Pressurized tankless boiler system and appartus

Abstract

The present invention is directed to a system and method for rapidly heating high volumes of fluids in a flow through process.

Description

[0001] PATENT APPLICATION of

[0002] Phoenix Heating Services Holdings, LLC for

[0003] PRESSURIZED TANKLESS BOILER

[0004] SYSTEM AND APPARTUS

[0005] TODD E. ZENGER

[0006] DUREN IP

[0007] 610 E. SOUTH TEMPLE STREET, SUITE 300

[0008] SALT LAKE CITY, UTAH 84102

[0009] TELEPHONE: (801) 869-8535 SUBSTITUTE SHEET RULE 26

[0010] BACKGROUND OF THE INVENTION

[0011] This application claims the benefit U.S. Provisional Patent Application Serial No. 63 / 638,767 filed April 25, 2024.

[0012] Field of the Invention

[0013] [0]0001 This application is directed to system and apparatus to superheat fluid to a high temperature, with a high flow rate, high pressure, and automated with minimal human intervention.

[0014] [0]0002 Hot fluid is needed in the oil field, train cars, city use and for many other purposes. It is needed for hydraulic fracturing jobs, cleaning pipes, well head maintenance, and many other common purposes. This system and apparatus may be portable and heats fluid hot enough to do most jobs with or without increased pressure. This system and apparatus permit uses of one or more separate subsystems to individually or collectively use heat, pressure, and variable fluid flow rates to solve many issue where fluids are used.

[0015] Background and Related Art

[0016] [0]0003 For example, currently in the oil field industry, there are many systems and apparatuses to heat fluids with or without using fluid tanks including hot oilers, super heaters, pump trucks and vacuum systems, each limited to the temperature the pumps can handle and the flow rate of the pumps and pipes contained in those machines. For example, fluid tanks can be slow and dangerous. They can have low and high flow rate systems. They can have high pressure and low-pressure systems. Each job requires a machine that is specific to what is needed for the particular job. Such systems and apparatuses may derive fluid direct from the native fluid source or from a holding tank to subsequently heat the fluid.

[0017] [0]0004 In FIG 1, FIG 2 and FIG 3 known heating and pumping systems are shown as used in contemporary settings. FIG. 1 shows a superheater used in hydraulic fracturing. The water is heated before entering a mixer that is then mixed with chemicals and sand. It creates a slick water that is sent down a well head to open stone below ground for the purpose of allowing more fluids and gases out of the well. An example of a super heater fluid systems is taught in U.S. Patent No. 9,103,561. FIG. 2 shows a hot oiler system for heating a well head for maintenance purposes. The hot oiler hooks up to the well head and typically sends hot water down to clean pipes or melt paraffin wax build ups. FIG. 3 shows a vacuum truck. Vacuum trucks draws or extracts material and moves it to a different location.

[0018] [0]0005 Generally, the higher the flow rate, the lower the effective heat transfer of the system or apparatus to the desired liquid. For example, if fluid is flowing in a given system or apparatus at less than 10 barrels (bbls) (420 gallons / 1587 liters) per minute, then that system or apparatus may increase temperature of the fluid as high as 275° F / 135° C. However, if the fluid flow in that same system or apparatus is 20 bbls (840 gallons / 3174 liters) per minute or more, typically the temperature of the liquid cannot be raised more than 20-50° F / l 1-30° C. [0]0006 The oil, trucking and railroad industry utilize various machinery for all different kinds of fluid needs. Within the fluid fields many tank systems are used to hold crude oil and other liquids that are commonly used in these industries. Unfortunately, the use of these tanks causes various issues. For example, when crude oil is stored in a tank without being properly heated, leftover sediment accumulates in the tanks and can plug up the tanks and connecting pipes, resulting in extra maintenance and even higher costs to fix or repair any issues caused by sediment. Additionally, the oil may need to be pressurized in many scenarios while in the tank to ensure proper use or transmission of the fluid. Also, when fluid is retained in a tank with a limited surface area, it takes an extremely long amount of time to properly heat the liquid while the fluid remains in the tank.

[0019] [0]0007 Furthermore, some have attempted to speed up the heating process by increasing the surface area containing a volume of fluid by decreasing for example, the pipe diameter though which the fluid is flowing. Although this method speeds up the amount of heat to the fluid, it can require decreased fluid flow rate, which in turn results in a longer time period for completing the process.

[0020] [0]0008 An objective of this present invention is to provide users with a boiler system and apparatus to help reduce sediment clog within piping and limit or decrease the amount of time needed to heat the liquid within the system or apparatus to the desired temperature. The present invention provide users with a system and apparatus which provide on-demand, rapid heating for high volume liquid pumped through the system or apparatus. [0]0009 To accomplish heating fluid in a shorter period of time, a preferred embodiment of the disclosed system and apparatus may comprise a fluid pump system, a power source / engine, a high-flow and high-heat boiler, an electrical system, hydraulic system, and / or a pneumatic system. The novel boiler system and apparatus causes the liquid within the system to be heated quickly as the fluid only passes through the system or apparatus providing for much higher temperatures at the output. Thus, this invention is a compact system and apparatus that provides on demand heating to heat liquids quickly and efficiently on site without leaving left over sediment that clogs the piping.

