Patent Description:
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 the use of conveying cleaning pigs through the pipes/tubes/coils.

When cleaning or inspecting furnaces, the furnaces may contain one or more manifolds, or 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, this is a custom build hydraulic apparatus that is placed inside the header pipe. The build of a header delivery system is costly and time consuming as it is generally custom built.

What is needed, is a more time and cost effective system and methodology to enable the performance of pigging and other operations on process tubes connected to a header pipe without the necessity of a custom built header delivery system. <CIT>, on which the preamble of claim <NUM> is based, discloses a pipe inspection system for accessing and inspecting a feeder tube extending from a larger header pipe at an angle, the pipe inspection tool including a head piece and a delivery tube position within the header pipe and aligned with the feeder tube using cameras or other alignment means, the head piece including a jack that presses the head piece against the interior surface of the header pipe at the feeder tube to create a sufficient seal to deliver a PIG or another pipe inspection device to the feeder tube.

According to the invention there is provided a header delivery system and a method of accessing a process tube extending from a header pipe, as defined by the appended claims.

Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It is emphasized that, in accordance with standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of various features may be arbitrarily increased or reduced for clarity of discussion. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and:.

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. 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 cost and time inefficiencies of using a custom header delivery system to enable a pigging operation for a process tube on a header pipe. Embodiments of the header delivery system of the present disclosure include a universal header delivery system that includes a hydraulically-actuated base assembly. The base assembly may be rotated with respect to a rotation assembly to adjustably align the header delivery system with a process tube to seal with a process tube that may be connected to the header pipe at different angular positions. The header pipe has a larger diameter than the diameter of the connected process tubes. In addition, components of the header delivery system are modular and may be replaced with different components that may be in a variety of shapes or sizes to accommodate header pipes and connected process pipes of different sizes. By adding different sized and shaped couplings and other accessories to the base assembly, the header delivery system of the present disclosure can accommodate a wide range of sizes of header pipes and process tubes, and thus be adjusted as needed to perform pigging services for a furnace requiring a service operation.

The header delivery system of the present disclosure enables quick response to perform pigging operations as the need to custom build a header delivery system is eliminated. The response time may be reduced from a couple of weeks of designing, manufacturing and testing the custom header delivery system to the amount of time needed to send the universal header delivery system to location.

Referring to <FIG>, a header delivery system <NUM> is shown. Header delivery system <NUM> includes a base assembly <NUM> connected to a rotation assembly <NUM> formed by a first rotation apparatus <NUM> and a second rotation apparatus <NUM> spaced from one another. First rotation apparatus <NUM> has a first ring opening <NUM> and the second rotation apparatus <NUM> has a second ring opening <NUM>. Base assembly <NUM> is attached between the rotation apparatuses <NUM>, <NUM>.

Base assembly <NUM> includes a launcher pipe <NUM> sealingly coupled at one end to a tube coupler <NUM> having a coupler opening <NUM>. In some embodiments, the tube coupler <NUM> may 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 coupler <NUM> may 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 coupler <NUM> may be made of a resilient material configured to form a seal.

Launcher pipe <NUM> extends though the first ring opening <NUM>. A first axis <NUM> extends through the ring openings <NUM>, <NUM>. First axis <NUM> may extend through a centerline of the rotation apparatuses <NUM>, <NUM>, as shown in <FIG>. In some embodiments, the first axis <NUM> may extend through a centerline of the ring openings <NUM>, <NUM>. In some embodiments, the first axis <NUM> may extend through a centerline of the base assembly <NUM>. In some embodiments, the first axis <NUM> may extend through the launcher pipe <NUM>.

Base assembly <NUM> includes a frame apparatus <NUM> formed by a first frame member <NUM> and a second frame member <NUM> that each have an elongated shape and are spaced from one another. Each frame member <NUM>, <NUM> has one end attached to the first rotation apparatus <NUM> and an opposite end attached to the second rotation apparatus <NUM>. Frame members <NUM>, <NUM> may be parallel to each other. A bumper <NUM> is connected to the second mounting plate <NUM> and is disposed opposite the tube coupler <NUM> with the bumper <NUM> and the tube coupler <NUM> disposed on opposite sides of the frame apparatus <NUM> and frame members <NUM>, <NUM>. A second axis <NUM> extends through the tube coupler <NUM> and the bumper <NUM>. Bumper <NUM> may be formed by a tube coupler that is like the tube coupler <NUM>. In some embodiments, the tube coupler forming the bumper <NUM> is identical to the tube coupler <NUM>. Using a bumper <NUM> that is like the tube coupler <NUM> has the benefit of reducing the number of different parts used for the header delivery system <NUM>.

