GB2572073A

GB2572073A - Low loss header

Info

Publication number: GB2572073A
Application number: GB1903355.4A
Authority: GB
Inventors: Caton Christopher
Original assignee: Ideal Boilers Ltd
Current assignee: Ideal Boilers Ltd
Priority date: 2018-03-14
Filing date: 2019-03-12
Publication date: 2019-09-18
Anticipated expiration: 2039-03-12
Also published as: GB201804081D0; GB201903355D0; GB2572073B

Abstract

A low loss header (LLH) having a magnetic component 2, 3 to attract magnetic deposits thereon. The magnetic component may be arranged within the LLH. The magnetic component may comprise a magnetic element and a non-magnetic element. The magnetic element may be a magnetic rod 2 and the nonmagnetic element may be a stainless steel tube 3, the rod being arranged in the tube. The magnetic rod may be arranged parallel to a long axis of the low loss header. One end of the magnetic component may comprise a stand 14 to prevent the magnetic component from becoming dislodged. The LLH may be located in a cascade boiler system or in a heating system which may comprise the cascade boiler system. A method of removing deposits from a cascade boiler system or a heating system comprises removing the magnetic component from the LLH, cleaning deposits off the magnetic component, and replacing the magnetic component in the LLH. Alternatively, the deposits may be removed by removing the magnetic rod from the tube, thereby allowing the deposits to sink to the bottom of the LLH, and then opening a drain valve 10 to drain the contents of the LLH.

Description

The present invention relates to a low loss header, and to systems and methods relating thereto.

More specifically, the present invention relates to a low loss header for use in a cascade boiler system, and to systems and methods relating thereto.

Cascade boiler systems, which include several boilers connected together, have advantages over single boiler systems. For example, by spreading the heating load over several boilers, cascade boiler systems can offer a greater heating load than single boiler systems. Furthermore, cascade boiler systems are often fitted with step or sequence controls, which can switch each boiler on or off in accordance with the heating load demand. Thus cascade boiler systems can be more cost and energy efficient than single boiler.

Cascade boiler systems often include a low loss header (LLH), which functions to protect the boilers from changes in the flow rate of water in the systems. In boiler systems absent of a LLH, various actions, e.g. closure of thermostatic radiator valves (TRVs), can cause an increase in the flow rate of water through the boilers, which can damage them. A LLH protects the boilers by providing hydraulic separation between the primary circuit having the boilers and the secondary circuit having the heating load. This allows the system to operate at an approximately constant flow rate of water though the primary circuit.

A LLH can also be useful for the collection of deposits, such as sludge, from the heating system. These deposits generally occur as a by-product of the chemical reaction between metal elements (e.g. that are corroded from radiators and pipework) and oxygen in the air within the heating system. Build-up of the deposits is undesirable and may result in damage to the boiler system. The low flow rate of water through the LLH allows the deposits within the LLH to sink and be collected for removal, for example, by isolating and draining the LLH before flushing out the deposits.

Typically, as best practice, heating systems often include an additional filtration system for removing the deposits. For example, an air and dirt separator may be fitted to the distribution circuit of a heating system and used to remove deposits. Filtration systems can benefit the reliability and lifespan of the boilers and therefore reduce operation and maintenance costs. Despite these advantages, filtration systems are often considered to be expensive and non-essential, and thus may be removed from design plans to save on cost. Furthermore, plant rooms in which boiler systems are installed often have limited space, with limited room for additional features.

The present invention has been made in consideration of these issues.

According to a first aspect of the present invention, there is provided a low loss header (LLH) comprising a magnetic component.

The LLH may be connectable to a cascade boiler system. The LLH may regulate pressure in and allow removal of deposits from said cascade boiler system. For example, the LLH may be connectable to a cascade boiler system for regulating pressure in and removing deposits from the cascade boiler system.

The LLH provides a single unit which can regulate pressure in and remove deposits from a cascade boiler system.

By “regulate pressure in a cascade boiler system”, we mean the LLH can allow for an approximately constant flow rate of water through the boilers (e.g. in the primary circuit).

