METHODS AND TOOLS FOR INSTALLING REACTOR COMPONENTS

Abstract

An installation tool for installing reactor components into a reactor is disclosed. The tool comprises a housing having a first end and a second end opposite the first end; a releasable attachment assembly for securing a reactor component support to the tool, the attachment assembly being pivotably inside the housing; a gas supply hose connected to the first end of the housing; and a gas outlet at the second end of the housing in fluid communication with the gas supply hose. The gas outlet is configured to provide gas to expand a reactor component secured by the releasable attachment assembly. A control line for the releasable attachment assembly runs inside the gas supply hose.

Claims

1. An installation of for installing reactor components into a reactor, the tool comprising: a housing having a first end and a second end opposite the first end; a releasable attachment assembly for securing a reactor component support to the tool, the attachment assembly being mounted inside the housing; a gas supply hose connected to the first end of the housing; and a gas outlet at the second end of the housing in fluid communication with the gas supply hose, wherein the gas outlet is configured to provide gas to expand a reactor component secured by the releasable attachment assembly and wherein a control line for the releasable attachment assembly runs inside the gas supply hose.

2. An installation tool according to claim 1, wherein the tool comprises a seal assembly mounted on the second end of the housing and the gas outlet is configured to provide gas to expand the reactor component via the seal assembly.

3. An installation tool according to claim 2, wherein the seal assembly is mounted on the second end of the housing by a twist-lock.

4. An installation tool according to claim 1, wherein the tool comprises more than one control line running inside the gas supply hose.

5. An installation tool according to claim 1, wherein the attachment assembly is pivotably mounted inside the housing.

6. An installation tool according to claim 1, wherein the gas supply hose has length markings on its outer surface.

7. An installation tool according to claim 1, wherein the tool comprises a pressure sensor to measure the pressure within the housing.

8. An installation tool according to claim 7, wherein a sensing hose runs inside the gas supply hose.

9. An installation tool according to claim 1, wherein the gas supply hose is configured to support the weight of the tool.

10. A method of installing a reactor component in a reactor, the method comprising: releasably attaching a reactor installation tool to a support of the reactor component; inserting the reactor component into the reactor, wherein the reactor installation tool is suspended from a gas supply hose as the reactor component is inserted into the reactor; supplying pressurised gas to expand the reactor component via the tool; disengaging the tool from the reactor component support; and removing the tool from the reactor.

11. A method according to claim 10, wherein the installation tool comprises a releasable attachment assembly, wherein a control line for the releasable attachment assembly runs inside the gas supply hose.

12. A method according to claim 10, wherein the gas supply hose has length markings on its outer surface and wherein the position of the reactor component is monitored using the length markings as the reactor component is inserted into the reactor.

13. A method according to claim 12, wherein the reactor component pivots relative to the installation tool during the insertion.

14. A method according to claim 10, wherein a pressure in the tool or the reactor component is monitored as the pressurised gas is supplied.

15. A method according to claim 14, further comprising determining information about the installation of the reactor component using the monitored pressure.

16. A method according to claim 15, wherein if a maximum pressure does not exceed a pre-determined threshold pressure, the reactor component is determined to not be correctly installed.

17. A method according to claim 15, wherein the reactor component is determined to be correctly installed based on a comparison of a characteristic of a measured pressure wave with a characteristic of an expected pressure wave.

Description

DESCRIPTION OF THE DRAWINGS

[0029] Embodiments of the present invention will now be described, by way of example, and not in any limitative sense, with reference to the accompanying drawings, of which:

[0030] FIG. 1 is a view of part of an installation tool according to the invention; and

[0031] FIG. 2 is a view of reactor components ready to be installed by an installation tool or method according to the present invention.

DETAILED DESCRIPTION

[0032] In FIG. 1 an installation tool 1 comprises a housing 2. At a first end of the housing 2 a gas supply hose 3 is attached to the housing 2. The gas supply hose 3, of which only a short length is depicted in FIG. 1, comprises markings 4 of a length scale. The tool 1 further comprises a gas outlet 5. The gas outlet 5 is in fluid communication with the gas supply hose 3 via the interior of the housing 2. A seal assembly 6 is mounted on a second end of the housing 2 so that compressed gas exiting the gas outlet 5 passes through the seal assembly 6. The seal assembly 6 comprises a flexible seal 7, through which the compressed gas passes. The seal assembly 6 is mounted on the housing 2 by a twist-lock quick release 8. Inside the housing 2 there is a releasable attachment assembly in the form of a ball-lock actuated by an air cylinder 9. The ball-lock and air cylinder 9 are mounted to the housing 2 at pivot points 10 so that the ball-lock and air cylinder 9 can pivot relative to the housing 2. A control line 11 for the ball-lock and air cylinder 9 and a pressure sensing line (not shown) run inside the gas supply hose 3 to the tool 1. The pivot points 10 can be locked, for example in situations where there are no clearance issues.

[0033] In FIG. 2, multiple structured catalyst-coated components 105 are stacked around the outside of an expansion tube 104, which is mounted on a center support 101. The support 101 and the expansion tube 104 together form a center arrangement. During installation, the center arrangement with the structured catalyst-coated components 105 stacked around it is grasped by the installation tool 1, with the ball-lock engaging with the top of the center support 101. The tool 1, with the reactor components 105 attached is then lowered on the gas supply hose 3 into a reactor tube until the markings 4 on the gas supply hose 3 indicate that it has reached its desired location. If there are obstructions above the reactor tube, the components 105 and tool 1 can be maneuvered around them by the pivoting of the ball-lock relative to the housing 2. That can allow the tool 1 to deflect from the centerline of the reactor tube, while still gripping the center support 101. Once the components 105 are at their desired location in the reactor tube, compressed gas is supplied via the gas supply hose 3, through the housing 2, to the gas outlet 5. The gas passes through the gas outlet 5 and the flexible seal 7, which creates a seal with the inside of the reactor tube or with the expansion tube 104. The compressed gas forces the expansion tube 104 and the components 105 to expand so that the components 105 are pressed outwardly toward the wall of the reactor tube. A locking arrangement, for example spring elements, within the expansion tube 104 provides a biasing force that prevents the expansion tube 104 from collapsing once the compressed gas is no longer supplied. In preferred embodiments, during the supply of the compressed gas, the pressure in the tool is monitored and the resulting pressure profile analysed to determine whether it follows the expected profile for a successful installation. If the profile indicates a successful installation the ball-lock is released from the center support 101 using the control line 11 running within the gas supply hose 3 and the tool 1 is withdrawn from the reactor tube leaving the center support 101, expansion tube 104 and reactor components 105 in place. The tool 1 may then be attached to another center support 101 of another stack of reactor components 105, which are then installed on top of the recently installed stack. In preferred embodiments the seal assembly 6 is pre-attached to the stack and is attached to the housing 2 using the twist-lock quick release 8 as the center support 101 is grasped by the ball lock 9. More than one seal assembly 6 may be provided so that one can be mounted on a waiting stack, while another is in use installing a preceding stack.

[0034] It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only, and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope of the invention as defined by the appended claims.