Bucket elevator replacement method

Abstract

To shorten a stop period of an unloader.SOLUTION: A bucket elevator replacement technique is for replacing the lower part of a bucket elevator suspended from a top frame 6 by a continuous type unloader from an existing unit 51 to a new unit 52, and comprises: a first step of previously assembling the new unit at a first position on the ground; a second step of moving the top frame and the existing unit to a second position on the ground after completing the assembling of the new unit and separating the existing unit from the top frame; and a third step of moving the top frame from the second position to the first position and uniting the top frame with the new unit.SELECTED DRAWING: Figure 8

Description

[Technical field]

[0001] The present disclosure relates to a bucket elevator replacement method in a continuous unloader. [Background technology]

[0002] In a continuous unloader, 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.

[0003] 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. This completes the replacement. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 58-130828 Summary of the Invention [Problem to be solved by the invention]

[0005] However, with the above replacement method, it takes a relatively long time from removing the existing equipment to installing the new equipment, and during that time 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.

[0006] The present disclosure has been devised in consideration of the above circumstances, and its purpose is to provide a bucket elevator replacement method that can shorten the unloader downtime. [Means for solving the problem]

[0007] 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:

[0008] Preferably, the unloader includes a ballast tank for balancing the weight of the bucket elevator; The second step involves hoisting the ballast tanks with a barge lift before separating the installation from the top frame.

[0009] Preferably, the third step includes moving the top frame from the second position to the first position while hoisting the ballast tank with the vessel crane.

[0010] Preferably, the third step includes lowering or raising a boom of the crane vessel in synchronism with the movement of the top frame.

[0011] Preferably, the third step includes winding up a wire suspending the ballast tank in synchronization with the lowering of a boom of the crane vessel, or winding down the wire in synchronization with the raising of a boom of the crane vessel.

[0012] Preferably, the third step includes positioning a barge underneath the ballast tank during movement of the top frame.

[0013] 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.

[0014] Preferably, the lower part of the bucket elevator comprises first, second and third casing parts connected in order from above, an extendable frame part positioned below the third casing part, and a supporting frame part connecting the third casing part and the extendable frame part. Effect of the Invention

[0015] According to the present disclosure, the downtime period of the unloader can be shortened. [Brief description of the drawings]

[0016] [Figure 1] FIG. [Diagram 2] FIG. 11 is a diagram for explaining a first step. [Diagram 3] FIG. 11 is a diagram for explaining a first step. [Figure 4] FIG. 11 is a diagram for explaining a first step. [Diagram 5] FIG. 11 is a diagram for explaining a first step. [Figure 6] FIG. 11 is a diagram for explaining a first step. [Figure 7] FIG. 11 is a diagram for explaining a second step. [Figure 8] FIG. 11 is a diagram for explaining a second step. [Figure 9] FIG. 11 is a diagram for explaining a second step. [Figure 10] FIG. 11 is a diagram for explaining the third step. [Figure 11] FIG. 11 is a diagram for explaining the third step. [Figure 12] FIG. 13 is a diagram showing a state in which the top frame is moved in a third step. [Figure 13]FIG. 13 is a diagram showing a state in which the top frame is moved in a third step. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. Note that the present disclosure is not limited to the following embodiments.

[0018] Figure 1 shows the entire continuous unloader 1. For convenience, the front, rear, left, right, top and bottom directions are defined as shown in the figure. However, please note that these directions are defined only 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.

[0019] The unloader 1 includes a traveling section 3 capable of traveling on the ground in the left-right direction along the quay 2, a rotating tower section 4 rotatably mounted on the traveling 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 having a 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.

[0020] The rotating tower section 4, boom 5, top frame 6 and balancing lever 7 form a parallel link, which keeps the posture 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.

[0021] The bucket elevator 8 is roughly divided into an upper part 8A located above the position of the top frame 6, and a lower part 8B located below the top frame 6. In this embodiment, the lower part 8B of the bucket elevator 8 is replaced with a new part from an existing part, for example, due to the expiration of its useful life, i.e., is updated. This embodiment relates to a replacement or updating method for this purpose.

[0022] The lower part 8B of the bucket elevator 8 can be divided into multiple blocks, five blocks 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 this 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.

[0023] The first to third casing portions 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 portion of the first casing portion 11 is inserted into and connected to the top frame 6.

