Fluid control system and fluid control method for recirculating high-density fluid

Abstract

Disclosed is fluid control system (100) for recirculating high-density fluid (HDF) comprising fluid storage tank (102) configured to retain volume of HDF, fluid storage tank having walls and floor, a base (such as a sloped base), tank outlet (104) located at substantially lowest point of fluid storage tank; Characterised in that the fluid control system further comprises a sludge line conduit (106) attached at first end to tank outlet; fluid storage tank has tank inlet (108) at or towards top of fluid storage tank and sludge line conduit is attached at second end to tank inlet; circulatory device (110) is operably attached to sludge line conduit for circulating flow of retained HDF from tank outlet to tank inlet;

Description

[0001] FLUID CONTROL SYSTEM AND FLUID CONTROL METHOD FOR RECIRCULATING HIGH-DENSITY FLUID

[0002] TECHNICAL FIELD

[0003] The description relates to a fluid control system. More particularly, the present invention relates to fluid control system for recycling a high-density fluid (HDF).

[0004] The present invention also relates to a fluid control method for controlling the sag (or build-up) in a fluid control system.

[0005] BACKGROUND

[0006] Advancement in the field of fluid management systems, particularly the ones related to high-density fluids for large-scale energy storage, has gained popularity over the years due to its potential applications in various industries such as oil and gas drilling, renewable energy, and environmental management. The fluid management systems play a crucial role in ensuring the efficient and effective operation of various processes such as handling, transport, and storage of the high-density fluids. The fluid management systems are designed to address challenges related to fluid sag or stratification, circulation, stability, and longevity.

[0007] However, in the fluid management systems, several problems have been identified, particularly in relation to the sag or build-up or stratification of fluids during periods of non-circulation of the high-density fluids or maintenance shutdowns. The sag or build-up or stratification occurs when heavier particles in the fluid settle at the bottom of the reservoir, creating a vertical gradient in fluid properties of the high-density fluids, which leads to uneven performance, reduced efficiency, and potential system failures. The present solution of fluid mixing and circulation in the fluid management systems have proven to be inefficient and energy-intensive, especially when dealing with large volumes of the high-density fluid. Additionally, the use of high-density fluids, such as those employed in pumped hydro energy storage systems, presents unique challenges in terms of maintaining the fluid's physical and chemical properties over long periods and large volumes.

[0008] In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.

[0009] SUMMARY OF THE INVENTION

[0010] It is an object of the present invention to provide a fluid control system for recirculating a high-density fluid (HDF), which goes some way to overcoming the abovementioned disadvantages or which at least provides the public or industry with a useful choice.

[0011] It is a further object of the present invention to provide a fluid control method for controlling sag (or build-up or stratification) in a fluid control system, which goes some way to overcoming the abovementioned disadvantages or which at least provides the public or industry with a useful choice.

[0012] The term "comprising" as used in this specification and indicative independent claims means "consisting at least in part of". When interpreting each statement in this specification and indicative independent claims that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner.

[0013] As used herein the term "and / or" means "and" or "or", or both.

[0014] As used herein "(s)" following a noun means the plural and / or singular forms of the noun.

[0015] Accordingly, in a first aspect the present invention may broadly be said to consist in a fluid control system for recirculating a high-density fluid (HDF), comprising: a fluid storage tank configured to retain a volume of HDF, the fluid storage tank having walls and a floor, a base (such as a sloped base), a tank outlet located at substantially the lowest point of the fluid storage tank; characterised in that the fluid control system further comprises a sludge line conduit attached at a first end to the tank outlet, wherein the fluid storage tank has a tank inlet at or towards the top of the fluid storage tank and the sludge line conduit is attached at a second end to the tank inlet; a circulatory device is operably attached to the sludge line conduit for circulating a flow of retained HDF from the tank outlet to the tank inlet.

[0016] In an embodiment, the fluid control system further comprises a sample outlet arranged at a first position on the wall of the fluid storage tank and a sample line conduit attached at a first end to the sample outlet.

[0017] In an embodiment, the fluid control system further comprises a dosing line conduit attached at a first end to a dosing fluid reservoir containing a dosing fluid and at a second end is attached to the sludge line conduit before to the inlet of the circulatory device.

[0018] In an embodiment, the interconnection of the dosing line conduit to the sludge line conduit provides a mixing chamber within the sludge line conduit for combining a HDF with the dosing fluid. In an embodiment, the sample line conduit further comprises a sensor device for generating data indicative of a property of the retained HDF extracted from the sample outlet of the fluid storage tank.

[0019] In an embodiment, the mixing chamber within the sludge line conduit further comprises a dispensing device for dispensing the dosing fluid provided by the dosing line conduit.

[0020] In an embodiment, the sludge line conduit comprises a first valve device arranged between the tank outlet of the fluid storage tank and the mixing chamber within the sludge line conduit.

[0021] In an embodiment, the sludge line conduit comprises a second valve device arranged between the mixing chamber and the circulatory device.

[0022] In an embodiment, the fluid control system further comprises a controlling means for processing the data indicative of a property of the retained HDF and controlling the communication of a dose substance to the mixing chamber within the sludge line conduit.

[0023] In an embodiment, the property indicated in the data is one of: pH, specific gravity (SG), viscosity, dissolved oxygen, total dissolved solids, and the like of the retained HDF.

[0024] In an embodiment, the wall of the fluid storage tank further comprises a second sample outlet arranged at a second position.

[0025] In an embodiment, the circulatory device is a bi-directional device which in a first rotational movement circulates a retained HDF within the sludge line conduit from the tank outlet of the fluid storage tank to the tank inlet of the fluid storage tank, and in a second rotational movement circulates a retained HDF within the sludge line conduit from the tank inlet of the fluid storage tank to the tank outlet of the fluid storage tank. In an embodiment, the circulatory device is a progressive cavity pump device.

[0026] In an embodiment, the circulatory device is a positive displacement device or centrifugal pump device.

[0027] In an embodiment, the fluid control system further comprises a spray bar arranged within the fluid storage tank.

[0028] In an embodiment, the spray bar extends across a width portion of the fluid storage tank.

[0029] In an embodiment, the spray bar comprises an array of orifices that are sized to provide a consistent pressure drop across the spray bar.

[0030] In an embodiment, the fluid control system further comprises an array of spray bars, wherein each spray bar in the array of spray bars is spaced along a length portion of the fluid storage tank.

[0031] In an embodiment, the fluid control system further comprises a valve arranged between the spray bar and the inlet of the fluid storage tank.

[0032] In an embodiment, the fluid control system further comprises a row of eductor jets arranged within the fluid storage tank. In a second aspect of the present invention may broadly be said to consist in a fluid control method for controlling sag or build-up in a fluid control system that comprises a fluid storage tank configured to retain a volume of High-Density-Fluid (HDF), the fluid storage tank having walls and a floor, a base (such as a sloped base), a tank outlet, a sludge line conduit attached at a first end to the tank outlet; the fluid storage tank further comprises a tank inlet and the second end of the sludge line is attached to the tank inlet, a circulatory device is operably attached to the sludge line conduit for circulating a flow of retained HDF from the tank outlet to the tank inlet, the method comprising: operating the circulatory device intermittently for a predetermined time and HDF flowrate for every hour in which the fluid control system is in use;

[0033] operating the circulatory device to circulate the retained HDF within the fluid storage tank within one day in the event of a fluid failure;

[0034] selecting a frequency and duration of operating the circulatory device to circulate the volume of retained HDF within the fluid storage tank within one week; and

[0035] operating the fluid control system independently from a primary control system in which the fluid control system is a secondary component thereof.

