Apparatus, system and method for maintaining a vessel

Abstract

An apparatus (10) for attachment with a rotating drill rod (12) and a cleaning head (14) to maintain a vessel (13). The apparatus (10) including a manifold (16) having a first end (18) adapted to be coupled to a first section (20) of the rod and a second end (22) adapted to be coupled to a second section (24) of the rod (12) such that rotary movement is transferred between the first and second sections (20, 24) of the rod via the manifold (16). The manifold (16) is adapted to carry the cleaning head (14) and includes a conduit arrangement (26) to communicate fluid from the first section (20) of the rod (12) to the cleaning head (14) and the second section (24) of the rotating rod (12). A related system and method are also disclosed.

Description

Apparatus., System and Method for Maintaining a VesselRelated Applications

[0001] This application claims priority from Australian provisional patent application no. 2024903877 filed on 25 November 2024, the contents of which is incorporated by reference.Technical Field

[0002] The invention relates to an apparatus, a system and a method for maintaining a vessel such as a reactor vessel containing a catalyst used in the oil refining process.Background

[0003] In oil refineries, particularly within catalytic reactors, regular maintenance of reactors involves the complex and time-intensive process of unloading and reloading of the catalysts materials. Such reactors comprise a vessel loaded with one or more catalysts.

[0004] Often the reactors have two or more beds of catalyst, the different beds of catalyst are connected by a transfer tube. In each maintenance cycle, the catalyst material needs to be removed from the reactors through the transfer tubes. The transfer tubes are initially blocked by a series of plates, these plates need to be removed to allow the catalyst to flow. Once the plates are removed, the catalyst can flow from the upper beds to the bottom beds of the reactor.

[0005] The current unloading procedure begins by using a drilling unit to puncture the plates in the transfer tube, thereby allowing catalyst to pass from the top bed to the bottom bed. Once the plates are punctured, the drilling unit is removed, and a cleaning head is inserted to break down the catalyst in the upper bed, allowing it to flow through the transfer tube into the lower bed. This process is required for achieving effective catalyst unloading, but it faces several critical challenges such as the available space and blockages.

[0006] If large chunks of catalyst fall into the tube, they often block the passage, requiring removal of the cleaning head, reinstallation of the drilling head to clear the blockage, and then another removal and reinstallation of the cleaning head to resume unloading.

[0007] This alternating between drilling and cleaning tools is labour-intensive and time-consuming. This extended downtime not only increases maintenance costs and labour requirements but also reduces overall operational efficiency and productivity, representing a significant expense for refineries.

[0008] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.Summary

[0009] In accordance with a first broad aspect there is provided, an apparatus for attachment with a rotating drill rod and a cleaning head to maintain a vessel, the apparatus including a manifold having a first end adapted to be coupled to a first section of the rod and a second end adapted to be coupled to a second section of the rod such that rotary movement is transferred between the first and second sections of the rod by the manifold, wherein the manifold is adapted to carry the cleaning head and includes a conduit arrangement to communicate fluid from the first section of the rod to the cleaning head and the second section of the rotating rod.

[0010] In an aspect, the conduit arrangement includes a first conduit in communication with the cleaning head and a second conduit arranged to bypass the cleaning head.

[0011] In another aspect, the manifold including a manifold body including a first manifold section at the first end, a second manifold section at the bottom end and a connecting section between the first manifold section and the second manifold section.

[0012] In yet another aspect, the cleaning head has an associated cleaning head manifold, and the manifold body is arranged to locate the cleaning head manifold between the first manifold section and the second manifold section.

[0013] In yet another aspect, the manifold body includes a recess in which the cleaning head manifold is at least partly received.

[0014] In yet another aspect, the cleaning head includes a rotating cleaning head coupled to the clearing head manifold.

[0015] In yet another aspect, the conduit arrangement includes a third conduit arranged to bypass with the cleaning head.

[0016] In yet another aspect, the second and third conduits are spaced apart on opposing sides of the cleaning head manifold.

