Description:“AN APPARATUS FOR FULLY AUTOMATIC GAS CUTTING OF HIGH THICKNESS PIPES OF VARIANT DIAMETER AND METHOD OF GAS-CUTTING”

FIELD OF INVENTION:
[001] The present invention relates to gas cutting of high thickness pipes. More particularly the invention relates to pipe gas cutting and machining for conventional welding process. More particularly the invention relates to joining of lines and links called steam generator package links in high pressure steam generators.

BACKGROUND OF INVENTION/PRIOR ART:
[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 closed stationary installation for transporting/distribution of fluids like steam and water in high pressure boilers is called as “stream generators package links”. These steam generator package links are made up of high thickness pipes ranging from (25mm to 102mm) and having outside diameter ranging from 813mm to 1016mm. The pipe materials are carbon steel and alloy steels of P22 grade. Different lengths of these pipes are to be joined by SAW (submerged arc welding) to form one link. For preparing for SAW, these pipes are required to be cut and edge-prepared to required length. The conventional way of cutting these pipes is by gas-cutting using oxy-acetylene torch. For this, pipes are marked with cutting tolerance and held in position with the help of crane. Cutting is carried out by cutting torch held manually and moving along the cutting line. As the cutting progresses pipe has to be rotated for every segment of cutting surface with the help of crane. During this time, the crane is fully engaged with one job. Since cutting is manual and the surface finish is uneven and also the final cut edge is very rough. Due to this, method of cutting tolerance required is more which in turn leads to longer cycle time and vibrations while edge-preparation.

[004] Hence there is a necessity to find out an alternate method to avoid continuous usage of crane and also the cutting allowance to be reduced to reduce the machining time further and also to save the high cost of material.

[005] In the above cutting process, due to uneven surfaces obtained at the end, the machining allowance required is 40mm and the time taken in the edge preparation machine is also more since the depth of cut is limited to 4mm at a time.

[006] Reference may be made to the flow diagram in fig-5 showing the cutting sequence of the exiting process.

Prior Art:
[007] Reference may be made to the below known arts:
• JP2013128954A – GAS CUTTING DEVICE, GAS CUTTING ROBOT EQUPIPPED WITH THE SAME, AND GAS CUTTING METHOD

[008] PROBLEM TO BE SOLVED : To provide a gas cutting device capable of easily switching /adjusting intensity of preheating flame according to a situation with no possibility of accidental fire. SOLUTION: The gas cutting device includes a cutting torch 11 which cuts a work 5,flow rate adjuster 20 which contains valve units 21-25 for adjusting flow rate of fuel gas, assisting oxygen supplied to the cutting torch 11 to a different flow rate ,and a control device 12 which ,according to a cutting condition, selects a combination of valve units from among the plurality of valve 21-25 which is suitable for the cutting condition, and drives the valve unit that supplies fuel gas or the like to the cutting torch 11.the flow rate adjuster 20 includes at least one ignition valve unit 21 in which flow rates of the fuel gas and the like are set to an ignition flow rate ,and a plurality of flow rate changing valve units 22-25 adjusted to a flow rate a different cutting condition respectively. The control device 1 is configured such that the ignition valve unit 21 is surely selected in all cutting conditions copyright©2013, JPO&INPUT

• IN 201731018127 - A DEVICE AND A METHOD FOR GAS CUTTING OF HIGH THICKNESS PIPES.

[009] The invention relates of a method of cutting process with the invented device having horizontal pipe loaded on the motorized roller with guide roller with help of crane. The motorized rotor is turned on for which speed can be maintained based on pipe thickness and cutting speed can be controlled by the speed regulator. The torch assembly is connected to oxygen and acetylene cylinder by means of oxy-acetylene special rubber hoses once fuel supply is formed on the flame setting an according for the thickness of pipe and the vertical movements arrested by the, locking Screw-I the locking screw-II depending on the outside diameter of the pipe 219 to 813 mm. The horizontal movement can be adjusted by sliding the moving carriage on the carriage polish rod and the finer adjustments of the torch can be done by torch vertical adjustment screw rod. Hence 6-meter length of the work piece can be marked and cut easily thereby avoiding the manual gas cutting. By the elimination of manual gas cutting the savings one accounted is man hour, material, power and consumables. [0010] However, the above invention is not relevant to the present invention.

OBJECTS OF THE INVENTION:
[0011] Primary object of the invention is to propose an apparatus for fully automatic gas cutting of high thickness pipes of variant diameter and method of gas-cutting to obtain pipe ends with smooth surface and good quality cut.

[0012] An objective of the invention is to propose method of gas-cutting to obtain pipe ends with smooth surface and good quality cut.

[0012] Another objective is to reduce the cycle time and improve productivity of the link fabrication especially in pipe edge-preparation.

[0013] A still further object of the invention is to avoid the crane usage for cutting.

[0014] 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 INVENTION:
[0015] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition 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.