[0036] In an embodiment, the fluid control method further comprises the step of:

[0037] withdrawing a sample of retained HDF from the fluid storage tank via a sample line conduit attached at a first end to a sample outlet arranged at a first position on the wall of the fluid storage tank.

[0038] In an embodiment, the fluid control method further comprises the step of:

[0039] dispensing a dosing fluid from a dosing line conduit attached at a first end to a dosing fluid reservoir and at a second end is attached to the sludge line conduit.

[0040] In an embodiment, the fluid control method further comprises the step of:

[0041] generating data indicative of a level of HDF fluid within the fluid storage tank; activating a first valve to allow the flow of HDF through a first spray bar at a first position within the fluid storage tank wherein the retained HDF is at a maximum level within the fluid storage tank; and

[0042] activating a second valve to allow the flow of HDF through a second spray bar at a second position within the fluid storage tank wherein the retained HDF is at a minimum level within the fluid storage tank.

[0043] With respect to the above description then, it is to be realised that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

[0044] This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[0045] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

[0046] Throughout the description and claims of this specification, the words "comprise" , "include", "have", and "contain" and variations of these words, for example "comprising" and "comprises" , mean "including but not limited to", and do not exclude other components, items, integers or steps not explicitly disclosed also to be present. Moreover, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0047] BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Further aspects of the invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings which show an embodiment of the device by way of example, and in which:

[0049] Figure 1 is a schematic illustration of a fluid control system for recirculating a high-density fluid (HDF), in accordance with an embodiment of the description.

[0050] Figure 2 is an illustration of a block diagram of a transition between modes of a fluid control system, in accordance with an embodiment of the description.

[0051] Figures 3A and 3B are illustrations of block diagrams of a hierarchy of operations in a fluid control system in different implementations, respectively, in accordance with an embodiment of the description.

[0052] Figure 4 is an illustration of a flow chart depicting the steps of a fluid control method for controlling sag or build-up in a fluid control system, in accordance with an embodiment of the description.

[0053] Figures 5A, 5B and 5C are illustrations of different views of a sludgebreaking assembly comprising a row of eductor jets, incorporated into the fluid control system, in accordance with an embodiment of the description.

[0054] DETAILED DESCRIPTION

[0055] The following detailed description illustrates embodiments of the description and ways in which they can be implemented. Those skilled in the art will recognize that other embodiments for carrying out or practising the present invention are also possible.

[0056] General Overview

[0057] A schematic illustration of a fluid control system 100 for recirculating a high-density fluid (HDF) according to an embodiment of the invention is shown in figure 1. The system 100 comprises a fluid storage tank 102 configured to retain a volume of HDF. The fluid storage tank 102 having walls and a floor, a base (such as a sloped base), a tank outlet 104 located at substantially the lowest point of the fluid storage tank 102. Moreover, the fluid control system 100 comprises a sludge line conduit 106 attached at a first end to the tank outlet 104, wherein the fluid storage tank 102 has a tank inlet 108 at or towards the top of the fluid storage tank 102 and the sludge line conduit 106 is attached at a second end to the tank inlet 108. Furthermore, the fluid control system 100 a circulatory device 110 is operably attached to the sludge line conduit 106 for circulating a flow of retained HDF from the tank outlet 104 to the tank inlet 108, characterised in that the wall of the fluid storage tank 102 further comprises a sample outlet 112 arranged at a first position and a sample line conduit 114 attached at a first end to the sample outlet 112. The sample line conduit 114 may further comprise a sensor device 116 for generating data indicative of a property of the retained HDF extracted from the sample outlet 112 of the fluid storage tank 102. The second end of the sample line conduit 114 is attached to a sample fluid holding reservoir. The fluid control system 100 may further comprise a dosing line conduit 118 attached at a first end to a dosing fluid reservoir 120 containing a dosing fluid and at a second end is attached to the sludge line conduit 106 before to the inlet of the circulatory device 110. The sludge line conduit 106 may comprise a first valve device 122 arranged between the tank outlet 104 of the fluid storage tank 102 and a mixing chamber within the sludge line conduit 102. The sludge line conduit may further comprise a second valve device 124 arranged between the mixing chamber and the circulatory device 110. The wall of the fluid storage tank 102 may further comprise a second sample outlet 126 arranged at a second position.

[0058] The described fluid control system can prevent and remove sag or buildup or stratification in the High-Density Fluid (HDF). The fluid control system effectively ensures fluid stability even during extended periods of inactivity. Moreover, the base (such as the sloped base) in the fluid storage tank enables to recirculate the HDF in an optimized manner, effectively re-agitating settled particles in the HDF with minimal energy consumption. Furthermore, the components of the fluid control system work synergistically to maintain homogeneity of the HDF and prevent sludge build-up or sag in the HDF.

[0059] The described system provides a fluid control method that can prevent and remove sag or build-up or stratification in the High-Density Fluid (HDF). The fluid control method effectively ensures fluid stability even during extended periods of inactivity. Moreover, the base (such as the sloped base) in the fluid storage tank enables to recirculate the HDF in an optimized manner, effectively re-agitating settled particles in the HDF with minimal energy consumption. Furthermore, the fluid control method works synergistically to maintain homogeneity of the HDF and prevent sludge build-up or sag in the HDF. Although some modes of carrying out the description have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practising the description are also possible.

[0060] The system elements and their inter-relationship are described below.

[0061] The fluid storage tank

[0062] Throughout the description, the term "high-density fluid (HDF)" refers to the specific fluid used in the high-density hydro energy storage applications and is subject to sag or build-up or stratification when not circulated for extended periods. The HDF, which consists of a suspension of fine solid mineral particles in water with a solid fraction close to 80%, is stored in large volumes within the fluid storage tank. Moreover, the solid mineral particles may be in the form of Barium Sulphate (also known as Barite) particles. Throughout the description, the term "fluid storage tank" refers to a container or vessel designed to hold and store the HDF used in the high-density hydro energy storage applications. Notably, the volume of the HDF retained by the fluid storage tank refers to the amount of space occupied by the fluid within the storage tank, typically measured in cubic units. Throughout the description, the term "walls" refers to the vertical structures that enclose the fluid storage tank and provide support for containment of the HDF within the fluid storage tank. Throughout the description, the term "floor" refers to the horizontal surface at the bottom of the reservoir on which the HDF rests. Throughout the description, the term "base" refers to the structural bottom portion of the fluid storage tank that supports and defines the lower boundary of the fluid storage tank's interior volume. The base provides mechanical stability and forms the foundation upon which the HDF rests when retained within the fluid storage tank. Moreover, the base serves as the primary interface between the fluid storage tank floor and the surrounding support surface or structural framework. The geometry of the base may vary depending on the application, such as being flat, curved, or sloped, to facilitate desired fluid movement and drainage characteristics. Notably, the base contributes to maintaining structural integrity under the load of the HDF and ensures proper flow paths towards the tank outlet when configured as a sloped base.

