Description:TECHNICAL FIELD
[0001] The present disclosure, in general, relates to an apparatus used in shot blasting process to remove a layer of deposits and impurities from the surface of metal and steel products. More particularly, the present disclosure relates to an apparatus used to hold the boiler fittings of different radius and diameter while shot blasting process.
BACKGROUND
[0002] 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.
[0003] The shot blasting is defined as a technological process of removing various impurities from different surfaces by using abrasive. It is used for a surface protection and also prior-preparation of surfaces prior to further processing, such as welding, colouring, etc. The present disclosure focusses on using the apparatus to hold the boiler fittings of different radius and diameter while shot blasting process. The present disclosure focusses on the boiler fittings that is safety valve nozzle.
[0004] The safety valve nozzle is an important boiler fitting that is used to release excess pressure in the boiler drum. It comes under different configuration Generally, six nozzles are used in typical drum that is used for 500MW electricity production and three nozzles are used in drum used for 270MW electricity production.
[0005] During the manufacturing of the safety valve nozzle, number of process are involved. The first step is to select the suitable raw material and kept inside a furnace for heat treatment process under the temperature of 900?.
[0006] After that, the resulted raw material is hot pressed to get the safety valve nozzle of require dimension. During the heat treatment and the hot pressing process the scale is formed on the surface of the safety valve nozzle. For descaling and chemical deposit removal the shot blasting operation is performed.
[0007] Generally, for shot blasting process on boiler fittings surface, the BMD SHOT BLASTING machine is used in press shop. In this process, boiler fitting are loaded on shot machine hanging hook manually with the help of floor car. Here, the weight of the job or boiler fitting is varying from 110 kg to 250 kg, so there is great chance of operator fatigue while job loading. There is also a chance of engagement of operator in risky material handling while loading process, because operator standing on the floor-car arm and he has to lift weight to 5 feet height from floor level. While doing this, there is huge chance that the operator may fall on shop floor, and results in major injury to the operator while loading process.
[0008] Mainly the problem arises due to the conventional system that involves the chain and the hook for job clamping purpose. In the conventional system, after the clamping of job at required level, the shot blasting process is started. After the completion of shot blasting process the job is unloaded by manually using the floor-car. Here the loading and unloading of the job involves more time, more operator fatigue and less safety to the operator and machine.
[0009] Moreover, in this chain clamping method at a time only one job is completed. It results in less productivity. In addition, the surface area of the job that is clamped by the chain is not properly shot blasted. Also, the slag formed at the bottom surface of the job is not fully cleared in this method. Furthermore, the slag formed in the inner surface is also not removed properly. This improper process results in more rework and poor quality of job surface finish. Also, this improper cleaning of slag formation suffer the setting rigidity while machining. To improve the quality of surface finish there is always a need of rework grinding on machined surface area.
[0010] Furthermore, the chain clamping method has less rigidity. While shot blasting process, there is great chance of fall of job on shot machine zone which results in major damage of machine parts. Moreover, in this process while cleaning of the job surface ,the shot ball spread over the shop floor that makes the condition unsafe to the employees at work spot.
[0011] In addition, different type of job need different cycle process, and the dust released during this process make the environment of the work spot polluted. Moreover, the improper shot blasting reduce the marking accuracy in the surface area of the job. Hence, there is always a need of an apparatus that is highly efficient while using in the shot blasting process.
OBJECTS OF THE DISCLOSURE
[0012] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0013] It is a general or primary object of the present disclosure is to propose the apparatus that reduce operator fatigue and ensure the safe work condition while job loading and unloading in shot blasting machine during shot blasting process.
[0014] It is an another object of the present disclosure is to reduce cycle time for safety valve nozzle setting and shot blasting process.
[0015] It is another object of the present disclosure is to increase the productivity of safety valve nozzle.
[0016] It is another object of the present disclosure is to minimize the use of crane and floor car while job loading and unloading.
[0017] It is another object of the present disclosure is to reduce the rework and improve shot blasting surface quality.
[0018] It is further object of the present disclosure is to eliminate air pollution while removing shot ball and shot dust accumulated at inside of the job.
[0019] Yet, another object of the present disclosure is to reduce cycle time for job holding and shot blasting process.
[0020] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.
SUMMARY
[0021] This summary is provided to introduce concepts related to an apparatus that facilitates an easy loading and unloading of the safety valve nozzle during shot blasting process. 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 is it intended to be used to limit the scope of the claimed subject matter.
