The present invention relates to ceramic ferrules for use in connection with tube sheets of waste heat boilers in general, and specifically, to a two-piece ceramic ferrule assembly including a ferrule head and a ferrule stem that are mechanically mated to one another prevent axial and radial disassociation during use.
Waste heat boilers are commonly used for the recovery of thermal energy from process gas in industrial applications. Waste heat boilers typically include an array of metallic tubes that are secured on each end by comparatively thick plates that are referred to in the art as tubesheets. The tubesheets are surrounded by a shell to form a pressure vessel. Hot process gas is introduced to the waste heat boiler at one end, and flows down the inside diameters of the tubes. Boiler feed water is fed to the other side of the tubes within the pressure vessel. Heat is transferred by conduction through the tube walls from the hot process gas to the boiler feed water, thereby producing pressurized steam for use in other processes.
Since the tubesheet has a greater thickness than that of the the boiler tube wall, heat transfer is retarded in this region, and tubesheet temperatures at the inlet end can reach levels where certain modes of corrosion are problematic. Accordingly, it is often necessary to protect the front plate of the waste heat boiler and the inlet ends of the tubes from such high temperatures and/or highly corrosive atmospheres. This is commonly achieved using a combination of ceramic ferrules and castable refractory pieces.
One common ceramic ferrule design is a two-piece design including a ferrule head piece, which protects the front face of the waste heat boiler, and a ferrule stem piece, which protects the tube inlet. During assembly, the ferrule stem is inserted into and passes through the ferrule head, and a sealing gasket of refractory ceramic fiber sleeve fills the space between the head and stem to secure the connection through compression of the fiber. One of these ferrule assemblies is inserted into each tube in the waste heat boiler and secured in place by additional fiber provided around the ferrule stem outside diameter and between the boiler tube inside diameter.
As described above, a piece of compressed high temperature ceramic fiber is used to secure the connection between the ferrule head land the ferrule stem of the two-piece ferrule 10. However, when the ferrules 10 are used in service, the forces present can cause separation between the respective heads 1 and the stems 2, resulting in the failure of that ferrule 10 from its intended use. At the minimum, this requires refractory repair and replacement of the ferrules 10 causing production down time, which is costly not only in terms of manpower and parts, but in terms of process down-time and lost productivity. More likely, however, is the potential for catastrophic failure of the boiler and tube due to the thermal degradation and corrosion that results from the ferrules not being properly in place. This scenario is significantly more costly than mere refractory replacement.
One mode of failure of the above-described two-piece design occurs when the stem 2 disassociates from or “backs out” of the head 1, which can be caused by vibrations in the system or any kind of resultant back pressure, which is common during cleaning operations. Once the stem 2 is unseated from its properly assembled position, it is possible for the process gas to bypass the ferrule 10 by transitioning along the stem 2 outer diameter (OD), contacting the waste heat boiler tubesheet area and causing unacceptable heating and subsequent corrosion.
The object of the present invention is to provide a two-piece ceramic ferrule that is not susceptible to the above-described drawbacks associated with the prior art two-piece ferrule design. In view of the above, the present invention aims to provide a two-piece ferrule assembly including mechanical features on the ferrule head that work in conjunction with corresponding mechanical features on the ferrule stem to secure the two pieces of the ferrule assembly together in order to prevent the ferrule stem and head from disassociating during service due to vibrations or other external forces.
According to one embodiment of the present invention, a ceramic ferrule assembly is provided, comprising a ferrule head and a ferrule stem. The ferrule head comprises at least one tab protruding outwardly from an inner peripheral surface thereof, and the ferrule stem comprises an annular flange about an outer peripheral surface thereof and has at least one slot formed therein. The slot is adapted to receive the tab and retain the tab in a stationary position when the ferrule stem is rotated relative the ferrule head, whereby the at least one tab and the at least one slot mechanically engage one another to secure the ferrule stem and the ferrule head to one another and to prevent axial and radial disassociation form one another without otherwise providing specific counter rotation.
