BACKGROUND OF THE INVENTION

[0001] The disclosed embodiments relate in general to a vacuum conduit head unit including jetting and positioning systems.

BRIEF SUMMARY

[0002] Various embodiments of a head unit for a vacuum conduit and associated methods are disclosed. In at least some embodiments, the head unit includes a jetting system having one or more pressurized nozzles configured to eject fluid jets at high velocity and a positioning system configurable to selectively position the head unit within a fluid medium.

[0003] In some embodiments, the vacuum conduit to which the head unit is coupled can be, for example, an elongate vacuum hose or pipe. In differing embodiments, the vacuum conduit can have differing degrees of flexibility along its long axis. For example, the vacuum conduit can be flexible, semi-flexible, semi-rigid, or rigid.

[0004] In some embodiments, the one or more pressurized nozzles of the jetting system are disposed about a periphery of a vacuum nozzle of the head unit. In some examples, one or more of the nozzles are configured to produce a fluid jet substantially aligned with a central axis of the vacuum nozzle at its terminus. The jetting system can be utilized, for example, for cutting, homogenizing, and/or mixing multi-phase fluids, solids, solids embedded in liquid, non- Newtonian materials, etc.

[0005] In some embodiments, the positioning system includes one or more selectively openable and/or closeable vacuum inlet ports. For example, the fluid control system may include a moveable sleeve that opens or closes vacuum inlet ports, for example, by rotating or sliding with respect to the vacuum nozzle. Alternatively or additionally, the fluid control system may include one or more moveable gates, which in some examples can be pivotally coupled to the head unit. In other examples, the positioning system may include one or more vector nozzles for expelling vector jet(s) of fluid. The vector nozzles may be configured at an angle greater than zero degrees relative to the central axis of the vacuum nozzle at its terminus (e.g., an acute angle or a right angle).

[0006] There has thus been outlined, rather broadly, some of the features of the disclosed embodiments in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. Additional features are described hereinafter. [0007] Before explaining various embodiments in detail, it should be understood that the claimed inventions are not limited in application to the details of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. The claimed inventions can be realized in other embodiments (or combinations of embodiments) and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0008] Figure 1 depicts a tank cleaning system in accordance with one embodiment;

[0009] Figure 2 is an elevation view of a head unit for a vacuum conduit in accordance with a first embodiment;

[0010] Figure 3 is a perspective view of the head unit for a vacuum conduit as illustrated in

Figure 2;

[0011] Figure 4 is a perspective section view of the head unit for a vacuum conduit taken along line 4 — 4 of Figure 3;

[0012] Figure 5 is an upper perspective view of a head unit for a vacuum conduit in accordance with a first embodiment;

[0013] Figures 6-7 depict a head unit for a vacuum conduit having a positioning system including one or more selectively openable and/or closeable vacuum inlet ports in accordance with a second embodiment;

[0014] Figure 8 illustrates a head unit for a vacuum conduit having a positioning system including one or more vector nozzles in accordance with a third embodiment; and

[0015] Figure 9 depicts a head unit for a vacuum conduit having a positioning system including one or more vector nozzles in accordance with a fourth embodiment.

DETAILED DESCRIPTION

[0016] With reference now to the figures, in which like reference numerals refer to like and corresponding parts throughout, and in particular with reference to Figure 1, there is illustrated a high-level block diagram of a tank cleaning system 110 that can be utilized to clean a tank 102 in an industrial environment 100 in accordance with one or more embodiments. As some examples, tank 102 can be located at a refinery or chemical plant, at a hydrocarbon production site, aboard or integral to an ocean-going vessel, etc. Tank 102 may have one or more unillustrated inlets and/or outlets.

[0017] In the illustrated example, tank 102 holds a liquid fluid mixture 104, which can contain components such as water, hydrocarbons, silt, chemicals, contaminants, non-Newtonian materials, etc. Depending on one or more factors, such as the composition of fluid mixture 104, environmental factors (e.g., temperature and pressure), and/or the holding time within tank 102, solids may remain entrained in fluid mixture 104 or may precipitate or otherwise become deposited on one or more surfaces of tank 102, as generally represented by deposited solids 106 (which may of course include some liquid fluid). In order to process the contents of tank 102, a tank cleaning system 110 may be utilized periodically or episodically to cut solids 106, to homogenize and/or mix fluid mixture 104, to mix fluid mixture 104 with at least some solids 106, and/or to remove at least some solids 106 from tank 102.

