Description:AN APPARATUS AND METHOD FOR BENDING HASTELLOY LINING CLAD SHEETS IN FGD CASING AND DUCTS
FIELD OF INVENTION
[0001] The present disclosure relates to an apparatus and method for bending Hastelloy lining clad sheets used in Flue Gas Desulphurisation (FGD) casing & ducts. More particularly the invention relates to a combined punch and die for all lining clad sheet bends used in FGD casings and ducts while enhancing safety and productivity with minimum setting time and manpower.
BACKGROUND OF INVENTION
[0002] The Flue Gas Desulphurization is a new product being supplied to all thermal power plants to bring the SOx levels within acceptable limits of the latest environmental norms.
[0003] Flue Gas Desulphurization (FGD) is a process of removal of Sulphur Dioxide (SO2) from the exit flue gas before feeding to stack (chimney). The FGD plant consist of an Absorber tank containing of a chemical slurry (Limestone). The SO2 in flue gas reacts with the limestone and the Sulphur gets converted as a by-product, Gypsum. The treated gas after Sulphur removal efficiency of 90%~99.9% is fed to the chimney.
[0004] As the FGD Absorber tank internal walls are continuously in contact with chemical, the internal surface is highly prone to corrosion. In order to prevent corrosion of internal walls, the plate material is cladded with high corrosion resistant material, C276 (Hastelloy) i.e. 7mm to 12mm thickness. Carbon steel plates will be cladded with 2mm thickness Hastelloy sheets. This cladding can be carried out as bonding or lining methods. The lining method is where our invention is used.
[0005] In the lining cladding method, 2mm C276 clad sheets are welded to the carbon steel plates. Adjacent clad sheets are welded by overlapping with lap joints. Butt joint welding of clad sheets will result in carbon inclusion which will cause corrosion at the joint welds and hence is not recommended in design.
[0006] For lap joints, the 2mm clad sheet ends are to be bent in a manner to ensure lap joint with clad sheets alone and ensures the carbon steel plate is not exposed to the slurry.
[0007] Using in-built punch and die of machine available at shop, the step bend profile in lining sheets cannot be bent. Hence for bending of lining clad sheets, a special punch and die set is required. The die changing process is also time consuming and laborious involving usage of cranes to shift the heavy punch and die from the bending machine, impacting the productivity.
[0008] The conventional method and apparatus that is adopted has a few drawbacks which include laborious die changing processes, limited bending capabilities, and risks of carbon inclusion and corrosion at joint welds. This leads to reduced efficiency, increased downtime, and higher operational costs in thermal power plants. These drawbacks highlight the need for innovative solutions to streamline the bending process and improve productivity in FGD operations.
OBJECTS OF THE INVENTION
[0009] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0010] It is an object of the present subject matter to overcome the aforementioned and other drawbacks in the prior art systems and methods.
[0011] It is a principal object of the present subject matter to introduce a method and an apparatus to eenhance productivity by minimizing press and die changes, reducing cycle time, and improving output quality.
[0012] It is another object of the present subject matter to introduce a method and an apparatus to reduce manual labour and operator fatigue associated with the conventional punch and die changing process.
[0013] It is another significant object of the present subject matter to propose the method and apparatus that improve safety in working conditions by mitigating risks of guide pin damage and equipment mishandling.
[0014] It is another significant object of the present subject matter to propose the method and apparatus optimizing operational efficiency in industrial settings for seamless production progress and reduces the generation of cut bits and scrapes and achieves substantial cost savings in industrial applications.
[0015] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taking into consideration with accompanied drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION
[0016] This summary is provided to introduce the concept that discloses an apparatus and method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts.The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor it is intended to be used to limit the scope of the claimed subject matter.
[0017] The present invention discloses an apparatus and a method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts. The apparatus comprises of a combined punch and die arrangement, where a punch is a L-shaped plate with a protrusion on the underside along the outer edge in the horizontal plane, and u-shaped grooves on the vertical plane on the outside to guide the punch, a die comprising of a flat plate with a protrusion on the upper side in the inner section, welded with rods and clamps for coupling with the punch and a spring-loaded system comprising a plurality of springs, a plurality of bolts and a plurality of lock nuts for securing the punch and the die together.
