Storage Tank Roof Module Assembly to Minimize Work at Height
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Solution Overview
Problem
Existing methods for replacing storage tank roofs are costly, time-consuming, and pose safety risks due to the need for extensive manual labor at height, with increased mass and costs from welded beams, and lack flexibility in maintenance scheduling.
Innovation Solution
A method and system for replacing the fixed roof of a storage tank involving pre-assembling modules on the ground, using a template, coil support, mooring eyelets, walking beam, and hauling means to efficiently assemble the roof at floor level, reducing manual labor and safety risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sheet-by-sheet hauling or ramping methods are used to replace the fixed roof, then the roof replacement can be completed, but the process requires extensive manual labor at height, increasing safety risks and man-hours
Solution Approach 1:
The patent applies preliminary action by pre-assembling complete roof modules on the ground before lifting them to the tank. The modules are prepared in advance with all components (sheets, beams, fasteners) assembled at ground level, eliminating the need for workers to perform assembly tasks at height. This preliminary preparation significantly reduces both safety risks and the number of man-hours required for the actual roof replacement operation.
Solution Approach 2:
The roof replacement system is segmented into modular units that can be independently assembled and lifted. Each module represents a discrete section of the roof that can be prepared separately on the ground and then installed as a complete unit. This segmentation allows for standardized ground-level assembly procedures and reduces the complexity of work at height.
2Strength
If welded beams are added to stiffen the roof during replacement, then structural integrity is improved, but the mass and costs of the roof increase
Solution Approach 1:
The patent applies parameter changes by modifying the structural design parameters of the roof modules. Instead of using traditional welded beams that add significant mass, the design changes to alternative stiffening approaches that maintain structural integrity while reducing weight. This may involve changing the configuration, material, or method of structural support to achieve the required strength with lower mass.
Solution Approach 2:
The patent employs composite materials in the roof module construction, combining different materials with complementary properties. The roof sheets are made from materials that provide both strength and lightweight characteristics, and the composite structure achieves the required structural integrity without the excessive mass that would result from traditional welded steel beam configurations.
3Device complexity
If extensive manual labor is used for roof replacement, then the work can be completed with simple equipment, but the costs and time required increase significantly
Solution Approach 1:
The patent replaces manual mechanical labor with a mechanical lifting system. Instead of workers manually assembling and positioning roof components at height, a crane-based mechanical system lifts the pre-assembled modules into position. This substitution of mechanical systems for manual labor dramatically reduces the time required for the operation while the modular design keeps the overall system relatively simple.
Solution Approach 2:
By performing all assembly operations at ground level before lifting, the patent eliminates the time-consuming process of assembling components at height. The preliminary ground-level assembly allows for more efficient work conditions and faster installation once the modules are lifted into position, significantly reducing the total replacement time.
4Ease of manufacture
If workers perform assembly operations at height, then the roof can be replaced in place, but safety risks and productivity losses increase
Solution Approach 1:
The patent applies preliminary action by completing all assembly operations at ground level before lifting the complete modules to the tank. This eliminates the need for workers to perform assembly tasks at height, thereby removing the associated safety risks while still achieving in-place replacement of the roof. The modules are prepared in advance on the ground and then installed as complete units.
Solution Approach 2:
The patent introduces an intermediary lifting system (crane) that transfers the pre-assembled roof modules from ground level to the tank. This intermediary mechanism allows the work to be performed at ground level while still achieving the result of in-place roof replacement, acting as a bridge between the ground-level preparation and the final installation position.
Data Source
AI summary
Embodiments of methods and systems for replacing a fixed roof of a storage tank. An embodiment of a method includes pre-assembling a roof on a floor of a tank basin in the form of modules, assembling the modules on a top of the tank, and welding the modules together to form the roof of the tank. An embodiment of a system for replacing the fixed roof of a storage tank includes a template, a coil support, a plurality of roof modules, a plurality of eyelets, a walking beam, and a hauler.