Claims:We claim
1. A device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers comprising a fixture having atleast three tubular members (101A, 101B) connected to each other by respective fin plate (106, 107) constituting a triangular structure, wherein the fin plate (106, 107) is placed at intermediate point of said tubes (104A, 104B).

2. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in claim 1, wherein the fixed connection between the tubular members (101A, 101B) can be established by welding.

3. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claim 1 or 2, wherein the tubular member (101A, 101B) includes a tube (104A, 104B) and a fastener including bolt (105), in which top of the tubes (104A, 104B) is screwed with the bolt (105).

4. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claims 1-3, wherein the length of the internal threads of said tube (104) is corresponding to length of said bolt (105) and the diameter of the bolt (105) is corresponding to the internal diameter of the tube (104).

5. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claims 1-4, wherein the tube (104A, 104B) is having the following dimensions: -

Length- 50-60mm as the distance between each lug plate is minimum of 102mm and maximum of 136mm.
Outer diameter- for example 24mm
Inner diameter- for example 12mm
6. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claims 1-5, wherein the two tubular members (104B) are connected with third tubular member (104A) at Apex by a fin plate (106), which involves the following dimensions: -

Thickness- for example 6mm
Length- 360-500mm
Width- for example 10mm
7. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claims 1-6, wherein the two tubular members (104B) are connected to each other with the help of another fin plate (107), which is associated with the following dimensions:-
Thickness- for example 6mm
Length- 150-300mm
Width- for example 10mm
8. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claims 1-7, wherein the fin plates (106, 107) are fixedly held to the tubular members (104A, 104B) preferably at the center of the tubes.

9. The device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers as claimed in the claims 1-8, wherein the angle subtended between the fin plates (106) is ?= 24-34° and the angle between the fin plates (106, 107) is ?= 63-78°.

10. A method for setting up of lug plates at bending areas of gang bend panels for high pressure boilers comprising steps of:-
- placement of first lug from bottom as per the ground layout,
- adjustment of height of the lug from ground floor by the nut provided on the top of the tubular members,
- placement of the lug on the fixture in alignment with the bend portion on the panel followed by tack welding
- placement of the fixture on the first lug for placing second lug and tack welding of the second lug. , Description:FIELD OF THE INVENTION

[001] The invention generally relates to manufacturing of water wall panels in High Pressure Boiler. The invention also relates to Lug setting operation at the gang bend areas of the second pass panels. More particularly, the invention relates to lug fit up accurately in less time and with less manpower at the gang bend areas of first pass and second pass gang bend panels. The Purpose of the lug plate is to give support to collector plate which is for hanging purpose at site.
BACKGROUND/PRIOR ART OF THE INVENTION

[002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[003] In Boilers, water wall panel is one of the important components. Water wall panel is of two types;
1) First pass water wall panels.
2) second pass water wall panels.

[004] The above said both panels are also subdivided into two types:
a) Straight panels.
b) Gang bend panel.

[005] The process for gang bend panels is as follows:
I. The panels have to undergo final inspection in straight Portion on stand.
II. It has to be moved for stress relieving and gang bending as per the drawing.
III. The gang bend panels are to be placed in vertical position as per ground lay out.
IV. For first pass gang bend panels, lug plates fit up is to be provided as per drawing. The purpose of lug plate is to give support for the collector plates (site welding).
V. For second pass gang bend panels, lug plates fit up and collector plates fit up are to be provided as per drawing. The purpose of the lug and collector plate is to carry the load of panels while hanging.

[006] In convectional method of manufacturing of first pass gang bend panels, individual lug is fitted at the bend portion of the tube manually and the straightness of the lug is determined visually. After all lugs are tack welded, the inspection is to be done by quality control department about the alignment of the lug slot. If it is correct, then further welding process can be done. Otherwise rework is to be done. The rework consists of removal of the lug, grinding and giving tacking the welds by visual inspection.
[007] For second pass gang bend panels, the above said same process is followed.
[008] Previously, lug fit up was given at the bend portion of the gang bend panels manually by holding the lug in hand.

[009] The inherent limitations of the present method of giving lug fit up by the conventional method are listed hereinbelow:
• more man powers required to hold the lug plates in straight portion.
• The lug plates should be parallel to ground and straight line as per the design which is judged only through visually in conventional method. Most of the cases, after lug fit up when the lug fit up is checked by the quality control department the lug plates are found not in straight line. So, once more the lug plates are to be removed, grinding is to be done for the tacked welded areas and the lug fit up is to be started from the starting which is time consuming. Also more reworks are occurred. More grinding wheels and electrodes are consumed for lug fit up.
• More cycle time is needed in conventional method and for lug fit up it is required minimum 3 shifts for first pass and second pass gang bend panels.