[0018] In this example, tank cleaning system 110 includes a controller 112, position sensors 114, vacuum pump 116, and jet pump 118. As shown, vacuum pump 116 is coupled to apply a vacuum to a proximal end of an elongate vacuum conduit 120, such as a pipe or hose. In differing embodiments, vacuum conduit 120 can have differing degrees of flexibility along its long axis. For example, vacuum conduit 120 can be flexible, semi-flexible, semi-rigid, or rigid. Vacuum conduit 120 is provided with a head unit 122 (described in detail below), which can be integral to or coupled to vacuum conduit 120, preferably at or near the distal end of vacuum conduit 120. When head unit 122 is submerged in fluid mixture 104 and controller 112 controls vacuum pump 116 to apply a vacuum to vacuum conduit 120, portions of fluid mixture 104 and/or solids 106 are extracted from tank 102 via head unit 122 and vacuum conduit 120 and deposited in an extract tank 128. In some examples, extract tank 128 may be transportable, for example, mounted on a semi-trailer, rail car, or ocean-going vessel.

[0019] Jet pump 118 is coupled to receive fluid from an inject tank 130, which in some embodiments can contain fluid processed from extract tank 128, for example, through an unillustrated filter or separator. When head unit 122 is submerged in fluid mixture 104 and controller 112 controls jet pump 118 to supply fluid, jet pump 118 supplies to head unit 122 one or more high pressure jets of fluid from inject tank 130 via a jet manifold 124.

[0020] As discussed in greater detail below, in some embodiments, controller 112 can selectively control the position, orientation, and movement of head unit 122 within fluid mixture 104 of tank 102. Because fluid mixture 104 may in some cases contain flammable and/or explosive components, it is preferred in at least some embodiments if control of the position, orientation, and movement of head unit 122 is achieved via a fluid control system rather than submerged electronics that may present a risk of spark or heating. Controller 112 can implement a closed loop control methodology for head unit 122 utilizing position sensors 114, which in some cases may be external to tank 102. In other embodiments, one or more of position sensors 114 may be disposed on vacuum conduit 120 and/or head unit 122. Position sensors 114 can include, for example, sonar equipment, a magnetometer, accelerometer, ring laser gyro, etc. that provide position data regarding head unit 122 to controller 112.

[0021] In some embodiments, controller 112 may independently control multiple head units 122 depending from multiple vacuum conduits 120 working within one or more tanks 102. It should also be appreciated that one vacuum pump 116 may supply suction to these multiple vacuum conduits 120 via an unillustrated vacuum manifold.

[0022] Referring now to Figures 2 to 5, there is illustrated a first exemplary embodiment of head unit 122 of vacuum conduit 120 of Figure 1. In particular, Figure 2 provides an elevation view of head unit 122, Figure 3 is a perspective view of head unit 122, Figure 4 is a perspective section view of head unit 122 taken along line 4 — 4 of Figure 3, and Figure 5 is an upper perspective view of a head unit for a vacuum conduit in isolation; [0023] In this example, head unit 122 includes a vacuum nozzle 200 that has a substantially hollow or fully hollow bore 500 forming an opening on either end of vacuum nozzle 200, as best seen in Figures 4 and 5. In this example, bore 500 has a substantially circular cross-section. Material within tank 102 (e.g., fluid mixture 104 and/or solids 106) is drawn into bore 500 of head unit 122 by the suction applied by vacuum pump 116 and then passes from bore 500, through vacuum conduit 120, and into extract tank 128. Vacuum nozzle 200 further includes multiple vacuum inlet ports 206 formed in a sidewall of vacuum nozzle 200 through which material within tank 102 can also be drawn into bore 500. For example, in some examples, vacuum nozzle 200 includes between 3 and 8 vacuum inlet ports 206 evenly distributed about the perimeter of the sidewall of vacuum nozzle 200.

[0024] Head unit 122 additionally includes a mounting collar 202. In the depicted embodiment, mounting collar 202 is integral with vacuum nozzle and can be removably coupled (e.g., by bolts or other fasteners) to a corresponding collar 204 mounted on the distal end of vacuum conduit 120. Although not required, a gasket, O-ring, or other seal can be disposed between the respective mating surfaces of collars 202, 204 to create a fluid-tight seal there between.

[0025] As best seen in Figures 4-5, mounting collar 202 includes a mating surface 400 having a radially central annular step 402 inset therein. Annular step 402 is sized to receive and retain therein a flange 404 of an inner sleeve 406 received within and rotatable with respect to bore 500. Annular step 402 thus provides a bearing surface on which flange 404 of inner sleeve 406 can rotate. The outer peripheral surface 408 of flange 404 preferably has a plurality of teeth formed therein, such that flange 404 is configured as a cog. The teeth of flange 404 are engaged with the teeth 502 of a pinion gear 504, which is rotatably coupled to a motor 300 (e.g., a pneumatic or hydraulic motor) controlled by controller 112. Based on this configuration, rotation of pinion gear 504 by motor 300 causes inner sleeve 406 to rotate within bore 500. In at least some embodiments, motor 300 includes an unillustrated position sensor that provides feedback to controller 112 regarding the angular position of pinion gear 504 and thus the angular position of inner sleeve 406 relative to bore 500.