[0021] SUMMARY OF THE INVENTION

[0022] [0]00010 The boiler system and apparatus of the present invention may comprise a power source providing electrical and mechanical power for system components, hydraulic system to provide power to system components, a fluid system for moving, heating and pressurizing fluids, a pneumatic system for purging the system, apparatus and associated equipment and to provide pneumatic pressure for oiling devices, an electrical system to ignite burners in the boiler for heating fluids coursing through boiler and to provide auxiliary power for individual uses, a fluid pressurization units, and / or a fuel / gas system to provide combustible fuel to burners of the boiler for heat to be applied to the fluid.

[0023] [0]00011 A power source may comprise an engine capable of producing providing electrical and mechanical power for system component. The engine may comprise components to produce electrical power. The engine may comprise components with produce mechanical power such as a drive train and any associated power take off (PTO) or other associated gearing to drive hydraulic pumps.

[0024] [0]00012 A hydraulic system to provide drive force for hydraulic motors, pumps or valves.

[0025] [0]00013 A fluid system comprising a boiler apparatus comprising fluid lines or pipes for conducting, heating and pressurizing fluid in the system, including a plurality of manifolds for line or conduit cross-sectional reduction or enlargement to accommodate volumetric fluid flow ranging from 1 to 1250 gallons per minute (3.78 to 4,725 liters per minute).

[0026] [0]00014 A pneumatic system for providing compressed air for purging fluid lines, fluid tanks, pumps and other connected equipment, and air pressure for oiling associated devices of the system.

[0027] [0]00015 An electrical system to electrical spark to ignite gas burners in the boiler for heating fluids coursing fluid lines in the boiler and to provide auxiliary power for ancillary 12V or 24V power needs of the system. The electrical system may also comprise a generator providing up to 20KW of power and 110V and 240V outlets for electrical power access within the system.

[0028] [0]00016 A fluid pressurization unit such as Triplex pump to increase pressure in the fluid lines up to 6,500 psi (44,817 kPa) to increase fluid flow through the system.

[0029] [0]00017 A fuel / gas system to provide combustible fuel to the heat burners of the boiler apparatus for producing heat to be applied to the fluid lines in the boiler apparatus capable of heating to 500° F / 260° C.

[0030] [0]00018 A combination of these system components provides a novel system and apparatus providing higher volumetric flow rates of fluid through the boiler system and apparatus, higher temperatures in the boiler and more efficient heat transfer to the fluid passing through the fluid lines. [0]00019 These and other features and advantages of the present invention will be set forth or will become more fully apparent in the description that follows and in the appended claims. The features and advantages may be realized and obtained by the structures outlined and particularly pointed out in the appended claims. Furthermore, the features and advantages of the invention may be learned by the practice of the invention or will be guided from the description, as set forth hereinafter.

[0031] BRIEF DESCRIPTION OF THE DRAWINGS

[0032] [0]00020 In order that the manner in which the above recited and other features and advantages of the present invention are achieved, a more particular disclosure and description of the invention will be rendered by reference to exemplary embodiments illustrated in the accompany drawings. Understanding that the drawings depict only exemplary embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional clarity, specificity and detail through the use of the accompanying drawings in which:

[0033] [0]00021 Figure 1 illustrates a schematic of one embodiment of a hydraulic system consistent with the invention disclosed herein;

[0034] [0]00022 Figure 2 illustrates a schematic of one embodiment of an engine and hydraulic system consistent with the invention disclosed herein;

[0035] [0]00023 Figure 3 illustrates a schematic of one embodiment of a fluid line system consistent with the invention disclosed herein;

[0036] [0]00024 Figure 4 illustrates a schematic of one embodiment of a pneumatic system consistent with the invention disclosed herein;

[0037] [0]00025 Figure 5 illustrates a schematic of one embodiment of an electrical system consistent with the invention disclosed herein;

[0038] [0]00026 Figure 6 illustrates a schematic of one embodiment of fuel system consistent with the invention disclosed herein;

[0039] [0]00027 Figure 7 illustrates one embodiment of fuel handling system consistent with the invention disclosed herein; [0]00028 Figure 8 illustrates a perspective view of one embodiment of the boiler apparatus in which fluid is heated consistent with the invention disclosed herein;

[0040] [0]00029 Figure 9 illustrates one embodiment of a fluid manifold for reduction of fluid line size consistent with the invention disclosed herein;

[0041] [0]00030 Figure 9 A illustrates another embodiment of a fluid manifold for reduction of fluid line size consistent with the invention disclosed herein;

[0042] [0]00031 Figure 10 illustrates one embodiment of one layer of serpentine fluid line layout consistent with the invention disclosed herein;

[0043] [0]00032 Figure 11 A illustrates a partial detailed view of Figure 8 of the boiler apparatus in which fluid is heated consistent with the invention disclosed herein;

[0044] [0]00033 Figure 1 IB illustrates a partial detailed end view of Figure 11 A of the boiler apparatus in which fluid is heated consistent with the invention disclosed herein; and

[0045] [0]00034 Figure 12 illustrates another serpentine fluid line layout consistent with the invention disclosed herein.

[0046] DETAILED DESCRIPTION OF THE INVENTION

[0047] [0]00036 The following detailed description discloses concepts and implementations of the concepts as illustrative of the present invention system. The disclosed fluid boiler system and apparatus components are fully integrated and may be fully automated for mobile or stationary use.

