FIELD OF INVENTION
The present invention in general relates to the optimization of the tubesettler performance through enhanced artificial intelligence and IoT based automated Flushing of tube settler through and a combination of electromechanical systems.
BACKGROUND ART
In water clarification, tube settlers which comprise a plurality of extended length tubes generally assembled into a tube settler tank which is part of water clarification plant. The water to be clarified runs through the tubes of the tube settler media and deposits sediments and other solids at the tube settler media surface which deposits at the bottom of tube settler. The purpose of the tube settler media is to increase the surface area exposed to the water such that the effective settling area is increased.
A problem with such tube settlers is that because of the solid deposition within the tubes, the tubes may become plugged. If the tubes become plugged, the performance and efficiency of the settlement process is adversely effected. In certain clarification procedures, the tube bundles can become so fouled with heavy sludge, collapse of the tube bundles and even the underlying support structure for the tube bundlers can occur. This is a costly and time consuming problem. Thus, intermittent flushing of the tubes to remove the buildup of sludge over time is required.
One existing method of flushing the tubes is by manually washing the tube profiles from above with a high pressure water jet directed at the tube profiles. While the tube profiles which are exposed to the water stream are cleaned in a satisfactory manner using this technique, the tube profiles that are not so exposed such as the bottom part of the tube settler profiles and beneath walkways are not cleaned thereby detracting from the overall performance of the tube settler.
Another technique is colloquially called “air lancing” which instead of water, uses high pressure air which plays on the tube openings in the settler. The tube profiles are, however, sensitive to the high pressure air and damage to the tube settler assembly can occur. Similar to the manual washing technique, not all tube profiles can be reached with the high pressure air. Also likewise, the procedure is labor intensive.
A further technique used provides a fixed air distribution grid under the tube settler profile assembly. While this technique shows promise, existing air distribution grids do not reach a substantial portion of the tube profile area and no air distribution into the tubes immediately above the support structure for the tube settler assembly is provided. Existing air grids, therefore, do not clean the tube settler profile assembly in these locations which is disadvantageous.
Given the difficulty of the problems posed, in which the complexity of the logic increases very rapidly with the number of operating rules employed, the process according to the invention advantageously has recourse to the techniques of artificial intelligence, i.e. to "expert systems", to influence the operating parameters of the installation as a function of the data provided in particular by the forecasts specified above and by the assessments of the instantaneous chocking at the various levels of the clarification process.
SUMMARY OF INVENTION
It is the principal objective of the present invention to optimise the tubesettler performance through an intermittent and automated tubesettler flushing system, ensuring a near constant surface area for settling of solids with a mean hydraulic radius of 17mm. Resulting in improved formation of a laminar flow and better clarification.
According to a first aspect of the invention, there is provided a method to dislodge sediment retained within individual tubes of a tube settler assembly used for water clarification, said method comprising entraining water and air released below said tube settler assembly with liquid and allowing said entrained air and water to move upwardly into said tube settler assembly and to dislodge sediment within said tubes of said tube settler assembly, said air and water entrainment taking place with air released from at least two adjacent tube laterals, said tube laterals being supplied with by an air supply, said air supply supplying air to a first of said two respective tube laterals independently of supplying said air to a second of said two respective tube laterals.
According to a further aspect of the invention there is provided apparatus to remove sediment retained with tubes of a tube settler assembly in a water clarification process, said apparatus comprising a tube settler assembly having a bottom area and a plurality of tubes, a plurality of tube laterals extending across substantially the entire bottom area of said tube settler assembly, water and air nozzles to emit air from said tube laterals, an air supply to provide air to said tube laterals, at least one of said tube laterals allowing air to exit from said air exit holes at a time different from air exiting from said air exist holes in a second of said tube laterals.
Accordingly, the present invention provides an Artificial Intelligence based Water + Air flushing system, which eliminates the downtime necessary for flushing of the tube settler profiles hence resulting in improved flow rate and treated water quality of the process. The system is easy to install and maintain. The product ensures an intermittent automated algorithmic flushing of the settler tubes ensuring reduced choking and a reduced sludge bulking in tube settler media.