[0024] 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 portion 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 plurality of buckets 22 attached thereto. The bucket chain 16 passes through the first to third casing sections 11 to 13. An elevator section 23 for lifting the scraped load is formed between the scraping section 17 and the upper end sprocket 20.

[0025] Although not shown in detail, the holding frame portion 15 includes a lift frame provided on the third casing portion 13 so as to be able to rise and fall, a hydraulic cylinder that connects the third casing portion 13 and the lift frame, and a hydraulic cylinder that connects the lift frame and the telescopic frame portion 14. The holding frame portion 15 supports the telescopic frame portion 14 relative to the third casing portion 13 so that it can be raised and lowered.

[0026] In this unloader 1, the load scraped by the scraping unit 17 is raised inside the first to third casing units 11 to 13 by the elevator unit 23 and discharged onto a belt conveyor provided inside the boom 5. Then, after passing through a chute, belt conveyor, etc. provided inside the rotating tower unit 4 and the traveling unit 3, the load is discharged onto a ground conveyor outside the machine.

[0027] 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.

[0028] First, the first step will be described with reference to Figures 2 to 6. It is characteristic that the unloader 1 is operated without being stopped during this first step.

[0029] 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 a rail on which the traveling part 3 runs, and reference numeral 25 denotes a ground conveyor.

[0030] On the land behind the unloader 1, i.e., the hinterland 26, a first position P1 for placing a new item 52 (see FIG. 6) is set on the right side, and a second position P2 for placing an existing item 51 is set on the left side. These are separated by a predetermined distance 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.

[0031] A pair of anti-lifting weights 27 and a pair of anti-tipping weights 28 are disposed at the first position P1 and the second position P2, respectively. The anti-lifting weights 27 are weights for preventing the top frame 6 from lifting up when the top frame 6 is separated from the bucket elevator lower portion 8B. The anti-tipping weights 28 are weights for preventing the connected first to third casing portions 11 to 13 from tipping over.

[0032] A work crane (eg, crawler crane) 29 is appropriately positioned in the hinterland 26.

[0033] 3, a casing part support stand 30 and a scaffolding 31 are arranged at a first position P1 and a second position P2, respectively. The casing part support stand 30 is a stand for supporting the first to third casing parts 11 to 13 (directly, the third casing part 13). The scaffolding 31 is a scaffolding on which workers stand during assembly and disassembly work.

[0034] Furthermore, at the first position P1, the bucket chain 16 is assembled.

[0035] 4, each block constituting the newly installed component 52, i.e., the first, second and third casing parts 11, 12 and 13, the expandable frame part 14 and the holding frame part 15, are carried in near the first position P1. Then, they are sequentially transported toward the receiving stand 30 at the first position P1.

[0036] In the illustrated example, the third casing part 13 is shown to have already been transferred from the carry-in 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 carry-in position P3. Reference 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 carry-in position P3 to the temporary placement position P4 and from the temporary placement position P4 to the receiving stand 30.

[0037] 5, at the loading position P3, the first casing portion 11 and the second casing portion 12 are assembled to each other by welding or the like. Then, the integrated first and second casing portions 11, 12 are lifted by a crane 29 and placed in an upright state on the third casing portion 13, and then assembled to the third casing portion 13 by welding or the like.

[0038] In this way, since the first casing portion 11 and the second casing portion 12 are assembled in advance, the casing portion assembly work on the support frame 30 can be completed in one operation. Also, since the integrated first and second casing portions 11, 12 are welded in a state in which they are placed on the third casing portion 13, the first and second casing portions 11, 12 can be welded while being supported from below with a jack or the like as necessary, and the welding accuracy can be improved.

[0039] When the first and second casing parts 11, 12 are assembled in this manner, the height of the casing parts increases and becomes unstable, so the integrated first to third casing parts 11 to 13 and the tip-over prevention weight 28 are connected 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.

[0040] Next, as shown in Fig. 6, the telescopic frame portion 14 and the holding frame portion 15 are assembled to the third casing portion 13. At this time, the holding frame portion 15 is first assembled to the third casing portion 13, and then the telescopic frame portion 14 is assembled to the holding frame portion 15. As a result, the telescopic frame portion 14 is assembled so as to hang from the third casing portion 13 via the holding frame portion 15. This completes the assembly of the new part 52, and the first step ends.

