Patent Application
20150122293
The present invention relates to methods and apparatuses for the removal materials from tanks or vessels, and in a particular though non-limiting embodiment, to machines and methods for removing solids, fluids, slurries, and sludge from the interior of a tank or other vessel.
Conventional tank cleaning is often a long, stringent, hazardous and labor-intensive task. Conventional methods of tank and vessel cleaning require human exposure to dangerous environments.
Most currently available remote tank cleaning systems and associated methods include one or more nozzles configured to direct a fluid stream to dislodge, dilute, or dissolve settled solids from tank interiors. Generally, the purpose of these systems is to “fluidize” the settled solids and/or sludge to an extent that it can be easily pumped out. However, in some instances, settled solids and/or sludge inside tanks or other vessels cannot be removed, dissolved, or otherwise “fluidized” by the aforementioned conventionally available systems due to the composition of the solids, conditions inside the tank, lack of sufficient water pressure etc. In such situations, the solids and/or sludge must be physically/mechanically removed from the tank interior. Such methods may be time-consuming and may require one or more workers to physically enter the tank or vessel to mechanically dislodge the solids/sludge—a process that may place such workers in a dangerous and/or toxic environment and therefore at greater risk of exposure to health hazards and injuries. Even existing remote cleaning systems require humans to enter a tank to set-up, change and/or remove the system. Furthermore, depending on the material needing removal, multiple tools and systems may be required, forcing the work to be stopped and restarted while the equipment is changed out. Additionally, often times the cleaning equipment is too large to fit through the vessel's access point, requiring further operator exposure inside of the vessel in order to assemble the equipment parts.
Therefore, there is a long-felt, but unmet, need for a remote and/or automated apparatus and method for the removal of materials, including settled solids, fluids, slurries, or sludge, from a tank interior in order to increase the efficiency of such removal and to protect human workers from health risks and injuries.
In an exemplary embodiment of the present invention, a device for removing material from a vessel is provided, having: a chassis, including: a central member; a first track member substantially parallel to the central member and connected to the central member via first and second track extensions; and a second track member substantially parallel to the central member and connected to the central member via the first and second track extensions; a remotely controllable articulating assembly connected to a top surface of the central member of the chassis. The articulating assembly includes an arm having a first arm member with a first end pivotally connected to the chassis and a second end pivotally connected to a first end of a second arm member. The second arm member has a second end rotationally connected to a tool member. The first and second track extensions are configured to rotate from an expanded position substantially perpendicular to the central member to a collapsed position less than forty-five degrees relative to the central member. At least one of the chassis and the articulating assembly are controlled remotely by an operator external to the vessel.
The device may include a control system operatively connected to the device and configured to control movement of at least one of the assembly and the chassis. The device may have a width of less than 18 inches when in the collapsed position. The device may be configured to fit into a hole of approximately 17.75 inches. The device may have a width of approximately 22.5 inches when in the expanded position. The tool member may be a claw arm. The claw arm may include a first end connected to the second arm member and a second end having opposing curved finger extensions. The device may include a control system operatively connected to the device and configured to open and close the opposing curved finger extensions. The device may include twist lock pins connecting the first and second track members to the first and second track member extensions. The twist lock pins may have locking grooves.
In an exemplary embodiment of the present invention, a device for removing material from a vessel is provided, having: a chassis and a remotely controllable articulating claw assembly connected to the chassis, the claw assembly having at least two joints and configured to manipulate equipment in an interior portion of the vessel. The chassis may have first and second track members attached to a central member. The first and second track members may be configured to collapse such that the track members are close to the central member when in a collapsed position and extended away from the central member when in an expanded position. The claw assembly may include an arm having a first end pivotally connected to the chassis and a second end pivotally connected to a claw arm. The device may have a control system operatively connected to the device and configured to control movement of at least one of the claw assembly and the chassis. The chassis may include a moving arrangement configured to traverse an interior surface of the vessel and is remotely controllable. The chassis may be stationary. The claw arm may include a first end connected to the arm assembly and a second end having a plurality of opposing curved finger extensions.
The device may have a control system operatively connected to the device and configured to open and close the opposing curved finger extensions. The device may have a spray nozzle arrangement between opposing fingers of the claw arm. The claw assembly may be configured to fold into the chassis. The device may be configured to fit into a hole of about 17.75 inches. The device may be configured to fit into a hole of about 17.75 inches when in the collapsed position. The first and second track members may be attached to the central member via twist lock pins having locking grooves.