The herein disclosed Artificial Intelligence based Water + Air flushing system, monitors real-time flow and provides real-time cleanliness detection with notification for tubesettlers. The air water flushing system is connected in series to the tubesettler or a plurality of tubesettlers connected with each other. The collection node is essentially a tubesettler which can include: one or more water flow rate sensors, one or more optional control valves, one or more optional temperature sensors, one or more optional pressures sensors, one or more optional camera sensors, and wireless radio technology. Use of the optional communication hub or receiving station provides longer wireless range capability. The collection node with or without the optional communication hub or receiving station can utilize long range wireless technology, limited range technology [Bluetooth, Bluetooth low energy (BLE), Zigbee], other wireless technology, wired and wired technology, and any combinations thereof.
In one embodiment, housing of the said flushing system collection node and optional communication hub or receiving station can be fabricated from materials of food grade and can use technologies that provide protection for moist and wet conditions, hot environments and cold/freezing situations. The flushing system includes a central processing unit (CPU), microprocessor and/or microcontroller, data storage, timing and wireless circuitry, water flow rate sensors, optional water quality cleanliness sensors (camera), optional pressure sensors, optional acoustic sensors, and a air water flushing means. The types of water flow rate sensor(s) can be invasive (i.e. within water pipe; e.g. turbine sensor), non-invasive (i.e. outside water pipe; e.g. ultrasonic sensor), and/or sensitive water flow sensors (e.g. pressure sensor). The flushing system has the capability to utilize several different sensors to accomplish the goals of real-time monitoring water use and detecting leaks and / or clogging. Optionally, a temperature sensor can be incorporated into the collection node to determine, communicate, and address temperature conditions, e.g. assess freezing conditions and communicate with the property structure's thermostat or heating system to maintain a specified temperature within the structure, drain water from pipes, and/or perform other damage protection techniques. The optional pressure sensor, with associated use of the control valve, can be used for detecting very small leaks / clogs. This is accomplished by automatically activating the flushing system attached at the collection node.
The artificial intelligence flush clean system can be operated manually or be programmed to run automatically when a clog / leak is detected, or program for a schedule using a cell or smart phone, computer, or similar electronic apparatus. The said system can also be programmed to follow a work, vacation, clog / leak monitoring or other schedule. Furthermore, the said system is designed with electrical and communication circuitry to send a signal to the cell or smart phone, computer, or similar electronic apparatus that the working of the tubesettler is on / off or need a flush.
In an embodiment, the disclosed system provides wireless remote clog / leak detection notification using event basis monitoring and software analysis. Alternately, continuous data monitoring can be stored in a data module in the collection node and periodically transferred wirelessly to a remote computer or server as described herein. The system monitors water supply and detects non-typical, abnormal, or continuous water supply and alerts, signals, or messages via a cell or smart phone, computer, or similar electronic apparatus to one or more owners, users, or responsible individuals of any clog / leak condition(s).
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
Fig 1 illustrates the flush cleaning mechanism using artificial intelligence in accordance with the present invention;
DETAILED DESCRIPTION
Referring to FIG. 1 the tube settlement with flush cleaning mechanism carries the tube settler assembly as generally illustrated. The tube settler assembly is supported by a plurality of steel I-sections which extend laterally across the bottom of the tube settler assembly on the top of each I-section and which are connected to support rails which extend normal to the tube laterals. Attachment clips secure the I-sections to the support rails. The air / water supply assembly used to carry air / water and distribute the air / water to the tube settler assembly simultaneously is generally illustrated.
The air / water supply assembly includes a plurality of air pipes, respectively, as seen in FIG. 1. Each of the said pipes extends the length of the bottom surface of tube settler assembly and each terminates with a closed end to prevent the exit of air / water under pressure from the ends of the pipes. A plurality of tube laterals as generally illustrated, are connected to the first and second air / water pipe. Each of the plurality of tube laterals extends normal or perpendicular to the air pipes and across substantially the entire area of the tube settler assembly. The plurality of tube laterals emit air / water under pressure below the tube settler assembly through the air / water discharge holes which are positioned so as to emit air / water upwardly or outwardly from the tube laterals as required and are positioned such that the emitted air / water enters the bottom of the tube settler assembly with some force which force of the emitted air / water and entrained liquid is intended to dislodge sediment within the tube settler assembly.