[0048] [0]00037 For initializing use of the boiler system and apparatus an operator attaches a fluid resource input line to system inlet 302 or 304 (Fig. 3) and fluid discharge output fluid line to the system at field outlet 306 A, 306B or 306C (Fig. 3.). Battery packs in battery box 504 (Fig. 5) are activated and placed in electrical connection to gas burners (not shown) disposed under boiler apparatus 700 (Fig. 8). The system may be activated using a 12V and 24V components to power system control panels and other components as discussed herein. A control panel may controlled by an electronic or digital humanmachine-interface (HMI) to monitor and control system functions. The control panel may control system operations to meet the fluid treatment need. For example, an operator will input job specific operational parameters into the control panel to govern operations of the system to achieve the job objectives. For example, a number of input parameters specific to each job may be the type of fluid, the fluid line pressure desired, the boiler heat desired, the fluid flow-rate desired, and size of the input line connected to the system.

[0049] [0]00038 The system may allow two different size input hook-ups 302 and 304 and up to three different sized output hook-ups 306 A, 306B and 306C for fluid transfers (Fig. 3). Once the operator inputs input and output parameters, the system may initiate fluid flow into the system to fill the desired fluid lines with fluid before fluid treatment begins. Once filled with fluid, the system processes the fluid consistent with the control inputs parameters. The system treats flowing fluid until the system pauses the flow, shuts it off, an automatic error shutdown sequence is activated, or the operator terminates fluid processing.

[0050] HYDRAULIC SYSTEM

[0051] [0]00039 The system comprises a hydraulic system. A schematic of the hydraulic system 100 is depicted in Fig. 3. Hydraulic system 100 may comprise the reservoirs, hydraulic pumps, hydraulic motors, valves, valves operation, and pressure relief systems indicated by the hydraulic symbols shown in Fig. 100. In one embodiment, three hydraulic subsystems 102, 104 and 105 are depicted in Figs. 1 and 2.

[0052] [0]00040 In the embodiment shown in Figs. 1 and 2, three hydraulic systems are used. The first hydraulic system 104 is attached to an engine 202 PTO. Hydraulic pump 104 may activate when engine 202 starts running. Pump 104 provides power to fluid pressurization component such as a Triplex high-pressure fluid pump 204.

[0053] [0]00041 Hydraulic pump 106 may be an open loop arrangement. Hydraulic pump

[0054] 106 drives a hydraulic motor air compressor 206 to provide compressed air. Air compressor motor 206 is controlled with a valve 212 which is opened and closed on demand. Air compressor motor 2026 is defaulted to closed or off until a command for compressed air is given by the control system or by operator manipulation. Compressed air may be used for a number of purposes, including draining or purging fluid lines, other compressed air needs of the job or ancillary equipment, and to provide air pressure that will push oil into the gear boxes such as the gear box of a water pump.

[0055] [0]00042 Hydraulic pump 106 may comprise an open loop configuration. Hydraulic pump 106 drives the fluid flow pumps such as a first centrifugal fluid pump 208, and drives a hydraulic motor for a second centrifugal fluid pump 210. Fluid pumps 208 and 201 pump draw the desired fluid into the system and push the fluid through the system. First pump 208 may comprise a 6 inch (15.25 cm) centrifugal fluid pump. Second pump 210 may comprise a 2 inch (5.1 cm) centrifugal fluid pump.

[0056] [0]00043 Engine 202 may also drive a closed loop hydraulic pump 102 system. The driving force of engine 202 for hydraulic pump 102 may comprise a geared coupling.

[0057] Hydraulic pump 102 powers a hydraulic generator 218. Generator 218 provides electrical power as needed to the boiler system. Generator 218 may be controlled by a variable axial pump on the flywheel of engine 202. When the engine RPMs change, the hydraulic flow into the generator is modified to maintain the same hydraulic flow rate to generator 218 regardless of engine RPMs.

[0058] [0]00044 The hydraulic lines are controlled by flow regulators so regardless of how high the RPMs on engine 202 are, the engine RPMs never exceed the maximum allowed or desired per pump. Without flow regulators, fluid flow would fluctuate with the engine RPM’s either up or down; the flow rate of fluid in the system would be proportional to the RPMs of engine 202. Fluid System

[0059] [0]00045 One embodiment of the fluid flow through the boiler system and boiler apparatus is depicted in Fig. 3. The system may comprise two fluid inputs connected to corresponding fluid input lines first input 302 and second input 304. First fluid input 302 is provided to connect with larger fluid source input lines, typically 6” (15.25 cm) diameter. The connection may be a quick release hose connector. Fluid input line 308 is designed to be the same size, 6” (15.25 cm) diameter, as the fluid source input line.

[0060] [0]00046 Upon entry into the boiler system, the fluid passes through an automated valve 314 and, depending upon other valve positions, flows either through T 315 and bypass line 312 or through larger system line 316 maintaining the size of first input line 308. Bypass line 312 allows fluid to be transferred without heat or pressure to outputs 306A, 306B and / or 306C as directed by valves such as valve 318, shown in Fig. 3, whereby fluid flowing through bypass line 312 is not subject to pressure and heat.

[0061] Outputs 306A, 306B and / or 306C having differing outlet sizes. Otherwise, fluid courses through line 316 past valve 318 into the system for processing.

[0062] [0]00047 The system may then provide a line T 320 . On one side of T 320 is a compressed air input 322 controlled by valve 324 which is preferably automated, but may be manual. When the fluid passes T 320 it continues into the system to valve 325 used to control which direction compressed air will be pushed through the system for draining purposes. After passing through valve 326 the fluid passes through first 6 inch (15.25 cm) centrifugal pump 208, sometimes called a trash pump. Pump 208 allows large foreign objects in the fluid to pass through for transfer purposes. The fluid continues to automated valve 328 used to isolate line 316 when fluid is pushed through smaller system line 310. The fluid passes through one-way (check-valve) 330. After passing through check valve 300, the fluid encounters T 322 joining to smaller 2 inch (5.1 cm) line 310.

