UPPER PART OF VARIABLE DIAMETER FOR A FILTER ELEMENT

Abstract

A filter element is provided configured for mounting to tubeplate openings of different diameters. The filter element includes a sealing member that can accommodate tubeplate openings of different diameters. Methods for mounting a plurality of identical filter elements to tubeplates are described.

Description

UPPER PART OF VARIABLE DIAMETER FOR A FILTER ELEMENT Field of Invention The present invention relates in general to air filtration and particularly to air filter systems and filter elements for use in air filter systems. Background of the Invention There is a desire to capture airborne particles to reduce airborne pollutants and emissions from certain industrial sources, as well as to reduce the number of airborne particles present in the air used in downstream systems, such as power plants and material production facilities worldwide. One known technique for controlling and capturing particles or emissions is to separate the particulate matter carried in a gas stream using filtration media. Historically, the filtration media was a fabric, and fabric filtration was carried out in a filter system in the form of a dust collection apparatus known in industry as a baghouse filter. A baghouse filter typically includes a housing divided into two chambers by a tube sheet. One chamber is a dirty air chamber that communicates with an inlet and receives dirty or particle-laden gas from a source within the plant. The other chamber is a clean air chamber that receives clean gas after filtration and communicates with an outlet to direct clean gas away from the baghouse filter. A plurality of relatively long, cylindrical fabric filter elements, commonly known as bags, pleated filters, pleated bags, or cartridges, are suspended from the tube sheet in the dirty air chamber. Each filter element has a closed lower end and is typically mounted on a cage. Each filter element is attached to the tube sheet at its upper end and hangs vertically downward within the dirty air chamber.The upper end portion of the filter element was open, and the interior of each filter element was in fluid communication with the clean air chamber. However, airflow in the opposite direction was also possible. One problem with bag filters is that the opening through the tube sheet connecting the clean air chamber and the dirty air chamber can often vary from one bag filter to another. Because of this, maintaining a large number of bag filters can be difficult, as a large number of different mounting interfaces may be needed for the various openings. This can necessitate keeping a large number of different filter elements on hand, which presents logistical challenges. Furthermore, due to the large number of filter elements, manufacturing efficiencies and the number of individual filters produced are reduced, further increasing the cost of filter production. Modalities of the invention provide improvements over the art because they relate to replaceable filter elements or cartridges for manqas filter filtration systems. 4 / 10 BRIEF DESCRIPTION OF THE INVENTION In one aspect, the invention provides a filter element having a sealing member configured to be mounted to an opening in a tube sheet having a first diameter or to an opening in a tube sheet having a second diameter. This allows a plurality of filter elements having the same configuration to be manufactured for use in different applications. Methods are also provided for providing a plurality of identical filter elements and mounting one or more of the filter elements in a tube plate opening having a first diameter and mounting one or more of the filter elements in a tube plate opening having a second diameter different from the first diameter. Other aspects, objects, and advantages of the invention will become more evident from the following detailed description when considered together with the accompanying drawings. Brief Description of the Drawings The accompanying drawings, which are incorporated into and form part of this specification, illustrate various aspects of the present invention and, together with the description, serve to explain the principles of the invention. The drawings show: Figure 1 is a schematic illustration of a bag filter for use with filter elements in accordance with embodiments of the invention; Figure 2 is an isometric illustration of a filter element for use in the bag filter of Figure 1; Figure 3 is a cross-sectional illustration of the filter elements of Figure 2 illustrated mounted on tube sheets having openings of different diameters; Figure 4 is a side view of Figure 3; Figure 5 is an exploded view illustration of one type of filter element; Figure 6 is an isometric illustration of the filter element in Figure 5; Figure 7 is a cross-sectional illustration of the filter element of Figure 5 mounted on a tube sheet; Figure 8 is an isometric illustration of one modality of a filter element mounted on a tube sheet; Figure 9 is a cross-sectional illustration of Figure 8; Figure 10 is an exploded view