In an exemplary embodiment of the present invention, a method of removing material from a vessel interior is provided, having the steps of: folding a device into itself, the device including: a chassis; and a claw assembly; the claw assembly having first end pivotally connected to the chassis and a second end connect to a claw arm, the claw assembly and claw arm configured to fold and align proximate to the chassis; collapsing first and second tracks of the chassis, where the first and second tracks are configured to have collapsed and expanded positions; placing the device in a vessel; extending the first and second tracks into the expanded position; placing a vacuum assembly in the vessel; positioning the vacuum assembly within the vessel with the claw arm of the device; placing a water line having a spray nozzle in the vessel; manipulating the spray nozzle with the claw arm of the device to apply a water stream to the materials to be removed; applying a suction force from the vacuum assembly, such that the materials are moved from the vessel interior into the vacuum assembly; and removing the materials from the vacuum assembly through a hose. The water line may be a high pressure water line. The water line may provide approximately 100 GPM at approximately 900 PSI.
In an exemplary embodiment of the present invention, an apparatus for transportation, lowering and raising of a cleaning device is provided, having: a lift platform; a box having an open top; two lift arms connected to the box at first ends of the two lift arms such that the arms may rotate relative to the box and connected to the lift platform at second ends of the lift arms via a pair of pin slots on opposite sides of the lift platform; a pair of cylinders connected to an interior of the box and a bottom surface of the lift platform; a wench at a first end of the lift platform; and a plurality of leg extensions extending from lower corners of the box. The cylinders are configured to raise and lower the lift platform relative to the box. The lift platform is configured to form a top surface of the box when the lift platform is in a lowered position. The two lift arms are configured such that, when the lift platform is raised, the lift platform is angled such that the first end of the lift platform is at a highest point of the lift platform. The cleaning device may be secured to the lift platform via the wench.
The apparatus may have a plurality of wheels attached to the plurality of leg extensions. The leg extensions may be telescoping leg extensions. The apparatus may have a plurality of leveling pins attached to the plurality of telescoping leg extensions. The pair of cylinders may be configured to be contained within the box when the lift platform is fully lowered. At least two of the plurality of wheels may be swivel wheels. At least one of the plurality of wheels may include a locking mechanism.
In an exemplary embodiment of the present invention, a crane is provided, having: a base, including: an annular section extending vertically from a bottom section having a first ring, a second ring, and a third ring formed around the annular section; a first set of tubes arranged vertically between the first ring and the second ring forming a first set of pin holes; a second set of tubes arranged vertically between the second ring and the third ring forming a second set of pin holes; a plurality of leg extensions, each connected to at least one of the first and second sets of pin holes such that the plurality of leg extensions may rotate at a first end of the plurality of leg extensions relative to the first and second sets of pin holes; an extender connected to the annular section of the base and extending vertically from the base; a wench connected to the extender; an arm section, including: a connector secured to a top of the extender and extending vertically from the extender; an arm holder attached to a top portion of the connector and arranged substantially parallel to a surface upon which the crane is installed; an arm passing within the arm holder and configured to extend or contract relative to the arm holder; and a wench ring attached at one end of the arm. The extender is configured to rotate along a central axis relative to the annular section of the base.
The crane may have a plurality of leveling pins attached to the plurality of leg extensions. Each of the plurality of leg extensions may have a leg extension member. A circumference of the first ring may be substantially the same as a circumference of the second ring. A circumference of the second ring may be larger than a circumference of the second ring.
In an exemplary embodiment of the present invention, a system of removing material from a vessel is provided, having the steps of: disassembling the device of claim 25 by releasing the twist lock pins such that the first and second track members are separated from the first and second track extensions; transporting the device in separate pieces to a site for installation; assembling the device by connecting the first and second tracks to the first and second track extensions via the twist lock pins; dissembling the crane of claim 34 into the base, the extender, the wench, and the arm section; transporting the base, the extender, the wench, and the arm section to the site for installation; assembling the crane at the site for installation; connecting the wench of the crane to the device; lowering the device into the vessel via the wench; removing the material using the device; and raising the device out of the vessel via the wench.
Like reference characters denote like parts in the several drawings.
Example embodiments of the present invention include a remotely-operated tracking device that provides a claw assembly and/or claw arm configured to manipulate tools and/or instruments within a vessel. Example embodiments of the present invention provide for the manipulation and/or placement of a vacuum within the vessel. Example embodiments of the present invention provide for manipulation of high pressure water/cleaning fluid lines and other tools. The high pressure lines may provide sufficient pressure to dislodge sludge and/or debris within a vessel that could not be dislodged with traditional fluid lines or fluidization methods. Embodiments of the present invention may include twist lock pins for attachment of tracks to the tracking device such that the tracks may be easily removed allowing for the tracking device to be disassembled and relocated in separate pieces. The tracking device may be taken to an install location using a lift box according to an example embodiment of the present invention. The tracking device may be lowered into a vessel using a squid crane according to an example embodiment of the present invention. The squid crane may allow for access to locations that could not be accessed with a lift box, traditional wench or other crane device.
