Note: Descriptions are shown in the official language in which they were submitted.
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S P E C I F I C A T I O N
TITLE
"METHOD AND APPARATUS FOR EXTRACTING AND INSTALLING
HEAT EXCHANGER BUNDLES"
BACKGROUND OF THB INVENTION
The present invention relates to a lifting and
moving device. More particularly, the present invention
relates to an apparatus and a method for removing and
installing horizontally disposed heat exchanger bundles.
Heat exchangers are used in chemical processing
plants, such as petroleum refineries and distilling
facilities for absorbing heat created by high temperature
reactions. These heat exchangers utilize long metal
tubes arranged in a cylindrical bundle. The bundle is
generally heavy and may vary in diameter and length. For
example, often these bundles may average one to six feet
in diameter, twelve to twenty-four feet long and may have
a weight of two to forty tons. Further, the preceding
diameter, length, and weight may be exceeded.
An individual bundle is typically inserted into a
horizontally disposed shell and coupled to an inlet and
an outlet in the heat exchanger system which typically
has multiple bundles. To facilitate heat exchange, fluid
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enters into a bundle from its inlet in the heat exchanger
thereby flowing through the individual tubes of the
bundle and exits via the outlet. Heat exchanger fluid
flows through the shell, past the outside of the tubes
and the tube and shell fluids may travel through a series
of horizontally stacked bundles before being collected
for reuse or recycling. During use, the individual tubes
of the bundle are subject to fouling and corrosion and
also have a limited life. Thus, each bundle in the heat
exchanger requires regular maintenance of the individual
tubes of the bundle and eventual replacement thereof.
The physical size and weight of the bundles create
significant obstacles for maintenance and replacement.
For maintenance, the bundle must be removed from its
shell by a bundle extractor and often transported to
another on-site location or an off-site facility more
suited to the work required. A large heat exchanger may
have multiple bundles arranged in stacks, one above the
other. Thus, the lowest bundle may be contained in a
shell a few feet off of the ground while the highest may
be over thirty feet above the ground.
Another obstacle is the need to support and balance
the bundle as the bundle is pulled from its shell. This
problem is compounded by the fact that these bundles vary
in length. Thus, a method and apparatus are needed for
removing these heat exchanger bundles at a wide variety
of heights from ground level while keeping the bundles
securely supported as they are pulled from their shells.
A heat exchanger bundle is typically removed from
its shell by a pulling car or sled of the extractor that
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exerts a pulling force on a tube sheet which is fixed to
the ends of the tube bundle. Significant force is often
required to break the bundle free from its shell due to
normal product corrosion between the bundle and tube
sheet and the shell. A pulling mechanism such as a
winch, hydraulic jack, or screw drive and motors are
typically used with the extractor pulling sled to break
the bundle free. Once free, the bundle is positioned on
a sliding carriage mounted on a frame of the extractor
such that the bundle carriage is moved along the frame as
the bundle is pulled from its shell. Due to the weight
and length of the bundle, the carriage and frame may be
tilted to balance the bundle as the bundle is removed.
Different types of equipment have been used to
support the carriage and frame of the extractors in their
operative position for pulling of heat exchanger tubes
bundles . United States Patent Nos . 3 , 83 , 015 and 4 , 053 , 062
to Travis and U.S. Patent Nos. 4,869,638 and 5,032,054 to
Kraj icek et al . disclose an aerial supported carriage and
frame for being lifted by a crane and which may be moved
off site using the crane or a helicopter. Another
approach is mounting the frame to a telescoping column on
a truck bed as disclosed in U.S. Patent No. 4,575,305 to
Krajicek et al. and U.S. Patent No. 5,403,145 to Cradeur
et al. Another extractor disclosed in U.S. Patent No.
5,373,271 to Amuny uses four telescoping cylinders to
support and lift the frame. U.S. Patent No. 5,562,400 to
Travis and U. S. Patent No. 5, 564, 179 to Amuny disclose
extractors that utilize wheels and drive means to provide
a self-propelled bundle extractor and have outrigger
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lifting columns which raise the frame to the height of
the bundle shell.
Extractors which require the use of cranes to
position the frame at the shell of the heat exchanger
bundle are not practical for use in areas with limited
clearance between the heat exchanger unit and other
structures. Similarly, extractors mounted on truck beds
present the same space concerns. In these limited
clearance areas, there may not be adequate space to
position a crane or truck between the structures. Thus,
a mobile extractor that is self-propelled and has a self-
contained mechanism for raising and lowering its
extractor frame is usually preferred due to the limited
clearances between structures.