Tube coupler <NUM> may be connected to a first mounting plate <NUM> and the bumper <NUM> may be connected to a second mounting plate <NUM>. Mounting plates <NUM>, <NUM> form part of a jack apparatus <NUM> for radially positioning the tube coupler <NUM> and the bumper <NUM> radially with respect to first axis <NUM>, as further described with respect to <FIG>. For example, the tube coupler <NUM> and bumper <NUM> connected respectively to mounting plates <NUM>, <NUM> may be positioned outwardly from a retracted position to an extended position. Jack apparatus <NUM> may be hydraulically powered. In some embodiments, jack apparatus <NUM> may be mechanically powered.

Referring to <FIG>, an exploded view of the header delivery system <NUM> is shown. Launcher pipe <NUM> is shown separated from the frame apparatus <NUM>. Launcher pipe <NUM> has a first pipe section <NUM> and a second pipe section <NUM> that may be connected, for example by welding. First pipe section <NUM> forms a first pipe opening <NUM> and the second pipe section <NUM> forms a second pipe opening <NUM>. An accessory member <NUM> may be attached to the launcher pipe <NUM> adjacent the first pipe opening <NUM>. Accessory member <NUM> has a first accessory mount member <NUM> and a second accessory mount member <NUM>. A camera, not shown, may be adjustably mounted on each of the accessory mount members <NUM>, <NUM> to position cameras on opposite sides of the second pipe opening <NUM>.

Tube coupler <NUM> and bumper <NUM> are shown separated from the frame apparatus <NUM> in <FIG>. Launcher pipe <NUM> may be connected to the frame assembly <NUM> by attaching the launcher pipe <NUM> to the first mounting plate <NUM>. Mechanical fasteners, such as bolts <NUM>, may be used to attach the launcher pipe <NUM> to the first mounting plate <NUM>. Tube coupler <NUM> may be attached to the first mounting plate <NUM> with mechanical fasteners, such as bolts <NUM>. Bumper <NUM> may be attached to the second mounting plate <NUM> with mechanical fasteners, such as bolts.

First rotation apparatus <NUM> is shown separated from one end of the frame apparatus <NUM> and second rotation apparatus <NUM> is shown separated from an opposite end of the frame apparatus <NUM> in <FIG>. Frame members <NUM>, <NUM> may each have frame connector members <NUM> on opposite ends to connect the frame members <NUM>, <NUM> to the rotation apparatuses <NUM>, <NUM>. A first wheel apparatus <NUM> may be connected to the first rotation apparatus <NUM> and a second wheel apparatus <NUM> may be connected to the second rotation apparatus <NUM>. Wheel apparatuses <NUM>, <NUM> each include a wheel support plate <NUM> and wheels <NUM> connected to the wheel support plate <NUM>. A wheel support plate <NUM> with attached wheels <NUM> may be connected to each of the rotation apparatuses <NUM>, <NUM>.

Referring to <FIG>, the first rotation apparatus <NUM> includes a first stationary ring <NUM> and the second rotation apparatus <NUM> includes a second stationary ring <NUM>. Stationary rings <NUM>, <NUM> are each connected to a respective wheel apparatuses <NUM>, <NUM>. Wheel apparatuses <NUM>, <NUM> connected to the stationary rings <NUM>, <NUM> are used to move the header delivery system <NUM> along a bottom surface, such as an internal diameter of a header pipe.

First rotation apparatus <NUM> includes a first rotational ring <NUM> and the second rotation apparatus <NUM> includes a second rotational ring <NUM>. First rotational ring <NUM> is connected to a first frame end and the second rotational ring <NUM> is connected to a second frame end of the frame apparatus <NUM>. Mechanical fasteners, such as bolts <NUM>, may be used to fix the rotational rings <NUM>, <NUM> to a respective frame end. First rotational ring <NUM> is rotatably connected to the first stationary ring <NUM>. Second rotational ring <NUM> is rotatably connected to the second stationary ring <NUM>. In some embodiments, the first rotational ring <NUM> rotatably connected to the first stationary ring <NUM> is formed by a slewing ring and the second rotational ring <NUM> rotatably connected to the second stationary ring <NUM> is formed by another slewing ring.

With the frame apparatus <NUM> connected to each of the rotational rings <NUM>, <NUM>, the base assembly <NUM> may be rotated with respect to the first axis <NUM> by rotating the rotational rings <NUM>, <NUM> each connected to one of the stationary rings <NUM>, <NUM>. Rotating the base assembly <NUM> positions the tube coupler <NUM> in a selected angular position with respect to the first axis <NUM>. For example, the base assembly <NUM> may be positioned in the selected angular position so that the tube coupler <NUM> is positioned to be coupled to a process tube connected to the header pipe. A header pipe may also be referred to as a manifold.

First rotation apparatus <NUM> has a first locking assembly formed by a first locking apparatus <NUM> and a second locking apparatus <NUM> configured to selectively fix the first rotational ring <NUM> to the first stationary ring <NUM>, as shown in <FIG>. Second rotation apparatus <NUM> has a second locking assembly formed by a third locking apparatus <NUM> and a fourth locking apparatus <NUM> configured to selectively fix the second rotational ring <NUM> to the second stationary ring <NUM>. See <FIG> for a view of the locking apparatuses <NUM>, <NUM>.

