US3094280A - Heating method and apparatus - Google Patents

Description

I J. F. MELZER HEATING METHOD AND APPARATUS June 18, 1963 2 Sheets-Sheet 1 Filed July 2, 1959 INVENTORY JUL [/5 F. MELZER nu n u HHIHIIIHHHHMH N u A1 TORNEY June 18, 1963 J. F. MELZER 3,094,230

HEATING METHOD AND APPARATUS Filed July 2, 1959 2 Sheets-Sheet 2 Fig-3 ATTORNEY United States Patent 3,094,280 HEATING METHOD AND APPARATUS Julius F. Melzer, 544 King St., Port Chester, N.Y. Filed July 2, 1959, Ser. N0.824,578 2 Claims. (Cl. 236-93) My present invention rel-ates to water heating and has, as a general object, the prevention of thermal shock to boilers. My invention is especially useful for large installations such as forced hot water heating systems for schools, hospitals, apartment houses, zoned heating systems, etc.

In 'such installations, distant heat radiating units are connected to a large central boiler by way of long lines or connecting pipes. Although for heating purposes, but water boilers are, in general, designed for a 20 F. temperature differential between outlet and inlet water flow, boiler operators, in order to bring heat up more quicloly have been known to increase water circulation to a point such that the water flow is 30 to 50 times greater than the heat input to, or heating capacity of, the boiler. 'As a result, the boiler is often subjected to a complete change of Water in as little as two minutes. Accompanying this rapid change in water, is a sudden temperature drop of as much as 150 F., giving rise to thermal shock in the boiler. This thermal shock is productive of severe stresses, violent and powerful enough to loosen tubes, crack plates and generally damage the boiler. The damage is aggravated in highly efficient boilers and is also more pronounced in cases wherein there is inadequate water treatment. In the latter instance, scale tormations cause still greater uneven contractions in the steel of the boiler with attendant cracking. To overcome these difficulties is a further object of my invention. In effiecting this object, I provide for initial circulation of water flow through the boiler, when started up, that is restricted or limited to a safe value within the heat recuperativ e capacity of the boiler. As the temperature throughout the system increases, my invention provides for automatic increase in water flow without exceeding a safe temperature difiie-rential between the inlet and outlet of the boiler. In other words, my invention reduces the possibility of thermal shock by admitting water to the boiler at a controlled rate which is matched by the recuperative capacity of the boiler, the relation of the feed and discharge Water temperature of the boiler being thermostatically controlled and narrowed down to a safe temperature ditferential at all times. This desirable condition also follows, with my invention, when full water flow, productive of a large amount of heat radiation, is established.

More specifically, I provide a restrictive orifice or limiting opening which, despite the pumping capacity in the system, admits approximately the pounds of water per minute equivalent to the heat input to the boiler. I also provide a thermostatically controlled arrangement for permitting greater water flow through the boiler as it absorbs heat and as the circulated water rises in average temperature. This controlling apparatus is mounted in such a Way as to be unresponsive to radiant heat firom the boiler or to the boiler temperature but is responsive, however, substantially only to the temperature of the circulating water. Further, in accordance another fieature of my invention, means are provided to enable inspection and repair of the control apparatus without removing water from the heating system.

My invention will be described hereinafter in greater detail with the aid of the accompanying drawing wherein:

FIG. 1 is a crosstsectional view of a hot Water boiler and shows the general positioning and relationship of the elements of my invention for preventing thermal shock to a boiler by circulating water;

Patented June 18, 1963 FIG. 2 is an end view of FIG. 1 taken on the line 1-1;

FIG. 3 is a top plan view of metering apparatus which limits and restricts water flow through the boiler of FIG. 1 at low temperatures despite the water pumping pressure in the system and permits increased flow as the temperature of the circulating water increases;

FIG. 4 is a sectional view of the apparatus of FIG. 3 taken on the line B-B;

FIG. 5 is a sectional view 0t FIG. 3 taken on line O-C;

A FIG. 6 a sectional view of FIG. 5 taken on the line FIG. 7 a plan view of a special valve part or ele ment especially adapted for my invention as embodied in part, in FIG. 5; and

FIG. 8 is a view, partly in seotionyof a modified form of water flow control apparatus which limits water fio-w at low temperatures, despite pumping pressure, and automatically admits more Water to the boiler, or permits increased circulation or flow only the temperature of the circulating water increases.

Referring to FIGS. 1 and 2, I have illustrated a water heating, Scot-ch marine type, return tubular boiler 2 having a firebox or combustion chamber 4. A suitable thermostatically controlled oil burner, diagrammatically illustrated at 6, is mounted Within the firebox. The products of combustion of burner 6 travel down the hollow central, cylindrical portion 8, forming part of the combustion chamber of the boiler, and return through fire tubes 10 to the smoke box 12. The smoke box 12 is provided with an outlet or stack 14 for connection to a chimney. The paths of the smoke, fire and other products of combustion are indicated diagrammatically in FIG. 1 by arrows 16, 18, 20 and '22.