U.S. Patent Nos. 5,562,400 and 5,564,179 disclose
self-propelled extractors a support frame and carriage
that are mounted on wheels with hydraulic cylinders or
telescoping lifting columns. The extractor of the latter
patent utilizes the lifting columns to raise both the
support frame and carriage to the vertical position of
the heat exchanger shell; whereas, U.S. Patent No.
5,562,400 uses the lifting columns to raise only a
carriage frame having a pulling sled and skids. Due to
the extreme weight of the heat exchanger bundle, which
can exceed forty tons, the use of rubber wheels is not
practical because they cannot support the weight.
Therefore, steel wheels with polyurethane shells are
used.
One problem with self-propelled extractors of this
type is that the heat exchanger units are typically
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located outside on asphalt or gravel surfaces which may
become soft due to rain or sun exposure such that the
steel wheels often dig into the surface as the extractor
is moved across the surface or when turning. After the
bundle is pulled onto the extractor, the added weight
often embeds the wheels into the surface making it
impossible for the extractor to move under its own power.
As an alternative, a self-propelled extractor may provide
for lifting the extractor with a crane such as that
disclosed in U.S. Patent No. 5,564,179. Due to the
weight of the extractor and bundle, which may be over
sixty-five tons, a large crane is required. Under some
union rules, the operation of a large crane requires two
workers, an operator and an oiler. However, for the
operation of smaller cranes, only one worker is required,
the operator. To support two shifts of extractor
operations, the added oiler increases the labor costs
approximately $6,000 to $8,000 per shift per week.
Another problem with known extractors is that the
telescoping columns which lift the support frame and
carriage of the extractor to the height of the shell
become very unstable when the support frame is near or at
the top of its vertical travel due to the progressive
upwardly shifting of the extractor's center of gravity.
The four telescoping columns usually have to support the
entire weight of the support frame carriage and
eventually the bundle, e.g. see U.S. Patent No.
5,564,179. Furthermore, as the bundle is being pulled
onto the carriage, the added weight of the bundle to the
front of the extractor adjacent the shell shifts the
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center of mass of the extractor, rendering it unstable.
Likewise, as the bundle is being pulled from the shell
and onto the carriage, the changing position of its
center of mass may tilt the extractor frame such that one
of the front or the rear columns may support more weight
than the others, which may cause the extractor to tilt or
rock. Thus, added precautions must be taken to prevent
or compensate for the sudden shifts in weight to prevent
the extractor from overturning.
Accordingly, a method and apparatus are needed that
provide a heat exchanger bundle extractor apparatus that
remains stable when removing or installing heat exchanger
bundles at high levels above ground surface. Further, a
method and apparatus which can fit into tight spaces for
accessing bundles, while still having stability during a
pulling operation with the ability to transport a pulled
bundle to another location thereafter, is needed.
SiJN~ARY OF THE INVENTION
In accordance with the present invention, a
continuous track having a predetermined surface area and
main frame having a carriage frame with four vertical
hydraulic cylinders may be used and may achieve the
stability necessary to support and level a heat exchanger
bundle during removal from its shell at various vertical
heights and to move the extractor, with or without a
bundle, across gravel, asphalt and uneven surfaces.
Preferably, two continuous tracks having flat plates,
such as, for example, polystyrene plates passing around
multiple wheels attached to a mainframe may be used to
support and provide movement to the extractor. An
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engine, preferably an air cooled diesel engine, may be
used to rotate the tracks and may allow the extractor to
be driven to and from the in-use location of the heat
exchanger bundles. The tracks may provide a large
predetermined and substantially constant surface area to
spread the load of the extractor and the bundle on the
ground. Accordingly, the large constant surface area may
prevent the track from becoming embedded into the ground
as the track rolls and the track may overcome the
limitations of steel wheels. Further, the track may
allow the extractor to traverse uneven, soft, or rough
ground which may be difficult for steel-wheeled
extractors to traverse.
Preferably, the lower portions of four hydraulic
cylinders may be vertically mounted at the corners of a
rectangular main frame of the extractor. The base of
each cylinder may have a pad of at least seventy-five
inches for engaging the ground and may have a spherical
joint. When the extractor is stationary for removing a
bundle, each pad may be positioned using the knuckle
joint to match the grade of the ground to balance and
support the extractor which may increase stability in its
stationary position.
The upper portion of the hydraulic cylinders may be
attached to a carriage frame and a piston may be attached
via a Siamese cylinder mounted to the main frame. (The
term "siamese" is defined as the connection of two or
more pipes so as to permit discharge in a single stream.)
