Header delivery system

A header delivery system and method for performing a pigging operation on a process tube connected to a header pipe. The header delivery system is insertable in the header pipe and has a launcher pipe for launching an inspection or cleaning tool to the process tube. A tube coupler for coupling to the process tube and a bumper are connected to the launcher pipe. A jack apparatus is configured to position the tube coupler and the bumper. A wedge assembly is connected to the launcher pipe and has a first actuating wedge and a first extension wedge. A first linear actuator is connected to the first actuating wedge and is configured to move the first extension wedge and the tube coupler mount apart from one another to position the tube coupler and the bumper from a retracted position to an extended position.

FIELD OF INVENTION

In general, the disclosure describes a system and methodology for a header delivery system for a header pipe for performing an operation on process tubes connected to a header pipe.

BACKGROUND OF INVENTION

Pigging of pipes or pipelines is performed to remove internal fouling, to inspect for defects in a pipe or to map the geographic location of the pipe. Pigging is done by pumping a device, i.e. a pig, through a pipe. Intelligent pigs have sensors that can record information on the condition of the pipe.

One example use of pigs is in cleaning fired heaters that are used in industries such as power and oil and gas. Fired heaters are typically insulated enclosures that use heat created by the combustion of fuels to heat fluids contained within coils, tubes, pipes, or the like. The type of fired heater is generally described by the structural configuration, the radiant tube coil configuration and the burner arrangement.

Over time, the internal coils/tubes/pipes of the fired heater are subject to pollution and wear during their work cycle. The internal coils/tubes/pipes may become internally fouled with coke. Coke is ash made of carbon fragments that lays down and coats the interior of the coils/tubes/pipes. Coke deposits drop out of the process stream if/when the stream gets too hot and starts to thermally degrade. Decoking is the industry term used to describe the process of removing coke or other types of internal fouling from a fired heater's inner pipes/tubes/coils. Presently, decoking is done by conveying cleaning pigs through the pipes/tubes/coils.

When cleaning or inspecting furnaces, the furnaces may contain one or more manifolds, also referred to as header pipes. A header pipe has process tubes connected to the header pipe at one or more angular positions around the header pipe. To enable the pigging company to perform an operation to clean or inspect the furnace, there needs to be a temporary header delivery system (HDS) installed in the header pipes to access one or more process tubes. In many cases, header delivery systems may not be configured for varying sizes of header pipes that have a wide range of internal diameters, including header pipes with small internal diameters. Header pipes below a certain internal diameter size may not have been inspected or cleaned because the header delivery systems may not have been available for such limited-sized header pipes.

What is needed, is a system and methodology to enable the performance of pigging and other operations on process tubes connected to a header pipe of a range of sizes, including header pipes with small internal diameters.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limited the scope of the claimed subject matter.

An embodiment of the disclosure provides a header delivery system for a header pipe having a process tube extending from the header pipe. The header delivery system includes a launcher pipe having a first pipe end forming a first pipe opening and a second pipe end forming a second pipe opening, a frame assembly connected to the launcher pipe, a tube coupler connected to the launcher pipe at the second pipe end, and a bumper connected to the launcher pipe, and a jack apparatus. The jack apparatus includes a tube coupler mount connected to the launcher pipe at the second pipe end and connected to the tube coupler, a wedge assembly connected to the launcher pipe and having a first actuating wedge and a first extension wedge disposed adjacent one another in a wedge configuration, and a linear actuator assembly. The linear actuator assembly has a first linear actuator connected to the first actuating wedge and configured to move the first actuation wedge in a first linear direction and to move the first extension wedge and the tube coupler mount apart from one another in response to the movement of the first actuation wedge in the first linear direction. The tube coupler and the bumper move from a retracted position to an extended position as the first extension wedge and the tube coupler mount move apart from one another.

Another embodiment of the present disclosure provides a method of accessing a process tube extending from a header pipe using a header delivery system of the present disclosure. The method includes inserting the header delivery system in the header pipe with the tube coupler and the bumper in a retracted position; aligning the header delivery system in the first header pipe with the process tube in an alignment position and with the tube coupler in a retracted position; after aligning the header delivery system, actuating the first linear actuator to move the first actuation wedge in the first linear direction to position the tube coupler and the bumper from the retracted position to an extended position to form a seal between the tube coupler and the process tube; and performing a first service operation on the process tube with the tube coupler and the bumper in the extended position using the launcher pipe to access the process tube.