[0063] Throughout the description, the term "flat base" refers to a substantially planar surface that may be arranged horizontally or with a minimal gradient, optionally supplemented by localized flow-directing elements such as baffles, recesses, or outlet funnels to promote flow paths toward the tank outlet. Moreover, the term "curved base" refers to a concave or arcuate surface contour that naturally guides the HDF and suspended solids toward a central or peripheral low point, enhancing flow convergence and minimizing accumulation zones.

[0064] Throughout the description, the term "sloped base" refers to a gradually inclined surface that facilitates the flow of the HDF towards the tank outlet. In this regard, the sloped base is formed or arranged with a gradient relative to the horizontal plane of the fluid storage tank bottom. Moreover, the sloped base of the fluid storage tank serves as a passive means that facilitates the natural movement of the heaviest particles of the HDF and any entrained solids, such as weighting agents or mineral solids, towards the lowest point where the tank outlet is located in the fluid storage tank, ensuring efficient collection and recirculation of the HDF. The uniform or variable angle of inclination of the sloped base typically depends on the geometry of the fluid storage tank and the rheological characteristics of the HDF. A technical effect of the sloped base is the enhancement of sediment management and circulation efficiency within the system, which also reducing the energy required for re-suspension. The sloped base minimizes stagnant zones, supports complete recirculation of the retained HDF. In certain implementations, the sloped base may be replaced or supplemented by an alternative base geometry, such as a curved, stepped, or channelled base, that similarly defines a preferred fluid flow path toward the tank outlet. In this regard, each alternative geometry is configured to direct the movement of the HDF under gravitational or induced flow conditions toward a defined low point or drainage region within the fluid storage tank. For example, a curved base may promote centripetal flow convergence, a stepped base may facilitate sequential sediment transfer, and a channelled base may provide confined flow paths that minimize stagnation and promote uniform withdrawal of the HDF. These alternative geometries may be integrally formed or retrofitted within the tank structure to achieve comparable flow control as the sloped base. A technical effect of such configurations is the maintenance of consistent fluid turnover and sediment management efficiency across varying tank designs, thereby sustaining the homogeneity of the HDF and reducing localized deposition or stratification. Accordingly, reference to the sloped base throughout the description should be understood as encompassing any base configuration that performs the equivalent function of facilitating the gravitational or flow-assisted migration of dense particulate material within the HDF toward the outlet region of the fluid storage tank.

[0065] Throughout the description, the term "tank outlet" refers to the opening or passage through which the HDF is discharged from the fluid storage tank. Notably, the tank outlet is located at substantially the lowest point in the fluid storage tank as the HDF settles and accumulates due to its higher density at the lowest point in the fluid storage tank.

[0066] Throughout the description, the term "tank inlet" refers to the opening in the fluid storage tank through which the HDF enters the fluid storage tank. Notably, the tank inlet being at or towards the top of the fluid storage tank ensures that the HDF is recirculated back into fluid storage tank from the top to remove separate the unsagged or unstratified HDF at the top of the fluid storage tank from the sag or stratified HDF accumulated at the lowest point of the fluid storage tank. Throughout the description, the term "sag" or "stratified" refers to dense, heavy, or settled fluid solid weighting agent building up in suspension. Throughout the description, the term "second end" refers to the opposite or far end of the sludge line conduit, which is used for the circulation or transfer of the HDF within the fluid control system. The sludge line conduit is attached at the second end to the tank inlet which ensures that the HDF is evenly distributed throughout the fluid storage tank, preventing localized sag or build-up of heavy particles in the HDF. The use of a tank inlet at or towards the top of the fluid storage tank, along with the attachment to second end the sludge line conduit, enables thorough mixing of the HDF and prevents sag or build-up or stratification.

[0067] Throughout the description, the term "sample outlet" refers to a specific opening or hole through which a small portion of the HDF within the fluid storage tank is extracted as a sample for analysis or testing purposes.

[0068] Sludge Line conduit

[0069] Throughout the description, the term "sludge line conduit" refers to a conduit or pipe that is specifically designed and positioned to remove or extract the heavier particles or sludge in the HDF settled at the lowest point of the fluid storage tank. Throughout the description, the term "first end" refers to one of the two ends of the sludge line conduit, with the first end being the end that is attached to the tank outlet. The sludge line conduit draws the HDF from the tank outlet, where the heaviest particles in the HDF have settled, and pumps it to the opposite end of the fluid storage tank, i.e., towards the tank inlet. The sludge line conduit is designed to recirculate the HDF to maintain the homogeneity and prevent sag or build-up or stratification in the HDF. It will be appreciated that attaching the sludge line conduit to the tank outlet ensures that the HDF is drawn from the lowest point of the fluid storage tank.

[0070] The sludge line conduit may comprise a first valve device arranged between the tank outlet of the fluid storage tank and the mixing chamber within the sludge line conduit. In this regard, the term "first valve device" refers to a mechanical component that controls the flow of the HDF from the tank outlet to the mixing chamber. Notably, the first valve device controls an amount of the HDF that flows from the fluid storage tank to the mixing chamber and prevents any undesired backflow or leakage of the HDF. A technical effect of the sludge line conduit comprising the first valve device enables to control and regulate the flow of the HDF in the sludge line conduit to ensure effective circulation of the HDF in the sludge line conduit.

[0071] The sludge line conduit may comprise a second valve device arranged between the mixing chamber and the circulatory device. In this regard, the term "second valve device" refers to a mechanical component or apparatus that is designed to control the flow of the HDF from the mixing chamber to the circulatory device. The presence of the second valve device in the sludge line conduit enables to optimize the recirculation process and prevent sag or build-up or stratification of the HDF. Notably, controlling the flow between the mixing chamber and the circulatory device ensures thorough mixing of the HDF and even distribution of heavier particles in the HDF. A technical effect is that the second valve device ensures effective recirculation of the HDF and prevents sag or build-up or stratification in the HDF to meet the desired specifications.

[0072] The sludge line conduit may comprise one or more sensors for sensing the pressure within the sludge line conduit. The sensors are preferably one or more pressure transducers that are suitable for sensing a pressure increase within the sludge line conduit, which is caused by a sag or buildup of HDF within the sludge line conduit.

[0073] Circulatory device

[0074] Throughout the description, the term "circulatory device" refers to a mechanical apparatus or unit that is designed to facilitate the movement or circulation of the HDF. The circulatory device being operably attached to the sludge line conduit implies that the circulatory device and the sludge line conduit are connected or linked in a manner that allows them to function together or interact with each other. The circulation of the flow of the retained HDF may be continuous or periodic from the tank outlet to the tank inlet. The term "retained HDF' refers to the HDF that is held or kept within the fluid storage tank.

