The present invention relates generally to fluid heating devices, sometimes commonly referred to as boilers or water heaters, and more particularly, to a fire tube heater assembly that maintains separation or segregation between hot combustion gas flows and the heated fluid flow while accommodating changes in the longitudinal length of the fire tubes during operation of the fire tube heater assembly associated with the thermal contraction and expansion of the fire tubes during operation the heater assembly.
Fire tube heater assemblies such as boilers and/or water heaters are commonly used for transferring heat from a hot fluid, such as a combustion gas or heating fluid, to a relatively cooler fluid or a heated fluid, such as water. Traditional heat exchangers, particularly fire tube heat exchangers, utilized a tube bundle made up of a plurality of tubes that each extend between a respective tube inlet end and respective tube outlet end. During operation of the heating device, the physical shape of these tubes changes in response to the thermal properties of the material that form the respective tubes as well as the operating parameters associated with utilization of the heating assembly. Generating the desired thermal exchange commonly requires a plurality of tubes and a spacing of the tubes that supports efficient thermal exchange associated with the flame or combustion gases and the surrounding fluid, such as water, that is to be heated.
The generally elongate shape of the plurality of tubes and the thermal exchange associated therewith, requires consideration as to the mounting of the alternate ends of the tubes and/or the construction of the tubes to accommodate elongation of the tubes in a manner that maintains a sealed interaction between the passages associated with the heating fluid flow, such as the combustion process, and the passages associated with the passage of the heated fluid flow through the assembly. Understandably, the combustion gas fluid flow and the heated fluid flow must remain isolated from one another throughout the heat exchange process. Significant temperature differences can exist between those parts of the heat exchanger which are in contact with the heating fluid and those parts which are in contact with cooler gases associated with the heating process and/or liquid associated with the heated fluid. It is further appreciated that significant temperature changes can occur throughout the heating process and or the respective or desired heating conditions and/or demands associated with use or operation of the fire tube heater assembly. These temperature differentials can result in thermal expansion and/or contraction of the fire tube heater tubes as well as temperature gradients between respective portions of the heating assembly and associated with the discrete portions of the heating and heated fluid flows associated therewith. These temperature differentials and gradients cause stresses in the joints between the various components and in the components themselves. If unaddressed or accommodated, these stresses can detract from efficient operation of the fire tube heater assembly and/or premature failure of the desired fluid operability of the fire tube heater assembly.
Fire tube heater assemblies generally include a housing that encloses a heated fluid path and a plurality of fire tubes which are contained within or otherwise pass through the housing. The fire tubes are supported and distributed in the volume of the housing to achieve an efficient thermal exchange between the heating fluid or combustion gas flow and the heated fluid material or flow that generally surrounds the plurality of fire tubes. The fire tubes are arranged in the housing to effectuate an efficient thermal exchange between the respective fluids and are supported in a manner that maintains fluid isolation between the respected heating and heated fluid flows. The fire tubes are commonly much hotter than the surrounding shell or housing of the fire tube heater assembly and can be subjected to various different operating temperatures as well as temperature deviations and rates of temperature change during operation of the fire tube assembly. That is, the various demands associated with operation of the fire tube heater assembly affect the relative temperature of the plurality of fire tubes. The relative temperature of so the fire tubes affects the longitudinal length of the discrete fire tubes. Said in another way, a longitudinal length of the fire tubes commonly changes during operation of the fire tube heater assembly due to thermal expansion and contraction of the fire tubes during operation of the fire tube heater assembly. Alternatively, if the fire tubes are so rigidly supported relative to the underlying fire tube heater assembly, the alternate ends of the discrete fire tubes can be subjected to undesirable stresses due to the heating and cooling cycles associated with operation of the fire tube heater assembly.
