WO2021072001A1 - Protective inserts and linings for nozzles and method of using same - Google Patents

Abstract

Provided herein are protective nozzle linings. The protective linings (1) include a portion adapted to engage an interior surface of a nozzle and are constructed of material that is resistant to corrosion. The liner comprises a leading end and a trailing end (4), wherein the trailing end may have a greater diameter than a diameter of the leading end, and wherein the trailing end may further comprise a tag (7) that provides information about the liner. The nozzle liners are easily installed and replaced and are useful for increasing the longevity of nozzles.

Description

PROTECTIVE INSERTS AND LININGS FOR NOZZLES AND METHOD OF USING SAME

TECHNICAL FIELD

[0001] Embodiments of the disclosure relate generally to protective inserts and more particularly, to linings for nozzles and methods of using same.

BACKGROUND OF THE INVENTION

[0002] It is known to provide vessels in hot service applications like vapor and piping to transfer. Generally, the vessels and piping are equipped with several branches and nozzles for different purposes such as connecting instrumentation for monitoring operation conditions. Low flow or dead end branches in hot service are subjected to rapid internal corrosion over short time periods resulting in loss of fluid. For example, several burners experience a high rate of failure specifically on the nozzle due to re-boiling. Typically, it is not possible to remove the damaged components piecemeal, and usually a nozzle must be replaced with an entirely new nozzle. This results in a large amount of labor and cost to replace the entire apparatus, even when the damage is basically limited to a smaller area.

[0003] One strategy for protecting nozzles involves lining them, however this strategy is not applicable for many vessels.

[0004] Nozzles are devices employed to control the direction or characteristics of a fluid or gas flow (especially to increase velocity) as it exits (or enters) an enclosed chamber or pipe. Nozzles often comprise pipe or tube of varying cross sectional area, and are frequently used to control the rate of flow, speed, direction, mass, shape, and/or the pressure of the stream that emerges from them. In a nozzle, the velocity of fluid increases at the expense of its pressure energy. Accordingly, nozzles are typically subjected to extreme and repetitive stress.

[0005] Numerous types of nozzles are used for a variety of functions and applications. For example, depending on the type of vessels and piping and the function of that piping or plumbing, nozzles may be designed to enable specific uses. In some cases, nozzles allow for the extrusion of gas or fluid in a coherent stream into a surrounding medium and thus accommodate gas jets, fluid jets, or hydro jets. Nozzles must ideally be designed to withstand force and pressure as well as high velocity propulsion, magnetic forces, vacuum and other physical stresses. In some applications, nozzles are used on fine piping mechanisms such as those utilized in instances where a fine jet is required. In other applications, nozzles are used on large industrial sized pipes, where massive amounts of materials, including water, chemicals, gases and the like must be transported. Especially on large scale and industrial size, it would be useful to improve the longevity of the apparatus as the fluctuation of hot and cold temperatures along with other stresses results in corrosion and damage to the nozzle itself. As discussed above, it may not be feasible, practical or cost-effective to replace entire piping infrastructure, and at a minimum it is desirable to at least replace nozzles or components thereof. Ideally, it would be advantageous to improve the longevity of nozzles by employing replaceable components such as liners that are preferably easily removed and replaced, in a cost-effective manner.

[0006] It is, therefore, desirable to provide a mechanism such as a lining for a nozzle that will improve the life of the nozzle and of the attached pipe and equipment. It is also desirable to provide a method for utilizing a protective nozzle liner such that the liner is designed to be easy to install, replace and monitor. It is still further desirable to provide a nozzle liner that is composed of durable material thereby improving the longevity of the overall device and apparatus. Therefore, there is a need in the art to provide a protective nozzle liner and method of using the same that meets at least one of these desires.

SUMMARY OF THE INVENTION

[0007] Embodiments of the invention solve the above-mentioned problems and provide a distinct advance in the improvement of vessels and piping systems by providing mechanisms for enhancing the longevity of nozzles, especially nozzles that are subjected to re-boiling. More particularly, the invention herein provides a nozzle liner that is less prone to corrosion and that is easy to install, remove and replace. The nozzle liner described also undergoes less deterioration than conventional pipe liners and induces little, if any, stress on the overall pipe system. Such nozzle liners are particularly desirable as they may be considered a “sacrificial part” that can be easily replaced as opposed to replacing the nozzles or an entire piping system. Ultimately, installation and use of nozzle liners according to the teachings of this invention significantly reduce production lost due to unplanned shutdown, reduce maintenance costs, increase overall safety and enhance efficiency.

