Patent Application
20180078947
The disclosure is related to a device for capturing and removing magnetic material in a flow of material, and more specifically related to a device which provides continuous capturing of unwanted magnetic material in a flow of material, while removing magnetic material.
It is known prior art solutions related to magnetized bars that are used to remove magnetic/metal material, such as metal cuttings, metal shavings, metal parts, and the like, in a flow of material, such as in a fluid stream of oil well drilling mud or flow of raw material. It is further known methods and apparatus for removing metal cuttings, metal shavings, metal parts captured by the magnetized bars by the use of a non-magnetic wiper assembly arranged slidable upon the magnetized bar between the ends thereof for removal of the captured metal from the magnetized bar.
Many of the metal parts that are collected by the magnetized bars, also known as ditch magnets, are pieces that have been cut or shaved and are thus of irregular shape and can have sharp edges/points, or the like. Safety is very important and meaningful in such operations including personnel handling equipment like this, especially in the oil and gas industry. Cuttings that are collected by a ditch magnet can include sharp edged debris that could possibly cut the hand of a worker who handles the ditch magnet.
Cuttings that have been retrieved from a ditch magnet can provide information that is beneficial to oil and gas well operators. These collected cuttings may indicate casing wear during ordinary drilling operations, pipe wear, or any other factor which could be used for economic or maintenance considerations.
In other industrial plants the supply of raw material includes unwanted microscopic foreign metal material or foreign metal bodies, in the form of metal fragments, screws, washers, or the like. Such unwanted metallic foreign contaminants are referred to as “tramp metals” in the industry. The presence of these metallic contaminants in the raw materials being processed in product-forming machines is undesirable for a variety of reasons. Contaminants may actually damage an industrial machine or render the finished part unusable or the presence of metal in the product may cause unacceptable structural, visual, or magnetic aberrations in the finished part.
Further, in the food industry, fish food industry or animal food industry also such equipment is favourable to use to detect unwanted metal material in the products.
Accordingly, the need for a device for removing unwanted metal material from a flow of material in many different areas, such as in oil well drilling mud, product-forming machines, granular handling equipment, and other plants (such as food) or processes where there is needed to remove metal material from a flow of material.
Different solutions have been proposed for providing methods and apparatus which are arranged for capturing unwanted metal material in a flow of material, and which at the same time should be easy to clean and simple to operate, which solutions will be discussed below.
U.S. Pat. No. 5,043,063 (Michael W. Latimer) discloses a magnetic trap made up of a hollow, generally cylindrical body, having an open top, an inlet and an outlet for connecting to a flow line for liquid containing entrained removable magnetic material. There is a removable cover for the hollow body, a plate is supported on the cover, and elongated, spaced non-magnetic tubes are fixed to the cover. Elongated stacks of permanent magnets are attached to the plate and extend through the cover into the tubes. When magnetic material held to the tubes by the magnets is to be removed, the cover can be removed from the body, the magnetic stacks can be pulled out of the non-magnetic tubes with the plate, thereby removing the magnetic fields from the tubes so that the magnetic material held to the tubes falls off of the tubes, thereby cleaning the tubes.
From U.S. Pat. No. 5,188,239 (Michael W. Stowe) it is disclosed a tramp metal separation device adapted to be removably inserted into a housing which directs pelletized raw material to an industrial machine and to separate tramp metal contaminants therefrom. A drawer frame having an outer face plate with a plurality of openings disposed therethrough is adapted to be removably inserted into the housing. A plurality of cylindrical magnets, adapted to be inserted through the plurality of openings in the outer face plate, is secured to a drawer plate. Described is also a plurality of silicon-based O-rings that may be disposed in grooves on the inner surface of the openings so as to form a wiper mechanism to aid in removing particles from the magnets.
U.S. Pat. No. 8,641,899 (James A. Branch) describes a method and apparatus for removing metal cuttings from an oil well drilling mud stream which provides a magnetic body or “ditch magnet” having end plates that extend radially and circumferentially from the magnetic body, the plates being positioned at end portions of the magnetic body. A third plate in the form of a wiper is used to dislodge metal cuttings and other metallic material from the magnetic body after the magnetic body has accumulated such metallic parts. One of the end plates can be removable to facilitate a complete scraping or wiping of the metallic parts from the metallic body by the wiper plate.