The LLH may be arranged to provide hydraulic separation between at least two flow circuits. The at least two flow circuits may comprise a primary circuit and a secondary circuit. The primary circuit may comprise each boiler of a cascade boiler system. The primary circuit may be arranged on the boiler side of a cascade boiler system. The secondary circuit may be arranged to distribute a heating load. The secondary circuit may be arranged on the heating load side of a cascade boiler system.

The deposits, otherwise known as sludge, may comprise a magnetic material, typically a ferrous material. The deposits may comprise, for example other metals, such as aluminium. The deposits may comprise magnetic material and non-magnetic material.

The magnetic component may attract deposits thereon. In use, some of the deposits, which may comprise both magnetic and non-magnetic materials, may attract to the magnetic component by virtue of the magnetic material in the deposits. Also, some of the magnetic material may settle out from the non-magnetic material in the LLH due to the low flow rate of water therein.

Thus, the LLH can be used to facilitate removal of deposits from the cascade boiler system by means of the magnetic component. In use, when the magnetic component is exposed to flowing water, deposits in the water can attract and stick to the magnetic component.

Once the deposits are stuck to the magnetic component, they can be removed from the system with ease, for example, by isolating and then disassembling the LLH.

The magnetic component may be arranged within the LLH. The magnetic component may be arranged approximately parallel to the long axis of the LLH.

The magnetic component may be dimensioned so as to prevent an undesirable restriction of the flow of water through the LLH and/or to prevent an undesirable effect on delta T.

By “prevent an undesirable restriction of the flow rate of water through the LLH’, we mean that the magnetic component does not block or otherwise have a noticeable effect on the flow rate of water through the LLH.

As the skilled person would appreciate, ‘delta T’ refers to the temperature differential of the water flow and water return from the cascade circuit (e.g. 80°C water flow and 60°C water return).

The magnetic component may be of any suitable magnetic strength. As the skilled person would appreciate, the magnetic strength of the magnetic component is not intended to be limited to particular values. This will vary in accordance with the particular application, conditions and requirements.

One end of the magnetic component may be arranged in the LLH and the other end of the magnetic component may be arranged away from the LLH.

In some embodiments, the magnetic component may comprise a magnetic rod. One end of the rod may be arranged in the LLH and the other end of the rod may be arranged away from the LLH.

In other embodiments, the magnetic component may comprise magnetic element and a non-magnetic element. For example, the magnetic element may be arranged within, e.g. overlapped by, the non-magnetic element. The magnetic element may be removably coupled to the non-magnetic element. Advantageously, in such an arrangement, when the magnetic element is removed from the non-magnetic element, any deposits on the non-magnetic element may easily be removed. For example, when the magnetic element is removed, any deposits on the non-magnetic element can sink to the bottom of the LLH and be removed, for example, using a drain valve.

The magnetic element may be a magnetic rod. The non-magnetic element may be a tube. The magnetic rod may be arranged in the tube. One end of the tube may be arranged within the LLH and the other end of the tube may be arranged away from, e.g. outside of, the LLH. The end of the tube arranged within the LLH may be closed. The other end of the tube may be open to the atmosphere. In this way, the magnetic rod may be arranged in the tube through the open end of the tube.

The magnetic rod may be isolated from the internal contents of the LLH. The tube may isolate the magnetic rod from the internal contents of the LLH. Thus, advantageously, in such an arrangement the magnetic rod may exhibit less rust and/or corrosion, and may be protected from loss of magnetism, thus improving on the maintenance requirements of the LLH. Furthermore, advantageously, in such an arrangement, when the magnetic rod is removed from the tube, any deposits on the tube may easily be removed. For example, when the magnetic rod is removed, any deposits on the tube can sink to the bottom of the LLH and be removed, for example, using a drain valve.

The tube may comprise a non-magnetic material, for example, stainless steel. The tube may consist essentially of stainless steel. The tube may consist of stainless steel.

Advantageously, by inclusion of stainless steel, the tube can exhibit improved resistance against rust and corrosion, thus improving on the maintenance requirements of the LLH.

The magnetic component may comprise one or more permanent magnetic materials, for example, neodymium.

