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NSCC2009

Ship loader, Mongstad


K. Thomsen1 & B. Ibsen2
1 2

Man. Dir. M.Sc. ISC Consulting Engineers A/S, Copenhagen, Denmark Chief Engineer B.Sc, ISC Consulting Engineers A/S, Viborg, Denmark

ABSTRACT: The present paper describes a new alternative pivot bearing concept for at turnable Ship loader, containing loading equipment and the conveying system for the loading of calcinated coke at the Statoil Hydro Mongstad oil refinery in Norway. The loading capacity is 1000 t/h.

Figure 1. General view. 1 INTRODUCTION

1.1 General

The main beam of the ship loader is turnable and is designed as a 75 m long truss beam with a height of 5.5 m cantilevered 40 m over the pivot support. The main lattice girder provides support for a 75 m long internal truss structure with a height of 3.2 m, which can be cantilevered further telescopic up to 26 m. The ship loader is supported on its pivot bearing and on the bogies placed on a radial rail near the quay. The pivot tower supports the pivot ring beam in the turnable bearing connection between the pivot tower and the main truss beam. Feeding of the ship loader is done by an ordinary belt conveyor from an opening in the top of the ship loader above the pivot bearing.

1.2 Special features

Of special features for this structure some shall be highlighted: The telescope concept with which a total cantilevered length of 26 meters is achieved. A new developed concept for the pivot bearing where the usual applied rotating ball bearing is replaced by a bearing with sliding pads made in high strength composite fiber material. The request for a generally hot dip galvanized structure has called for special structural attention to the joint design and subdividing the structures in the transportable sections.
1.3 Design

The detail design phase was carried out in 2008. The bearing structure for the ship loader is made of hot dip galvanized rolled steel sections in material S355. All design of structural steel is made by ISC Consulting Engineers. The scope of work includes production drawings and NC-interface files for the production and fabrication in Denmark. After assembly of the structural elements into main sections, the transportation was carried out by ship to the installation at site in Norway. The total weight of the structure is approximately 350 ton.
1.4 Construction & operation

The construction and assembly of the steel superstructures at site was carried out in August 2008 to January 2009. The ship loader will be operational in May 2009.
2 STEEL STRUCTURES

2.1 Steel Superstructure

All structural components for the superstructure are prefabricated to max 12 m x 3 m LxH, corresponding to the maximum dimensions set by the hot dip galvanizing process. The structure is all bolted in connections arranged close to the shop welded nodes this keeping the max section length under 12m.
2.2 Main structures for the ship loader

The steel superstructure is structurally divided into following main structural items. The 75 m long truss beam constituting the main beam. The internal telescopic 75 m long truss structure with a total cantilevered length of 26 m. The pivot tower acting as central primary support The pivot ring beam and the pivot bearing supported by the pivot tower The front support fixed by the bogies on the radial rail. The telescopic steering cabin and platform supported by the front support and the main beam

Figure 2. Side view.

2.3 Pivot bearing

A study showed, that it was not feasible to use ordinary slewing bearings based on crossed roller or ball design. With a required diameter on the pivot bearing of approximately 5.5m this called for special attention. Conditions and terms, in relation to the expensive cost, delivery time and especially conditions ensuring a low maintenance, held up against the limited operational time was taking into consideration. Based on experiences from other projects a concept with sliding pads was designed. New laminated composite materials developed in the recent years offer superior performance regarding high compressive strength, lubricity and wear compared to traditional materials as PTFE ect. On top of the ring beam the sliding pads is fastened with bolts in the flange. The tight tolerance for the sliding arrangement was met by the line up procedure using epoxy resin. The connection to the main girder is bolted. Three pinned spherical bearings transmit horizontal and vertical load to the trusses in the pivot tower. Slope on the quay require spherical bearings in order to allow vertical movement during slewing the ship loader.

Figure 3. Pivot tower and slewing bearing

2.4 Conclusion

The slewing design developed for the current project, has shown that slewing bearings with laminated composite materials, under special purposes can be advantageous and feasible compared to ordinary slewing bearings based on crossed roller or ball design.

3 SEI DATA BLOCK Owner / Client: Design & Engineering: Main Contractor: Steel (t): Structural bolts: Service date: StatoilHydro Mongstad ISC Consulting Engineers A/S, Copenhagen, Denmark Cimbria Bulk Technology A/S, Sunds, Denmark 350 15,000 May 2009

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