[0008] Accordingly, the present invention provides a protective nozzle liner (or insert). The protective liner includes a portion adapted to engage an interior surface of a nozzle and is constructed of material that is resistant to corrosion. The liner may comprise a leading end (a first end) and a trailing end (also characterized as a disc-shaped plate), wherein the trailing end may have a greater diameter than a diameter of the leading end, and wherein the trailing end may further comprise a tag that provides information about the liner. In an embodiment, the leading end may optionally comprise a guiding component to facilitate positioning of the liner. [0009] In an embodiment, the protective lining, also referred to as a nozzle insert, may be installed in the nozzle of dead ended pipes, particularly on dead ended pipes subject to extreme conditions such as high temperature vapor, high pressure and the like. In such pipes, as gas condenses upon cooling in the pipe, when the liquid returns and comes into contact with a hot nozzle, it boils and causes high levels of corrosion. As described herein, use of protective nozzle inserts, wherein such inserts are made of corrosion resistant material, improves the functionality and overall longevity of the apparatus. For example, nozzles that are resistant to corrosion are likely to last longer, have less build up and accordingly improved performance. Furthermore, as a result of the unique design of the protective nozzle inserts, when necessary they may be easily removed and replaced without having to incur substantial time and expense associated with replacing an entire pipe or device.

BRIEF DESCRIPTION OF THE FIGURES

[0010] Figures 1-4 provided herewith show schematic views of nozzle inserts. Figure 1 shows a proposed insert for a 1/2” nozzle. Figure 2 shows a proposed insert for a 3/4” nozzle. Figure 3 shows a proposed insert for a 1 1/2” nozzle. Figure 4 shows a proposed insert for a 2” nozzle.

[0011] Figure 5 provides a schematic of a nozzle insert.

DETAILED DESCRIPTION

[0012] The following detailed description is exemplary and explanatory and is intended to provide further explanation of the present disclosure described herein. Other advantages and novel features will be readily apparent to those skilled in the art from the following detailed description of the present disclosure.

[00010] As discussed above, a recurrent problem associated with piping systems is the effect of corrosion due to harsh environments such as extreme temperatures, extreme pressure, caustic chemicals and the like. In particular, high corrosion and plugging (clogging) issues on nozzles connected to dead ended line on hot vapor services constitute a prevalent problem costing companies significant time and expense in maintenance, repairs and replacement. As provided herein, the use of novel liners or sleeves that may be inserted into nozzles may significantly extend the life of the nozzle and the piping system dependent thereon. In an embodiment, the liner/sleeve or protection insert is constructed of upgraded and durable material and may serve as sacrificial material to protect the nozzle from corrosion. In an embodiment, the liner/sleeve is ‘slipped’ into the nozzle and is not welded to it. As a result of the unique design and construction, the nozzle liners described herein protect the nozzle from internal corrosion resulting from condensate re-boiling, eliminate the risk of false instrument reading due to build up, enable the use of upgraded material on specific location without requiring upgraded material throughout the field, eliminate heat trace and result in lower maintenance and repair/replacement costs.

[00011] The protection insert claimed herein is generally a liner with upgraded material which may be installed in the nozzle on dead ended pipes on high temperature vapor services. Gas condenses as it cools in the pipe, when it returns and comes into contact with hot nozzle surface in the vessel, boils and causes high corrosion. Using upgraded material which is not welded to vessel improves the longevity of the nozzle.

[00012] In an embodiment, a liner for a nozzle is provided wherein the liner comprises: a disc-shaped plate; and an elongated member interfacing with the disc-shaped plate, the elongated member having a first end welded to the disc-shaped plate and a second end opposite the first end such that the liner may be positioned within an interior of the nozzle, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion.

[00013] In an embodiment, a processing apparatus is provided wherein the processing apparatus comprises a body defining an interior volume; an inlet configured to deliver process gas to the interior volume; a heating element disposed in the interior volume, the heating element configured to heat the interior volume of the apparatus; a nozzle coupled to the body, the nozzle providing an exit path for the process gas, the nozzle comprising a first end coupled to the body, a second end opposite the first end, and an elongated body extending from the first end to the second end, the elongated body having an opening formed therein; and a liner positioned at least partially in the opening of the elongated body. The liner positioned in the elongated body may comprise a disc-shaped plate; and an elongated member interfacing with the disc-shaped plate, the elongated member having a first end coupled to the disc-shaped plate and a second end opposite the first end, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion. [00014] In an embodiment, a processing apparatus is provided wherein the processing apparatus comprises a body defining an interior volume; a nozzle coupled to the body, the nozzle providing fluid communication between the interior volume of the body and an exterior of the body, the nozzle comprising a first end coupled to the body, a second end opposite the first end, and an elongated body extending from the first end to the second end, the elongated body having an opening formed therein; and a liner positioned at least partially in the opening of the elongated body, the liner comprising an elongated member having a first end coupled to the disc-shaped plate and a second end opposite the first end, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion.