According to another aspect of the present invention, a ceramic ferrule assembly is provided, comprising a ferrule head having a hexagonal outer peripheral shape and extending from a first end to an opposed second end and defining a length thereof The ferrule head has a central bore extending from a hexagonal opening at the first end of the ferrule head to a circular opening at the second end of the ferrule head along the length thereof defining a longitudinal extension axis (central axis) thereof The central bore has an inner peripheral surface defined by a first section having a tapered hexagonal shape extending from the first hexagonal opening to an annular ridge, and a second section having a cylindrical shape extending from the annular ridge to the circular opening at the second end. At least one tab is provided, extending from a portion of the inner peripheral surface of the ferrule head. The ceramic ferrule assembly also includes a ferrule stem extending from a first end toward an opposed second end and defining a length thereof along a longitudinal extension axis (central axis) of the ferrule stem. A first radial flange is spaced a distance away from the second end of the stem along the longitudinal extension direction of the ferrule stem and has a slot formed therein. A second radial flange is located proximate and defining the second end of the ferrule stem. The at least one tab of the ferrule head resides in the slot in a rotatably engaged position, securing the ferrule stem to the ferrule head without adhesive or additional sealing means, and the second flange of the ferrule stem is seated on the annular ridge of the inner peripheral surface of the ferrule head.
Preferably, the outer diameter of the second flange of the ferrule stem is greater than an outer diameter of the first flange of the ferrule stem, and the outer diameter of the first flange is greater than an outer diameter of the ferrule stem.
According to one aspect, the opening of the at least one slot is parallel with respect to the longitudinal extension axis of the ferrule stem. According to another aspect, the opening of the at least one slot is helically-shaped. When the opening/slot is helically-shaped, it is preferred that the slot has an angle of 45° or less with respect to the longitudinal extension axis of the ferrule stem.
According to another aspect of the present invention, the at least one tab comprises two tabs diametrically opposed to one another on the inner peripheral surface of the ferrule head. In accordance with this embodiment, it is preferred that the at least one slot likewise comprises at least two slots diametrically opposed to one another on the first annular flange. According to one aspect of this embodiment, the openings of the two slots are parallel with respect to the longitudinal extension axis of the ferrule stem. According to another aspect of this embodiment, the two slots are helically-shaped.
The ceramic ferrule head and ferrule stem are preferably formed from ceramic materials including, but not limited to alumina, mullite and silicon carbide, for example. The slot and tab features can be integrally formed with the respective ferrule stem and ferrule head pieces when the respective pieces are initially formed by casting, molding or other suitable ceramic forming processes, such as extruding and machining Alternatively, the slots and tabs can both be subsequently formed by known ceramic machining processes.
For a better understanding of the nature and object of the present invention, reference should be made to the following detailed description of a preferred mode of practicing the invention, read in connection with the accompanying drawings, in which:
The outer diameter of the second flange 212 is greater than the outer diameter of the first flange 211, and the outer diameter of the first flange 211 is greater than the OD of the ferrule stem 200. Preferably, the outer diameter of the first flange 211 is 1.5 inches, the outer diameter of the second flange 212 is 1.3 inches and the OD of the ferrule stem 200 is 1.1 inches. It is also preferred that the first flange 211 is spaced a distance of 1.0 inch, more preferably 0.250 inches, from the second end 202 of the ferrule stem 200 in the longitudinal extension direction.