Locking apparatuses <NUM>-<NUM> may be used to fix the tube coupler <NUM> in a selected angular position with respect to the first axis <NUM>. Locking apparatuses <NUM>-<NUM> are configured to adjustably fix the tube coupler <NUM> in a plurality of angular positions. A pair of lock brackets <NUM> are attached to each of the stationary rings <NUM>, <NUM>, as shown in <FIG>. Each of the locking apparatuses <NUM>-<NUM> may be attached to one of the brackets <NUM>. Each of the locking apparatuses <NUM>-<NUM> may have an elongated shape and have a pin <NUM>.

Referring to <FIG>, the rotational rings <NUM>, <NUM> have a plurality of ring lock slots <NUM> that extend around the periphery of the ring openings <NUM>, <NUM>. Locking apparatuses <NUM>-<NUM> are configured to couple with a selected one of the ring lock slots <NUM> to fix the rotational rings <NUM>, <NUM> to a respective stationary ring <NUM>, <NUM>. Each pin <NUM> extends though one of the ring lock slots <NUM> on a rotational ring <NUM>, <NUM> to fix the rotational rings <NUM>, <NUM> to a respective stationary ring <NUM>, <NUM> to prevent rotation of the rotational rings <NUM>, <NUM> with respect to the stationary rings <NUM>, <NUM>. Pins <NUM> prevent rotation of the rotational rings <NUM>, <NUM> with respect to the stationary rings <NUM>, <NUM>. Pin <NUM> may be spring-loaded and biased in an extended position. An adjustment arm <NUM> may be connected to the pin <NUM> to move the pin <NUM> from the extended position to a non-extended position.

When the rotational rings <NUM>, <NUM> each are fixed to its respective rotation apparatuses <NUM>, <NUM>, the base assembly <NUM> is fixed in a selected angular position. Pins <NUM> each may be removed from ring lock slots <NUM> to enable the rotation of the rotational rings <NUM>, <NUM> with respect to the stationary ring <NUM>, <NUM> to enable rotation of the base assembly <NUM> and adjustment of the angular position of the base assembly <NUM> and the connected tube coupler <NUM>. In this manner, the tube coupler <NUM> may be positioned and locked in a plurality of different angular positions.

Referring to <FIG>, a back view of the header delivery system <NUM> is shown. Tube coupler <NUM> is positioned in a vertical position and the second axis <NUM> extends through the tube coupler <NUM> and the bumper <NUM>. Tube coupler <NUM> and the bumper <NUM> may be at an angular position of zero degrees. Second axis <NUM> is perpendicular to a horizontal axis <NUM>. Second wheel apparatus <NUM> is shown attached to the second stationary ring <NUM>. Wheel plate <NUM> has multiple angular wheel slots <NUM> for positioning the wheels <NUM> at different angular positions. Second wheel apparatus <NUM> has radial wheel slots <NUM> for adjusting the radial position of the wheels <NUM>.

Referring to <FIG>, a side view of the header delivery system <NUM> is shown. Tube coupler <NUM> is connected to the first mount plate <NUM> and the bumper <NUM> is connected to the second mount plate <NUM>. Tube coupler <NUM> connected to the first mount plate <NUM> and bumper <NUM> connected to second mount plate <NUM> may be positioned outwardly from the first axis <NUM> in opposite directions along the second axis <NUM> from a retracted position to an extended position. A first extension assembly <NUM> is connected to the first mounting plate <NUM> and is configured to position the first mounting plate <NUM> in a first radial direction from a retracted position to an extended position. The first radial direction of the first mounting plate <NUM> connected to the tube coupler <NUM> is indicated by the arrows <NUM>. A second extension assembly <NUM> is connected to the second mounting plate <NUM> and is configured to position the second mounting plate <NUM> in a second radial direction from a retracted position to an extended position. The second radial direction of the second mounting plate <NUM> connected to the bumper <NUM> is indicated by the arrows <NUM>.

Tube coupler <NUM> and the bumper <NUM> move opposite one another when moving from a retracted position to an extended position and the movement is in an axial direction along the second axis <NUM>. When in either the retracted position or the extended position, the tube coupler <NUM> and the bumper <NUM> may have equal distances from the first axis <NUM>. The distance between tube coupler <NUM> and the bumper <NUM> along second axis <NUM> increases when the jack apparatus <NUM> positions the header delivery system <NUM> from a retracted position to an extended position. Second axis <NUM> may shift in a direction perpendicular to the second axis <NUM> as the jack apparatus <NUM> positions the header delivery system <NUM> from a retracted position to an extended position.

First extension assembly <NUM> includes a first carrier member <NUM>, a first carrier arm <NUM>, and a pair of first pivot arms <NUM>. First carrier member <NUM> is movably connected to the frame apparatus <NUM>. First carrier arm <NUM> is pivotally connected at one end to the first carrier member <NUM> and pivotally connected at an opposite end to the first mount member <NUM>. First pivot arms <NUM> are pivotally connected at one end to the frame apparatus <NUM> and pivotally connected at the opposite end to the first mount member <NUM>.