Actuating the piston may raise and lower the carriage
frame with respect to the main frame. Accordingly, each
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cylinder may be independently controlled to tilt and
level the carriage frame to compensate for a grade in the
surface and the changing center of gravity of the
extractor during removal of the bundle from its shell and
during the raising and lowering of the carriage frame.
Alternatively, the extractor may be raised or moved
using a crane or helicopter by removing the carriage
frame from the main frame at disconnects located at the
hydraulic cylinders and the main frame. Cylindrical
horizontal shafts may be provided at each corner of the
carriage frame for attaching slings to lift the carriage
frame and bundle. Disconnecting the carriage frame from
the main frame provides a lightweight, aerial extractor
by eliminating the main frame, track, drive motor, and/or
hydraulic cylinders.
The preferred configuration allows the main frame,
hydraulic cylinders, pads and/or tracks which provide a
large surface area on the ground, to remain on the ground
as the hydraulic cylinders raise the carriage frame to
the height of the bundle shell. Thus, the present
invention increases the surface area for supporting the
load of the extractor over previously available
extractors. Further, the stationary rectangular main
frame which remains near the ground when the carriage
frame is raised and the large surface area of the tracks
increase stability. Moreover, the tracks may overcome
the obstacles presented by steel wheels, thereby allowing
the self-propelled extractor to move over gravel,
asphalt, and/or soft and uneven surfaces without becoming
embedded into the surface.
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_ g _
To this end, in an embodiment of the present
invention, an apparatus is provided for removing a heat
exchanger bundle. The apparatus has a frame, a
propelling mechanism on the frame, a vertically shiftable
portion of the frame, and a track associated with the
propelling mechanism. A flat portion is in engagement
with a predetermined area of the ground.
In an embodiment, lifting members are provided
having feet wherein the plurality of lifting members
raise the frame.
In an embodiment, power cylinders having feet are
provided wherein the power cylinders raise the frame.
In an embodiment, a pulling member is associated
with the frame wherein the pulling member attaches to the
heat exchanger bundle.
In an embodiment, the track is an articulated track
having segmented portions.
In an embodiment, the flat portion of the track
extends lengthwise.
In an embodiment, a base frame and an upper frame
are provided wherein the base frame is larger than the
upper frame and the base frame remains fixed as the upper
frame vertically shifts.
In an embodiment, a base frame portion and a smaller
frame portion of the frame is provided wherein the
smaller frame portion is detachable from the frame such
that the heat exchanger bundle and the smaller frame
portion may be lifted from the base frame portion.
In an embodiment, a connection is provided between
the base frame portion and the smaller frame portion.
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In an embodiment, the frame has a length
substantially aligned with that of the heat exchanger
bundle.
In an embodiment, a track is provided on either side
5 of the frame.
In another embodiment of the present invention, a
method is provided for supporting a load to be removed
from an in-use location. The method comprises the steps
of: providing an apparatus for removing the heavy load;
10 providing a propelling mechanism on the apparatus;
providing a track associated with the propelling
mechanism where the track has a flat portion in
engagement with a predetermined area of the ground;
aligning a vertically shiftable frame portion of the
apparatus with the load; removing the load from the m-
use location; shifting the load onto the frame portion;
spreading the load over a predetermined area on a support
surface adjacent to the in-use location; and stabilizing
the apparatus as the load is shifted.
In an embodiment, spreading of the load is provided
by at least one substantially flat load spreading surface
portion in engagement with the support surface over the
predetermined area on the support surface.
In an embodiment, integrating the propelling
mechanism is provided with the apparatus such that the
apparatus is self-propelled.
In an embodiment, maneuvering the apparatus onto the
support surface is provided.
In an embodiment, rolling a continuous propelling
surface of the propelling mechanism of the apparatus is
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provided.
In an embodiment, a method is further provided for
including the flat load spreading surface portion along
the support surface.
In an embodiment, maintaining substantially the same
predetermined area of engagement between the load
spreading surface portion of the propelling surface and
support surface to propel the apparatus to a remote
location from the in-use location is provided.
In an embodiment, sizing the flat load spreading
surface portion so that the predetermined area of
engagement with the support surface attempts to avoid
deforming the support surface with the load carried on
the apparatus is provided.
In an embodiment, propelling the apparatus carrying
the load to a remote location from the in-use location
while minimizing deformation of the support surface
during transport is provided.
In an embodiment, a first frame portion and a second
frame portion of the apparatus is provided wherein the
first frame portion is aligned with the load to be
removed and wherein the first frame portion has
connections associated with the second frame portion.
In an embodiment, connecting a lifting device to the
connections on the first frame portion is provided.
In an embodiment, disconnecting the first frame
portion from the second frame portion is provided.
In an embodiment, lifting the first frame portion
and the load is provided.
In an embodiment, the load is one of a plurality of
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heat exchanger bundles that are at various levels of
elevation relative to the support surface.
In an embodiment, pulling the load and progressively
shifting the load onto the frame portion is provided.
In another embodiment of the present invention, a
method is provided for supporting and moving a heat
exchanger bundle over a transport surface. The method
comprises the steps of: providing a mobile extractor
apparatus having a carriage frame and a main frame;
providing a propelling mechanism for moving the apparatus
along the transport surface; raising the carriage frame
relative to the main frame to the height of the heat
exchanger bundle wherein the main frame remains near the
transport surface; pulling the heat exchanger bundle onto
the carriage frame; lowering the carriage frame and the
heat exchanger bundle toward the transport surface;
rotating an engaging surface of the propelling mechanism
in contact with the transport surface; transporting the
heat exchanger bundle; and supporting the heat exchanger
bundle with the apparatus, the carriage frame, and the
main frame while maintaining a surface area of engagement
between the engaging surface and the transport surface.
In another embodiment of the present invention, the
method actuates hydraulic cylinders of the mobile
extractor apparatus to raise the carriage frame.
In another embodiment of the present invention, a
method is provided for supporting and moving a heat
exchanger bundle. The method comprises the steps of:
providing a mobile extractor apparatus having a carriage
frame, a main frame, and a propelling mechanism; moving
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the mobile extractor apparatus along the transport
surface with the propelling mechanism; raising the
carriage frame relative to the main frame; lifting the
carriage frame from the main frame to the height of the
heat exchanger bundle while the main frame remains near
the transport surface; pulling the heat exchanger bundle
onto the carriage frame; lowering the carriage frame and
the heat exchanger bundle toward the transport surface;
connecting a lifting device to the carriage frame;
disconnecting the carriage frame from the main frame; and
lifting the carriage frame and the heavy heat exchanger
bundle supported by the carriage frame while the main
frame and propelling mechanism remain in contact with the
engaging surface.
In an embodiment, the method actuates hydraulic
cylinders of the mobile extractor apparatus to life the
carriage frame.
In another embodiment of the present invention, an
apparatus is provided for removing a heat exchanger
bundle. The apparatus has a frame, a propelling mechanism
on the frame, a vertically shiftable portion of the
frame, and power cylinders wherein the power cylinders
raise the vertically shiftable portion of the frame.
In an embodiment, a plurality of lifting members are
provided wherein the plurality of lifting members raise
the frame.
In an embodiment, feet are associated with the power
cylinders.
In an embodiment, a pulling member is associated
with the frame wherein the pulling member attaches to the
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heat exchanger bundle.
In an embodiment, a base frame portion of the frame
and a smaller frame portion of the frame are provided
wherein the smaller frame portion is detachable from the
frame such that the heat exchanger bundle and the smaller
frame portion may be lifted from the base frame portion.
In an embodiment, a connection is provided between
the base frame portion and the smaller frame portion.
In an embodiment, the frame has a length
substantially aligned with that of the heat exchanger
bundle.
In an embodiment, a track is provided on each side
of the frame.
It is, therefore, an advantage of the present
invention to provide an apparatus and a method for
removing and installing horizontally disposed heat
exchanger bundles.
Another advantage of the present invention is to
provide an apparatus and a method having a track with
plates associated with the apparatus such that the track
may provide surface area to spread the load of the
apparatus and heat exchanger bundles and attempt to
prevent the track from becoming embedded into the ground.
Another advantage of the present invention is to
provide an apparatus and a method having a track
associated with the apparatus such that the apparatus may
traverse uneven, soft, or rough ground.
Moreover, an advantage of the present invention is
to provide an apparatus and a method having four
hydraulic cylinders with pads vertically mounted at the
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corners of the apparatus such that the pads may be
positioned to match the grade of the ground.
Yet another advantage of the present invention is
provide an apparatus and a method having pistons attached
to a carriage frame such that the piston may be actuated
to raise and lower the carriage frame.
Another advantage of the present invention is to
provide an apparatus and a method having cylinders that
may be independently controlled to tilt and level the
carriage frame to compensate for a grade in the surface
and to compensate for the changing center of gravity of
the apparatus.
Still further, an advantage of the present invention
is to provide an apparatus and a method allowing the
extractor to be raised or moved by a crane or helicopter.
Another advantage of the present invention is to
provide an apparatus and a method having a heat exchanger
bundle extractor apparatus that remains stable when
removing or installing heat exchanger bundles at high
levels above ground surface.
Another advantage of the present invention is to
provide an apparatus and a method having a heat exchanger
bundle extractor apparatus which can fit into tight
spaces for accessing bundles.
Yet, another advantage of the present invention is
to provide an apparatus and a method having a heat
exchanger bundle apparatus that will have stability
during a pulling operation.
Still further, another advantage of the present
invention is to provide an apparatus and a method having
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a heat exchanger bundle apparatus that will have the
ability to transport a pulled bundle to another location.
Additional features and advantages of the present
invention are described in, and will be apparent from,
the detailed description of the presently preferred
embodiments and from the drawing.
BRIEF DESCRIPTION OF THE DRAWING
Figure 1 illustrates a perspective view of an
embodiment of the apparatus for extracting and installing
heat exchanger bundles.
Figure 2 illustrates a perspective view of another
embodiment of the apparatus for extracting and installing
heat exchanger bundles.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED
EMBODIMENTS
As shown in drawings for purposes of illustration,
the invention is embodied in a heat exchanger tube bundle
extractor apparatus 10. As shown in Figure 1, the
extractor apparatus 10 is embodied in a rectangular main
frame 12 having a long pair of parallel members 14 and
shorter parallel cross members 16. At each intersection
of the long member 14 and the cross members 16 is a base
cylinder 18 which may be attached thereto. Each base
cylinder 18 may have a support pad 20 having
approximately seventy-five square inches of surface area
for engaging the ground. The support pad 20 may be
attached to eight inner cylinders 22 which may be
received by the base cylinder 18 such that the support
pad may be lowered to the ground.
One form of the extractor apparatus 10 may utilize
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a spherical joint (not shown) so that the angle in which
support pad 20 may engage the ground may be adjusted to
accommodate the grade of the ground at a location of each
of the support pads 20. Thus, each of the support pads
20 and the inner cylinder 22 may have a spherical joint
so that each of the support pads 20 may be independently
adjusted to increase stability of the extractor apparatus
when in a stationary position.
The base cylinder 18 may also receive a piston 24
10 from a hydraulic cylinder 26. The upper portion of the
hydraulic cylinder 26 may be attached to a carriage frame
28. The carriage frame 28 may also be rectangular;
however, it is smaller than the main frame 12. The
carriage frame 28 may have two shorter cross members 30
at each end which may be detachably mounted to the
hydraulic cylinders 26 by disconnects (not shown). When
the piston 24 of the hydraulic cylinder 26 is actuated,
the carriage frame 28 may be raised above main frame 12.
Each of the hydraulic cylinders 26 may be independently
actuated Lo raise and tilt the carriage frame 28 to
compensate for any grade in the support surface and the
changing center of gravity due to the weight of the heat
exchanger bundle (not shown) as the heat exchanger bundle
is pulled onto the carriage frame 28 as described herein.
Independent actuation of the hydraulic cylinders 26 may
eliminate the need for leveling devices on the carriage
frame 28, thereby reducing weight and minimizing the
number of moving parts requiring maintenance.
When the hydraulic cylinders 26 are actuated, the
pistons 24 may be driven downward which in turn may raise
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the carriage frame 28 above main frame 12 which may
remain stationary. With the main frame 12 position close
to the ground, the extractor apparatus 10 may maintain
stable as the carriage frame 28 rises . In its lowest
position above the main frame 12, the carriage frame 28
may be used to remove heat exchanger bundles as low as
forty-three inches off of the ground. When the hydraulic
cylinders 26 are actuated to the their full length of the
pistons 24, the carriage frame 28 may be approximately
fifteen feet above the ground.
Mounted to each parallel long member 14 of the main
frame 12 may be tracks 32 and 34. The tracks 32 and 34
have plates 36 which may be made from polystyrene and may
have a large smooth surface for engaging the ground. The
smooth surface of the plates 36 as compared to those
having ridges or tread, may maximize the surface area of
the plate for supporting the weight of the extractor
apparatus 10 and heat exchanger bundle (not shown).
Alternatively, the smooth surface of the plates 36
may be replaced with a surface having tread for use on
slippery terrain such as mud or loose gravel. The plates
36 may be approximately fourteen inches in width and may
be positioned one after the other with a space between
each of the plates 36. The plates 36 may be joined by
fastening devices to compose the continuous eight foot
tracks 32 and 34.
The tracks 32 and 34 may be supported by a frame
(not shown) with a drive member (not shown) to rotate the
tracks 32 and 34 about the frame which, in turn, provides
translation of the extractor apparatus 10. The tracks 32
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and 34 and frame configuration may provide a
predetermined, large area of approximately sixteen square
feet in contact with the ground at all times. An engine
(not shown) may provide the power to rotate the tracks 32
and 34 about the f rame . As known in the art of track
driven equipment, the tracks 32 and 34 are independently
driven such that the extractor apparatus 10 may be turned
by holding one track stationary while rotating the
opposite track, which causes the extractor apparatus 10
to rotate in the direction of the track being held.
On the carriage frame 28 may be a series of sliding
cross members 38 which may allow for adjusting the width
of carriage frame 28 to accommodate the heat extractor
bundles of varying width. The width of the carriage frame
28 may be adjusted for a particular diameter of the heat
extractor bundle before or after transporting the heat
exchanger bundle and the extractor apparatus 10 to the
shell.
The extractor apparatus 10 may be transported to the
work location by an engine that may provide power to the
tracks 32 and 34. The support pads 20 may be lowered to
the ground by extending the inner cylinder 22 downwards
from the base cylinder 18 such that the support pad 20 is
firmly planted on the ground. The support pads 20 may
have a diameter of approximately seventy-five square
inches and may be twice as great as that of the inner
cylinder 22.
Each of the base cylinders 18 may have independent
movement to accommodate uneven surfaces. After the
support pads 20 are firmly planted, the hydraulic
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cylinders 26 may be used to raise the carriage frame 28
to the height of the shell where the heat exchanger
bundle is located. The carriage frame 28 may rise as the
piston 24 of each of the hydraulic cylinders 26 is
actuated. The system of the hydraulic cylinders 26 and
the pistons 24 may allow the main frame 12 to remain low
to the ground to provide stability and a low center of
gravity. Furthermore, each of the hydraulic cylinders 26
may be independently actuated to compensate for uneven
surfaces by leveling the carriage frame 28.
After the carriage frame 28 is at the proper height
location at the shell, the width of the carriage frame 28
may be adjusted using the sliding cross members 38 to
accommodate the diameter of the heat exchanger bundle.
A sled (not shown) that is mounted to carriage frame 28
may be used to attach the heat exchanger bundle to the
extractor apparatus 10. A chain or wire cable may be
used to secure the heat exchanger to the sled (not
shown). The sled may also utilize a small motor (not
shown) on the main frame 12 to move the sled that in turn
may pull the attached heat exchanger bundle on to the
carriage frame 28. As the weight of the heat exchanger
bundle shifts on the carriage frame 28, the hydraulic
cylinders 26 may be adjusted to keep the heat exchanger
bundle level or parallel with the ground and to keep the
apparatus stable and prevent tipping of the apparatus.
When the heat exchanger bundle is completely removed
from the shell, the extractor apparatus 10 may be used to
transport the heat exchanger bundle to a remote location
for further inspection and maintenance work. The tracks
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32 and 34 may be used to move the extractor apparatus 10
with the heat exchanger tube bundle carried on the
carriage frame 28. This method of movement may be used
to transport the heat exchanger tube bundle to the remote
location, or in the alternative, the carriage frame 28
may be removed from the main frame 12 at the base
cylinders 18 or alternatively at the hydraulic cylinders
26. Cables or chains (not shown) may be attached to
hooks 40 to provide a means for lifting the carriage
frame 28 and the heat exchanger bundle from the main
frame 12 and thereby leaving the tracks 32 and 34 on the
ground along with the engine. This provides a lighter
weight system that may be aerially removed using a crane
or helicopter. Furthermore, the carriage frame 28 and
heat exchanger bundle may be aerially removed and loaded
on a flatbed truck or railcar for transportation offsite.
Referring now to Figure 2, in another embodiment of
the present invention, another extractor apparatus 50 is
illustrated. As shown in Figure 2, the extractor
apparatus 50 is embodied in a rectangular main frame 52
having a long pair of parallel members 54 and shorter
parallel cross members 56. At each intersection of the
long member 54 and the cross members 56 is a siamese
cylinder 58 which may be attached thereto. Each siamese
cylinder 58 may have a support pad 60 having
approximately seventy-five square inches of surface area
for engaging the ground. The support pad 60 may be
attached to eight inner cylinders (not shown) which may
be received by the Siamese cylinder 58 such that the
support pad 60 may be lowered to the ground.
