Rotatable Header Coupling for Angled Process Tube Access
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Solution Overview
Problem
The existing methods for decoking fired heaters are inefficient and costly due to the need for custom-built header delivery systems, which are time-consuming and expensive to design, manufacture, and install, especially when accessing process tubes connected to header pipes at various angular positions.
Innovation Solution
A universal header delivery system featuring a hydraulically-actuated base assembly that can be rotated to align with process tubes at different angular positions, using a modular design with adjustable couplers and a jack apparatus to form a seal, allowing for quick and cost-effective access to process tubes without the need for custom-built systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom-built header delivery system is used to access process tubes, then the system can be tailored to specific header pipe configurations, but the design, manufacture, and installation time and cost increase significantly
Solution Approach 1:
The patent applies universality by designing a standardized header delivery system that can be used across multiple header pipe configurations without custom fabrication. The system uses universal components including a standardized launcher, universal couplers, and adjustable positioning mechanisms that adapt to different tube locations and angles through configuration rather than custom design, thereby eliminating the time-consuming custom build process while maintaining adaptability
Solution Approach 2:
The patent applies dynamics through the use of adjustable and reconfigurable components. The header delivery system incorporates movable positioning mechanisms, adjustable couplers that can accommodate different angular positions, and reconfigurable tooling that can be adapted to various tube orientations. This dynamic adjustability replaces the need for static custom-built systems, allowing rapid reconfiguration for different header pipe arrangements
2Manufacturing precision
If a custom-built header delivery system is manufactured for each specific application, then the system fits the exact requirements, but the manufacturing cost increases
Solution Approach 1:
The patent applies universality by creating a standardized header delivery system with universal components that can be repeatedly manufactured using the same processes and specifications. The standardized launcher, universal couplers, and modular tooling can be produced through efficient batch manufacturing rather than costly custom fabrication for each application, significantly reducing manufacturing costs while maintaining precise fit through standardized design
Solution Approach 2:
The patent applies segmentation by dividing the header delivery system into modular components including a launcher, couplers, positioning mechanisms, and tooling elements. This modular architecture allows each component to be manufactured independently using optimized processes, enabling precise manufacturing of individual parts that assemble to meet exact requirements, while avoiding the cost of manufacturing complete custom systems
3Object-generated harmful factors
If traditional decoking methods are used, then the process can remove coke deposits, but the operation requires costly and time-consuming custom system installation
Solution Approach 1:
The patent applies the extraction principle by removing the header delivery system from the header pipe during the decoking operation. The system is inserted through existing pipe openings, positioned to access the process tubes, used to deploy cleaning tools, and then removed without requiring permanent installation or complex structural modifications to the header pipe, thereby simplifying the overall device complexity
Solution Approach 2:
The patent applies the intermediary principle by using a header delivery system as a temporary mediator to access process tubes within the header pipe. The system serves as an intermediate platform that can be inserted and positioned to deliver cleaning tools to tube locations, perform the decoking operation, and then removed, avoiding the need for complex permanent installation structures
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
This solution reduces the time and cost associated with decoking operations by enabling rapid deployment and adaptation to various header pipe configurations, eliminating the need for custom-built systems and allowing for efficient service operations across a range of sizes and shapes of header pipes and process tubes.
Implementation Method 1
a jack apparatus connected to the tube coupler and configured to adjustably position the tube coupler
Implementation Method 2
The rotation assembly including a first rotation apparatus connected to the first frame member at the first frame end and a second rotation apparatus connected to the first frame member at the second frame end
Data Source
AI summary
A header delivery system and method for performing a pigging operation on a process tube connected at an angle to a header pipe. The header delivery system includes a base assembly coupled to a rotation assembly. The base assembly has a frame member supporting a launcher pipe coupled to a tube coupler and a jack apparatus. The rotation assembly is configured to position the base assembly with respect to the rotation assembly to adjust an angular position of the base assembly. The header delivery system may be aligned with a process tube in the header pipe and the jack apparatus may position the tube coupler from a first retracted position to an extended position to form a seal between the tube coupler and the first process tube. A service operation may be performed on the first process tube with the tube coupler in the extended position.