[0022] In an embodiment the present disclosure provides an apparatus for holding the boiler fittings during shot blasting process comprising a bottom ring plate formed at the base of the apparatus; a vertical suspension rod welded on bottom ring plate, a upper lifting rod welded on top portion of the vertical suspension rod, a middle lifting rod welded on middle portion of the vertical suspension rod, a locking hole formed at the end of the vertical suspension rod, a plurality of inner rod welded on inner periphery of bottom ring plate, a plurality of outer rod welded on bottom supporting pad attached to an outer periphery of bottom ring plate, and a plurality of load balancing rod formed on the outer side of the bottom supporting pad .
[0023] In an aspect, the present disclosure provides the bottom ring plate that is circular in shape.
[0024] In an aspect, the present disclosure provides the inner rod welded on the inner periphery of the bottom ring plate that are eight in number.
[0025] In an aspect, the present disclosure provides the outer rod welded on the bottom supporting pad attached to the outer periphery of bottom ring plate.
[0026] 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 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 methods that are consistent with the subject matter as claimed herein, wherein:
[0028] Figure-1 illustrates the conventional system in which the shot ball is accumulated inside the boiler fittings during shot blasting process in accordance with the prior art.
[0029] Figure-2 shows the boiler fitting safety valve nozzle in accordance with the prior art.
[0030] Figure-3 shows the single chain sling used for lifting boiler fitting safety valve nozzle in accordance with the prior art.
[0031] Figure-4 shows the single chain sling alongwith the boiler fitting safety valve nozzle in shot blasting zone in accordance with the prior art.
[0032] Figure-5 shows the problem of accumulation of slag inside the boiler fitting safety valve in accordance with the prior art.
[0033] Figure-6 shows the apparatus used for material handling in accordance with the present disclosure.
[0034] Figure-6a shows the top view of new apparatus in accordance with the present disclosure.
[0035] Figure -6b shows the elevation view of new apparatus in accordance with the present disclosure.
[0036] Figure-7 shows the new apparatus carrying 8 number of boiler fitting in accordance with the present disclosure.
[0037] Figure-8 shows the new apparatus carrying 12 number of boiler fitting in accordance with the present disclosure.
DETAILED DESCRIPTION
[0038] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0039] 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.
[0040] As per the conventional apparatus, the user always has to problem in loading and unloading of safety valve nozzle in shot blasting machine during shot blasting process.
[0041] To overcome the issues related to the existing apparatus, the present disclosure herein provides an apparatus that facilitates easy loading and unloading of safety valve nozzle in shot blasting machine during shot blasting process.
[0042] Fig.1 shows the conventional system that involves the chain and the hook for job clamping purpose. In the conventional system, after the clamping of job at required level, the shot blasting process is started. After the completion of shot blasting process the job is unloaded by manually using the floor-car. Here the loading and unloading of the job involves more time, more operator fatigue and less safety to the operator and machine.
[0043] Moreover, in this chain clamping method at a time only one job is completed. It results in less productivity. In addition, the surface area of the job that is clamped by the chain is not properly shot blasted. Also, the slag formed at the bottom surface of the job is not fully cleared in this method. Furthermore, the slag formed in the inner surface is also not removed properly. This improper process results in more rework and poor quality of job surface finish. Also, this improper cleaning of slag formation suffer the setting rigidity while machining. To improve the quality of surface finish there is always a need of rework grinding on machined surface area.
[0044] Furthermore, the chain clamping method has less rigidity. While shot blasting process, there is great chance of fall of job on shot machine zone which results in major damage of machine parts. Moreover, in this process while cleaning of the job surface ,the shot ball spread over the shop floor that makes the condition unsafe to the employees at work spot.
[0045] In addition, different type of job need different cycle process, and the dust released during this process make the environment of the work spot polluted. Moreover, the improper shot blasting reduce the marking accuracy in the surface area of the job. Hence, there is always a need of an apparatus that is highly efficient while using in the shot blasting process.
[0046] Fig.2 illustrates the structure of the boiler fitting safety valve nozzle 10 in accordance with the prior art.
[0047] Fig.3 illustrates the structure of the single chain sling 11 which is used for lifting boiler fitting safety valve nozzle 10 in accordance with the prior art.
[0048] Fig.4 illustrates the single chain sling 11 along with the boiler fitting safety valve nozzle 10 in shot blasting zone in accordance with the prior art.
[0049] Fig.5 illustrates the problem of accumulation of slag inside the boiler fitting safety valve in accordance with the prior art.