[0063] [0]00048 As shown in Fig. 3, the system provides alternative input 304, typically an industry 2 inch (5.1 cm) diameter input configuration. Fluid entering the system through input 304 passes through smaller line 310 to an automated valve 322. Valve 332 controls which input line is used to bring fluid into the system. Valve 332 also controls direction of drain or purge flow from the system. After passing through that valve 332, the fluid approaches T 334. T 334 direct fluid flow, dependent on other valve settings, into bypass line 336 or on into line 305 in the system. Bypass line 336 is also a drain line on the small line side and has an automated valve on both ends of it so that fluid in line 336 is not subject to pressure and heat. Bypass line 336 joins tees joins large line 316 at T 338 and also discharges at outputs 306 A, 306B and / or 306C.

[0064] [0]00049 If bypass mode via line 316 is not configured by valving, fluid flows past

[0065] T 334 continuing in system line 310 automated valve 340. Valve 340 controls direction of fluid and / or compressed air, discussed below. Flowing past valve 340 fluid approaches T 342. T 342 permits an automated valve 336 to permit compressed air input at 338. As fluid flows past T 342, the fluid approaches valve 344 used to prevent fluid from entering pump 210, if desired. Flowing through valve 344, the fluid is directed to 2 inch (5.1 cm) pump 210, also called a lobe pump. Pump 210 provides self-priming of line 310 and pumps a mass amount of fluid through small 2 inch (5.1 cm) line 310. After flowing through pump 210, fluid moves to valve 346 which when closed prevents fluid from backflowing through line 310 when fluid is passing through larger 6 inch (15.1 cm) diameter line 316. Otherwise, with valve 346 open, fluid flowing in line 310 passes through check valve 348 flowing on to T 332 and joins into larger 6 inch (15.1 cm) line 316 where all fluid flows in larger 6 inch (15.1 cm) line 316.

[0066] [0]00050 Past T 332, fluid flowing in continuing larger 6 inch (1.51 cm) line, the fluid passes through flow meter 350. Flow meter 350 measure volumetric flow. This measure of flow rate may be displayed on the HMI. After passing through flow meter 350, the fluid flows to T 352 where line 354 branches off from line 316 toward Triplex pump 204. Line 354 is smaller than line 316, reducing down to a one and one-half inch (3.8 cm) line in preparation for entering Triplex pump 204. Automated valves 356 and 368 control whether fluid moves through Triplex pump 204. Check valve 358 ensures one-way fluid flow through line 354 in the direction of arrow 359.

[0067] [0]00051 Triplex pump 204 is a variable pump which can pressurize the fluid system up to 6500 psi (44,817 kPa) to maintain or increase volumetric flow of fluid through the fluid system 300. At pump 204, fluid may bypass being heated in boiler 700 by continuing in line 354 through check valve 360 and automated valve 362 to rejoin 6 inch (15.1 cm) line 316 at T 374 and be directed by automated valve 376 and check valve 378 toward outlets 306A, 306B and 306C.

[0068] [0]00052 At Triplex pump 204, or after pump 204 at an alternative T (not shown), fluid may be directed through return line 364, check valve 366 and automated valve 358 to T 372 to rejoin 6 inch (15.1 cm) line 316 and flow in the direction of arrow 369 as controlled by automated valve 370 to push the fluid to boiler apparatus 700 for heating. [0]00053 In the alternative, if no additional fluid system pressure is needed from

[0069] Triplex pump 204 fluid flowing at T 352 pay be directed straight to check valve 353 and through automated valve 370 to boiler apparatus 700 for heating.

[0070] THE BOILER APPARATUS

[0071] [0]00054 The boiler comprises a series of manifolds and reduced stainless steel lines that allow the same volumetric flow rate through reduced line sizes , thereby maximizing the heated surface area of lines conducting the fluid. Depending on if the small inlet line 310 or large inlet line 316 is used may determine whether fluid enters boiler 700 at two locations or at one location only. The preferred embodiment is described below for entry into boiler 700 at one location receiving fluid pumped by 6 inch (15.1 cm) pump 208 through 6 inch (15.1 cm) line 316.

[0072] [0]00055 The boiler is the key to the system. The large fluid input line 316 may enter into boiler apparatus 700 from above apparatus 700 as it that handles fluid flow from large fluid pump 208. Boiler 700 reduces fluid lines multiple times. The first time line 316 reduces, it splits off from the front to the back making two heated sides.

[0073] [0]00056 An embodiment of this split is illustrated in Fig. 8 with a split or first reduction at 702 to sides 704A and 704B. The first reduction may comprise fluid lines 706A and 706B which are smaller in diameter than fluid line 316. For example, fluid line 706A and 70bB may be 4 inch (10.15 cm) diameter fluid lines for heating from two sides. In this embodiment, fluid then enters manifolds 706A and 706B filing from the bottom upward. [0]00057 The fluid line enters a manifold, a first manifold, that reduces it again to a very small size for the purpose of more surface area for heating per cubic inch of water.

[0074] This allows the system to super heat very rapidly. That is, each manifold has multiple lines attached to it, reducing it more. Each line 712 is disposed in a serpentine configuration and terminates at another manifold where the fluid is brought back together for discharge. Once in this manifold, fluid fills the manifold and leaves again in multiple lines. This process continues multiple times until the last manifold exits the boiler by joining the two lines back together.