Not only can removal tasks be accomplished in a remote, safe manner, but they may be effectively and efficiently performed simultaneously or consecutively with a single operator. Moreover, removal may be accomplished without a human entering a vessel. To facilitate effective and efficient services, in accordance with an exemplary embodiment of the present invention, a cleaning device may be equipped with a claw assembly and/or claw arm having opposing finger-like extensions capable of grasping equipment and/or tools inside the vessel. Other securing mechanisms may be used other than a claw. Additionally, according to exemplary embodiments of the present invention, the cleaning device may be configured to change its shape such that it can enter a tank or vessel through an opening with minimal space. For example, accordingly to an exemplary embodiment of the present invention, a device may be provided that folds into itself such that its largest dimensions allow it to enter a cylindrical access hole with a diameter of about 17.75 inches. In exemplary embodiments of the present invention provide collapsible tracks that can be collapsed such that the cleaning device may be passed through an access hole with a diameter of about 17.75 inches. The collapsible tracks may be expanded once the cleaning device is inside the vessel to be cleaned. After expansion, the tracks provide a wider base than could be passed through the access hole, increasing the stability of the cleaning device and allowing it to withstand larger forces (such as high pressure water lines). Further, according to example embodiments of the present invention, the device may be driven with electric over hydraulic directional control valves. In example embodiments, the hydraulic directional control valve used may support up to 30 gallons per minute at 5000 pounds per square inch, which is the equivalent of about 87.515 horse power. However, other drive sources can be used, such as pneumatics, electronics, hydraulic over hydraulic, or pneumatics over hydraulics, or any applicable combination thereof. The unique device and system configuration, along with the novel tools/attachments discussed herein, provide for a high power, compact and effective cleaning device and system.
The control station 137 and device 150 are operatively connected to a power source 160 to provide power for the system 100. According to example embodiments, the device 150 is driven with electric over hydraulic directional control valves. However, other drive sources can be used, such as pneumatics, electronics, hydraulic over hydraulic, or pneumatics over hydraulics, or any applicable combination thereof.
Tank cleaning system 100 may be used to clean settled solids from a storage tank 127 or storage vessel 127. Such a tank or vessel 127 may contain a material 141 that has settled into solid and/or semi-solid matter, such as drilling mud. Tank 127 includes a side wall 112, bottom or bottom wall 113 and a top wall or roof 114. Interior 131 contains the settled material 141 to be removed. Tank 127 may further include an access opening or entry hatch 116 for gaining access to interior 131. In certain embodiments opening 116 may be a part of roof or top wall 114. Entry hatch 116 may have a limited diameter opening which may be approximately 18 inches. A lifting device such as a hoist, crane, wheeled crane, mobile crane or any other such suitable device may be used to lift cleaning device 150 into tank 127. In certain embodiments, such a lifting device or crane 117 may provide boom 118, lifting lines and a lifting hook. Such a lifting device 117, boom 118, lifting line and hook are known and commercially available.
In the example embodiment of the present invention shown in
In the alternative, twist lock pins 1565 (
In an expanded position as shown in the exemplary embodiment of
When collapsed such as the embodiment shown in
In embodiments of the present invention, various tools can be lowered into the tank and grabbed by a claw or other securing mechanism attached to the arm. These tools, including high pressure cleaning fluid hoses, can be fished down to the claw and then fished back out when work is complete. In embodiments of the present invention a vacuum assembly, separate from the cleaning device, can be lowered into the tank and the cleaning device can direct material to be removed to the vacuum assembly.
Embodiments of the present invention include a lift box 800 that may be used to transport device 500 to a location and/or lower device 500 into a vessel for cleaning. See, e.g.
Lift box 800 may have leg extensions 810 extending from corners of box 805 and having wheels 815 attached thereto, which may be swivel wheels and may include locking mechanisms to prevent rolling. See, e.g.,
In embodiments of the present invention, squid crane 900 is provided, which may be employed to lower and/or raise materials such as device 500. See, e.g.,
Extender 925 is an annular extension connected to annular section 922 such that extender 925 may rotate along a central annular axis relative to annular section 922. Wench 921 may be attached to extender 925 and configured such that a wire 944 of wench 925 is passed through wench ring 945.
