Heavy Component Lateral Alignment Using Integrated Lift and Crawl System
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Solution Overview
Problem
The oil and gas industry faces challenges in maintaining heavy power generation equipment, such as gas turbines and generators, on offshore platforms, where the process is dangerous and time-consuming due to the need for large cranes and the risk of equipment damage or injury from hanging heavy parts, especially considering the movement of the sea and the complexity of aligning turbine and generator axes for maintenance.
Innovation Solution
A method and system for laterally and axially aligning heavy components using a lifting system, guiding pins, and moving cylinders to facilitate the removal and reinstallation of these components without the need for powerful cranes, utilizing a rail system and crawling mechanisms to move the equipment safely and efficiently, and a computerized control system to manage the alignment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional maintenance methods using large cranes are used to remove and reinstall heavy turbine and generator components, then the equipment can be maintained, but the process is dangerous and time-consuming with potential equipment damage or personnel injury from hanging heavy parts
Solution Approach 1:
The system divides the heavy component removal and installation process into discrete steps using multiple movable cylinders positioned at different locations. Each cylinder pair independently controls a section of the component, allowing staged movement and alignment rather than single-lift operations with cranes.
Solution Approach 2:
Movable cylinders act as intermediary devices between the heavy components and the support structure. These cylinders provide controlled support and movement capabilities, eliminating the need for crane-based lifting while enabling precise positioning during maintenance operations.
2Ease of operation
If powerful cranes are used to handle heavy turbine and generator equipment, then components can be removed and reinstalled, but the risk of equipment damage or personnel injury increases due to hanging heavy parts
Solution Approach 1:
The system uses movable cylinders that can dynamically adjust their position and support capacity during the component removal and installation process. This dynamic support system eliminates the need for static crane positioning, allowing continuous controlled movement without creating dangerous hanging loads.
Solution Approach 2:
The heavy components are supported and moved by the movable cylinder system that is integrated with the component mounting structure itself, rather than requiring external crane equipment. This self-contained system reduces operational complexity and eliminates the hazards associated with external lifting equipment.
3Manufacturing precision
If traditional alignment methods are used for turbine and generator axes, then the components can be aligned, but the process requires precise manual positioning and takes significant time
Solution Approach 1:
The system replaces manual mechanical alignment operations with an automated movable cylinder system that can precisely position components along the longitudinal axis. The computerized control system coordinates cylinder movements to achieve accurate alignment without requiring time-consuming manual measurement and adjustment.
Solution Approach 2:
The system incorporates sensors and computerized control that provide feedback on component position and alignment status. This feedback mechanism enables real-time adjustments by the movable cylinders, ensuring precise alignment is achieved efficiently without repeated manual intervention.
4Productivity
If offshore platform space is utilized for power generation equipment, then energy can be generated off-shore, but maintenance access becomes difficult and dangerous due to limited space and sea movement
Solution Approach 1:
The movable cylinder system serves multiple functions: it supports heavy components during installation, enables controlled movement for positioning, provides alignment capabilities, and facilitates maintenance operations. This multi-functional system replaces multiple specialized equipment needs, making the compact offshore platform design viable.
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
This approach reduces the time required for maintenance from 45 days to around 22 days, enhances safety by eliminating the need for heavy cranes, and ensures precise alignment of the turbine and generator axes, thereby reducing the risk of equipment damage and personnel injury.
Implementation Method 1
lowering the first heavy component with the lifting system on the base plate such that guiding pins provided on a skid of the first heavy component enter guiding holes provided in the base plate
Implementation Method 2
pushing the skid of the first heavy component along the lateral axis with a lateral aligning system that includes at least two moving cylinders provided on a first side of the skid and configured to push the skid along the lateral axis
Data Source
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AI summary
Method for laterally replacing a heavy component (10) of a plant assembly, the method including disconnecting the heavy component (10) from other components (20) of the plant assembly and from a base plate (40) to which the heavy component (10) is fixed; lifting the heavy component (10) above the base plate (40) with a lifting system (100) provided within the base plate (40); connecting at least a pair of rails (60) to the base plate (40), under the lifted heavy component (10), such that the at least a pair of rails (60) extends at substantially a right angle relative to a longitudinal axis of the heavy component (10); lowering the heavy component (10) on crawling mechanisms (70) disposed on the at least a pair of rails (60); and laterally replacing the heavy component (10) from the base plate (40) and the other components (20) of the plant assembly by actuating the crawling mechanisms (70).