CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority from Canadian Patent Application No. [to be completed], filed Feb. 2, 2017, entitled “Founding System” having Stephen Wilson as inventor; the entire contents of which are incorporated herein by reference.
FIELD The present disclosure relates to founding systems used in reconditioning systems such as industrial coking systems.
BACKGROUND Scaffolding is often used in construction, maintenance, and general access to buildings and other industrial structures. The layout of the scaffolding is typically designed based the structure being repaired. Scaffolding is typically made of straight and flat components. Accordingly, scaffolding components are well suited for a typically shaped square or rectangular structure. However, fitting scaffolding components to a round structure is challenging.
Accordingly, new structures to provide access with round structures and associated installation techniques are desirable.
SUMMARY In some aspects, there is a coker frame, having horizontal, generally polyhedral layers, with each vertex of each layer supported at the coker surface, three ladders extending at one apex, along the coker wall, with one ladder at the vertex and two on either side at equal spacing; and a bottom support platform, having vertical supports extending upwardly to the first polyhedral layer.
In some aspects, there is a founding system for mounting in the interior of a structure having rounded interior walls. The founding system includes a generally horizontal support layer having n support beams, n connection elements, each of said n connection element comprising a flat edge tangential to the rounded interior walls of the structure, a foot extending from the flat edge to abut the interior of said rounded interior walls, and two mounts for mounting two of said n support beams at an angle of about (n−2)*180/n degrees.
In some aspects, there the founding system also includes n ladders, each interconnected with one of the n connection elements, to extend with rungs parallel to the flat edge of said one of the n connection elements, along the rounded interior walls.
BRIEF DESCRIPTION OF THE DRAWINGS In the figures which illustrate example embodiments,
FIG. 1 shows a side plan view of a coker;
FIG. 2A shows a perspective view of a connection element;
FIG. 2B shows a perspective view of a support beam;
FIG. 2C shows a side plan view of a connection element;
FIG. 2D-2E show a perspective view of a frame assembly in the closed position;
FIG. 2F shows a perspective view of the support beam installed in the connection element;
FIG. 2G-2H show a perspective view of a frame assembly in the open position;
FIG. 2I shows a top plan view of the connection element;
FIG. 2J shows a perspective view of an example frame assembly in the open position;
FIGS. 3A-3B show a perspective view of a first horizontal support layer;
FIGS. 4A-4D show in perspective view a frame stabilizer jack;
FIG. 5 shows a perspective view of a second horizontal support layer;
FIGS. 6A-6D show in perspective view a primary ladder connector;
FIG. 7A shows in perspective view a secondary ladder connector;
FIG. 7B shows in top plan view installed horizontal support layers and ladders;
FIGS. 8A-8B show in perspective view ladder brace tubes;
FIGS. 9A-9B show in perspective view a ladder support jack;
FIGS. 10A-10B show in perspective view an installed ladder support jack;
FIG. 11A shows in perspective view a chair for use with a ladder;
FIGS. 11B-11D show top and side plan views of a chair;
FIGS. 11E-11F show the chair installed onto a ladder;
FIGS. 12A-12B shows in perspective view beams installed on a chair;
FIGS. 13A-13C shows in perspective view and plan views installed horizontal support layers, beams, chairs, and ladders; and
FIGS. 14A-14E show forces acting against coker walls.
DETAILED DESCRIPTION Various types of cokers, such as coker 100 shown in FIG. 1, are used in different applications including steam boilers for generating electrical power and oil refinery. Typically cokers include upper vertical walls 106 and lower converging coker walls 102, with an open bottom portion 104, as shown in FIG. 1 (in other words, cokers are have at least a partially frustoconical interior). Coker interior walls 102 and 106 are generally rounded.
Cokers, from time to time, require access and/or maintenance and such access typically requires the erection of a founding system within the interior walls 106, 102 of coker 100 which can be several building stories high. Access to these cokers can be limited and there can be a very significant cost associated with such a coker being down for maintenance. For many applications repairs must be completed quickly to return the unit to normal operation. To accomplish such repairs to cokers generally, founding systems may be used.