The above mentioned solutions suffer from that they will not provide a continues capturing of unwanted metal material, as the flow of material will need to be stopped at the time of cleaning of magnetic material in the magnets or the flow of material will be left without magnets at the time of cleaning. In e.g. a drilling operation there will be sufficient costs with stopping the drilling while the magnets are cleaned for metal material. Continuing the flow of material while the magnets are cleaned is usually not an option as this will result in that equipment could be damaged due there is no capturing of magnetic material.
There exists some solutions is arranged for continuous capturing, which will be discussed below.
WO 2009124342 describes magnetic separation apparatus for separating magnetic materials from non-magnetic materials in a material flow comprising self cleaning magnetic separators comprising: a cylinder having a first end closer to a material flow than its second end in use, a piston slidingly mounted within the cylinder, and a magnetic shaft extending from the piston, the piston and cylinder adapted to move the magnetic shaft between an extended position and a retracted position, such that in the extended position, at least a sleeveless portion of an outer surface of the magnetic shaft is exposed to the material flow and in the retracted position the magnetic portion is retracted substantially or wholly within the cylinder, the apparatus including a protected shaft wiper and shaft seal; within the first end of the cylinder for removing extracted magnetics. Accordingly, it is described an automatic solution where a piston and cylinder are used for retracting the magnetic shaft, which will be both complex and expensive to install and maintain. Further, it will not be suitable for use in capturing and removing metal cuttings from an oil well drilling mud stream onshore or offshore due to the harsh environment. This solution will also have a problem getting rid of the collected material. Further, the magnetic shafts are arranged in parallel in width direction and in the longitudinal direction, which will not be the most effective manner for capturing metal cuttings.
U.S. Pat. No. 8,132,674 B1 describes a device for magnetic separation of tramp metal, which consists of a first and a second housing. The first housing has an inlet and an outlet, a first drawer and a second drawer. Each of the drawers has a plurality of magnets and a wiper assembly for each of the magnets. The drawers are supported with respect to the first housing such that each of the drawer is moveable between an extended position and a retracted position. In the extended position, the magnets of the respective drawer is positioned within the first housing and are adapted to be in contact with the stream of raw materials. In the retracted position, the magnets of the respective drawer are positioned outside of the first housing. The drawers move independently of each other and the device is so constructed that one set of magnets is always in contact with the fluid, which requires cleaning. This solution also suffer from the disadvantages as mentioned above for WO 2009124342, but in addition this solution is arranged for arranging the magnets in the horizontal plane, which would be a severe problem if used in a oil well drilling mud stream onshore or offshore, and would require complex sealing means to avoid mud from leaving when a magnet is drawn out for cleaning.
U.S. Pat. No. 5,190,159 a reveals a device for magnetic separation and removing magnetic material from a fluid flow. The device comprises of arrays of magnet tubes, which are in contact with the fluid stream. Each magnet tube has a wiper assembly, which removes the attached magnetic particles when the arrays are retracted from the stream. The magnetic particles are deposited in a separate compartment. The arrays are retracted by handles and can be move independently of each other. It is shown in one of the Figures that the magnet tube may consist of a plurality of magnets segments indicating that a magnetic field with switched polarisation may be used, however there are now description of this leaving it unclear how this will work or the purpose of this. This solution also suffer from the disadvantages as mentioned above for WO 2009124342, but in addition this solution is arranged for arranging the magnets in the horizontal plane, which would be a severe problem if used in a an oil well drilling mud stream onshore or offshore, and would require complex sealing means to avoid mud from leaving when a magnet is drawn out for cleaning.
A further disadvantage with the three latter solutions is that they would need to be sufficiently displaced from each other to ensure that the magnetic force of each magnet does not affect an adjacent magnet as this will result in problems with withdrawing the magnets in an automated manner.
Another disadvantage with the latter solutions is that the use of automatic control will considerably increase the space needed for installation and use of the solutions.
The present disclosure provides a device for capturing and removing magnetic material in a flow of material which solves the above mentioned drawbacks of prior art.
Also provided herein is a device for capturing and removing magnetic material in a flow of material which provides continuous collection of magnetic materials while removing and cleaning.
The disclosure further provides a device for capturing and removing magnetic material in a flow of material where one or more sets of magnet rods are arranged to provide a magnet grid providing the best possible magnetic field over the area which the material is flowing through the device.