Second extension assembly <NUM> includes the first carrier member <NUM>, a second carrier arm <NUM>, and a pair of second pivot arms <NUM>. Second carrier arm <NUM> is pivotally connected at one end to the first carrier member <NUM> and pivotally connected at an opposite end to the second mount member <NUM>. Second pivot arms <NUM> are pivotally connected at one end to the frame apparatus <NUM> and pivotally connected at the opposite end to the second mount member <NUM>.

A first linear actuator <NUM>, shown in <FIG>, is mounted to the frame apparatus <NUM> in a first axial configuration and connected to the first carrier member <NUM> of the first extension assembly <NUM> and the second extension assembly <NUM>. First linear actuator <NUM> is connected to the first carrier member <NUM> with a connector member <NUM> and slidably moves the first carrier member <NUM> in a first axial direction parallel to the first axis <NUM> to move the tube coupler <NUM> and bumper <NUM> from a retracted position to an extended position. The movement of the first carrier member <NUM> in the first axial direction is depicted by arrows <NUM>. The first linear actuator <NUM> is configured to provide a first axial force in a first axial direction to the first extension assembly <NUM> and the second extension assembly <NUM>. First extension assembly <NUM> uses the first axial force for moving the tube coupler <NUM> from a first retracted position to a first extended position. Second extension assembly <NUM> uses the first axial force for moving the bumper <NUM> from a second retracted position to a second extended position.

Referring to <FIG>, a cross-section of the header delivery system <NUM> is shown. Second rotational ring <NUM> is rotatably coupled to the second stationary ring <NUM>. Second rotational ring <NUM> has a first external lip <NUM> that has a ring shape and extends around the body of the second rotational ring <NUM>. Second stationary ring <NUM> has a second external lip <NUM> that has a ring shape and extends around the body of the second stationary ring <NUM> First external lip <NUM> and the second external lip overlap and the first external lip <NUM> is rotatable around the second external lip <NUM> to enable rotation of the second rotational ring <NUM> around the second stationary ring <NUM>. A bearing <NUM> may be disposed between the external lips <NUM>, <NUM>.

Third locking apparatus <NUM> is shown in a locking position to secure the second rotational ring <NUM> in a selected angular position with respect to the second stationary ring <NUM>. Pin <NUM> of the third locking apparatus <NUM> extends through a ring lock slot <NUM> in the second rotational ring <NUM>. The locking position blocks the second rotational ring <NUM> from rotating with respect to the second stationary ring <NUM>. First rotational ring <NUM> is rotatably coupled to the first stationary ring <NUM> of the first rotation apparatus <NUM> in a similar manner as described with respect to the second rotation apparatus <NUM>.

Launcher pipe <NUM> extends from a first pipe end <NUM> to a second pipe end <NUM>. First pipe end <NUM> forms the first pipe opening <NUM> and the second pipe end <NUM> forms the second pipe opening <NUM>. First pipe end <NUM> extends through the tube coupler <NUM>. Tube coupler <NUM> forms a seal around the first pipe end <NUM>.

Referring to <FIG>, a top perspective view of the jack apparatus <NUM> connected to the frame apparatus <NUM> is shown. First mounting plate <NUM> has a first mount opening <NUM>. Mount opening <NUM> is configured for the launcher pipe <NUM>, not shown in <FIG>, to extend through the mount opening <NUM>, as shown in <FIG>. Fastener openings <NUM> may be used to connect the tube coupler <NUM> to the first mounting plate <NUM>. Mechanical fasteners, such as bolts, and the fastener openings <NUM> may be used to connect the tube coupler <NUM> to the first mounting plate <NUM>.

Jack apparatus <NUM> is in a retracted position in <FIG> and is in an extended position in <FIG>. Jack apparatus <NUM> includes the first linear actuator <NUM> mounted on the first frame member <NUM> and the second linear actuator <NUM> mounted on the second frame member <NUM>. Linear actuators <NUM>, <NUM> are hydraulically powered and a hydraulic apparatus <NUM> is connected thereto. Hydraulic apparatus <NUM> includes an actuator tubing <NUM> that connects to each of the linear actuators <NUM>, <NUM> and a fluid conduit formed by an actuator hose <NUM> connected to the actuator tubing <NUM>. Actuator hose <NUM> may be connected to a hydraulic pump for actuating the linear actuators <NUM>, <NUM>.

