AN APPARATUS TO HOLD AND ALIGN OF DISH TYPE END VESSEL WITH THE SEPARATOR OF THE HIGH-PRESSURE STEAM GENERATOR

FIELD OF INVENTION

[0001] The present disclosure, in general, relates to the design and development of a fixture to hold and align of dish type end vessel with the separator of the High-Pressure Steam Generator. More particularly, the present invention relates to the process of holding and aligning the dish type end vessel with the separator encounters so many difficulties. Design and Development of fixture to hold and align of dish type end vessel with the separator of High-Pressure Steam Generator have almost eradicated/minimized the difficulties encountered.
BACKGROUND OF 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] The boiler is a steam generator that is used to generate steam by applying heat energy to water. A steam separator, is a device for separating water droplets from steam. In separator dish type end vessel needs to be welded at its both the ends. Normally separator is made out of pipe of size 610 mm or 660 mm outer diameter and collector is fabricated from size 760 mm outer diameter pipe. Thickness of these pipes is 100 mm. Bottom dished end vessel is made from the pipe of outer diameter 710 mm to 760 mm. Material used for separator is SA 335 P 91 and nozzle is made out of SA182F22CL3. Its weight varies from 650 kg to 1350 kg.
[0004] The dish end vessel is to be welded with the separator vessel. First heavy hook is welded on the dish type vessel for lifting by crane after pre heating. To position the dish type end vessel with the separator pipe reference rods are welded inside the separator pipe. Then guide pieces are welded inside the hole in the separator. Then the dish end vessel is lifted by electric crane and aligned with separator axis. In the existing position i.e. by holding the dish end by crane, bridge pieces fit up between dish end and separator is completed by means of tack welding at number of places around its periphery. After fit up is completed the rods are removed. After the completion of the welding between dish end vessel and separator, places where hook and bridge pieces were welded are to be ground and MPI inspection is to be carried out. In total present procedure consists of 19 activities to complete the welding between dish type end vessel and separator pipe.
[0005] The difficulties encountered by the present method are:
? Bridge pieces and guide pieces welding required.
? Preheating before tack welding of these pieces are mandatory.
? More fatigue for crane operators, fitters, welders.
? More usage of manpower.
? Grinding for removal Bridge pieces and guide pieces after welding.
? Need for the MPI inspection.
? More cycle time.
? More power consumption.
[0006] Therefore, there is a need to develop an apparatus to hold and align of dish type end vessel with the separator of High-Pressure Steam Generator in a simplified way, to reduce the crane dependency, with reduced manpower, and to reduce cycle time in Toto. Hence, the present invention has been introduced.

OBJECTS OF THE INVENTION
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0008] It is a general or primary object of the present disclosure is to design and develop an apparatus to hold and align of dish type end vessel with the separator of High-Pressure Steam Generator pipes of the boiler to facilitate welding between them, which obviates short comings of the prior arts.
[0009] Another object of the invention is to avoid the dependency on the EOT crane and also to reduce cycle time.
[0010] Further object of the invention is to eradicate the welding of bridge pieces and guide plates inside and outside the components and to reduce the grinding action in removing them.
[0011] These and other objects and advantages of the present disclosure 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 disclosure is illustrated.
SUMMARY OF THE INVENTION
[0012] This summary is provided to introduce concepts related to an apparatus to hold and align of dish type end vessel with the separator of the high-pressure steam generator. 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.
[0013] According to this invention, it has been principally decided to develop the fixture to design and develop an apparatus to hold and align of dish type end vessel with the separator of High-Pressure Steam Generator pipes of the boiler to facilitate welding between them. The developed apparatus comprises of top slab, bottom and side slabs. Top slab has a hole for eye bolt. Top slab and bottom and side slabs has a hole for fixture and joining parts holding bolt and a hole for dish end holding bolt. Further, these Top slab and bottom and side slabs have fixture and joining parts holding bolt. These Top slab and bottom and side slab are also fitted with dish end holding bolt. Apparatus also has three Round Type Base Plate. It is also provided with dish end with nozzle locking bolt, dish end with nozzle holding base point and dish end with nozzle locking bolt holding nut. Drum is placed upon the adjustable roller stand. At one end of the drum, dish end with nozzle is fitted and at the other end, plain dish end is attached.
[0014] Holding and aligning of dish type end vessel with the separator of High-Pressure Steam Generator pipes of the boiler by the developed apparatus instead of the present cumbersome process results in following advantages:
? Processing time is decreased.
? Avoiding the bridge piece eliminates the preheating for bridge piece welding.
? Avoiding the bridge piece reduces the welding work.
? Operator fatigue is reduced.
? Grinding is eliminated.
? An increase in the number of fit-ups.
? Reduces the rework arising due to bridge piece tack welding on high alloy steel pipes.
? Reduces the cycle time and operator fatigue.
? Improves productivity and safety.
[0015] 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
[0016] 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:
[0017] Fig. 1a shows the isometric view of apparatus for Holding and aligning of dish type end vessel with the separator in accordance with an embodiment of the present disclosure;
[0018] Fig. 1b shows the view of apparatus for Holding and aligning of dish type end vessel with the separator and top slab, in accordance with an embodiment of the present disclosure;
[0019] Fig. 1c shows the isometric view of apparatus for Holding and aligning of dish type end vessel with the separator and, bottom slab and side slab in accordance with an embodiment of the present disclosure;
[0020] FIG. 2a shows the top of the developed fixture, in accordance with an embodiment of the present disclosure;
[0021] FIG. 2b shows the front view of the developed fixture, in accordance with an embodiment of the present disclosure;
[0022] FIG. 3a shows the left side view of the developed fixture, in accordance with an embodiment of the present disclosure;
[0023] FIG. 3b shows the right side view of the developed fixture, in accordance with an embodiment of the present disclosure;
[0024] FIG. 4a shows the south east isometric view of dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0025] FIG. 4b shows the front view of dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0026] FIG. 5a shows the south east isometric view of the dish end, in accordance with an embodiment of the present disclosure;
[0027] FIG. 5b shows the front view of the dish end, in accordance with an embodiment of the present disclosure;
[0028] FIG. 6a shows the top dished end with fixture south west isometric view of developed apparatus with plain dish end, in accordance with an embodiment of the present disclosure;
[0029] FIG. 6b shows the top dished end with fixture north east isometric view of developed apparatus with plain dish end, in accordance with an embodiment of the present disclosure;
[0030] FIG. 7a shows the bottom dished end with fixture south west isometric view of developed apparatus with dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0031] FIG. 7b shows the bottom dished end with fixture north east isometric views of developed apparatus with dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0032] FIG. 8a shows the top dished end with fixture front view of developed apparatus with plain dish end and dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0033] FIG. 8b shows the bottom dished end with fixture front view of developed apparatus with plain dish end and dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0034] FIG. 9a shows the pipe with roller stand south west isometric view of drum placed over the supporting rollers, in accordance with an embodiment of the present disclosure;
[0035] FIG. 9b shows the pipe with roller stand south east isometric view of drum placed over the supporting rollers, in accordance with an embodiment of the present disclosure;
[0036] FIG. 10a shows the bottom dished end fit-up south west isometric view of developed apparatus with dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0037] FIG. 10b shows the bottom dished end fit-up front of developed apparatus with dish end with nozzle, in accordance with an embodiment of the present disclosure;
[0038] FIG. 11a shows the top dished end fit-up south west isometric view of developed apparatus with dish end with nozzle and plain dish, in accordance with an embodiment of the present disclosure;
[0039] FIG. 11b shows the top dished end fit-up front view of developed apparatus with dish end with nozzle and plain dish, in accordance with an embodiment of the present disclosure;
[0040] FIG. 12a shows the top dished end and bottom dished end welded south west isometric view after the completion of welding with dish end with nozzle and plain dish, in accordance with an embodiment of the present disclosure; and
[0041] FIG. 12b shows the top dished end and bottom dished end welded front view after the completion of welding with dish end with nozzle and plain dish, in accordance with an embodiment of the present disclosure.
[0042] The figures depict embodiments of the present subject matter for illustration only. 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.

DETAIL DESCRIPTION OF INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS OF THE PREFERRED EMBODIMENTS
[0043] 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 con all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0044] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes
[0045] 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.
[0046] The present invention makes a disclosure regarding an invention pertaining to a fixture to hold and align of dish type end vessel with separator of the high-pressure steam generator.
[0047] The present apparatus comprises a top slab (1), a bottom and a side slabs (8). The top slab (1) and the bottom, and the side slabs (8) are connected to round type base plate (9) with the help of hole for fixture and joining parts holding bolt (4) and joining parts holding bolt (5). Apparatus is assembled as shown in figures from figure 1a to figure 12a. While using of apparatus, a drum (14) is joined at one end with a drum dish end with nozzle (15). The drum dish end with nozzle (15) is secured firmly with the help of the dish end with a nozzle locking bolt (10), dish end with a nozzle holding base point (11) and dish end with a nozzle locking bolt holding nut (12).
[0048] The top slab (1) has a hole (2) for an eye bolt (3). The top slab (1), the bottom and the side slabs (8) has a hole for fixture and the joining parts holding bolt (4) and a hole for dish end holding bolt (6). Further, the top slab (1) and bottom, and side slabs (8) has fixture and joining parts holding bolt (5). The top slab (1), bottom and the side slabs (8) is also fitted with a dish end holding bolt (7). Apparatus also has a three Round Type Base Plate (9). It is also provided with dish end with the nozzle locking bolt (10), dish end with the nozzle holding base point (11) and dish end with the nozzle locking bolt holding nut (12). The drum (14) is placed upon the adjustable roller stand (13). At one end of the drum dish end with the nozzle (15) is fitted and at the other end plain dish end (16) is attached.
[0049] The following are the steps of operation for the developed fixture:
[0050] The Drum (14) is placed upon the adjustable roller stand (13). The drum dish end with the nozzle (15) is inserted inside the developed fixture and tightened with the help of the dish end with the nozzle locking bolt (10) curved type holding a base point bolt (18). Nozzle part is secured by dish end with the nozzle locking bolt (10). Then it is lifted with the help of the eye bolt (3) and aligned with the drum (14) and a fit up welding (17) is carried out.
[0051] Similarly, a plain dish end (16) is put inside the developed fixture and held in its position firmly with the help of the curved type holding base point bolt (18) and the dish end holding bolt (7). Then it is lifted with the help of the eye bolt (3) and aligned with the drum (14) and the fit up welding (17) is carried out. The drum is held in its position with the help of the joining parts holding bolt (5) and the dish end holding bolt (7).
[0052] The developed fixture can be used for various sizes of drum and dish fit up. Dependency on crane is reduced considerably. Welder dependency during fit-up is eliminated. Bridge piece welding, cutting and grinding activities are eradicated in Toto. Preheating, post heating and MPI activities are no longer required when fit-up is accomplished with the help of the developed fixture.
[0053] Working of the invention:
[0054] The design and development of a fixture to hold and align of dish type end vessel with the separator of the High-Pressure Steam Generator. Presently the process of holding and aligning the dish type end vessel with the separator encounters so many difficulties. To position the dish type end vessel with the separator pipe reference rods are welded inside the separator pipe. Then guide pieces are welded inside the hole in the separator. Then the dish end vessel is lifted by electric crane and aligned with separator axis. In the existing position i.e. by holding the dish end by crane, bridge pieces fit up between dish end and separator is completed by means of tack welding at number of places around its periphery. After fit up is completed the rods are removed. After the completion of the welding between dish end vessel and separator, places where hook and bridge pieces were welded are to be ground and MPI inspection to be carried out. The developed fixture provides versatility and also by using the developed apparatus instead of the present cumbersome process eliminated the drawbacks said in the background with substantial saving in manpower and cost
[0055] TEST RESULT
[0056] Cycle time before the development of fixture:

