Decoking Tool Testing Device for High-Pressure Water Jet Analysis
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Solution Overview
Problem
Current methods for testing decoking tools are limited, as they can only be tested under reduced conditions, making it difficult to evaluate the effectiveness of novel nozzle geometries and water jet performance, which are crucial for cutting and boring operations in coke drums.
Innovation Solution
A testing device that connects a decoking tool to a high-pressure water conduit, allowing for the examination of high-pressure water jets under conditions similar to actual operation, using a jet housing to safely contain and analyze the water jet, and incorporating optical and sensor means for detailed testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If decoking tools are tested under reduced conditions with model calculations and assumptions, then testing can be performed with simplified equipment, but the reliability and accuracy of test results deteriorate because conclusions about actual function in practice cannot be drawn safely
Solution Approach 1:
The patent creates a scaled-down copy of the actual coke drum environment by constructing a test rig with a model coke drum that reproduces the essential geometry and material properties. This allows full-scale testing conditions to be replicated in a controlled laboratory setting, enabling reliable measurement of water jet performance on actual coke material without requiring access to full-size industrial coke drums.
Solution Approach 2:
The test rig is designed as a universal testing platform that can evaluate multiple decoking tool configurations, nozzle geometries, and operational parameters within a single facility. The system serves multiple functions including housing the model coke drum, providing high-pressure water supply, incorporating measurement equipment, and enabling various testing scenarios, thereby replacing multiple separate testing approaches.
2Productivity
If novel nozzle geometries are developed to improve cutting performance, then water jet effectiveness may be enhanced, but the ability to evaluate these improvements deteriorates because testing must rely on theoretical calculations and assumptions about jet profile rather than direct observation
Solution Approach 1:
The test rig incorporates measurement equipment that provides direct feedback on water jet performance parameters such as jet profile, pressure distribution, and cutting effectiveness. This empirical feedback allows for precise evaluation of novel nozzle geometries under controlled conditions, enabling iterative optimization of nozzle design based on actual performance data rather than theoretical assumptions.
Solution Approach 2:
The patent replaces theoretical and computational methods for evaluating nozzle performance with direct physical measurement using instrumentation within the test rig. Sensors and measurement devices directly observe water jet characteristics and cutting performance, substituting mechanical and optical measurement systems for computer simulations and theoretical calculations.
3Reliability
If decoking tools are tested in actual coke drums during practical operation, then real-world performance can be observed, but the ability to conduct distinguished and detailed testing deteriorates because only rough functional testing is possible due to harsh conditions
Solution Approach 1:
The patent extracts the essential testing function from the harsh environment of actual coke drums by creating a controlled model environment. The model coke drum isolates the water jet-coke interaction from the complicating factors of full-scale industrial operation, allowing detailed measurement and observation that would be impossible in the actual coke drum while maintaining authentic material and geometric conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable testing of decoking tools under practical conditions, allowing for the optimization of nozzle geometry and water jet performance, reducing the risk of performance-reducing turbulences and enhancing cutting efficiency.
Implementation Method 1
a high-pressure jet corresponds to the water jet with which coke is crushed when coke drums are being emptied
Implementation Method 2
connected to a high-pressure water conduit at a water pressure of appr. 350-380 bar
Data Source
AI summary
A device for testing decoking tools comprises means 30 for receiving the decoking tool 31 which can be connected to a high-pressure water conduit, as well as means for testing the water jet which exits from a nozzle of the decoking tool 31 following the opening of the high-pressure water conduit. It is possible to test, measure and analyse the high-pressure water jet exiting from the nozzle by means of this testing device in order to optimize the performance of the decoking tool on the basis of the results of this examination. According to the method of the invention the high-pressure water jet generated by means of the nozzles of the decoking tool is exposed to means for testing the high-pressure water jet.