In embodiments where the magnetic component is a magnetic rod, the magnetic rod may comprise one or more permanent magnetic materials, for example, neodymium.

In embodiments where the magnetic component comprises a tube and a magnetic rod, the magnetic rod may comprise one or more permanent magnetic materials, for example, neodymium.

In embodiments where the magnetic component is a magnetic rod, the end of the rod arranged in the LLH may comprise a stand.

In embodiments where the magnetic component comprises a tube and a magnet, the closed end of the tube may comprise a stand.

The stand may be dimensioned to support the magnetic component within the LLH.

When present, the stand can prevent the magnetic component from becoming dislodged due to the force of flowing water.

The magnetic component may comprise a flange assembly. The flange assembly may comprise a seal to seal the internal contents of the LLH from the atmosphere.

Thus, advantageously, in use the internal contents of the LLH may not leak from the LLH.

In embodiments where the magnetic component comprises a tube and a magnet, the tube may be fabricated to the flange assembly, suitably at the open end of the tube. The open end of the tube may project through a hole the flange assembly such that an outer surface of the tube and the flange assembly provide a seal between internal contents of the LLH and the atmosphere. The open end of the tube may project through hole in the centre of the flange assembly.

The tube may be arranged approximately perpendicular to the plane of the flange assembly.

The magnetic rod may be approximately the same length as the tube.

The magnetic rod may include a tag. The tag may be fitted to the end of the tube arranged away from the LLH. Advantageously, the tag can facilitate removal of the magnetic rod from the tube.

The LLH may comprise an air vent. The air vent may be operable to vent a buildup of pressure within the LLH. The air vent may be connectable to the flange assembly. The air vent may be connectable to the flange assembly by a threaded boss. The air vent may be an automatic air vent. The air vent may comprise a non-return valve.

The LLH may be intended to be arranged in a vertical position in use. By arranging the LLH in a vertical position, the LLH may more effectively collect deposits from water in passing through the LLH.

The LLH may comprise a drain valve. The drain valve may be arranged and the bottom of the LLH and be operable to drain the internal contents of the LLH. In this way, to disassemble the LLH, the user can isolate the LLH and then drain the internal contents of the LLH by means of the drain valve. The skilled person will be aware of how to isolate and disassemble the LLH. The drain valve may be connectable to the lower portion of the LLH.

The LLH may have a pressure rating of up to 10 bar. The pressure rating defines the maximum allowable pressure at which the LLH can operate.

The LLH may be insulated by use of an insulating material. For example, suitable insulating materials include clad sheets, foil backed mineral wool, wired insulation mattresses, foam insulation materials, and fibreglass. Any other suitable insulating material may be used.

The LLH of the present invention is suitable for use in a cascade boiler system. The cascade boiler system may comprise at least two boilers, suitably three boilers, for example four boilers, or even five or more boilers. The skilled person will appreciate that the present invention may be used with any particular number of boilers.

The LLH provides a single unit which offers protection to a cascade boiler system from changes in the flow rate of water, and includes a means for removing deposits.

The LLH is compact and may improve on efficiency of space, and may remove the need to install separate filtration means.

The LLH may improve on cost efficiency.

The LLH may exhibit improved performance, by providing a more effective means of removing deposits from the system.

The aforementioned statements of suitable features and advantages of the first aspect apply to any other aspects as described herein, without departing from the scope of the invention.

According to another aspect of the present invention, there is provided a cascade boiler system comprising the LLH of the first aspect.

According to a yet another aspect of the present invention, there is provided a heating system comprising the LLH according to the first aspect.

The heating system may comprise a central heating system, e.g. a domestic central heating system. However, the skilled person will appreciate that any suitable heating system may be used, as required.

According to a further aspect of the present invention, there is provided a method of removing deposits from a cascade boiler system and/or a heating system, optionally including any of the optional features as defined in any previous aspect, the method comprising: removing the magnetic component from the LLH; cleaning the deposits off the magnetic component; and replacing the magnetic component in the LLH.

Where the magnetic component comprises a magnetic element and a nonmagnetic element, and a drain valve, the method may comprise removing the magnetic element such that the deposits drop off the non-magnetic element; and opening the drain valve to remove the deposits.