[0041] Next, the second step will be described with reference to Figures 7 to 9. During this second step, the unloader 1 is substantially stopped. For convenience, the casing part receiving stand 30 and the scaffolding 31 are shown only in simplified form in Figures 7 to 9(B).

[0042] As shown in Figure 7, the unloader 1 is moved to a fore-aft position equivalent to the second position P2 by the travel of the traveling part 3. The unloader 1 is also positioned so that the boom 5 is parallel to the fore-aft direction and the top frame 6 faces forward. As a result, the ballast tank 9 is stationary in the air at the second position P2.

[0043] In this state, a scaffold (not shown) for subsequent slinging is installed 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 on attached to the end of the crane arm.

[0044] Next, as shown in FIG. 8, the position and attitude of the unloader 1 are changed, and the existing product 51 and the top frame 6 to which it is attached are moved to the second position P2.

[0045] At this time, the unloader 1 travels leftward from the position in Fig. 7, the boom 5 rotates about the vertical axis C1, and the top frame 6 is changed to a posture in which it faces diagonally rearward to the right (the ballast tank 9 faces diagonally forward to the left). The existing equipment 51 is installed on the casing section support stand 30 at the second position P2 that was already installed in the first step. Then, the first to third casing sections 11-13 of the existing equipment 51 are connected to the anti-tip weight 28 by wires (not shown), and tipping of the casing sections is prevented.

[0046] On the other hand, the top frame 6 is connected to a weight 27 for preventing the top frame 6 from floating up by a wire, a chain block, or the like (not shown). This restrains the top frame 6 from below and prevents it from floating up.

[0047] Next, as shown in Figure 9, the ballast tank 9 located on the sea is lifted up by a crane barge 36. At this time, a wire 37 hanging down from a boom 39 of the crane barge 36 is connected to the ballast tank 9. Standing on the scaffolding installed at the step in 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.

[0048] Also here, a barge 38 is positioned directly below the ballast tanks 9, for reasons that will be understood later.

[0049] 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, since the ballast tank 9 has already been lifted by the crane ship 36, the top frame 6 is prevented from floating up, and safety can be ensured.

[0050] 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.

[0051] Next, the third step will be described with reference to Figures 10 and 11. The unloader 1 is substantially stopped during this third step as well. Note that the casing part receiving stand 30 and the scaffolding 31 are also shown in schematic form in Figure 10(B).

[0052] 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 traveling part 3. The top frame 6 is aligned so as to be approximately coaxial with the new product 52 already installed at the first position P1.

[0053] Next, the arm 5 is lowered, and the top frame 6 is lowered. As a result, the top frame 6 is 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.

[0054] 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 completed. At this time, the wire, chain block, etc. connecting the top frame 6 and the anti-floating weight 27 are tensioned, and the top frame 6 is pulled downward. Also, the wire 37 of the crane ship 36 is slightly wound down and relaxed, and the ballast tank 9 is removed.

[0055] After this, as shown in Fig. 11, a combination operation is performed to completely combine the top frame 6 and the new component 52. When this combination operation is completed, the combination is completed, and the unloader 1 is essentially ready to operate. In parallel with this, the existing component 51 in the second position is dismantled and removed. This completes the third step.

[0056] 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. In addition, in synchronization with the movement of the top frame 6, the boom 39 of the crane ship 36 is lowered. In addition, in synchronization with the lowering of the boom 39 of the crane ship 36, the wire 37 of the crane ship 36 suspending the ballast tank 9 is wound up. Meanwhile, the barge 38 is held in a fixed position.

[0057] In the initial state where the top frame 6 is at the second position P2, the crane barge 36 is positioned on the sea to the left of the ballast tank 9, and the boom 39 is tilted (tipped over) 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 barge 36 is moored almost alongside the quay 2, or more precisely, it is moored alongside the quay 2 at a slight angle so that the right side approaches the quay 2.

[0058] On the other hand, the barge 38 is positioned on the sea so that the ballast tank 9 is located directly above the left end of the barge 38. The barge 38 is brought alongside the quay 2 in parallel, and is positioned to the right of the crane barge 36 and is brought closer to the quay 2.

[0059] 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 part 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.

