In-Situ Vessel Cladding Removal With Surface Mapping Control
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Solution Overview
Problem
Current methods for reconditioning industrial pressure vessels, such as COKER vessels, are costly, time-consuming, and hazardous due to the manual process of arc gouging and grinding, which results in an uneven surface and poses safety risks for workers.
Innovation Solution
A computer-driven system that uses a SCANNER to map the surface of the vessel and a processor to control a cutting head, allowing for the precise removal of metal cladding and preparation of the surface for new welds, thereby eliminating the need for manual grinding and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual arc gouging and grinding is used to remove cladding, then metal removal is achieved, but the surface becomes uneven and worker safety is compromised
Solution Approach 1:
The patent replaces manual mechanical arc gouging and grinding with an automated robotic system that uses controlled cutting tools to remove cladding. The robotic system executes pre-programmed paths to achieve uniform material removal, eliminating the uneven surfaces produced by manual operations while removing workers from hazardous environments.
Solution Approach 2:
The system incorporates real-time scanning capabilities that automatically map the vessel interior surface and adjust the cutting depth and path without human intervention. The robotic system self-regulates the material removal process based on feedback from sensors, ensuring consistent surface finish and eliminating the need for manual grinding operations.
2Productivity
If automated robotic system is implemented, then productivity and safety are improved, but device complexity increases
Solution Approach 1:
The robotic system is designed as a multi-functional platform that can perform multiple operations including cladding removal, surface preparation, and inspection tasks. By consolidating these functions into a single automated system, the patent improves productivity while managing complexity through integration rather than proliferation of separate devices.
Solution Approach 2:
The patent introduces a sophisticated control system that acts as an intermediary between the complex robotic hardware and the operator. This control layer manages the complexity by providing user-friendly interfaces, pre-programmed operation sequences, and automated path planning, allowing operators to control the sophisticated system without needing to understand its underlying complexity.
3Manufacturing precision
If precise control of metal removal is achieved, then surface finish is improved, but process time increases
Solution Approach 1:
The system performs preliminary scanning and mapping of the vessel interior before actual material removal begins. This preliminary action creates a digital model of the surface topology, allowing the robotic system to plan optimal cutting paths and depths in advance. This pre-planning enables precise control during execution without requiring multiple trial passes or post-processing adjustments.
Solution Approach 2:
The robotic system operates continuously along pre-determined paths without interruption, maintaining constant cutting speed and depth control. The automated system eliminates the stop-start nature of manual operations, keeping the cutting tool engaged with the material throughout the removal process, thereby achieving precision without sacrificing productivity.
Data Source
AI summary
This is a method and device for removing metal or depositing metal from the base metal of a vessel or performing crack and/or defect removal via excavation or other machine work in situ on cylindrical or other surfaces. In a one embodiment, the method and device is used for removing bonded alloy from carbon steel substrate in-situ. In one embodiment, the inventive system and method is used inside a coker unit to remove existing cladding along the weld seams and to prepare the machined area for application of new weld metal. In one embodiment, the method and device is used to deposit weld metal on a surface or in a groove. In one or more embodiments, the groove weld is then inspected for defects and repaired by the device, if required. In one or more embodiments, mapping is performed to autonomously direct the device.