[0017] In yet another aspect, the first manifold section includes an inlet adapted to couple with the first section of the rod and the second manifold section includes an outlet adapted to couple with the second section of the rod.

[0018] In yet another aspect, the manifold is formed of one or multiple parts coupled together.

[0019] In yet another aspect, the conduit arrangement is adapted to selectively transfer fluid to one or both of the cleaning head and the second section of the rotating rod.

[0020] In yet another aspect, the apparatus is configured to allow simultaneous drilling using the rotating drill rod and cleaning using the cleaning head.

[0021] In accordance with a second broad aspect there is provided, a system for maintaining a vessel , the system including: a rotating drill rod having a first section and a second section; a rotating cleaning unit; and, a manifold, wherein the manifold includes a first end adapted to be coupled to the first section of the rod and the second end adapted to be coupled to a second section of the rod such that rotary movement is transferred between the first and second sections of the rod by the manifold, wherein the manifold is adapted to carry the cleaning unit and includes a conduit arrangement to communicate fluid with the cleaning unit and the second section of the rotating rod.

[0022] In an aspect, the rotating cleaning unit comprises a 360-degree cleaning head that is operable to break up catalyst deposits within the vessel

[0023] In another aspect, the 360-degree cleaning head is configured to operate simultaneously with the rotating drill rod.

[0024] In yet another aspect, the manifold is configured to accommodate a removable connection between the rotating drill rod and the cleaning unit.

[0025] In accordance with a third broad aspect there is provided, a method for maintaining a vessel including drilling and cleaning, the method including: actuating a drill rod within the vessel to break up material within the vessel, the drill rod having a first section and a second section with a manifold connecting the first and second sections; selectively providing a fluid to the drill rod, the manifold being configured to distribute at least some of the fluid to the second section of the rod and at least some of the fluid to a cleaning unit which is carried by the manifold thereby enabling cleaning.

[0026] In an aspect, the method includes simultaneously rotating the drill rod and providing fluid to the manifold to operate the cleaning head.

[0027] In yet another aspect, the step of actuating the drill rod includes rotating the drill rod to puncture through obstructions in the vessel such as hardened catalyst deposits.

[0028] In yet another aspect, the cleaning unit includes a 360-degree cleaning head.

[0029] In yet another aspect, the 360-degree cleaning head and the drill rod operate simultaneously within the vessel

[0030] In yet another aspect, the step of providing fluid to the drill rod includes directing fluid through the conduit arrangement to flow selectively to the drill rod and / or the cleaning head.

[0031] In accordance with a fourth broad aspect there is provided, an manifold for attachment with a rotating drill rod and a cleaning unit to maintain a vessel , the manifold having a first end adapted to be coupled to a first section of the rod and a second end adapted to be coupled to a second section of the rod such that rotary movement is transferred between the first and second sections of the rod by the manifold, wherein the manifold is adapted to carry the cleaning head and includesconduit arrangement to communicate fluid between the first section of the rod, and the cleaning head and the second section of the rotating rod.

[0032] In accordance with a fifth broad aspect there is provided, an apparatus for attachment with a rotating drill rod and a cleaning head to maintain a vessel the apparatus including a manifold having a first end adapted to be coupled to a first section of the rod and a second end adapted to be coupled to a second section of the rod such that rotary movement is transferred between the first and second sections of the rod by the manifold, wherein the manifold is adapted to carry the cleaning head and includes conduit arrangement to simultaneously communicate fluid between the first section and second section of the rod and between the first section of the rod and the clearing unit.Brief Description of the Figures

[0033] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which;

[0034] Figure 1 is a front perspective view illustrating an example of an apparatus including a manifold fitted with a cleaning unit manifold with a cleaning head removed;

[0035] Figure 2 is another front perspective view illustrating the apparatus including the manifold fitted with the cleaning unit manifold with the cleaning head removed;

