Claims:WE CLAIM:
1. A method (101) for manufacturing of headers of steam boilers, the method (101) comprising:
mounting (102) of a header pipe (21) on a plurality of V-shaped blocks (23) such that the longitudinal ends of header pipe are mounted on two V-blocks (23) from the plurality of V-blocks (23) and supported by rest of the plurality of V-blocks (23) at equidistance from each other;
fastening (103) of plurality of an apparatus (100) on the header pipe (21) to secure the header pipe (21) and plurality of apparatus (100) are spaced apart from each other at a pre-calculated equidistance for fit-up of a rectangular plate (24) and bracing plate (20) over the header pipe (21);
placing of (104) a rectangular plate (24) over the plurality of the apparatus (100) and fastened at its edge to the horizontal channel (5) of the apparatus (100) through the L-shaped plate (07);
placing and spacing (105) of a plurality of bracing plate (20) onto the rectangular plate (24) at pre-calculated equidistance; and
placing (106) of a plurality of stubs (22) at a uniform distance from each other on the header pipe (21) through the holes (18) provided at the top face of the header pipe (21).
2. The method (101) for manufacturing of headers of steam boilers as claimed in claim 1, wherein the apparatus 100 comprises:
a bottom clamp (01) defining a first semi-circular structure with two flanges (16a, 16b) elongated longitudinally at the ends of the bottom clamp (01);
a top clamp (02) defining a second semi-circular structure with two flanges (17a, 17b) elongated longitudinally at the ends of the top clamp (02);
a vertical post (03) defining a rectangular structure to which the top clamp (01) is welded through the outer periphery, and
a horizontal channel (05) fastened to the vertical post (03) by a plurality of fastening means (09),
wherein the bottom clamp (01) and the top clamp (02) are fastened together to define a circle.
3. The apparatus (100) as claimed in claim 2, wherein the vertical post (03) is provided with plurality of pair of holes (11) at the front face, spaced apart from each other, and a vertical cover plate (04) at the rear face of the vertical post (03), aligned parallel to the pair of plurality of holes (11).
4. The apparatus (100) as claimed in claim 2, wherein the horizontal channel (05) is provided with a detachable first horizontal cover plate (06) at the front face of the horizontal channel (05) through which the horizontal channel (05) is fastened to the vertical post (03).
5. The apparatus (100) as claimed in claim 2, wherein an L-shaped plate (07) is provided at both longitudinal ends of the horizontal channel (05) to fasted the rectangular plate (24) during fit-up of bracing plates (20). , Description:FIELD OF INVENTION
[001] The present invention, in general, relates to steam boilers or generators and in particular relates to the steam and water circuits. More particularly, the invention relates to an apparatus and method for the manufacturing of header of steam boilers with stubs.
BACKGROUND
[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] The steam generator also is known as the boiler, is the equipment to convert water to high-pressure steam for power generation. The water and steam circuits of the boiler involve the union and bifurcation of different pipes and tubes. This union and bifurcation are made using the headers. This invention describes the method of manufacturing of the header with stubs.
[004] In header manufacturing, bracing plate fit-up is the main stage. Works involved in the bracing plate fit-up are as follows:
I. Pad plate fit-up and welding on the header pipe.
II. Guide stub fit-up and welding on the pad plate.
III. Stub alignment involving, heating the stub to red hot condition, manual hammering for straightening, leveling, pitch correction of stubs as per drawing.
IV. Clearance pin welding with the guide stub, for angle welding and providing clearance between successive stubs.
V. Angle welding on the support pin on both longitudinal and crosswise direction.
VI. Completion of the above activities is required for setting up the rectangular frame above the header pipe.
VII. Bracing plates fit-up and welding on the rectangular frame.
VIII. This bracing plate would be customized for a number of stubs per row and pitch as per drawing. 8. Stub fit-up and welding on the header pipe.
IX. In the existing method of manufacturing of the headers following are the drawbacks; which creates the need for the inventive method.
[005] In header manufacturing, bracing plate fit-up is the main stage. In this stage, the old method is being used. in bracing plate fit-up by eliminating the pads, clearance pins and setting studs. In reference to Fig. 1 that illustrates the existing method of manufacturing of header for steam boilers. A header pipe 21 is mounted on a plurality of V blocks 23 and leveling is done before assembling a plurality of stubs 22 onto the header pipe 21. In the existing method, a pad plate 25 is to be welded on to a header pipe 21 along with a clearance pin 26 and plurality of guide stubs 27. All the aforesaid assembly constitutes the support for a rectangular plate 24 which acts as the guide for a plurality of stubs 22 to be welded on to the header pipe 21. In reference to Fig. 2 which illustrates a manufactured header using the existing method and Fig.3 is expanded the view of the pad plate 25 which is welded to the header pipe 21. In header manufacturing, a bracing plate 20 fit-up is the main stage. Bracing plate 20 fit-up operation is carried out in complex methodology. Crane engagement for this job setup might have an impact on the other works queued. Therefore, there is a need in the art to develop an apparatus and method of manufacturing headers to overcome the technical problem in the existing art, as discussed above.