illustration of one type of filter element; and Figure 11 is a cross-sectional illustration of the filter element in Figure 10. Although the invention will be described in relation to certain preferred embodiments, it is not intended to be limited to those embodiments. Rather, it is intended to cover all alternatives, modifications, and equivalents included within the spirit and scope of the invention as defined by the appended claims. DETAILED DESCRIPTION OF THE INVENTION Certain terminology used herein is for convenience only and should not be considered a limitation of the present invention. The terminology used herein is best understood with reference to the drawings, in which the ML / a / ZUZZ / Ul 4 / 10 Similar numbers are used to identify similar or like elements. In addition, in the drawings, certain features may be shown in a somewhat schematic way. A filter system in the form of a bag filter is illustrated in the figure. The bag filter 20 is defined by an enclosed housing 22. The housing 22 is made of a suitable material, such as a metal sheet. Particle-laden gas D flows into the bag filter 20 from an inlet 24. The particle-laden gas D is filtered by a plurality of relatively long filter elements or filter assemblies 26 constructed in accordance with an aspect of the invention located within the bag filter 20. Clean gas C exits through an outlet 28 of the bag filter 20. The bag filter 20 is divided into a dirty air chamber 40 and a clean air chamber 42 by means of a tube sheet 44 made of a suitable material, such as sheet metal. The tube sheet 44 has at least one portion that is substantially flat. The inlet 24 is in fluid communication with the dirty air chamber 40. The outlet 28 is in fluid communication with the clean air chamber 42. A plurality of openings 46 extend through the flat portion of the tube sheet 44. A filter element 26 is installed in a respective opening 46 and may optionally extend at least partially through the respective opening 46. The filter element 26 may be suspended by means of the tube sheet 44 or any support adjacent to the openings 46 in which the filter element 26 is to be installed. The clean air chamber 42 has a minimum clearance dimension or height, measured in a direction normal to the tube sheet 44, defining an access space. The dirty air chamber 40 has a height, measured in a direction normal to the tube sheet 44, in which a filter element 26 can be installed without touching the housing 22 of the bag filter 20. The height of the dirty air chamber 40 is typically greater than the height of the clean air chamber 42. The bag filter housing 20 includes sides 60 and a roof 62. The bag filter 20 is illustrated with a non-movable roof 62. Therefore, access to the clean air chamber 42 and the bag filter 20 is limited for the installation of the filter assemblies 26. It will be evident to someone with experience in the art that the roof 62 may have access panels that are removable to a position that does not impede access to the clean air chamber 42. The bag filter 20 also has an accumulation chamber defined by inclined walls 64 located at a lower end of the dirty air chamber 40. The filter assemblies 26 are illustrated without extending into the accumulation chamber, but it will be evident that the filter assemblies can extend into the accumulation chamber. Unfortunately, as stated above, the diameter Di of the opening 46 of one bag filter may be different from the diameter of another bag filter. Figures 2-4 illustrate one embodiment of a filter element 26 in more detail. The filter element 26 includes a sealing member 100 operably attached to a filter medium 102. The filter medium 102 may be a fabric bag, pleated material, or another type of filter medium known in the art. The sealing member 100 is operably attached to the filter medium 102 to prevent fluid bypass. With primary reference to Figure 3, the sealing member 100 is designed so that the filter element 26 can be mounted to tube sheets with openings of different diameters. In Figure 3, the openings 46A of tube sheet 44A have a diameter D3 that is larger than the diameter D4 of the openings 46B of tube sheet 44B. However, the sealing member 100 is configured so that it can provide a sealing seal with either opening 46A having a diameter D3 or opening 46B having a diameter D4. Although it is illustrated in Figures 3 and 4 as mounted to two separate tube sheets 44A and 44B, this is merely for illustrative purposes to demonstrate the ability to mount it to different tube sheets with varying opening diameters. The filter element 26 would typically be mounted to a single tube sheet. The sealing member 100 includes a sealing arrangement configured to cooperate with openings 46A and 46B of different diameters. The sealing arrangement in this embodiment consists of a plurality of grooves 106, 108, 110, and 112, each with a different diameter defined by a radially outward-facing surface that forms the bottom of the grooves 106, 108, 110, and 112. Each groove 106, 108, 110, and 112 is configured to match the filter element 26 with openings 46 of different diameters. With reference to slot 110, each slot has a bottom region 120 that is axially bounded by axially oriented wall portions 122, 124 formed by radially extending projections. The axially oriented wall portions 122, 124 are used to axially position the filter element 26 within the opening 46 of the tubesheet. The wall portions 122, 124 preferably engage the tubesheet on both the clean and dirty sides to hold the filter element 26 in place. The bottom portion 120 and / or one or more wall portions 122, 124 may provide a seal between 4 / 10 the sealing member 100 and the tube sheet 44 to prevent fluid deflection. Preferably, the inner diameter of the openings 46 presses radially inward and compresses the sealing member 100 to form a radial seal between the sealing member 100 and the tube sheet 44. The filter element 26 will typically be installed by inserting it through the opening 46 from the clean side 42 illustrated by arrows 130 in Figures 1 and 3. As such, one axial side of the projection includes a tapered region that facilitates the insertion of the filter element 26 into the opening 46. The sealing member 100 can be molded onto, bonded to, or otherwise secured to the filter medium 102. The sealing member could be formed from a flexible elastomeric material, a nonwoven textile material, or a combination of rigid and flexible materials. In one embodiment, the sealing member 100 could be formed from a urethane, such as foamed urethane. Additionally, a reinforcing member can be provided to support the sealing member 100 and improve its sealing bond with the tube sheet 46. For example, an annular reinforcing member could be pressed radially inward onto an internal surface 132 of the sealing member (e.g., a snap-fit ​​ring or expander). Furthermore, a reinforcing ring could be integrated into the sealing member 100. Furthermore, a seal member could have one or more seals attached to a rigid structure such as a plastic support structure to which one or more flexible seals are mounted. Figures 5-7 illustrate an additional modality of a filter element 226 configured to couple with tube plate openings having different diameters. In this modality, the seal member 300 is a multi-component seal member 300 operationally and sealingly secured to the filter medium 302. In this embodiment, the sealing member 300 includes a packing 304 that is supported by a flange member 306. The sealing member 300 also includes an axially mounting clamping member 308. The packing 304 is configured to provide at least an axial seal over a clean-side surface 45 of the tubesheet 44. The clamping member 308 presses axially against a dirty-side surface 47 of the tubesheet 44. The packing 304 includes a main body 310 and a radially extending flange portion 312 that defines an axially oriented sealing surface 314 which cooperates with the tubesheet surface 45 to effect a seal between them. The sealing surface 314 is formed on an axially extending projection 316 that extends from a flange portion 312. In this embodiment, the main body 310 is generally tubular and extends through the opening 46 when the filter element 226 is mounted to the tubesheet 44. The radial dimension R1 of the 312 flange portion allows it to accommodate openings 46 in tube plates 44 that have different internal diameters. Ideally, R1 is at least 1 / 4 inch, more preferably 1 / 2 inch, and in some cases, it may be greater than 3 / 4 inch. The 304 gasket may be made of a compressible elastomeric material or a nonwoven textile material. The external diameter of the 312 flange portion is such that it can cover multiple openings 46 that have different internal diameters. The 306 flange member provides axial support for the 312 flange portion. The 306 flange member can also help secure the 302 filter media to the 304 packing. The flange member includes a 320 main body, which is generally tubular and internal to the 310 main body of the 304 packing. The 310 and 320 main bodies form an annular cavity between them in which the 302 filter media can extend to provide a sealing engagement between the 300 seal member and the 302 filter media. The main body 320 may include a groove 322 in which a portion of the filter medium 310 and / or a portion of the packing 304 (main body 310) may be radially compressed to form a mechanical connection between the packing 304 and the flange member 306 to axially secure the two components to each other. A radially extending support flange portion 324 extends radially outward from the main body 320 and provides axial support to the flange portion 312. In the illustrated embodiment, an axially extending flange 326 extends from the flange portion 324. The annular flange 326 is positioned radially outward from the flange portion 312. Preferably, the flange member 306 is formed from a rigid material to support the gasket 304 and provide durability. The clamping member 308 includes a main ring 340 and a plurality of axially extending fasteners 342. The clamping member 308 is used to axially secure the filter element 226 onto a