[00015] In certain embodiments, the corrosion resistant material of the liner described for the above embodiments may be formed materials known to those skilled in the art, including but not limited to steel, stainless steel, hardened steel, chrome steel, manganese steel, zirconium, zirconium oxide, tungsten carbide, iron, copper, titanium, sintered aluminum oxide porcelain, silicon nitride, plastic, cement or stone and combinations thereof. The liners may be formed of stainless steel materials including, but not limited to, austenitic stainless steels and duplex stainless steels. In certain specific embodiments, the corrosion resistant material may be formed of stainless steel such as SS304, SS316, SS310, SS317 or SS825, and/or combinations thereof.

[00016] The configuration of the liner may be customized for the configuration of the nozzle. In some embodiments, the liner comprises an elongated member including one or more openings formed therein, the one or more openings aligned across a longitudinal axis of the elongated member. The opening of the liner may have a diameter ranging from 1-30mm, 2- 20mm, or 3- 10mm, depending on the dimensions of the nozzle.

[00017] In certain embodiments, the liner may further comprise one or more tags. As used herein, the tag may comprise any suitable material that is coupled to a plate, such as a disc shaped plate at a location proximate the one or more openings, such that the tag signals information about the liner, for example the location and position of the liner at the one or more openings, the date of installation, the composite material of the liner.

[00018] In an embodiment, the elongated member of the liner may have an outer diameter between about lmm-70mm, 2mm-60mm, or 3mm-50mm. In an embodiment, the disc-shaped plate of the liner has an inner diameter between about lmm-70mm, 2mm-60mm, or 3mm- 50mm. In an embodiment, the disc-shaped plate of the liner has a thickness between about 3 mm and 10 mm. In an embodiment, the elongated member of the liner may have a length of between 100mm- 1000mm, 200mm-800mm, 250mm-750mm, or 300mm-600mm.

[00019] In an embodiment, a processing apparatus is provided wherein the processing apparatus comprises a body defining an interior volume; an inlet configured to deliver process gas to the interior volume; a heating element disposed in the interior volume, the heating element configured to heat the interior volume of the apparatus; a nozzle coupled to the body, the nozzle providing an exit path for the process gas, the nozzle comprising a first end coupled to the body, a second end opposite the first end, and an elongated body extending from the first end to the second end, the elongated body having an opening formed therein; and a liner positioned at least partially in the opening of the elongated body. The liner positioned in the elongated body may comprise a disc-shaped plate; and an elongated member interfacing with the disc-shaped plate, the elongated member having a first end coupled to the disc-shaped plate and a second end opposite the first end, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion. The liner may extend at least partially within the interior volume of the body for the above described processing apparatus.

[00020] The present invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.

[00021] The description of the invention references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

[00022] In this description, references to "one embodiment", "an embodiment", or "embodiments" mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to "one embodiment", "an embodiment", or "embodiments" in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the current technology can include a variety of combinations and/or integrations of the embodiments described herein.

[00023] Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present invention may be practiced other than as specifically described.

EXAMPLES

[0010] Examples are provided below to facilitate a more complete understanding of the invention. The following examples illustrate the exemplary modes of making and practicing the invention. However, the scope of the invention is not limited to specific embodiments disclosed in these Examples, which are illustrative only, since alternative methods can be utilized to obtain similar results.

EXAMPLE 1

[0011] As demonstrated herein, one purpose of the novel nozzle liner as described herein is to protect the nozzles from corrosion due a multitude of causes, such as re-boiling. The issue of re-boiling typically occurs on dead-end lines. The vapor on these lines condensate as they lose the heat and return to nozzles. The liquid re-boils when it reaches the hot nozzle and causes heavy corrosion and leakage at the re-boiling area. Use of the liner protects the nozzle from direct contact to liquid and corrosion.

[0012] In an embodiment, nozzles are connected to differential pressure transmitters and dip legs are equipped by the liner.