Each of the tube laterals is connected to a bar housing which is connected to the clarifier tank. The bar housing provides support for each of the tube laterals. An air / water deflector is positioned over the tube laterals. The bar housing is rotatable around central axis configured for 180 degrees to 360 degrees movement. The air / water deflector assembly may conveniently be perforated with a predetermined number of perforations (not illustrated). The deflector, traps air / water beneath it and redistributes the air / water to the tubes within the tube settler assembly which are located above the support structure or I-beams which tubes of the tube settler assembly would otherwise not be reachable by the emitted air / water leaving the tube laterals.
The salient feature of this invention is the automated Artificial Intelligence based flushing system for dislodging the build-up from the tubes using a combination of electromechanical and pneumatic systems. This ensures reduced choking across the internal cross-sectional area of the tubesettler profiles .The system is not only easy to install but it also renders the system to be almost maintenance free. The equipment has uses in clarification of raw water, secondary clarification after aeriation systems. The system can be applied for any tubesettler system application where frequent clogging and chocking is a major concern.
The plurality of air / water pipes are connected to the tube laterals. By using air / water generated by each of the pipes, may be supplied only to one set of the tube laterals. Thereafter, air / water supplied by the other of the pipes is supplied to the other set of tube laterals. By the use of appropriate controls such as solenoids and interruption switches (not illustrated) which stop and release the supply of air / water from each of the said pipes, independently and alternatively, air / water can be supplied to each of the tube laterals which sets up a continuous supply bearing on the bottom of the tube settler assembly which is found to be beneficial for the dislodgement of sediment and debris within the tubes of the tube settler assembly as will be explained in greater detail.
The tube settler assembly with the above located collector node water troughs. As the water proceeds to move upwardly within the tubes of the tube settler assembly, the individual tubes will also act as a depository of sediment and other debris over time. This sediment will, over time, settle within the tubes of the tube settler assembly and will degrade the water clarification process so it is desirable to remove this sediment in accordance with the invention. Following the sediment removal within the tubes of the tube settler assembly, the water will then pass to a filtration station and will also pass to an ozone or chlorination treatment (not illustrated) before being considered satisfactory for potable uses.
Referring to FIG. 2, the tube settler assembly generally illustrated at (shown more clearly in FIGS. and ). The air supply assembly used to carry air and water distribute the air and water to the tube settler assembly is generally illustrated at Fig 2

The air supply assembly includes a first and second nozzle fitted air / water pipe respectively, as seen in FIG. 2. Each of the pipes , extends the length of the tube settler assembly and each terminates with a closed end to prevent the exit of air under pressure from the ends of the said pipes , . A plurality of tube laterals generally illustrated at , are connected to the first and second air pipe , . Each of the plurality of tube laterals extend normal or perpendicular to the first and second air pipes , and across substantially the entire area of the tube settler assembly . The plurality of tube laterals emit air and water under pressure below the tube settler assembly through the air discharge holes which are positioned so as to emit air upwardly or outwardly from the tube laterals as required and are positioned such that the emitted air enters the bottom of the tube settler assembly with some force which force of the emitted air and entrained liquid is intended to dislodge sediment within the tube settler assembly .
Each of the tube laterals is connected to a bar which is connected to the clarifier cell . The bar provides support for each of the tube laterals . An water / air deflector is positioned over the tube laterals as also seen in FIG. 2. The said deflector assembly may conveniently be perforated with a predetermined number of nozzles. The deflector , traps water air beneath it and redistributes the water and air to the tubes within the tube settler assembly which are located above the support structure or I-beams which tubes of the tube settler assembly would otherwise not be reachable by the emitted air leaving the tube laterals .
The tube settler assembly is supported by a plurality of steel I-sections (FIGS. 1 and 2) which extend laterally across the bottom of the tube settler assembly on the top of each I-section and which are connected to support rails which extend normal to the tube laterals . Attachment clips secure the I-sections to the support rails .
