Decoking Plant Crosshead Brake Testing Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing safety measures for crossheads in decoking plants are inadequate for ensuring the timely maintenance and operability of brakes, leading to potential accidents and damage due to the difficulty in testing brake functionality on-site, which has resulted in deferring maintenance and increasing the risk of crosshead falls during operations.
Innovation Solution
A testing apparatus is provided that allows on-site testing of brake functionality by simulating a free fall of the crosshead using a brace and an arrestor device, enabling the evaluation of brake effectiveness without removing the crosshead, thereby reducing the risk of accidents and facilitating regular maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the crosshead is lowered by means of the cable of the winch during drum emptying, then the decoking tool can traverse the entire height of the drum interior, but the crosshead is exposed to knocks and vibrations that may compromise brake reliability
Solution Approach 1:
The patent applies preliminary action by providing a testing apparatus that can be activated before actual failure occurs. The apparatus includes a triggering mechanism that can initiate a controlled fall test of the crosshead, allowing the brakes to be tested under simulated emergency conditions prior to any actual accident, thus preventing potential failures from escalating into dangerous situations.
Solution Approach 2:
The patent implements feedback through a testing apparatus that monitors and evaluates brake performance during controlled fall tests. The system provides feedback about the operational status of the brakes, allowing operators to assess whether the braking system is functioning correctly under simulated emergency conditions and trigger warnings or maintenance requirements based on the test results.
2Productivity
If brake maintenance is deferred until components appear impeccable from the outside, then operational disruption is minimized, but the risk of crosshead fall increases due to untested brake functionality
Solution Approach 1:
The patent applies preliminary action by providing a testing apparatus that can be activated before actual failure occurs. The apparatus includes a triggering mechanism that can initiate a controlled fall test of the crosshead, allowing the brakes to be tested under simulated emergency conditions prior to any actual accident, thus preventing potential failures from escalating into dangerous situations.
Solution Approach 2:
The patent implements self-service by enabling the brake system to test its own functionality through the integrated testing apparatus. The crosshead can undergo controlled fall tests without requiring external intervention or removal from service, allowing the braking system to self-evaluate its performance and trigger maintenance requirements automatically based on test results.
3Reliability
If the crosshead is tested for brake operability by removing and testing in the workshop, then brake functionality can be assessed, but operational disruption and time loss increase
Solution Approach 1:
The patent implements self-service by enabling the brake system to test its own functionality through the integrated testing apparatus. The crosshead can undergo controlled fall tests without requiring external intervention or removal from service, allowing the braking system to self-evaluate its performance and trigger maintenance requirements automatically based on test results.
Solution Approach 2:
The patent applies preliminary action by providing a testing apparatus that can be activated before actual failure occurs. The apparatus includes a triggering mechanism that can initiate a controlled fall test of the crosshead, allowing the brakes to be tested under simulated emergency conditions prior to any actual accident, thus preventing potential failures from escalating into dangerous situations.
4Device complexity
If no testing apparatus is provided, then device complexity is minimized, but the ability to detect brake failures on-site is lost
Solution Approach 1:
The patent implements self-service by enabling the brake system to test its own functionality through the integrated testing apparatus. The crosshead can undergo controlled fall tests without requiring external intervention or removal from service, allowing the braking system to self-evaluate its performance and trigger maintenance requirements automatically based on test results.
Solution Approach 2:
The patent implements feedback through a testing apparatus that monitors and evaluates brake performance during controlled fall tests. The system provides feedback about the operational status of the brakes, allowing operators to assess whether the braking system is functioning correctly under simulated emergency conditions and trigger warnings or maintenance requirements based on the test results.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient and regular testing of brake operability on-site, reducing the risk of crosshead falls and associated damages, and ensuring the safety of personnel and equipment by allowing for timely identification and servicing of brake components.
Implementation Method 1
an arrestor device (30) for the crosshead (37) releasably attachable on the frame (1) at a distance below the brace (6)
Implementation Method 2
Each of the spring brackets (24, 25) comprises a coil spring (33), which is guided in a guide sleeve (33), mounted on a plate (36)
Data Source
AI summary
The invention relates to a safety device for a crosshead of a decoking plant arranged by means of a carrying device to be liftable and lowerable on profiles of a frame above a drum adapted to receive material, such as coke, and guided on guide rails of the profiles by means of rolls, and carried by a cable of a winch slung around return pulleys at the top of the frame and around a carrying pulley rotatably supported at the top end of the crosshead; and equipped with brakes for stopping the crosshead in an emergency, when the carrying device fails, and for intercepting the crosshead and fixing it on the guide rails or on the profiles. For a safety device, a test apparatus is provided for testing the brakes on site, comprising a carrying device, such as a brace, attachable on the frame, on which the crosshead is mountable for simulating a free fall of the same by means of a release device, and an arrestor device for the crosshead releasably attachable on the frame at a distance below the brace.