Linear actuators <NUM>, <NUM> may be actuated to position the jack apparatus <NUM> from the retracted position, shown in <FIG>, to the extended position, shown in <FIG>. Linear actuators <NUM>, <NUM> are hydraulically actuated via the actuator hose <NUM> that may extend along the launcher pipe <NUM>, shown in <FIG>. When the linear actuators <NUM>, <NUM> are hydraulically actuated, the linear actuators <NUM>, <NUM> apply an axial force to the carrier members <NUM>, <NUM> and the carrier members <NUM>, <NUM> slidably move on respective frame members <NUM>, <NUM>. The sliding movement of the carrier members <NUM>, <NUM> from a first carrier position, shown in <FIG>, to a second carrier position, shown in <FIG>, with respect to the respective frame members <NUM>, <NUM> forces the first mounting plate <NUM> to move in a first radial direction from the frame apparatus <NUM> and forces the second mounting plate <NUM> to move in an opposite second radial direction from the frame apparatus <NUM> to the extended position, shown in <FIG>.

First extension assembly <NUM> converts the axial force of the linear actuators <NUM>, <NUM> to a first radial force in the first radial direction to move the first mounting plate <NUM> from the retracted position to the extended position. Second extension assembly <NUM> converts the axial force of the linear actuators <NUM>, <NUM> to a second radial force in the second radial direction to move the second mounting plate <NUM> from the retracted position to the extended position. First mounting plate <NUM> and the second mounting plate <NUM> move in opposite radial directions in synchronization.

First extension assembly <NUM> is formed by the first carrier member <NUM> slidably connected on the first frame member <NUM>, a second carrier member <NUM> slidably connected to the second frame member <NUM>, the first carrier arms <NUM> pivotally connected to the first mounting plate <NUM>, and the first pivot arms <NUM> pivotally connected to the first mounting plate <NUM>. Second extension assembly <NUM> is formed by the first carrier member <NUM> slidably connected on the first frame member <NUM>, the second carrier member <NUM> slidably connected to the second frame member <NUM>, the second carrier arms <NUM> pivotally connected to the second mounting plate <NUM>, and the second pivot arms <NUM> pivotally connected to the second mounting plate <NUM>.

Referring to <FIG>, a bottom perspective view of the jack apparatus <NUM> connected to the frame apparatus <NUM> is shown. Second mounting plate <NUM> is disposed below and the first mounting plate <NUM> is disposed above the frame members <NUM>, <NUM>. Second mounting plate <NUM> has a second mount opening <NUM>. Fastener openings <NUM> may be used to connect the bumper <NUM> to the second mounting plate <NUM>. Mechanical fasteners, such as bolts, and the fastener openings <NUM> in the second mounting plate <NUM> may be used to connect the bumper <NUM>, shown in <FIG>, to the second mounting plate <NUM>.

Referring to <FIG>, cross-sectional views of the jack apparatus <NUM> are shown. Jack apparatus <NUM> is shown in the retracted position in <FIG> and in the extended position in <FIG>. First linear actuator <NUM> is connected to the first frame member <NUM> and is mounted inside the first frame member <NUM>. First linear actuator <NUM> includes a cylinder <NUM> and a piston <NUM> attached at one end to the first carrier member <NUM>. Piston <NUM> may be connected to an elongated member <NUM> that extends through a frame slot <NUM> that extends axially along the first frame member <NUM>. Elongated member <NUM> may be attached to the first carrier member <NUM> by a connector member <NUM>, shown in <FIG>.

When the first linear actuator <NUM> in a retracted position is actuated, a hydraulic force in the cylinder <NUM> moves the piston <NUM> to slidably move the connected first carrier member <NUM> in a first axial direction along the first frame member <NUM>, as depicted by arrows <NUM>. First linear actuator <NUM> is positioned in an axial configuration to move the first carrier member <NUM> in the first axial direction. The first axial direction may be along a first frame axis <NUM> that extends through the first frame member <NUM>. First frame axis <NUM> may be parallel to the first axis <NUM> extending through header delivery system <NUM> shown in <FIG>. Piston <NUM> moves the carrier member <NUM> in the first axial direction to position the first mounting plate <NUM> and the second mounting plate <NUM> from a retracted position to an extended position.

When in the retracted position shown in <FIG>, the distance between the first mounting plate <NUM> and the second mounting plate <NUM> is at a first distance D1. When in the extended position shown in <FIG>, the distance between the first mounting plate <NUM> and the second mounting plate <NUM> increases and is at a second distance D2. Distance D2 is greater than distance D1.

When in the retracted position shown in <FIG>, the distance between the first mounting plate <NUM> and the first frame axis <NUM> is at a third distance D<NUM>, and the distance between the second mounting plate <NUM> and the first frame axis <NUM> is at a fourth distance D<NUM>. Distance D<NUM> and distance D<NUM> may be equal. When in the extended position shown in <FIG>, the distance between the first mounting plate <NUM> and the first frame axis <NUM> is at a fifth distance D<NUM>, and the distance between the second mounting plate <NUM> and the first frame axis <NUM> is at a sixth distance D<NUM>. Distance D<NUM> and distance D<NUM> may be equal. The tube coupler <NUM> connected to the first mounting plate <NUM> and the bumper <NUM> connected to the second mounting plate <NUM> have like distances between them as described above. For example, the distance between the tube coupler <NUM> and the bumper <NUM> increases when the jack apparatus <NUM> positions the header delivery system <NUM> from a retracted position to an extended position.

