JP7660440B2 - Bucket elevator replacement method - Google Patents

Description

This disclosure relates to a bucket elevator replacement method for a continuous unloader.

In continuous unloaders, for example, as the useful life of the bucket elevator expires, the lower part of the bucket elevator that is suspended from the top frame may be replaced with a new part, and the bucket elevator may be updated.

Generally, this replacement is carried out as follows: First, the bucket elevator is moved to the ground, and the existing equipment is dismantled block by block and removed from the top frame. After that, the new equipment is attached to the top frame block by block in sequence. This completes the replacement.

Japanese Unexamined Patent Publication No. 58-130828

However, with the above replacement method, it takes a relatively long time from removing the existing equipment to installing the new equipment, during which the unloader must be shut down. During the unloader's downtime, a daily demurrage fee is incurred, so the longer the unloader is shut down, the higher the construction costs will naturally be.

Therefore, this disclosure was devised in consideration of these circumstances, and its purpose is to provide a bucket elevator replacement method that can shorten the downtime of the unloader.

According to one aspect of the present disclosure,
A construction method for replacing the lower part of a bucket elevator suspended and supported by a top frame in a continuous unloader from an existing part to a new part,
A first step of pre-assembling the new installation at a first location on the ground;
A second step of moving the top frame and the existing equipment to a second position on the ground after the assembly of the new equipment is completed and separating the existing equipment from the top frame;
a third step of moving the top frame from the second position to the first position and associating the top frame with the new product;
A bucket elevator replacement method is provided, comprising:

Preferably, the unloader includes a ballast tank for balancing the weight of the bucket elevator;
The second step involves lifting the ballast tanks with a barge lift before separating the installation from the top frame.

Preferably, the third step includes moving the top frame from the second position to the first position while lifting the ballast tank with the crane vessel.

Preferably, the third step includes lowering or raising the boom of the crane vessel in synchronization with the movement of the top frame.

Preferably, the third step includes winding up the wire suspending the ballast tank in synchronization with the lowering of the boom of the crane vessel, or winding down the wire in synchronization with the raising of the boom of the crane vessel.

Preferably, the third step includes positioning a barge directly beneath the ballast tank while the top frame is moving.

Preferably, the unloader includes a traveling section capable of traveling along a quay,
In the third step, the movement of the top frame is performed by the traveling of the traveling part.

Preferably, the lower part of the bucket elevator comprises a first, second and third casing parts connected in order from above, an expandable frame part positioned below the third casing part, and a holding frame part connecting the third casing part and the expandable frame part.

This disclosure makes it possible to reduce the downtime of the unloader.

FIG. FIG. 11 is a diagram for explaining a first step. FIG. 11 is a diagram for explaining a first step. FIG. 11 is a diagram for explaining a first step. FIG. 11 is a diagram for explaining a first step. FIG. 11 is a diagram for explaining a first step. FIG. 11 is a diagram for explaining a second step. FIG. 11 is a diagram for explaining a second step. FIG. 11 is a diagram for explaining a second step. FIG. 11 is a diagram for explaining the third step. FIG. 11 is a diagram for explaining the third step. 13A and 13B are diagrams showing the state when the top frame is moved in the third step. 13A and 13B are diagrams showing the state when the top frame is moved in the third step.

Embodiments of the present disclosure will be described below with reference to the accompanying drawings. Please note that the present disclosure is not limited to the following embodiments.

Figure 1 shows the entire continuous unloader 1. For convenience, the front, back, left, right, top and bottom directions are defined as shown. However, please note that these directions are defined merely for convenience of explanation. The right side of the figure is the front side, which is the sea side. The left side of the figure is the rear side, which is the land side.