[0075] Moreover, the circulatory device may be configured as a bi-directional device which in a first rotational movement circulates the retained HDF within the sludge line conduit from the tank outlet of the fluid storage tank to the tank inlet of the fluid storage tank, and in a second rotational movement circulates the retained HDF within the sludge line conduit from the tank inlet of the fluid storage tank to the tank outlet of the fluid storage tank. In this regard, the term "bi-directional device" refers to a component capable of facilitating movement of the HDF in two opposite directions. Throughout the description, the term "first rotational movement" refers to the circular movement of the HDF from the tank outlet of the fluid storage tank to the tank inlet of the fluid storage tank in a repetitive manner. Throughout the description, the term "second rotational movement" refers to the circular movement of the HDF from the tank inlet of the fluid storage tank to the tank outlet of the fluid storage tank in a repetitive manner. Notably, the first rotational movement and second rotational movement of the retained HDF in the sludge line conduit is bi-directional (i.e., in opposite directions) which ensures that the retained HDF in the sludge line conduit is thoroughly mixed for maintaining homogeneity in the retained HDF in the sludge line conduit. A technical effect is that the circulatory device being the bidirectional device enables to circulate the retained HDF in the sludge line conduit in the first rotational movement and the second rotational movement to effectively remove any sag or build-up or stratification in the retained HDF.

[0076] The circulatory device may be configured as a progressive cavity pump device. In this regard, the term "progressive cavity pump device" refers to a type of positive displacement pump that consists of a helical rotor and a stator, where the rotor rotates eccentrically within the stator to create a series of sealed cavities that progress from the suction side to the discharge side, thereby effectively pumping the HDF with a smooth and continuous flow. The progressive cavity pump device is designed to draw the HDF from the lowest point of the fluid storage tank, where the heaviest particles of the HDF have settled and pumps the HDF at the opposite end towards the top of the fluid storage tank. The circulatory device being the progressive cavity pump device provides a reliable and effective means to circulate the HDF in the sludge line conduit. Notably, the progressive cavity pump device can circulate the HDF bi-directionally in the first rotational movement and the second rotational movement, allowing for optimal fluid mixing of the HDF in the sludge line conduit. A technical effect of the circulatory device being the progressive cavity pump is the efficient handling of the HDF and reliable circulation of the HDF in the sludge line conduit.

[0077] Alternatively, the circulatory device may be configured as a positive displacement device or centrifugal pump device. In this regard, the term "positive displacement device" refers to a mechanical apparatus that moves a fixed volume of the HDF through the sludge line conduit by trapping a discrete volume of the HDF and forcing that volume from the suction side to the discharge side. The positive displacement device maintains a nearly constant flow rate irrespective of pressure variations within the sludge line conduit, thereby ensuring uniform circulation of the HDF even when the fluid exhibits high viscosity or contains dense particulate matter. Throughout the description, the term "centrifugal pump device" refers to a pump that imparts kinetic energy to the HDF by means of a rotating impeller, converting the mechanical energy of rotation into velocity head and subsequently into pressure head as the HDF exits the impeller through the diffuser. The centrifugal pump device is designed to draw the HDF from the tank outlet located at the lowest point of the fluid storage tank, accelerate the HDF radially outward by centrifugal action, and discharge the HDF into the sludge line conduit toward the tank inlet. A technical effect of the circulatory device being the positive displacement device or centrifugal pump device is that it enables reliable recirculation of the HDF across various densities and flow regimes. The positive displacement configuration ensures consistent volumetric throughput and pressure stability for viscous or high-solids HDF, while the centrifugal configuration provides high flow efficiency and reduced pulsation for lower-viscosity HDF during rapid circulation cycles. Consequently, such implementation enhances the operational flexibility, energy efficiency, and reliability of the overall recirculation process within the sludge line conduit.

[0078] Notably, the circulatory device being operated intermittently implies that the circulatory device is operated in a non-continuous manner for the predetermined time for every hour in which the fluid control system is in use. The term "predetermined time" refers to a specific duration or period during which the circulatory device is intermittently operated for every 1 hour in which the fluid control system is in use. The term "HDF flowrate" refers to the rate at which the HDF is circulated or moved through the fluid control system, typically measured in volume per unit of time. The circulatory device being operated intermittently for the predetermined time and the HDF flowrate for every hour in which the fluid control system is in use enables to save power and resources by not operating the circulatory device when the fluid control system is not in use. Throughout the description, the term "fluid failure" refers to a scenario in which the sag or build-up or stratification of the HDF occurs. Notably, operating the circulatory device to circulate the retained HDF within the fluid storage tank within one day in the event of the fluid failure enables to recirculate the HDF to remove the sag or build-up or stratification of the HDF in the event of the fluid failure. Moreover, the selection of the frequency and duration of operating the circulatory device to circulate the volume of retained HDF within the fluid storage tank within one week enables to determine that how many time and for how much duration the circulatory device is to be operated within one week. Throughout the description, the term "primary control system" refers to a control system in which the main function in not carried out by the fluid control system. Subsequently, the fluid control system being the secondary component of the primary control system implies that the fluid control system is operated independently to carry out a secondary operation in the primary control system.

[0079] In an exemplary implementation, the circulatory device is operated for around 1 hour every six hours. In this regard, the intermittent operation cycle of around one hour every six hours activates the circulatory device periodically at predetermined intervals, specifically once within each six-hour operational window of the fluid control system. The periodic activation ensures that the HDF retained within the fluid storage tank remains in a dynamic state of suspension during extended idle periods of the primary control system. This prevents the accumulation of heavy particulates along the base and within the sludge line conduit while avoiding unnecessary energy consumption. The intermittent operation is configured through the controlling means to align with the measured parameters of the HDF, including specific gravity, viscosity, and yield point, thereby maintaining the rheological stability of the HDF without continuous energy input.

[0080] Sample line conduit

[0081] Throughout the description, the term "sample line conduit" refers to a conduit or pipe that connects the sample outlet to a measuring or sampling device, allowing the extracted fluid sample to be transported for further examination. Throughout the description, the term "first position" refers to a specific position or orientation at which the sample outlet is arranged on the fluid storage tank. The sample outlet and the sample line conduit are designed to enable the extraction of sample HDF for monitoring of various fluid properties, such as pH, specific gravity, viscosity, dissolved oxygen, and total dissolved solids in the HDF. Notably, the sample HDF is extracted from different heights within the fluid storage tank to detect signs of sag or build-up or stratification and provide valuable data for analysis of the HDF. The presence of the sample outlet and the sample line conduit allows for continuous monitoring of the HDF's properties at different levels within the fluid storage tank, which helps in identifying any sag or build-up or stratification that may occur, ensuring the HDF remains homogeneous. The data gathered from the sampling line aids in maintaining fluid stability in the HDF and enables dose chemicals into the sludge line conduit if required effectively.

[0082] The wall of the fluid storage tank may further comprise a second sample outlet arranged at a second position. In this regard, the term "second position" refers to a position within the fluid storage tank where the second sample outlet is placed. Throughout the description, the term "second sample outlet" refers to another opening or hole through which another small portion of the HDF within the fluid storage tank is extracted as the sample for analysis or testing purposes. The second sample outlet is strategically placed at the second position to extract another sample from the HDF at a different height within the fluid storage tank, allowing for the monitoring of various fluid properties such as the pH, the specific gravity, the viscosity, the dissolved oxygen, and the total dissolved solids at different heights in the fluid storage tank. A technical effect is that the presence of the second sample outlet at the second position enables the detection of any signs of sag or build-up or stratification in the HDF at different heights in the fluid storage tank, which is crucial for maintaining fluid homogeneity and preventing the formation of layers with varying properties in the HDF.