Also provided is a device for capturing and removing magnetic material in a flow of material where two or more magnet rods are arranged together to form a set of magnet rods of magnet assembly and where the magnet assembly is arranged in a sliding system for easy insertion and removing from the device.
Also provided is a device for capturing and removing magnetic material in a flow of material including several rows of magnet assemblies spaced apart in the flow direction of the material to enable continuous capturing of magnetic material.
Also provided is a device for capturing and removing magnetic material in a flow of material which provides efficient and safe cleaning of the magnet assemblies for personnel during continuous flow of material (production), so that one do not need to stop the flow of material (production) during cleaning of the magnet assemblies for captured metal material.
Also provided by the disclosure is a device for capturing and removing magnetic material in a flow of material which has low weight and can be handled in an easy way by a single person and which satisfies the requirements of HES (Health, Environment and Safety).
The disclosure also provides a device for capturing and removing magnetic material in a flow of material which satisfies the requirements of explosion hazard environments.
The disclosure also provides a device for capturing and removing magnetic material in a flow of material which can easily be adapted to new and existing system, and at the same time be space saving.
The disclosure also provides a device for capturing and removing magnetic material in a flow of material which can easily be extended by adding additional modules including magnet assemblies.
Further embodiments and characteristics will appear from considering the following description, drawings and claims.
A device for capturing and removing magnetic material from a flow of material, according to the disclosed embodiments includes magnet assemblies formed by a set of magnet rods including at least two magnet rods arranged together at upper end by means of a magnet handle device and at the lower end by means of a magnet guider. Flow of material does herein mean a material in a condition able to flow through the device according to the disclosure, such as fluids, raw material and so on. The magnet rods are further enclosed in a non-magnetic material, such as a sleeve or an encapsulating non-magnetic material, as well known for a skilled person. The magnet assembly is further provided with non-magnetic end areas of the magnet rods. The magnet rods can include permanent magnets or controllable magnets, depending on the area of use. In e.g. explosion hazard areas where there are possibilities for gas being present, such as on offshore installations, permanent magnet rods will be used to avoid possibilities for sparks which could set gas on fire.
The magnet handle device is formed by a fixing plate for fixation of the magnet rods upper end and a handle for easy carrying and handling.
The magnet assembly further includes a wiper assembly being movably arranged to the magnet rods, between the upper magnet handle device and lower magnet guider.
The shape of the handle bar, together with the handle bar guides in the frame, prevents the opportunity for incorrect mounting of the magnet rods during maintenance, interrupting the optimized calculated magnetic field setup of the assembly.
The disclosed device further includes a frame assembly for arrangement of the magnet assemblies to form a defined magnet grid assembly. The frame assembly includes a mainly U-shaped frame where an upper plate is arranged in transversal direction between the legs of the U-shaped frame.
Further, the upper plate and bottom of the U-shaped frame are provided with corresponding holes for receiving the above described magnet assemblies.
Further, between the holes of the upper plate and bottom of the U-shaped frame, a sliding system for accurate positioning and fixation of the magnet assemblies are arranged. The sliding system consists of mainly U-shaped guiding bars for guiding and holding the magnet assemblies in place in the U-shaped frame.
The U-shaped guiding bars are preferably arranged such that the opening thereof is facing along the flow of material, and in this way the bottom of the U-shaped guiding bars act as a protection for the magnet assemblies arranged therein, and also ensures that the magnet bars do not bend during insertion and removal. The sliding system is further necessary to make it possible to insert or remove the magnet assemblies when the flow of material is continuous.
Depending on how many magnet assemblies to be arranged in the transversal direction of the U-shaped frame, the upper plate and bottom of the U-shaped frame will be provided with holes and guiding bars such that the magnet assemblies are evenly distributed over the cross-sectional area of the U-shaped frame, which defines the area where the material flows through the device.
Accordingly, the magnet assemblies and the frame assembly together form a module for the device. The device can thus easily be adapted to include several modules like this, and where the device at least includes two modules like this, further explained below.
As mentioned the magnetic assemblies includes a set including at least two magnet rods, and the magnet assemblies are further arranged in the U-shaped frame such that the sets of magnet rods form a magnet grid where the at least two magnet rods of each set are displaced in transversal and longitudinal direction of the frame assembly and in relation to each other, seen in the flow direction of the material. E.g. this is achieved by that the holes and guiding bars the magnet assemblies are arranged to position the magnet assemblies in a direction deviating from the longitudinal or transversal direction of the U-shaped frame and upper plate. By this can be achieved a magnet grid, where the magnet rods of the sets are not positioned on the same line, but positioned to provide a magnetic grid providing a stronger magnetic field over an area of the frame assembly.