The jack apparatus <NUM> is configured to position the header delivery system <NUM> in a retracted position when moving a header delivery system <NUM> from an end opening in a header pipe to a selected location in the header delivery system <NUM> adjacent to a process tube connected to the header pipe. After the header delivery system <NUM> is positioned in the header pipe adjacent to the process tube, the jack apparatus <NUM> is configured to position the header delivery system <NUM> in an extended position to place the header delivery system <NUM> in an installed position. Further discussion of the operation of the header delivery system <NUM> is provided below, for example see <FIG>.

Referring to <FIG>, the jack apparatus <NUM> is shown in the extended position. Jack apparatus <NUM> is also shown in dashed lines when in the retracted position. An axis <NUM> extends through a center of the mounting plates <NUM>, <NUM> when the jack apparatus <NUM> is in the extended position. Axis <NUM> may be a vertical axis and may be perpendicular to the axis <NUM>. An axis <NUM> extends through a center of the mounting plates <NUM>, <NUM> when the jack apparatus <NUM> is in the retracted position, as shown by dash lines depicting the jack apparatus in <FIG>. Mounting plates <NUM>, <NUM> are shifted in a first axial direction when moving from the retracted position to the extended position and an opposite second axial direction when moving from the extended position to the retracted position, as depicted by arrows <NUM>. As discussed with respect to <FIG>, the mounting plates <NUM>, <NUM> and the connected tube coupler <NUM> and bumper <NUM> move in first and second radial directions, as depicted by arrows <NUM>, <NUM>.

Referring to <FIG>, an alternative embodiment of a header delivery system is shown and identified with reference number <NUM>. In <FIG> and <FIG>, the header delivery system <NUM> is shown with the tube coupler <NUM>, the bumper <NUM>, and the wheel support plate <NUM> removed to help show components of the base assembly <NUM>. In <FIG>, the tube coupler <NUM>, the bumper <NUM>, and the wheel support plates <NUM> are shown connected in the assembled position. Header delivery system <NUM> is like the header delivery system <NUM> with an alternative embodiment of the rotation assembly identified with reference number <NUM>. Like parts of alternative embodiments of the header delivery systems <NUM>, <NUM> are identified with like reference numbers. Header delivery system <NUM> includes a base assembly <NUM> connected to a rotation assembly <NUM> formed by a first rotation apparatus <NUM> and a second rotation apparatus <NUM> spaced from one another. First rotation apparatus <NUM> has a first ring opening <NUM> and the second rotation apparatus <NUM> has a second ring opening <NUM>. Base assembly <NUM> is attached between the rotation apparatuses <NUM>, <NUM>. As shown in <FIG>, a wheel support plate <NUM> is attached to each of the rotation apparatuses <NUM>, <NUM>, and the first wheel apparatus <NUM> is attached to the first rotation apparatus <NUM> and the second wheel apparatus <NUM> is attached to the second rotation apparatus <NUM>.

Rotation apparatuses <NUM>, <NUM> each may be formed by a single ring. Rotation apparatuses <NUM>, <NUM> each have a plurality of connector openings <NUM> that extend around the periphery of the ring openings <NUM>, <NUM>. Frame members <NUM>, <NUM> are shown in <FIG> connected to the rotation apparatuses <NUM>, <NUM> at opposite ends to position the base assembly at a selected angular position. Mechanical fasteners, such as bolts <NUM>, may be used to connect the rotation apparatuses <NUM>, <NUM> to the frame members <NUM>, <NUM>.

Base assembly <NUM> may be rotated with respect to the first axis <NUM> to position the tube coupler <NUM> and the bumper <NUM>, shown in <FIG>, in a plurality of different angular positions with respect to the first axis <NUM>. Rotation apparatuses <NUM>, <NUM> may remain stationary as the base assembly <NUM> is rotated from a first angular position to a second angular position. Bolts <NUM> and connector openings <NUM> extending around the periphery of each of the ring openings <NUM>, <NUM> may be used to adjustably position the base assembly <NUM> in a first angular position and a second angular position.

In <FIG>, base assembly <NUM> is shown in a first angular position with the ends of the frame members <NUM>, <NUM> attached to the rotation apparatuses <NUM>, <NUM>. Bolts <NUM> extend through bolt connectors <NUM> on the rotation apparatuses <NUM>, <NUM> and adjacent to the ends of the frame members <NUM>, <NUM> to connect the base assembly <NUM> to the stationary rotation apparatuses <NUM>, <NUM> in the first angular position. To position the base assembly <NUM> from the first angular position to a second angular position, the bolts <NUM> are detached from the frame members <NUM>, <NUM> and the detached base assembly <NUM> is rotated to the second angular position. Bolts <NUM> may be extended through bolt connectors <NUM> on the rotation apparatuses <NUM>, <NUM> and adjacent to the ends of the rotated frame members <NUM>, <NUM> to connect the base assembly <NUM> to the stationary rotation apparatuses <NUM>, <NUM> in the second angular position. Adjusting the angular position of the base assembly <NUM> adjusts the angular position of the connected tube coupler <NUM> and the connected bumper <NUM>.