Another embodiment of the present disclosure provides a header delivery system for a header pipe having a process tube extending from the header pipe. The header delivery system includes a launcher pipe, a tube coupler connected to the launcher pipe at the second pipe end, a bumper connected to the launcher pipe, and a jack apparatus. The jack apparatus includes a tube coupler mount connected to the launcher pipe at the second pipe end and connected to the tube coupler, a wedge assembly connected to the launcher pipe and having a first actuating wedge and a first extension wedge disposed adjacent one another in a first wedge configuration and a second actuating wedge and a second extension wedge disposed adjacent one another in a second wedge configuration, a linear actuator assembly having a first linear actuator connected to the first actuating wedge and a second linear actuator connected to the second actuating wedge, and the linear actuator assembly configured to move the first actuation wedge and the second actuator wedge in a first linear direction and to move the first extension wedge and the second extension wedge apart from the tube coupler mount in response to the movement of the first actuation wedge and the second actuation wedge in the first linear direction. The tube coupler and the bumper move from a retracted position to an extended position as the first extension wedge and the tube coupler mount move apart from one another.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.

As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”; “upper” and “lower”; “top” and “bottom”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. As used herein, the terms “coils”, “pipes”, and “tubes” are used individually or in combination to mean the internal fluid carrying elements of a fired heater.

The present disclosure generally relates to a system and method addressing the need for a header delivery system that is sized to be inserted into a header pipe or manifold that may have a small diameter. The header delivery system of the present disclosure is designed with system components that allow the header delivery system to be sized to be fit in headers pipes of limited size. In embodiments of the present disclosure, linear actuators are mounted in alignment with a launcher pipe and connected to a wedge assembly disposed on opposite sides of the launcher pipe and that is configured to be contained between a tube coupler mount and a bottom of the launcher pipe when in a retracted position. The wedge assembly converts the linear motion of the linear actuators to radial motion that moves the tube coupler and a bumper from a retracted position to an extended position. The header delivery system of the present disclosure provides a header delivery system that is efficiently designed for limited-sized header pipes.

Referring toFIG.1, a header delivery system100is shown. Header delivery system100includes a launcher pipe102coupled to a tube coupler104and a bumper106disposed opposite one another and a jack apparatus. The jack apparatus is formed by a tube coupler mount114, a wedge assembly118, and a linear actuator apparatus110formed by a first linear actuator120and a second linear actuator122, as shown inFIG.1andFIG.2. Tube coupler104and the bumper106may be disposed on opposite sides of a first axis112extending through the launcher pipe102. The first axis112may be a center line that extends through a section of the launcher pipe102. First linear actuator120is shown inFIG.1and the second linear actuator122is shown inFIG.2. Linear actuators120,122each include a cylinder123and a piston124. The linear actuator apparatus110and the wedge assembly118of the jack assembly are configured to move tube coupler104and the bumper106between a retracted position and an extended position to adjustably position the radial spacing between one another, as discussed in more detail below.

A wheel apparatus126is formed by a wheel plate128connected to the tube coupler mount114and a wheel130connected to the wheel plate128. Wheel130is axially spaced from the launcher pipe102at one end of the launcher pipe102. Positioning the wheel130on the wheel plate128provides the benefit of helping to limit the outer diameter of the header delivery system100between the tube coupler104and the bumper106to enable the header delivery system100to be inserted in header pipe of a limited or small diameter. For example, the wheel130may be connected to the wheel plate128so that the wheel130is contained within a top surface of the tube coupler104and bumper106when in a fully retracted position, as shown inFIG.1. Wheel apparatus126may be used in inserting and positioning the header delivery system100in a header pipe. Header delivery system100may be positioned in a header pipe by positioning the wheel130against an internal surface of the header pipe and pushing or pulling the header delivery system100with the wheel rolling on the internal surface of the header pipe. In some embodiments, an accessory mount126may be connected to the tube coupler mount114and an accessory, such as a camera, not shown, may be mounted on the accessory mount134. A mounted camera may be used in positioning the header delivery system100in a header pipe.

