Jacking System for Crane-Free Column Lowering in Cold Box Modules
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Solution Overview
Problem
Large air separation plants face challenges in transportation and installation due to the need for on-site construction, as prefabricated components are limited by transportation constraints, leading to increased installation time and costs, especially for larger plants.
Innovation Solution
A jacking system that allows for the controlled lowering of upper column sections without the use of cranes, utilizing roof lock nuts, hydraulic lift jacks, and column supports to transfer weight to suspension rods, enabling rapid vertical assembly of cold box modules and reducing the need for large lifting equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large air separation plants are prefabricated in factories, then manufacturing precision and quality control are improved, but transportation constraints prevent the delivery of large-scale plants
Solution Approach 1:
The cold box module is divided into transportable segments that can be assembled on-site. The framework is pre-assembled in factory conditions with high precision, then transported in manageable sections to the installation site where they are connected to form the complete large-scale plant structure.
Solution Approach 2:
Column sections are nested within the framework structure during transportation and assembly. The upper column section is positioned within the upper module section of the framework, allowing compact transport while maintaining the ability to form large-scale installations at the destination.
2Length of moving object
If on-site construction is used for large plants, then transportation constraints are avoided, but installation time and costs increase
Solution Approach 1:
Framework sections and column components are pre-assembled and prepared in factory conditions before transportation. Shipping spacers are pre-installed in the framework to facilitate precise positioning during on-site assembly, reducing the time required for field construction while enabling large-scale plant delivery.
3Force
If cranes are used to lower upper column sections, then lifting capacity is sufficient, but risks and expenses associated with large lifting equipment increase
Solution Approach 1:
A jacking system with suspension rods acts as an intermediary mechanism between the upper column section and the cold box roof. This system distributes the lifting force through multiple suspension rods and roof lock nuts, eliminating the need for large cranes while providing controlled lowering capability. The shipping spacers serve as temporary intermediaries to support the upper column section during assembly.
4Length of moving object
If prefabricated packages are transported horizontally, then transportation constraints are satisfied, but vertical assembly requires additional time and resources
Solution Approach 1:
The framework is designed with shipping spacers that create equal support points for the upper column section during vertical assembly. The suspension rods are positioned to distribute weight evenly across multiple support points, facilitating smooth vertical lowering without requiring complex alignment procedures or additional heavy equipment.
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 solution enables the rapid and controlled assembly of large air separation plants, minimizing installation time and costs, while avoiding the risks and expenses associated with using large cranes, and allowing for the prefabrication of modules that can be easily transported and assembled on-site.
Implementation Method 1
the means for elevating the lifting frame off the shipping spacers comprises a plurality of hydraulic lift jacks
Implementation Method 2
the means for lowering the upper column section in a controlled manner comprise a set of roof lock nuts engaged with the plurality of suspension rods, wherein the roof lock nuts are configured to provide a set stopping point for lowering the upper column section
Implementation Method 3
utilizing roof lock nuts, hydraulic lift jacks, and column supports to transfer weight to suspension rods
Implementation Method 4
column supports disposed on the upper column section, wherein the column supports are configured to engage with the suspension rods and transfer the weight of the upper column section to the suspension rods
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 3
AI summary
A jacking system (90) for use in lowering an upper column section (3) without the use of a crane configured to be disposed on a roof (100) of a cold box module and including: a structural assembly (7); and a plurality of suspension rods (57) supported at an upper end by the structural assembly, wherein the plurality of suspension rods is configured to provide support to the upper column section.