Referring to <FIG>, a back view of the header delivery system <NUM>, also shown in <FIG>, is shown in three different angular positions. Rotation assembly <NUM> is configured to rotate the base assembly <NUM> and the tube coupler <NUM> and the bumper <NUM> connected to the base assembly <NUM> to a plurality of angular positions. In <FIG>, the tube coupler <NUM> and the bumper <NUM> is shown in a zero degree angular position. The zero degree angular position may be referred to as a vertical angular position. In <FIG>, the tube coupler <NUM> and the bumper <NUM> is shown in a forty-five degree angular position. In <FIG>, the tube coupler <NUM> and the bumper <NUM> is shown in a ninety degree angular position. The ninety degree angular position may be referred to as a horizontal angular position. The tube coupler <NUM> and the bumper <NUM> may be rotated in a plurality of angular positions to position the tube coupler <NUM> and the bumper <NUM> in a selected angular position to couple with a process tube that may be connected at different angular positions to a header pipe.

Referring to <FIG>, a first header delivery system 100A is shown in an inlet header pipe <NUM> and a second header delivery system 100B is shown in an outlet header pipe <NUM>. Inlet header pipe <NUM> has a cut-away section in a first side wall <NUM> and the outlet header pipe <NUM> has a cut-away section in a second side wall <NUM> to illustrate the header delivery systems 100A, 100B. First header delivery system 100A has a first position bar <NUM> attached to a first rotation assembly 104A on the first header delivery system 100A. Second header delivery system 100B has a second position bar <NUM> attached to a second rotation assembly 104B on the second header delivery system 100B. Position bars <NUM>, <NUM> each may be used to position a header delivery systems 100A, 100B in the header pipes <NUM>, <NUM> by pushing or pulling on a position bar <NUM>, <NUM>. The header delivery systems 100A, 100B may be positioned when the tube couplers 120A, 120B are in a retracted position to align the header delivery systems 100A, 100B with the process tube <NUM> to be sealed. A retracted position is selected for the header delivery systems 100A, 100B so that the height of the header delivery systems 100A, 100B is less than the internal diameter of the respective header pipe <NUM>, <NUM> to allow the header delivery systems 100A, 100B to be axially moved into an alignment position with the process tube <NUM> to be sealed.

Inlet header pipe <NUM> has a first header pipe opening <NUM> and the outlet header pipe <NUM> has a second header pipe opening <NUM>. A process tube <NUM> extends between the inlet header pipe <NUM> and the outlet header pipe <NUM> as shown by line <NUM>. As shown in <FIG>, a plurality of process tubes may extend between the inlet header pipe <NUM> and the outlet header pipe <NUM>. Seven process tubes are shown in <FIG>.

Process tube <NUM> has a first tube end <NUM> that connects to the inlet header pipe <NUM> at a fluid opening in the first side wall <NUM>. Process tube <NUM> has a second tube end <NUM> that connects to the second outlet header pipe <NUM> at a fluid opening in the second side wall <NUM>. First tube end <NUM> is connected to the inlet header pipe <NUM> at a first angular position and the second tube end <NUM> is connected to the outlet header pipe <NUM> at a second angular position. The first angular position of the first tube end <NUM> may be a zero degree angular position with respect to first axis <NUM>, as shown in <FIG>. The second angular position of the second tube end <NUM> may be a ninety degree angular position with respect to the first axis <NUM>, as shown in <FIG>. Header pipes <NUM>, <NUM> may have a cylindrical shape.

First header delivery system 100A is in an extended position and is at a first angular position. In this first angular position, the first tube coupler 120A and the first bumper 132A has a first angular position that corresponds to the first tube angular position of the first tube end <NUM> of the first process tube <NUM>, as shown in <FIG>. In this extended position, the first header delivery system 100A is aligned with the first process tube <NUM>. First tube coupler 120A and bumper 132A are each pressed against opposite sides of the internal diameter of the side wall <NUM> to form a seal between the first tube coupler 120A and the process tube <NUM>. In more detail, the tube coupler 100A is positioned against the internal diameter of the first side wall <NUM> to form a seal around the fluid opening in the first side wall <NUM>, and the bumper 132A is positioned opposite the first tube coupler 120A against the internal diameter of the first side wall <NUM>. First coupler tube 120A and first bumper 130A press against the internal diameter of the first header pipe <NUM> to secure the first header delivery system 100A in an installed position in the first header pipe <NUM> where the tube coupler 120A is sealed to the process tube <NUM>.