An example founding system may be installed within coker 100, as illustrated in FIGS. 13A-13C. As seen in in FIG. 13A, scaffolding 300 is typically used during the installation process of various components of the founding system. Scaffolding 300 provides a bottom support platform and has vertical supports extending upwardly to first polyhedral layer of coker 100. Scaffolding 300 may optionally be removed once installation of the founding system is complete.
The founding system of FIGS. 13A-13C has at least one horizontal support layer 502, but as shown includes a further, optional, horizontal support layer 500 mounted below horizontal support layer 502. As will become apparent, horizontal support layer 500, and horizontal support layer 502 are generally polygonal in shape, In the depicted embodiment, horizontal support layers 500 and 502, are generally quadrilateral (e.g. square).
Once the founding system is mounted inside the interior walls of coker 100, the founding system is typically used to support a further scaffolding and other loads (as shown in FIG. 13C). In some embodiments, additional horizontal support layers may be included to support greater loads, as additional horizontal support layers allow for the loads onto the founding system to be split. Similarly, if the founding system is needed for a smaller load, fewer horizontal support layers will be included in the system.
Each horizontal support later 500, 502 includes n support beams 202 and n connection elements 204, forming an n sided polygon. As shown in FIG. 2A, each of the n connection elements includes a flat edge 225 tangential to the interior walls 102 of the rounded coker 100, a foot 225 extending from the flat edge 225 to abut the interior of the rounded interior walls 102, and two mounts 230 for mounting two of the n support beams at an angle of about (n−2)*180/n degrees, relative to each other.
Connection elements 204 of each of first level horizontal support layer 502 and second level horizontal support layer 500 are in contact with interior coker walls 102, and provide support to each of horizontal support layer 502, 500. Primary and secondary ladders 620, 720 are mounted to second level horizontal support layer 500. Secondary ladders 720 are further supported by ladder support jacks 900, having feet 902 resting against cocker walls 102 (FIG. 10A).
At each apex of second level horizontal support layer 500, three ladders extend along coker wall 102 with one primary ladder 620 at the vertex and two secondary ladders 720 on either side at equal spacing from primary ladder 620. Upper and lower brace tubes 802, 804 connect two secondary ladders 720 horizontally.
Each of primary and secondary ladders 620, 720 has one or more chairs 1100 installed thereto for receiving loads. Beams 1200 may rest on at least some of the available chairs 1100 (as shown, beams 1200 rest on chairs 1100 installed to primary ladders 620 mounted at the apex points of second level horizontal support layer 500). Beams 1200 have beam plates 1202 installed thereto for receiving loads (FIG. 12A).
As shown, remaining chairs 1100 are available to receive further loads (as shown, secondary ladders 720 have chairs 1100 mounted at the top thereof and available to receive further loads, for example, additional scaffolding).
Further, as shown in the example embodiment of FIG. 13C, first level horizontal support layer 502 may be at a substantial height (e.g. approximately 72 inches), and second horizontal support layer 500 may be above horizontal support layer 502 (e.g. at a height of approximately 101 inches), and beams 1200 may be further thereabove,—e.g. at a height of 214 inches. Beams 1200 may be proximate to the top edge of converging walls 102 and are proximate to vertical walls of coker 100. However, it should be noted that other heights are contemplated.
Having provided an overview of the founding system, specific a discussion of various components of the founding system follows.
Shown in FIGS. 2B and 2C is a support beam 202 having two openings on each side there to receive bolts for mounting to a connection element 204. In one example, beams 202 are elongate and made of aluminum. In some embodiments, four beams 202 (i.e. n=4) of equal length may be used in each of horizontal support layers 500, 502. However, a different number (e.g. n=3, 4, 5, 6, 8, etc.) of support beams may be used. An example embodiment with eight beams 202 and eight connection elements 204 is shown in FIG. 2J.
Connection element 204 is shown in perspective view in FIG. 2A and in top plan view in FIG. 21. Each connection element 204 has two mounts 230, each mount 230 suitable for receiving and mounting one support beam 202. To secure beams 202 to connection elements 204, each mount of each connection element 204 has three openings 206, 208, 210 on each side thereof to receive bolts.
