Description:AN APPARATUS FOR MOUNTING A PLUNGER

FIELD OF THE INVENTION
[0001] The present subject matter described herein relates to valve in a steam generator in a thermal power plant. More specifically, the present invention relates to an apparatus for mounting the plunger in valves during hydro testing in a steam generator in a thermal power plant.

BACKGROUND OF THE INVENTION
[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] Normally, high pressure casted valves i.e. QCNRV (Quick Closing Non-Return Valve), CRHNRV (Cold Re-Heater Non-Return Valve) and CRHIV (Cold Re-Heater Isolating Valve) valves are used for various systems in a steam generator and a steam turbine like a main steam line, a drip pump suction line, a recirculation line, a discharge line, a super heater outlet line and a main steam ERV isolation line in the thermal power plant.
[0004] The size of valve ranging from 3” to 38” depends upon the pipeline where these valves are used for high temperature and different pressure ratings (150,300,600,900,1500,2500 and 3500 Class rating) in various applications. Materials used for the valves are WCB grade material (carbon steel), WCC grade material (low alloy steel), C12A grade material (high alloy steel) and F92 grade material. Manufacturing of the valve consists of various steps i.e. raw material receiving, welding and heat treatment, shot blasting, valve components machining, valve assembly, inspection, actuator mounting, motor function testing, hydro testing, edge preparation, valve painting and final inspection.
[0005] Among the all processes, ‘Hydro testing’ is an important process where the customer witnesses the product in person. This test involves filling a testing fluid, which is commonly water. Then the pressure is applied over a specific period of time. The time and level of pressure varies depending on the factors including the valve material, valve size and category of pressure test.
[0006] Referring to Fig. 1, hydro testing of valve consists of the following steps. The hydro testing of valve assembly is usually conducted by both an inlet (04) and an outlet (05) closing method with a plunger (06) so that the plunger (06) is threaded externally and the inlet (04) and the outlet (05) of the valve body (01) are having internal threads. The hydro testing of valve starts with valve loading in a ‘V’ block (02) properly by an EOT (Electric Overhead Travelling) crane (07). Normally the valve weighs around 4 to 11 tons. Then the plunger (06) is selected by the factor of valve size and class rating.
[0007] The plunger (06) selected for the testing is thoroughly cleaned and ensured free from the thread damage and lubricant is employed to all threads for reduction of friction. The plunger (06) weighs around 1000kg each. A steel rope (03) is used to carry the plunger (06) by the EOT crane. The plunger (06) is supported by three or four persons to maintain the balancing. And the plunger (06) is engaged with the inlet (04) of valve body (01) which is around 1000mm diameter.
[0008] Particularly, engagement of starting thread with the valve body (01) is challenging. Here, if there is any damage in starting thread in the valve body (01) then the threads are to be reworked. Once the threads are engaged then a lengthy rod (08) is used to screwed the plunger (06) by deploying five to six persons.
[0009] Similarly, the outlet (05) of the valve body (01) is also closed by another plunger (06). Before testing following activities must be done, ensuring the calibration date of bench and pressure gauges, water level in the tank and checking the electrical connectivity are done properly by the operators.
[0010] Generally, there are three type of tests that are conducted for assembled valves, first one is a seat test which is tested in fully closed condition of the valve, second one is a backseat test which is tested in a fully opened condition (where ever applicable) and third one is a shell test which is tested in a partially opened condition. If any leakage observed during hydro testing of the valve, the assembled valve will be dismantled for rectifying the problems. After completion of testing, the plunger (06) is dismantled in same way.
[0011] In this method, the plunger mounting is hard, because the plunger (06) is heavy and can only be handled with a steel rope (03) which creates unbalancing in mounting. Then, the entry of thread is further challenging due to large size of the plunger (06). And more manpower is needed to perform the task. Sometimes, jamming in threads is also happenes. Further, assembling and dismantling of the plunger (06) is very hard. Many times, at the end of dismantling process, the plunger (06) is tends to fall down due to without support. These things led to customer dissatisfaction, are time consuming, create operator fatigue and are unsafe.
[0012] Thus there exists a need to provide solution for the above mentioned problem.

OBJECTS OF THE DISCLOSURE
[0013] It is therefore the object of the present disclosure to overcome the aforementioned and other drawbacks in prior arts.
[0014] It is another object of the present disclosure to provide a apparatus for mounting of a plunger in hydro testing.
[0015] It is a primary object of the present disclosure to reduce the cycle time and wastage of material in manufacturing of valves.
[0016] It is another object of the present disclosure to perform hydro testing of valves without strain.
[0017] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.

