD ATTACHMENTS Item 50mm UIS Level Head Attachment 63mm UIS Level Head Attachment 75mm UIS Level Head Attachment 90mm UIS Level Head Attachment 110mm UIS Level Head Attachment 125mm UIS Level Head Attachment 140mm UIS Level Head Attachment 160mm UIS Level Head Attachment 180mm UIS Level Head Attachment UIS PIPE ENTRY GUIDE Item 3 inch UIS Pipe Entry Guide 4 inch UIS Pipe Entry Guide 6 inch UIS Pipe Entry Guide 8 inch UIS Pipe Entry Guide 10 inch UIS Pipe Entry Guide 12 inch UIS Pipe Entry Guide 14 inch UIS Pipe Entry Guide 16 inch UIS Pipe Entry Guide 18 inch UIS Pipe Entry Guide 20 inch UIS Pipe Entry Guide 22 inch UIS Pipe Entry Guide 24 inch UIS Pipe Entry Guide PRODUCT STORAGE amp CONTENTS Item Unit Storage Box Shim Storage Box Holdall Bag Lifting Handles 17mm Spanner omm Allen Key Rubber Floor Liner Operators Manual Product Risk Assessment Two Man Lift Stickers Wheels for Box WWW UISLTD CO UK e T 0161 428 7959 e F 0161 428 7933 E info uisltd co uk Quantity Quantity a a a a a ap ap Quantity cmt eee ame ee eet cee A a ee A a A ee Quantity Order Code UIS PP 042 UIS PP 043 UIS PP 044 UIS PP 045 UIS PP 046 UIS PP 047 UIS PP 048 UIS PP 049 UIS PP 050 iS PROS Order Code UIS PP 052 UIS PP 053 UIS PP 054 UIS PP 055 UIS PP 056 UIS PP 057 UIS
12. m debris 4 Bolts on Head Bracket all in place and secure All 5 countersunk bolts in place for shims Daily maintenance checks should be carried out in accordance with the UIS Operators Daily Inspection checklist which are supplied by UIS Ltd If you suspect that there are any problems faults with your UIS Power Push then either contact your site supervisor or UIS Ltd direct on 0161 428 7959 If you nave the UIS Power Pusn on a long term hire after a 6 month period the unit will be recalled by UIS Ltd for a 6 month inspection where the unit will be thoroughly checked and serviced by a competent person i UTILITY INNOVATIONS Operators Daily Inspection SOLUTIONS Check Sheet LIMITED Name Week Commencing Date Company UIS Ltd Unit 2 Hargreaves Court Hargreaves Ro Northwich Cheshire CW9 BL T 0161 428 7959 F 0161 428 7955 E info uisitd co uk www uisitd co uk Plant Number Item Description The below checks MUST be completed prior to and during the use of the product If any of the inspections result in fail STOP and report it Note oat to your supervisor immediately prior to use aa pah Check to be performed ek Ta gg eneric Inspection Checks Pressure test completed and satisfactory Visual condition satisfactory Pressure test completed and satisfactory Hydraulic Hoses Visual condition satisfactory Free from outer casing damage H
13. olts 2 300mm with Counter Sunk Bolts 2 315mm with Counter Sunk Bolts 2 355mm with Counter Sunk Bolts WA 400mm with Counter Sunk Bolts 2 SHIM CLAMPING BOLTS Item Quantity Counter Sunk Bolts 6 HYDRAULICS Item Quantity Feed Hose 2 1 4 inch Bulk Head Fittings 2 Link Hose 2 Tea Adaptor Z Male Female Adaptor 4 Dowty Washer 6 Continued over page LEADING THE WAY IN UTILITY INNOVATIONS Order Code UIS PP 001 UIS PP 002 UIS PP 003 UIS PP 004 UIS PP 005 UIS PP 006 UIS PP 007 UIS PP 008 UIS PP 009 UIS PP 010 UIS PP 011 UIS PP 012 Order Code UIS PP 013 UIS PP 014 UIS PP 015 UIS PP 016 Order Code UIS PP 017 UIS PP 018 UIS PP 019 UIS PP 020 UIS PP 021 UIS PP 022 UIS PP 023 UIS PP 024 UIS PP 025 UIS PP 026 UIS PP 027 UIS PP 028 UIS PP 029 UIS PP 030 UIS PP 031 UIS PP 032 UIS PP 033 UIS PP 034 Order Code UIS PP 035 Order Code UIS PP 036 UIS PP 037 UIS PP 038 UIS PP 039 UIS PP 040 UIS PP 041 Notes Made to order Made to order Notes Notes Made to order Made to order Made to order Made to order Made to order Made to order Made to order Made to order Notes Made to order Notes UTILITY INNOVATIONS SOLUTIONS LIMITED i STOCK LIST SPARE amp REPLACEMENT PARTS HYDRAULICS Continued Item 1 2 inch x 1 4 inch Adaptor 1 2 inch Quick Release Male Coupling 1 2 inch Quick Release Female Coupling 1 2 inch Dowty Rams Ram lop Pin Ram Bottom Pin 6mm Botto