[0018] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0019] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0020] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which
[0021] Fig. 1 illustrates the flow chart of a conventional method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with the disclosure;
[0022] Fig 2 illustrates the 3D view of an apparatus for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure;
[0023] Fig 3 illustrates the front view of an apparatus for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure;
[0024] Fig 4 illustrates the side dimensional view of an apparatus for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure;
[0025] Fig 5 illustrates the flow chart of a method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure;
[0026] Fig 6(a) illustrates the diagram before the bending 2mm lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure;
[0027] Fig 6(b) illustrates the diagram of the bending 2mm lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure;
[0028] Fig 6(c) illustrates the diagram after the bending 2mm lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure; and
[0029] Fig 6(d) illustrates the diagram of the 2mm lining clad sheets after bending in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure.
[0030] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
[0031] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.
[0032] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0033] Each of the appended claim s defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0034] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.
[0035] Various embodiments are further described herein with reference to the accompanying figures. It should be noted that the description and figures relate to exemplary embodiments and should not be construed as a limitation to the subject matter of the present disclosure. It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the subject matter of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the subject matter of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof. Yet further, for the sake of brevity, operation or working principles pertaining to the technical material that is known in the technical field of the present disclosure have not been described in detail so as not to unnecessarily obscure the present disclosure.
[0036] Fig. 1 illustrates the flow chart of a conventional method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with the disclosure. Conventional way of removing in-built machine punch and die using gantry crane is time consuming and labour intensive. During this changing, chances of guide pin damage while changing the punch and damage to punch and die while handling are high. Improper setting during this operation may also affect job quality while leading to unsafe condition. As the operation is time and labour intensive, other jobs need to be queued till bend completion and may result in delay in job progress, if there is non-sequential material supply. There is also no option for immediate changeover of punch and die in case of job urgency. It also leads to operator fatigue.
[0037] Fig 2 illustrates the 3D view of an apparatus for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure. The apparatus (100) for bending Hastelloy lining clad sheets in Flue Gas Desulphurization (FGD) casing and ducts comprises a combined punch and die arrangement. The punch (1) is constructed as an L-shaped plate with a protrusion (3) on the underside along the outer edge in the horizontal plane, accompanied by u-shaped grooves (4) on the vertical plane to guide its movement. Complementing this, the die (2) features a flat plate with a bend protrusion (8) on the upper side in the inner section, welded with rods (7) and clamps (6) for coupling with the punch (1). Facilitating their cohesion is a spring-loaded system (5) comprising multiple springs, bolts, and lock nuts, ensuring a secure attachment during operations.
[0038] The punch (1) is a pivotal element of the apparatus. Crafted as an L-shaped plate with a protrusion (3) on its underside, it facilitates precise bending of the clad sheets. Additionally, u-shaped grooves (4) on the vertical plane guide the punch(1) for accuracy during operations.
[0039] The die (2) plays a crucial role in the bending process. It consists of a flat plate with a bend protrusion (8) on its upper side, designed to seamlessly align with the punch (1) for efficient bending. The die (2) is further reinforced by welded rods (7) and clamps (6), ensuring stability and alignment during bending operations.
[0040] The spring-loaded system (5) comprising of multiple springs, bolts, and lock nuts, this mechanism secures the punch (1) and die (2) together, ensuring a firm connection throughout the bending process. Its robust design enhances stability and precision, resulting in high-quality bends.
[0041] The guiding plates (9) assist in locating the die (2) within the die setups, ensuring accurate positioning for seamless operations. Additionally, the crane hook facilitates easy lifting and manoeuvring of the apparatus, streamlining setup and maintenance procedures.
[0042] Fig 3 illustrates the front view of an apparatus for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure. The apparatus (100) features a punch (1) with coupled with a die (2) having bend protrusions(5) and reinforcement, all secured by a spring-loaded system (5). Additional guiding plates (9) aid in precise alignment within setups, while a crane hook facilitates easy handling. This design streamlines the bending process for Hastelloy lining clad sheets in FGD applications, ensuring accuracy, stability, and efficiency.
[0043] Fig 4 illustrates the side view of an apparatus for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure. The apparatus(100) can be inserted into any punch and die loaded onto the bending press. When the sheet is inserted into the new punch & die set apparatus, it gets bent to the required shape and the apparatus can be easily removed after the job is done without removing the original punch and die which would have involved a lot of manual labour, time and operation of gantry crane.
WORKING OF EMBODIEMENT:
[0044] Fig 5 illustrates the flow chart of a method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in accordance with an embodiment of the present disclosure. Firstly, the apparatus (100), featuring the punch (1), die (2), and spring-loaded system (5), is inserted into the punch and die setup. Once in place, the metal cladding sheet is fed into the apparatus(100), guided by the punch(1) with protrusions(3) and grooves(4), and the bending operation is executed. Upon completion, the apparatus(100) is promptly removed, ensuring a streamlined process that optimizes productivity and quality in FGD applications.