[006] Issues in the existing method are: Cycle time is high, up to six shifts of manpower is required for setting up the job. Material and consumables consumption is high (Such as Grinding wheels, welding electrodes, coal gas, Acetylene, Oxygen, and Compressed Air and Non-Destructive Testing consumables. Grinding and welding have more impact on personal health, safety, and the environment. Probability of repair and rework on header material welding is high since there are a lot of additional materials such as guide stubs, clearance pin and pad plates that are involved in the manufacturing process. The employee fatigue rate is higher. The cost of manufacturing is high due to the aforesaid reasons Bracing plate fit-up operation is carried out in complex methodology. Crane engagement for this job setup might have an impact on the other works queued.
[007] Hence to solve the demerits aforesaid, the present disclosure proposes an apparatus for the frame and bracing plate fit up, for all headers, without affecting the header material, guide stubs, clearance pin, and pad plates. By using this fixture, we can achieve the result by eliminating many processes during bracing plate & angle fit-up. The step by step problem-solving method is provided in the detailed description. spindles basically fulfill two tasks, one, to rotate the tools (drilling, milling, and grinding) or workpiece (turning) precisely in space and, two, to transmit the required energy to the cutting zone for metal removal. Obviously, spindles have a strong influence on metal removal rates and the quality of the machined parts.
OBJECTS OF THE INVENTION
[008] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow.
[009] The principal objective of the present invention is to provide a method for the manufacturing of headers of steam generators.
[0010] Another objective of the present invention is to provide an apparatus for the manufacturing of headers of steam generators.
[0011] Yet another objective of the present invention is to provide a method and apparatus for the manufacturing of headers of steam generators that reduces the time required for the manufacturing of headers for steam generators.
[0012] Yet another objective of the present invention is to provide a method and apparatus for the manufacturing of headers of steam generators that avoids the welding process on the material.
[0013] Still another objective of the present invention is to provide a method and apparatus of manufacturing of headers of steam generators that reduce the chances of crack development on the material and eliminates rework and rejection of final manufactured header.
[0014] Still another objective of the present invention is to provide a method and apparatus for manufacturing of headers of steam generators that avoids process like machine-cutting, pad plate shearing and bending, setting stub bending, pads and stubs grinding, welding of the pad with header pipe, pad with stub & alignment of stubs.
SUMMARY OF THE INVENTION
[0015] The present invention relates to a method of manufacturing of headers of steam generators. The method comprises a first step mounting of a header pipe on a plurality of V-shaped blocks such that the longitudinal ends of the header pipe are mounted on two V-blocks from the plurality of V-blocks and supported by rest of the plurality of V-blocks at a uniform distance from each other. The next step includes fastening of the plurality of an apparatus on the header pipe spaced apart from each other at a pre-calculated uniform distance for fit-up of a rectangular plate and bracing plate over the header pipe, followed by placing of a rectangular plate over the plurality of the apparatus and fastened at its edge to the horizontal channel of the apparatus through the L-shaped plate. The next step includes placing and spacing of the plurality of bracing plate onto the rectangular plate at a pre-calculated uniform distance. The last step includes placing a plurality of stubs at a uniform distance from each other on the header pipe through the holes provided at the top face of the header pipe.
[0016] In an aspect of the present invention, the apparatus employed or fit-up of a rectangular plate and bracing plate over the header pipe consists of a bottom clamp defining a first semi-circular structure with two flanges elongated longitudinally at the ends of the bottom clam. Further, the top clamp defines a second semi-circular structure with two flanges elongated longitudinally at the ends of the top clamp. Further, it includes a vertical post defining a rectangular structure to which the top clamp is welded through the outer periphery, and a horizontal channel fastened to the vertical post by a plurality of fastening means wherein the bottom clamp and the top clamp are fastened together to define a circle.
[0017] In an aspect of the present invention, the vertical post is provided with a plurality of pair of holes at the front face, spaced apart from each other, and a vertical cover plate at the rear face of the vertical post, aligning parallel to the pair of the plurality of holes.
[0018] In an aspect of the present invention, the horizontal channel is provided with a detachable first horizontal cover plate at the front face of the horizontal channel through which the horizontal channel is fastened to the vertical post.
[0019] In an aspect of the present invention, an L-shaped plate is provided at both longitudinal ends of the horizontal channel to fasted the rectangular plate during the fit-up of bracing plates.