14. ontai ae he end e Enables the handling of coil dp ipe easie Bane safer on ground es in the reparation of the coiled pipe from trailer to host main CONNECT _ gt LEADING THE WAY IN UTILITY INNOVATIONS e Significantly r o es the scraping grating of the inserted pipe on the up si ah the host main reducing the wall damage throu hart e inserted ne and ensuring ene iness of pipe e Could be utilised and have same benefits and effects for traditional winching activities Head has more enhanced protection and wastage in preparation for e The UIS Level thus eliminating cu connections e Reduces overs insertions Dack all t mi and resistance encol tensio D UTILITY INNOVATIONS SOLUTIONS LIMITED wW A common occul _ i EN KN KN ni 3 N l aa gt J J AN E ferries aa TEE AN Eo mi mg AN E TTi j A E WA 4 A l J 4 Fi d Ww The UIS Pipe Entry Guide is produced from recycled plastic amp is available in all diameter ranges that enables a safer more comi amp fluent insertion 0 whils CONNECT ENVIRONM GINEERING E c 4 4 l OAA CHcCT VAr ATTACTIV C z LO W CO st Wel Y el CO T E ME S training e Simple e Man UI LULL Q Pan a CTOAIN
15. uipment Operation e Chapter 7 Emergency Shut Down Procedure e Chapter 8 Inspection amp Maintenance Procedures e Chapter 9 Safety e Chapter10 Advisories amp Control Measures e Chapter 11 Additional Extras The UIS Level Head e Chapter12 Additional Extras The UIS Pipe Entry Guide e Chapter13 Stock List Spare amp Replacement Parts INSERT CONNECT gt _ gt UTILITY INNOVATIONS SOLUTIONS LIMITED LEADING THE WAY IN UTILITY INNOVATIONS DESIGN BASIS amp SPECIFICATIONS The UIS Power Push has been designed tested and implemented to suit the needs of small large scale gas water electric mains replacement schemes SPECIFICATIONS amp RECOMMENDATIONS 63mm gt 180mm Pipe Pusher Weight 46KG Height 420mm Length 310mm Width 335mm Jaw Opening Width 100mm Clamping Force 1200KGF Recommended Working Pressure 200 Bar Max Recommended Excavator Size Excavator Size 1 51 Pipe Diameter 63mm 75Mm 90mm 110mm amp 125mMm SDR Range 11 amp 17 6 Excavator Size 37 Pipe Diameter 1440mm 160mm 180mm SDR Range 11 amp 17 6 Carrier Head Bracket amp Pin 4 Bolt Plate Connection Hydraulic Cylinders Lock Mechanism Clamp Pivot Point Shim Inserts Flat Stand Plate Ram Guard ONATRWNr gt 200mm gt 400mm Pipe Pusher Weight 172KG e Height 600mm Length 460mm Widi
16. ydraulic Rams 2 Hydraulic Connectors Correct connectors which are free from dirt debr Head Bracket Free from signs of damage stress Swivel unit free from obstructions and fit for use Head brag in place ang 2 I This is just a section of one of our Operators Daily Inspection Sheets ff UTILITY INNOVATIONS N SOLUTIONS LIMITED LEADING THE WAY IN UTILITY INNOVATIONS SAFETY To be using the UIS Power Push in the safe and correct manner the operator should have completed the following before using the equipment e Make sure the person using the Carrier Excavator nas all of the correct qualifications and is competent in the use of an excavator e Make sure the correct PPE is being worn Items such as Safety Glasses Hard Hat Safety Toe Cap Boots High Visibility Work Wear and Protective Gloves Additional PPE may be required dependant on Site Specific requirements e Ensure it is as safe working environment before attaching the product to the carrier excavator i e Inside a clear and safe area away from members of public etc the attachment outside the parameters of the information contained in this manual may cause harm disruption and damage e Any existing gas pipe and other utilities to be adequately ADVISORIES amp TUNG protected against accidental
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