[0036] Figure 3 is a backside perspective view illustrating the apparatus including the manifold fitted with the cleaning unit manifold with the cleaning head removed;

[0037] Figure 4 is another frontside perspective view illustrating the apparatus including the manifold fitted with the cleaning unit manifold and the cleaning head;

[0038] Figure 5 is a frontside perspective in use view illustrating an example of a system including a drill rod arrangement, the cleaning unit and the apparatus including the manifold to which the cleaning unit is fitted; and,

[0039] Figure 6 is a cutaway perspective in use view illustrating an example of the system within a vessel.Detailed Description

[0040] Referring to Figures 1 to 6 there is illustrated an example of an apparatus 10 for attachment to a rotating drill rod 12 and a cleaning head 14 for maintaining a vessel 13. The apparatus 10 includes a manifold 16 which allows for both mechanical and fluid communication between the components, enabling efficient vessel maintenance. The rotating drill rod 12 is driven by a drilling unit (not shown) and may include a drill head or tip (not shown). The rotating drill rod 12 may be hollow to allow fluid transfer therethrough.

[0041] In more detail, the manifold 16 serves as an intermediary connection between a first section 20 of the rod 12 and a second section 24 of the rod 12. The manifold 16 has a first end 18 that couples with the first section 20 of the drill rod 12 and a second end 22 that couples with the second section 24. This configuration allows for the transfer of rotary motion of the rod 12 via the manifold 16, thus ensuring the rotation of both the cleaning head 14 and drill rod 12 during operation.

[0042] The manifold 16 includes fluid conduit arrangement 26, which is configured to receive fluid from the first section 20 and deliver fluid to both the cleaning head 14 and the second section 24 of the rotating drill rod 12. This dual-purpose function allows for the simultaneous application of mechanical and cleaning actions within the vessel 13, providing an effective and streamlined maintenance solution.

[0043] The conduit arrangement 26 within the manifold 16 is structured to accommodate multiple fluid paths between a first manifold section 34 at the first end 18 and a second manifold section 36 at the second end 24. In more detail, the conduit arrangement 26 includes a first conduit 28 that is in direct communication with the cleaning head 14. This conduit 28 directs fluid from the first manifold section 34 to the cleaning head 14 for vessel washing, cleaning or clearing operations and any excess fluid may enter the second manifold section 36.

[0044] Additionally, the conduit arrangement 26 further includes a second conduit 30 between the first manifold section 34 and second manifold section 36 which is arranged to bypass the cleaning head 14, allowing fluid to flow directly into the second section24. In this example, the conduit arrangement 26 within the manifold 16 may still further includes a third conduit 46 that provides an additional fluid bypass option.

[0045] Turning to the manifold 16 in more detail, the manifold 16 includes a body 32 that including the first manifold section 34 located at the upper end 18 of the body 32, designed to couple with the first section 20 of the drill rod 12 via an inlet 48; a second manifold section 36 positioned at the lower end 22 of the body 32, which includes an outlet 50 to couple with the second section 24 of the drill rod 12; and a connecting section 38 between the first manifold section 34 and the second manifold section 36, which provides the structural link between the drill rod sections and allows for fluid passage through the manifold 16. The manifold 16 may include lifting couplings or hooks 25 fitted to the top and bottom of the body 32.

[0046] The connecting section 38 also ensures that the cleaning unit 59 is not subject to rotation forces. In this example, the connecting section 38 may be structural steel plate. However, other suitable structural configurations may be used. The cleaning head 14 is equipped with an associated cleaning head manifold 40, which is seated within a recess 42 in the manifold body 32. Together the cleaning head manifold 40 and cleaning unit 59 provide the cleaning unit 59.

[0047] The recess 42 allows the cleaning head manifold 40 to be located between the first 34 and second 36 manifold sections, ensuring stable and efficient operation. The cleaning head manifold 40 is partially or fully received within this recess 42, securing the cleaning head 14 and allowing it to rotate in conjunction with the drill rod 12.