Recognizing such concerns, others have provided fire tube heater assemblies and/or heater exchanger arrangements wherein a plurality of tubes are constructed to accommodate changes to longitudinal lengths of the discrete tubes in response to the operating state of the underlying heating device. Such configurations commonly provide a slidable header arrangement, such as arrangements similar to those disclosed in U.S. Pat. No. 7,220,392 and U.S. Patent Application Publication No. 2014/0000845, wherein one end of a plurality of heating tubes are rigidly secured to a header arrangement and another end of the plurality of tubes are supported by a header arrangement that slideably cooperates with the underlying housing associated with the heater or heat exchanger assembly. Still others, such as U.S. Pat. No. 8,844,471, provided arrangements that include deformable tube assemblies that accommodate the longitudinal thermal expansion and contraction of the discrete tubes by accommodating lateral deflection of the discrete tubes during elongation and/or contraction of the discrete tubes. Each approach includes respective drawbacks.
First, providing a slidable but sealed connection between a header that supports a plurality of tubes and an underlying housing associated with the heater assembly complicates the construction of the housing and heater assembly and increases the potential for fluid failure of heating arrangement. That is, the repeated oscillation of the header relative to the housing increases the potential for the development of system leakage associated with the movable sealed interaction between the header assembly and the housing. Although the laterally deformable tube assemblies negate this consideration, such arrangements complicate manufacture of the discrete tubes and complicate the considerations associated with tube layout so as to accommodate the various lateral deflections associated with the plurality of tubes. Further, such arrangements are susceptible to detracted thermal efficiencies and greater thermal gradients associated with the thermal exchange between the discrete fluids due to the various positions of the tubes relative to one another and the surrounding fluid during the thermal expansion and contraction of the discrete tubes. That is, during different operating conditions and/or temperatures, portions of discrete tubes may achieve different relative orientations such that non-uniform spacing occurs between the discrete portions of discrete tubes thereby affecting the fluid exchange associated with the surrounding heated fluid. Further, such approaches can result in undesirable concentrations and directions associated with tube stresses during elongation and contraction of the discrete tubes.
Accordingly, there is a need for a fire tube heater assembly that accommodates thermal expansion and contraction of the plurality of fire tubes in a manner that maintains segregation between the discrete fluid flows and does not undesirably affect the thermal efficiently or create) undesirable thermal gradients associated with operation of the of result fire tube heater assembly.
The present invention discloses a fire tube heater assembly that overcomes one or more of the drawbacks discussed above. A fire tube heater assembly, sometimes referred to as boilers and/or water heaters, and method of accommodating elongation of the fire tubes associated with such heating devices are disclosed. The fire tube heater assembly includes a plurality of fire tubes that are configured and oriented to effectuate efficient thermal exchange between the heating fluid, commonly a gas combustion product, and the fluid being heated. At least one end of the plurality of tubes are supported by a tube support. The tube support includes a bellows or other deformable structure that accommodates changes in the longitudinal length associated with thermal expansion and contraction of the fire tubes during operation of the first tube heater assembly and in a manner that maintains segregation between the heating and heated fluid flows.
Another aspect of the invention that includes one or more features or aspects that are usable or combinable with the above aspect discloses a fire tube heater assembly having a housing and a plurality of tubes disposed in the housing. The assembly includes a tube support that is constructed to support at least two of the plurality of tubes and maintain a segregation between a combustion gas flow and a fluid disposed in the housing and effectuate thermal exchange therebetween. The tube support includes a bellows section that is constructed to accommodate changes in the length of the at least two of the plurality of tubes caused by thermal response to operation of the fire tube heater.
A further aspect of the invention that includes one or more features or aspects that are combinable with the features and aspects above discloses a method of accommodating elongation of fire tube heater tubes during operation of a fire tube heater. The method includes supporting a plurality of fire tubes with a tube support structure that is deformable to concurrently accommodate changes in a longitudinal length of more than one of fire tubes during operation of the fire tube assembly.
