APS System

Hebetec Engineering AG Sagi 1 CH-3324 Hindelbank Tel: +41 34 411 71 71 Fax: +41 34 411 71 70 e-mail: [email protected]

Documentation APS-System

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Hebetec Engineering Ltd Documentation APS-System

Table of contents 1. Description APS – System ................................................................................ 3

1.1 Introduction .................................................................................................................. 3 1.2 Components of a APS set ............................................................................................... 3 1.3 Functionality of the APS System...................................................................................... 6 1.4 Safety considerations ..................................................................................................... 7

2. Technical specification APS – System .............................................................. 8 2.1 Load Carrying Module Type APS M – 250......................................................................... 8 2.2 Load Carrying Module Type APS M – 385......................................................................... 8 2.3 Power Pack PA-2-16/2-8 (up to 18 modules) ................................................................... 9 2.4 Power Pack PA-4-33/2-8 (for more than 18 modules)....................................................... 9 2.5 Push Pull Unit PPU – 32.................................................................................................10 2.6 Push Pull Unit PPU – 100 ...............................................................................................10 2.7 Push Pull Unit PPU – 160 ...............................................................................................10 2.8 Cradle for APS ..............................................................................................................11 2.9 Skidway light ................................................................................................................11 2.10 Skidway heavy..............................................................................................................11

3. Application possibilities.................................................................................. 12 APS-Modules ...........................................................................................................................13 Push-Pull-Unit..........................................................................................................................13

4. Pictures .......................................................................................................... 14 5. Datasheets ..................................................................................................... 29

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1. Description APS – System

1.1 Introduction The APS-System (AirPad – transport – System) is a system that works with an air pad to move heavy loads with a minimum friction of <1%. This system was built because the loads that have to be moved are getting heavier and the moving time has to be less. The APS-System consists essentially of individual or coupled load modules, a slide way and the associated supply systems (hydraulic and compressed air). The advantages of the APS-System:

- Sliding friction resistance < 1% (0.3 - 1%) - Lifting and shifting with the same device - Possibility of direction change without changeover - Turning of loads on the spot - Smallest fitting space with maximum achievement

Typical applications of the APS-System

- Moving of ships and part of ships (Load out) - Moving of building parts (bridges, underpasses, …) - Moving and turning of heavy machines (tunneling machines, generators, …)

1.2 Components of a APS set

The following equipment belongs to a regular set of APS:

Load Carrying Module type APS Hydraulic Power Unit Compressed Air Supply Devices Push Pull Unit Skidding Elements or a suitable sliding area

The development and permanent improvement of the system and the individual components is performed by employees of Hebetec Engineering AG. Any components are checked at the headquarters of Hebetec according to predetermined processes, and combined into system components. The actual installation and commissioning of the system components takes place on site before lifting the load.

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1.2.1 Load Carrying Module type APS

The load module forms the main component of the APS system and essentially comprises a solid carrier plate with an integrated sealing ring as well as a lifting hydraulic jack, spherically borne on the support plate. In the standard version, the hydraulic jack has a stroke of 400 mm. Each of the hydraulic jacks is equipped with overload valves and pipe-break protection. Thus the load is secured even in case of hydraulic defects or inadmissible load shifts.

For controlling the compressed air, a control valve is used, which was especially developed for this purpose.

There are two different module types to choose from:

- APS M-250 ⇒ capacity 2500 kN per module, stroke 330 - APS M-385 ⇒ capacity 3850 kN per module, stroke 400

1.2.2 Hydraulic power pack The HPU is especially built for the requirements of the APS. A maximum of 32 modules and two or four Push-Pull units respectively with clamping devices can be driven with this power pack. The power pack can be controlled directly or with the external control panel. During the displacement the power pack will be pulled with the load.

1.2.3 Compressed air supply devices

The most common system is to use compressed air or nitrogen bottles; the advantage is a high flexibility. The numbers of bottles has to be planned carefully and an adequate number of spare bottles have to be available. Regularly one container is equipment with 12 bottles with a volume of 50 liters each bottle. The pressure is normally 200 bars and in some case 300 bars. In different countries there are different rules about high pressure containments. On the container a pressure reduction valve has to be installed to adjust the pre pressure of the system (This pressure is 5 …. 10 bar higher than the working pressure in the APS chambers). In each project the system of supplying the compressed air or the nitrogen gas has to be decided to the circumstances on site. By using steel skidding elements the air consumption amounts to approximate 5 – 10m3/h. The most of the volume is used to fill up the system.

