Tube Stub Removal Using Induction Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for removing tube stubs from structures like boilers and heat exchangers often damage the tube sheet and require multiple operators or devices, leading to increased downtime and breakage risks.
Innovation Solution
A tube pulling apparatus comprising an induction heating coil attached to an inner ram, a concentric outer ram, and a sheath, which heats the tube stub to soften it and then elongates it for easy removal by a single operator without damaging the tube sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical force or deformation is used to remove tube stubs, then tube stubs can be removed from the tube sheet, but the tube sheet is damaged and holes are enlarged
Solution Approach 1:
The patent applies thermal energy to change the physical state of the tube stub material, heating it to softening temperature to enable easier removal without mechanical damage to the tube sheet. This parameter change (temperature) allows the tube stub to be removed while preserving the integrity of the tube sheet holes.
2Reliability
If multiple devices or operators are used for tube stub removal, then complete removal can be achieved, but downtime and breakage risk increase
Solution Approach 1:
The patent combines heating function and pulling function into a single integrated device. The heating element and pulling mechanism are merged into one apparatus that can be operated by a single technician, eliminating the need for multiple devices or operators and reducing downtime while ensuring complete tube stub removal.
Solution Approach 2:
The removal device performs multiple functions: heating the tube stub to softening temperature, applying pulling force, and supporting the tube sheet. This multi-functional design replaces what would traditionally require multiple specialized tools and operators, reducing both downtime and breakage risk.
3Productivity
If traditional mechanical methods are used, then tube stubs can be removed, but the process requires multiple operators and increases costs
Solution Approach 1:
The patent integrates heating and pulling operations into a single device that can be controlled by one operator. The heating element, pulling mechanism, and support structure are combined into one apparatus, eliminating the need for multiple operators and reducing operational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and efficient removal of tube stubs by a single technician, reducing the risk of damage to the tube sheet and minimizing downtime, while allowing for the use of a single operator to handle the process.
Implementation Method 1
an induction heating coil attached to an inner ram
Data Source
AI summary
An improved apparatus and method of removing tubes and/or tube stubs from structures comprising multiple tubes wherein induction heating is utilized to heat the tube stub prior to removal.