Further, the guiding bars will result in turbulence behind them, seen in the material flow direction, which improves the effect of the magnet rods, resulting in higher efficiency and more captured unwanted metal material. Reference is made to
The magnet rods of each set are arranged with switched polarisation at any horizontal section, creating a magnetic field working together between the separate magnet rods of each set and magnet rods of neighbouring sets of magnet rods. Like vice each magnet rod is divided in at least two vertical magnet segments inside the rod with opposite polarisation, creating the same effect vertically on the magnet rod. This creates a cross web of magnetic field on both the horizontal and vertical section of the set of magnet rods and between magnet rods of neighbouring sets of magnet rods.
The small diameter of the magnet rods, together with the calculated pattern of magnet rods and flow breakers, decreases the speed of flow through the magnetic grid, without significantly increasing the pressure drop through the magnetic grid assembly.
The small diameter of the magnet rods gives the opportunity to customize by magnetic field calculation and simulation, the setup of the magnetic field optimized for efficiency, pressure drop or magnetic field intensity based on the flow media.
The assembly can be equipped with sensors measuring the difference in height of the fluid on both sides of the magnetic grid assembly, indicating the pressure drop over the assembly, trigging an alarm for magnetic filter cleaning.
According to a further embodiment of the disclosure, the device includes at least two modules as described above, positioned in series in the flow direction to provide at least two separate rows of magnet assemblies, seen in the material flow direction. It should be mentioned that the U-shaped frame also could consist of one U-shaped frame and upper plate being arranged to receive at least two separate rows of magnet assemblies. By this is achieved that one can clean the first row or second row etc. while the other row of magnet assemblies continuously performs capturing of magnetic material. By this is achieved that there will be no need for stopping the material flow or leaving the material flow unprotected when cleaning.
The number of magnet rods per set in the magnet assembly, the number of magnet assemblies per row, the number of rows of magnet assemblies, as well as the number of vertical magnet segments inside the magnet rod and polarisation of each magnet segment can easily be adapted to the actual application. Usually one will use magnet rods/magnet segments being as strong as possible, but e.g. in applications where other equipment close to the disclosed device will be sensitive for magnetic field, the device can include less strong magnet rods/magnet segments and more of them either in transversal direction, i.e. per row, or more rows of magnet assemblies or higher number of vertical magnet segments. With the inclusion of modules, the disclosed device can be tailored to the available space in the application where it is to be used.
The device disclosed herein will be arranged in a flow line for material, such as a fluid line or raw material flow line offshore or onshore or in industrial plants, and the magnet assemblies are arranged to be inserted and removed in a vertical direction upwards from the flow of material, i.e. not from the sides of the flow of the material.
Another feature of the disclosed device is that the magnet assemblies are easy to remove and insert. When there is a need for cleaning, the separate magnet assembly can easily be removed from the frame assembly while remaining rows of magnet assemblies continue the capturing of magnetic material. By means of the device including a wiper assembly, the captured magnetic material can easily be removed by moving the wiper assembly between the upper magnet handle device and lower magnet guider. As the magnet rods at the lower end are free of magnets, total removal of the magnetic material is achieved in an easy way. After the cleaning process is performed, the magnet assembly again is inserted in the guiding bars and safely inserted into the frame assembly, whereupon the next magnet assembly can be cleaned. The functionality of the guiding bars will be essential to allow the magnet assembly to be inserted again after removal when the material flows continuously, as the flow will otherwise affect the magnet assembly and it will be difficult for the operating person to arrange the magnet assembly again in the holes of the bottom of the U-shaped frame.
Depending of the application the flow velocity of the material can be reduced or increased in front of the device.
With the disclosed embodiments, one can also arrange means in front of the device for measuring the material level, which could be used to detect when the magnet assemblies should be cleaned. When the material level has increased above a certain level, this will indicate that the material flow through the device is low and that the magnet assemblies should be cleaned.
The magnet assemblies of the device can include sets of permanent magnet rods or controllable magnet rods which can be switched on and off, or even controllable magnet rods where one can control the properties/effect thereof by means of a control device arranged for this.