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1.2.4 Push Pull Unit Normally a push pull unit is used for sliding the load. The advantage of this unit is that the load is prevented in every position against uncontrolled movement of the load. Normally there is always one pair of PPU in use. Two are active during movement. During the retraction of the PPU one pair is always fixed to secure the load while the other one is retracting. In case of higher load to be moved, we can operate (if the APS- System is equipped accordingly) with 4 pairs of PPU. Instead of the PPU other equipment can be used

(Winches, strand jacks, large Machines s.o.) If other equipment is used instead of the PPU it has to be guaranteed, that the load can be fixed always in every direction.

1.2.5 Skidding Elements or a suitable sliding area The modules can be used on any air-tight and sufficiently resistant surface. Normally skidways especially developed for this purpose are used. Depending on the quality of the subsurface (bearing capacity), the skidway type heavy or light is used. Both types have a guide board. The board serves guidance and is also used for additional clamping of the PPU. One skidway is defined as a guide way. This skidway has a width of 1200 mm and guides the load during the sliding process. The other skidways are wider, so that the modules can slide on them without any restrictions.

The light skidways are welded tightly at the joints and dowelled to the ground approx. every 1.5 – 2 m. The heavy skidways can be placed onto the ground without additional fixture. The skidways have self-sealing joints. The skidways are respectively pulled together laterally with threaded bars.

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1.3 Functionality of the APS System

The arrangement and the number of modules and skidways depend on the load to be moved and the centre of gravity. Nearly any number of modules can be used together. The modules can be operated in hydraulic groups or individually. The minimum superimposed load per module is approx. 500 kN, using several modules there are hardly any limits in total load.

1.3.1 Lifting the load Following the assembly of the APS modules and connection of the hydraulic and compressed-air lines, the load can be lifted. In normal use, the load is lifted by approx. half the stroke (200 mm). The various modules or module groups are hydraulically coupled that way that the load is respectively borne in a statically determined manner (3-point-support). With this support and the cylinder position (lift +/- 200 mm), the hydraulic cylinders can also even out height differences in the skidways. Thus the requirements of height tolerances in the skidways are small, and it is also possible to overcome ramps or changing inclinations. The required drive unit (PPU, winch, etc.) can be adjusted or combined according to the respective requirements. During sliding, the height can be adjusted to the circumstances at the construction site.

1.3.2 Generation of the compressed air layer

Once the load has been taken over by the hydraulic cylinders, the ring chambers and the main chambers of the support plates are filled with compressed air. The sealing rings in the support plates move out by approx. 20 mm. This generates a compressed air layer underneath the support plates. The effect of the sealings largely avoids an escape of compressed air. As soon as the sealing rings are moved out, the modules are ready for sliding. Since the load is positioned on a compressed air layer, friction values of below 0,5 % can be achieved on the test stand. In practice, the values lie between 0.5 and a maximum of 1 %. The generation of the compressed air layer takes approx. 2 - 3 minutes, depending on the number of modules and availability of compressed air. The required air pressure for full load is approx. 30 bar for the module APS M-250 and approx. 45 bar for the module APS M-385. The actually required air pressure results from the superimposed load. The primary pressure (at the output of the gas cylinder manifold) is about 10 bar higher.

Since the friction values are very low, the load must be safeguarded in advance against unintentional sliding. Even small external influences like slope or wind can move the load.

1.3.3 Sliding with the Push-pull Unit Normally, in combination with the skidway types “heavy” or “light”, the Push-Pull Unit (PPU) is used. As a standard, 4 units are used. In the initial position, two devices are respectively active, i.e. the clamping device is activated and the other two units are passive. At the clamped units, the feed cylinders are activated and the load moves. After the displacement (1.25/2 meters), the other

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clamping units are activated and thus the load secured against unintentional sliding. Following retraction of the feed cylinders, the clamping can be relocated and the new sliding step can be started. These steps are repeated, until the object has reached its destination. If required, two or, for doubling the sliding capacity, four units can be used.