In some embodiments, the tube coupler104may have a curved outer surface configured to conform to a curved surface of the inner diameter of a header pipe. In some embodiments, the tube coupler104may have a curved outer surface of a different radius or a flat outer surface configured to conform to the internal surface of the header pipe. In some embodiments, the tube coupler104may be made of a resilient material configured to form a seal. Tube coupler104forms a tube coupler opening116that extends through the tube coupler104and adjacent an opening in the launcher pipe102.

The linear actuator apparatus110and the wedge assembly118of the jack apparatus are configured to radially position the tube coupler104and the bumper106with respect to one another. For example, the linear actuator apparatus110and the wedge assembly118are configured to position the tube coupler104and the bumper106radially apart from one another as the tube coupler104and the bumper106are positioned from a retracted position to an extended position. Linear actuator apparatus110and the wedge assembly118are configured to position the tube coupler104and the bumper106radially toward one another as the tube coupler104and the bumper106are positioned from an extended position to a retracted position. Tube coupler104and the bumper106may move in radial directions along a second axis132as the tube coupler104and the bumper106are positioned between an extended position and a retracted position. Second axis132may be perpendicular to the first axis112. Second axis132may form a centerline of the tube coupler104, as shown inFIG.1. In some embodiments, the tube coupler104and the bumper106move radially with respect to the first axis112when the header delivery system100moves between a retracted position and an extended position.

Referring toFIG.1andFIG.2, wedge assembly118includes a first actuating wedge140, a second actuating wedge142, a first extension wedge144and a second extension wedge146.FIG.1shows a perspective view of one side of the header delivery system100and shows a first portion of the wedge assembly118and a first portion of the linear actuator apparatus110. The opposite side of the header delivery system100includes a similar second portion of the wedge assembly100and a similar second portion of the linear actuator apparatus110, as shown inFIG.2.

Actuating wedges140,142are each connected to a piston124of one of the linear actuators120,122. Each of the pistons124may have a wedge connector136configured to connect an end of the piston124to an end of one of the actuating wedges140,142. Each of the pistons124may have a piston coupler137connected to one of the wedge connectors, as shown inFIG.7.FIG.1shows the first actuating wedge140connected at one end to the piston124of the first linear actuator120. Referring toFIG.2, the second actuating wedge142may be connected at one end to the piston124of the second linear actuator122. A support member125may be connected to each of the pistons124. Support member125is disposed between the piston connectors136and the cylinders123of the linear actuators120,122. Support member125may be rigid and have a U-shape, as shown inFIG.2, or a curved shape that is configured to accommodate the outer diameter of the launcher pipe102. Support member125connects to the pistons to synchronize the extension and retraction of the pistons124of the spaced-apart cylinders123. Actuating wedges140,142are connected to linear actuators120,122to position the tube coupler104and the bumper106between the retracted position and the extended position.

Actuating wedges140,142each have a first tapered face150and an opposite first base face. Tube coupler mount114may include a first wedge channel154and a second wedge channel156. A base face of each of the actuating wedges140,142may be configured to slidably move within the wedge channels154,156as the actuating wedges140,142are extended and retracted by the pistons124to move the tube coupler104and the bumper106between a retracted position and an extended position. Extension wedges144,146each have a second tapered face152and an opposite second base face. First tapered faces150of the actuating wedges140,142have the same taper angle as the second tapered faces152of the extension wedges144,146. First tapered faces150each are adjacent and slide against one of the second tapered faces152, as shown inFIG.1, as the actuating wedges140,142are moved to position the tube coupler104and the bumper106between a retracted position and an extended position. First actuating wedge140and the first extension wedge144with the tapered faces150disposed adjacent one another may be referred to as being in a wedge configuration.

Actuating wedges140,142each include an actuating wedge tapered end158and an actuating wedge non-tapered end159. Actuating wedge non-tapered end159may also be referred to as a tall end. As shown inFIG.1, the actuating wedge tapered end158of the first actuating wedge140is disposed between the tube coupler mount114and the first extension wedge146.

First extension wedge144and the second extension wedge146together may form a bumper mount for bumper106. Extension wedges144,146are spaced apart from one another and an end plate148, as shown inFIG.1, may be connected at one end of each of the extension wedges144,146to connect the extension wedges144,146in a spaced-apart configuration. A bumper106may be connected to the extension wedges144,146and the bumper106extends outward from the base face on each of the extension wedges144,146.