The method may further comprise removing the non-magnetic element from the LLH and cleaning any deposits off it.

In order that the invention may be more clearly understood, an embodiment thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows an exploded perspective view of the component parts of a LLH according to an embodiment of the present invention;

Figure 2 shows a side view of the LLH of Figure 1; and

Figure 3 shows a cross sectional side view of the LLH of Figures 1 and 2.

With reference to the drawings, there is illustrated a LLH according to an embodiment of the present invention.

Figure 1 shows the separate components of a low loss header (LLH) 1 according to an embodiment of the present invention. The LLH 1 comprises a magnetic component having a magnetic rod 2, a stainless steel tube 3 and a first flange assembly 4 fabricated to the tube 3.

The LLH 1 is of an approximately cylindrical form and includes a primary inflow means 5, a primary out-flow means 6, a secondary in-flow means 7, a secondary out-flow means 8, and a main chamber 9. When the LLH 1 is installed in a cascade boiler system, the primary in-flow means 5 and primary out-flow means 6 form part of a primary circuit (boiler side) and the secondary in-flow means 7 and secondary out-flow means 8 form part of a secondary circuit (heating load side). Each of the primary flow means 5, 6 is connector which is connectable to the pipework of a cascade boiler system. Each of the secondary flow means 7, 8 is a connector which is connectable to the pipework to the heating load. A drain valve 10 is fitted to a lower portion (e.g. the base of the main cylindrical surface) of the LLH 1 and is operable to drain the internal contents of the LLH 1.

The LLH 1 also includes a second flange assembly 11, the upper face of which is connectable to the lower face of the first flange assembly 4. The flange assemblies 4, 11 can be fastened together using a series of threaded fasteners positioned around the circumference of the mating flange assemblies 4, 11. When the LLH 1 is assembled, the internal contents of the LLH 1 are sealed from the atmosphere (see below). The flange assembly 4 of this assembly comprises a threaded boss 15, which is connectable to an air vent 16, for example an automatic air vent (see Figures 2 and 3). The air vent 16 is operable to vent a build-up of pressure within the LLH 1.

The magnetic rod 2 is dimensioned to fit within, and along approximately the entire inside length of, the stainless steel tube 3. In this embodiment the magnetic rod comprises neodymium. The magnetic rod 2 of this embodiment includes a tag 13 affixed on an end of the magnetic rod 2. When the LLH 1 is assembled, such that the magnetic rod 2 is arranged in the tube 3, the tag 13 projects out of the open end of the tube 3. Thus, the tag may 13 provide a handle that allows the user to remove the magnetic rod 2 from the tube 3.

The stainless steel tube 3 is a hollow, cylindrical tube, which is closed at one end and open at the other. At the closed end of the tube 4 is fitted a circular stand 14, which supports the stainless steel tube 3 within the main chamber 9 of the LLH 1. In this way, when the LLH 1 is assembled the stand 14 can contact with the bottom surface of the main chamber 9 such that the underside of the stand 14 is flush with the bottom surface of the main chamber 9. The stand can prevent the magnetic component (i.e. the magnetic rod 2 and tube 3) from becoming dislodged due to the force of flowing water.

The open end of the tube 3 is fabricated to, and projects through a hole in the centre of, the first flange assembly 4, such that the open end of the tube 3 is open to the atmosphere, and such that the inner surface of the hole of the first flange assembly 4 is connected to the outer cylindrical surface of the open end of the tube. Thus, in order to arrange the magnetic rod 2 in the tube 3, the magnetic rod 2 may be inserted through the open end of the tube 3 into tube 3. In this configuration, the tube 3 isolates the magnetic rod from contact the internal contents of the LLH 1.

The tube 3 is arranged approximately parallel to the long axis of the LLH and approximately perpendicular to the long axis of the first flange assembly 3. The magnetic component is of approximately the same height as the LLH. The cross sectional area of the tube 3 is less than or equal to 10% of the free cross sectional area of the LLH. In this way, the magnetic component is dimensioned so as to prevent undesirable restriction of flow of water through the LLH and to prevent an undesirable effect on delta T.