1.3.4 Lubricating the skidways The skidways are lubricated with silicone oil before the sliding process (also underneath the module). The lubricant film reduces friction and avoids abrasion of the module sealing.

1.4 Safety considerations

Due to the system design, the load is always borne in a statically determined position, i.e. in three hydraulic groups. Thus, even in case of level changes in the skidways, the load distribution is clearly defined and overloading of individual components is excluded. Additionally, all hydraulic cylinders are equipped with special overload valves and pipe-break protection. Though loss of oil can cause retraction of the cylinders and thus a loss in lifting height, it cannot cause local overload. The system respectively evens out the height according to the circumstances. The lift or the sliding force, respectively, is limited via the hydraulic power pack. The load or the maximum pressure, respectively, may also be set at the hydraulic power pack. The power pack is equipped with a manometer, so that the pressures can be permanently monitored. Above all, the sliding force is an indication for good functioning (low friction values) of the APS modules.

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2. Technical specification APS – System

2.1 Load Carrying Module Type APS M – 250 Nominal bearing capacity ⇒ 2'500 kN

Stroke ⇒ Hydraulically: 330 mm Pneumatically: 20 – 30 mm

Sliding speed ⇒ Maximal: 5 meters / min Nominal: 1 meter / min

Pressure level (according capacity) ⇒ Hydraulically: 360 bars Pneumatically: 25 bars

Normal range of operation temperature ⇒ - 20° C …. + 40°C

Dimensions ⇒ Bearing plate: 1’100 x 1’100 mm Total height: 868 mm Adapter: 410 x 410 mm Connection: 4 x M24 Weight: 1’600 kg

2.2 Load Carrying Module Type APS M – 385

Nominal bearing capacity ⇒ 3'850 kN

Stroke ⇒ Hydraulically: 400 mm (280 mm) Pneumatically: 20 – 30 mm

Sliding speed ⇒ Maximal: 5 meters / min Nominal: 1 meter / min

Pressure level (according capacity) ⇒ Hydraulically: 350 bars Pneumatically: 35 bars

Normal range of operation temperature ⇒ - 20° C …. + 40°C

Dimensions ⇒ Bearing plate: 1’100 x 1’100 mm Total height: 973 mm (843 mm) Adapter: 500 x 500 mm Connection: 4 x M30 Weight: 1’900 kg

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2.3 Power Pack PA-2-16/2-8 (up to 18 modules) Delivery jacking outlets ⇒ Pressure line: 2 x 16 liter/min Return line: 2 x 16 liter/min

Delivery sliding outlets ⇒ Pressure line: 2 x 16 liter/min Return line: 2 x 16 liter/min

Maximum working pressure jacking ⇒ Pressure line: 400 bar Return line: 250 bar


Dimension ⇒ Length: 1’650 mm Height 1’420 mm Width: 1’020 mm

Weight with oil ⇒ 1’170 kg

Oil filling ⇒ 520 liters

Oil specification ⇒ HLP ISO-VG 32

Power supply ⇒ Voltage: 380 - 440 V Frequency: 50/60 Hz Power: 45 kVA Plug: EURO A 125

2.4 Power Pack PA-4-33/2-8 (for more than 18 modules) Delivery jacking outlets ⇒ Pressure line: 4 x 33 liter/min Return line: 4 x 33 liter/min

Delivery sliding outlets ⇒ Pressure line: 4 x 33 liter/min Return line: 4 x 33 liter/min



Dimension ⇒ Length: 3’100 mm Height: 1’236 mm Width: 1’001 mm

Weight with oil ⇒ 2’800 kg

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Oil filling ⇒ 1’200 liters

Oil specification ⇒ HLP ISO-VG 32

Power supply ⇒ Voltage: 380 - 440 V Frequency: 50/60 Hz Power: 135 kVA Plug: EURO A 125

2.5 Push Pull Unit PPU – 32

Capacity (2 Push Pull cylinder) ⇒ Pushing: 320 kN Pulling: 160 kN

Push – Pull long stroke jack ⇒ Capacity: 160 kN Stroke: 1’250 mm Pressure max: 250 bar