The unloader 1 is equipped with a running section 3 capable of running on the ground in the left-right direction along the quay 2, a rotating tower section 4 rotatably mounted on the running section 3 around a vertical axis C1, a boom 5 rotatably mounted on the rotating tower section 4 around a rotation axis C2 and capable of being raised and lowered, a top frame 6 rotatably mounted on the tip of the boom 5 around a rotation axis C3, a balancing lever 7 rotatably mounted on the rotating tower section 4 around a rotation axis C4 and its tip connected to the top frame 6 around a rotation axis C5, and a ballast tank (or counterweight) 9 fixed to the base end of the balancing lever 7. A bucket elevator 8 is provided on the top frame 6. The ballast tank 9 is located on the opposite side of the bucket elevator 8 with respect to the rotation axis C4, and functions to balance the weight of the bucket elevator 8.

The rotating tower section 4, boom 5, top frame 6 and balancing lever 7 form a parallel link, which keeps the position of the top frame 6 constant regardless of the elevation angle of the boom 5. These together with the running section 3 are called the boom device.

The bucket elevator 8 is roughly divided into an upper portion 8A located above the top frame 6, and a lower portion 8B located below the top frame 6. In this embodiment, the lower portion 8B of the bucket elevator 8 is replaced with a new part, i.e., updated, for example, due to the expiration of its useful life. This embodiment relates to a replacement or updating method for this purpose.

The lower part 8B of the bucket elevator 8 can be divided into multiple blocks, five in this embodiment. That is, the lower part 8B of the bucket elevator 8 includes first, second and third casing parts 11, 12 and 13 connected in order from above, an extendable frame part 14 located below the third casing part 13, and a holding frame part 15 connecting the third casing part 13 and the extendable frame part 14.

The first to third casing sections 11 to 13 each include a cylindrical casing that is connected coaxially and in series in the vertical direction, and its accessories. The upper end of the first casing section 11 is inserted into and connected to the top frame 6.

The telescopic frame section 14 is combined with the bucket chain 16 to form a scraping section 17 for scraping loose loads. The telescopic frame section 14 has a lower end sprocket 18 and a movable sprocket 19 that can move toward and away from the lower end sprocket 18 in the horizontal direction. An upper end sprocket 20 is provided on the upper part 8A of the bucket elevator 8. The bucket chain 16 is wound around the lower end sprocket 18, the movable sprocket 19, and the upper end sprocket 20. The bucket chain 16 is composed of an endless chain 21 and a number of buckets 22 attached to it. The bucket chain 16 passes through the first to third casing sections 11 to 13. An elevator section 23 that lifts the scraped load is formed between the scraping section 17 and the upper end sprocket 20.

The holding frame section 15, not shown in detail, includes a lifting frame that is mounted on the third casing section 13 so that it can be raised and lowered, a hydraulic cylinder that connects the third casing section 13 and the lifting frame, and a hydraulic cylinder that connects the lifting frame and the telescopic frame section 14. The holding frame section 15 supports the telescopic frame section 14 so that it can be raised and lowered relative to the third casing section 13.

In this unloader 1, the load scraped by the scraping section 17 is raised inside the first to third casing sections 11 to 13 by the elevator section 23 and discharged onto a belt conveyor installed inside the boom 5. It then passes through the chutes, belt conveyors, etc. installed inside the rotating tower section 4 and the running section 3, and is then discharged onto a ground conveyor outside the machine.

Next, a method for replacing the bucket elevator lower part 8B in this embodiment will be described. The method includes the following steps.
(1) A first step of pre-assembling the new equipment at a first location on the ground.
(2) A second step of moving the top frame 6 and the existing equipment to a second position on the ground after the assembly of the new equipment is completed and separating the existing equipment from the top frame 6.
(3) A third step of moving the top frame 6 from the second position to the first position and associating the top frame 6 with the new product.

First, the first step will be described with reference to Figures 2 to 6. It is characteristic that during this first step, the unloader 1 is operated without being stopped.

In FIG. 2, (A) is a plan view, and (B) is a cross-sectional view at position b. The unloader 1 to which the existing part 51 of the bucket elevator lower part 8B is attached is in operation, and loading and unloading work is being performed by the unloader 1. Reference numeral 24 denotes the rails on which the traveling part 3 runs, and reference numeral 25 denotes the ground conveyor.

