Documentation APS-System
Hebetec Engineering AG
Sagi 1
CH-3324 Hindelbank
Tel: +41 34 411 71 71
Fax: +41 34 411 71 70
e-mail: info@hebetec.com
Information
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Table of contents
1.
Description APS System ................................................................................ 3
1.1
1.2
1.3
1.4
2.
3.
4.
5.
Introduction .................................................................................................................. 3
Components of a APS set ............................................................................................... 3
Functionality of the APS System...................................................................................... 6
Safety considerations ..................................................................................................... 7
Technical specification APS System .............................................................. 8
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
Load Carrying Module Type APS M 250......................................................................... 8
Load Carrying Module Type APS M 385......................................................................... 8
Power Pack PA-2-16/2-8 (up to 18 modules) ................................................................... 9
Power Pack PA-4-33/2-8 (for more than 18 modules)....................................................... 9
Push Pull Unit PPU 32.................................................................................................10
Push Pull Unit PPU 100 ...............................................................................................10
Push Pull Unit PPU 160 ...............................................................................................10
Cradle for APS ..............................................................................................................11
Skidway light ................................................................................................................11
Skidway heavy..............................................................................................................11
Application possibilities.................................................................................. 12
APS-Modules ...........................................................................................................................13
Push-Pull-Unit..........................................................................................................................13
Pictures .......................................................................................................... 14
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
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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
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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
Stroke
Hydraulically:
Pneumatically:
330 mm
20 30 mm
Sliding speed
Maximal:
Nominal:
5 meters / min
1 meter / min
Pressure level (according capacity)
Hydraulically:
Pneumatically:
360 bars
25 bars
Normal range of operation temperature
Dimensions
2'500 kN
- 20 C . + 40C
Bearing plate:
Total height:
Adapter:
Connection:
Weight:
1100 x 1100 mm
868 mm
410 x 410 mm
4 x M24
1600 kg
2.2 Load Carrying Module Type APS M 385
Nominal bearing capacity
Stroke
Hydraulically:
Pneumatically:
400 mm (280 mm)
20 30 mm
Sliding speed
Maximal:
Nominal:
5 meters / min
1 meter / min
Pressure level (according capacity)
Hydraulically:
Pneumatically:
350 bars
35 bars
Normal range of operation temperature
Dimensions
Hebetec Engineering Ltd
3'850 kN
- 20 C . + 40C
Bearing plate:
Total height:
Adapter:
Connection:
Weight:
1100 x 1100 mm
973 mm (843 mm)
500 x 500 mm
4 x M30
1900 kg
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2.3 Power Pack PA-2-16/2-8 (up to 18 modules)
Delivery jacking outlets
Pressure line:
Return line:
2 x 16 liter/min
2 x 16 liter/min
Delivery sliding outlets
Pressure line:
Return line:
2 x 16 liter/min
2 x 16 liter/min
Maximum working pressure jacking
Pressure line:
Return line:
400 bar
250 bar
Maximum working pressure jacking
Pressure line:
Return line:
350 bar
350 bar
Dimension
Length:
Height
Width:
1650 mm
1420 mm
1020 mm
Weight with oil
1170 kg
Oil filling
520 liters
Oil specification
HLP ISO-VG 32
Power supply
Voltage:
Frequency:
Power:
Plug:
380 - 440 V
50/60 Hz
45 kVA
EURO A 125
2.4 Power Pack PA-4-33/2-8 (for more than 18 modules)
Delivery jacking outlets
Pressure line:
Return line:
4 x 33 liter/min
4 x 33 liter/min