[0013] The general process for replacing a nozzle liner is provided below: a. Disconnect piping from the nozzle. b. Clean inside of the nozzle for any build up, using stainless steel tube brush. c. Inspect the nozzle for any corrosion and replace as needed. The corrosion usually occurs on the bottom side close to the vessel’s wall in small area and should scan the nozzle if using UT. d. Measure the nozzle length and cut the liner to pass 1/8” inside the vessel. e. Install the liner putting the handle facing up (which marks the holes on top) using gaskets on both side of the face. [0014] There are several nozzles in a variety of vessels wherein the failure intervals have been as low as two years causing multiple shutdown failures and shutdowns each year. The frequency of failure increases as the equipment ages. As a result of the present invention, implementation of the novel nozzle inserts described herein resulted significant decreases in the failure rate. It is expected that the failure rate will approach zero.

[0015] While the present disclosure has been discussed in terms of certain embodiments, it should be appreciated that the present disclosure is not so limited. The embodiments are explained herein by way of example, and there are numerous modifications, variations and other embodiments that can be employed that would still be within the scope of the present disclosure.

Claims

1. A liner for a nozzle, comprising: a disc-shaped plate; and an elongated member interfacing with the disc-shaped plate, the elongated member having a first end welded to the disc-shaped plate and a second end opposite the first end such that the liner is positionable within an interior of the nozzle, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion.

2. The liner of claim 1 , wherein the liner is formed from SS 304, SS310, SS825, zirconium and other material.

3. The liner of claim 1, wherein the elongated member includes one or more openings formed therein, the one or more openings aligned across a longitudinal axis of the elongated member.

4. The liner of claim 3, wherein each opening has a diameter between about 3-10 mm.

5. The liner of claim 3, further comprising: a tag, wherein the tag is coupled to the disc-shaped plate at a location proximate the one or more openings, such that the tag signals the location of the liner and position of the one or more openings.

6. The liner of claim 1, wherein the elongated member has an outer diameter between about 3 mm and about 50 mm.

7. The liner of claim 6, wherein the disc-shaped plate has an inner diameter between about 3 mm and about 50 mm.

8. The liner of claim 1 , wherein the disc-shaped plate has a thickness between about 3 mm and 10 mm.

9. The liner of claim 1, wherein the elongated member has a length between about 250 mm and 750 mm.

10. A processing apparatus, comprising: a body defining an interior volume;. an inlet configured to deliver process gas to the interior volume; a heating element disposed in the interior volume, the heating element configured to heat the interior volume of the apparatus; a nozzle coupled to the body, the nozzle providing an exit path for the process gas, the nozzle comprising a first end coupled to the body, a second end opposite the first end, and an elongated body extending from the first end to the second end, the elongated body having an opening formed therein; and a liner positioned at least partially in the opening of the elongated body, the liner comprising: a disc-shaped plate; and an elongated member interfacing with the disc-shaped plate, the elongated member having a first end coupled to the disc-shaped plate and a second end opposite the first end, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion.

11. The processing apparatus of claim 10, wherein the liner is formed from SS 304, SS310, SS825, zirconium and other material.

12. The processing apparatus of claim 10, wherein the elongated member includes one or more openings formed therein, the one or more openings aligned across a longitudinal axis of the elongated member.

13. The processing apparatus of claim 12, wherein each opening has a diameter between about 3-10 mm.

14. The processing apparatus of claim 12, further comprising: a tag, wherein the tag is coupled to the disc-shaped plate at a location proximate the one or more openings, such that the tag signals the location of the liner and position of one or more openings.

15. The processing apparatus of claim 10, wherein the elongated member has an outer diameter between about 3 mm and about 50 mm.

16. The processing apparatus of claim 15, wherein the disc-shaped plate has an inner diameter between about 3 mm and about 50 mm.

17. The processing apparatus of claim 10, wherein the disc-shaped plate has a thickness between about 3 mm to about 10 mm.

18. The processing apparatus of claim 10, wherein the elongated member has a length between about 250 mm and about 750 mm.

19. The processing apparatus of claim 10, wherein the liner extends at least partially within the interior volume of the body.

20. A processing apparatus, comprising: a body defining an interior volume;. a nozzle coupled to the body, the nozzle providing fluid communication between the interior volume of the body and an exterior of the body, the nozzle comprising a first end coupled to the body, a second end opposite the first end, and an elongated body extending from the first end to the second end, the elongated body having an opening formed therein; and a liner positioned at least partially in the opening of the elongated body, the liner comprising: an elongated member having a first end coupled to the disc-shaped plate and a second end opposite the first end, the elongated member formed from a corrosion resistant material, such that the elongated member protects the nozzle from corrosion.