On the land behind the unloader 1, i.e., the hinterland 26, a first position P1 for placing new items 52 (see Figure 6) is set on the right side, and a second position P2 for placing existing items 51 is set on the left side. These are spaced a predetermined distance apart in the left-right direction, and are equidistant from the wall surface 2A of the quay 2. The unloader 1 performs loading and unloading operations at a work position to the left of the second position P2.

A pair of anti-lift weights 27 and a pair of anti-tip weights 28 are arranged at the first position P1 and the second position P2, respectively. The anti-lift weights 27 are weights for preventing the top frame 6 from lifting up when the top frame 6 is separated from the lower bucket elevator portion 8B. The anti-tip weights 28 are weights for preventing the connected first to third casing sections 11 to 13 from tipping over.

A work crane (e.g., crawler crane) 29 is appropriately positioned in the hinterland 26.

Next, as shown in FIG. 3, a casing support stand 30 and scaffolding 31 are placed at a first position P1 and a second position P2, respectively. The casing support stand 30 is a stand for supporting the first to third casing sections 11 to 13 (directly, the third casing section 13). The scaffolding 31 is a scaffolding on which workers stand during assembly and disassembly work.

The bucket chain 16 is also assembled at the first position P1.

Next, as shown in FIG. 4, each block constituting the new component 52, i.e., the first, second and third casing sections 11, 12 and 13, the expandable frame section 14 and the holding frame section 15, are brought in near the first position P1. They are then transported sequentially toward the receiving stand 30 at the first position P1.

In the illustrated example, the third casing part 13 is shown to have already been transferred from the loading position P3 onto the receiving stand 30. The third casing part 13 is supported by the receiving stand 30 in an upright position. Meanwhile, the remaining blocks remain at the loading position P3. The symbol P4 indicates a temporary placement position closer to the receiving stand 30. The number of cranes 29 is increased to two, and these cranes 29 are used to sequentially transfer each block from the loading position P3 to the temporary placement position P4 and from the temporary placement position P4 to the receiving stand 30.

In parallel with this transportation, as shown in FIG. 5, at the loading position P3, the first casing part 11 and the second casing part 12 are assembled to each other by welding or the like. Then, these integrated first and second casing parts 11, 12 are lifted by a crane 29 and placed in an upright position on the third casing part 13, and then assembled to the third casing part 13 by welding or the like.

In this way, since the first casing part 11 and the second casing part 12 are assembled in advance, the casing part assembly work on the support stand 30 can be completed in one go. In addition, since the integrated first and second casing parts 11, 12 are welded while placed on the third casing part 13, the first and second casing parts 11, 12 can be welded while being supported from below with a jack or the like as necessary, improving welding accuracy.

When the first and second casing parts 11, 12 are assembled in this way, the height of the casing parts becomes too high and unstable, so the integrated first to third casing parts 11 to 13 are connected to the anti-tip weight 28 by wire 32 to prevent the casing parts from tipping over. In addition, the height of the scaffolding 31 is increased in accordance with the increase in the height of the casing parts.

Next, as shown in FIG. 6, the telescopic frame section 14 and the holding frame section 15 are assembled to the third casing section 13. At this time, the holding frame section 15 is first assembled to the third casing section 13, and then the telescopic frame section 14 is assembled to the holding frame section 15. As a result, the telescopic frame section 14 is assembled so that it hangs from the third casing section 13 via the holding frame section 15. This completes the assembly of the new part 52, and the first step ends.

Next, the second step will be described with reference to Figures 7 to 9. During this second step, the unloader 1 is essentially stopped. For convenience, the casing support stand 30 and the scaffolding 31 are shown only in simplified form in Figures 7 to 9 (B).

As shown in FIG. 7, the unloader 1 is moved to a fore-aft position equivalent to the second position P2 by the running part 3. The unloader 1 is also positioned so that the boom 5 is parallel in the fore-aft direction and the top frame 6 faces forward. This causes the ballast tank 9 to be stationary in the air at the second position P2.

