Pipeline Magnetic Separator Inline Ferrous Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Oil and gas pipelines suffer from corrosion and erosion due to ferrous contamination, leading to reduced operational life, flow accuracy issues, and equipment failure, with traditional filtration technologies being expensive and inefficient.
Innovation Solution
A magnetic separation system with a housing and magnetic separator assembly is installed inline in the pipeline to attract and remove ferrous particles, utilizing a cleaning plate and crane system for safe and efficient cleaning, minimizing human contact and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional filtration technology (cyclone or centrifuge filters, media filters) is used to remove ferrous contamination, then some contamination removal is achieved, but the system becomes expensive, inefficient, and creates flow restrictions that can even cause collapse from back pressure
Solution Approach 1:
The patent replaces traditional mechanical filtration systems (cyclone filters, centrifuge filters, media filters) with a magnetic field-based separation system. Magnetic separator assemblies with magnetic members generate magnetic fields that attract and remove ferrous contamination from fluid flow without the mechanical complexity, flow restrictions, and maintenance issues of traditional filters.
Solution Approach 2:
The patent changes the separation mechanism from mechanical filtration (physical blocking of particles) to magnetic field interaction (attractive force on ferrous particles). This parameter change allows for effective ferrous contamination removal without the flow restrictions and back pressure problems inherent in mechanical filtration systems.
2Object-affected harmful factors
If magnetic separator assemblies are used to remove ferrous contamination, then contamination removal effectiveness is improved, but the magnetic members require cleaning which involves safety concerns and operational downtime
Solution Approach 1:
The patent implements self-service cleaning mechanisms where cleaning members (such as scraping members or flushing systems) automatically clean the magnetic members during or between operational cycles. This eliminates or reduces the need for manual cleaning operations, thereby improving safety by minimizing human contact with magnetic fields and contaminated materials, and reducing operational downtime.
Solution Approach 2:
The patent incorporates preliminary cleaning actions where cleaning members are positioned to prevent excessive contamination buildup on magnetic members before it becomes problematic. This proactive approach reduces the frequency and intensity of cleaning operations required, thereby improving ease of operation by reducing safety risks and downtime.
3Ease of manufacture
If pipeline quality is lowered to reduce manufacturing costs, then manufacturing expense is reduced, but black powder formation increases significantly reducing operational life
Solution Approach 1:
The patent converts the harmful effect of ferrous contamination (which accelerates pipeline degradation) into a beneficial separation process. By installing magnetic separator assemblies that actively remove ferrous particles from the fluid flow, the system compensates for using lower-grade pipeline materials, thereby extending operational life without sacrificing manufacturing cost benefits.
Solution Approach 2:
The patent changes the operational parameters by introducing magnetic field-based contamination removal, which fundamentally alters the degradation trajectory of the pipeline. This allows lower-grade materials to achieve comparable operational lifetimes to higher-grade materials by actively managing ferrous contamination levels in the fluid flow.
4Productivity
If ferrous contamination accumulates in the pipeline, then transportation distance can be extended, but equipment wear (meters, valves, pumps, compressors) increases significantly
Solution Approach 1:
The patent extracts ferrous contamination from the fluid flow at strategic locations along the pipeline using magnetic separator assemblies. This continuous or periodic removal of contaminants prevents their accumulation and subsequent damage to equipment such as meters, valves, pumps, and compressors, thereby maintaining equipment reliability over extended transportation distances.
Solution Approach 2:
The patent implements a feedback mechanism where magnetic separator assemblies continuously or periodically remove ferrous contamination, preventing the cumulative damage that would otherwise occur over long transportation distances. This active management of contamination levels allows the system to maintain equipment reliability while achieving extended transportation distances.
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
The magnetic separation system effectively removes ferrous contamination, extending pipeline life, maintaining flow accuracy, and reducing equipment wear, while being cost-effective and environmentally friendly by minimizing filter media disposal issues.
Implementation Method 1
a magnetic separator assembly having a header and a plurality of magnetic members, each of the magnetic members attached to the header at a first end and extending away from the header to a second end
Data Source
AI summary
A system, apparatus and method for magnetically separating a fluid flow passing through a pipeline are provided. A magnetic separator assembly having a plurality of elongate magnetic members is provided. Each magnetic member can have a first end and a second end. A cleaner plate can be provided that can move along the magnetic members. After the magnetic separator assembly is used to collect magnetic particles from a fluid flow in a pipeline, the magnetic separator assembly can be cleaned by sliding the cleaning plate along the magnetic members.