Water is returned to the boiler from distant heating units such as radiators (not shown), through return line 33 by the action of a water pump P. The pump drives Water through the unit B, which will be described in greater detail later, back into the boiler. Unit B, acts to limit or meter the feed or return water flow into the boiler by means of a restrictive orifice. At the beginning of heating operations, this restrictive orifice retards and restricts boiler water feed to the heat recuperative capacity of the boiler or to the fuel heat input delivered by the burner at the start of heating operations. Additional means are provided within unit B, as will be described more fully later, thermostatically responsive to the relation of the water feed and water discharge temperatures so as to maintain a narrow, predetermined temperature differential between the same while increasing water flow, until full flow is established.

The thermostatic valve unit B, containing a restrictive orifice and a thermostatically controlled orifice, is mounted on a curved feed pipe or cooling Water leg 26 Which acts to heat insulate or isolate valve unit B from the heat of the boiler thereby providing a more stable ambient temperature condition for unit B. In other words, leg 26 affords a measure of separation from and reduces the influence of boiler heat from afiecting the operation of unit B.

Water, returning to the boiler by way of return pipe 33, pump P, return line section 31, unit B and curved leg 26, is introduced and fed into the boiler Water through the openings 28 at the extreme left hand end of the closed off feed line 30 as shown in FIG. 1 suitably mounted, fixed Within, or otherwise made integral with boiler 2. Feed line 30 tempers the water and feeds it into the boiler at points 28 which are remote from the water outlet 32 located in the water back section 34 located at the opposite end of the boiler. In brief, the internal feed line 30 provides a more uniform tempering of the inlet water to the boiler and carries the inlet or feed water to the end of the boiler which is remote from and opposite to that of the water discharge or outlet 32 of the boiler.

The unit B, which limits water flow into the boiler to a value which falls well within the recuperative heat input to the boiler and admits more water to the boiler as the circulated water in the system increases in temperature, while, however, maintaining a safe temperature differential between water input and output of the boiler, is illustrated in greater detail in FIGS. 3 to 8 inclusive, to which specific reference is now made.

As best seen in FIGS. 4 and 5, the water flow controlling unit is provided with a cast iron or steel casing 40 having a water inlet connection 42 to which water is fed from the pump P of FIG. 1. An outlet or discharge port 44, is provided from which controlled water flow through the unit passes into the leg 26 of FIG. 1. Inlet and outlet ports 42, 44 are at right angles to each other and are provided with connecting flanges 43 and 45.

Cam operated valve heads 49, 50 are integrally provided to shut off a space Within casing or housing 4% which contains the flow controlling equipment, so that the latter may be inspected and adjusted through access door 110, which may be removably bolted in place. Threaded opening 54, in axial alignment with opening 42, is provided with a closing off or plug member (not shown). This plug should be removed to let out water in the shut off space, before the access door 110 is removed.

Normally with the valve heads 49, 50 in their open positions as shown in FIG. 5, water flows or is pumped into the casing 40 through inlet 42. Water then flows through the conical knife edge openings 46, provided in the valve head 48, into the lower space 60 of casing 40. The water then passes through the open valve to the outlet port 44. It should be noted that the sharp edged openings 46 in the valve head 48 are aligned with openings 62 in the supporting valve part or base 64. A plan view of this valve part or valve base 64 is given in FIG. 7. The arrangement is such that the openings 62 are aligned with the sharp edged openings 46 in the valve head 48. The valve part 64 is provided with a shoulder 66 so as to firmly and relatively fixedly engage and be supported by cooperating shoulders 68 carried by and made integral with housing 40.

The orifices or holes 46 are designed to restrict the flow of water therethrough to a safe value well within the heat recuperative power of the boiler when it is started up. The orifices 46 therefore, restrict, limit, meter or control the flow of circulating water, despite the starting up capacity of the pump P brought about by a demand for increased heating by the distant heating units. In this way, my invention prevents the injection of a large mass of cold water into the boiler at such a rate as would cause damage to the boiler.

As the temperature of the water in the boiler increases, I have provided, also in accordance with my present invention, means for automatically increasing the amount of water admitted or fed to the boiler, and therefore, the circulation of water, until full water flow or circulation is established. This increase in flow is only carried out and permitted, according to my invention, while maintaining a safe diflerential in temperature between inlet and outlet water for the boiler. As best seen in FIGS. 4 and 5, the means for accomplishing the foregoing, is in the form of the temperature operated or thermostatically operated bellows system 70, mounted within a support 72, carried by the valve part 64. This bellows is filled with a suitable temperature responsive fluid which expands with increase of temperature. The end result of the expansion of the bellows is to drive the valve supporting rod 74 upwardly against the normal valve closing action of helical safety spring 76. As a result, the rod 74, to which valve head 48 is attached, raises the latter and permits additional water flow around the valve head bevelled edge 80 (see FIG. 4), and through the additional openings 82 (FIG.