Mounts 230 mount support beams 202 at an angle of about (n−2)*180/n degrees relative to one another, where n is the number of support beams 202 used in the horizontal support layer. For example, if four support beams are used, then each is mounted at 90 degrees. Accordingly, as shown in FIG. 21, each mount 230 has edges tapered at an angle equal to (n−2)*180/n+90 degrees, and interior vertical walls extended from the tapered edges. The interior vertical walls of each mount limit the horizontal movement of support beams 202 mounted to connection element 204.
Further as shown in FIG. 3A, each connection element 204 has a flat edge 225 which, when installed in coker 100, is generally tangential to the interior walls 102 of coker 100. Extending from flat edge 225 is foot 222 having a flat surface configured to abut the interior coker walls 102. Foot 222 is pivotally mounted on cylindrical frame pin 404 (FIG. 2D), which allows foot 222 to pivot vertically such that, when installed, foot 222 abuts the interior coker walls 102 at an angle equal to the pitch angle of the interior walls 102 relative to the horizontal. This shifts the weight of the founding system, including horizontal support layer 500, 502, and any loaded supported on the founding system, to walls 102 of coker 100. By shifting the weight of the founding system and of the loads to walls 102, larger and heavier loads can be supported by the founding system using fewer and lighter components. Further, because fewer and lighter components are used, installation may be effected in a shorter time frame at a lower cost.
In one embodiment, connection element 204 is made of aluminum or other lightweight and high strength material. In one embodiment, foot 222 is made of a steel plate.
As shown in FIG. 2D and 2E, mounts 230 of connection element 204 receive and secure first and second support beams 202 in a substantially fixed vertical position. Further, Lock pins 216 pass through a first side of connection element 204, first and second support beams 202 and to the other side of connection element 204; thereby rotatably securing first and second beams 202 to connection element 204. Each Lock pin 216 thus provides a pivot point at which first and second support beams 202 may rotate.
As shown in FIGS. 2F-2G, support beams 202 may be locked in either an open position or closed position using a lock pin 220. When in the closed position, first and second support beams 202 are substantially parallel to one another. The closed position is suitable for storing, transporting, and installing the frame assembly. When in the open position, first and second support beams 202 are substantially perpendicular to one another (when four beams are used). Support beams 202 are in the open position when used in horizontal support layers 502, 500.
As shown in FIG. 2H, two frame assemblies 200a, 200b are required to complete a full square frame for use as a horizontal support layer. To connect the first and second frame assemblies 200, one beam 202 from each frame assembly 200 is released from connection element 204 and connected to a connection element 204 of the mating frame assembly; thereby forming a full square frame, as shown in FIG. 2H.
As shown four connection elements 204 and four support beams are used to create a single horizontal support layer. In alternative embodiments (not shown), the number of connection elements and support beams may vary. For each support beam to be used, at least one connection element with two mounts is used. Accordingly, if n support beams are used, n connection elements will be used. Further, each connection element includes a mount configured to mount two of the n support beams at an angle of about (n−2)*180/n degrees. When n=4, as shown in FIG. 2H, the angle between beams 202 is 90 degrees.
As will be appreciated, for the proper length of beams 202, each horizontal support layer takes the general form of a regular n-sided polygon, that is circumscribed by the interior wall of coker 100. As will become apparent, multiple horizontal layers may be formed at different heights within bottom portion 104 of coker 100, with the length of beams 202 chosen based on the interior radius of the bottom portion 104 at the desired position of the horizontal layer to be defined by those beams 202.
Shown in FIGS. 3A and 3B is coker 100 with scaffolding 300 rising through open bottom portion 104 of coker 100. Scaffolding 300 provides a bottom support platform during installation of founding system, and has vertical supports extending upwardly to first polyongal layer.
In FIG. 3A, a single frame assembly 200a, in an open position, is resting on scaffolding 300. Frame assembly 200a may be raised through the open bottom portion in the closed position then opened to the open position once it is resting on the top of scaffolding 300 inside coker 100.
A second frame assembly 200b is required to complete a full square frame for use as a horizontal support layer. Accordingly, as shown in FIG. 3B, a second frame assembly 200b may be raised through the open bottom portion of coker 100 and then connected with first frame assembly 200a to create horizontal support layer 500. Once horizontal support layer 500 is assembled, it may be lowered until the feet 222 of connection elements 204 contact the abut coker walls 102; thereby shifting the load of horizontal support layer 500 from scaffolding 300 to interior coker walls 102.