[0048] The cleaning head 14 includes a rotating cleaning component 44, which is coupled to the cleaning head manifold 40 and provides active cleaning action within the vessel. The rotating cleaning component 44 may be a 360-degree spray or cleaning head. However, other suitable clearing heads or arrangements may also be used.

[0049] The second conduit 30 and third conduit 46 are spaced apart on opposing sides of the cleaning head manifold 40, creating a balanced flow system around the cleaning head manifold 40 to ensure uniform distribution of fluid. The manifold 16 may be fabricated as a single unit or as multiple parts that are securely joined together fordurability and operational consistency. Some examples of the manifold 16 may be machined.

[0050] The conduit arrangement 26 within the manifold 16 is designed to selectively transfer fluid to one or both of the cleaning head 14 and the second section 24 of the rotating rod 12. Preferably, in this example, the conduit arrangement 26 provides simultaneous flow to the cleaning head 14 and second section 24 of the drill rod 12. However, controls such as valves could be included to allow for selective operation such as turning off the cleaning head 14.

[0051] The described apparatus 10 can be implemented as part of a vessel maintenance system 54, best shown in Figure 5. This system 54 includes a rotating drill rod 12 with the first section 20 and the second section 24, the rotating cleaning unit 59 for cleaning operations within the vessel, and the manifold 16, which serves to transfer rotary motion between the sections of the drill rod 12 while supporting the cleaning unit 56 and facilitating fluid communication through the conduit arrangement 26.

[0052] In this example, the rotating cleaning unit 59 is a separate unit to the manifold 16. However, it is noted that in some examples, the manifold 16 and rotating cleaning unit 59 could be manufactured and provide as a single unit with common parts such as, but not limited to, a common manifold.

[0053] The system 54 operates by utilising the manifold 16 to transmit rotational movement and fluid to both the cleaning unit 56 and the drill rod 12. The conduit arrangement 26 enables fluid to flow through the manifold 16 to the cleaning unit 56 and the second section 24 of the drill rod.

[0054] Turning to a method for vessel maintenance, the method may include the following steps: fitting the cleaning unit 56 to the manifold 16 and using the manifold 16 to connect the first section 20 and the second section 24 of the drill rod 12; actuating the drill rod 12 within the vessel 13 to break up material deposits or the like; and, providing fluid through the manifold 16 to both the cleaning unit 56 and the second section 24 of the drill rod 12, thereby enabling a selective and preferably simultaneous drilling and cleaning or clearing operations.

[0055] This apparatus 10, the system 54, and the method provide an efficient solution for vessel maintenance by integrating a rotating drill rod 12, manifold 16, and rotating cleaning unit 56 within a single, cohesive design. The manifold 16 serves as both a mechanical support and fluid conduit, facilitating simultaneous drilling and cleaning operations, reducing maintenance time. It is noted that in some examples, the manifold 16 and the cleaning head 14 may be formed as a single integrated product or unit.

[0056] Advantageously, the proposed solution involves a specialised apparatus including a manifold that allows for the simultaneous operation of both a drilling unit and a cleaning unit. This manifold integrates the functions of both tools, enabling continuous drilling that may include catalyst breakdown and cleaning that may include transfer tube clearance without the need to alternate tools.

[0057] In a more specific example, in the case of catalyst reactors, the drilling nozzle within the manifold maintains an open passage in the transfer tube, preventing blockages, while the 360-degree cleaning head actively breaks down the catalyst in the upper bed, allowing for uninterrupted catalyst flow. This integrated approach drastically reduces the time and resources needed for reactor maintenance, minimizing operational downtime and improving efficiency in catalyst unloading operations. The apparatus may also find use in other applications which require drilling and cleaning operations.

[0058] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0059] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

[0060] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein.