[0026] Still referring to Figures 4-5, inner sleeve 406 has a sidewall having at least one through hole 410 formed therein. A through hole 410 can be selectively aligned (or partially aligned) with one of vacuum inlet ports 206 through rotation of inner sleeve 406 by motor 300 and pinion gear 504 in order to allow material to be drawn through the vacuum inlet port 206 into bore 500, thus providing propulsion to head unit 122. Alternatively, inner sleeve 406 can be rotated such that a given through hole 410 is not aligned with any of vacuum inlet ports 206. As will be appreciated by those skilled in the art, by selectively controlling alignment (or partial alignment) of through hole(s) 410 with various ones of vacuum inlet ports 206, controller 112 can control the position, orientation, and movement of head unit 122 in three-dimensional space within fluid mixture 104.

[0027] Head unit 122 additionally includes a jetting system coupled to jet manifold 124. In the illustrated example, the jetting system includes a plurality of jet tubes 208 that are coupled at mounting collar 202 for fluid communication with corresponding tubes of jet manifold 124. Jet tubes 208 terminate in a plurality of jet orifices 412 distributed about the periphery of nozzle 200. In at least some embodiments, controller 112 controls jet pump 118 to individually supply (or to not supply) a fluid jet 416 of desired velocity to each of jet orifices 412. The fluid jets 416 can be utilized to cut solids 106, to homogenize and/or mix fluid mixture 104, to mix fluid mixture 104 with at least some solids 106, to move or disturb solids 106 to aid in the removal of solids 106 from tank 102 by the vacuum applied via bore 500. In addition, the fluid jets 416 can be controlled by controller 112 to position, orient, and propel head unit 122 in three-dimensional space based on the forces imparted by the fluid jets 416 on head unit 122. In the illustrated embodiment, all of jet orifices 412 are configured to create fluid jets 416 substantially aligned (i.e., parallel) with the central axis 414 of bore 500. In other embodiments, one or more of jet orifices 412 can be configured to direct a fluid jet 416 at a different angle relative to the central axis 414 or at an acute angle to central axis 414 selectable (e.g., via application of pneumatic or hydraulic pressure) by controller 112.

[0028] Referring now to Figures 6-7, there is depicted a second embodiment of a head unit 122’ having an integral positioning system. In this example, head unit 122’ includes one or more selectively openable and closeable gates for vacuum inlet ports 206 in accordance with a second embodiment. In the second embodiment, head unit 122’ includes jet tubes 208 and jet orifices 412 as previously described. However, in this example, a separate collar 204 for vacuum conduit 120 is omitted, and mounting collar 202 of head unit 122’ is directly attached to the distal end of vacuum conduit 120. Head unit 122’ also omits inner sleeve 406.

[0029] In the second embodiment, the positioning system of head unit 122’ includes a plurality of hinged gates 600 pivotally coupled to vacuum nozzle 200. Each gate 600 is sized to cover a respective one of vacuum inlet ports 206 formed in vacuum nozzle 200. Each gate 600 can be individually and selectively opened (or partially opened) or closed by controller 112 to allow material from tank 102 to enter, or to preclude material from tank 102 from entering, the associated vacuum inlet port 206. In this example, each gate 600 is actuated by a respective associated piston 602, whose operation in turn controlled by the pressure (e.g., hydraulic pressure or pneumatic pressure) applied by controller 112 to an associated one of control lines 604 in fluid communication with that piston 602. Figure 6 specifically illustrates a first operating state of head unit 122’ in which all of gates 600 are closed to preclude material from entering bore 500 via vacuum inlet ports 206; Figure 7 illustrates a second operating state of head unit 122’ in which at least one of gates 600 is open to allow material to enter bore 500 via at least one of vacuum inlet ports 206. Again, by selectively controlling the opening (or partial opening) and closing of the gates 600 covering various ones of vacuum inlet ports 206, controller 112 can control the position, orientation, and movement of head unit 122 in three-dimensional space within fluid mixture 104.

[0030] With reference now to Figure 8, there is illustrated a third embodiment of a head unit 122” for a vacuum conduit 120 in which the positioning system includes one or more vector nozzles. In this example, head unit 122” includes jet tubes 208 and jet orifices 412 as previously described. However, in this example, a separate collar 204 for vacuum conduit 120 is omitted, and mounting collar 202 of head unit 122’ is directly attached to the distal end of vacuum conduit 120. In addition, head unit 122” omits inner sleeve 406 and vacuum inlet ports 206.

