Rotating Header Launcher Assembly for Angled Tube Pigging
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Solution Overview
Problem
The existing custom-built header delivery systems for pigging operations in fired heaters are costly and time-consuming, requiring extensive design, manufacturing, and testing, which hinders efficient access and maintenance of process tubes connected to header pipes.
Innovation Solution
A universal header delivery system with a hydraulically-actuated base assembly that can be rotated to align with process tubes at different angular positions, featuring modular components and adjustable couplings to accommodate various header pipe and process tube sizes, allowing for quick deployment and adaptation to different furnace configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom-built header delivery system is used for pigging operations, then the system can be tailored to specific furnace configurations, but the development 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 furnace configurations. The system includes universal components such as a standardized base assembly, rotation apparatus, and launcher assembly that can accommodate different header pipe sizes and process tube angular positions without requiring custom fabrication. This allows the same system design to serve multiple functions across different furnace types, thereby reducing development time while maintaining adaptability.
Solution Approach 2:
The patent applies dynamics through the rotation apparatus that enables the base assembly to rotate to different angular positions. This dynamic capability allows the launcher assembly to align with process tubes at various angular positions around the header pipe, providing adaptability to different furnace configurations without requiring multiple custom-built systems. The rotational mechanism enables the system to dynamically adjust to different operational requirements.
2Adaptability or versatility
If a custom-built header delivery system is used for pigging operations, then the system can be tailored to specific furnace configurations, but the manufacturing cost increases
Solution Approach 1:
The patent applies universality by designing a standardized header delivery system that can be used across multiple furnace configurations. The system includes universal components such as a standardized base assembly, rotation apparatus, and launcher assembly that can accommodate different header pipe sizes and process tube angular positions without requiring custom fabrication. This allows the same system design to serve multiple functions across different furnace types, thereby reducing manufacturing cost while maintaining adaptability.
Solution Approach 2:
The patent applies segmentation by dividing the header delivery system into modular components: a base assembly, a rotation apparatus, and a launcher assembly. Each component can be manufactured independently using standardized processes and then assembled together. This modular approach reduces manufacturing complexity and cost compared to building custom integrated systems for each furnace configuration, while still allowing adaptation to different applications through component reconfiguration.
3Loss of time
If a universal header delivery system is used, then deployment time is reduced, but the system must accommodate various header pipe and process tube sizes
Solution Approach 1:
The patent applies dynamics through the rotation apparatus that enables the base assembly to rotate to different angular positions. This dynamic capability allows the launcher assembly to align with process tubes at various angular positions around the header pipe, providing adaptability to different furnace configurations without requiring multiple custom-built systems. The rotational mechanism enables the system to dynamically adjust to different operational requirements.
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 custom system development, enabling rapid response and efficient pigging operations by eliminating the need for custom-built systems, allowing for quick alignment and sealing with process tubes at various angular positions, thus enhancing operational efficiency.
Implementation Method 1
a hydraulically-actuated base assembly
Data Source
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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.