[0045] The reduction in steps from 19 to just 5 signifies a remarkable improvement, drastically minimizing time, effort, and manpower required for bending operations. This enhancement underscores the apparatus's efficiency and its potential to revolutionize bending processes in industrial settings
[0046] Figure 6(a) illustrates the diagram before the bending 2mm lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure. Initially, the clad sheet is shown in its original state before bending, followed by the intermediate stage during the bending operation.
[0047] Figure 6(b) illustrates the diagram of the bending 2mm lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure. This is the intermediate stage where the sheet undergoes the process of bending.
[0048] Fig 6(c) illustrates the diagram after the bending 2mm lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure. The sheet develop a visible lap joint through the bending.
[0049] Fig 6(d) illustrates the diagram of the 2mm lining clad sheets after bending in Flue Gas Desulphurisation (FGD) casing and ducts in in accordance with an embodiment of the present disclosure. The clad sheet after bending have a visible overlapping lap joint formed through welding. This lap joint serves the crucial function of safeguarding the underlying material, ensuring enhanced protection against corrosion. The sequential depiction highlights the efficacy of the invention in facilitating the bending process while ensuring the integrity of the clad sheet and the underlying material.
[0050] The apparatus(100) is used for bending 2mm C726 clad plate used for creating a lap joint to protect the carbon steel FGD casing and lining from corrosion. The method and apparatus(100) can be easily set up and removed for the job without requiring much labour or time. The apparatus(100) can be used with any punch and dye without removing it and can be easily adjusted to suit different bend thickness or plate lengths and improve the productivity and quality while ensuring safety of the human personnel and equipment.
ADVANTAGES OF THE INVENTION
[0051] The proposed apparatus and method have the following advantages over the contemporary system:
• Quick and easy setup: The apparatus enables rapid installation and removal, minimizing labor and time requirements for bending operations.
• Compatibility: It can be utilized with punch and die setups without the need for their removal, enhancing versatility and convenience.
• Adjustable: Easily adaptable to accommodate different bend thicknesses or plate lengths, offering flexibility in various applications.
• Enhanced productivity: Streamlined workflow reduces the number of steps involved in the bending process, leading to increased efficiency.
• Improved quality: Precise bending ensures high-quality results, contributing to overall product excellence.
• Safety assurance: By minimizing manual labor and facilitating swift setup and removal, it helps mitigate risks to personnel and equipment.
WORKING OF INVENTION
[0052] The present invention is used in the field of metal fabrication or manufacturing, specifically for bending metal sheets. It is particularly relevant for applications involving the bending of clad sheets used in Flue Gas Desulphurization (FGD) casing and ducts, where corrosion resistance is crucial. Therefore, the invention is tailored for industries such as power generation, environmental engineering, and industrial manufacturing, where FGD systems are employed to reduce emissions and comply with environmental regulations.
[0053] The above materials are given as example without restricting scope of the invention to the same. Thus, other materials readily apparent to a person skilled in the art are understood to be within purview of the invention.
[0054] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0055] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0056] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0057] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
, Claims:
We Claim:
1. An apparatus(100) for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing and ducts, the apparatus(100) comprising:
a combined punch and die arrangement, wherein a punch (1) is a L-shaped plate with a protrusion(3) on the underside along the outer edge in the horizontal plane and u-shaped grooves(4) on the vertical plane on the outside to guide the punch(1);
a die(2) comprising of a flat plate with a bend protrusion(8) on the upper side in the inner section, welded with rods(7) and clamps(6) for coupling with the punch(1); and
a spring-loaded system(5) comprising a plurality of springs, a plurality of bolts and a plurality of lock nuts for securing the punch and the die together.
2. The apparatus(100) as claimed in the claim 1, wherein the punch(1) and the die(2) are coupled using the spring-loaded mechanism(5), ensuring secure attachment and facilitating easy removal after the bending operation.
3. The apparatus as claimed in the claim 1, wherein the die(2) comprises a plurality of guiding plates(9) for locating the die in die setups and a hook for lifting with a crane, enhancing ease of use and installation.
4. A method for bending Hastelloy lining clad sheets in Flue Gas Desulphurisation (FGD) casing & ducts, the method comprising:
inserting the apparatus(100) into the punch and die setup;
feeding the metal cladding sheet into the apparatus(100);
performing the bending operation; and
removing the apparatus (100) after completion of the bending operation.
Dated this 29th day of March, 2024.

SOMA RANI MISHRA
IN/PA – 1159
L. S. DAVAR & CO.,