[0083] The sample line conduit may further comprise a sensor device for generating data indicative of a property of the retained HDF extracted from the sample outlet of the fluid storage tank. In this regard, the term "sensor device" refers to a device that detects and measures physical or chemical properties of the HDF and converts them into electrical signals. Throughout the description, the term "data" refers to information of the HDF that is collected, stored, and processed by the sensor device. Throughout the description, the term "property" refers to a characteristic or attribute of the retained HDF indicated in the data generated by the sensor device. Notably, the data generated by the sensor data being indicative of the property of the retained HDF provides insights into the properties of the retained HDF and enables effective monitoring of the HDF. A technical effect is that the sag or build-up or stratification in the HDF is effectively detected by analysing and monitoring the data generated by the sensor device that is indicative of the property of the retained HDF.

[0084] The property indicated in the data may be one of: pH, specific gravity (SG), viscosity, dissolved oxygen, total dissolved solids, and the like of the retained HDF, and in-line yield point measurement and in-line temperature. In this regard, the term "pH" refers to the measure of acidity or alkalinity of the HDF, indicating the concentration of hydrogen ions present in the HDF. Throughout the description, the term "specific gravity (SG)" refers to the ratio of the density of the HDF to the density of a reference substance, typically water. Throughout the description term "viscosity" refers to the measure of the HDF's resistance to flow, indicating its internal friction. Throughout the description, the term "dissolved oxygen" refers to the amount of oxygen gas that is dissolved in the HDF. Throughout the description, the term "total dissolved solids" refers to the measure of all inorganic and organic substances that are dissolved in the HDF, typically expressed in parts per million (ppm) or milligrams per litre (mg / L). A technical effect of the property indicated in the data being one of the aforementioned properties is that a wide range of characteristics associated with the HDF are indicated in the data for further analysis.

[0085] Throughout the description, the term "in-line yield point measurement" refers to a real-time determination of the yield stress of the retained HDF as it flows through the sludge line conduit. The in-line yield point measurement provides a quantitative indication of the shear stress required to initiate flow in the HDF, which directly correlates to the degree of particle interaction and structuring within the suspension. The measurement is typically derived from torque, differential pressure, or acoustic response sensors integrated into the flow path of the sludge line conduit or sample line conduit. Monitoring the in-line yield point measurement enables the controlling means to assess the onset of gel formation, detect early signs of sag, and determine when to activate the circulatory device or sludge-breaking assembly to maintain fluid mobility.

[0086] Throughout the description, the term "in-line temperature" refers to the temperature of the HDF measured directly within the active circulation loop during system operation. The in-line temperature measurement provides a continuous indication of the thermal state of the HDF, which affects its viscosity, density, and yield behaviour. The in-line temperature data may be used by the controlling means to compensate for thermally induced viscosity changes, adjust pump duty cycles, and regulate dosing of stabilising or rheology-modifying agents via the dosing line conduit.

[0087] A technical effect of continuously monitoring both rheological and thermal parameters, i.e., the in-line yield point measurement and in-line temperature, is to dynamically maintain optimal flow conditions, prevent sag formation, and improve the overall stability and energy efficiency of the HDF during recirculation.

[0088] Dosing line conduit

[0089] The fluid control system may further comprise a dosing line conduit attached at a first end to a dosing fluid reservoir containing a dosing fluid and at a second end is attached to the sludge line conduit before to the inlet of the circulatory device. In this regard, the term "dosing line conduit" refers to a channel or passage that is used to transport the dosing fluid from the dosing fluid reservoir to the sludge line conduit. Throughout the description, the term "dosing fluid reservoir" refers to a container or storage unit that holds the dosing fluid, which is used to counteract the sag or build-up or stratification of the HDF. Throughout the description, the term "dosing fluid" refers to a specific fluid or solution that is added in controlled quantities to the HDF to adjust its properties, such as pH, and mitigate the effects of sag or build-up or stratification. Throughout the description, the term "inlet" refers to a hole or opening towards the circulatory device. Notably, the second end of the dosing line conduit is first attached to the sludge line conduit and then to the inlet of the circulatory device, which ensures that the dosing fluid from the dosing fluid reservoir is properly mixed with the HDF in the sludge line conduit before being reintroduced into the circulatory device. A technical effect is that integrating the dosing line conduit with the sludge line conduit ensures that the dosing fluid is added to the HDF for correcting specific properties in the HDF containing heavier particles.

[0090] The interconnection of the dosing line conduit to the sludge line conduit may provide a mixing chamber within the sludge line conduit for combining a HDF with the dosing fluid. In this regard, the term "interconnection" refers to the connection or linkage between the dosage line conduit and the sludge line conduit, facilitating the transfer of the dosing fluid from the dosing line conduit to the sludge line conduit. Subsequently, the interconnection of the dosing line conduit to the sludge line conduit creates the mixing chamber within the sludge line conduit. Throughout the description, the term "mixing chamber" refers to a specific area in the sludge line conduit where the HDF and the dosing fluid are combined and thoroughly mixed to achieve a homogeneous fluid composition in the HDF. The dosing line conduit uses data gathered from the sampling line to dose chemicals into the sludge line conduit, facilitating the combination of the HDF with the dosing fluid. Notably, combining the HDF with the dosing fluid in the mixing chamber ensures homogeneity and prevents the sag or build-up of heavy particles in the HDF, which is crucial for maintaining fluid stability and optimizing the performance of the HDF in energy storage applications. A technical effect is that the sag or build-up or stratification in the HDF is prevented by providing the mixing chamber within the sludge line conduit via the interconnection of the dosing line conduit to the sludge line conduit.

[0091] Controlling means

[0092] The fluid control system may further comprise a controlling means for processing the data indicative of the property of the retained HDF and controlling the communication of a dose substance to the mixing chamber within the sludge line conduit. In this regard, the term "controlling means" refers to a device or apparatus having processing or computing capabilities. Notably, the processing of the data indicative of the property of the retained HDF enables to determine a real-time condition of the retained HDF. Throughout the description, the term "dose substance" refers to a substance that is administered or delivered in a measured quantity or dosage for a specific purpose or effect in the sludge lie conduit. Notably, the controlling means being configured to control the communication of the dose substance to the mixing chamber implies that the exchange of information between the mixing chamber and the dose substance is controlled by the controlling means. The controlling means processes the data to determine the appropriate level of the dose substance required to correct specific properties of the retained HDF. Subsequently, the determined appropriate level is communicated to the dosage substance via the controlling means. A technical effect is that by processing the data and controlling the communication of the dose substance sag or build-up or stratification in the HDF is effectively detected and the appropriate amount of the dosage substance is added to the mixing chamber.