[010] Due to the above shortcomings, the finishing of the lug plate fit up is also not satisfactory.
[011] Hence it was necessary to develop a method and device for easy fit up operation of the lug plate in less time at the bend portion for the first pass and second pass water wall panels, wherein the present invention involves automatic operation.
[012] Therefore, the present invention has been introduced.
OBJECTS OF THE INVENTION

[013] The principal objective of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which overcomes disadvantages of prior art.
[014] Another object of the invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which is simple in construction.
[015] Still another object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which involves automatic operation.
[016] Yet another object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which involves no chance of any reworks and no scope of any height variances.
[017] A further object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which requires less man power.
[018] Still further object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which avoids slippage thereby ensuring safety.
[019] Still another object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which results in less time consumption.
[020] Still further object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which leads to reduction in fatigue to manpower.
[021] Yet further object of this invention is to provide a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers which improves in quality of finishing job.
[022] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.
SUMMARY OF THE INVENTION

[023] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.
[024] According to this invention, there is provided a device for setting up of lug plates at bending areas of gang bend panels for high pressure boilers comprising a fixture having atleast three tubular members connected to each other by respective fin plate constituting a triangular structure, wherein the fin plate is placed at intermediate point of said tubes.
[025] The fixed connection between the tubular members can be established by welding.
[026] The tubular member includes a tube and a fastener including bolt, in which top of the tubes is screwed with the bolt.
[027] The length of the internal threads of said tube is corresponding to length of said bolt and the diameter of the bolt is corresponding to the internal diameter of the tube.
[028] The tube is having the following dimensions: -
Length- 50-60mm as the distance between each lug plate is minimum of 102mm and maximum of 136mm.
Outer diameter- for example 24mm
Inner diameter- for example 12mm
[029] The two tubular members are connected with third tubular member at Apex by a fin plate, which involves the following dimensions: -
Thickness- for example 6mm
Length- 360-500mm
Width- for example 10mm
[030] The two tubular members are connected to each other with the help of another fin plate, which is associated with the following dimensions: -
Thickness- for example 6mm
Length- 150-300mm
Width- for example 10mm

[031] The fin plates are fixedly held to the tubular members preferably at the center of the tubes.
[032] The angle subtended between the fin plates is ?= 24-34° and the angle between the fin plates is ?= 63-78°.
[033] A method for setting up of lug plates at bending areas of gang bend panels for high pressure boilers comprising steps of: -

- placement of first lug from bottom as per the ground layout,
- adjustment of height of the lug from ground floor by the nut provided on the top of the tubular members,
- placement of the lug on the fixture in alignment with the bend portion on the panel followed by tack welding
- placement of the fixture on the first lug for placing second lug and tack welding of the second lug.

[034] 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.
[035] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[036] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[037] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein, wherein: -
Fig 1 -Shows the first pass gang bend panel placed on layout in vertical position.

Fig 2 -Shows the second pass gang bend panel on layout in vertical position.

Fig 3 - Shows the first pass gang bend panels with lug plate fit up.

Fig 4 - Shows the second pass gang bend panel with lug plate fit up.

Fig 5 -Shows the fixture for lug fit up according to present invention.

Fig 6 -Shows the parts of the fixture in accordance with present invention.

[038] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily 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.
DETAIL DESCRIPTION OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERRED EMBODIMENTS

[039] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
[040] The present invention is pertinent to a technology regarding a device and a method for setting up of lug plates at the bending areas for first pass and second pass gang bend panels for high pressure boilers. Now, reference may be made to Fig. 5 depicting fixture for lug fit up of the instant invention. The fixture comprises of atleast three tubular members (101A, 101B), which are fixedly connected to each other by means of fin plate (106, 107). The fixed connection between the tubular members (101) can be established by welding.
[041] The tubular member (101A, 101B) includes a tube (104A, 104B) and a fastener including bolt (105).
[042] The tube (104A, 104B) is having the following dimensions: -
Length- 50-60mm as the distance between each lug plate is minimum of 102mm and maximum of 136mm.
Outer diameter- for example 24mm
Inner diameter- for example 12mm
[043] The tube (104A, 104B) is having internal threads at the top.
[044] The top of the tubes (104A, 104B) is screwed with the bolt (105). The length of the internal threads of said tube (104A, 104B) is corresponding to length of said bolt (105). Similarly, the diameter of the bolt (105) is corresponding to the internal diameter of the tube (104A, 104B). The purpose of the bolt is to do height adjustment.
[045] The two tubular members (104B) are connected with third tubular member (104A) at apex by a fin plate (106). The fin plate (106) involves the following dimensions: -
Thickness- for example 6mm
Length- 360-500mm
Width- for example 10mm
[046] The two tubular members (104B) are connected to each other with the help of another fin plate (107). Said fin plate (107) is associated with the following dimensions:
Thickness- for example 6mm
Length- 150-300mm
Width- for example 10mm
[047] The fin plates (106, 107) are fixedly held to the tubular members (104A, 104B) at 25-30mm preferably at the center of the tubes. Thus, the fin plates are placed above the ground.
[048] Now, the angle subtended between the fin plates (106) is ?= 24-34°. The angle between the fin plates (106, 107) is ? = 63-78°.
[049] The fixture of present invention can be placed easily on the ground floor easily as the bottom legs are flat. While giving lug fit up, the fixture can be placed and height adjustment can be done through the bolts. The lug can be placed on the top of the bolt.
[050] Accordingly, the fixture has been devised to reduce the human efforts and mistakes due to visual inspection. while giving lug fit up, the first lug is to be placed from bottom as per the ground layout. Hence, the fixture is placed on the ground floor. The height of the lug from ground floor is adjusted by the nut provided on the top of the fixture. After adjusting the height, the lug is placed on the fixture in alignment with the bend portion on the panel & tack welded.
[051] Due to the method, there is no need to hold the lug manually, instead it can be simply placed on the fixture and tack weld can be done with the panel.