SUMMARY OF THE INVENTION
[0018] 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.
[0019] Solution to one or more drawbacks of existing technology and additional advantages are provided through 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 a part of the claimed disclosure.
[0020] The present disclosure offers a solution in the form of an apparatus for mounting a plunger in hydro testing of valves. The apparatus includes a plurality of channels extended vertically having a top side and a bottom side, wherein the top side of the plurality of channels is fitted with a square plate to mount a shaft and the bottom side of the plurality of channels is welded with a stepped flange, a hollow bush welded at the top of the square plate and supported with ‘L’ angles, a rectangle plate welded at the end of the shaft, wherein the rectangle plate is assembled on a hole with a bolt and a nut, an adjustable pipe comprising of a plunger holding unit is provided at one end and a stopper is provided at another end, wherein the plunger holding unit has a guide shaft inserted in a middle with a set of roller bearings and a flange connected to a plunger holding unit has holes to connect the apparatus with the plunger.
[0021] In an aspect of the invention, the adjustable shaft is inserted into a hollow bush.
[0022] In a further aspect of the invention, a nut is welded with the hollow bush at a top side and a bolt is screwed with the nut.
[0023] In an aspect of the invention, a step is provided at one end of the shaft and an another end is welded with the stopper.
[0024] In an aspect of the invention, the shaft has a counter step to assemble the lifting eye bolt unit.
[0025] In an aspect of the invention, multiple eye bolts ‘B’ are attached at the top of the square plate.
[0026] In an aspect of the invention, a lock bolt is provided in the stepped flange to lock the adjustable pipe.
[0027] In an aspect of the invention, a multitude of eye bolts ‘A’ are mounted for lifting the apparatus during assembling the plunger in a horizontal position.
[0028] In an embodiment of the invention, an interconnect header is used for connecting multiple pitot cylindrical pitot tubes including multiple average static pressure taps and multiple average total pressure taps.
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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
[0033] 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:-
[0034] 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 present disclosure may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0035] Fig. 1 illustrates sectional views of a valve assembly with a plunger in accordance to the prior art;
[0036] Fig. 2 illustrates an apparatus in accordance to the present invention;
[0037] Fig. 3 illustrates a sectional views of a modified plunger in accordance to the present invention;
[0038] Fig. 4 illustrates a side elevation view of assembly of the apparatus on the plunger in accordance to the present invention.
[0039] A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
[0040] 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 INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS OF THE PREFERRED EMBODIMENTS:
[0041] While the embodiments of the disclosure are subject to various modifications and alternative forms, a specific embodiment thereof has 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 alternatives falling within the scope of the disclosure.
[0042] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.
[0043] The present invention is related to an apparatus for mounting a plunger in a hydro testing of High Pressure Casted Valves, QCNRV, CRHNRV and CRHIV valves. The apparatus is supposed to maintain the center of gravity during the plunger mounting with the valve body. In the present disclosure, a method is used for plunger mounting in hydro testing that avoids the irrespective loads that are given manually.
[0044] Referring to Fig. 2and Fig. 4, a plurality of “C” channels (25a, 25b) are taken to construct a main frame which carries the whole load of the apparatus (200) and a top side of the channels (25a, 25b) is fitted with a square plate (18) to mount an adjustable shaft (13). The channels (25a, 25b) are extended vertically having a top side and a bottom side.
[0045] A plurality of support pieces (31a, 31b) are welded to connect the channels (25a, 25b) with the square plate (18N) for ensuring the additional strength. A bottom side of the channels (25a, 25b) is welded with a stepped flange (28). Then, a multitude of eye bolts ‘A’ (19) are mounted for lifting the apparatus (200) during assembling the plunger (06) in horizontal position.
[0046] A hollow bush (15) is welded at the top of the square plate (18) and the hollow bush (15) is supported with ‘L’ angles (11). The hollow bush (15) allows the adjustable shaft (13) to get inserted into the same. A step (32) is provided at one end of the adjustable shaft (13) and another end is welded with the end stopper (29) to limit the movement of the adjustable shaft (13).
[0047] The adjustable shaft (13) has a counter step (33) to assemble a lifting eye bolt unit (12) which is used only at the time of mounting of the plunger (06) so it is made heavy. A rectangle plate (10) is welded at the end of the adjustable shaft (13) where a step (32) is provided. The rectangle plate (10) has a plain hole assembled with a bolt and and a lock nut (17).