Mechanical fasteners, such as bolts160may connect the bumper106to the extension wedges144,146. Bolts160may be disconnected from the wedges144,146to allow for different sized bumpers106to be connected to the extension wedges144,146. Different sized bumpers106may be connected to the extension wedges144,146to accommodate header pipes having varied internal diameters. Bumper106may have a convex shape that is configured to conform to an internal wall of a header pipe. Bumper106may have other shapes that conform to an internal wall of header pipes of different shapes.FIG.1andFIG.2show a bumper106having three convex members162and a support bar164extending through an opening in each of the convex members162to provide support to the bumper106. Extension wedges144,146are disposed on opposite sides of the launcher pipe102and form an extension wedge cavity166configured to accommodate the launcher pipe102.

Referring toFIG.2, launcher pipe102may include a first pipe section170and a second pipe section172. First pipe section170is connected to the second pipe section172in an end-to-end configuration. Second pipe section172forms a 90-degree elbow section of the launcher pipe102with one end connected to the first pipe section170and an opposite end connected to the tube coupler mount104. Pipe sections170,172may be welded together or otherwise securely joined together. Tube coupler mount114may be welded to an end of the second pipe section172. Mechanical fasteners138may be used to connect the tube coupler104to the tube coupler mount114. Reducer pipe173may be used as a coupler to the launcher pipe102with the reduced pipe173having a reduced diameter at one end so that a fluid hose may be connected. The fluid hose may be connected to a pump to provide hydraulic power to pump a cleaning or inspection tool, such as a pig, through a launcher pipe and a process tube connected to the launcher pipe102. In some embodiments, the reducer pipe173may be removed from an end of the first section pipe170and an inspection or cleaning tool may be inserted in the end of the first pipe section170. Reducer pipe173may be reconnected to the end of the first pipe section170after the inspection or cleaning tool has been inserted.

A frame assembly is formed by a first frame apparatus174and a second frame apparatus176axially spaced from one another and connected to the launcher pipe102. Frame apparatuses174,176may be welded to the launcher pipe102. First frame apparatus174may include a first bracket member178and a second bracket member180each connected on an opposite side of the first pipe section170. A cylinder connector184may be connected to each of the bracket members178,180. Second frame apparatus176is spaced between the first frame apparatus174and the second pipe section172. Second frame apparatus176may extend around the launcher pipe102and forms an external bracket extending outwardly form an outer surface of the launcher pipe102. Second frame apparatus176has frame openings182disposed on opposite sides of the launcher pipe102.

A first linkage member188and a second linkage member190each have a pivot connection to the second frame apparatus176. A first pivot connector192may be used to pivotally connect one end of each of the linkage members188,190to the second frame apparatus176. First pivot connectors192may be formed by a mechanical fastener such as a bolt that extends through a first pivot opening in each of the linkage members188,190and is connected to the second frame apparatus176. Linkage members188,190each have a pivot connection at a second end to one of the extension wedges144,146. A second pivot connector194may be used to pivotally connect an opposite end of each of the linkage members188,190to one of the extension wedges144,146. Second pivot connectors194each may be formed by a mechanical fastener such as a bolt that extends through a second pivot opening196in each of the linkage members188,190and is connected to one of the extension wedges144,146.

First linkage member188has a first pivot connection to the first extension wedge144and a second pivot connection to the first frame apparatus174and is configured to pivot at the first pivot connection and the second pivot connection to move the tube coupler mount114and the first extension wedge144apart as the tube coupler104and the bumper106are positioned from a retracted position, as shown inFIG.8, to an extended position, as shown inFIG.9. Referring toFIG.1andFIG.2, second linkage member190has a third pivot connection to the second extension wedge146and a fourth pivot connection to the first frame apparatus174and is configured to pivot at the third pivot connection and the fourth pivot connection to move the tube coupler mount114and the second extension wedge146apart as the tube coupler104and the bumper106are positioned from the retracted position to the extended position.

