The present invention relates to systems, apparatuses, and methods for the removal of materials from surfaces, and in particular though non-limiting embodiments, to systems, apparatuses, and methods for cleaning inner surfaces of tanks and cuttings boxes.
Boreholes include oil and gas wells, water wells, and holes drilled for geotechnical investigation or exploration. During this drilling process, a drill bit may be advanced through solid materials within the boreholes and produce waste, including drill cuttings, mud, debris, chemicals, and wastewater. Drill cuttings are broken bits of the solid material removed from the borehole. The cuttings and/or other waste/debris are carried to the surface using a drilling fluid circulating up from the drill bit.
The drill cuttings and/or other waste are typically collected for treatment and disposal. For example, drill cuttings from an offshore operation may be placed in containers, such as cuttings boxes and/or tanks for transport to onshore locations for disposal and/or treatment. Usually, the containers, including the cuttings boxes and/or tanks are removed by a crane and the contents are dumped for disposal. The boxes and/or tanks often contain residual materials that need to be cleaned out.
The containers, including boxes and/or tanks, may be placed on a portable skid for cleaning and individual workers generally clean each container by hand. Cleaning may take thirty minutes or more to complete. In addition to worker time, there is risk associated with workers manually cleaning out the tanks and/or boxes, including exposure to the contents of the tanks and/or boxes.
Therefore, there is a long-felt, but unmet, need for improved systems, apparatuses, and methods for cleaning inner surfaces of containers, including tanks and/or cuttings boxes, which are more efficient, safe, and eliminate exposing workers to potentially hazardous materials.
In an embodiment of the present disclosure, a cleaning system is provided. The cleaning system has a frame, a table attached to the frame, a gantry system secured above the table and attached to the frame, and a cleaning attachment secured to the gantry system and having a cleaning tool. The cleaning attachment may be positionable using the gantry system to fit in an opening of a container placed on the table. The cleaning tool may be remotely operable. The frame may have a plurality of beams extending vertically from corners of a base. Safety walls may extend between lower portions of the plurality of beams. Safety walls may be configured to contain materials within the system during cleaning and prevent accidents. Safety bumper may extend from a front end of the base. Safety bumper may be configured to ensure that the container stays in place during cleaning. The table may be adjustable.
The system may further have a lifting system configured to lift the table or a portion thereof. The lifting system may have hydraulic cylinders located at a corner of that table. The hydraulic cylinders may be configured to lift the table such that any items or materials placed upon the table move to a single lowest point at a diagonally opposing corner of the table. The opposing corner of the table may pivot when the corner of the table is lifted and lowered. The table may pivot via a hinge mechanism. The hinge mechanism may have a hinge pin attached to a bottom portion of the frame and a hinge clamp enveloping the hinge pin. The hinge clamp may be attached to the opposing corner of the table such that the opposing corner of the table and attached hinge clamp pivot around the hinge pin when the corner of the table is lifted and lowered.
The gantry system may have elbow extensions extending from the plurality of beams or from a collar attached to the plurality of beams, a first horizontal member and second horizontal member disposed between pairs of the elbow extensions and perpendicular to the plurality of beams, a cross bar disposed between the first and second horizontal members, and a hoist attached to the cross bar at a first end and the cleaning attachment at a second end. The cross bar may be configured to move horizontally along the first and second horizontal members. The hoist may be configured to move horizontally along the cross bar.
The cleaning tool may have a high pressure water line having a gamma jet disposed at one end. The high pressure water line may be pre-formed into an L-shape prior to cleaning. The cleaning attachment may be hydraulic or pneumatic. The cleaning attachment may have an inverted trapezoid shape. The cleaning attachment may have a hollow interior configured to be filled with fluids to ensure stability during cleaning. The cleaning attachment may have openings in its top and bottom portions such that the cleaning tool is inserted into and through the cleaning attachment. The cleaning attachment may have a retaining mechanism configured to control the cleaning tool during cleaning. The retaining mechanism may have three rods vertically extending from the bottom portion and attaching to a substantially circular shape. The cleaning attachment may have swivel handles configured to manipulate and position the cleaning tool, and hydraulic dampers and hydraulic cylinders to operate and hydraulically lock the cleaning attachment in place on the container prior to cleaning.
