Remote Decoking Tool Flow Diversion Apparatus
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Solution Overview
Problem
The existing systems for removing coke from coke drums are inefficient and hazardous due to the need to manually switch between cutting and boring modes, which can lead to accidents and compromised coke-cutting efficiency, as the mode changes occur within the drum and are difficult to determine.
Innovation Solution
A system that allows remote activation and switching between cutting and boring modes without removing the drill bit from the coke drum, utilizing a flow diversion apparatus with rotational ratcheting mechanisms and nitrogen springs to control the flow of high-pressure water between nozzles, ensuring safe and efficient coke removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual switching between cutting and boring modes is used, then the system is simpler, but safety is compromised and operator exposure to high-pressure water jets increases
Solution Approach 1:
The patent replaces manual mechanical switching with an automated hydraulic control system. A control valve directs high-pressure water flow to different nozzle groups based on operational mode requirements, eliminating the need for operators to manually position or reconfigure cutting tools within the drum. This substitution of manual mechanical operations with automated fluid-based control resolves the safety contradiction by removing operators from hazardous exposure while maintaining system functionality.
Solution Approach 2:
The patent introduces a control valve as an intermediary device between the water supply and the nozzles. This intermediary component automatically routes high-pressure water flow to either cutting nozzles or boring nozzles based on the selected mode, preventing direct operator intervention in the high-pressure water jet path. The control valve acts as a safe mediator that manages the hazardous energy transfer without requiring operator proximity to the cutting zone.
2Reliability
If mode switching occurs within the drum, then the drill bit remains in position, but it becomes difficult to determine the current mode and accidents may occur
Solution Approach 1:
The patent implements a feedback mechanism where the control system provides information about the current operational mode. The control valve's position or state can be monitored to indicate whether the system is in cutting mode or boring mode, giving operators clear feedback about the active configuration without requiring them to visually inspect or manually verify the mode within the drum. This feedback loop resolves the contradiction by providing unambiguous mode identification while maintaining the benefit of in-position switching.
3Productivity
If manual mode changes are performed, then fewer components are needed, but coke-cutting efficiency is compromised due to time loss and potential accidents
Solution Approach 1:
The patent enables continuous operational action by allowing mode switching to occur without removing the drill bit from the drum or interrupting the overall decoking process. The hydraulic control system can transition between cutting and boring modes instantly by redirecting water flow, eliminating the downtime associated with manual tool retrieval, reconfiguration, and repositioning. This continuity of useful action directly addresses the productivity contradiction by maintaining operational flow while incorporating an automated switching mechanism.
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
Enhances safety and efficiency by allowing operators to switch modes remotely, reducing the risk of accidents and improving coke-cutting efficiency by eliminating the need for manual mode changes within the drum.
Implementation Method 1
a flow diversion apparatus with rotational ratcheting mechanisms and nitrogen springs to control the flow of high-pressure water
Implementation Method 2
utilizing a flow diversion apparatus with rotational ratcheting mechanisms and nitrogen springs to control the flow of high-pressure water
Data Source
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AI summary
A system allows an operator to remotely switch between cutting and boring while removing solid carbonaceous residue from large cylindrical vessels called coke drums. The system comprises a cutting head for ejecting high pressure fluids into the coke bed; a flow diversion apparatus; and a shifting apparatus. A drill stem allows for the movement of fluids through the interior of the drill stem to a cutting tool. High pressure fluids can flow through the stem to cutting tool the cutting nozzles and out through boring nozzles or cutting nozzles. Flow of liquid either into the boring nozzles or cutting nozzles can be controlled with a flow diversion apparatus. The flow diversion apparatus can include a main body, a flow diversion cap, and a shifting apparatus.