First linear actuator120is connected to the first actuating wedge140and is configured to move the first actuation wedge140in a first linear direction parallel to the first axis112and to move the first extension wedge144and the tube coupler mount114apart from one another in response to the movement of the first actuating wedge140in the first linear direction. Tube coupler104and the bumper106move from a retracted position to an extended position as the first extension wedge144and the tube coupler mount114move apart from one another.

First linear actuator120is configured to move the first actuation wedge140in a second linear direction parallel to the first axis112and to move the first extension wedge144and the tube coupler mount114towards one another in response to the movement of the first actuation wedge140in the second linear direction. Tube coupler104and the bumper106move from the extended position to the retracted position as the first extension wedge140and the tube coupler mount114move toward one another.

Second linear actuator120is connected to the second actuating wedge142and is configured to move the second actuation wedge142in the first linear direction parallel to the first axis112and to move the second extension wedge146and the tube coupler mount114apart from one another in response to the movement of the second actuating wedge142in the first linear direction. Tube coupler104and the bumper106move from a retracted position to an extended position as the second extension wedge146and the tube coupler mount114move apart from one another.

First linear actuator120is configured to move the second actuation wedge142in the second linear direction parallel to the first axis112and to move the second extension wedge146and the tube coupler mount114towards one another in response to the movement of the second actuation wedge142in the second linear direction. Tube coupler104and the bumper106move from the extended position to the retracted position as the second extension wedge146and the tube coupler mount114move toward one another.

Linear actuators120,122may be actuated together to move the actuating wedges140,142together in either the first linear direction or the second linear direction. Actuating wedges140,142move together in response to movement of the linear actuators120,122to position the tube coupler104and the bumper106between the retracted position and the extended position.

Referring toFIG.3, frame apparatuses174,176are used in connecting the linear actuators120,122and the linkage members188,190to the launcher pipe102. Spaced-apart cylinders123are each connected to the first frame apparatus174at one end by one of the cylinder connectors184. A second end of each of the cylinders123is positioned adjacent to the second frame apparatus176. Each of the pistons124extend through the frame openings182in the second frame apparatus176. Cylinders123are mounted to the frame apparatuses174,176in an axial direction parallel to the first axis112to position the linear actuators120,122in an axial position with respect to the launcher pipe102and the first axis112. Cylinders123may be parallel with one another. Cylinders123may be parallel to the first axis112. Linkage members188,190each are pivotally connected at one end to the second frame apparatus176and pivotally connected at an opposite end to one of the extension wedges144,146. Each actuating wedge142is disposed between the tube coupler mount114and one of the extension wedges144,146.FIG.3shows the second actuating wedge142disposed between the tube coupler mount114and the second extension wedge146. Wheel plate128and wheel130are axially spaced from the end plate148and the launcher pipe102.

Referring toFIG.4, an end view of the header delivery system100is shown. Header delivery system100may be at an angular position of forty-five degrees with respect to a vertical axis133. Bumper106is connected to the first extension wedge144. Second pipe section172is shown disposed behind the end plate148and the wheel plate128. Wheel plate128is connected to the tube coupler104, as shown inFIG.4. Wheel130extends outwardly from the wheel plate128and is disposed within an outer periphery of the header delivery system100so that the wheel130does not increase the diameter of the header delivery system100. In some embodiments, the wheel130is disposed within the outer periphery of the header delivery system100when the header delivery system100is in a fully retracted position, as shown inFIG.4. In some embodiments, the wheel130is disposed within the outer periphery of the header delivery system100when the header delivery system100is in a fully extended position.

A plurality of wheel connection openings129may be formed adjacent a periphery of the wheel plate128and are configured to allow the wheel to be position in a plurality of different positions, such as different circumferential positions, on the wheel plate128. Wheel130may have a wheel bracket131configured to attach the wheel130in different positions on the wheel plate128. Mechanical fasteners, not shown, such as bolts may be used to connect the wheel bracket131to the wheel plate128.

Referring toFIG.5, a cross-section of the header delivery system100ofFIG.3along plane5-5is shown. Tube coupler104is connected to the tube coupler mount114with mechanical fasteners138. Tube coupler mount114forms a mount opening204leading from the tube coupler opening116to a second launcher pipe opening199and the internal diameter of the second pipe section172of the launcher pipe102. Bumper106is connected to the base face of each of the extension wedges144,146. Actuation wedges140,142are each shown positioned adjacent and abutting one of the extension wedges144,146at mating tapering faces in a wedge configuration.