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One form of the extractor apparatus 50 may utilize
a spherical joint (not shown) so that the angle in which
the support pad 60 may engage the ground may be adjusted
to accommodate the grade of the ground at a location of
each of the support pads 60. Thus, each of the support
pads 60 and the inner cylinders (not shown) may have a
spherical joint so that each of the support pads 60 may
be independently adjusted to increase stability of the
extractor apparatus 50 when in a stationary position.
The siamese cylinder 58 may also receive a piston 64
from a hydraulic cylinder 66. The upper portion of the
hydraulic cylinder 66 may be attached to a carriage frame
68. The carriage frame 68 may also be rectangular. The
carriage frame 68 may have two shorter cross members 70
at each end which may be detachably mounted to the
hydraulic cylinders 66 by disconnects (not shown). When
the piston 64 of the hydraulic cylinder 66 is actuated,
the carriage frame 68 may be raised above main frame 52.
Each of the hydraulic cylinders 66 may be independently
actuated to raise and/or tilt the carriage frame 68 to
compensate for any grade in the support surface and the
changing center of gravity. The center of gravity may
change due to the weight of the heat exchanger bundle
(not shown) as the heat exchanger bundle is pulled onto
the carriage frame 68 as described herein. Independent
actuation of the hydraulic cylinders 66 may eliminate the
need for leveling devices on the carriage frame 68,
thereby reducing weight and/or minimizing the number of
moving parts requiring maintenance.
When the hydraulic cylinders 66 are actuated, the
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pistons 64 may be driven downward which in turn may raise
the carriage frame 68 above the main frame 52 which may
remain stationary. With the position of the main frame
52 close to the ground, the extractor apparatus 50 may
maintain stable as the carriage frame 68 rises. In the
range from the lowest position and the highest position
of the carriage frame 68 above the main frame 52, the
carriage frame 68 may be used to remove heat exchanger
bundles. The carriage frame 68 may be positioned as low
as forty-three inches off of the ground. When the
hydraulic cylinders 66 are actuated to the their full
length of the pistons 64, the carriage frame 68 may be
positioned approximately fifteen feet above the ground.
Mounted to each parallel long member 54 of the main
frame 52 may be tracks 72 and 74. The tracks 72 and 74
have plates 76 which may be made from polystyrene and may
have a large smooth surface for engaging the ground. The
smooth surface of the plates 76 as compared to those
having ridges or tread, may maximize the surface area of
the plate for supporting the weight of the extractor
apparatus 50 and heat exchanger bundle (not shown).
Alternatively, the smooth surface of the plates 76
may be replaced with a surface having tread for use on
slippery terrain, such as mud or loose gravel. The plates
76 may be any length, however, preferably, the plates are
approximately fourteen inches in width and may be
positioned one after the other with a space between each
of the plates 76. The plates 76 may be joined by
fastening devices (not shown) to compose the continuous
eight foot tracks 72 and 74.
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The tracks 72 and 74 may be supported by a frame 62
with a drive member (not shown) to rotate the tracks 72
and 74 about the frame which, in turn, provides
translation of the extractor apparatus 50. The tracks 72
and 74 and the configuration of the frame 62 may provide
a predetermined, large area in contact with the ground at
all times. Preferably, predetermined large area of the
track may be approximately sixteen square feet. An
engine 78 may provide the power to rotate the tracks 72
and 74 about the frame 62. As known in the art of track
driven equipment, the tracks 72 and 74 may be
independently driven such that the extractor apparatus 50
may be turned by holding one track stationary while
rotating the opposite track, which causes the extractor
apparatus 50 to rotate in the direction of the track
being held.
On the carriage frame 68 may be a series of sliding
cross members (not shown) which may allow for adjusting
the width of carriage frame 68 to accommodate the heat
extractor bundles of varying width. The width of the
carriage frame 68 may be adjusted for a particular
diameter of the heat extractor bundle before or after
transporting the heat exchanger bundle and the extractor
apparatus 50 to the shell.
The extractor apparatus 50 is transported to the
work location by the engine 78 that may provide power to
the tracks 72 and 74. After the extractor apparatus 50
is at the proper location, the support pads 60 may be
lowered to the ground by extending the inner cylinders
downwards from the siamese cylinder 58 such that the
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support pads 60 may be firmly planted on the ground. The
support pads 60 may have a diameter of approximately
seventy-five square inches and may be twice as great as
that of the inner cylinders.