Reference is made to FIG 2 wherein the first and second pipes , are illustrated as being connected to the tube laterals . Only two tube lateral is shown but it will be appreciated that there is a series of tube laterals located immediately behind tube lateral extending the extent of the area of the tube settler assembly . Second pipe is connected through a manifold which is also connected to tube laterals (not illustrated) directly behind tube lateral . First pipe is connected through a manifold directly to tube laterals . Thus, the plurality of tube laterals are connected alternatively to the said pipes , across the bottom of the tube settler assembly; that is, a first one of the said pipes , is connected to a first one of the tube laterals with the tube laterals on either side of the first one of the tube laterals being connected to the other of the said pipes , as seen more clearly in FIG. 2. By using air and water generated by each of the air pipes , air may be supplied only to one set of the tube laterals and water with other or both through one pipe intermittently . Thereafter, air supplied by the other of the air pipes , is supplied to the second set of tube laterals as also seen in FIG. 2. By the use of appropriate controls such as solenoids and interruption switches with IoT and artificial intelligence which stop and release the supply of watyer / air from each of the said pipes, independently and alternatively, water / air can be supplied to each of the tube laterals which sets up a rhythmic air supply bearing on the bottom of the tube settler assembly which is found to be beneficial for the dislodgement of sediment and debris within the tubes of the tube settler assembly as will be explained in greater detail.
The tube settler assembly with the above located water troughs. As the water proceeds to move upwardly within the tubes of the tube settler assembly , the individual tubes will also act as a depository of sediment and other debris over time. This sediment will, over time, settle within the tubes of the tube settler assembly and will degrade the water clarification process so it is desirable to remove this sediment in accordance with the invention described. Following the sediment removal within the tubes of the tube settler assembly , the water will then pass to a filtration station generally (not illustrated) before being considered satisfactory for potable uses.
The tube settler assembly provides an increased effective settling area for the settleable solids in the flocculated water. In addition to settling on the bottom of the lamella clarifier as seen in FIG. 1, the sediment will also be deposited in the individual tubes . In due course, the tubes will become blocked or partially blocked with sediment which will degrade the sediment settling process significantly. When that occurs, the air and water dislodgement technique according to the invention is utilized to clean the tubes of the tube settler assembly .
With reference to FIG. 2 water / air under pressure is provided to each of the said pipes , being under individual control. The tube laterals extend beneath substantially the entire area of the tube settler assembly and have discharge nozzles which allows the discharged water / air to be directed outwardly and upwardly into the tubes of tube settler assembly . The water / air emitted by the holes mixes with the water in the clarifier cell and will act to assist in the dislodgement of the sediment settled within the tubes of the tube settler assembly .
Two pipes , are referred to although more may be conveniently used if desired. First pipe provides water / air to the first set of tube laterals and second pipe provides water / air to the second set of tube laterals . Thus and since the operation of each said pipes , is independent of the other, the tube laterals may be operated in a way best deemed necessary to dislodge the sediment and other debris and offers significant advantages in the cleaning operation of the tube settler assembly .
Pressurized Water and Air from one of the air pipes , may be emitted from its connected tube laterals at a pressure different from that of the other one of the air pipes. Likewise, it may be desired to emit air from one set of the tube laterals at a time different from the time of emission of the remaining set of the tube laterals . Or, if desired, the air can be emitted for a predetermined period from one set of tube laterals and then shut off. The remaining set of tube laterals can then emit air for a second predetermined period while the first set of tube laterals is not emitting air.
Referring now to the drawings and particularly to FIG. 1, shown is an illustrative view of the air water flush cleaning system connected in series to the tubsettler water supply lines in an appropriate location for cleaning the tubesettler pipes with forced air and water shots simultaneously. The system is connected with controlled motor for controlled rotation and pump (integrated or separate) with piping system for pumping of controlled programmable pressurized air and water simultaneously in accordance with user desire and maintain threshold limits of the tubesettler. The programming is based on IoT and Artificial Intelligence based on feedback from a plurality of sensors present in the aid tubesettler.
The disclosed artificial intelligence flush clean system is configured to remove sediment retained with tubes of a tube settler assembly in a water clarification process, said system comprising of a tube settler assembly having a bottom area and a plurality of tubes, a plurality of tube laterals extending across substantially the entire bottom area of said tube settler assembly, water and air nozzles to emit air from said tube laterals, an air supply to provide air to said tube laterals, at least one of said tube laterals allowing air to exit from said air exit holes at a time different from air exiting from said air exist holes in a second of said tube laterals. The said Artificial Intelligence based Water + Air flushing system, eliminates the downtime necessary for flushing of the tube settler profiles hence resulting in improved flow rate and treated water quality of the process.