[0016] Considering the requirement of good quality gas-cutting, the technique was established.

[0017] The invention relates to a method of cutting process by invented device. Horizontal pipe (not shown) is loaded on the motorized roller with guide roller (not shown) with the help of crane. Once motorized rotor is turned on, the speed can be maintained based on pipe thickness by controlling the speed regulator (not shown).

[0018] The torch assembly (06,07,10,11) is connected to oxygen and acetylene cylinder by means of oxy-acetylene special rubber hoses (12 and 13). Fuel supply is adjusted to form flame setting according to the thickness of the pipe. The vertical movement is adjusted and arrested by the locking Screw-I (09) and locking screw-II (05) depending on the outside diameter of the pipe 819 to 1016 mm.
[0019] The horizontal movement can be adjusted by placing the moving base plate (01) on the floor and the finer adjustments of the torch can be done by torch vertical and horizontal adjustment rake (07) and pinion screw rod (10).

[0020] Hence up to a length of 10meter work pieces can be marked and cut easily. Hence avoiding the manual gas cutting. By eliminating manual gas cutting, the savings accounted are man hours, material, power and consumables.

[0021] According to the present invention, there is provided an apparatus for fully automatic gas cutting of high thickness pipes of variant diameter comprising of torch assembly (06,07,10,11) connected to oxygen and acetylene cylinder by oxy-acetylene special rubber hoses (12 and 13), wherein Fuel supply is adjusted to form flame setting according to the thickness of the pipe, in which the vertical movement is adjusted and arrested by the locking Screw-I (09) and locking screw-II (05) depending on the outside diameter of the pipe;
[0022] the adjustable torch assembly comprises a torch with vertical adjustment mechanism, which is connected to backup plate (04) which is in turn connected to the torch assembly (06,07,10,11) for up and down of vertical movement (08).

[0023] Further according to the present invention, there is provided a method of gas-cutting to obtain pipe ends with smooth surface and good quality cut comprising of following steps:

- Work piece total length marking
- Inspection
- If inspection is not ok, below steps need to be followed:
- Pilot hole drilling
- Work piece loading on roller stand
- Auto gas cutting
- Single pass facing
- Edge preparation.

[0024] 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.

[0025] 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.

[0026] 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 DECRPTION OF THE ACCOMPANIYING DRAWINGS:
[0027] 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:-
Figure 1 shows: base plate.
Figure 2 shows: vertical post.
Figure 3 shows: collar sleeve with backup plate.
Figure 4 shows: locking screw.
Figure 5 shows: adjustable torch assembly.
Figure 6 shows: the developed device with cutting set in the assembled condition.
Figure 7 shows: the flow diagram for the prior art.
Figure 8 shows: the flow diagram for the cutting process with developed apparatus.

[0028] 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.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION WITH REFERENCE TO THE ACCOMPANIYING DRAWINGS:

[0029] 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.

[0030] The present invention makes a disclosure regarding a technology pertaining to invention directing to an apparatus for fully automatic gas cutting of high thickness pipes of variant diameter and method of gas-cutting to obtain pipe ends with smooth surface and good quality cut.

[0031] Now, reference may be made to Figure 1 showing the Base plate (01), which is machined and made smooth. It works as strong base for the invention and also it is very handy to move easily to required place on floor.

[0032] Referring to Figure 2 showing Vertical post (02), which is welded at centre of base plate (01).

[0033] Figure 3 indicates Collar sleeve (03), having internal thread on one side, over which backup plate (04); having a hole for torch assembly is welded vertically.

[0034] Figure-4 showing locking screw II (05); which is made easy for hand tightening. It is used to lock the collar sleeve (03) over vertical post (02) at required height in accordance with job size.

[0035] Figure-5 shows adjustable torch assembly which comprises a torch with vertical adjustment mechanism, which is connected to backup plate (04) which in turn connected to the torch assembly (06); (07); (10); (11); for up and down of smaller vertical movement (08).

[0036] Reference may be made to Figure 6 showing the developed device with cutting set in the assembled condition which includes the torch assembly (06); (07); (10); (11); is connected to oxygen and acetylene cylinder by means of oxy-acetylene special rubber hoses (12); and (13). Fuel supply is adjusted to form flame setting according to the thickness of the pipe. The vertical movement is adjusted and arrested by the locking Screw-I (09) and locking screw-II (05) depending on the outside diameter of the pipe of 819 to 1016 mm.

[0037] Referring to Figure 7 showing the flow diagram for the prior art which takes more cycle time as the number of operations are more. The process involves the below steps:
- Work piece total length marking
- Inspection if not ok then following steps need to be followed:
- pilot hole drilling
- Work piece setting on ground floor
- Manual gas cutting
- First pass facing
- Second pass facing
- Third pass facing
- Fourth pass facing
- Fifth pass facing
- Edge preparation

[0038] Figure 8 shows the flow diagram of the new process of cutting operation with developed device which describes minimal number of operation in turn savings accounted are man hours, material, power and consumables.
[0039] The new process involves the following steps sequentially:
- Work piece total length marking
- Inspection
- If inspection is not ok then below steps need to be followed:
- Pilot hole drilling
- Work piece loading on roller stand
- Auto gas cutting
- Single pass facing
- Edge preparation.