Preferably, horizontal support layer 500 is lowered in small increments to ensure that the frame is level. Further, in some embodiments, interior coker wall 102 may be reinforced with wood packing before lowering the full square frame.
Optionally, horizontal support layers may be added at multiple levels, as shown in FIG. 5. To aid with the installation and stabilization of an additional horizontal support layer, a height adjustable stabilizer jack 400 is attached to each connection element 204 of first lever horizontal support layer 502. As shown in FIG. 4A, stabilizer jack 400 has an elongate cylindrical shape. In one example, support jack 400 is set to an approximate length of 30 inches. At one end thereof, support jack 400 has a perpendicular rod 408 and the opposing end thereof, support jack 400 has a barrel-vault shaped end 406.
As shown in FIG. 4B, each connection element 204 of each frame assembly 200 has a cylindrical frame pin 404, suitable for securely receiving end 406. In the installed position, end 406 of support jack 400 securely mates with frame pin 404 of connection element 204, as shown in FIG. 4C.
Further, as shown in FIG. 4D, each connection element 204 has a gusset 410 on a bottom side thereof, suitable to receive perpendicular rod 408 of stabilizer jack 400. In the installed position, rod 408 of stabilizer jack 400 securely mates with the bottom side of connection element 204 to stabilize a second level horizontal support layer 502.
As shown in FIG. 5, a second level horizontal support layer 500 may be installed inside coker 100 above first level horizontal support layer 502. Because converging walls 102 of coker 100 have an expanding diameter as higher vertical levels, second horizontal support layer 500 typically includes longer support beams 202 than first level horizontal support layer 502. In one example, first level horizontal support layer 502 includes seven foot beams 202 and second level horizontal support layer 500 includes nine foot beams 202.
To install second level horizontal support layer 500, the base of each connection element 204 of second level horizontal support layer 500 is stabilized by one stabilizer jack 400, as shown in FIG. 4D. Once second level horizontal support layer 500 is fully assembled, support jacks 400 may be retracted to allow feet 222 of connection elements 204 of second level horizontal support layer 500 to abut interior wall 102 of coker 100. After stabilizer jacks 400 are retracted, walls 102 of coker 100 support second level horizontal support layer 500 and any loads attached thereto. Preferably, second level horizontal support layer 500 is lowered in small increments to ensure that the frame is level. In some embodiments, a laser may be used to check alignment of both first level horizontal support layer 502 and second level horizontal support layer 500. Further, in some embodiments, interior wall 102 of coker 100 may be reinforced with wood packing before lowering second level horizontal support layer 500.
Primary ladders 620 may be added may be added at each corner or vertex of level horizontal support layers 500, 502. In one embodiment, as shown in FIGS. 13A-13C, primary ladders 620 are only added to second level horizontal support layer 500.
A primary ladder connector 600, as shown in FIGS. 6A and 6B may be attached to a cylindrical corner shaft 608 of frame pin 404 of each connection element 204. Primary ladder connector 600 has brackets 602 on each side, each of which interlocks with cylindrical corner shaft 608. Further, cotter pins 606, or an alternative safety locking mechanism, are preferably used to ensure brackets 602 are locked into the desired position.
As shown in FIGS. 6C and 6D, ladder 620 may then be guided and secured to primary ladder connector 600. Locating pins 622 positioned on the upper side of each bracket 602 guide ladder 620 into place, and swing bolts 624 secure primary ladder 620 into place.
At each of the corners of horizontal support layers 502, 500, a ladder 620 is interconnected with each one of the connection elements 204. Each ladder 620 extends along the rounded interior walls 102 with rungs 650 parallel to the flat edge of each of the connection elements 204.
In addition to primary ladders 620 at each of the four corners of horizontal support layers 502, 500, secondary ladders 720 may also be added. In one embodiment, as shown in FIGS. 13A-13C, secondary ladders 720 are only added to second level horizontal support layer 500. In one embodiment, as shown in FIG. 7A, two secondary ladder connectors 700 are attached to each support beam 202 (one at each end of each support beam 202). In one embodiment, each secondary ladder connector 700 is secured one inch away from the trailing edge of each connection element 204.