4 7) provided between the cross arms 83, 85, of the valve part 64 (FIGS. 4 and 5).

The apparatus is so designed that when the temperature of the Water circulated through the unit B has the greatest temperature differential between the outgoing and incoming water, the only water that can be circulated through this unit B and the boiler will be through the orifices 46 and openings 62 (FIG. 4). This circulated amount would then be the equivalent to the fuel thermal input to the boiler. Excess Water circulated by reason of the capacity of the pump P is by-passed externally to the system. As the circulated water through the orifices becomes heated, the valve 48, attached to the thermostatic element 70, is expanded, allowing a greater capacity flow through unit B until the differential is reduced and the temperatures become so close that the thermostatic valve has opened to its maximum opening and the full pump capacity will then be circulated throughout the system.

If it is desired to inspect the fixed orifice 46 and/or the thermostatic element 70-72-76 with its valve 48; the disc valves 49 and 50 are first closed by rotating shafts -92 (FIGS. 4 and 5). Shaft 90 rotates the cam element 94, fastened thereto (see FIG. 4) to an open or shut position as desired. Similarly, cam 96 (FIG. 5) is driven by shaft 92 to open or shut valve 50. Pointers 98, are provided to indicate whether valves 50 and 49 are closed or open. These valves are provided with guiding spiders 102, 104, as shown in FIG. 5. With earns 94 and 96 driven by the shafts 90 and 92 to the closed positions, access door may be removed as for example by removing bolts or other fastening means (not shown). Before removing the access door 110, the plug (not shown), in screw threaded opening 54 should be unscrewed to remove the trapped water in the space within housing 40 between cut off valves 49 and 50. The metering equipment including valve 48 and thermostatic controlling elements 70, 76 will, upon removal of door 110, be accessible for inspection and adjustment.

To summarize, the unit B, as described, constitutes a metering unit which, by virtue of the sharp edged conioally shaped orifices 46, limits water flow through the system, when valve head 48 is in its lowermost position, so as to be effectively restricted to the heat input of the burner or the heat recuperation of the boiler. The water circulation is permitted to increase only when a predetermined temperature differential exists between boiler inlet and outlet by the action of thermostatically controlling apparatus 70, 76.

The integral valve cutoffs 49, 50 permit retention of the water in the boiler and throughout the heating system while allowing access to the thermostatic control and other elements within housing 40. The unit B is mounted on a cooling or tempering water leg or pipe 26 spaced from the boiler so as to prevent boiler heat from affecting the thermostatic control element within housing 40. My improved system also contemplates the use of an integral, boiler tempering, water feed 30 from the cooling leg 26 to the end of the boiler opposite to and remote from the discharge end 32 or water outlet or output end of the boiler.

In FIG. 8, I have illustrated another form of fiow controlling or metering unit. As shown, water flows into the unit through the input end 200 thereof and out through outlet 202. Coupling flanges 204, 206 are provided for connecting input and Output water pipes thereto. The casing 208 has, integral therewith, a web 210 and a base or bottom 212. As shown, one or more hollow cylinders 214 are carried by the base 212 and extend through suitable openings in web 210. Each of the cylinders 214 is provided with a fixed water flow orifice or opening 216. These fixed orifices 216 have sharp edges and limit the .water flow through the system to a safe value when the system is started up. The water flowing through the fixed openings 216 reaches the outlet 202 through the slots or other side openings 220 in the hollow walls of the cylinders 214. The openings 220 are located below web 210 as shown. Also, one or more thermostatically controlled valves 230 are provided in the arrangement of FIG. 8. These elements 230 are diagrammatically illustrated in FIG. 8 and are supported by the base 212 in any suitable way. As the temperature of the Water through the system increases, thermostatic elements 230 permit additional water flow until full flow is established. The thermostatically controlled valves 230 of FIG. 8 are preferably of the type described in FIGS. 4 and and each makes use of a bevelled valve head 48, thermostatic bellows 30 and a safety closing spring 76. These springs, it should be noted, close the thermostatically operated valves, should they become defective, as for example, through loss of temperature responsive operating fluid.