[0093] Mixing chamber

[0094] The mixing chamber within the sludge line conduit may further comprise a dispensing device for dispensing the dosing fluid provided by the dosing line conduit. In this regard, the term "dispensing device" refers to a mechanism or apparatus designed to distribute or release the dosing fluid in a controlled manner, typically through a nozzle, outlet, or similar means in the mixing chamber within the sludge line conduit. Notably, the presence of the dispensing device in the mixing chamber ensures that the dosing fluid is properly dispensed into the sludge line conduit to be mixed with the HDF. Subsequently, dispensing the dosing fluid directly into the mixing chamber, the dosing fluid is thoroughly blended with the HDF, enhancing the effectiveness of any chemical additives or corrections being made. A technical effect is that the presence of the dispensing device within the mixing chamber allows for precise and controlled dispensing of the dosing fluid and ensures that the dosing fluid is evenly distributed throughout the HDF in the sludge line conduit, promoting thorough mixing and preventing any localized sag or build-up of heavy particles in the HDF.

[0095] Spray bar

[0096] The fluid control system may further comprise a spray bar arranged within the fluid storage tank. In this regard, the term "spray bar" refers to a device or mechanism that is used to distribute a liquid, such as the HDF in the fluid storage tank, in a controlled and uniform manner by spraying it over a specific area or surface in the fluid storage tank. The spray bar is equipped with orifices that are sized to ensure consistent pressure drop. Notably, the spray bar spans the width of the fluid storage tank and is placed at various locations along the length of the fluid storage tank. The spray bar is arranged within the fluid storage tank to distribute the HDF evenly throughout the tank, it ensures that settled particles in the HDF are effectively re-agitated with minimal energy consumption. The arrangement of the spray bar within the fluid storage tank, improves the fluid control system's ability to maintain fluid stability and prevent sag or build-up or stratification. A technical effect is that the HDF is evenly redistributed into the fluid storage tank in a controlled manner to maintain the homogeneity of particles in the HDF after redistribution into the fluid storage tank.

[0097] The spray bar may extend across a width portion of the fluid storage tank. In this regard, the term "width portion" refers to the horizontal extent or dimension of the fluid storage tank. The spray bar extending across the width portion of the fluid storage tank enables to evenly distribute the HDF across the width portion of the fluid storage tank. The placement of spray bar across the width of the fluid storage tank ensures consistent pressure and fluid distribution, preventing sludge sag or build-up during recirculation in the sludge line conduit. A technical effect is that the even redistribution of the HDF into the fluid storage tank is ensured across the width portion of the fluid storage tank.

[0098] The spray bar may comprise an array of orifices that are sized to provide a consistent pressure drop across the spray bar. Notably, the array of orifices implies that the orifices are arranged in a regular pattern or gridlike formation in the spray bar. In this regard, the term "orifices" refers to small openings or apertures that are intentionally created or arranged in the spray bar to allow the controlled flow or passage of the HDF. Throughout the description, the term "pressure drop" refers to the decrease in pressure that occurs in the HDF while passing through the spry bar. Notably, the consistent pressure drop across the spray bar provided by the array of orifices facilitates the even redistribution of the HDF by the spray bar into the fluid storage tank. The size of the orifices is selected such that to maintain the consistent pressure drop across the spray bar. A technical effect is that the presence of the array of orifices in the spray bar effectively provides the consistent pressure drop across the spray bar and facilitates the even redistribution of HDF by the spray bar into the fluid storage tank.

[0099] The fluid control system may comprise an array of spray bars, wherein each spray bar in the array of spray bars is spaced along a length portion of the fluid storage tank. Notably, the array of spray bars implies that the spray bars are arranged in a regular pattern or grid-like formation along the length portion of the fluid storage tank. Throughout the description, the term "length portion" refers to the vertical extent or dimension of the fluid storage tank. Notably, each spray bar from amongst the plurality of spray bars comprises the array of orifices that are sized to provide the consistent pressure drop. The array of spray bars that are spaced along the length portion of the fluid storage tank, span across a whole width of the fluid storage tank. It will be appreciated that the array of spray bars being paced along the length portion of the fluid storage tank implies that each spray bar amongst the array of spray bars is arranged at a different position along the length portion of the fluid storage tank, such that whole of the length portion of the fluid storage tank is uniformly covered with the array of spray bars arranged thereon. A technical effect is that the even redistribution of the HDF into the fluid storage tank is further reinforced by presence of the array of spray bars in the fluid control system.

[0100] The fluid control system may further comprise a valve arranged between the spray bar and the inlet of the fluid storage tank. Throughout the description, the term "valve" refers to a mechanical device that controls the flow of the HDF by opening, closing, or partially obstructing a passageway between the spray bar and the inlet of the fluid storage tank, thereby regulating the rate, direction, and pressure of the HDF from the spray bar to the inlet of the fluid storage tank. The valve may be selected to be one of: a gate valve, a globe valve, a ball valve, a diaphragm valve, a solenoid valve, and the like. A technical effect of the valve arranged between the spray bar and the inlet of the fluid storage tank is that the flow of the HDF between the spray bar and the inlet of the fluid storage tank is effectively controlled and managed.

[0101] EDUCTOR JET

[0102] The fluid control system may further comprise a row of eductor jets arranged within the fluid storage tank. Herein, the term "eductor jet" refers to a mechanical component, fluidly coupled to the sludge line conduit, configured for sludge breaking. The eductor jet provides the effect of imparting sufficient shear force to redistribute settled weighting agent (or sludge or sag), to prevent or reduce dynamic sag. The dynamic sag is a phenomenon where slow or weak circulation makes the sag (settling) prominent and difficult to clear, thereby impacting the process.

[0103] Typically, the eductor jet uses the Venturi principle to convert the pressure energy of a motive fluid into kinetic energy, to produce a high-velocity jet that entrains and mixes a surrounding secondary fluid. Typically, the eductor jet comprises a converging-diverging nozzle, an inlet port for the motive flow, and a diffuser section that restores pressure after entrainment. Optionally, multiple eductor jets may be distributed and oriented toward key sediment-prone regions, such as near the sludge port, pump port, and trench walls. Beneficially, the eductor jet induces circulation and localized turbulence to maintain uniform density and viscosity of the HDF within the storage tank, without requiring additional mechanical components or moving parts (such as mechanical impellers or agitators). Thus, the eductor jets are both energy and cost efficient.

[0104] It may be appreciated that in specific implementations of the fluid control system comprising both the spray bars and the eductor jets, the eductor jets work in conjunction with the circulatory device (e.g., progressive cavity pump device, positive displacement device, or centrifugal pump device) and the spray bars, providing a dual-mode mixing pattern comprising horizontal shear from the eductor jets and vertical redistribution from the spray bars, to yield a complete re-agitation cycle.

[0105] Beneficially, when used in combination with the sludge line conduit, the circulatory device, or the sludge-breaking assembly (namely, the row of eductor jets, spray bars, etc.), the sloped base enables the eductor-induced shear flow to act tangentially along the lower surface of the fluid storage tank, thereby enhancing the agitation of dense regions and promoting uniform re-entrainment of the weighting agent.