In this state, a scaffold (not shown) for subsequent slinging is set up on the ballast tank 9 using a crane 29 and a sky basket 35. The sky basket 35 is a gondola that people can ride in attached to the end of the crane arm.

Next, as shown in Figure 8, the position and posture of the unloader 1 are changed, and the existing item 51 and the top frame 6 to which it is attached are moved to the second position P2.

At this time, the unloader 1 travels to the left from the position shown in Figure 7, the boom 5 rotates about the vertical axis C1, and the top frame 6 is changed to a position facing diagonally rear to the right (the ballast tank 9 faces diagonally forward to the left). The existing item 51 is installed on the casing support stand 30 at the second position P2 that was already installed in the first step. The first to third casing sections 11 to 13 of the existing item 51 are then connected to the anti-tip weight 28 by wires (not shown), preventing the casing section from tipping over.

Meanwhile, the top frame 6 is connected to the anti-floating weight 27 by a wire, chain block, etc. (not shown). This restrains the top frame 6 from below and prevents it from floating up.

Next, as shown in Figure 9, the ballast tank 9 located on the sea is lifted by the crane ship 36. At this time, a wire 37 hanging from the boom 39 of the crane ship 36 is connected to the ballast tank 9. Standing on the scaffolding installed in the step of Figure 7, a worker slings the wire 37 onto the ballast tank 9. When the wire 37 is reeled in, the ballast tank 9 is pulled upward, which doubles as a prevention of the top frame 6 from floating up.

Here, too, a barge 38 is positioned directly below the ballast tank 9. The reason for this will be understood later.

Next, the existing item 51 is separated and separated from the top frame 6. At this time, the connection between the top frame 6 and the anti-floating weight 27 is released. Even in this case, the ballast tank 9 has already been lifted by the crane ship 36, so the top frame 6 is prevented from floating up, and safety can be ensured.

Next, the arm 5 is raised, and the top frame 6 is raised. This causes the top frame 6 to be removed from the existing item 51. In synchronization with the raising of the arm 5, the wire 37 of the crane ship 36 is wound down, and the ballast tank 9 is lowered. This completes the separation of the existing item 51, and the second step ends.

Next, the third step will be described with reference to Figures 10 and 11. During this third step, the unloader 1 is essentially stopped. Note that Figure 10(B) also shows a simplified view of the casing support stand 30 and the scaffolding 31.

As shown in FIG. 10, the unloader 1 is moved to the first position P1 while maintaining the posture shown in FIG. 9. This movement is performed by the running part 3. The top frame 6 is aligned so that it is approximately coaxial with the new product 52 that is already installed at the first position P1.

Next, the arm 5 is lowered, and the top frame 6 is lowered. This allows the top frame 6 to be fitted to the new product 52. In synchronization with the lowering of the arm 5, the wire 37 of the crane ship 36 is reeled in, and the ballast tank 9 is raised.

Next, the top frame 6 is connected to the anti-floating weight 27 by a wire, chain block, etc. (not shown). This prevents the top frame 6 from floating up, and the lifting of the ballast tank 9 by the crane ship 36 is terminated. At this time, the wire, chain block, etc. connecting the top frame 6 and the anti-floating weight 27 is tensioned, and the top frame 6 is pulled downward. In addition, the wire 37 of the crane ship 36 is wound down slightly to slacken it, and the ballast tank 9 is removed.

After this, as shown in FIG. 11, a combination operation is carried out to completely combine the top frame 6 and the new item 52. Once this combination operation is complete, the combination is complete and the unloader 1 is essentially ready to operate. In parallel with this, the existing item 51 in the second position is dismantled and removed. This completes the third step.