[0061] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims

The claims defining the Invention are as follows:

1. An apparatus for attachment with a rotating drill rod and a cleaning head to maintain a vessel, the apparatus including a manifold having a first end adapted to be coupled to a first section of the rod and a second end adapted to be coupled to a second section of the rod such that rotary movement is transferred between the first and second sections of the rod via the manifold, wherein the manifold is adapted to carry the cleaning head and includes a conduit arrangement to communicate fluid from the first section of the rod to the cleaning head and the second section of the rotating rod.

2. The apparatus according to claim 1, wherein the conduit arrangement includes a first conduit in communication with the cleaning head and a second conduit arranged to bypass the cleaning head.

3. The apparatus according to claim 2, wherein the manifold includes a manifold body including a first manifold section at the first end, a second manifold section at the bottom end and a connecting section between the first manifold section and the second manifold section.

4. The apparatus according to claim 3, wherein the cleaning head has an associated cleaning head manifold, and the manifold body is arranged to locate the cleaning head manifold between the first manifold section and the second manifold section.

5. The apparatus according to claim 4, wherein the manifold body includes a recess in which the cleaning head manifold is at least partly received.

6. The apparatus according to claim 4, wherein the cleaning head includes a rotating cleaning head coupled to the clearing head manifold.

7. The apparatus according to claim 3, wherein the conduit arrangement includes a third conduit arranged to bypass with the cleaning head.

8. The apparatus according to claim 7, wherein the second and third conduits are spaced apart on opposing sides of the cleaning head manifold.

9. The apparatus according to claim 3, wherein the first manifold section includes an inlet adapted to couple with the first section of the rod and the second manifold section includes an outlet adapted to couple with the second section of the rod.

10. The apparatus according to claim 3, wherein the manifold is formed of one or multiple parts coupled together.

11. The apparatus according to claim 1 , wherein the conduit arrangement is adapted to selectively transfer fluid to one or both of the cleaning head and the second section of the rotating rod.

12. The apparatus according to claim 1, wherein apparatus is configured to allow simultaneous drilling using the rotating drill rod and cleaning using the cleaning head.

13. A system for maintaining a vessel, the system including: a rotating drill rod having a first section and a second section; a rotating cleaning unit; and, a manifold, wherein the manifold includes a first end adapted to be coupled to the first section of the rod and the second end adapted to be coupled to a second section of the rod such that rotary movement is transferred between the first and second sections of the rod by the manifold, wherein the manifold is adapted to carry the cleaning unit and includes a conduit arrangement to communicate fluid with the cleaning unit and the second section of the rotating rod.

14. The system according to claim 13, wherein the rotating cleaning unit comprises a 360-degree cleaning head that is operable to break up catalyst deposits within the vessel.

15. The system according to claim 14, wherein the 360-degree cleaning head is configured to operate simultaneously with the rotating drill rod.

16. The system according to claim 13, wherein the manifold is configured to accommodate a removable connection between the rotating drill rod and the cleaning unit.

17. A method for maintaining a vessel including drilling and cleaning, the method including: a. Actuating a drill rod within the vessel to break up material within the vessel, the drill rod having a first section and a second section with a manifold connecting the first and second sections; b. Providing a fluid to the drill rod, the manifold being configured to distribute at least some of the fluid to the second section of the rod and at least some of the fluid to a cleaning unit which is carried by the manifold thereby enabling cleaning.

18. The method according to claim 17, wherein the method includes simultaneously rotating the drill rod and providing fluid to the manifold to operate the cleaning unit.

19. The method according to claim 17, wherein the step of actuating the drill rod includes rotating the drill rod to puncture through obstructions in the vessel, such as hardened catalyst deposits.

20. The method according to claim 17, wherein the cleaning unit includes a 360- degree cleaning head.

21. The method according to claim 20, wherein the 360-degree cleaning head and the drill rod operate simultaneously within the vessel.

22. The method according to claim 17, wherein the step of providing fluid to the drill rod includes directing fluid through the conduit arrangement to flow selectively to the drill rod and / or the cleaning head.

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