Boiler assembly alignment tool apparatus and method

Abstract

A boiler assembly alignment tool can include a base and a plurality of projections attached to the base. The projections can be configured to align two or more flue sections of a boiler subassembly. The cross section of the projections can be configured in a shape that complements or matches the configuration of one or more corresponding sets of convective fins on the boiler flue sections, such that when a flue section is placed on the alignment tool the flue section is brought into a unique alignment with the alignment tool. Thus, multiple flue sections placed onto the alignment tool are brought into a proper alignment with one another to facilitate assembly of the boiler subassembly. In addition, a method or process for assembling a boiler subassembly can include placing two or more flue sections onto an alignment tool and fastening the flue sections to each other.

1 . A boiler assembly alignment tool, comprising: 
 a base; and    a first projection attached to the base, the first projection being configured to substantially align a plurality of flue sections.    
   
   
       2 . The alignment tool of  claim 1 , wherein each of the flue sections includes a sealing interface and an attachment interface, and the sealing interfaces and the attachment interfaces of the flue sections are substantially aligned when the flue sections are substantially aligned.  
   
   
       3 . The alignment tool of  claim 1 , wherein each of the flue sections includes a corresponding set of convective fins, and the first projection is configured to pass between the sets of convective fins when the flue sections are properly aligned for assembly and not to pass between the sets of convective fins when the flue sections are not properly aligned for assembly, so as to substantially align the flue sections when the flue sections are placed on the alignment tool.  
   
   
       4 . The alignment tool of  claim 3 , wherein a cross section of the first projection is configured to have a clearance of one-tenth of an inch or less with one or more of the convective fins when the first projection extends between the convective fins.  
   
   
       5 . The alignment tool of  claim 3 , wherein a cross section of the first projection is configured to engage one or more of the convective fins when the first projection extends between the convective fins.  
   
   
       6 . The alignment tool of  claim 1 , further comprising one or more additional projections configured to substantially align the plurality of flue sections.  
   
   
       7 . The alignment tool of  claim 1 , wherein the base is configured to support and stabilize the alignment tool and the plurality of flue sections when placed on the first projection.  
   
   
       8 . A boiler assembly alignment tool, comprising: 
 means for aligning a plurality of corresponding sets of convective fins on a plurality of flue sections; and    means for supporting and stabilizing the means for aligning.    
   
   
       9 . A method of assembling a boiler, comprising the steps of: 
 placing a first end flue section on an alignment tool that includes a projection configured to substantially align a plurality of flue sections; and    placing a second end flue section on the alignment tool such that the second end flue section is substantially aligned with the first end flue section.    
   
   
       10 . The method of  claim 9 , wherein an attachment interface on the second end flue section is substantially aligned with a corresponding attachment interface on the first end flue section when the second end and first end flue sections are placed on the alignment tool.  
   
   
       11 . The method of  claim 9 , further comprising the step of fastening the second end flue section to the first end flue section.  
   
   
       12 . The method of  claim 9 , further comprising the step of placing an intermediate flue section on the alignment tool such that the intermediate flue section is aligned with the first end flue section.  
   
   
       13 . The method of  claim 12 , further comprising the step of fastening the intermediate flue section to the first end flue section.  
   
   
       14 . The method of  claim 12 , further comprising the step of fastening the second end flue section to the intermediate flue section.  
   
   
       15 . The method of  claim 9 , further comprising the step of placing a plurality of intermediate flue sections on the alignment tool such that each of the intermediate flue sections is aligned with the first end flue section and with the previously placed intermediate flue sections.  
   
   
       16 . The method of  claim 15 , further comprising the step of fastening one of the intermediate flue sections to another of the intermediate flue sections.  
   
   
       17 . The method of  claim 9 , wherein a sealing interface on each of the flue sections is substantially aligned with a corresponding sealing interface on an adjacent flue section when the flue sections are placed on the alignment tool.  
   
   
       18 . The method of  claim 9 , wherein the step of placing a first end flue section on the alignment tool further includes orienting a first end set of convective fins on the first end flue section with respect to the projection such that the projection passes between the convective fins, and the step of placing a second end flue section on the alignment tool further includes orienting a second set of convective fins on the second end flue section with respect to the projection such that the projection passes between the convective fins.  
   
   
       19 . The method of  claim 18 , wherein the step of placing a first end flue section on the alignment tool further includes orienting the first end set of convective fins with respect to the projection such that the first end set of convective fins has a first clearance with a cross section of the projection, and the step of placing a second end flue section on the alignment tool further includes orienting the second set of convective fins with respect to the projection such that the second set of convective fins has a second clearance with the cross section of the projection.  
   
   
       20 . The method of  claim 9 , further comprising the steps of: 
 orienting the first end flue section with respect to the alignment tool such that the projection is able to pass between a first set of convective fins on the first end flue section when the first end flue section is placed on the alignment tool; and    orienting the second end flue section with respect to the alignment tool such that the projection is able to pass between a second set of convective fins on the second end flue section when the second end flue section is placed on the alignment tool.