Integrated Collector Pipe Nipple Design for High-Pressure Steam Systems
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Solution Overview
Problem
Existing methods for connecting pipe nipples to collectors in high-pressure steam power plant apparatuses are labor-intensive and prone to incomplete welding and material deformation, particularly in large collectors with many pipes.
Innovation Solution
A one-piece pipe nipple is formed from the collector wall through machining, eliminating the need for alignment, welding, and annealing, and featuring a thicker wall thickness and concave collar for enhanced strength and reduced notch stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pipe nipples are connected to collectors by welding separate parts, then connection reliability can be achieved, but the manufacturing process becomes labor-intensive and time-consuming
Solution Approach 1:
The pipe nipple and collector wall are merged into a single integrated component formed from one piece of material. The pipe nipple protrudes directly from the collector wall as a continuous structure, eliminating the need for separate welding operations and achieving both high reliability and manufacturing efficiency.
2Ease of manufacture
If pipe nipples are formed by drawing or welding separate parts, then connections can be made, but material deformation and embrittlement occur
Solution Approach 1:
The manufacturing process parameters are changed from high-deformation methods (drawing, welding) to a low-deformation machining process. The pipe nipple is formed by machining a protrusion from the collector wall, which removes the harmful effects of material deformation and embrittlement while maintaining manufacturing feasibility.
3Ease of manufacture
If pipe nipples are made with uniform wall thickness, then manufacturing is simpler, but connection strength is insufficient
Solution Approach 1:
The pipe nipple features variable wall thickness with local quality optimization: thicker walls at the base where it connects to the collector wall for maximum strength, and thinner walls toward the tip where less structural support is needed. This achieves both strong connections and reasonable manufacturing complexity.
4Ease of manufacture
If sharp transitions are used in pipe nipple geometry, then manufacturing is easier, but notch stresses increase
Solution Approach 1:
The pipe nipple incorporates rounded transitions and curved geometries instead of sharp corners. The transition from the collector wall to the pipe nipple body features smooth curved surfaces that eliminate stress concentration points while remaining manufacturable through standard machining operations.
Data Source
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AI summary
The invention relates to a manifold (2, 3) for a high-pressure apparatus of steam power plants, wherein the manifold (2) has at least one pipe nipple (5) for welding on pipes (6) for feedwater, and the pipe nipple (5) projects outwards from the manifold wall (21). In the manifold (2, 3) according to the invention, the pipe nipple (5) is formed integrally with the manifold wall (21). This eliminates the need for a welded connection between the pipe nipple (5) as a first part and the wall (21) of the manifold as a second part, thus significantly reducing manufacturing costs for large manifolds (2, 3) with many pipe nipples (5).