The present invention will below be described in further detail with reference to the attached drawings, where
Reference is now made to
The magnet assembly 10 further includes a wiper assembly 20 formed by upper and lower scraper bodies 21a and 21b having a mainly elliptic shape provided with through holes 22a-b for accommodating the permanent magnet rods 11. Between the scraper bodies 21a-b and in connection with the through holes 22a-b are arranged metal wipers 23a-b of non-magnetic material, one for each permanent magnet rod 11, which metal wipers 23a-b having a central opening adapted to outer surface of the permanent magnet rods 11. In this way the metal wipers 23a-b are movably arranged along the permanent magnet rods 11 by means of the scraper bodies 21a-b.
Reference is now made to
Reference is now made to
Between the holes 34 of the bottom 33 of the U-shaped frame 31 and the holes 35 of the upper plate 35 there are arranged pairs of U-shaped guiding bars 36a-b, arranged at the tapering distal ends of the holes 34, 35, which guiding bars 36a-b are arranged for guiding and retaining the permanent magnet assemblies 10 by that the openings of the U-shaped bars 36a-b are arranged facing each other.
The frame assembly 30 is further at the upper side of the upper plate 32 provided with perpendicularly projecting flanges 37, arranged on both sides of the holes 35, which flanges 37 are provided with recesses 38 adapted for receiving and retaining the handle 15 of the permanent magnetic assembly 10.
In this way the permanent magnet assemblies 10, when inserted into the holes 34, 35 and guiding bars 36a-b, and the handle 15 is secured in the recesses 38, the permanent magnet assemblies 10 will be locked for movement in any direction as a consequence of a material flowing past the permanent magnet rods 11.
The holes 35 and 34 of the upper plate 32 and bottom 33, respectively, are further arranged so that they extend in a direction between longitudinal sides of the upper plate 32 and bottom 33, respectively, with an angle deviating from a straight line between the longitudinal sides, for in this way to position the sets of at least two permanent magnet rods 11 of a permanent magnet assembly 10 in a fixed position in the frame assembly 30, and so that the permanent magnet rods 11 are displaced both in longitudinal direction and transversal direction in relation to the frame assembly 30. In this way the permanent magnet assemblies 10, when arranged in the frame assembly 30 will form magnet grids of permanent magnet rods 11 being displaced in lateral and transversal direction in relation to each other, as well as in relation to the flow direction of the material. With the shown example where each permanent magnet assemblies 10 includes a set of two permanent magnet rods 11, a magnet grid of two rows of permanent magnets will be provided, where the first and second row of permanent magnets are displaced in relation to each other both in transversal and longitudinal direction of the frame assembly 30. If the permanent magnet assembly 10 includes a set of three permanent magnet rods 11, three rows of permanent magnet rods 11 will be provided per magnet assembly 10, and so on.
It should be noted, that the distance between the respective permanent magnet rods 11 of a set in a permanent magnet assembly 10, and the distance between the respective permanent magnet assemblies 10 will be dependent on the properties of the permanent magnets in the permanent magnet rods 11.
Reference is now made to
Reference is now made to
It is further achieved a device 100 where the permanent magnet assemblies 10 are easily insertable and removable from the frame assembly 30 by means of the guiding rods 36a-b which ensures correct insertion and removing of the permanent magnet assemblies 10. The guiding bars 36a-b is further arranged for decreasing speed of material flow through the device (100, and creating turbulence behind them, without significantly increasing pressure drop through the device 100, as shown in
It is further achieved a device 100 where the permanent magnet assemblies 10 are easy handable due to the limited number of permanent magnet rods 11 which make them handable for a single person. By this the low weight requirements according to HES (Health, Environment and Safety) are fulfilled.
By that the permanent magnet assemblies 10 are provided with a wiper assembly 20, the captured unwanted metal material can easily be removed from the permanent magnet assemblies 10 by a single person moving the wiper assembly 20 from the handle device 14 and down to the end of the permanent magnet assemblies 10 and back to the handle device 14.
The disclosed embodiments are especially suitable for capturing and removing metal cuttings from an oil well drilling mud stream onshore or offshore, metal material in a flow of raw material, process lines in food industry (animal, fish and human food) and also recovery or recycling plants, etc.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20150389 | Mar 2015 | NO | national |
| 20151424 | Oct 2015 | NO | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/NO2016/050057 | 3/30/2016 | WO | 00 |