[0060] 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 lowering. This keeps the height of the ballast tank 9 constant.

[0061] On the other hand, the position of the ballast tank 9 is moved to directly above the right end of the barge 38. During the movement of the ballast tank 9, 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.

[0062] Next, the advantages of this embodiment will be described.

[0063] 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 at once, the separation can be completed in a shorter time than when the existing item 51 is dismantled in blocks. Therefore, it is possible to shorten the downtime of the unloader, which prevents the occurrence of unnecessary demurrage charges and reduces construction costs. In addition, the overall construction period can be shortened, which also reduces construction costs.

[0064] In this embodiment, the ballast tank 9 is lifted by the crane ship 36 before the existing equipment 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 equipment 51 is separated from the top frame 6, thereby improving the efficiency and safety of the construction work.

[0065] 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 being lifted by the crane ship 36. Therefore, by effectively utilizing the crane ship 36, it is possible to reliably prevent the top frame 6 from floating up during the movement.

[0066] 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.

[0067] In this embodiment, since the wire 37 is wound up in synchronization with the lowering of the boom 39, the height of the ballast tank 9 can be kept constant.

[0068] In this embodiment, while the top frame 6 is moving, a person on the barge 38 performs work while monitoring the condition of the unloader 1, etc. 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, but if this synchronization is not performed properly, problems such as the boom 5 of the unloader 1 rotating may occur.

[0069] In this embodiment, the barge 38 is always positioned directly below the ballast tank 9 while the top frame 6 is moving. Therefore, the operator on the barge 38 can always monitor the condition of the unloader 1, etc. from the most visible position. This increases the accuracy of the work.

[0070] Although the embodiment of the present disclosure has been described in detail above, various embodiments and modifications of the present disclosure are possible.

[0071] (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, when the crane ship 36 is positioned on the opposite side, i.e., on the right side of the unloader 1, the operations of the boom 39 and the wire 37 may be reversed. That is, the boom 39 of the crane ship 36 may be raised in synchronization with the movement of the top frame 6, and the wire 37 may be wound down.

[0072] (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.

[0073] (3) The lower portion 8B of the bucket elevator 8 does not necessarily have to be divided into the five blocks described above, and the number and method of division are arbitrary.

[0074] (4) In the above embodiment, the ballast tank 9 is directly lifted. However, the ballast tank 9 may be indirectly lifted by lifting the balancing lever 7 .

[0075] The embodiments of the present disclosure are not limited to the above-described embodiments, and all modifications, applications, and equivalents encompassed within the spirit of the present disclosure as defined by the claims are included in the present disclosure. Therefore, the present disclosure should not be interpreted as being limited, and can be applied to any other technology that falls within the spirit of the present disclosure. [Explanation of symbols]

[0076] 1 Unloader 2. Quay 3 Running part 6 Top Frame 8 Bucket Elevator 8B Lower 9. Ballast Tanks 11 First casing section 12 Second casing part 13 Third casing section 14 Extendable frame section 15 Retaining frame part 36 Hoist ship 37 Wire 38 Barge 39 Boom 51 Existing items 52 New products P1 1st position P2 2nd position

Claims

1. 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:

2. The unloader includes a ballast tank for balancing the weight of the bucket elevator. The second step includes lifting the ballast tank with a vessel lift before separating the existing structure from the top frame. The bucket elevator replacement method according to claim 1.

3. 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 2.

4. The third step includes lowering or raising the boom of the crane vessel in synchronization with the movement of the top frame. The bucket elevator replacement method according to claim 3.

5. The third step includes winding up a wire suspending the ballast tank in synchronization with the lowering of the boom of the crane ship, or winding down the wire in synchronization with the raising of the boom of the crane ship. The bucket elevator replacement method according to claim 4.

6. The third step includes positioning a barge beneath the ballast tank during movement of the top frame. The bucket elevator replacement method according to any one of claims 2 to 5.

7. The unloader includes a traveling section that can travel along a quay, In the third step, the movement of the top frame is performed by the traveling part. The bucket elevator replacement method according to any one of claims 1 to 6.

8. The lower part of the bucket elevator includes a first, second and third casing parts connected in order from above, an expandable frame part located below the third casing part, and a support frame part connecting the third casing part and the expandable frame part. The bucket elevator replacement method according to any one of claims 1 to 7.

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