[0040] Assembly of apparatus for fully automatic gas cutting of high thickness pipes of variant diameter by placing the work piece on the rollers nearer to the apparatus comprising the following steps:
- A fabricated frame having a vertical post (02) is connected with base plate (01), wherein the collar sleeve (03) is welded vertically with backup plate (04) to ensure vertical distance of ⁓1000 mm between the collar sleeve (03) and the base plate (01);
- A collar sleeve (03) can be moved on vertical post (02) to a required height by locking with locking screw-II (05);
- A rotatable collar sleeve (03) is inserted on the vertical post (02) having backup plate (04) on one side of the collar sleeve (03) which ensures swivel movement to rotate any angle that is locked by locking screw-II (05);
- A torch with vertical adjustment mechanism is connected to backup plate (04) which in turn is connected to the torch assembly (06), (07), (10), (11) for up and down of smaller vertical movement (08);
- Vertical adjustment of 100 mm can be done by moving the collar sleeve (03) on vertical post (02) and locked by locking screw- II (05).

ADVANTAGES OF INVENTION:
[0041] Pipe ends with smooth surface and good quality cut;
[0042] To reduce the cycle time;
[0043] To improve productivity of the link fabrication especially in pipe edge-preparation;
[0044] To avoid the crane usage for cutting;
[0045] Avoids manual gas cutting, by eliminating manual gas cutting the savings accounted are man hours, material, power and consumables.

WORKING OF INVENTION:
[0046] In this, the job is placed in between the motorized roller and guide roller. One of this is motorized for which speed can be controlled by means of speed regulator. Once the roller is switched on the job will rotate on the rollers. The auto gas cutting-torch is placed on the developed device. The device has arrangement for changing height and also can be moved right and left. It can be rotated along hinge. The torch is connected to oxygen and acetylene cylinders by means of special rubber hose. Once fuel supply is turned on, the flame mixture at cutting torch nozzle can be maintained by knob controls provided in the torch. The high temperature at flame tip starts melting the metal at end and slowly by moving the swivel head of torch, flame is progressed into metal. This avoids need for drilling a pilot hole for heavy thickness pipes. Along with this the motorized rotor is turned on for which speed can be maintained based on pipe thickness and cutting speed. As the flame progresses, the rotation of rotor brings new pipe surface under flame and thus no need for engaging cranes for cutting. The cut portion of pipe automatically gets separated from pipe due the rotation of job. Once cutting is completed, this scrap portion comes out in the form of ring and falls down on the scrap tray by gravity. Since the torch is fixed and flame strength is uniform, the end surface received is very smooth and cutting tolerance is reduced to 10 mm. For final edge preparation due to smooth surface and lesser excess stock, time taken is reduced, thus leading to increased productivity in cutting, edge-preparation and material saving.

[0047] 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.

[0048] 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.

[0049] 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 analogues 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”.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.
, Claims:WE CLAIM:

1. An apparatus for fully automatic gas cutting of high thickness pipes of variant diameter comprising of torch assembly (06,07,10,11) connected to oxygen and acetylene cylinder by oxy-acetylene special rubber hoses (12 and 13), wherein Fuel supply is adjusted to form flame setting according to the thickness of the pipe, in which the vertical movement is adjusted and arrested by the locking Screw-I (09) and locking screw-II (05) depending on the outside diameter of the pipe;
the adjustable torch assembly comprises a torch with vertical adjustment mechanism, which is connected to backup plate (04) which is in turn connected to the torch assembly (06,07,10,11) for up and down of vertical movement (08).

2. The apparatus as claimed in claim 1, wherein the outside diameter of the pipe is 819 to 1016 mm.

3. The apparatus as claimed in claim 1 or 2, wherein a Base plate (01) works as strong base and is handy to move to required place on floor.

4. The apparatus as claimed in claims 1-3, wherein a Vertical post (02) is welded at centre of the base plate (01).

5. The apparatus as claimed in claims 1-4, wherein a Collar sleeve (03), having internal thread on one side, over which backup plate (04) having a hole for torch assembly is welded vertically.

6. The apparatus as claimed in claims 1-5, wherein the locking screw II (05) is provided to lock the collar sleeve (03) over vertical post (02) at required height in accordance with job size.

7. A method of gas-cutting to obtain pipe ends with smooth surface and good quality cut comprising of following steps:
- Work piece total length marking
- Inspection
- If inspection is not ok, below steps need to be followed:
- Pilot hole drilling
- Work piece loading on roller stand
- Auto gas cutting
- Single pass facing
- Edge preparation.