As shown in Figures 2 and 3, the LLH 1 is assembled. To obtain this arrangement, the magnetic rod 2 is arranged within the stainless steel tube 3, and the magnetic component is mounted on the LLH 1.

The ways of installing the LLH 1 in a cascade boiler system will be known to the skilled person. For example, the primary in-flow means 5 and primary out-flow means 6 may be connected to the primary circuit, and the secondary in-flow means 7 and secondary out-flow means 8 may be connected to the secondary circuit. When installed, the LLH 1 is arranged approximately vertically (with the base of the LLH 1 comprising the drain valve 10 at the bottom and the flange assembly 4 at the top). The orientation of the LLH 1 can be determined using any suitable tool, for example a spirit level, which will be known to the skilled person.

When the LLH 1 is connected to a cascade boiler system, and the system is activated, heated water from the boilers is directed through the primary in-flow means 5 into the main chamber 9 and then through the secondary out-flow means 7 out of the main chamber 9 towards the heating load. Water returning from the heating load is directed through the secondary in-flow means 8 into the main chamber 9 and then through the primary out-flow means 6.

Due to the low flow rate of water within the main chamber 9, ferrous deposits in the water within the main chamber 9 undergo a reduction in flow rate and are attracted to the magnetic rod 2 and stick to the outside surface of the stainless steel tube 3 in which the magnetic rod 2 is arranged. As more water passes through the main chamber 9 of the LLH 1, the deposits can collect on the surface of the tube 3. The deposits that are stuck to the surface of the tube 3 may be removed by isolating and then disassembling the LLH

1. Alternatively, the deposits that are stuck to the surface of the tube 3 may be removed by removing the magnetic rod 2 from the tube 3, thereby allowing the deposits to sink to the bottom of the LLH 1, and then by opening the drain valve 10 to drain the contents of the LLH 1.

The LLH 1 can be isolated using any suitable means as will be known to the skilled person. For example, the LLH 1 can be isolated by closure of valves on the pipework to the LLH 1. Once the LLH 1 is isolated it can be disassembled.

The LLH of this embodiment has a pressure rating of up to 10 bar.

The above embodiment is described by way of example only. Many variations are possible without departing from the scope of the invention.

Claims

1. A low loss header comprising a magnetic component to attract magnetic deposits thereon.

2. A low loss header according to claim 1, wherein the magnetic component is arranged within the low loss header.

3. A low loss header according to claim 1 or 2, wherein the magnetic component comprises a magnetic element and a non-magnetic element.

4. A low loss header according to claim 3, wherein the non-magnetic element comprises stainless steel.

5. A low loss header according to any preceding claim, wherein the magnetic component comprises a magnetic rod.

6. A low loss header according to claim 5, wherein the magnetic rod is arranged approximately parallel to a long axis of the low loss header.

7. A low loss header according to claim 5 or 6 when dependent directly or indirectly on claim 3 or 4, wherein the magnetic element is a magnetic rod and the nonmagnetic element is a tube, wherein the magnetic rod is arranged in the tube.

8. A low loss header according to any preceding claim, wherein one end of the magnetic component comprises a stand.

9. A low loss header according to any preceding claim, wherein the magnetic component comprises a flange assembly.

10. A low loss header according to claims 8, wherein flange assembly comprises a seal for sealing the internal contents of the low loss header from the atmosphere.

11. A low loss header according to any preceding claim, wherein the low loss header comprises an air vent.

12. A low loss header according to any preceding claim, wherein the low loss header comprises a drain valve.

5

13. A low loss header according to any preceding claim, wherein the low loss header is insulated using an insulating material.

14. A cascade boiler system comprising the low loss header according to any of claims 1 to 13.

15. A heating system comprising the low loss header according to any of claims 1 to

10 13, or the cascade boiler system of claim 14.

16. A method of removing deposits from a cascade boiler system and/or a heating system, the method comprising: removing the magnetic component from the low loss header according to any of claims 1 to 13; cleaning deposits off the magnetic component; and replacing the magnetic component in the low loss header.