Referring toFIG.6, a cross-section of the header delivery system100ofFIG.4is shown. Launcher pipe102has a first launcher pipe opening198formed at a first end of launcher pipe102and a second launcher pipe opening199formed at an opposite end of the launcher pipe102. Header delivery system100is shown in a fully retracted position. In the fully retracted position, the header delivery system100has a height D1from an outer surface of the tube coupler104and an outer surface of the bumper106. Wheel plate128has a height D3from one end to the opposite end. Wheel130is contained within the height D1between the outer surface of the tube coupler104and the outer surface of the bumper106. Wheel130may also be contained with the height D3of the wheel plate128in some embodiments. The positioning of the wheel plate128and the wheel130to have a height D3not exceeding height D1helps provide a limited height for the header delivery system100to allow the header delivery system100to be inserted and used in header pipes of limited or small diameters. Height D1and Height D3may be measured along axis that are parallel to the vertical axis132.

Referring toFIG.7, a bottom view of the header delivery system100is shown. Linear actuators120,122each may include a cylinder123that is a dual-acting cylinder, as shown inFIG.7. In some embodiments, cylinder123may be a single-acting cylinder. Cylinders123each may include a first port206and a second port208leading to the internal diameter of the cylinder123. A first actuator tubing212is connected to the first ports206and a second actuator tubing214is connected to the second ports208on the cylinders123. A first actuator hose216is connected to the first actuator tubing212and a second actuator hose218is connected to the second actuator tubing214. Actuator hoses216,218may extend from the actuator tubing212,214along the launcher pipe202and extend outside of a header pipe and may be connected to a hydraulic pump for actuating the linear actuators120,122.

Fluid may be pumped through the first actuator hose216to each of the first ports206to apply a hydraulic force to each of the cylinders123to perform a piston extension actuation. A piston extension actuation forces each of the pistons124to extend in a first axial direction, as shown in arrow222inFIG.8, thereby applying an extension force to each of the actuating wedges140,142. Fluid may be pumped through the second actuator hose218to each of the second ports206to apply a hydraulic force to each of the cylinders123to perform a piston retraction actuation. A piston retraction actuation forces each of the pistons124to retract in a second axial direction, as shown in arrow224inFIG.9, thereby applying a retraction force to each of the actuating wedges140,142. The first axial direction222may bt opposite to the second axial direction224, and the first and second axial directions222,224may be parallel to the first axis112.

FIG.8andFIG.9show a side view of the header delivery system100to show operation of one side of the jack apparatus. Each side of the jack apparatus includes one of the linear actuators120,122, the actuating wedges142,144, and the extension wedges144,146. The opposing sides of the jack apparatus operate in a similar manner. The spaced-apart distance between a bumper outer surface of the bumper106and a tube coupler outer surface of the tube coupler104when in a retracted position shown inFIG.8is a distance D1. The spaced-apart distance between a bumper outer surface of the bumper106and a tube coupler outer surface of the tube coupler104when in an extended position shown inFIG.9is a distance D2. D2is greater than D1. Distance D1and D2may be referred to as a radial distance with respect to the first axis112.

Header delivery system100is shown in a retracted position inFIG.8, where the linear actuator120is being actuated in the first axial direction222towards the extended position inFIG.9. Conversely, the extended position shown inFIG.9shows the linear actuator120being actuated in the second axial direction224back to the retracted position as shown inFIG.8. In more detail,FIG.8shows the actuating wedge tapered end158of the first actuating wedge140disposed between the tube coupler mount114and the first extension wedge144and axially spaced adjacent to the launcher pipe102when the header delivery system100is in the retracted position.FIG.9shows the actuating wedge tapered end158of the first actuating wedge140axially spaced from the launcher pipe102with the actuating wedge tapered end158extending outwardly from a portion of the first actuating wedge140disposed between both the tube coupler mount114and the first extension wedge144. Actuating wedge tapered end158may be disposed in an end space168located between the wheel plate128and the first extension wedge144. In some embodiments, the end space168provides the benefit of providing additional space for the linear actuators to be mounted on the launcher pipe102. End space168may be an axial space extending axially with respect to the first axis112.