In an embodiment of the present disclosure, a method for cleaning a container is provided. The method includes placing the container inside a cleaning system, cleaning an interior of the container using a cleaning tool, removing water and other materials from the interior of the container, and removing the container from the cleaning system. The cleaning system has a frame, a table attached to the frame, a gantry system secured above the table and attached to the frame, and a cleaning attachment secured to the gantry system and having a cleaning tool. The cleaning attachment may be positionable using the gantry system to fit in an opening of a container placed on the table. The cleaning tool may be remotely operable. The container may be a Marine Portable Tank (MPT) or cuttings box. The table may be adjustable.
The method further includes using a lifting system configured to lift the table or a portion thereof. The lifting system has hydraulic cylinders located at a corner of the table. The hydraulic cylinders may be configured to lift the table such that any items or materials placed upon the table move to a single lowest point at a diagonally opposing corner of the table. The water, materials, and items are removed using a vacuum system. The method includes lifting the table such that the water, materials, and items move to the single lowest point for removal using the vacuum system. The method includes pressure washing an outer surface of the container. The cleaning tool may include a high pressure water line having a gamma jet disposed at one end. The cleaning of the interior of the cleaning system may take approximately 6 minutes. The method includes lifting a top cover of the container to reveal an opening into the interior of the container, placing the cleaning attachment onto the container via the opening, and hydraulically locking the cleaning attachment in place via hydraulic dampers and hydraulic cylinders located on the cleaning attachment. The method includes covering open left and right sides of the opening with a covering material to prevent cleaning water and other materials from exiting the container during cleaning. The covering material may be a Hypalon® rubber material.
In an embodiment of the present disclosure, a system is provided. The system includes a cleaning system, a container placed within the cleaning system for cleaning, and a vacuum system attached to the container to remove cleaning water and other materials from the container after cleaning. The cleaning system has a frame, a table attached to the frame, a gantry system secured above the table and attached to the frame, and a cleaning attachment secured to the gantry system and having a cleaning tool. The cleaning attachment may be positionable using the gantry system to fit in an opening of a container placed on the table. The cleaning tool may be remotely operable. The system may further have a lifting system configured to lift the table or a portion thereof. The lifting system has hydraulic cylinders located at a corner of the table. The hydraulic cylinders may be configured to lift the table such that any items or materials placed upon the table move to a single lowest point at a diagonally opposing corner of the table. The cleaning tool may include a high pressure water line having a gamma jet disposed at one end.
Like reference characters denote like parts in the several Figures.
Embodiments of the present invention include a cleaning station/system that may be used to clean containers, including tanks and/or boxes. Cleaning station/system provides for automated cleaning of inner surfaces of containers with shorter cleaning times than existing approaches. Cleaning system may include a frame, a table, and a gantry system. Frame may be configured such that containers may fit within the frame. Table may be configured to lift and/or tilt at an angle and may be connected to a single point vacuum system to remove materials from a corner of the system. Gantry system may attach at upper ends of the frame structure and be connected to a cleaning attachment. Cleaning attachment may include a cleaning tool and may be positionable using the gantry system to fit in an opening of a container placed on the table. Cleaning tool may be remotely operable. Cleaning tools may include high pressure water lines having gamma jets disposed at their ends. Gamma jets provide automated cleaning of containers within the cleaning station/system. In embodiments, a method for cleaning a container is provided that includes placing a container into a cleaning station, cleaning the container with high pressure fluids, and removing materials from the container and/or station using a vacuum system.
Referring to
In embodiments of the present invention, table 24 is provided above base 12, and within the plurality of beams 14.
In embodiments of the present invention, table 24 is combined with a vacuum system, which may be located at or near the single lowest point of table 24 when table 24 is lifted at the corner 24A. Vacuum system may be configured to remove materials and/or water from the single lowest point. Vacuum system may also be inserted directly into a container being cleaned and configured to remove waste and/or water from the container. Vacuum system may pull solid waste, including drill cuttings, from the container being cleaned into other containers and/or boxes near the station 10 for storing waste. Vacuum system may also pull liquid waste from the container being cleaned into other containers and/or tanks near the station 10 for additional storage and filtration.
Referring back to
High pressure water lines are connected to cleaning attachment 28. High pressure water lines may include a jet at one end, which may be a gamma jet. Gamma jets are used to clean interiors of containers, including cuttings boxes and/or tanks, by insertion into openings on the containers. Utilizing high pressure lines and/or gamma jets within cleaning station/system 10 allows for interiors of containers to be cleaned without direct worker manipulation. Methods and apparatuses of using gamma jets to clean tanks and/or other containers are disclosed in U.S. Pat. Nos. 8,133,328 and 8,627,838, both of which are expressly incorporated herein by reference. The gamma jets clean the container utilizing a 360° spherical spray pattern/movement. In exemplary embodiments, high pressure lines and gamma jets are inserted into an opening of a container and used to clean the interior of the container in approximately 6 minutes, rather than approximately 30 minutes for typical manual cleaning. In embodiments, cleaning of station/system 10 using water lines and gamma jets may be performed via fully automated controls connected to station 10.
Referring to
Cleaning attachment 28 as disclosed herein may be a cuttings box cleaning attachment 28B configured for use in cuttings boxes and/or any other container having an opening A at its top portion such that cuttings box cleaning attachment 28B may be inserted into the opening A for cleaning See
Referring to
In embodiments of the present invention, a method for cleaning a container, including an MPT 100 and cuttings box 102, is provided. The method includes using an adjustable gantry system 50 and cleaning attachment 28, as well as tilting table 24, all of which can be automated and operated remotely, thereby providing for fast and efficient cleaning of MPT 100 and/or cuttings box 102. The method includes placing the container, including the MPT 100 and/or cuttings box 102, to be cleaned inside a cleaning station/system 10, 11 described herein, cleaning inner surfaces of the containers, removing waste material from the containers, and removing the containers from cleaning station 10, 11. Cleaning stations/systems 10, 11 may include all the features described herein. The containers are automatically cleaned via high pressure water lines 39 having gamma jets 38, and the materials and cleaning water may be removed using a vacuum system. The vacuum system may be utilized concurrently with the cleaning process, or may be utilized after cleaning. The method further includes pressure washing the outer surface of the containers, either concurrently with the cleaning process, or after cleaning.
In embodiments of the present invention, a method for cleaning an MPT 100 is provided. The method includes placing the MPT 100 inside cleaning station/system 10, 11 described herein, cleaning inner surfaces of the MPT 100, removing waste material from the MPT 100, and removing the MPT 100 from cleaning station 10, 11. Cleaning stations/systems 10, 11 may include all the features described herein. Particularly, the method includes lifting a top cover of MPT 100 to reveal an opening, O, into interior of MPT 100, inserting MPT cleaning attachment 28A through the opening, and cleaning inner surface of the MPT 100 using a gamma jet 38 manipulated by MPT cleaning attachment 28A. The method further includes pressure washing the outer surface of the MPT 100, and removing materials and cleaning water via a vacuum system attached to MPT 100.
In embodiments of the present invention, a method for cleaning a cuttings box 102 is provided. The method includes placing the cuttings box 102 inside cleaning station/system 10, 11 described herein, cleaning inner surfaces of the cuttings box 102, removing waste material from the cuttings box 102, and removing the cuttings box 102 from cleaning station 10, 11. Cleaning stations/systems 10, 11 may include all the features described herein. Particularly, the method includes lifting a top cover of cuttings box 102 to reveal an opening A into interior of cuttings box 102, and placing cuttings box cleaning attachment 28B onto cuttings box 102 via opening A. The method includes hydraulically locking cleaning attachment 28B in place via hydraulic dampers and/or hydraulic cylinders located on cleaning attachment 28B. The method includes covering open left and right sides of opening A with a covering fabric, plastic, and/or other material to prevent cleaning water and/or other waste from exiting the cuttings box 102 during cleaning Doing so provides for reduced worker exposures to the contents being cleaned from cuttings box 102, which may be toxic and/or dangerous. In exemplary embodiments, a Hypalon® rubber material is used to cover the left and right sides of opening A. The Hypalon® fabric/material may have magnets at its ends to affix the material onto the box 102 during the cleaning process. The method includes cleaning inner surfaces of the cuttings box 102 using gamma jets 38 manipulated by cuttings box cleaning attachment 28B. The method further includes pressure washing the outer surface of the cuttings box 102, and removing materials and cleaning water via a vacuum system attached to cuttings box 102.
In embodiments of the present invention, a system for cleaning an interior of a container is provided. The system includes cleaning station/system 10, 11 described herein, a container placed within the cleaning station/system 10, 11 for cleaning, and a vacuum system attached to the container and/or system 10, 11 to remove waste materials and cleaning water from the container and/or system 10, 11. Cleaning stations/systems 10, 11 may include all the features described herein.
While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventions is not limited to them. Many variations, modifications, additions, and improvements are possible. Further still, any steps described herein may be carried out in any desired order, and any desired steps added or deleted.
This application claims the benefit of U.S. Provisional Patent Application No. 62/017,585, filed on Jun. 26, 2014, which is incorporated herein by reference.
Number | Date | Country | |
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62017585 | Jun 2014 | US |