Second header delivery system 100B is in an extended position and is at a second angular position. In this second angular position, the second tube coupler 120B and the second bumper 132B has a second angular position that corresponds to the second tube angular position of the first tube end <NUM> of the first process tube <NUM>, as shown in <FIG>. In this extended position, the second header delivery system 100B is aligned with the first process tube <NUM>. Second tube coupler 120B and second bumper 132B are each pressed against opposite sides of the internal diameter of the second side wall <NUM> to form a seal between the second tube coupler 120B and the process tube <NUM>. In more detail, the second tube coupler 100B is positioned against the internal diameter of the second side wall <NUM> to form a seal around the fluid opening in the second side wall <NUM>, and the second bumper 132B is positioned opposite the second tube coupler 120B against the internal diameter of the second side wall <NUM>. Second coupler tube 120B and second bumper 132B press against the internal diameter of the second header pipe <NUM> to secure the second header delivery system 100B in an installed position in the second header pipe <NUM> where the second tube coupler 120B is sealed to the process tube <NUM>.

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 flowchart shown in <FIG>, a user may determine a first tube angular position of a first process tube in a first header pipe [block <NUM>]. The user may determine the first tube angular position of the first process tube using information, such as equipment plans. In addition, the user may visually or use cameras to determine the first tube angular position.

The base assembly may be positioned with respect to the first rotation apparatus and the second rotation apparatus to position the header delivery system in a first angular position [block <NUM>]. For example, the base assembly may be rotated to the first angular position with the rotation apparatuses each having a stationary ring that allows the base assembly to be rotated while the stationary ring remains relatively stationary. The base assembly may be connected to the first rotation apparatus and the second rotation apparatus to fix the header delivery system in the first angular position [block <NUM>]. After fixing the header delivery system in the first angular position, the header delivery system may be inserted in the first header pipe with the tube coupler in a retracted position [block <NUM>].

The header delivery system may be aligned in the first header pipe with the first tube coupler in an alignment position and with the tube coupler in the retracted position [block <NUM>]. After aligning the header delivery system, the jack apparatus may be actuated to position the tube coupler from the retracted position to the extended position to form a seal between the tube coupler and the first process tube [block <NUM>]. A first service operation may be performed on the first process tube with the tube coupler in the extended position using the launcher pipe to access the first process tube [block <NUM>].

After the first service operation is performed, the jack apparatus may be de-actuated to remove hydraulic pressure from the jack apparatus and position the tube coupler from the extended position to the retracted position. The retracted position may be any position of the tube coupler where hydraulic pressure has been reduced to allow the tube coupler to move away from an extended position and towards a retracted position. The extended position may be any position of the tube coupler where the tube coupler has been extended to seal with a process tube. The header delivery system may be removed from the first header pipe after the jack apparatus has been de-actuated. After removal from the first header pipe, the angular position of the header delivery system may be adjusted for another process tube on the first header pipe or a different header pipe. The adjusted header delivery system may be used on the first header pipe or a second header pipe with another process tube connected to a header pipe at a different angular position, as described previously.

The header delivery system provides a universal header delivery system that allows for convenient adjustment of the angular position of the base assembly to allow a tube coupler to seal with a process tube at a tube angular position with respect to the header pipe. In addition, the jack apparatus provides linear actuators that are mounted adjacent the frame members to provide a compact jack apparatus and header delivery system that may be used for header pipes of different sizes.

Claim 1:
A header delivery system (<NUM>) for a header pipe having a process tube extending from the header pipe, comprising:
a base assembly (<NUM>) coupled to a rotation assembly (<NUM>);
the base assembly (<NUM>) including:
a first frame member (<NUM>) having a first frame end and a second frame end,
a second frame member (<NUM>) spaced apart from the first frame member and having a third frame end and a fourth frame end,
a jack apparatus (<NUM>) connected between the first frame member (<NUM>) and the second frame member (<NUM>),
a launcher pipe (<NUM>) connected to the jack apparatus (<NUM>),
a tube coupler (<NUM>) connected to the jack apparatus (<NUM>),
a bumper (<NUM>) connected to the jack apparatus (<NUM>), and
wherein the jack apparatus (<NUM>) is configured to adjustably move the tube coupler (<NUM>) and the bumper (<NUM>) in opposite radial directions when moving between a retracted position and an extended position; and
the rotation assembly (<NUM>) including:
a first rotation apparatus (<NUM>) connected to the first frame member (<NUM>) at the first frame end and the second frame member (<NUM>) at the third frame end, and
a second rotation apparatus (<NUM>) connected to the first frame member (<NUM>) at the second frame end and the second frame member (<NUM>) at a fourth frame end, and the first rotation apparatus (<NUM>) and the second rotation apparatus (<NUM>) configured to rotate the base assembly (<NUM>) with respect to the rotation assembly (<NUM>) to adjust an angular position of the tube coupler (<NUM>) and the bumper (<NUM>),
characterized in that the first rotation apparatus (<NUM>) includes a first stationary ring (<NUM>) and a first rotational ring (<NUM>) connected to the first frame end and rotatably coupled to the first stationary ring (<NUM>).