To position the header delivery system100from a retracted position to an extended position, as the arrows inFIG.8indicated, a piston extension actuation may be performed. The piston extension actuation moves the pistons124in the first axial direction to move the actuating wedges140,142in the first axial direction. Actuating wedges142,144each are slid in the first axial direction between the tube coupler mount114and one of the extension wedges144,146, as depicted by arrow222.

When moving between the retracted position and the extended position as the arrows inFIG.9indicated, the actuating wedges140,142move in the first axial direction, as depicted by arrow222. There is a wedging action between the actuating wedges140,142and the extension wedges144,146as the actuating wedges140,142move in the first axial direction and the actuating wedges140,142force the extension wedges144,146and the tube coupler mount114apart from one another. Bumper106connected to the extension wedges144,146and the tube coupler104connected to the tube coupler mount114are forced apart from one another to position the tube coupler104and the bumper106in the extended position shown inFIG.9.

When moving between the extended position and the retracted position, the actuating wedges140,142move in the second axial direction, as depicted by arrow224. There is a wedging action between the actuating wedges140,142and the extension wedges144,146as the actuating wedges140,142move in the second axial direction and the actuating wedges140,142the force from the actuating wedges is removed to allow the extension wedges144,146and the tube coupler mount114to move toward one another. Bumper106connected to the extension wedges144,146and the tube coupler104connected to the tube coupler mount114may move toward one another to position the tube coupler104and the bumper106in the retracted position shown inFIG.8.

FIG.8shows that in some embodiments the wedge assembly formed by the actuating wedges140,142and the extension wedges144,146when in the retracted position are contained between the outer diameter of the first pipe section170of the pipe launcher102and the tube coupler mount114and the second launcher pipe opening199, as depicted by D4.FIG.9shows that in some embodiments the wedge assembly formed by the actuating wedges140,142and the extension wedges144,146when in the extended position are contained between the outer diameter of the first pipe section170of the pipe launcher102and the tube coupler mount114and the second launcher pipe opening199, as depicted by D5. D5is larger than D4. In some embodiments, the linear actuators120,122are contained between the outer diameter of the first pipe section170of the pipe launcher102and the tube coupler mount114when the header delivery system100in in the retracted position, as depicted by D4. The efficient mounting of the linear actuators120,122and the wedge assembly to contain system components between the tube coupler mount114and the pipe launcher102provides the benefit of reducing the diameter or system height of the header delivery system100as measured by the distance D1in the retracted position and D2in the extended position.

Referring toFIG.10, a first header delivery system100A is shown in an inlet header pipe12and a second header delivery system100B is shown in an outlet header pipe14. Inlet header pipe12has a cut-away section in a first side wall30and the outlet header pipe14has a cut-away section in a second side wall32to illustrate the header delivery systems100A,100B. The header delivery systems100A,100B may be positioned when the header delivery systems100A,100B are in a retracted position to align the header delivery systems100A,100B with the process tube22to be sealed. A retracted position is selected for the header delivery systems100A,100B so that the height of the header delivery systems100A,100B is less than the internal diameter of the respective header pipes12,14to allow the header delivery systems100A,100B to be axially moved into an alignment position with the process tube22to be sealed.

Inlet header pipe12has a first header pipe opening16and the outlet header pipe14has a second header pipe opening18. A process tube22extends between the inlet header pipe12and the outlet header pipe14as shown by line20. As shown inFIG.10, a plurality of process tubes may extend between the inlet header pipe12and the outlet header pipe14. Ten process tubes are shown inFIG.10.

Process tube22has a first tube end24that connects to the inlet header pipe12at a fluid opening in the first side wall30. Process tube22has a second tube end26that connects to the second outlet header pipe14at a fluid opening in the second side wall32. First tube end24is connected to the inlet header pipe12at a first angular position with respect to a first axis122A as shown inFIG.10andFIG.11, and the second tube end24is connected to the outlet header pipe14at a second angular position with respect to a second axis122B as shown inFIG.10andFIG.12. Header pipes12,14may have a cylindrical shape.