[0050] Fig.6 illustrates the apparatus 12 used for boiler fitting safety valve nozzle 10 in shot blasting zone in accordance with the present disclosure.
[0051] Figure-5a illustrates the top view of new apparatus in accordance with the present disclosure.
[0052] Figure -5b illustrates the elevation view of new apparatus in accordance with the present disclosure. This apparatus 12 consist of vertical suspension rod 4 welded on bottom ring plate 7 shown in fig.5 (a). It has an upper lifting rod 1 that is welded on top portion of the vertical suspend rod 4 and a middle lifting rod 3 welded on middle portion of the vertical suspend rod 4, a locking hole 2 is designed at end of the vertical suspension rod 4. It further comprises eight Numbers of inner row load carrying rod 5 that are welded on bottom ring plate 7. In addition, it comprises four number of outer row load carrying rod 6 with bottom supporting pad 8 shown in fig. 5 (a) welded on outer peripheral of bottom ring plate 7. The four number of load balancing rod (9) shown in fig.5 (a) are provided on outer side of the bottom supporting pad 8. These load balancing rod (9) are used to balance the apparatus 12 while holding the safety valve nozzle 10. This fabricated apparatus 12 is placed on the shop floor near the shot blasting machine.
[0053] After the hot forming and the hot pressing of the safety valve nozzle, the eight numbers of hot forming completed safety valve nozzle 10 are vertically loaded to inner row load carrying rod 5 that are welded on the bottom ring plate 7 during the shot blasting process. Another four numbers of hot formed and hot pressed completed safety valve nozzle 10 are vertically loaded to outer row load carrying rod 6. Hence, the new apparatus12 carrying maximum 12 number of hot formed and hot pressed completed safety valve nozzle 10.
[0054] Here, the floor car carrying the apparatus 12 with safety valve nozzle 10 towards the shot blasting machine, where the sling is used to load the apparatus 12 having safety valve nozzle 10 on shot blasting machine through the locking arm 2.
[0055] This new apparatus avoid risky manual material handling and operator fatigue while loading and unloading of components. This apparatus helps in handling 12 number of safety valve nozzle at a time. After using this apparatus in shot blasting process, the shot balls are easily fall down in the shot blasting zone thus reducing the chances of accumulation of shot ball inside the job during shot blasting. It also eliminate the chances of frequent cleaning of the job. In this method we eliminate the chain clamping (11) while shot blasting. So, there is no chain impression mark on outer surface of the boiler fittings 10.
[0056] Moreover, after completion of shot blasting process, the apparatus 12 with jobs are easily unloaded from shot blasting machine by using floor car.
[0057] In addition, by using this apparatus (12) human activities are reduced (ergonomics) as the material handling is reduced. Furthermore, this single apparatus (12) helps in shot blasting of boiler fittings having varying shape and size.
[0058] Thus, with the apparatus described in the present disclosure, various technical problems of the state of the art are resolved. Also, although a number of exemplary method options are described herein, those skilled in the art can appreciate that the proposed locking structure helps in safe and easy retention of clip over the dog house, without deviating from the scope of the subject matter of the present disclosure.
[0059] Further, it will be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within its scope.
[0060] Furthermore, all examples recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention 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. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments.
[0061] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow.
[0062] The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

Claims:1. An apparatus (12) for holding the boiler fittings during shot blasting process comprising
a bottom ring plate (7) formed at the base of the apparatus;
a vertical suspension rod (4) welded on bottom ring plate (7);
a upper lifting rod (1) welded on top portion of the vertical suspension rod (4);
a middle lifting rod (3) welded on middle portion of the vertical suspension rod (4);
a locking hole (2) formed at the end of the vertical suspension rod (4);
a plurality of inner rod (5) welded on inner periphery of bottom ring plate (7);
a plurality of outer rod (6) welded on bottom supporting pad (8) attached to an outer periphery of bottom ring plate (7); and
a plurality of load balancing rod (9) formed on the outer side of the bottom supporting pad (8).
2. The apparatus (12) as claimed in claim 1, wherein the bottom ring plate (7) is circular in shape.
3. The apparatus (12) as claimed in claim 1, wherein the inner rod (5) welded on the inner periphery of the bottom ring plate (7) are eight in number.
4. The apparatus (12) as claimed in claim 1, wherein the outer rod (6) welded on the bottom supporting pad (8) attached to the outer periphery of bottom ring plate (7).