[0020] 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
[0021] 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, the left-most digit(s) of 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 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:
[0022] Fig. 1 illustrates the front view of the existing method of constructing the frame with pad, clearance pin, guide stub welded to each other mounted on V-block;
[0023] Fig. 2. shows a manufactured header using the existing method;
[0024] Fig. 3 illustrates the pad plate used in the existing method;
[0025] Fig. 4 schematically illustrates the isometric view of the assembled apparatus as disclosed in the present disclosure for manufacturing of header;
[0026] Fig. 5 schematically illustrates the exploded view of components of the apparatus as disclosed in the present disclosure;
[0027] Fig. 6 schematically illustrates the mounting of the apparatus on the header pipe;
[0028] Fig. 7 schematically illustrates an angular view of header pipe mounted with apparatus;
[0029] Fig. 8 illustrates the mounting of a rectangular plate on the apparatus;
[0030] Fig. 9 illustrates an expanded view of a mounted rectangular plate on the apparatus;
[0031] Fig. 10 illustrates a side view of the frame and bracing plate fit up with stubs on the header pipe;
[0032] Fig. 11 illustrates the final manufactured header pipe; and
[0033] Fig. 12 illustrates a flow chart depicting steps of the method of manufacturing headers for steam generators.

DETAILED DESCRIPTION OF THE CURRENT INVESTIGATION
[0034] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
[0035] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and detailed in the following description. Descriptions of well-known components and processing techniques are omitted to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0036] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
[0037] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
[0038] In reference to Fig. 4 which illustrates an assembled view of an apparatus 100, as per an embodiment of the present disclosure that is employed in the method of manufacturing of header. The apparatus 100 consists of a bottom clamp 01 that defines a first semi-circular structure and a top clamp 02 that defines a second semi-circular. The bottom clamp 01 and the top clamp 01 further includes two flanges elongated longitudinally at each of the longitudinal ends of the bottom clamp 01 and top clamp 02. The apparatus 100 further comprises a vertical post 03 that defines a rectangular structure. The top clamp 1 is welded to the vertical post 03 is welded through the outer periphery of the top clamp 1 such that the vertical post remains at a right angle to the horizontal plane of the top clamp 02.
[0039] Further, the apparatus includes a horizontal channel 05 which is fastened to the vertical post 03 by a plurality of fastening means 09, preferably nut-bolt mechanism but without deferring from the scope of the present disclosure, any fastening means can be employed to fasten the horizontal channel 05 to the vertical post 03. The bottom clamp 01 and the top clamp 02 are fastened together through any fastening means to define a circle.
[0040] Further, the vertical post 03 is provided with a plurality of pair of holes at the front face, spaced apart from each other, and a vertical cover plate 04 at the rear face of the vertical post, aligning parallel to the pair of the plurality of holes.
[0041] Furthermore, the horizontal channel 05 is provided with a detachable first horizontal cover plate 06 at the front face of the horizontal channel 05 through which the horizontal channel 05 is fastened to the vertical post 03. Further, an L-shaped plate 07 is fastened at both longitudinal ends of the horizontal channel 05.
[0042] In reference to Fig 5 that illustrates the exploded view of the apparatus 100, it can be clearly seen all the parts of the apparatus 100.
[0043] In reference to Fig. 6, that illustrates the mounting of the apparatus 100 to the front face of the header pipe 21. The apparatus 100 is tightly fastened to hold the header pipe such that the header pipe is incapable to make swing motion at its transverse sides. The header pipe 21 is further placed on the plurality of V-shaped blocks 23 such that the longitudinal ends of the header pipe are mounted on the two of the plurality of V-blocks 23 and supported by rest of the plurality of V-blocks 23 at a uniform distance from each other.
[0044] The rear angular view of the header pipe 21 mounted with a plurality of the apparatus 100 is illustrated in Fig. 7. The plurality of apparatus is mounted at a pre-calculated distance from each other on the top face of the header pipe 21.
[0045] In reference to Fig. 8, a rectangular plate 24 is placed on the plurality of apparatus and fastened to the apparatus 100. Fig. 9 which shows an expanded view of the fastened rectangular plate at its edge to the horizontal channel 05 of the apparatus 100 through fastening means, preferably nut-bolt mechanism.
[0046] In reference to Fig. 10 which shows a side view of the frame and bracing plate fit up and a plurality of stubs are placed onto the front face of the header pipe 21 through the plurality of holes 18 provided on the header pipe 21.
[0047] Fig. 11 shows finished and final manufactured header pipe using the method and apparatus as disclosed in the present disclosure.
[0048] The manufacturing method and apparatus as disclosed in the present disclosure
[0049] As per a method, 110 is disclosed in the present disclosure to frame and bracing plate fit-up for headers is described with the help of a flow chart in fig. 12. The method comprises mounting 102 of the header pipe 21 on the plurality of V-shaped blocks 23 such that the longitudinal ends of header pipe are mounted on the two of the plurality of V-blocks 23 and supported by rest of the plurality of V-blocks 23 at a uniform distance from each other. The next step as per the method 110 includes fastening 103 of the plurality of the apparatus 100 on the header pipe spaced apart from each other at a pre-calculated uniform distance and placing 104 of a rectangular plate 24 over the plurality of the apparatus 100 and the rectangular plate is fastened at its edge to the horizontal channel 05 of the apparatus 100 through the L-shaped plate 07. In the next step, a plurality of bracing plate 20 is placed onto the rectangular plate at a pre-calculated uniform distance. In the last step, a plurality of stubs 22 is placed at a uniform distance from each other on the header pipe 21 through the holes provided at the top face of the header pipe 21.