Delivery sliding outlets
Pressure line:
Return line:
4 x 33 liter/min
4 x 33 liter/min
Maximum working pressure jacking
Pressure line:
Return line:
360 bar
260 bar
Maximum working pressure jacking
Pressure line:
Return line:
360 bar
260 bar
Dimension
Length:
Height:
Width:
3100 mm
1236 mm
1001 mm
Weight with oil
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Oil filling
1200 liters
Oil specification
HLP ISO-VG 32
Power supply
Voltage:
Frequency:
Power:
Plug:
380 - 440 V
50/60 Hz
135 kVA
EURO A 125
2.5 Push Pull Unit PPU 32
Capacity (2 Push Pull cylinder)
Pushing:
Pulling:
320 kN
160 kN
Push Pull long stroke jack
Capacity:
Stroke:
Pressure max:
160 kN
1250 mm
250 bar
Clamping long stroke jack
Capacity:
Stroke:
Pressure max:
50 kN
170 mm
250 bar
Weight
484 kg
2.6 Push Pull Unit PPU 100
Capacity (2 Push Pull cylinder)
Pushing:
Pulling:
1000 kN
530 kN
Push Pull long stroke jack
Capacity:
Stroke:
Pressure max:
500 kN
2000 mm
250 bar
Clamping long stroke jack
Capacity:
Stroke:
Pressure max:
50 kN
250 mm
250 bar
Weight
2850 kg
2.7 Push Pull Unit PPU 160
Capacity (2 Push Pull cylinder)
Pushing:
Pulling:
1600 kN
800 kN
Push Pull long stroke jack
Capacity:
Stroke:
Pressure max:
800 kN
2000 mm
250 bar
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Clamping long stroke jack
Weight
2850 kg
Capacity
7700 kN
Dimension
Weight (without modules)
Capacity:
Stroke:
Pressure max:
50 kN
250 mm
250 bar
2.8 Cradle for APS
Length:
Height:
Width:
4000 mm
1864 mm
1500 mm
4200 kg
2.9 Skidway light
Weight
1200:
1360:
2.2 to
2.3 to
Dimension
Track width:
Length:
Height:
Width:
1200 mm/1360 mm
9m
166 mm
1500 mm/1600 mm
Capacity
1200:
1360:
7.8 to
8.3 to
Dimension
Track width:
Length:
Height
Width:
1200 mm/1360 mm
10 m
437 mm
1464 mm/1624 mm
2.10 Skidway heavy
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3. Application possibilities
Length
Width
Moving of ships (Example : 16 loudouts in Korea, 22'000 t/Ship )
244 m
42 m
Height
Weight
32 m
22'000 t
Sliding distance
Entire carrying capacity
91 m
350'000 kN
On eight fixed installed slidingways (concrete and structural steelwork) the hulls are shifted with a shifting
speed of 30 m/h .
Hebetec Engineering Ltd
Documentation APS-System
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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
APS M-250
APS M-385
Dimension
Stroke
1100x1100 mm
1100x1100 mm
Capacity
330 mm
400 mm
2500 kN
3850 kN
Push-Pull-Unit
Module
PPU-032
PPU-160
PPU-100
Hebetec Engineering Ltd
Total legth
Stroke
Height
Capacity
776 mm
1454 mm
287 mm
1560 mm
1500 mm
380 mm
1560 mm
1500 mm
365 mm
320 kN
1600 kN
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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PPU-32
Controlldesk for HHI Loadouts
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Controlldesk for HHI Loadouts
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Skidway heavy
Skidway heavy joint
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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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Linkbeam HHI
Sliding heavy structures
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After Loadout, Hull on barge
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Load Out HHI
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5. Datasheets
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Documentation APS-System
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Partdeclaration Push-Pull-Unit
Long stroke jack
Cross connection
for stabilisation
Guidance of
skidding way
Clamping unit
Clamping cylinder
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Tel:
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Skidway light 1200
Technical Data
Weight:
Dimension b x h:
2.2 to
1500 x 166 mm
1500
150
30
75
1200
166
9000
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Skidwy light 1360
Technical Data
Weight:
Dimension b x h:
2.3 to
1600 x 166 mm
1600
150
30
75
1360
166
9000
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Sagi 1
CH-3324 Hindelbank (Switzerland)
Tel:
Fax:
e-mail:
Web:
+41 34 411 71 71
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Skidway heavy 1200
Technical Data
Weight:
Dimensions b x h:
7.8 to
1464 x 437 mm
Lifting points
10000
1464
228
437
1200
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Hebetec Dokumentation
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Skidway heavy 1360
Technical data
Weight:
Dimensions b x h:
8.3 to
1624 x 437 mm
Lifting points
10000
1624
228
437
1360
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Web:
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