Another aspect of the invention that includes one or more features or aspects that are combinable with the features and aspects above discloses a boiler tube support assembly. The boiler tube support assembly includes a body that is configured to sealing cooperate with an end portion of a plurality of fire tubes. A bellows section extends in an outward direction that is aligned with a longitudinal axis of the plurality of fire tubes and is disposed between a first portion of the body and a second portion of the body. The first portion of the body is positionally secured relative to a housing disposed about the plurality of fire tubes and the second portion of the body is movable relative to the first portion of the body along the longitudinal axis in response to changes in temperature of the plurality of fire tubes.
These and other aspects, features, and advantages of the present invention will be made apparent for the following detailed description and the drawings.
The drawings illustrate preferred embodiments presently contemplated for carrying out the invention. In the drawings:
Fire tube heater assembly 10 includes a plurality of fire tubes or simply tubes 20, 22 that extend in a longitudinal direction, indicated by arrow 24, within the confines of housing 12. Fire tube heater assembly 10 includes a first or top tube sheet or upper tube support 28 and a second or bottom or lower tube support 30. Understandably, the terms top, bottom, upper, and lower are indicative of heater assemblies having generally vertical operating orientations but it is appreciated that the present invention is applicable to other heater configurations and that the functions associated with the same could be provided in alternate orientations.
Tube supports 28, 30 are disposed at generally opposite longitudinal ends of tubes 20 and/or tubes 22 and are constructed to provide a desired orientation of the plurality of tubes 20, 22 relative to the generally surrounding housing 12. A heated fluid cavity 34 is formed to generally encircle the surface areas associated with tubes 20, 22 to effectuate an efficient thermal exchange between tubes 20, 22 and the fluid, such as water, that surrounds them.
Although described hereafter as water and/or combustion gas fluid passages and/or portions thereof, it is appreciated that fire tube heater assembly 10 can be utilized to effectuate thermal exchanges between various fluid flows wherein it is desired to maintain fluid isolation between the respective fluid flows regardless of the composition or constituencies of the discrete fluid flows. For brevity, the fluid flow passage associated the combustion gas fluid path is hereafter referred to as heating fluid flow path and features whereas the fluid paths associated with the alternate fluid, whether provided as water or another fluid, are referred to as features of the heated fluid flow path and/or features. It should be appreciated that such monikers or nomenclature are utilized to designate the discrete features of fire tube heater assembly 10 associated with the direction of the thermal exchange between the respective fluid flows during operation of the fire tube heater assembly during demand or “ON” conditions. When utilized as a water heating appliance, fire tube heater assembly 10 includes a heated fluid inlet or water inlet 36 and a heated fluid outlet or water outlet 38 associated with the flow of the heated fluid through fire tube heater assembly 10. As should be appreciated, during a demand condition, the temperature associated with the fluid flow at heated fluid inlet 36 is less than the temperature associated with the fluid flow at heated fluid outlet 38 due to the thermal exchange associated with the thermal interaction of the water fluid flow being directed over and about tubes 20, 22 associated with the combustion gas flows.
During operation, heated combustion gases travel through tubes 20 in a generally downward direction, indicated by arrows 40, pass through lower tube support 30, are directed toward the plurality of radially outward oriented tubes 22, and exit fire tube heater assembly 10 at a vent pipe 46. Such a flow methodology is only one exemplary flow methodology associated with the present invention. Any condensate generated on the heating fluid side of fire tube heater assembly 10 during the thermal exchange with the heated fluid can be removed from the system via a condensate trap and/or drain 47 disposed in a lower portion of fire tube heater assembly 10.
During operation, such as during start up, shut down, and deviations associated with the load or demand upon fire tube heater assembly 10, the longitudinal length of one or more of tubes 20, 22 changes in response to the thermal exchange between the combustion gases associated with the internal volume defined by tubes 20, 22 and the flow of the heated fluid around the tubes 20, 22. That is, as the thermal output of the combustion process increases and/or decreases, the temperature of the input water increases and/or decreases, and/or the demand increases and/or decreases, the longitudinal lengths of tubes 20, 22 increases and decreases due to the thermal properties of tubes 20, 22 and in response to the deviations in the thermal operations of fire tube heater assembly 10.