The different Stages of cleaning Cycle of the tubesettler comprises the steps of :-
1. Water / Air deflector Nozzle assembly will turn 180 degree upward to start operation.
2. Drain Valve will open.
3. Air injection valve will open
4. Blower/ Air injection start
5. Air injection carried out for preset time.
6. Stop Blower/ Air injection.
7. Water injection start
8. Water injection carried out for preset time.
9. Water injection stop.
10. All valves closed
11. Water / Air deflector Nozzle assembly will turn 180 degree downward to stop the operation.

The system is easy to install and maintain. The product ensures an intermittent automated AI and IoT flushing of the settler tubes ensuring reduced choking and a reduced sludge bulking in tube settler media.
The system monitors real-time flow and provides real-time cleanliness detection with notification for tubesettlers. The air water flushing system is connected in series to the tubesettler or a plurality of tubesettlers connected with each other. The collection node is essentially a tubesettler which can include: one or more water flow rate sensors, one or more optional control valves, one or more optional temperature sensors, one or more optional pressures sensors, one or more optional camera sensors, and wireless radio technology. The housing of the said flushing system collection node as shown in figure 1 and optional communication hub or receiving station can be fabricated from materials of food grade and can use technologies that provide protection for moist and wet conditions, hot environments and cold/freezing situations. The flushing system includes a central processing unit (CPU), microprocessor and/or microcontroller, data storage, timing and wireless circuitry, water flow rate sensors, optional water quality cleanliness sensors (camera), optional pressure sensors, optional acoustic sensors, and a air water flushing means. The types of water flow rate sensor(s) can be invasive (i.e. within water pipe; e.g. turbine sensor), non-invasive (i.e. outside water pipe; e.g. ultrasonic sensor), and/or sensitive water flow sensors (e.g. pressure sensor). The flushing system has the capability to utilize several different sensors to accomplish the goals of real-time monitoring water use and detecting leaks and / or clogging. Optionally, a temperature sensor can be incorporated into the collection node to determine, communicate, and address temperature conditions, e.g. assess freezing conditions and communicate with the property structure's thermostat or heating system to maintain a specified temperature within the structure, drain water from pipes, and/or perform other damage protection techniques. The optional pressure sensor, with associated use of the control valve, can be used for detecting very small leaks / clogs. This is accomplished by automatically triggering / activating the flushing system attached at the collection node
The artificial intelligence flush clean system can be operated manually or be programmed to run automatically when a clog / block / leak is detected, or program for a schedule using a cell or smart phone, computer, or similar electronic apparatus. The said system can also be programmed to follow a work, vacation, clog / block / leak monitoring or other schedule. Furthermore, the said system is designed with electrical and communication circuitry to send a signal to the cell or smart phone, computer, or similar electronic apparatus that the working of the tubesettler is on / off or need a flush.
In an exemplary embodiment the Artificial intelligence application: AI applicable in three ways in this system.
1. Flow measurement: There is an online flow measurement meter to measure flow. If flow reduce by 10% of pre set value threshold limit of cleaning system will start operating.
2. Weight measurement: There is a weight measurement chip in between of tube modules and support system. If weight increases by 10 % threshold limit then also cleaning system will start.
3. Timer: There is also a timer cycle based on which the flushing system will start. Generally 10 hours of operating cycle is recommended.
In an embodiment, the disclosed system provides wireless remote clog / leak detection notification using event basis monitoring and software analysis. Alternately, continuous data monitoring can be stored in a data module in the collection node and periodically transferred wirelessly to a remote computer or server as described herein. The system monitors water supply and detects non-typical, abnormal, or continuous water supply and alerts, signals, or messages via a cell or smart phone, computer, or similar electronic apparatus to one or more owners, users, or responsible individuals of any clog / leak condition(s).
Use of the optional communication hub or receiving station provides longer wireless range capability. The collection node with or without the optional communication hub or receiving station can utilize long range wireless technology, limited range technology [Bluetooth, Bluetooth low energy (BLE), Zigbee], other wireless technology, wired and wired technology, and any combinations thereof.
