The present invention relates to water blasting equipment and more particularly to high pressure water blasting devices adapted to clean equipment such as heat exchangers, falling pressure evaporators, storage tanks, tubes, piping, towers and similar equipment.
There are a variety of industrial piping systems using in conjunction with different industries, such as, chemical processing, recycling, polymer forming, oil and gas refining and other industries. These industrial piping systems frequently require cleaning, resurfacing, painting and/or coating. As an example, in the oil refining industry, special equipment such as heat exchangers and evaporators are utilized. Over time, the bores and exterior walls of the heat exchanger's tubes can corrode, scale or exhibit excessive residue and buildup. This buildup and/or residue can decrease the efficiency of heat transfer through the heat exchanger. In turn, operating costs for the heat exchanger can significantly increase.
Thus, the cleaning of such equipment has spawned an industry. Some manufacturers make special water blasting equipment that operates at high pressures, greater than 10,000 psi in some cases, to create a jet stream that effectively blasts or removes the scale, residue, corrosion, etc. from equipment. In connection with equipment such as heat exchangers, a small diameter lance is typically inserted into the heat exchanger tubes. High pressure water is pumped through the lance to clean the interior of the tube as it travels through the tube. In other applications, a hand-held portable cleaning lance can be held by a user who sprays equipment. The lance can include a nozzle. The user carefully inserts the nozzle and a portion of the lance into piping of the equipment to blast the unwanted material out from the piping interior. In other applications, the equipment can include a pipeline. To clean the pipeline, a user can cut into the pipeline, or remove a dedicated access panel, and then insert a lance into the pipeline to clean it under high pressure.
In all of the above equipment cleaning applications, there are inherent dangers. For example, the lances typically are difficult to prevent from buckling and/or bending while being guided into a tube. In cases where the lance is more rigid and adapted to insert into the opening of the pipe, the jet reaction from a high pressure stream shooting from the nozzle can create major safety issues. Because the water is forced through the nozzle at significant pressures, the jet from the nozzle can frequently blow backward, striking the operator. In other cases, if an operator becomes fatigued and accidentally drops the water blasting lance, it sometimes can violently thrash around under the propulsion of the jet stream. In yet other cases, the pipe to be cleaned is elevated overhead. Some operators will take shortcuts, and insert the lance into the elevated piping. This can increase the likelihood that the device will become loose and violently thrash around. In all of the above cases, there is an issue with the water blasting lances being manually handled by the users. There can be a high propensity for accidents to occur when those devices unintentionally depart from the user's hands.
Some manufacturers have attempted to address the dangers inherent with some water blasting lances, at least in connection with the cleaning of heat exchangers. For example, there are automated remote control lances, which are mechanically inserted into a heat exchanger. These assemblies, however, require the labor intensive bolting of a complex frame around the heat exchanger to properly index the lance relative to the tubes of the heat exchanger to be cleaned. The extra effort to bolt on the frame can be particularly cumbersome and time consuming. In other cases, an operator frequently has to assemble or modify a fixture or framework to adequately hold the lance so that it can be inserted into the appropriate tubes of the heat exchanger.
While there are devices to secure cleaning lances to equipment such as heat exchangers or other structures, and these devices can enhance the safety afforded to the operator, there remains room for improvement with regard to securing a water blasting device in a generally fixed location relative to the equipment and/or structure.
A water blasting apparatus and related method are provided to enhance the safety of an operator engaged in cleaning certain equipment and structures. In one embodiment, the apparatus can include a track, a connector moveable along the track, and a water blasting device adapted to shoot water at a pressure above 1000 psi, joined with the connector. One or more high strength magnets join the track with a ferromagnetic structure, such as the equipment or structure itself or facility framework near the equipment, thereby holding the track in a fixed orientation relative to the equipment or structure to be cleaned.
In another embodiment, the track can include first and second rails that telescope relative to one another so that the length of the track can be modified to fit in a desired location. Optionally, the track can include a first section and a second section, with an intermediate or middle portion therebetween. The first rail can be the first and/or second sections, and the second rail can be the intermediate portion.
In still another embodiment, the apparatus can include a sensor, optionally a proximity sensor, to ensure the track is adequately anchored to the ferromagnetic structure, and an automatic shut-off system when it is not adequately anchored to the ferromagnetic structure.
In yet another embodiment, the magnets can be ceramic or rare earth magnets, optionally having residual inductions ranging from 2,000 Gauss to 40,000 Gauss, further optionally about 10,000 Gauss to about 20,000 Gauss.
In even another embodiment, the magnets can be outfitted with an actuator configured to selectively configure the magnet in either a magnetic mode, in which the magnet magnetically attracts to a ferromagnetic structure, or a disengaging mode, in which the magnet is able to be disengaged from the ferromagnetic structure.