ACTIVITIES TIME(Hours) CUM % CUM%
A RING WELDING 1 1 15 15
B SETTING TIME 1 2 15 30
C CRANE USAGE 1 3 15 45
D BRIDGE PIECE 1 4 15 60
E WET MPI 1 5 15 75
F GRINDING 1 6 15 90
G INSPECTION 0.5 6.5 10 100
TOTAL Hours 6 hour and 5 Minutes 100

[0057] Cycle time After the development of fixture:

ACTIVITIES TIME(Hours) CUM % CUM%
A SETTING TIME 0.30 1 30 30
B FIT-UP TIME 0.30 2 30 60
C INSPECTION 0.30 3 30 90
D FIXTURE REMOVING 0.10 4 10 100
TOTAL Hours 1 hour and 40 Minutes 100

Advantages

- Cycle time reduced from 6.5 hours to 1.4 hours for one nozzle fit up.
- Enables to accomplish accurate dimension and exact root gap.
- Facilitates fool proof fit up.
- Reduction in man power and better crane utilization.
- Eliminates the welding of lifting ring and bridge piece.
- Enhanced quality and better safety standards are obtained.
- Eliminates the process of wet MPI.
- Ensures simplified process and less fatigue to the workforce.

[0058] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.

We Claim:

1. An apparatus to hold and align of dish type end vessel with the separator of the High-Pressure Steam Generator, the apparatus comprising:
a top slab (1), a bottom slab and a side slabs (8) connected to a round base plate (9) with the help of a hole for fixture, a joining parts holding bolt (4), and a joining parts holding bolt (5); and
a drum (14) joined at one end with a drum dish end with nozzle (15), the drum dish end with nozzle (15) is secured with the help of the dish end with a nozzle locking bolt (10), a dish end with nozzle holding base point (11) and dish end with a nozzle locking bolt holding nut (12).

2. The apparatus as claimed in claim 1, wherein the top slab (1) has a hole (2) for an eye bolt (3).

3. The apparatus as claimed in claim 2, wherein the top slab (1), the bottom and the side slabs (8) has a hole for fixture, the joining parts holding bolt (4), and a hole for dish end holding bolt (6).

4. The apparatus as claimed in claim 3, wherein the top slab (1), the bottom slab, and the side slabs (8) has the fixture and the joining parts holding bolt (5).

5. The apparatus as claimed in claim 4, wherein the top slab (1), the bottom slab and the side slabs (8) is fitted with a dish end holding bolt (7).

6. The apparatus as claimed in claim 1, wherein a three round type base plate (9) is provided with the dish end with nozzle locking bolt (10), the dish end with nozzle holding base point (11) and the dish end with nozzle locking bolt holding nut (12).

7. The apparatus as claimed in claim 1, wherein the drum (14) is placed upon the adjustable roller stand (13).

8. The apparatus as claimed in claim 1, wherein at one end of the drum dish end with nozzle (15) is fitted and at the other end plain dish end (16) is attached.

9. A method for marking of location of carrier plate upon pipes used in boiler, the method comprising:
- placing the drum (14) upon the adjustable roller stand (13), wherein the drum dish end with the nozzle (15) is inserted inside a fixture and tightened with the help of the dish end with a nozzle locking bolt (10) curved type holding a base point bolt (18);
- securing a nozzle part by the dish end with the nozzle locking bolt (10), wherein the nozzle locking bolt (10) is lifted with the help of the eye bolt (3) and aligned with the drum (14) followed by fit up welding (17);
- providing a plain dish end (16) inside the fixture and held in its position with the help of the curved type holding base point bolt (18) and dish end holding bolt (7), wherein the plain dish end (16) is lifted with the help of the eye bolt (3) and aligned with the drum (14) followed by fit up welding (17).
10. The method as claimed in claim 9, wherein the drum is held in its position with the help of the joining parts holding bolt (5) and the dish end holding bolt (7).