Thus, the sediment dislodged from the tubes in the tube settler assembly may allow the dislodged sediment to move downwardly and through the adjacent tubes within the tube settler assembly to the bottom of the lamella clarifier basin where it can be removed as has been described with the settled sludge using the sludge pump or manually as noted. In any event, the use of independent water and air supplies for the said pipes , allows significant cleaning advantages over the prior art and allows more efficient water clarification within the lamella clarifier basin without the necessity of extended downtime and the requirement for using significant manual labor for cleaning the tube settler assembly .
The water filtration step takes place in an open top tank or basin is defined by a hopper bottom or flat bottom slab, side walls and end walls. A partition, parallel to side wall, define an overflow trough. The troughs distribute the incoming water into the basin for filtration.
Many modifications may readily be contemplated by those skilled in the art to which the invention relates. Many further modifications may readily be contemplated. The description set out above is particularly applicable to high rate clarification applications. However, in conventional clarification where the upstream or downstream processes herein described are not used, the teachings according to the invention may have considerable merit and are also applicable. The specific embodiments described, therefore, should be taken as illustrative of the invention only and not as limiting its scope as defined in accordance with the accompanying claims.

CLAIMS-
We Claim
1. An artificial intelligence based flush clean system for tubesettler comprising of :
a tube settler assembly having a bottom area connected with a collection node and a plurality of tubes laterals extending across substantially the entire bottom area of said tube settler assembly;
each of the said tube laterals is connected to a bar housing which is connected to the clarifier cell;
an water / air deflector assembly is disposed over the tube laterals; wherein
said deflector assembly is perforated with a predetermined number of nozzles configured to trap water air beneath it and redistributes the water and air to the tubes within the tube settler assembly; and

wherein the said collection node includes a plurality of sensors configured for monitoring real-time flow and provides real-time cleanliness detection with notification for cleaning tubesettler.

2. The flush cleaning system as claimed in claim 1, wherein sensor include one or more water flow rate sensors, weight measuring sensor, one or more optional control valves, one or more optional temperature sensors, one or more optional pressures sensors, one or more optional camera sensors, and wireless radio technology.
3. The flush cleaning system as claimed in claim 1, wherein said water air deflector assembly is configured for cleaning the tubesettler pipes with forced air and water shots simultaneously; and said assembly is connected with controlled motor for controlled rotation and pump (integrated or separate) with piping system for pumping of controlled programmable pressurized air and water simultaneously and maintain threshold limits of the tubesettler.
4. The flush cleaning system as claimed in claim 1, wherein the said bar housing is rotatable around central axis configured for 180 degrees to 360 degrees movement.
5. The flush cleaning system as claimed in claim 1, wherein said sensors are configured for flow measurement, weight measurement, and timer feedback of crossing threshold for triggering of IoT and Artificial Intelligence based flushing schedule.
6. The flush cleaning system as claimed in claim 1, wherein the said artificial intelligence system is configured to be operated manually or be programmed to run automatically when a clog / block is detected, or program for a schedule using a cell or smart phone, computer, or similar electronic apparatus.
7. The flush cleaning system as claimed in claim 1, wherein the water / air is emitted by the holes mixes with the water in the clarifier cell and act to assist in the dislodgement of the sediment settled within the tubes of the tube settler assembly .
8. The flush cleaning system as claimed in claim 1, wherein for the supply of air and water two pipes are used wherein first pipe provides water / air to the first set of tube laterals and second pipe provides water / air to the second set of tube laterals.
9. An artificial intelligence based flush clean method for tubesettler comprising the steps of :-
turning the water air deflector assembly to 180 degree upward beneath the tubesettler to start operation;.
Opening the Drain Valve, Air injection valve for starting the Blower/ Air injection which is carried out for preset time and thereafter stopping Blower/ Air injection;
Starting Water injection which is carried out for preset time and thereafter stopping Blower/ Air injection;
closing all valves closed and returning the Water / Air deflector nozzle assembly to 180 degree downward to stop the operation; and
monitoring vide a plurality of sensors the real-time water flow and providing real-time cleanliness detection with notification for cleaning tubesettler.
10. The artificial intelligence based flush clean method as claimed in claim 9, wherein said sensors are configured for flow measurement, weight measurement, and timer feedback of crossing threshold for triggering of IoT and Artificial Intelligence based flushing schedule; and .
said artificial intelligence system is configured to be operated manually or be programmed to run automatically when a clog / block is detected, or program for a schedule using a cell or smart phone, computer, or similar electronic apparatus.