First header delivery system100A is in an extended position and is at a first angular position. In this first angular position, the first tube coupler104A and the first bumper106A have a first angular position that corresponds to the first tube angular position of the first tube end24of the first process tube22, as shown inFIG.10andFIG.11. In this extended position, the first header delivery system100A is aligned with the first process tube22. First tube coupler104A and the first bumper106A are each pressed against opposite sides of the internal diameter of the side wall30to form a seal between the first tube coupler104A and the process tube22. In more detail, the tube coupler104A is positioned against the internal diameter of the first side wall30to form a seal around the fluid opening in the first side wall30, and the bumper106A is positioned opposite the first tube coupler104A against the internal diameter of the first side wall30. First coupler tube104A and the first bumper106A press against the internal diameter of the first header pipe12to secure the first header delivery system100A in an installed position in the first header pipe12where the tube coupler104A is sealed to the process tube22.

Second header delivery system100B is in an extended position and is at a second angular position. In this second angular position, the second tube coupler104B and the second bumper106B have a second angular position that corresponds to the second tube angular position of the first tube end24of the first process tube22, as shown inFIG.10andFIG.12. In this extended position, the second header delivery system100B is aligned with the first process tube22. Second tube coupler104B and second bumper106B are each pressed against opposite sides of the internal diameter of the second side wall32to form a seal between the second tube coupler104B and the process tube22. In more detail, the second tube coupler100B is positioned against the internal diameter of the second side wall32to form a seal around the fluid opening in the second side wall32, and the second bumper106B is positioned opposite the second tube coupler104B against the internal diameter of the second side wall32. Second coupler tube120B and second bumper106B press against the internal diameter of the second header pipe14to secure the second header delivery system100B in an installed position in the second header pipe14where the second tube coupler104B is sealed to the process tube22.

Referring toFIG.11, a back view of the first header delivery system100A ofFIG.10is shown. Wheel plate128is connected to the first tube coupler mount114A, shown inFIG.10. A wheel130is not connected to the wheel plate128. In some embodiments, the header delivery system100A, without a wheel130, may be inserted in the first header pipe12by sliding the header delivery system100A in the header pipe12on either the first bumper106A or the first tube coupler104A.

Referring toFIG.12, a back view of the second header delivery system100B ofFIG.10is shown. Wheel plate128is connected to the second tube coupler mount114B, shown inFIG.10. Wheel130is connected to the wheel plate128in a first position. Header delivery system100A may be inserted in the first header pipe12by rolling the wheel130of the header delivery system100A on the internal wall32of the header pipe14.

Referring toFIG.13, a back view of the first header delivery system100A ofFIG.10in a third angular position is shown. The third angular position may be one hundred and thirty-five degrees. Wheel plate128is connected to the second tube coupler mount114A, shown inFIG.10. Wheel130is connected to the wheel plate128in a second position. Header delivery system100A may be inserted in the first header pipe12by rolling the wheel130of the header delivery system100A on the internal wall32of the header pipe14.

In operation, a method of accessing a process tube extending from a header pipe may be performed using a header delivery system of the present disclosure. Referring to the flow chart ofFIG.14, the header delivery system is inserted in the header pipe with the tube coupler in a retracted position. [block1402]. The header delivery system is aligned in the header pipe with the process tube in an alignment position and with the tube coupler and the bumper in a retracted position [block1404]. A user may determine a tube angular position of a process tube in a first header pipe. The user may determine tube angular position of the process tube using information, such as equipment plans. In addition, the user may visually or use cameras to determine the tube angular position. After aligning the header delivery system, the first linear actuator is actuated to move the first actuation wedge in the first linear direction to position the tube coupler and the bumper from the retracted position to an extended position to form a seal between the tube coupler and the process tube [block1406]. A first service operation is performed on the process tube with the tube coupler and the bumper in the extended position using the launcher pipe to access the process tube [block1408]. The first service operation may be a cleaning or an inspection of the process tube using a pig.

After performing the first service operation, the first linear actuator may be actuated to move the first actuation wedge in a second linear direction to position the tube coupler and the bumper from the extended position to the retracted position [block1410]. The header delivery system may be removed from the header pipe with the tube coupler and the bumper in a retracted position [block1412].

The header delivery system of the present disclosure is designed with system components that allow the header delivery system to be sized to be fit in headers pipes of limited size. Linear actuators and the wedge assembly and other components are configured to enable the header delivery system to be built and used for limited-sized header pipes.

Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. The scope of the invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open group. The terms “a,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded.