SAFELY AND PRE­CISELY LIFT, SHIFT AND BAL­ANCE MAS­SIVE AND ODD-SHAPED LOADS

DEMM Engineering & Manufacturing - - PRODUCT WATCH -

RE­SOURCES AND in­fra­struc­ture in­dus­tries present some of the most chal­leng­ing heavy lifts, be­cause of the large and some­times ir­reg­u­larly shaped loads that must be balanced and po­si­tioned safely and time-ef­fi­ciently.

The tow­ers, tanks, tur­bines, trans­form­ers, crush­ers, con­vey­ors, mills and process in­fra­struc­ture in­volved in project de­vel­op­ment and main­te­nance all need to be lifted and shifted with con­sid­er­able care – yet with the min­i­mum de­lay fea­si­ble to en­sure multi­bil­lion­dol­lar projects pro­ceed with­out the huge costs as­so­ci­ated with de­lay.

Two of En­er­pac Heavy Lift­ing Tech­nol­ogy’s time-sav­ing so­lu­tions em­ployed in such ap­pli­ca­tions in­clude:

• The lat­est SFP-Se­ries split flow pumps, specif­i­cally de­signed to as­sist in safely and cost- ef­fi­ciently lift­ing evenly distributed loads.

• EVO-Se­ries PLC-con­trolled syn­chro­nous lift­ing sys­tems, con­trolled by just one per­son, that pre­ci­sion-man­age lifts of un­evenly loaded and oddly shaped plant and equip­ment.

The lat­est SFP-Se­ries elec­tri­cally driven 700 bar split flow pumps are an ideal so­lu­tion for lift­ing ap­pli­ca­tions with mul­ti­ple lift points where lift­ing syn­chro­ni­sa­tion of a max­i­mum

± 4% is ap­pro­pri­ate to en­sure safety of the job. Where such lim­its are ap­pro­pri­ate, the SFP-Se­ries split flow pumps are a safe and eco­nom­i­cal so­lu­tion to en­sure load is evenly distributed over the lift­ing points, says En­er­pac.

SFP-Se­ries split flow pumps are par­tic­u­larly ben­e­fi­cial when lift­ing com­plex loads with mul­ti­ple lift points and are a far more ef­fi­cient and safe op­tion than us­ing sep­a­rately op­er­ated pumps, as they pro­vide greater con­sis­tency of flow.

The load can be lifted si­mul­ta­ne­ously us­ing sin­gle or dou­ble-act­ing cylin­ders. De­pend­ing on the ap­pli­ca­tion, the lift­ing points can be op­er­ated in­di­vid­u­ally or si­mul­ta­ne­ously.

For even more pre­cise lifts, split flow pumps are com­ple­mented by the PLC-con­trolled EVOSeries Syn­chro­nous Lift­ing Sys­tems, by which one per­son can safely con­trol mul­ti­ple cylin­ders from a sin­gle point.

EVO-Se­ries sys­tems are the lat­est evo­lu­tion of En­er­pac’s 25 years of ex­pe­ri­ence in spe­cialised hy­draulic en­gi­neer­ing and lift­ing tech­nol­ogy and have an ac­cu­racy of ± 1mm for ap­pli­ca­tions re­quir­ing high lev­els of pre­ci­sion.

These sys­tems link to En­er­pac high­ton­nage cylin­ders us­ing stroke sen­sors’ sig­nals for syn­chro­nised lif ting and low­er­ing of mul­ti­ple lif ting points.

De­pend­ing on the model and so­phis­ti­ca­tion re­quired, EVO sys­tems can ex­tend from EVO B units – with pumps con­trol­ling four or eight lift­ing points

– through to cus­tom-en­gi­neered sys­tems gov­ern­ing scores of cylin­ders with to­tal lift­ing ca­pac­i­ties of thou­sands of tonnes.

Both split flow and EVO pump sys­tems can be adapted to the needs of par­tic­u­lar ap­pli­ca­tions and dif­fer­ent sites as far apart as the Out­back of Aus­tralia and the frozen ex­panses of Canada.

HEAVY LIFT EX­AM­PLE – SPLIT FLOW PUMPS

En­er­pac split-flow pumps were used in Aus­tralia to lift and lower into place large con­veyor sec­tions, achiev­ing far more ef­fi­cient in­stal­la­tion pro­ce­dures.