[0075] [0]00058 That is, fluid comes in from either the large input or the small input and large input. Pipes and tubes are used to reduce lines. It splits to left / right sides with an even water flow on both sides (preventing a loss of flow). Those two lines are the exact same. Each side is reduced again to a much smaller tube size. The smaller size is ran multiple times out of the manifold. There are multiple serpentines before meeting back together in the next manifold.

[0076] [0]00059 An embodiment of this second multiple reductions is illustrated in Figs. 8, 11 and 11 A. Manifolds 708A and 708B are capped at the top and have further reducers 710B spaced vertically in manifold 708B, for example to about one half inch (about 1.25 cm) diameter openings and coupled to corresponding one half inch (1.25 cm) fluid lines 712B also spaced vertically. In the embodiment shown in Figs. 8, 10, 11 and 11 A there are nine (9) reducers 710B and reduced lines 712B. Each fluid line 712 is an inlet to a serpentine arrangement, Fig. 10. Reducers openings similar to reducers 71 OB are also vertically disposed in manifold 708A (not shown) and coupled to corresponding one half inch (1.25 cm) fluid lines 712A also spaced vertically. Each fluid line 712A is an inlet to a serpentine arrangement as illustrated in Fig. 10. Each serpentine of line 712A terminate at and the fluid is brought back together in and fills another manifold 704D, preferably a

[0077] 4 inch (10.15 cm), discharge line. Each serpentine of line 712B terminate at and the fluid is brought back together in and fills another part of manifold 704D. As shown in Fig. 11, nine layers of fluid lines 712A from side 704A are inter-layed with nine fluid lines 712B from side 704B to create a set of 18 serpentine one half inch (1.25 cm) line arrangements. In the preferred embodiment, five set of 18 serpentines are configured as depicted in Fig.

[0078] 8. Discharge manifold 704 D collects fluid from all five sets of fluid lines 712A and 712B.

[0079] [0]00060 Once brought back together multiple lines comprising in manifold 704D, fluid fills the manifold 704D and leaves again through its another multiple lines and fluid is conduct through corresponding fluid lines to another manifold 750.

[0080] [0]00061 The manifolds are split into a front / back system but also a top / bottom system. The top / bottom system stays a larger size but is still a reduced size from the manifold flow size. This allows the fluid to flow at full system flow and still be heated. The fluid is reunited from small to large again before leaving the boiler. No loss of flow is created.

[0081] [0]00062 The multiple lines out of the manifold are serpentined multiple times to get maximum surface area for heating before being manifolded back together. This process is continued multiple times linking all serpentine tubes and manifolds together, along with the overflow pipes. The large line (overflow pipe) is dropped to the bottom of the boiler and the same process is continued with serpentined lines before being brought back together into the last manifold before leaving the boiler.

[0082] [0]00063 On the reverse side of the manifold (708A AND 708b) is another reduction line. It takes all overflow out of the top the manifold.

[0083] [0]00064 A third reduction occurs in this overflow process as depicted in Figs. 8, 9, 9 A, 11, and 11 A. Manifolds 708A, 720A, 708B and 720B are capped. On the reverse side of the manifold, Fig. 9 is the third line reduction. Manifolds 708A and 708B have a reduction at 722 through which overflow fluid enters overflow fluid line 724 near the top of the capped manifold. Overflow fluid is pushed up line 724 and discharges in the vertically adjacent manifold 720, Fig. 9A. The process of filling another set of 18 one half inch (1.25 cm) lines proceeds. This process is repeated again with overflow being conduced upward through line 726 to the vertically adjacent manifold 720 (Fig. 9 A), and so on up through lines 728 and 730. Overflow is then discharged from the top manifolds 720 out lines 732A and 732B and in top to bottom flow to another larger serpentine arrangement (not shown) comprising a single layer serpentine arrangement below the five sets depicted in Fig. 8. The larger serpentine arrangement also discharges back into manifold 704D at 738. In this way, three line reductions significantly increase the surface are of the fluid lines heated by the burners of the boiler while retaining the desired volumetric flow. If increase fluid flow volume is desired, Triplex pump 204 can be activated to augment the volume of fluid flow.

[0084] [0]00065 All fluid is carried back to line 316 to be conducted toward outlets 306A, 306B and 306C. [0]00066 The boiler system is encased in 3 layers of insulation. Each layer is separated from the next layer by a sheet of steel. Two layers may be used on the sides. This allows the heat to be dispersed evenly for a cooler exterior layer. This system causes super heating of fluids from below freezing to above 350 degrees.

[0085] GAS SYSTEM AND BURNERS

[0086] [0]00067 As depicted in Figs. 6-7, a corresponding gas system 600 is set up for LP or NG. The present invention can use diesel if needed. The fuel is stored in a tank 60 and is conducted through input line 602. Input line 602 feeds two vaporizers, collectively 604. Those vaporizers feed six individual burner gas lines (two burner gas / fuel line connection points lines shown as 614 and 616) to six burners for heating the fluid lines in boiler 700. From vaporizers 604, the fuel goes to a regulator 606 coupled to burner gas / fuel line connections 614 and 616, and others not shown, drops the pressure from 250 psi ( about 1725 kPA) to 15-25 psi (about 103 to 172 kPa). Regulator 606 comprises conventional components such a ball valve 618 at input of vaporized gas / fuel, once regulator 620, low pressure sensor 622, flexible conduit 624, high pressure sensor 626, supplies wires, and another ball valve 630 at output vaporized gas / fuel to burner. Eventually gas system 600 drops the vaporized gas to water column inches (wci). The wci is set for each burner’s specifications.