Each Siamese cylinder 58 may have independent
movement to accommodate uneven surfaces. After the
support pads 60 are firmly planted, the hydraulic
cylinders 66 may be used to raise the carriage frame 68
to the height of the shell where the heat exchanger
bundle is located. The carriage frame 68 may rise as the
piston 64 of each of the hydraulic cylinders 66 is
actuated. The system of the hydraulic cylinders 66 and
the pistons 64 may allow the main frame 52 to remain low
to the ground to provide stability and a low center of
gravity. Furthermore, each of the hydraulic cylinders 66
may be independently actuated to compensate for uneven
surfaces by leveling the carriage frame 68.
After the carriage frame 68 is at the proper height
location at the shell, the width of the carriage frame 68
may be adjusted, and a grabber 80 that may be mounted to
carriage frame 68 may be used to attach the heat
exchanger bundle (not shown) to the extractor apparatus
50. A chain or wire cable (not shown) may be used to
secure the heat exchanger to the grabber 80 and to
cylinders 86. A grabber cylinder 88 on each of beams 90
of the carriage frame 68 may move the grabber 80 a
distance out relative to the carriage frame 68.
The carriage frame 68 may have a plate 84. A motor
82 on the carriage frame 68 may rotate a pump (not shown)
that may power a hydraulic motor (not shown) which may
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power a hydraulic brake (not shown) that may power an
actuator (not shown) that, in turn, may rotate a screw
92. The screw 92 may be attached at to the plate 84 at
one end and to a trough 94 at another end. The trough 94
holds a sled 96. The sled 96 may be moved forward or
back by the screw 92. The sled 96 moves within the
trough 94. The trough 94 may be housed within the beams
90. Beam cylinders 98 may move the beams 90 forward and
back relative to the carriage frame 68. Thus, the
carriage frame 68 preferably has three sections that may
move relative to the carriage frame: the grabber 80, the
beams 90 and the sled 96. The grabber 80 and the beams
90 may extend the length of the carriage frame 68.
After the carriage frame 68 is in place, the chain
or wire cable may be used to secure the heat exchanger to
the grabber 80 and to cylinders 86. The grabber 80 may
then be pulled back by the grabber cylinder 88 on each of
the beams 90. The grabber 80 and the cylinders 86 may
break the heat exchanger bundles out of their shell and
pull the heat exchanger bundles onto the sled 96 of the
carriage frame 68. The sled 96 and the beams 90 may
retract to pull the heat exchanger bundle fully onto the
carriage frame 68.
As the weight of the heat exchanger bundle shifts on
the carriage frame 68, the hydraulic cylinders 66 may be
adjusted to keep the heat exchanger bundle level or
parallel with the ground and to keep the extractor
apparatus 50 stable and prevent tipping of the extractor
apparatus 50.
When the heat exchanger bundle is completely removed
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from the shell, the extractor apparatus 50 may be used to
transport the heat exchanger bundle to a remote location
for further inspection and maintenance work. The tracks
72 and 74 may be used to move the extractor apparatus 50
with the heat exchanger tube bundle carried on the
carriage frame 68. This method of movement may be used
to transport the heat exchanger bundle to the remote
location, or in the alternative, the carriage frame 68
may be removed from the main frame 52 at the Siamese
cylinders 58 or alternatively at the hydraulic cylinders
66.
Cables or chains (not shown) may be attached the
carriage frame 68 to provide a means for lifting the
carriage frame 68 and the heat exchanger bundle from the
main frame 52 and thereby leaving the tracks 72 and 74 on
the ground along with the engine 78. Removing the
carriage frame 68 from the main frame 52 provides a
lighter weight system that may be aerially removed using
a crane or helicopter. Furthermore, the carriage frame
68 and the heat exchanger bundle may be aerially removed
and loaded on a flatbed truck or railcar for
transportation offsite.
Alternatively, the carriage frame 68 may be removed
from the mainframe 52 and aerially transported without
the mainframe 52 and engine 78 to the work location
before extracting the heat exchanger bundles. After the
carriage frame 68 is transported to the work location and
is at the proper height location at the shell, the sled
80 that is mounted to the carriage frame 68 may be used
to attach the heat exchanger bundle to the carriage frame
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68. The small motor 82 may move the sled 80 that, in
turn, may pull the attached heat exchanger bundle onto
the carriage frame 68.
It should be understood that various changes and
modifications to the presently preferred embodiments
described herein will be apparent to those skilled in the
art. Such changes and modifications may be made without
departing from the spirit and scope of the present
invention and without diminishing its attendant
advantages. It is, therefore, intended that such changes
and modifications be covered by the appended claims.