Figures 12 and 13 show the state when the top frame 6 is moved from the second position P2 to the first position P1 in the third step. At this time, the crane ship 36 is moved from the second position Pc2 to the first position Pc1 while hoisting the ballast tank 9. The boom 39 of the crane ship 36 is lowered in synchronization with the movement of the top frame 6. The wire 37 of the crane ship 36, which is hoisting the ballast tank 9, is wound up in synchronization with the lowering of the boom 39 of the crane ship 36. Meanwhile, the barge 38 is held in a fixed position.

In the initial state where the top frame 6 is in the second position P2, the crane ship 36 is positioned on the sea to the left of the ballast tank 9, and the boom 39 is tilted (tipped) to the right at a predetermined tilt angle θ2. A wire 37 hanging down from the tip of the boom 39 suspends the ballast tank 9 at a predetermined height. The crane ship 36 is moored almost alongside the quay 2, or more precisely, at a slight angle so that the right side is closer to the quay 2.

Meanwhile, the barge 38 is positioned on the sea so that the ballast tank 9 is located directly above its left end. The barge 38 is moored parallel to the quay 2, positioned to the right of the crane barge 36 and close to the quay 2.

Next, when the top frame 6 is moved from the second position P2 to the first position P1, the crane ship 36 is moved a relatively short distance to the right. The movement distance Lc of the crane ship 36 is shorter than the movement distance Lt of the top frame 6. The movement distance Lt of the top frame 6 is equal to the movement distance of the traveling section 3. The unloader 1 is translated in the longitudinal direction (left-right direction) of the quay 2 while keeping the angular position of the boom 5 around the vertical axis C1 constant.

The boom 39 of the crane ship 36 is lowered (tilted) to the right, i.e., toward the first position P1, until the inclination angle θ1 becomes smaller. Then, the wire 37 of the crane ship 36 is wound up to counteract this downward movement. This keeps the height of the ballast tank 9 constant.

Meanwhile, the position of the ballast tank 9 is moved to directly above the right end of the barge 38. While the ballast tank 9 is moving, the barge 38 is always positioned directly below the ballast tank 9, and the initial position of the barge 38 is set so that this is the case.

Next, we will explain the advantages of this embodiment.

In this embodiment, the new item 52 is assembled in advance, and then the existing item 51 is separated from the top frame 6 of the unloader 1, and the new item 52 is combined with the top frame 6. Therefore, the unloader 1 can be operated to perform loading and unloading work while the new item 52 is being assembled. In addition, since the entire existing item 51 is separated from the top frame 6 all at once, the separation can be completed in a shorter time than if the existing item 51 were to be dismantled in blocks. This makes it possible to shorten the downtime of the unloader, preventing the occurrence of unnecessary demurrage charges and reducing construction costs. The overall construction period can also be shortened, which also makes it possible to reduce construction costs.

In addition, in this embodiment, the ballast tank 9 is lifted by the crane ship 36 before the existing item 51 is separated from the top frame 6. This prevents the top frame 6 from floating up due to the weight of the ballast tank 9 immediately after the existing item 51 is separated from the top frame 6, improving the efficiency and safety of the construction work.

In addition, in this embodiment, the top frame 6 is moved from the second position P2 to the first position P1 while the ballast tank 9 is lifted by the crane ship 36. Therefore, the crane ship 36 can be effectively used to reliably prevent the top frame 6 from floating up during the movement.

In this embodiment, the boom 39 of the crane ship 36 is lowered in synchronization with the movement of the top frame 6, so that the movement distance Lc of the crane ship 36 can be made shorter than the movement distance Lt of the top frame 6, thereby improving work efficiency.

In this embodiment, the wire 37 is wound up in synchronization with the lowering of the boom 39, so the height of the ballast tank 9 can be kept constant.

In this embodiment, while the top frame 6 is moving, a person on the barge 38 monitors the status of the unloader 1 and other equipment while performing work. While the top frame 6 is moving, the boom 39 is lowered in synchronization with the movement of the top frame 6, and the wire 37 is wound up. However, if this synchronization is not performed properly, problems such as the boom 5 of the unloader 1 rotating may occur.