Attached to extender 925 is arm section 927 having connector 939 secured to a top of extender 925. Arm holder 928 is attached and may be perpendicular to connector 939 such that arm holder 928 is substantially parallel to a surface upon which squid crane 900 is installed. Other configurations of arm holder 928 are possible. Passing within arm holder 928 is arm 929 with wench ring 945 attached at one end of arm 929. Arm 929 is configured such that is may extend or contract with regard to arm holder 928, allowing the location of wench ring 945 to be laterally adjusted with respect to base structure 923.
Squid crane 900 may be quickly dissembled into base structure 923, extender 925, wench 921 and arm section 927. With the total weight of squid crane being such that a single worker can locate and assemble the pieces of the squid crane 900 at a desired location. This is particularly helpful for situations where the deck is cluttered and/or the location is difficult to access. Allowing the squid crane 900 to be transported in pieces and assembled on location substantially increases the areas of access for squid crane 900. Squid crane 900 may be utilized to lower and/or raise device 500 into or out of a vessel having a difficult access point location. In example embodiments of the present invention, squid crane 900 is rated for up to 1000 pound loads and has a safety factor of 2.5.
In embodiments of the present invention, a device may include an articulating assembly 590 attached to a top surface of the chassis. See, e.g.,
In embodiments of the present inventions, methods of removing material from a vessel interior are provided having steps of: folding a device into itself, the device including: a chassis; and a claw assembly; the claw assembly having first end pivotally connected to the chassis and a second end connected to a claw arm, the claw assembly and claw arm configured to fold and align proximate to the chassis; collapsing first and second tracks of the chassis, where the first and second tracks are configured have collapsed and expanded positions; placing the device in a vessel; extending the first and second tracks into the expanded position; placing a vacuum assembly in the vessel; positioning the vacuum assembly within the vessel with the claw arm of the device; placing a water line having a spray nozzle in the vessel; manipulating the spray nozzle to apply a water stream to the materials to be removed; applying a suction force from the vacuum assembly, such that the materials are moved from the vessel interior into the vacuum assembly; and removing the materials from the vacuum assembly through a hose. Embodiments of the present invention include the use of high pressure water lines, which provide approximately 100 GPM at approximately 900 PSI. The high pressure lines allow removal of materials not previously removed with lower water pressures and volumes. Expanding the base of the device allows for manipulation of a high pressure line without pushing over the device. The device may be moved around the vessel to provide additional water line direction or the device may remain stationary within the vessel.
In embodiments of the present invention, a system of cleaning a vessel in need of cleaning is provided. In certain embodiments, device 500 may be transported to a desired location via lift box 800 and dropped into the vessel using wench 835. In other embodiments, device 500 may be disassembled, by separating the tracks via twist lock pins, and carried to a desired location in separate pieces. Once at the desired location, device 500 may be reassembled. Disassembly and transport may provide substantial benefits over utilizing a separate device to locate an assembled device 500. Particularly, cluttered decks and/or difficult to reach locations may make transport of device 500 using a transportation device impractical or impossible. Disassembly substantially increases the areas of access for device 500. Once assembled on site, device 500 may be lowered and/or raised using lift box 801 or squid crane 900. Squid crane 900 may also be transported in pieces and assembled on site, substantially increasing the areas of access for squid crane 900. Accordingly, use of both squid crane 900 and disassembled device 500 creates overall improvement with regard to access to difficult locations.
According to another embodiment for a cleaning device, a remotely operated tracking device may be deployed to clean a vessel such as the embodiments disclosed in
The foregoing embodiments are presented by way of example only. While the embodiments are described herein with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the invention(s) is not limited to them. In general, embodiments of a method and/or apparatus for removing material from storage tanks as described herein may be implemented using methods, facilities, and devices consistent with any appropriate structural or mechanical system(s). Many variations, modifications, additions, and improvements are possible and the various aspects of the different embodiment described herein may be incorporated into each of the different exemplary embodiments described as appropriate to accomplish to tasks specified herein.
For example, plural instances may be provided for components, operations or structures described herein as a single instance. Boundaries between various components, operations and functionality are depicted somewhat arbitrarily, and particular operations are illustrated within the context of specific illustrative configurations. Other allocations of functionality will also fall within the scope of the inventive subject matter. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.
This application claims benefit of U.S. Provisional Application 61/899,690 filed Nov. 4, 2013, and U.S. Provisional Application 61/951,806 filed Mar. 12, 2014, which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61899690 | Nov 2013 | US | |
| 61951806 | Mar 2014 | US |
