The first grain system to be supplied by Cleveland Cascades Ltd was in 1997. Over 60 systems have been designed and supplied since then for applications involving loading grains. The system types include Cascade and both Freefall variations for which Cleveland Cascades supplies as either telescopic cones or tubes. The uses for the systems range from large shiploaders to smaller dedicated vehicle/tanker loaders.
A major consideration for systems loading grains are the hazardous area requirements. It is extremely important that these are understood from the off-set and that the components selected are approved for use by a notified or certified body.
This is respective of the customers’ requirements and also the final destination of the system as these will determine the project approvals to be satisfied whilst also identifying the applicable standards and regulations.
There are a variety of Cleveland Cascades Systems in use globally loading a variety of organic materials, some of which are:
Supplied back in 2000, this system has been operating for over 20 years loading grains at Bristol Ports in the UK. During this time the system has seen extensive use and the fact that it is still operating today is testament to the quality of the systems which Cleveland Cascades Ltd supplies.
The systems end user reached out to Cleveland Cascades Ltd for support in updating the electrical system installed to ensure compliance with current ATEX regulations. This work was carried out with regards to the original system provided and not for the shiploader as a whole.
Following an initial site survey visit, the scope of work was determined. Modifications to the electrical layout of the system were proposed whilst notifying the customer which equipment would have to be replaced. ATEX zoning and safe areas were identified and agreed upon during the visit allowing Cleveland Cascades Ltd to source the correct equipment.
A further site visit allowed the works to be completed and verified by one of Cleveland Cascades Ltd CompEx certified commissioning engineers before cold commissioning could take place to ensure that the system was back operational and ready to load again.
This system is a cascade shiploader specified for loading grain and was supplied in 2013 to Derince Port, Turkey. The fully extended length of the system is 18m with an operational retracted length of 3.8m.
The selected cone size for the project was Cleveland Cascades Ltd 1500 GRP cones featuring 6mm thickness UHMW PE liners. These cones have a volumetric throughput capacity of 2,000m3/hr surpassing the 1,470m3/hr requirements of the customer for the given material specification and feed rate. By selecting a cone with a higher volumetric throughput capacity for the project, it is possible to allow for material surges which may occur. With this in mind, the volumetric throughput is expected to increase to 1,765m3/hr should the shiploader experience a surge in material.
Due to the liner selection and hazardous area requirements, an anti-static system had to be installed to the cones. This is done in the form of static earthing straps being attached between each of the cones, the top strap is then connected to the head chute with the bottom strap being connected to the carrier. This provides an earthing path for the static charge to dissipate during loading operations.
The system was provided with two alternative outlets, these being a heavy rubber skirted outlet and a rotating trimmer spout. These serve unique purposes with the skirt being used for loading in vertical piles, by maintaining contact with the material pile the quality of the product is maintained whilst suppressing any dust generated. Installing the trimmer spout provides the opportunity to reach the further corners of a ships hatch utilizing the available loading space more efficiently.
C896 – 898
Three identical cascade shiploader systems were supplied in 2018 by Cleveland Cascades Ltd to load grains in New Orleans, USA. The expected material throughput per annum was declared as 3.4 million metric tonnes. Because of the large quantities of material to be loaded through the system, it was of utmost importance to provide a robust loading solution.
A drum winch sourced by Cleveland Cascades facilitates the extension and retraction of the system, this is installed on the customer’s shiploader. In a fully extended state, the system reaches 39.6m long with a retracted length being either 9.0m or 11.6m, depending upon the attachment installed at the outlet, these being a skirt or trimmer spout respectively.
Cleveland Cascades Ltd 1700 GRP cones are used and feature ceramic tiles as a wear liner, the advantage here is that the wear resistance properties are suited to the abrasive nature of the fast, free flowing abrasive material. The selection of ceramic tiles also eliminates the need for a static earthing system to be installed to the cone stack.
Due to the varying product densities the system was setup such that all of the products could be loaded at acceptable rates. The volumetric capacity of the 1700 cones is 2,800m3/hr and it was advised by Cleveland Cascades that the best results would be achieved at a volumetric throughput of up to 2600m3/hr.
Both a skirt and trimmer spout were included in the original supply for the system. Following a commissioning trip by Cleveland Cascades Ltd engineers it was expressed that loading operations had to cease during any rainfall. The solution of implementing hatch chargers was proposed and subsequently designed and supplied to fit the existing system with all the necessary electrical equipment required for implementation to the shiploader PLC. This allowed loading to continue to during adverse weather conditions and reduced the downtime which had previously been experienced.