Accordingly, as shown in FIG. 7B in top plane view, at each of the four corners of the full frame, three secondary ladders 720 may be added. Accordingly, three ladders extend at one apex, along the coker wall 102, with one primary ladder 620 at the vertex and two secondary ladders 720 on either side of primary ladder 620 at equal spacing. In one embodiment, with a four sided horizontal support layers, secondary ladders 720 are at a 45 degree angle to primary ladder 620.
In one embodiment, secondary ladders 720 are connected to one another using horizontal cylindrical brace tubes for additional support. As shown in FIGS. 8A and 8B, upper and lower tubes brace 802, 804 are secured horizontally (perpendicular to ladders 720, which rise vertically). In one embodiment, braces 802, 804 are clamped to the ladders using 2×2 swivel wedge clamps.
In one embodiment, upper and lower tube braces 802, 804 are separated by approximately five feet along the ladder. Upper tube brace 802 should be placed at the approximate position of the chair (shown in FIG. 11A).
In addition, attached to each secondary ladders 720 is at least one support jack 900, shown in FIGS. 9A, 9B, 10A, and 10B. Support jacks 900 are connected to the vertical ladder rails, as shown in FIG. 10A. Each support jack 900 has a flat foot 902, which is configured to abut interior walls 102 of coker 100. Support jacks 900 therefore transfer the load to interior walls 102 of coker 100. Since loads may be added to chairs 1100 mounted on ladders 720, support jacks 900 are ideally positioned proximate to the position of the chairs. In one embodiment, support jacks 900 are positioned within two inches on each side of each chair, as shown in FIG. 11F.
In one embodiment, upper most secondary ladders 720 have a top ladder support 1000 attached at the top thereof, as shown in FIG. 10B.
FIGS. 11A-11D show chair 1100. Aspects relating to chair 1100 are disclosed in the Applicant's Granted U.S. Pat. No. 8,579,084, all of which is herein incorporated by reference.
Chair 1100 is installed onto primary and/or secondary ladders 620, 720 by engaging chair teeth 1102 over the ladder railing, as shown in FIGS. 11E and 11F. Chair teeth 1102 allow chair 1100 to ratchet up in two inch horizontal movements, to allow for positional accuracy.
Further, as shown, chair 1100 includes a pivot plate 1104 and pivot plate bolts 1106. Pivot plate 1104 may be adjusted using pivot plate bolts 1106 to level the plate. Once leveled, bolts 1106 are torqued into position.
As shown in FIGS. 12A and 12B, beams 1200 may be installed on pivot plate 1104 and on chair 1100. Beams 1200 should be parallel and square with one another and may be aligned using lasers. Scaffolding loads may be added onto beam plates 1202.
FIGS. 14A-14C illustrate an example installation of the disclosed founding system. As shown, the installation includes a horizontal support layer 500 with one primary ladder 620 at each apex thereof. Beams 1200 rest on chairs 1100 mounted on primary ladders 620. In addition, optional scaffolding legs 1400 rest on connection elements 204 of horizontal support layer 500 and on beams 1200.
The maximum load on each chair 1100 may vary depending on the coker wall 102 angle. As shown in FIGS. 14B and 14C, a Chair Load ‘Fv’ acts downwardly against coker wall 102. Accordingly, as coker wall angle increases, a larger chair load is permitted. Further, legs 1400 provide support for an additional load, Load ‘P’. Thus, a larger chair load is permitted when legs 1400 are included.
FIGS. 14D-E illustrate a second example setup of the disclosed founding system. As shown, the setup includes a horizontal support layer 500 with one primary ladder 620 at each apex thereof. Beams 1200 rest on chairs 1100 mounted on primary ladders 620. The maximum load on each chair 1100 may also vary depending on the coker wall 102 angle. As shown in FIGS. 14D-E, a Chair Load ‘Fv’ acts downwardly against coker wall 102.
Of course, the above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments are susceptible to many modifications of form, arrangement of parts, details and order of operation. The invention is intended to encompass all such modification within its scope, as defined by the claims.