In a further embodiment, first and second magnets can be pivotally joined with each opposing end of the track. Each magnet can be attached to separate and spaced apart ferromagnetic structures adjacent or on the equipment to be cleaned. The magnets can effectively secure the ends to two locations, thereby positioning the track, and thus the water blasting equipment in a fixed orientation relative to the equipment or structure.
In still a further embodiment, the connector can be in the form of a tractor that is controlled by a control unit. The tractor can include a gear or sprocket that engages the track to propel the connector, and thus the connected water blasting equipment along the track to various desired locations. Optionally, the track can include teeth or slots that cooperate with and engage the sprocket to facilitate the movement.
In yet a further embodiment, the tractor can include an actuator adapted to engage a holder or bracket contacting the water blasting device. The actuator can effectively move the holder, thereby reorienting the nozzle in varying directions to clean or blast a particular area. Due to the restraint of the device by the connector and track, its movement can be limited to a particular area of cleaning until the control unit moves the tractor again with the water blasting device.
In even a further embodiment, the method can include connecting the water blasting device to the track, magnetically coupling the track to a ferromagnetic structure so that the nozzle is proximal the equipment to be cleaned, and so that the elongated track is maintained in a fixed orientation, and shooting water at high pressure toward the equipment, while safely restraining the water blasting device.
In another, further embodiment, the method can include providing the track with a first rare earth magnet and a second rare earth magnet in different locations along the track. Each magnet can include an actuator configured to configure the respective magnet into a magnetic mode or a disengaged mode. The method can include placing the first rare earth magnet adjacent the ferromagnetic structure and moving the actuator to configure the first rare earth magnet into the magnetic mode whereby the magnet magnetically couples to the ferromagnetic structure.
In still another, further embodiment, the method can include moving the water blasting device linearly along the track from a first location to a second location along an x-axis, and/or moving or tilting the water blasting device linearly from a first location to a second location along a y-axis.
In even another further embodiment, the method can include automatically ceasing the shooting of water from the nozzle upon decoupling of the track from the at least one ferromagnetic structure. This decoupling can be detected by a sensor, such as a proximity sensor or other sensor. The sensor can send a signal to a control unit that the decoupling has occurred, and the control unit can trip a dump valve so that high pressure water is no longer conveyed to the water blasting device.
With the current embodiments of the water blasting apparatus and method, improved levels of safety for operators can be realized. Where the track and connector constrain a water blasting device for movement within a limited area to clean equipment, the water blasting device can be less likely to become loose and violently thrash around, thereby presenting a danger to the operator. With the water blasting device attached to the track and oriented in a specific manner, an operator can consistently and methodically clean a surface of certain equipment. This can result in faster cleaning times, as well as reduced power consumption and man hours. Where the track includes first and second magnetics attached to ends of the track, the track can be highly modifiable to fit a variety of configurations and spaces near equipment to be cleaned. For example, the track can be extended in length to accommodate structures, to which the magnets are attached, that are spaced apart from one another. The track also can be oriented vertically, horizontally or in various other planes, all depending on the location of the magnets coupling the device to structures surrounding the equipment. Further, given the variable length of the track, the apparatus can be quickly and efficiently positioned in confined spaces or large spaces. Where the apparatus includes a sensor, such as a proximity sensor, this can enhance safety for the operator, generally ensuring automatic shutdown of the system upon any decoupling of the track/magnets from a ferromagnetic support structure.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.
A water blasting apparatus and related method in accordance with the current embodiment is illustrated in
Generally, as illustrated in
As further shown in
The specific construction, components and operation of one embodiment of water blasting apparatus 10 will now be described in further detail. As mentioned above, the water blasting apparatus 10 can include a track 20, magnets 31 and 32, a connector 50 and a water blasting device 40. The water blasting device can be a lance or gun, and can be interchangeable with any type of mechanism including a nozzle defining at least one orifice, where the blasting device is joined with a water source 80 configured to deliver water to the nozzle at a pressure optionally above 1,000 psi, further optionally above 5,000 psi, even further optionally above 5,000 psi, yet further optionally above 10,000 psi, still further optionally above 20,000 psi, more optionally above 40,000 psi, and even further optionally up to 100,000 psi.