The annular flange 211 has a slot 220 formed therein with an opening portion that extends parallel to the longitudinal extension axis of the stem 200, and has a general L-shape according to one aspect of the present invention. That is, as shown in
The outer diameter of the second flange 212′ is greater than the outer diameter of the first flange 211′, and the outer diameter of the first flange 211′ is greater than the OD of the ferrule stem 210. Like with the embodiment described in connection with
The annular flange 211′ of the ferrule stem 201 has a slot 230 having a helically-shaped opening 231 (slot first part), rather than the axially parallel-oriented opening 221 (slot first part) shown in
Preferably, the angle of the helically-shaped opening (slot first part 231) of the slot 230 extends at an angle in a range of 25-35°, more preferably not more than 45° with respect to the longitudinal extension axis (central axis) of the ferrule stem 210. In connection with the above, the dimensions of the slot first part 231 (i.e., width and length) must at least matingly correspond to the dimensions of the tab T, so that the T is able to pass through the angled slot first part 231 of the helically-shaped slot 230 and then reside within the adjacent slot second part 232, in a similar manner as that described above in connection with the slot 220 shown in
The varied shape of the inner peripheral surface of the ferrule head 100 is provided for several reasons. One such reason is that having a hexagonal opening 111 at one end and a hexagonal inner peripheral surface 112 that transitions in a tapered manner toward the circular opening 114 decreases thermal stresses and provides an improvement in pressure loss as opposed to having a straight, open central bore construction along the length of the ferrule head 100. Another reason is that the inner annular ridge 122 provides not only a geometrical transition point between the tapered hexagonal section 112 and the cylindrical section 113 of the central bore 110, but also provides a seat surface for enabling at least some degree of axial retention of the ferrule stem 200 in the insertion direction (see, e.g.,
At least one locking member, such as tab T, is provided on a portion of the inner peripheral surface of the second section 113 of the ferrule head 100, preferably proximate the second end 102 thereof The preferred location for the tab(s) is in the lower section of the ferrule head 100 so as to engage the slot 220 on the first flange 211 of the ferrule stem 200, although if wall thickness restrictions dictate, it is possible to locate the tab(s) in the upper section of the ferrule head 100 to instead engage a similar slot that can likewise be provided in the second flange 212 of the ferrule stem 200.
As shown, the tab T extends from the cylindrical inner peripheral surface of the second section 113 of the central bore 110 of the ferrule head 100 inwardly, substantially perpendicular to the longitudinal extension axis of the ferrule head 100. The tab T on the inside of the ceramic ferrule head 100 may have any suitable shape that appropriately engages the appropriate slot in the stem 200, but is preferably round, trapezoidal, or square. In order to ensure adequate strength of the tab T, the aspect ratio of the minimum radial width (extending along the inside diameter of the ferrule head 100) to the height (outwardly projecting distance dimension) of the tab T should be at least 2:1.
The ferrule stem 100 is then rotated about its longitudinal extension axis (central axis), thereby directing the radially oriented tab T of the ferrule head 100 into the circumferential extension portion 222 of the slot 220 in the ferrule stem 200. Because of the interlocking mechanical relationship or interference between the tab T and the slot 220, the ferrule stem 200 cannot then be removed from the ferrule head 100 by a single force in the axial direction. That is, once tab T passes through the slot 220, the ferrule stem 200 is rotated into a position such that tab T cannot pass back through the slot 220 without purposefully performing a precise counter rotation.
The requirement for rotation, as well as axial extraction of the ferrule stem 200 to disassemble the ferrule assembly 500 significantly reduces the chances that the ferrule stem 200 might undesirably disassociate from the ferrule head 100 during operation. The ferrule stem 200 is preferably rotated about 0.25 inches or about 10°, depending on the precise dimensions of the slot 220 and tab T, so that the tab T resides in the correct position within the second portion 222 of the slot 220 (see, e.g.,
As shown in
Although no fiber wraps or gaskets are shown in the accompanying Figures, it should be readily understood that they may still included in the overall design, but were removed for simplicity of view and explanation. Such fiber wraps and gaskets are not needed in order to functionally secure the ferrule stem 200 and head 100 to one another, as in the prior art design, however.
While the present invention has been shown and described above with reference to specific examples, it should be understood by those skilled in the art that the present invention is in no way limited to these examples, and that variations and modifications can readily be made thereto without departing from the scope and spirit of the present invention.
Filing Document | Filing Date | Country | Kind |
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PCT/US15/30120 | 5/11/2015 | WO | 00 |
Number | Date | Country | |
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61993326 | May 2014 | US |