dirty side 47 of the tube sheet 44. The fasteners 342 include radially tapered sections used to guide the filter element 226 when it is inserted into the opening 46. A distal end of the fasteners 342 has a radially inward step. This stepped region 346 includes a radially inwardly extending stop 348 and an axially extending point 350. Although not illustrated, the stop 348 may preferably make contact with a dirty side 47 of the tubesheet, while the point 350 extends axially into the opening 46 of the tubesheet 44. The points 350 will press radially outward on the internal diameter of the opening 46 and radially position the filter element 226 into the opening 46, while the stop 348 axially positions the filter element. The clamping member 308 can be mechanically, adhesively, or otherwise attached to the rest of the filter element to prevent axial movement of the clamping member 308. In some embodiments, the clamping member can radially or axially secure the filter element 226 to the tube plate 44. In addition, the clamps 342 can be driven into place by inserting the filter element 226 into the opening or by rotating the filter. The 342 fasteners are radially elastic in such a way that the 342 fasteners can be located in openings 46 that have different diameters. Although the 304 packing includes a 310 main body, some embodiments may use only a packing (e.g., the 312 structure) axially pressed between the 308 flange member and the 44 tube plate. The 308 flange member could be a reusable component. Figures 8-9 illustrate an additional modality of a 426 filter element configured to seal with openings that have different dimensions. Seal member 500 is similar to seal member 100 discussed previously. Seal member 500 includes grooves 506 and 508, which have different external radial dimensions to accommodate different orifice diameters. Grooves 506 and 508 are formed between radially extending projections that radially capture the tube sheet 44 between sidewall portions 512 and 514. Again, the projections may be tapered to aid in inserting / removing the filter element 426. In this embodiment, the 100 seal member is expandable and is made of a flexible elastomeric material or a combination of rigid and elastomeric materials. An expander 528 is used to expand the outside diameter of the various grooves to accommodate different opening diameters. When different grooves 506 and 508 are provided, a wider variety of openings can be accommodated, with each groove being able to be manipulated within a predetermined amount of deformation. Once significantly more deformation is required, the next larger groove size can be used. In one embodiment, the expander 528 could be configured to provide sufficient offset for both the large slot 506 and the smaller slot 508. In other embodiments, multiple expanders could be provided, for example one for each of the different sized slots. The expander 528 presses radially outward on the radially inner surface of the sealing member 500 to displace the outer periphery of the sealing member 500 radially within the inner diameter of the opening 46. The expander may be in the form of a press-fit ring. In some embodiments, the expander may be integrated into the sealing member. The expander may be mechanically adjustable, such as with screws. The expander may include radially offset steps, with one step located near each groove. Additionally, a tapered expander may be provided, and the inner surface of the sealing member 500 may be similarly tapered. Once again, ideally a radial seal is provided between the 500 seal member. However, other portions of the 500 seal member may seal with the tube sheet. Figures 10 and 11 illustrate an additional embodiment of a filter element 626 that includes a sealing member 700 configured to mate with tube plate openings having different diameters. The filter element 626 includes a sealing member 700 that operates similarly to the sealing members 100 and 500 discussed above. This sealing member 700 seals the filter medium 702 to the tube sheet 44 and includes grooves 706, 708 that cooperate with openings of different diameters. In this configuration, the upper member 710 supports the sealing member 700. The upper member 710 is made from a polymer resin and woven or non-woven textile. The woven or non-woven textile in the upper member 710 may be integrated into the filter medium 702. The upper member 710 has one end of the filter medium 702 integrated into the polymer resin. The upper member 710 includes a main body 712 and a pair of radially extending flanges 714, 716 forming a groove between them. In this embodiment, the sealing member 700 is located within the groove. The flange 716 may be tapered to facilitate mounting the filter element 626 as well as mounting the sealing member 700 to the upper member 710. In some embodiments, the sealing member 700 may be molded directly onto the upper member 710. Additionally, the sealing member 700 may be formed separately and then joined to the upper member 710. An adhesive may be provided between the sealing member 700 and the upper member 710. 