Process Industries Tools and their Usage

Tools in Process Industries

• A tool is designed to provide mechanical advantage to make a task easier.
• Hand tools are operated manually, for example, pliers, valve wheel wrench, pipe wrench, hammer, bolt cutter, knife, tubing cutter, wire stripper.

Types of Hammers

• Ball Peen Hammer
• Brick Hammer
• Claw Hammer
• Drywall Hammer
• Electrician's Hammer
• Framing Hammer

Different Types of Pliers

• Crimping pliers (crimping tools)
• Needle nose pliers (long-nosed pliers)
• Diagonal pliers (diagonal cutting pliers, flush cut pliers, side cutting pliers, wire cutters)
• Locking pliers (vise grips)
• Snap ring pliers (retaining ring pliers, circlip pliers, C clip pliers, lock ring pliers)
• Tongue and groove pliers (channel locks)
• Nail puller pliers
• Slip joint pliers (water pump pliers)
• Combination pliers

Tubing Cutter and Flaring Tool

• Tubing cutter: used to cut copper, aluminum, or stainless-steel tubing; most devices include tubing reamer to remove any burrs from the end of tubing.
• Flaring tool: device used to create a cone-shaped enlargement at the end of a piece of tubing so the tubing can accept a flare fitting.
• As a general rule, the maximum flare diameter can be no more than 1.4 times the diameter of the tube to prevent the possibility of splitting the tubing material.
• Wrenches: tools used for gripping jaws to turn bolts, nuts, or other hard to turn items.

Power Tools

• Power tools are driven by electricity, pneumatic power, hydraulic pressure, or powder charges.
• A drill contains a rotating bit designed to bore holes into various types of materials.
• A grinder is used to rotate force one material against another to reduce modify the shape and size of an object.
• A reciprocating saw uses the back and forth motion of a saw blade to cut materials that range from wood to metal pipe.

Lifting Equipment

• Hoists are devices composed of a pulley or gear system with a cable or chain used to lift and move heavy objects. Basic safety: operate under specific weight limits; do not operate if the weight is unknown; chains and ropes should be free of kinks; individuals must not be under equipment; ropes should be inspected for fraying; loads should be properly secured.
• Cranes are mechanical lifting devices that can be used to lift and lower materials or move horizontally.
• There are four main types of cranes: overhead traveling bridge cranes, gantry cranes, jib cranes, and monorail cranes.
• Overhead traveling bridge cranes run on an elevated rail system along the length of a warehouse and provide three axes of hook motions (up, down, and side to side).
• Gantry cranes run on elevated rails attached to frame or set of legs and provide same performance as a bridge crane.
• Jib cranes consist of pivoting head and boom assembly that carries a hoist and trolley unit.
• Monorail cranes travel on a single runway beam. They are specialized, very effective, and move in two directions (up and down) and along axis of the beam.
• Crane safety includes operation by trained personnel only; proper load and angle balance must be used; load limits must be known and respected; never work directly under; chains and ropes must be free of kinks and inspected.
• Forklifts are vehicles with elongated prongs used for lifting and transporting equipment or pallets of product, often used to lift items placed on pallets or high elevations.
• Forklift safety includes knowing load limits, only trained and certified individuals may operate, carrying load must not exceed, leaking hydraulic system must not be used, travel area must be free of personnel, use caution when used on ramps or loading docks to avoid falls, and operate only in ventilated areas.
• Personal lifts (manlifts, cherry pickers, condors, or JLGs) contain pneumatic, hydraulic, or electric arms with personnel bucket attached at the end.
• Personal lift safety includes operation by certified and trained professionals; a second or third individual must be on the ground to monitor clearances and to warn other personnel if lift is busy; power lines and overhead obstructions must be avoided; proper safety procedures and PPE must be in place; tolls must be secured; area must be barricaded when in use; outrigger stabilizer feet must be properly positioned on a solid surface.
• Dollies are wheeled carts or hand trucks used to transport heavy items such as barrels, drums, and boxes.
• Dolly safety includes being pushed not pulled, operated below recommended weight limits, the load must be secured, the path needs to be clear and well-lighted, slip-resistant footwear must be worn, and a safe angle must be maintained to prevent tipping.

Basic Hand and Power Tool Safety

• Use non-sparking tools that are made of brass, bronze, copper alloys, or plastic, which do not create a spark.

Safety Tips for Tool Use

• Never engage in horseplay, always obtain required work permits to do any jobs, use the right tool, understand how to properly use and maintain tools, review safety procedures and familiarize yourself with hazards associated with specific tools, inspect the condition of the tools, check that edge tools are sharp, inject metal tools for slivers, cracks, or rough spots, check for wear or damage on any plastic or rubber parts or coatings, inspect wooden handles for splinters, chips, or weathering, do not use damaged tools, wear appropriate PPE, avoid loose clothing or jewelry, make sure the work area is clear, keep a firm grip on tools and maintain proper balance and footing, do not leave tools in walkways or high-traffic areas, make sure the work area is properly lighted, maintain a safe distance from other workers when using tools, do not distract others, clean the tool when done and return it to proper storage, and be aware of other work that may affect the usage of the tools in the area.
• General hazards include sparks, impact from flying parts, burns, lacerations, contusions, and muscle strain, harmful dust, fumes, mists, vapors, impalement, injury from a tool that is dropped from up high, ergonomics hazards, noise hazards, falls, and forceful ejections.
• The greatest hazard associated with hand tools is misuse and improper maintenance.
• To avoid hazards, do not overexert yourself and keep your hands dry and vision is not blurred in moist environments. Also, do not overtighten fasteners.
• Power tool hazards include power source related injuries, high speed impact, injuries from contact with moving parts, vibrations and loud noises, fall or trip hazards, and hot surfaces caused by use.
• Always follow manufacturer instructions, understand limitations, and check all safety features.
• Do not use tools that are too heavy or difficult to control.
• Electric tools must be grounded or double insulated, and do not use if they become wet.
• Pneumatic tools: make sure attachments are put in correctly, never kink hoses, check for proper pressure, ensure it is maintained and not damaged.
• Hydraulic tools powered by liquid have the same safety considerations as pneumatic tools.
• Fuel operated tools, operated by the power of combustion, make sure that proper grounding is in place when refueling.
• Powder actuated tools use a small explosive charge to drive a fastener into hard surfaces such as concrete, stone, or metal. These should always be handled with caution, as many will not be activated unless they have pressure on the work surface, but there are still dangers.

Process Technician's Role in Tool Care and Maintenance

• All tools must be properly maintained and stored inside a properly sealed container or toolbox to prevent exposure to moisture or other corrosives, and always inspect all tools.