Lead­ing heavy lift­ing and mul­ti­modal trans­port so­lu­tions spe­cial­ist, Mam­moet, needed to in­stall 98 such con­veyor sec­tions as part of Rio Tinto’s West­ern Turner Syn­cline Project, at their open pit mine 20km north­west of Tom Price, in the out­back of West­ern Aus­tralia.

En­er­pac helped Mam­moet achieve a four­fold pro­duc­tiv­ity in­crease by de­liv­er­ing two stagelift­ing sets, both con­sist­ing of four BLS506 cylin­ders op­er­ated by a ZE split flow pump.

With En­er­pac’s sys­tem, Mam­moet was able to sig­nif­i­cantly in­crease its con­veyor in­stal­la­tion rate, low­er­ing four con­veyor sec­tions per day and in­creas­ing their ef­fi­ciency four­fold, de­spite the rugged con­di­tions of the site

HEAVY LIFT EX­AM­PLE – EVO

An EVO cus­tom sys­tem in Canada, mean­while, in­volved the lift­ing of the base be­neath a 600-ton coker at an oil sands de­vel­op­ment that needed to be re­paired in or­der to sta­bilise the foun­da­tion.

To per­form the base re­pair, the mas­sive ves­sel needed to be lifted ap­prox­i­mately 100mm. This in­volved lift­ing a ves­sel weigh­ing 600 tons, 9m in di­am­e­ter and 40m tall, which re­quired a so­lu­tion with a high de­gree of safety, ca­pa­ble of main­tain­ing the bal­ance of the load through­out the lift.

The cus­tom-lift sys­tem de­signed for this ap­pli­ca­tion in­cluded eight En­er­pac high- ton­nage hy­draulic cylin­ders with stroke sen­sors and cus­tom cold-weather ca­bles, man­i­folds, load hold­ing valves, Arc­tic hy­draulic oil and hy­draulic power unit. En­er­pac worked closely with HyPower Sys­tems and the site con­trac­tor to de­sign a sys­tem to lift the coker with the high­est de­gree of safety. HyPower Sys­tems’ on-site train­ing, su­per­vi­sion, and 24-hour tech­ni­cal sup­port, along with close col­lab­o­ra­tion with En­er­pac en­sured the cus­tom synch-lift sys­tem com­pleted the lift suc­cess­fully.

EVO SAFETY BEN­E­FITS

Safety ben­e­fits of EVO PLC-con­trolled sys­tems in­clude elim­i­na­tion of the po­ten­tial for er­ror that ex­ists with older, multi-op­er­a­tor man­ual con­trol, of heavy lifts. The dig­i­tally pre­cise EVO-sys­tem in­cor­po­rates warn­ings and stop func­tions. It of­fers full mon­i­tor­ing and con­trol, with pro­gram­mable fail­safe mon­i­tor­ing and safety alarms.

The pre­ci­sion con­trol of­fered by the EVO sys­tem re­duces the risk of struc­tural da­m­age by bend­ing, twist­ing or tilt­ing due to un­even weight dis­tri­bu­tion or load-shifts be­tween lift­ing points.

The easy-to-use and very user-friendly touch screen in­ter­face dis­plays the move­ment process, cylin­der po­si­tions and load read-outs by lift­ing points and to­tal load.

The sys­tem in­cor­po­rates a vari­able fre­quency drive ( VDF) mo­tor, which fa­cil­i­tates low­er­ing of en­gine speeds and oil flows as re­quired to op­ti­mise con­trol of the speed of lift­ing. This fea­ture also makes it pos­si­ble to use the sys­tem with var­i­ous ca­pac­i­ties of cylin­ders.

Us­ing this abil­ity to safely and pre­cisely con­trol lift­ing op­er­a­tions, as well as in­put pa­ram­e­ters for load and stroke tol­er­ance, users can safely and ef­fi­ciently per­form chal­leng­ing lift­ing ap­pli­ca­tions.

DE­TAIL, NEVILLE STU­ART, PH: 021 667 716, E-MAIL: [email protected]­ER­PAC.CO.NZ

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