[0106] As shown figure 2, a block diagram of a transition between modes of a fluid control system is illustrated, in accordance with an embodiment of the description. As shown, controller modes of the fluid control system are a manual mode 200, an automatic mode 202, a fault mode 204, an emergency stop mode 206, and an off mode 208. The states in the automatic mode 204 are an empty state 210, a non-empty state 212, and a fluid flow 214 state. In the empty state 210, the operating modes in the fluid control system are a sludge mode 216 and a sampling water flush mode 218. Similarly, in the non-empty state 212, the operating modes in the fluid control system are a sampling mode 220, a dosing mode 222, the sludge mode 216 and the sampling water flush mode 218. Similarly, in the fluid flow state 214, the operating modes in the fluid control system are a turbine sampling mode 224, a pump sampling mode 226, and the sludge mode 216.

[0107] As shown in figures 3A and 3B, block diagrams of a hierarchy of operations in a fluid control system are illustrated in different implementations, respectively, in accordance with an embodiment of the description. As shown in FIG. 3A, a fault mode 300 of the fluid control system comprises a failure mode 302 and an emergency stop mode 304.

[0108] Moreover, the fluid control system comprises an automatic mode 306, a sleep mode 308, and a manual override mode 310. Furthermore, the automatic mode 306 comprises a pump / turbine sampling 312, and a fluid storage tank sampling 314, wherein the fluid storage tank sampling 314 comprises a pigging chamber residual fluid 316, a pump residual fluid 318, a turbine residual fluid 320, a sampling line conduit flush 322, a sludge line conduit operation 324, and a dosing 326. Furthermore, the manual override mode 310 comprises the pump / turbine sampling 312, and the fluid storage tank sampling 314, wherein the fluid storage tank sampling 314 comprises the pigging chamber residual fluid 316, the pump residual fluid 318, the turbine residual fluid 320, the sampling line conduit flush 322, the sludge line conduit operation 324, and the dosing 326. As shown in FIG. 3B, the fault mode 300 of the fluid control system comprises the failure mode 302 and the emergency stop mode 304.

[0109] Moreover, the fluid control system comprises the automatic mode 306, the sleep mode 308, and the manual override mode 310. Furthermore, the automatic mode 306 comprises the pump / turbine sampling 312, the fluid storage tank sampling 314, the sludge line conduit operation 324, the dosing 326, and the sampling line conduit flush 322. Furthermore, the manual override mode 310 comprises the pump / turbine sampling 312, the fluid storage tank sampling 314, the sludge line conduit operation 324, the dosing 326, and the sampling line conduit flush 322.

[0110] As shown in figure 4, a flowchart depicting steps of a fluid control method for controlling sag or build-up in a fluid control system that comprises a fluid storage tank configured to retain a volume of high-density fluid (HDF) is illustrated. The fluid storage tank having walls and a floor, a base (such as a sloped base), a tank outlet, a sludge line conduit attached at a first end to the tank outlet; the fluid storage tank further comprises a tank inlet and the second end of the sludge line is attached to the tank inlet, a circulatory device is operably attached to the sludge line conduit for circulating a flow of retained HDF from the tank outlet to the tank inlet, in accordance with an embodiment of the description. At step 400, the circulatory device is operated intermittently for a predetermined time and HDF flowrate for every hour in which the fluid control system is in use. At step 402, the circulatory device is operated to circulate the retained HDF within the fluid storage tank within one day in the event of a fluid failure. At step 404, a frequency and duration of operating the circulatory device are selected to circulate the volume of retained HDF within the fluid storage tank within one week. At step 406, the fluid control system is operated independently from a primary control system in which the fluid control system is a secondary component thereof. The description also relates to the fluid control method as described above. Various embodiments and variants disclosed above, with respect to the aforementioned fluid control system, apply mutatis mutandis to the fluid control method.

[0111] Optionally, the method further comprises the following steps:

[0112] generating data indicative of a level of HDF fluid within the fluid storage tank;

[0113] activating a first valve to allow the flow of HDF through a first spray bar at a first position within the fluid storage tank wherein the retained HDF is at a maximum level within the fluid storage tank; and

[0114] activating a second valve to allow the flow of HDF through a second spray bar at a second position within the fluid storage tank wherein the retained HDF is at a minimum level within the fluid storage tank.

[0115] In this regard, the term "first valve" refers to a valve that controls and regulate the flow of the HDF through the first spray bar at the first position. Notably, the presence of the first spray bar at the first position enables the HDF to be redistributed in the fluid storage tank at that position where the retained HDF is at the maximum level within the fluid storage tank. Throughout the description, the term "second valve" refers to a valve that controls and regulate the flow of the HDF through the second spray bar at the second position. Notably, the presence of the second spray bar at the second position enables the HDF to be redistributed in the fluid storage tank at that position where the retained HDF is at the minimum level within the fluid storage tank. A technical effect of activating the first valve and the second valve is that the HDF is evenly redistributed in the fluid storage tank at those positions where the HDF is at the maximum level and the minimum level in the fluid storage tank. The aforementioned steps are only illustrative, and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.

[0116] As shown in figures 5A, 5B and 5C, various views of a sludge-breaking assembly 500 comprising a row of eductor jets 502, incorporated into the fluid control system 100, in accordance with an embodiment of the description.

[0117] Figure 5A is a general view of the sludge-breaking assembly 500, in accordance with an embodiment of the description. The sludge-breaking assembly 500 comprises a network of header lines 504 (that may be implemented as for example, solvent-welded 110 mm PVC header lines) supported along the base of the fluid storage tank 102. The header lines 504 are connected by connecting elements 506A and 506B (implemented as for example DN100 PN16 flanged joints and elbows) and are supported on double-stack strut 508 secured to the base using saddle clamps (as shown in figure 5B). The sludge-breaking assembly 500 includes a plurality of eductor jets 502 fluidly connected to the sludge line conduit 106 and oriented toward critical sludge accumulation regions, specifically, toward the FMS sludge port, the pump port, and along the lower-reservoir trench. Each eductor jet 502 produces a high-velocity jet of motive flow derived from the sludge line conduit 106, generating shear and localised turbulence across the base of the fluid storage tank 102 to prevent deposition and promote re-entrainment of settled solids.

[0118] Figure 5B is a side view of the sludge-breaking assembly 500, in accordance with an embodiment of the description. The figure 5B shows a manifold connection through the connecting elements 506A and 506B (implemented as a DN100 PN16 flanged joint or tee, a long-radius 90° elbow) leading to the header lines 504 (implemented as solvent-welded 110 mm PVC header lines), and multiple branch lines 510 (implemented as 50 mm PVC pipe) coupled to eductor jets 502 by connectors 512 (implemented as 50 mm to 1-1 / 2 inch BSPT connector) and nipples 514.

[0119] The eductor jets 502 are arranged along the base 102A of the fluid storage tank 102 at approximately 20 degrees inclination relative to the horizontal plane thereof. The supporting framework includes saddle clamps 516 that attaches the header lines 504 to the double-stack strut 508 for secure installation. The motive flow entering each eductor jet 502 generates an induced flow region that entrains fluid along the lower-reservoir trench, ensuring continual scouring of sediment layers and conveying re-suspended particles toward the tank outlet 104.

[0120] Figure 5C is a top view of the sludge-breaking assembly 500, in accordance with an embodiment of the description. The figure illustrates the layout of ten eductor jets 502 positioned along the lower-reservoir trench 520 and distributed across the base of the fluid storage tank 102.

