Back Ground
Cove Engineering
Wollongong, NSW
Cove Engineering was looking for a drop-stitched matrix-web isolation plug to allow their clients to work on the vibratory feeders below their coal hopper openings in a 3000 t coal bin.
Cove Engineering specialises in providing innovative solutions, including conveyor system design, installation, and maintenance. Their services include comprehensive inspections, thermographic imaging, vibration analysis, and 3D laser scanning. They are known for tackling complex issues, particularly with large gearboxes and crane systems, ensuring safe and efficient operations across various industrial sectors.
Challenge
Cove Engineering approached Giant Inflatables Industrial with a requirement to design a drop-stitched matrix-web isolation plug to block the entrance of hoppers in a 3,000-ton coal bin. The primary objective was to prevent residual coal debris from falling onto workers performing maintenance on the vibratory feeders below the hopper openings. The solution needed to be inserted through a small access hole while providing effective isolation during maintenance.
Given these constraints, they sought a plug that could be inserted through a minimal opening, necessitating a compact yet highly effective inflatable design. The isolation plug required the capability to withstand up to 200 kg of coal debris without collapsing and had to fit securely within the tapered walls of the hopper, minimising the need for additional structural support. To achieve this, our engineers at Giant Inflatables Industrial meticulously designed a frustum-shaped drop-stitched matrix-web isolation plug, a unique design that inflates and conforms to the hopper’s throat, effectively sealing it off.
To meet these requirements, the shutdown crew cut a hole in the chute of the hopper, just large enough to accommodate the uninflated plug. This minimised the impact on the existing structure while allowing for easy insertion and removal of the plug. The installers would support the plug with scaffold planks across the access holes.
Results
During inflation, the isolation plug unfolded strategically. It expanded snugly into position, effectively isolating the area beneath the hopper and preventing debris from falling, thus assuring the safety of workers during maintenance. This successful outcome demonstrates the effectiveness of the drop-stitched inflatable plug in addressing safety and operational needs, enabling the maintenance crew to perform necessary maintenance without the risk of injury.
A closer look
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