Referring to
Although bellows 120 is disclosed below as accommodating changes to the longitudinal length of tubes 20, associated with the primary heat exchange with the heated fluid, it is appreciated that fire tube heater assembly 10 could be configured so that all of tubes 20, 22 were associated with the movable portion of lower tube support 30.
Bellows 120 is defined by a first portion 122 that extends in a generally downward and circumferential direction from first portion 102 of lower tube support 30. A second portion 124 of bellows 120 extends from a free or cantilevered end of first portion 122 of bellows 120 in a circumferential and longitudinal direction toward second portion 104 of lower tube support 30. An upper circumferential edge associated with second portion 124 of bellows 120 is sealingly secured to second portion 104 of lower tube support 30. Second portion 124 of bellows 120 has a generally serpentine cross-sectional shape whereas first portion 122 of bellows 120 has a generally planar tubular shape. The generally serpentine cross-sectional shape of first portion 122 of bellows 120 accommodates translation of second portion 104 of lower tube support 30 in a direction aligned with the longitudinal axis 24 of tubes 20, 22 relative to first portion 102 of lower tube support 30 during thermal expansion and contraction of tubes 20 during operation of fire tube heater assembly 10.
Said in another way and referring to
Lower tube support 30 includes a generally circumferential groove 130 that is formed between first portion 102 and second portion 104 of lower tube support 30 such that a volume 132 formed between first portion 122 and second portion 124 of bellows 120 can be occupied the heated fluid flow during operation of fire tube heater assembly 10 thereby maintaining a desired operating pressure associated with a pressurized side of fire tube heater assembly 10. A volume 140 that generally underlies second portion 104 of lower tube support 30 accommodates the passage of the combustion gases or heating fluid flow associated with the internal passages of tubes 20, supported by second portion 104 of lower tube support 30, between tubes 20, around baffle 120, and toward the radially outward oriented tubes 22.
Referring to
Regardless of the discrete orientations of tubes 20 relative to tubes 22, and vice versa, it should be appreciated from
The movable association of second portion 104 of lower tube support 30 relative to first portion 102 of lower tube support 30 accommodates changes to the longitudinal length of tubes 20 secured thereto in response to deviations associated with the operating load caused by the thermal expansion of the respective tubes 20 and/or 22. As should be appreciated, second portion 104 of lower tube plate 30 accommodates the elongation of a plurality of tubes 20 associated with operation of fire tube heater assembly 10. That is, rather than providing discrete tubes that are each individually tailored and constructed to accommodate the thermal elongation and/or contraction associated therewith, or providing a slidable association between discrete separate portions of housing 12, deformable lower tube support 30 facilitates a robust and secure tube mounting structure such that body 100 associated with lower tube support 30 accommodates deviations in the longitudinal length associated with the plurality of the respective tubes 20, 22 of fire tube heater assembly 10 caused by changes in the thermal loading associated therewith while maintaining of the desired fluid isolation between the combustion gas or heating fluid side or passages and the water or heated fluid side or passages associated with operation of fire tube heater assembly 10.
Referring to
Those skilled in the art will appreciate that other advantages and features can be realized from the operating parameters associated with fire tube heater assembly 10 which are only exemplary of specific implementations of the present invention. While certain embodiments of the invention have been illustrated and described for purposes of the present disclosure, changes in the arrangement and construction of parts may be made by those skilled in the art and such changes are encompassed within the scope and spirit of the present invention as defined by the appended claims. The present invention has been described in terms of the preferred embodiment, the embodiment disclosed herein is directed to the assembly as generally shown in the drawings. It is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, to the embodiments summarized, or the embodiment shown in the drawings, are possible and within the scope of the appending claims. The appending claims cover all such alternatives and equivalents.
This application claims priority to U.S. Provisional Patent Application No. 62/107,062 filed on Jan. 23, 2015 titled “Fire Tube Heater” and the disclosure of which is expressly incorporated herein.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2016/000082 | 1/25/2016 | WO | 00 |
Number | Date | Country | |
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62107062 | Jan 2015 | US |