In this embodiment, the barge 38 is always positioned directly below the ballast tank 9 while the top frame 6 is moving. Therefore, the worker on the barge 38 can always monitor the status of the unloader 1, etc. from the most visible position. This increases the accuracy of the work.

Although the embodiments of the present disclosure have been described in detail above, various embodiments and variations of the present disclosure are possible.

(1) In the above embodiment, in the third step, the boom 39 of the crane ship 36 is lowered and the wire 37 is wound up in synchronization with the movement of the top frame 6. However, if the crane ship 36 is positioned on the opposite side, i.e., to the right of the unloader 1, the operations of the boom 39 and the wire 37 may be reversed. In other words, the boom 39 of the crane ship 36 may be raised and the wire 37 may be wound down in synchronization with the movement of the top frame 6.

(2) In the above embodiment, the first position P1 and the second position P2 are set apart in the traveling direction of the traveling part 3, i.e., in the longitudinal direction or left-right direction of the quay wall 2, but other setting methods are also possible. For example, the first position P1 and the second position P2 may be set apart in the rotation direction around the vertical axis C4 of the unloader 1.

(3) The lower part 8B of the bucket elevator 8 does not necessarily have to be divided into the five blocks mentioned above; the number of divisions and the division method are arbitrary.

(4) In the above embodiment, the ballast tank 9 is lifted directly, but the ballast tank 9 may be lifted indirectly by lifting the balancing lever 7.

The embodiments of the present disclosure are not limited to the above-mentioned embodiments, and all modifications, applications, and equivalents encompassed within the concept of the present disclosure as defined by the claims are included in the present disclosure. Therefore, the present disclosure should not be interpreted in a limited manner, and may be applied to any other technology that falls within the scope of the concept of the present disclosure.

Reference Signs List 1 Unloader 2 Quay 3 Traveling section 6 Top frame 8 Bucket elevator 8B Lower section 9 Ballast tank 11 First casing section 12 Second casing section 13 Third casing section 14 Expandable frame section 15 Holding frame section 36 Crane ship 37 Wire 38 Barge 39 Boom 51 Existing item 52 New item P1 First position P2 Second position

Claims (8)

A construction method for replacing the lower part of a bucket elevator suspended and supported by a top frame in a continuous unloader from an existing part to a new part,
A first step of pre-assembling the new installation at a first location on the ground;
A second step of moving the top frame and the existing equipment to a second position on the ground after the assembly of the new equipment is completed and separating the existing equipment from the top frame;
a third step of moving the top frame from the second position to the first position and associating the top frame with the new product;
A bucket elevator replacement method comprising: The unloader includes a ballast tank for balancing the weight of the bucket elevator.
The bucket elevator replacement method according to claim 1 , wherein the second step includes lifting the ballast tank with a crane ship before separating the existing equipment from the top frame. The bucket elevator replacement method according to claim 2 , wherein the third step includes moving the top frame from the second position to the first position while lifting the ballast tank with the crane ship. The bucket elevator replacement method according to claim 3 , wherein the third step includes lowering or raising a boom of the crane ship in synchronization with the movement of the top frame. The bucket elevator replacement method according to claim 4, wherein the third step includes winding up a wire suspending the ballast tank in synchronization with lowering of a boom of the crane ship, or winding down the wire in synchronization with raising of a boom of the crane ship. The bucket elevator replacement method according to any one of claims 2 to 5, wherein the third step includes positioning a barge directly under the ballast tank while the top frame is moving. The unloader includes a traveling section that can travel along a quay,
The bucket elevator replacement method according to any one of claims 1 to 6, wherein in the third step, the movement of the top frame is performed by the traveling of the traveling part. The bucket elevator replacement method according to any one of claims 1 to 7, wherein a lower part of the bucket elevator includes first, second and third casing parts connected in this order from above, an extendable frame part located below the third casing part, and a holding frame part connecting the third casing part and the extendable frame part.

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