Although not illustrated in FIG. 8, there may be used, integral with the input and output sections 208, 210, disc cutoif valves such as 49, 50 of the type shown in FIGS. 3 and 4. Instead of the access door 110 shown in FIGS. 4 and 5, the units are made as integral parts, the orifice units 214 and the thermostatic elements 230 are self contained and are inserted in the bottom of container or housing 208. The cutolf valves 49 and 50 are the same as shown in FIGS. 4 and 5 and, as shown in FIG. 8 are provided with indicators 100 and 98.

Although I have described my invention in connection with the heating of water, it should be clear that the invention is also adapted and useful for the heating of other fluids. Hence, in the claims which follow, the term water is intended to include such other fluids as lend themselves to the use of my invention. Also, other changes within the scope of my invention may be made without deviating from the spirit and scope thereof, as for example, other types of boilers may be employed, cast iron, steel, brass, or other material may be used tor the housings, and so on.

Having thus described my invention, what I claim is:

1. -A water flow controlling unit comprising a metal casing, having a water inlet connection and a water outlet connection, arranged at tight angles to each other; a re movable plug in the casing opposite the inlet connection; disc valves integral with the casing for shutting off the space between the inlet and outlet connections, an access door in said casing leading to said shut off space; a valve in the shut oif space of said casing having a perforated disc valve head and a stem mounted within said casing in alignment with said inlet opening, the perforations in said head having sharp edges, a valve seat carried by said casing against which said valve head closes, a safety spring surrounding said valve stem for normally closing said valve head against said valve seat; a valve pant mounted beneath said valve head, said part having cross arms with openings in the cross arms aligned with the perforations in said valve head and a temperature responsive bellows, supported by said valve pant, connected to said valve stem for moving said valve stem against said safety spring and thereby separating said valve head from said valve seat and valve part.

2. A Water flow controlling unit comprising a metal casing, having a water inlet connection and a water out let connection; a removable plug in the casing opposite the inlet connection; disc valves adjacent the inlet and outlet connections mounted within the casing for shutting 01f the space between the inlet and outlet connections, an access door in said casing leading to said shut off space; a valve having a perforated disc valve head and a stem mounted within said casing in said shut ofl space in alignment with said inlet opening, the perforations in said head having sharp edges, a valve seat carried by said casing against which said valve head closes, a safety spring surrounding said valve stem for normally closing said valve head against said valve seat; a valve part mounted beneath said valve head, said part having cross arms with openings in the cross arms aligned with the perforations in said valve head and a temperature responsive bellows, supported by said valve part, connected to said valve stem for moving said valve stem against said safety spring and thereby separating said valve head from said valve seat and valve part.

References Cited in the file of this patent UNITED STATES PATENTS 1,406,922 'Boyce Feb. 14, 1922 1,806,530 Giesler May 19, 1931 1,880,539 Wald Oct. 4, 1932 2,081,831 Moore May 25, '1937 2,086,360 Hill July 6, 1937 2,340,844 Dillman Feb. 1, 1944 2,461,136 Bomquist Feb. 8, 1949 2,895,496 Sanctuary July 21, 1959

Claims (1)

1. A WATER FLOW CONTROLLING UNIT COMPRISING A METAL CASING, HAVING A WATER INLET CONNECTION AND A WATER OUTLET CONNECTION, ARRANGED AT RIGHT ANGLES TO EACH OTHER; A REMOVABLE PLUG IN THE CASING OPPOSITE THE INLET CONNECTION; DISC VALVES INTEGRAL WITH THE CASING FOR SHUTTING OFF THE SPACE BETWEEN THE INLET AND THE OUTLET CONNECTIONS, AN ACCESS DOOR IN SAID CASING LEADING TO SAID SHUT OFF SPACE; A VALVE IN THE SHUT OFF SPACE OF SAID CASING HAVING A PERFORATED DISC VALVE HEAD AND A STEM MOUNTED WITHIN SAID CASING IN ALIGNMENT WITH SAID INLET OPENING, THE PERFORATIONS IN SAID HEAD HAVING SHARP EDGES, A VALVE SEAT CARRIED BY SAID CASING AGAINST WHICH SAID VALVE HEAD CLOSES, A SAFETY SPRING SURROUNDING SAID VALVE STEM FOR NORMALLY CLOSING SAID VALVE HEAD AGAINST SAID VALVE SEAT; A VALVE PART MOUNTED BENEATH SAID VALVE HEAD, SAID PART HAVING CROSS ARMS WITH OPENINGS IN THE CROSS ARMS ALIGNED WITH THE PERFORATIONS IN SAID VALVE HEAD AND A TEMPERATURE RESPONSIVE BELLOWS, SUPPORTED BY SAID VALVE PART, CONNECTED TO SAID VALVE STEM FOR MOVING SAID VALVE STEM AGAINST SAID SAFETY SPRING AND THEREBY SEPARATING SAID VALVE HEAD FROM SAID VALVE SEAT AND VALVE PART.

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