Coke Drum Decoking Safety System with Remote Containment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The decoking process of coke drums is hazardous and time-consuming, particularly when dealing with shot coke, as it exposes workers to risks of coke avalanches and requires manual intervention, leading to potential injuries and operational delays.

Innovation Solution

A safety system comprising a continuous containment system, a top valve/gate system, and a bottom deheader system that allows for remote operation, including a drill stem containment system and a remotely switchable cutting system, enabling operators to safely manage the decoking process without manual intervention, thereby reducing exposure to hazards and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual intervention is used during decoking, then workers can directly manage the process, but workers are exposed to hazards such as coke avalanches and operational delays occur

Engineering Contradiction:

Improvemanual management capabilityVSAvoidworker exposure to hazards

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A containment system acts as an intermediary barrier between workers and the coke drum. The system includes a containment structure with a viewing port that allows workers to observe and manage the decoking process from a safe distance, eliminating direct exposure to coke avalanches and other hazards while maintaining operational control

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces manual mechanical operations with automated drilling and cutting equipment. The drilling apparatus and cutting system can be operated remotely or automatically, substituting direct worker intervention with mechanized systems that reduce human exposure to hazardous environments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If traditional decoking methods are used, then the process can be completed, but the time required to return the coke drum to service is extended

Engineering Contradiction:

Improvedecoking completionVSAvoidtime to return drum to service

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The containment system enables continuous operation by allowing multiple coke drums to be processed in sequence without interrupting the overall decoking workflow. While one drum is being decoked, another can be prepared or is already in the decoking process, eliminating idle time and maintaining continuous productive action across the system

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The containment system and drilling apparatus are pre-positioned and prepared before the decoking process begins. The drilling bit is lowered into the coke drum through the containment structure before drilling commences, and all necessary equipment is staged in advance to eliminate setup time during the actual decoking operation

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7632381B2Systems for providing continuous containment of delayed coker unit operations

Publication Date: 2009.12.15 DELTAVALVE LLC

AI summary

The present invention relates to a safety system during the entire delayed coker operation. The present invention preferably comprises a coke drum; a first coke drum de-header system coupled to the bottom of the coke drum; a second coke drum de-header system coupled to the top of the coke drum; a containment system coupled to the second coke drum de-header system; and a remote switching system. Hence, the present invention provides system for cutting coke within a coke drum with increased safety, efficiency and convenience.