[0031] In the third embodiment, the positioning system of head unit 122” includes a plurality of vector nozzles 800 distributed about a periphery about the outlet of vacuum nozzle 200. Each vector nozzle 800 has a fluid connection to a corresponding vector tube 802, which in turn has a fluid connection via collar 202 to a vector tube 804 within jet manifold 124. In the illustrated embodiment, each of vector nozzles 800 is configured to direct a vector jet 806 of fluid at a fixed acute angle relative to the central axis 414 of central axis of bore 500; in some embodiments, the angle of each vector nozzle 800 to central axis 414 can be independently selectable (e.g., via application of pneumatic or hydraulic pressure) by controller 112. Controller 112 can independently control the velocity of the vector jet 806 emitted from each vector nozzle 800 to control the position, orientation, and movement of head unit 122” in three-dimensional space within fluid mixture 104. In some embodiments, the pressures and velocities of vector jets 806 are controlled by controller 112 to be significantly less than the pressures and velocities of fluid jets 416. For example, fluid jets 416 may exert a pressure of greater than 5,000 psi, while vector jets may exert a pressure of 100 psi or less. Thus, in these embodiments, separate nozzles/orifices are employed for position control and jetting.

[0032] Referring now to Figure 9, there is depicted a fourth embodiment of head unit 122’” for a vacuum conduit 120 in which the positioning system includes one or more vector nozzles. The fourth embodiment can be configured the same as the third embodiment, except for the direction of vector jets 806. Specifically, in the fourth embodiment, vector nozzles 800 distributed about the periphery of vacuum nozzle 200 are configured to impart thrust to head unit 122’” via vector jets 806 orthogonal to central axis 414 (and fluid jets 416).

[0033] In operation, a head unit for a vacuum conduit in accordance with the disclosed embodiments provides a vacuum nozzle through which a vacuum can be applied to remove material (e.g., liquids, solids, non-Newtonian fluids, or any target material) from a tank via the head unit and vacuum conduit. The head unit also includes a jetting system that can utilized to provide fluid jets to cut, move, mix, and/or disturb materials disposed in the tank. The head unit further includes an integral positioning system that enables a surface controller to achieve a desired position, orientation, and/or motion of the head unit within the fluid mixture contained in the tank utilizing fluid propulsion and without the requirement of a separate submersible vehicle or motion control system.

[0034] The head unit can be utilized in combination with a tank cleaning (or processing) system having a vacuum pump that supplies vacuum to the vacuum conduit, a jet pump that supplies high pressure fluid to the jetting system, and a controller that maneuvers the head unit as required to process the materials in the tank. The controller can control the position, orientation, and movement of the head unit, for example, utilizing pneumatic or hydraulic control systems and without the need for high power electronics. (In some embodiments or use cases, the controller can employ low power electronics to implement desired control while still avoiding risk of fire and explosion.) The controller can be, for example, a special-purpose processing system or an appropriately programmed general-purpose data processing system. The controller can monitor the position, orientation, and/or motion of the head unit utilizing one or more position sensors, such as a sonar sensor, magnetometer, accelerometer, gyro, etc. Based on the feedback provided by the position sensors, the controller can change the amount of vacuum and jetting pressure provided by the vacuum pump and jet pump and maneuver the head unit utilizing the positioning system. In so doing, controller may process the materials in the tank and/or clean the tank utilizing a sequence of locations of the head unit forming a pre-planned trajectory selected to provide the most effective and efficient results. In at least some cases, the controller can process and/or clean the tank without the need for human input or external controls.

[0035] Those skilled in the art will further appreciate that a single tank cleaning system as herein described may be utilized to control a plurality of head units within the same tank or different tanks. In such use cases, the controller can control the head units to avoid collisions between head units based on the separate location information for each head unit provided by the position sensors, while enabling the processing of the materials in the tank in parallel to improve operational efficiency. It will be appreciated that head units may be designed with different vacuum nozzle bore volumes and different fluid jet pressure ratings. For example, head units with larger vacuum nozzle bore volumes can be utilized for processing of materials for which lower vacuum pressures are sufficient (or in larger volume spaces), while head units with smaller vacuum bore volumes and higher vacuum pressures can be utilized for processing other materials (or in more constricted spaces).

[0036] As described, the positioning system can utilize a combination of vacuum pressure and/or jet pressure to provide fluid propulsion. The controller can regulate the vacuum pressure and jet pressure to create a pressure-balanced motion control system. Those skilled in the art will appreciate that a variety of other moveable members can be utilized to employ vacuum and/or fluid jets to implement position control. For example, in some embodiments, sliding gate(s) or a sliding sleeve may be utilized as a moveable member instead the pivoting gates and rotating sleeve disclosed herein.

[0037] While various embodiments have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and detail may be made to the disclosed embodiments without departing from the scope of the appended claims and these alternate implementations all fall within the scope of the appended claims. It should be understood that the invention is not limited in its application to the details of construction or to the arrangements of the components set forth in the description or illustrated in the drawings. The claimed inventions are capable of being realized in other embodiments and of being practiced and carried out in various ways, including through the combination of selected elements of multiple of the disclosed embodiments. It should also be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.