[0087] [0]00068 The vaporized gas / fuel is conduct to burner sensors to ensure conformance to burner specification including high and a low-pressure requirements. When within the burner specification, the vaporized gas / fuel is transmitted to the burners (not shown) disposed in boiler 700 below the five vertical sets of serpentined one half inch (1.25 cm) fluid lines 712A and 712B in boiler apparatus 700. At the burners the vaporized gas / fuel is ignited by components of the electrical system. The burners of the boiler apparatus produce heat to be applied to the fluid lines in the boiler apparatus capable of heating up to 500° F / 260° .

[0088] [0]00069 The boiler system and apparatus has the capability to run on LP gas, natural gas, diesel or wet natural gas. The wet natural gas would require the removal of the vaporizers and the installation of a scrubbing system to dry the gas. The diesel option would require the removal of the vaporizers and a large diesel tank to be installed. The natural gas option would require the removal of the vaporizers and the installation of a drain port. Each option requires the burners to be configured with different orifices, and also would allow for a different engine to be used.

[0089] PNEUMATIC SYSTEM

[0090] [0]00070 The pneumatic system 400 is depicted schematically in Fig. 4.

[0091] Compressor 206 (Fig. 2) generates compressed air which is conducted to compressor tank 610 until compressor tank is pressurized to about 20 psi (about 138 kPa). Compressor 206 runs right when the engine runs. Once 410 tank is filled, compressed air is used to fill an oil tank with air pressure to push oil into the two-inch pump 210. Once that is done, the pneumatic system does not get used again until the pneumatic system 400 is used to ensure drainage or purging of boiler system 100. Once it drains, it runs in this process: [0]00071 While the system is in the draining to Output state, an operator user will direct drainage based on the inlet selection as follows.

[0092] [0]00072 As depicted if Figs. 2 and 3, when small inlet 304 / 310 is selected, valve 344 (FVA-2114) will CLOSE, air compressor will kick on, (the System will wait for valve 344 (FVA-2114) to CLOSE completely), it will then OPEN 336 (PVA-2091) and valves 332 (FVA-2111) and 340 (FVA-2112) for 1 minute to drain back to the source, any fluid left in the line. Then a user will CLOSE 332 (FVA-2111), and 340 (FVA-2112), (wait for valves to shut completely), then OPEN valves 344 (FVA-2114), 346 (FVA- 2115), 370 (FVA-2119), 376 (FVA-2301), and 380 (FVA-2261) to drain. Valves 314 (FVA-2041), 318 (FVA-2042), 326 (FVA-2044), 328 (FVA-2072), 356 (FVA-2142), 368 (FVA-2143), 362 (FVA-2282), 382 (FVA-2223), 384 (FVA-2222), 386 (FVA-2171), 388 (FVA-2202), and 324 (PVA-2021), will remain CLOSED. Once the system has drained for 2 minutes, if PUMP 204 was used, valves 356 (FVA-2142) and 368 (FVA-2143) will OPEN for the duration of the draining process while valve 370 (FVA-2119) closes.

[0093] [0]00073 When the Large Pipe System inlet is selected, valves 326 (FVA-2044) and 328 (FVA-2072) 5 will CLOSE, while a user turns on the air compressor, (the system will wait for valves 326 (FVA-2044) and 328 (FVA-2072) to CLOSE completely), then the system will OPEN valve 324 (PVA 2021) and valves 314 (FVA-2041) and 318 (FVA-2042) for 1 minute to drain back to the source, any fluids left in the line. Then a user will CLOSE 314 (FVA-2041) and 318 (FVA-2042), (wait for valve to shut completely), then OPEN 326 (FVA-2044), 328 (FVA-2072), 370 (FVA-2119), 376 (FVA-2301), and 380( FVA-2261) to drain. Valves 332 (FVA-2111), 340 (FVA-2112), 336 (PVA-2091), 344 (FVA-2114), 346 (FVA-2115), 356 (FVA-2142), 368 (FVA-2143), 384 (FVA-2222), 362 (FVA-2282), 386 (FVA-2171), and 388 (FVA-2202) will remain CLOSED. Once the system has drained for 2 minutes, if PUMP 204 was used, valves 356 (FVA-2142) and 368 (FVA-2143) will OPEN for the duration of the draining process while 370 (FVA-2119) closes.

[0094] [0]00074 While the System is in the Draining to Inlet state, a user will direct drainage based on the inlet selection.

[0095] [0]00075 For Small Pipe System inlet, a user will CLOSE valves 380 (FVA-2261) and 340 (FVA-2112), turn on air compressor, (wait for valves 380 (FVA-2261) and 340 (FVA-2112) to CLOSE completely), OPEN valves 336 (PVA-2091), 332 (FVA-2111), 344 (FVA-2114), 346 (FVA-2115), 370 (FVA-2119), 376 (FVA-2301), and 386 (FVA- 2171). Valves 314 (FVA-2041), 318 (FVA-2042), 324 (PVA-2021), 328 (FVA-2072), 356 (FVA-2142), 368 (FVA-2143), 362 (FVA-2282), 384 (FVA-2222), and 388 (FVA- 2202) will remain CLOSED. Once the system has drained for 2 minutes, if PUMP 204 was used, valves 356 (FVA-2142) and 368 (FVA-2143) will OPEN for the duration of the draining process while 370 (FVA-2119) closes.