The track 20 includes a first end 21 and a second end 22. The track 20 can be comprised of one or more rails that are telescopingly joined with one another. For example as shown in
The first and second sections 25 and 26 can be configured in the form of tubes or rails that extend outwardly away from the middle portion 23. The first and second sections can be joined with the middle portion by positioning the sections within the opening 23O a preselected distance. The middle portion and sections can be locked to one another utilizing a pin 23P that extends through a pin hole 23H defined by the middle portion 23. The pin 23P can also extend through one or more holes 25H of the respective sections, for example, the first section 25. The pin 23P can include a head and a nut to secure the spatial relationship between the middle portion 23 and the sections 25 and 26. Generally, the pin 23P and pin hole 23H can be oriented on a side of the intermediate portion 23 upon which the slots 24 are not defined. Put another way, the pin 23P and its hole 23H can be disposed parallel to the wall 24W within which the slots 24 are defined.
Optionally, the first and second sections 25 and 26 can be configured to include a longitudinal recess or slot 25R as illustrated in
As shown in
As shown in
The track itself can be constructed from metal, polymers and/or composite materials sufficiently rigid to support the connector and water blasting equipment and hold the same in proximity to the equipment being cleaned.
The track again is configured so that when set up, its ends 21 and 22 are magnetically coupled to ferromagnetic structures FMS adjacent or included in the equipment to be cleaned. Referring to
With reference to
The connector 50 also can include and/or house various other components for moving the water blasting device, and in particular the nozzle 42, along a Y axis as shown in
The tipping plate 58 moves relative to the fulcrum 58F, and again can pivot about the pivot axis PA in the tilt or tipping direction T shown with arrows in
The movement of the tipping plate 58 can be affected via a pneumatic or hydraulic cylinder or solenoid 55C. The cylinder 55C can include a ram 55R that attaches to the tipping plate 58. The cylinder 55C can extend and retract the ram 55R therefrom to provide the tilting, tipping or movement of the tipping plate 58 and thus the movement of the water blasting device 40 along the Y axis. Control unit 60 can enable an operator to control this movement and manipulation of the ram or cylinder 55C.
Optionally, in some embodiments, Y axis movement might not be desired. In such a case, the mechanisms and components described above to provide the Y axis movement can be deleted from the construction. Further optionally, Y axis movement may be desired in a different manner, in which case the components above can be modified to include any type of mechanism capable of moving the nozzle 42 in the Y axis. As an example, the holder 56 can be joined with a rack and pinion structure (not shown) that is associated with a connector to move the gun and/or nozzle along the Y axis across a preselected region R. As another example, the holder 56 can be constrained within an elongated slot, and an operator can use manual force to move the holder 56 within the slot, thereby moving the nozzle along the Y axis.
As mentioned above, the water blasting device 40 can be in fluid communication with a water source 80 via one or more hoses or tubes 82. The water source 80 is also in communication and controlled by the control unit 60. The water source can be configured to deliver water under high pressure through the hose 82 to the water blasting device 40, out the nozzle and in particular out orifices 420 defined by the nozzle 42 to project water in a predetermined spray pattern. The water source can be any type of high pressure pump capable of delivering water to the nozzle to a pressure above 1,000 psi, further optionally above 4,000 psi, even further optionally above 10,000 psi, yet further optionally above 20,000 psi, event further optionally above 40,000 psi, and even further optionally up to 100,000 psi. Even under these high pressures, the water blasting device 40 can always be accurately and mechanically controlled and restrained within predetermined areas of movement, with the magnet holding the elongated track and connector in a fixed orientation relative to the equipment to be cleaned, and in particular to the region of cleaning R. Again, with the connector 50, the nozzle 42 is constrained to move within a preselected area relative to the equipment, while the magnets maintain the track 20 in a fixed orientation relative to that equipment and/or other structures surrounding the equipment.
The first and second magnets 31 and 32 used herein can be identical, and are generally illustrated in
The magnet 31 can include an actuator 31L, which is shown as a lever or cam. This actuator can turn the magnet “on” and “off,” increasing and/or decreasing respectively the magnet flux MF generated by an internal magnet 31M disposed in the housing 31H. An exemplary magnet suitable for use with the apparatus 10 is a Mag-Mate Powerlift® magnet available from Industrial Magnetics, Inc., of Boyne City, Mich. The magnet can generally include an interface surface 31I that is adapted to interface with and engage a ferromagnetic surface of a ferromagnetic structure FMS as shown in
Returning to
The actuator 31L is adapted to selectively configure the magnet in a disengaging mode, in which the magnet is able to be removed under minimal manual force from the ferromagnetic structure FMS. The actuator 31L is moved to the position shown in solid lines to turn the magnet “off” in order to minimize the amount of magnet flux MF emitted through the interface surface 31I. The magnetic flux MF created by the magnet 31, 32 is magnetically engageable with a variety of ferrous metals or materials of the type commonly found in facilities, and around equipment to be cleaned with the water blasting apparatus of the current embodiments.