4 / 10 upper limb 710. Polymer resin can be a flexible elastomeric material or it can be rigid. Although this embodiment includes a 700 seal member that includes grooves similar to the 100 and 500 seal members, other embodiments could include a seal member similar to the 300 seal member that includes the radially extending flange 312 that provides an axial seal with the tube sheet. By providing filter elements with a configuration that can be mounted and otherwise sealed with openings of different sizes, only a single filter element needs to be produced to replace several openings of varying sizes. This single-element configuration can be used to replace multiple different-sized configurations. Accordingly, methods are provided for supplying multiple identical filter elements and mounting one or more of the filter elements in a first opening of a certain diameter and mounting another filter element in a second opening of a different diameter. All references, including publications, patent applications, and patents cited herein are incorporated by reference to the same extent as if individually and specifically indicated as being incorporated by reference and as if presented herein in their entirety. The use of the terms "a" and "an" and similar references in the context of describing the invention (especially in the context of the following claims) shall be deemed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. The terms "comprises," "has," "includes," and "contains" shall be deemed to be open terms (i.e., meaning "includes" but not limited to) unless otherwise indicated. Mention herein of ranges of values ​​is intended merely as a shorthand method for referring individually to each separate value lying within the range, unless otherwise indicated herein, and each separate value is incorporated in the specification as if mentioned herein individually.All methods described herein may be performed in any suitable order unless otherwise stated herein or otherwise clearly contradicted by the context. The use of any and all examples, or example language (e.g., such as) provided herein is merely for the purpose of clarifying the invention and does not impose a limitation on the scope of the invention unless otherwise claimed. None. 4 / 10 Language in the specification should be considered as indicative that any unclaimed element is essential to the practice of the invention. Preferred embodiments of the present invention are described herein, including the best means known to the inventors for carrying out the invention. Variations of these preferred embodiments may be apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect that skilled technicians will employ such variations as appropriate, and the inventors expect that the invention will be practiced in a manner different from that specifically described herein. Accordingly, the present invention includes all modifications and equivalents of the object cited in the appended claims to the extent permitted by applicable law. Furthermore, any combination of the aforementioned elements in all their possible variations is contemplated by the invention unless otherwise stated herein or otherwise clearly contradicted by the context.

Claims

1. A filter element configured for use with tube plate openings having different diameters, the filter element characterized in that it comprises: filter media; a multi-component sealing member operatively coupled to the filter media, the sealing member being configured to seal a first tube plate opening having a first diameter and to seal a second tube plate opening having a second diameter different from the first diameter; the multi-component sealing member including a gasket offset radially outward from the filter media, the gasket providing an axial sealing surface; a fastening member having a plurality of angularly spaced fasteners, each fastener including: a tapered section extending radially outward, extending axially toward the gasket, and terminating in a stepped distal end,the stepped distal end including an inwardly extending radial stop extending inward from the tapered section and an axially extending tip which extends axially from a radially internal portion of the tapered section radially from the inwardly extending stop, the inwardly extending radial stop being axially separated from the axial sealing surface of the joint forming a gap between them such that, when installed, the tubesheet is positioned between the axial sealing surface of the joint and the inwardly extending radial stop with the joint pressing against a first side of the tubesheet and the inwardly extending radial stop pressing against a second opposite side of the tubesheet,the plurality of fasteners being radially elastic such that the axially extending tip can be inserted into the first and second openings of the tube plate.

2. The filter element of claim 1, further characterized in that the outer diameter of the gasket is greater than the first and second diameters.

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