Clamping long stroke jack ⇒ Capacity: 50 kN Stroke: 170 mm Pressure max: 250 bar

Weight ⇒ 484 kg


Capacity (2 Push Pull cylinder) ⇒ Pushing: 1’000 kN Pulling: 530 kN



Weight ⇒ 2’850 kg


Capacity (2 Push Pull cylinder) ⇒ Pushing: 1’600 kN Pulling: 800 kN


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Weight ⇒ 2’850 kg

2.8 Cradle for APS Capacity ⇒ 7’700 kN

Dimension ⇒ Length: 4’000 mm Height: 1’864 mm Width: 1’500 mm

Weight (without modules) ⇒ 4’200 kg

2.9 Skidway light

Weight ⇒ 1200: 2.2 to 1360: 2.3 to

Dimension ⇒ Track width: 1’200 mm/1’360 mm Length: 9 m Height: 166 mm Width: 1’500 mm/1’600 mm

2.10 Skidway heavy

Capacity ⇒ 1200: 7.8 to 1360: 8.3 to

Dimension ⇒ Track width: 1’200 mm/1’360 mm Length: 10 m Height 437 mm Width: 1’464 mm/1’624 mm

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3. Application possibilities

• Moving of ships (Example : 16 loudouts in Korea, 22'000 t/Ship )

On eight fixed installed slidingways (concrete and structural steelwork) the hulls are shifted with a shifting speed of 30 m/h .

Length 244 m Height 32 m Sliding distance 91 m Width 42 m Weight 22'000 t Entire carrying capacity 350'000 kN

Information


Totally 140 pieces of APS-250 modules, which are evenly distributed on the four skidways, are in use. The shifting force is produced by four Push-Pull units. The measured friction resistance is under 0.5%. Further application possibilities:

• Moving of building parts (bridges, underpasses ect.) • Moving and turning of heavy machines (tunnelling machines, generators ect.)

The advantages of the APS system:

• Sliding friction resistance < 1% (0.3 – 1%) • Lifting and shifting with the same device • Possibility of direction change without changeover • Turning of loags on the spot • Smallest fitting space with maximum achievement

APS-Modules

Module Dimension Stroke Capacity APS M-250 1100x1100 mm 330 mm 2500 kNAPS M-385 1100x1100 mm 400 mm 3850 kN

Push-Pull-Unit

Module Total legth Stroke Height Capacity PPU-032 776 mm 1454 mm 287 mm 320 kNPPU-160 1560 mm 1500 mm 380 mm 1600 kNPPU-100 1560 mm 1500 mm 365 mm 1000 kN

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4. Pictures

APS-385

Air valve

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APS-250

APS-Sealing

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PPU-32

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Controlldesk for HHI – Loadouts

PPU-32

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Controlldesk for HHI – Loadouts

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Skidway heavy joint

Skidway heavy

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Cradle with APS-Modules

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Cradle with APS-Modules

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Preinstallation: PPU-32

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Installation of Cradles

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Megablock during Loadout

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Megablock during Loadout

Megablocks on barge

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Sliding heavy structures

Linkbeam HHI

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After Loadout, Hull on barge

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Load Out HHI

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5. Datasheets

Partdeclaration Push-Pull-Unit

[email protected]+41 34 411 71 70+41 34 411 71 71Hebetec Engineering AG

CH-3324 Hindelbank (Switzerland)Sagi 1

hebetec.comWeb:e-mail:Fax:Tel: Hebetec Documentation

15.09.2008/PrA

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Clamping unit

Long stroke jack

Cross connection

for stabilisation

Clamping cylinder

Guidance ofskidding way

1200

1500

9000

15075

30

166

Skidway light 1200



hebetec.comWeb:e-mail:Fax:Tel:

Technical Data

Hebetec Dokumentation

17.09.2008/PrA

Dimension b x h:

Weight:

1500 x 166 mm

2.2 to

1360

1600

9000

15075

30

166

Skidwy light 1360




Technical Data


17.09.2008/PrA

Dimension b x h:

Weight:

1600 x 166 mm

2.3 to

10000

Lifting points

1200

1464

437

228

Skidway heavy 1200




Technical Data


17.09.2008/PrA

Dimensions b x h:

Weight:

1464 x 437 mm

7.8 to

10000

Lifting points

1360

1624

437

228

Skidway heavy 1360




Technical data


17.09.2008/PrA

Dimensions b x h:

Weight:

1624 x 437 mm

8.3 to

APS System

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