[0121] The 50 mm PVC branch lines 510 extend from the 110 mm PVC manifold, terminating at the 50 mm to 1-1 / 2 inch BSPT connector 512. The spatial arrangement of the eductor jets 502 provides directional coverage along three axes: toward the FMS sludge port 522, toward the pump port 524, and along the longitudinal trench axis 526. This configuration enables the eductor jets 502 to generate intersecting jet flows that synergistically complement the vertical redistribution provided by the spray bars 134, thereby achieving a three-dimensional re-agitation pattern within the fluid storage tank 102.

[0122] Modifications to the embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure are defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also be present. Reference to the singular is also to be construed to relate to the plural.

Claims

CLAIMS1. A fluid control system (100) for recirculating a high-density fluid (HDF), comprising:a fluid storage tank (102) configured to retain a volume of HDF, the fluid storage tank having walls and a floor, a base, a tank outlet (104) located at substantially the lowest point of the fluid storage tank;Characterised in thatthe fluid control system further comprises a sludge line conduit (106) attached at a first end to the tank outlet, wherein the fluid storage tank has a tank inlet (108) at or towards the top of the fluid storage tank and the sludge line conduit is attached at a second end to the tank inlet;a circulatory device (110) is operably attached to the sludge line conduit for circulating a flow of retained HDF from the tank outlet to the tank inlet.

2. A fluid control system (100) as claimed in claim 1, further comprising a sample outlet (112) arranged at a first position on the wall of the fluid storage tank and a sample line conduit (114) attached at a first end to the sample outlet.

3. A fluid control system (100) as claimed in claim 1 or claim 2, further comprising a dosing line conduit (118) attached at a first end to a dosing fluid reservoir (120) containing a dosing fluid and at a second end is attached to the sludge line conduit (106) before to the inlet of the circulatory device (110).

4. A fluid control system (100) as claimed in any one of claims 1 to claim 3, wherein the interconnection of the dosing line conduit (118) tothe sludge line conduit (106) provides a mixing chamber within the sludge line conduit for combining a HDF with the dosing fluid.

5. A fluid control system (100) as claimed in any one of claims 1 to 4, wherein the sample line conduit (114) further comprises a sensor device (116) for generating data indicative of a property of the retained HDF extracted from the sample outlet (112) of the fluid storage tank (102).

6. A fluid control system (100) as claimed in claim 4, wherein the mixing chamber within the sludge line conduit (106) further comprises a dispensing device for dispensing the dosing fluid provided by the dosing line conduit (118).

7. A fluid control system (100) as claimed in any one of claims 1 to 6, wherein the sludge line conduit (106) comprises a first valve device (122) arranged between the tank outlet (104) of the fluid storage tank (102) and the mixing chamber within the sludge line conduit.

8. A fluid control system (100) as claimed in any one of claims 1 to 7, wherein the sludge line conduit (106) comprises a second valve device (124) arranged between the mixing chamber and the circulatory device (110).

9. A fluid control system (100) as claimed in claim 5, further comprising a controlling means for processing the data indicative of a property of the retained HDF and controlling the communication of a dose substance to the mixing chamber within the sludge line conduit (106).

10. A fluid control system (100) as claimed in any one of claims 1 to 9, wherein the property indicated in the data is one of: pH, specific gravity (SG), viscosity, dissolved oxygen, total dissolved solids, and the like of the retained HDF, and in-line yield point measurement and in-line temperature.

11. A fluid control system (100) as claimed in any one claim 1 to claim 10, wherein the wall of the fluid storage tank (102) further comprises a second sample outlet (126) arranged at a second position.

12. A fluid control system (100) as claimed in any one of claims 1 to 11, wherein the circulatory device (110) is a bi-directional device which in a first rotational movement circulates a retained HDF within the sludge line conduit (106) from the tank outlet (104) of the fluid storage tank (102) to the tank inlet (108) of the fluid storage tank, and in a second rotational movement circulates a retained HDF within the sludge line conduit from the tank inlet of the fluid storage tank to the tank outlet of the fluid storage tank.

13. A fluid control system (100) as claimed in any one of claims 1 to 12, wherein the circulatory device (110) is a progressive cavity pump device.

14. A fluid control system (100) as claimed in any one of claims 1 to 12, wherein the circulatory device is a positive displacement device or centrifugal pump device.

15. A fluid control system (100) as claimed in any one of the claims 1 to 14, further comprising a spray bar arranged within the fluid storage tank (102).

16. A fluid control system (100) as claimed in claim 15 wherein the spray bar extends across a width portion of the fluid storage tank (102).

17. A fluid control system (100) as claimed in claim 15 or claim 16, wherein the spray bar comprises an array of orifices that are sized to provide a consistent pressure drop across the spray bar.

18. A fluid control system (100) as claimed in anyone of claims 15 to 17, further comprises an array of spray bars, wherein each spray bar inthe array of spray bars is spaced along a length portion of the fluid storage tank (102).

19. A fluid control system (100) as claimed in any one of claims 15 to 18, further comprises a valve arranged between the spray bar and the inlet of the fluid storage tank (102).

20. A fluid control system (100) as claimed in any one of claims 1 to 19, further comprises a row of eductor jets (502) arranged within the fluid storage tank (102).

21. A fluid control method for controlling sag in a fluid control system (100) that comprises a fluid storage tank (102) configured to retain a volume of high-density fluid (HDF), the fluid storage tank having walls and a floor, a base, a tank outlet (104), a sludge line conduit (106) attached at a first end to the tank outlet; the fluid storage tank further comprises a tank inlet (108) and the second end of the sludge line is attached to the tank inlet, a circulatory device (110) is operably attached to the sludge line conduit for circulating a flow of retained HDF from the tank outlet to the tank inlet, the method comprising the following steps:operating the circulatory device intermittently for a predetermined time and HDF flowrate for every hour in which the fluid control system is in use;operating the circulatory device to circulate the retained HDF within the fluid storage tank within one day in the event of a fluid failure;selecting a frequency and duration of operating the circulatory device to circulate the volume of retained HDF within the fluid storage tank within one week; andoperating the fluid control system independently from a primary control system in which the fluid control system is a secondary component thereof.

22. A fluid control method as claimed in claim 21, further comprising the step of withdrawing a sample of retained HDF from the fluid storage tank via a sample line conduit attached at a first end to a sample outlet arranged at a first position on the wall of the fluid storage tank.

23. A fluid control method as claimed in claim 21 or claim 22, further comprising the step of: dispensing a dosing fluid from a dosing line conduit attached at a first end to a dosing fluid reservoir and at a second end is attached to the sludge line conduit.

24. A fluid control method as claimed in anyone of claims 21 to 23, further comprises the steps of:generating data indicative of a level of HDF fluid within the fluid storage tank (102);activating a first valve to allow the flow of HDF through a first spray bar at a first position within the fluid storage tank wherein the retained HDF is at a maximum level within the fluid storage tank; andactivating a second valve to allow the flow of HDF through a second spray bar at a second position within the fluid storage tank wherein the retained HDF is at a minimum level within the fluid storage tank.

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