[0048] A nut (14) is welded with the hollow bush (15) at the top side then a bolt (16) is screwed with the nut (14). Now, the adjustment of the adjustable shaft (13) is achieved by rotation of bolt (16) so that the balancing of the plunger (06) is maintained while mounting the plunger (06). And this adjustment also helps to maintain the balancing of the plunger (06) in different size because each of the plunger (06) differs in weight. A multiple set of eye bolts ‘B’ (09) is attached at the top of the square plate (18). The purpose of the eye bolts ‘B’ (09) is for lifting the apparatus (200) during dismantling from the plunger (06) in a vertical position.
[0049] An adjustable pipe (26) comprises of a plunger holding unit (24) at the one end and a stopper (20) at another end. The plunger holding unit (24) have a guide shaft (22) in a middle and a set of roller bearings (21). A flange (23) in the plunger holding unit (24) has four plain holes. The hole are used to connect the apparatus (200) with the plunger (06). A guide shaft (22) ensures the concentricity of the apparatus (200). A lock bolt (27) is provided in the stepped flange (28) to lock the adjustable pipe (26).
[0050] Further, a modified plunger has multiple thread holes (30) and the purpose of the thread holes (30) is to connect the plunger (06) with the apparatus (200) as shown in fig.3.
TECHNICAL ADVANTAGES
[0051] With the help of the solution as proposed herein in the context of the present disclosure, the plunger mounting operation is performed in well and balanced manner.
[0052] With the help of the solution as proposed herein in the context of the present disclosure, dismantling the plunger is very easy.
[0053] Centre of gravity of the plunger with the apparatus is maintained in correct way during the plunger mounting thereby sudden load is avoided, thus avoiding thread damage
[0054] The man power is less required. Thus, it simplifies the lot of processes in hydro testing so that the resources are utilized in better way. Thereby, creating substantial savings in time and money.
[0055] 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 particular claim containing such introduced claim recitation to disclosures 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. Also, 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 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 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.”
[0056] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present disclosure contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the disclosure, and other dimensions or geometries are possible. Also, while a feature of the present disclosure may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present disclosure. The present disclosure also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
[0057] 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.
[0058] 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.
[0059] 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”.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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 (200) for mounting a plunger (06) in hydro testing of valves, the apparatus (200) comprising of:
a plurality of channels (25a, 25b) extend vertically having a top side and a bottom side, wherein the top side of the plurality of channels (25a, 25b) is fitted with a plate (18) to mount a shaft (13) and the bottom side of the plurality of channels (25a, 25b) is fixed to a stepped flange (28);
a hollow bush (15) fixed at the top of the plate (18) and supported with ‘L’ angles (11);
a plate (10) connected at the end of the shaft (13), wherein the plate (10) is assembled on a hole;
an adjustable pipe (26) comprising of a plunger holding unit (24) is provided at one end and a stopper (20) is provided at another end,
wherein the plunger holding unit (24) has a guide shaft (22) inserted therein with a set of roller bearings (21); and
a flange (23) connected to a plunger holding unit (24) has holes to connect the apparatus (200) with the plunger (06).

2. The apparatus (200) as claimed in claim 1, wherein the adjustable shaft (13) is inserted into a hollow bush (15).

3. The apparatus (200) as claimed in claims 1-2, wherein a nut (14) is welded with the hollow bush (15) at a top side and a bolt (16) is screwed with the nut (14).

4. The apparatus (200) as claimed in claims 1-3, wherein a step (32) is provided at one end of the shaft (13) and another end is welded with the end stopper (29).
5. The apparatus (200) as claimed in claims 1-4, wherein the shaft (13) has a counter step (33) to assemble the lifting eye bolt unit (12).

6. The apparatus (200) as claimed in claims 1-5, wherein multiple eye bolts ‘B’ (09) are attached at the top of the plate (18).

7. The apparatus (200) as claimed in claims 1-6, wherein a lock bolt (27) is provided in the stepped flange (28) to lock the adjustable pipe (26).

8. The apparatus (200) as claimed in claims 1-7, wherein a multitude of eye bolts ‘A’ (19) are mounted for lifting the apparatus (200) during assembling the plunger (06) in a horizontal position.

9. The apparatus (200) as claimed in claims 1-8, wherein the rectangle plate (10) is assembled on a hole with a bolt and a nut (17).