[0096] [0]00076 For Large Pipe System inlet, a user will CLOSE 318 (FVA-2042) and 380 (FVA-2261), turn 25 on air compressor, (wait for valves 318 (FVA-2042) and 380 (FVA-2261) to CLOSE completely), OPEN 324 (PVA-2021), 314 (FVA-2041), 326 (FVA-2044), 328 (FVA-2072), 370 (FVA-2119), 376 (FVA-2301), and 388 (FVA- 2201). Valves 332 (FVA-2111) 340 (FVA-2112), 336 (PVA-2091), 344 (FVA-2114), 346 (FVA-2115), 356 (FVA-2142), 368 (FVA-2143), 362 (FVA-2282), 384 (FVA-2222), 386 (FVA-2171), and 380 (FVA-2261) will remain CLOSED. [0]00077 Once the system has drained for 2 minutes, if PUMP 204 was used, valves 356 (FVA-2142) and 368 (FVA-2143) will OPEN for the duration of the draining process while 370 (FVA-2119) closes. While draining the bypass line on the Triplex pump, each line will remain the same except 368 (FVA-2143) and 376 (FVA-2301) will close while 362 (FVA-2282) will open.

[0097] ELECTRICAL SYSTEM

[0098] [0]00078 The electrical system 500 is represented in Fig. 5. The present invention has three sources of electrical power. The first source is a 12V system 503. It is a dual battery pack that starts the engine 202. The 12V system is charged by the engine 202 running. This system also runs various components within the working area of the machine.

[0099] [0]00079 The second system is a 24V system 504. 24V system 504 is a dual battery pack that runs with a control panel 516. This system also runs various components within the working area of the machine as well as the HMI.

[0100] [0]00080 The third system is a generator system 218. It runs off of hydraulic power from pump 102 on engine 202. It provides 20KW of power and runs all electrical needs of the system components including igniters for the burners in boiler apparatus 700.

[0101] There are 240V and 110V outlets that run from a breaker box. The rest of the power is sent to a breaker box for the machinery that is hard wired to breakers to control the power for the system. SAFETY FEATURES

[0102] [0]00081 Safety on the system 100 is also important. There are numerous redundant features. The present invention has an automated control system. If that fails, it has individual control modules. If those don’t work, it has manual controls on each component. There are electrical pressure sensors on every line with manual gauges as well.

[0103] [0]00082 The gas system is vented out of the confined space. If any gas issues arise, there are four emergency shut off buttons (one on each side of the machine). There is no pressurizing or heating during transport so there is no concern of gas leaks or overheating with pressure while the machine is not being watched.

[0104] [0]00083 The system has internal controls to prevent over-pressurizing and overheating. A user can turn off the automated system and control it manually if needed. The state-of-the-art control system allows for different fluids to be heated or transferred without concern of heating a specific fluid over its ignition temperature.

[0105] [0]00084 The system 100 is cooled and vented in the working compartment and around the boiler.

[0106] [0]00085 The control system is all kept internally in its own control room, away from the working area. [0]00086 All line connections are kept away from operator work areas.

[0107] [0]00087 There is an explosion wall to prevent any fires or pressure blow outs from hitting the operator. The pressure relief 390 is safely away from any work areas also. The electrical system is set on breakers that will pop and can be reset when the issue is resolved. The pneumatic system has its own shut down system and if needed a relief valve (away from operators’ zones). The hydraulic system will shut down on any overheating and has its own cooling systems.

[0108] [0]00088 A prototype of the embodiment of the system shown herein was tested and verified all sections of the system worked as described. In the test, a 4,000-gallon truck was brought in and was connected to the prototype of system 100. The first part of the test was to transfer water in the system and then out. Then the line were blown empty by the pneumatic system 400. The prototype team then checked the self-priming pump as input into the Tri- Pl ex high-pressure pump 210 to pressurize the hot liquid system. Once the heated pipes were full and cold water was coming out of the output pipes, the six burners were turned on putting 13.8 million BTU heat into the boiler in a short period. The temperature rose to above 250 degrees and the adjustable high temperature switches cut off the burners one at a time and then back on to get the temperature down to 180-200 degrees Fahrenheit. Later with the burners off, cold water was run through the liquid system 400 to cool it for a while and then switched to compressed air to blow all water out of the system 400 and back up the hoses into the truck tanks. This complete test proved that the invention works as described. [0]00089 While preferred embodiments of the invention have been shown and described, modifications thereof may be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described herein are exemplary only and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

[0109] What is claimed is:

Claims

AMENDED CLAIMS received by the International Bureau on 26 August 2025 (26.08.2025)1. A fluid line configuration for a boiler apparatus, the fluid line configuration comprising:A single fluid input line;A first reduction in the fluid input line whereby the input line is divided into a first reduced fluid input line and a second reduced fluid input line, the first and second reduced lines being smaller than the single fluid input line;A first manifold coupled to the first reduced fluid input line, the first manifold defining a plurality of further reduced outlet openings smaller than the first reduced fluid input line;A second manifold coupled to the second reduced fluid input line, the second manifold defining a plurality of further reduced outlet openings smaller than the second reduced fluid input line;A fluid conduit coupled separately to a plurality of outlet openings of the first manifold, each fluid conduit coupled to the first manifold having a length shaped into a substantially planar and laterally coextensive serpentine configuration, the fluid serpentine shaped conduits disposed in a spaced relationship to each other in substantially parallel planes with defining a space between each serpentine configuration thereby forming a first layered set of reduced fluid conduits;A fluid conduit coupled separately to a plurality of outlet openings of the second manifold, each fluid conduit coupled to the second manifold having a length shaped into a substantially planar and laterally coextensive serpentine configuration, the fluid serpentine shaped conduits disposed in a spaced relationship to each other in substantially parallel planes defining a space between each serpentine configuration thereby forming a second layered set of reduced fluid conduits; and wherein the first layered set of reduced fluid conduits is disposed in the spaces between the layers of conduits in the second set.A boiler apparatus comprising:A fluid line configuration comprising a single fluid input line;A first reduction in the fluid input line whereby the input line is divided into a first reduced fluid input line and a second reduced fluid input line, the first and second reduced lines being smaller than the single fluid input line;A first manifold coupled to the first reduced fluid input line, the first manifold defining a plurality of further reduced outlet openings smaller than the first reduced fluid input line;A second manifold coupled to the second reduced fluid input line, the second manifold defining a plurality of further reduced outlet openings smaller than the second reduced fluid input line;A fluid conduit coupled separately to a plurality of outlet openings of the first manifold, each fluid conduit coupled to the first manifold having a length shaped into a substantially planar and laterally coextensive serpentine configuration, the fluid serpentine shaped conduits disposed in a spaced relationship to each other in substantially parallel planes with defining a space between each serpentine configuration thereby forming a first layered set of reduced fluid conduits;A fluid conduit coupled separately to a plurality of outlet openings of the second manifold, each fluid conduit coupled to the second manifold having a length shaped into a substantially planar and laterally coextensive serpentine configuration, the fluid serpentine shaped conduits disposed in a spaced relationship to each other in substantially parallel planes defining a space between each serpentine configuration thereby forming a second layered set of reduced fluid conduits;Wherein the first layered set of reduced fluid conduits is disposed in the spaces between the layers of conduits in the second set;The fluid line configuration coupled to a source of fluid;The fluid line configuration coupled to a pump system to draw fluid from the source of fluid and pump the fluid through the fluid line configuration;A heating system with burners disposed below the reduced fluid conduits capable of heating the reduced fluid conduits when fluid if pumped through the reduced fluid conduits.

3. The fluid line configuration of claim 2, wherein the layered conduits are displaced from each such that air can pass around each side of each conduct.

4. The fluid line configuration of claim 2 wherein the conduits are stainless steel.

5. The fluid line configuration of claim 2 wherein each conduit layer of conduit terminates without connection to an adjacent conduit layer.

6. The fluid line configuration of claim 2 wherein the reduced outlet openings of the first manifold comprise of set of at least one reduced outlet opening that is larger the other reduced outlet openings, the larger opening defining a third reduction.

7. The fluid line configuration of claim 6 further comprising a conduit coupled to the larger outlet opening and forming a supplemental serpentine configuration.

8. The boiler apparatus of claim 2 wherein the first and second manifolds are disposed vertically such that the plurality of reduced outlet opening are one above the other.

9. The boiler apparatus of claim 8 further comprising one or more manifolds disposed above the first and second manifold and wherein the vertically adjacent manifolds are in fluid communication with each other through the third reduction outlet openings.

10. A boiler system comprising:A boiler fluid line configuration comprising fifty or more layers of serpentine configured fluid conduits, each layer having a separate inlet and outlet;A plurality of stacked manifolds disposed vertically, each manifold providing reduced outlet openings as inlet couplings for less than all the layered fluid conduits;A fluid inlet line connected to the bottom manifold;A heating system to heat the fifty or more layers of serpentine configured fluid conduits;A fluid pumping system to pump fluid through the fluid inlet line; andA vertical fluid line connected between two vertically disposed manifolds establishing fluid communication between an upper portion of a lower manifold and an upper portion of an upper manifold.

11. The boiler system of claim 10 further comprising a pneumatic system, the pneumatic system comprising compress air lines coupled to the fluid conduits for purging the fluid lines when pumping is discontinued.[0001][0002]STATEMENT UNDER ARTICLE 19(1)[0003]The cited Corona ‘367 reference does not anticipate amended claim 10. The Corona ‘367 reference does not disclose or teach a plurality of vertically disposed, separate manifolds, but discloses and teaches only one inlet manifold 30. The Corona ‘367 reference does not disclose fluid communication between separate, vertically stacked manifold via a separate, vertical fluid line to distribute fluid upward to a higher, separate manifold. Amended Claim 10 is not anticipated by the Corona ‘367 reference.[0004]The Corona ‘367 reference does not render amended claim 10 obvious. The amendments to claim 10 include clarifying the plurality of vertically disposed, separate manifolds feeding multiplied layers of fluid conduit unlike the single inlet manifold 30 of the Corona ‘367 reference. Further, the amendments to claim 10 also clarify that a separate, vertical fluid line between vertically disposed, separate manifolds permits fluid flow up through the boiling systems many layers of fluid conduits, unlike the uni-manifold of the Corona ‘367 reference.[0005]The Corona ‘367 reference teaches away from adding many layers of fluid conduits to the height of the system. The Corona ‘367 reference seeks to reduce, not enlarge, the size of the boiler system. The Corona ‘367 reference technology seeks to reduce the size of the entire boiler device, including height. That is, the height direction of the secondary heat exchanger can be compressed and the entire boiler equipment is made smaller and compact. Amended Claim 10 is not obvious in light of the Corona ‘367 reference.

Images