[052] For placing second lug, the fixture is placed on the first lug and second lug is also tack welded in the same process. In the same sequence, all the lugs are to be tack welded.

[053] As all lugs are placed on the fixture, there is no chance of any reworks.
[054] As all the legs of the fixture are of same height, there is no scope of any height variances.
[055] With only one-man power the lug fit up can be completed.
[056] In conventional method, there is a chance of slippage of lug plate from hand as it was done manually. Now, as the lug plate is placed on the fixture, there is no chance of slippage. Hence, safety is ensured.
[057] In conventional method, more time is required for fit up, but now with new fixture less time is required.
[058] With the new method, Fatigue to manpower is reduced. Also quality of the finishing job is improved.
Benefits in term of
A. Productivity:
? Time taken for conventional method of lug fit up was 3 days. but with new developed fixture the lug fit up operation is completed within in one shift.
So time is reduced.
? In conventional method, the lug fit up is done through visual. while checking by quality control department, most of the time the straight ness of the lug and collector plates are not in a straight line. Further reworks like removing the lug plates and grinding at the tack welded portion is done. but in new method of lug fit up the reworks are totally avoided as the straightness of the lug plates are automatically judged by the new fixture. The cost to company through the rework is saved totally.
? The utilization of grinding wheel is also minimized.
B. Quality:
? As the removing of the lug plates and collector plates is avoided totally, hence quality wise the product is satisfactory.
C. Safety and Environment aspects:
? maximum safety and good working environment are ensured in present invention by eliminating the usage of grinding operation.
? Man power fatigue is minimized with easy setting.
D. Health & Working Conditions:
? Safer work condition to the operator thus promoting higher industrial safety standards and occupational health standards.
Advantageous Features
- Involves automatic operation
- No chance of any reworks
- No scope of any height variances
- Requirement of less man power
- Avoids slippage thereby ensuring safety
- Less time consumption
- Reduction in fatigue to manpower
- Improvement in quality of finishing job.
Test Results
BEFORE IMPLEMENTATION
WO DU Ground layout drawn Panel loading Panel setting Panel bow correction Lug cutting and grinding Lug plate fit up Inspection rework TOTAL TIME( IN HRS)
1816-06-741 002 0.5 1 1 2 1 16 1 8 30.5
1816-06-741 010 0 1 1 2 1 14 1 3 23
1820-06-741 003 0.5 1 1 2 1 12 1 7 25.5
1816-11-767 002 0.5 1 1 2 1 14 1 6 26.5
1816-11-767 003 0 1 1 2 1 14 1 8 28
Average time to perform lug fit up operation 26.7 Hrs
AFTER IMPLEMENTATION:
WO DU Ground layout drawn Panel loading Panel setting Panel bow correction Lug cutting and grinding Lug plate fit up Inspection rework TOTAL TIME( IN HRS)
1720-06-741 002 0.5 1 1 2 1 16 1 0 22.5
1720-06-741 003 0 1 1 2 1 14 1 0 20
1716-06-741 002 0.5 1 1 2 1 12 1 0 18.5
1713-06-767 002 0.5 1 1 2 1 16 1 0 22.5
1714-06-967 003 0 1 1 2 1 16 1 0 22
Average time to perform lug fit up operation 21.1 Hrs

SO, AVERAGE REDUCED CYCLE TIME PER PANEL: 5.6 HRS

[059] Each of the appended claims 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.
[060] 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.
[061] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.
[062] The above description does not provide specific details of 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.
[063] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present 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.
[064] 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.
[065] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.