Pump Lifting Device

Custom Lifting Device for Industrial Pump Removal

Safely removing large industrial pumps in constrained, high-risk environments requires purpose-built lifting devices engineered for safety, compliance, and limited headroom conditions. At this facility, energized overhead powerlines, restricted vertical clearance, multiple pump configurations, and outdoor operating conditions created significant challenges for routine pump removal operations. Unified Engineering was engaged to design and fabricate a custom ASME BTH-1 Certified Category B lifting device to support safe, reliable, and compliant industrial pump lifting.

The Challenge:

The facility required a custom lifting device capable of safely removing large industrial pumps while accounting for potential built-up silt and standing water, increasing the effective lifted weight. A minimum Working Load Limit (WLL) of 23,000 lbs was specified to ensure adequate capacity under worst-case conditions. The lifting operation was further constrained by limited headroom due to energized 230 kV overhead powerlines. With a ground elevation of 591’ and the lowest powerline at approximately 664’, the restricted vertical window necessitated a low-profile design. Furthermore, because the pumps must be extracted from within the pumphouse and transitioned outdoors, all evolutions required coordinated tailing using the facility’s Grove GMK5250L (main) and Grove RT890E (tail) cranes to maintain control beneath the energized infrastructure.

Additional complexity arose from the presence of two different pump configurations on site—the Stork model (without lifting eyes) and the Flowserve/HydroAire models (with lifting eyes). Existing lifting eyes were not to be used, and the lifting device was required to clamp directly onto the motor mounting flange while clearing potential interferences. The lifting system also needed to perform reliably in outdoor environments, including winter conditions with temperatures below 0°C.

The Solution:

Unified Engineering developed a custom ASME BTH-1 Category B clamp-style lifting device designed specifically for industrial pump lifting and removal applications. The lifting device interfaces directly with the pump motor mounting flange, eliminating reliance on existing lifting eyes and improving consistency across varying pump configurations. The device was engineered to provide a minimum 23,000 lb WLL while maintaining a compact, low-profile geometry to ensure clearance beneath energized overhead powerlines.

Drawing from a proven sister-station lifting device design, Unified Engineering adapted and optimized the concept to accommodate the specific dimensions and configurations of the BA series pumps. Detailed engineering analysis and structural calculations were completed to verify load paths, clamp forces, and overall lifting device performance under all anticipated operating conditions, including cold-weather use.

Project deliverables included preliminary concept development and proposal drawings, an Ontario P.Eng–sealed General Arrangement drawing, comprehensive design calculations, and fabrication-ready shop drawings. Unified Engineering also completed fabrication of the lifting device, followed by 125% load testing to confirm ASME BTH-1 Category B compliance. Upon completion, a site visit was conducted and a Pre-Start Health & Safety Review (PSR) issued in accordance with Occupational Health & Safety Act regulations.

The Benefit:

The custom industrial pump lifting device provides a safe, reliable, and fully compliant solution for critical pump removal operations in constrained environments. By reducing overall lift height and eliminating dependence on pump-mounted lifting eyes, the device significantly improves safety during complex lifting evolutions near energized infrastructure. Its robust clamp-based design accommodates multiple pump configurations while remaining compatible with existing crane fleets and established lifting procedures. 

With full ASME BTH-1 Category B compliance, verified load testing, and engineered redundancy, the lifting device enhances operational confidence, reduces risk to personnel, and supports long-term reliability. Unified Engineering’s end-to-end approach—from concept development and engineering analysis through fabrication, testing, and PSR sign-off—delivered a tailored lifting solution aligned with the facility’s operational, safety, and regulatory requirements.