If desired, the actuator 31L can include one or more stops to physically interfere with the travel of the actuator, in order to lock the magnets in the magnetic mode or the disengaging mode. Optionally, the actuator 31L can be accommodated with a grip of rubber or plastic material to provide a surface with an improved coefficient of friction for grasping by an operator.
Of course in other embodiments, the actuator 31L and the internal magnets 31M can be modified. Another suitable structure for the magnets, which allows removal and engagement of the magnets, is disclosed in U.S. Pat. No. 6,471,273 to Friedrich, which is hereby incorporated by reference in its entirely. Yet other types of magnets, different from that shown in
As shown in
Operation of the water blasting apparatus and related methods of the current embodiments will now be described. Generally, the method for using the apparatus can include connecting a water blasting device 40 to a track 20, magnetically coupling the track 20 to a ferromagnetic structure FMS so that the nozzle 42 of the device 40 is proximal the equipment 100, 99 to be cleaned. The elongated track is maintained in a fixed orientation via the track and magnetic coupling. Water is shot at high pressure toward the equipment, out the nozzle, while safely restating the water blasting device. Optionally, the device can be constrained to clean along predefined X and Y axes and predefined regions as explained above.
The apparatus can be used in conjunction with cleaning a variety of different structures and equipment such as heat exchangers, falling pressure evaporators, storage tanks, tubes, piping, towers and similar equipment or structures. With reference to
The operator can actuate the actuators of the respective magnets, thereby exerting a magnetic force through the interface 31I and attracting the magnet to the respective ferromagnetic surface. With the magnetic flux in the ranges of Gauss explained above, the magnets are securely magnetically coupled to the ferromagnetic structure FMS. If desired, the operator can rotate or pivot the track 20 at an angle α relative to the magnet as shown in
The operator can insert the water blasting device 40 and in particular the barrel 43 through the holder 46. The barrel can be held in place in relation to the holder 56 via a set screw 56S or other connector. The operator can connect the water blasting device 40 via a hose 82 to a water source 80. The user can also connect the cylinder 55C and motor 55 of the tractor to a control unit 60. The water source and associated valve 80V can also be electrically or otherwise coupled to the control unit 60. The control unit 60 further can be placed in communication with sensors 80 via a hard wire or wireless connections. Again, the sensor can detect whether respective magnets 31, 32 are satisfactorily or unsatisfactorily engaging the associated ferromagnetic structures. If at any time during the process the track and/or magnets become decoupled or disengaged from the respective ferromagnetic surfaces, the sensor 80 detects this. It sends a signal to the control unit 60 which, in turn relays a control signal to the dump valve 80V. This in turn trips the dump valve so that the high pressure water is no longer delivered from the source 80 to the hose 82 and thus the water blasting device 40.
By controlling the air motor 55 and the gear 52, the operator can tractor the connector 50 along the track 20 as shown in
Optionally, where the water blasting device 40 includes a lance and a movable tube, the tube can be inserted into a tube of a heat exchanger or other piping traversing along it, being propelled by the nozzle expelling or shooting water therefrom.
During the cleaning process, water is shot from the nozzle 42 of the blasting device 40 at a pressure above 1,000 psi toward the equipment to clean the equipment. While the water is shot, the water blasting device 40 is safely constrained within an area or region R of movement via connection to the track. The operator can move the water blasting device 40 linearly along the track 20 or X axis while expelling water from the nozzle. The operator also can manipulate the nozzle in the Y axis to shoot water along the Y axis.
In some cases, multiple pipes or pieces of equipment near one another may be cleaned. This is illustrated in
A first alternative embodiment of the water blasting apparatus is illustrated in
In addition, the track can include a connector 150. This connector 150 can include a ball and socket joint 151. The ball and socket joint 151 is further coupled to a linkage 152 which is directly clamped or otherwise joined with the water blasting device 140 which as illustrated is in the form of a high pressure water blasting gun. This gun includes a nozzle 142 that can expel water from the gun.
The track 120, and in particular the second rail 123, also can define multiple holes 124. The connector 150 can define a hole 150H through which a pin 120P is placed to register the connector 150 in a fixed orientation relative to the respective holes 124 defined by the track 120. This in turn can precisely position the connector and thus the water blasting device relative to the pipe P3. In this configuration it is noted that the linkage 152 can provide an extended amount of articulation, movement and relative rotation of the nozzle 142 and the gun 140. With this linkage 152, the movement of the gun and its nozzle are restrained within a predetermined area.
Another application of this embodiment is illustrated in
A second alternative embodiment of the water blasting apparatus is illustrated in
Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.
Number | Date | Country | |
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62120087 | Feb 2015 | US |