Foster Wheeler Corp. v. BABCOCK & WILCON CO.

512 F. Supp. 792, 210 U.S.P.Q. (BNA) 232, 1981 U.S. Dist. LEXIS 9536
CourtDistrict Court, S.D. New York
DecidedApril 8, 1981
Docket76 Civ. 1224 (WCC)
StatusPublished
Cited by7 cases

This text of 512 F. Supp. 792 (Foster Wheeler Corp. v. BABCOCK & WILCON CO.) is published on Counsel Stack Legal Research, covering District Court, S.D. New York primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Foster Wheeler Corp. v. BABCOCK & WILCON CO., 512 F. Supp. 792, 210 U.S.P.Q. (BNA) 232, 1981 U.S. Dist. LEXIS 9536 (S.D.N.Y. 1981).

Opinion

OPINION

CONNER, District Judge.

This action was brought by plaintiffs (collectively “Foster Wheeler”) against defendant (“Babcock”) for a declaratory judgment that Babcock’s U.S. patents Nos. 3,834,358 and 3,927,646 (“the ’358 and ’646 patents,” respectively) relating to steam generators are invalid and do not cover any of the steam generators built and sold by Foster Wheeler.

With the consent of the parties, the Court conducted a separate trial limited to the issues:

(1) whether Claims 6, 7 and 8 of the ’646 patent and Claim 11 of the ’358 patent (the claims on which Babcock has elected to stand or fall) cover the following steam generator units built and sold by Foster Wheeler: Units 3 and 4 at the Gibson Generating Station of Public Service Indiana (“Gibson 3 and 4”), Units 1 and 2 of the Pleasants Power Station of Allegheny Power Service Corporation (“Pleasants 1 and 2”) and Unit 3 of the Bruce Mansfield Plant of Pennsylvania Power Company (“Mansfield 3”) (collectively, the “accused” units);

(2) whether any of the claims in suit could be construed to cover any of the accused units without being invalidated as unsupported by and/or inconsistent with the disclosures of the patent specifications, in contravention of the requirement of 35 U.S.C. § 112.

This Opinion incorporates the Court’s findings of fact and conclusions of law with respéct to these issues, pursuant to Rule 52(a), F.R.Civ.P.

BACKGROUND

The Babcock developments and patent applications

The patented inventions relate to “once-through” boilers (in which a fluid, e. g., distilled water, is heated above its boiling point in a single pass through a network of tubes surrounding the combustion chamber) of the welded “membrane wall” type (in which the combustion chamber is fully enclosed laterally by all-metal, gas-tight boundary walls formed by spaced, parallel tubes having coplanar metal webs or fins interposed between them and welded to the tubes at either side) operating in a “super-critical” mode (in which the water is confined under very high pressure — e. g., up to about 5,000 p. s. i. — so that it will not boil at the normal temperature, but can be heated up to the order of 1100 °F.). The steam produced by such boilers is used to drive steam turbines, for example for generating electric power. A typical electric power plant boiler of this type may be several hundred feet in height, more than fifty feet across, and may produce steam energy sufficient for the generation of as much as one thousand megawatts of electric power or more.

In the mid 1950’s Babcock installed its first commercial supercritical once-through (“SCOT”) steam generator, known as “UP-1,” at American Gas & Electric Co. (“AG&E”). Shortly thereafter, Babcock installed two more SCOT steam generators at AG&E, which were its first membrane-wall units. The membrane wall construction has the advantage of eliminating the pressure-tight casing and refractory liner which had theretofore been used to back up the heating tubes and enclose the combustion chamber.

*794 Each of these first three AG&E units employed “up-down-up” circuitry in which the fluid flowed upwardly in one heating “pass” (consisting of a number of vertical tubes connected in parallel), downwardly in the next pass, and so on in alternation around the periphery of the boundary wall. This arrangement was found to present serious operating difficulties due to the substantial differences in temperatures of the adjacent tubes of different passes (since the outlet end of each subsequent pass was opposite the inlet end of the previous pass). The resulting differences in thermal expansion of the tubes imposed severe shear stresses at the welded joints between passes, requiring expensive redesign and reconstruction of the units.

In order to avoid the necessity of using in the fabrication of the tubes and webs special, expensive alloys capable of withstanding such temperatures and mechanical stresses, Babcock determined that the temperature differential between no pair of adjacent tubes should exceed a “critical” limit of approximately 100 F.°, a condition difficult to achieve in large-scale boilers having an up-down-up configuration.

Some time in the early 1960’s, one of Babcock’s engineers, Arthur Frendberg (“Frendberg”), suggested an alternative circuit arrangement in which the flow of fluid is upward through all of the tubes in the membrane wall, with the downward return flow between successive passes being “out of the heat” in large-diameter “downcomer” conduits located outside the walls. This “up-up” circuitry arrangement has the advantage of utilizing the reduction in density of the fluid as it absorbs heat to create a natural fluid drive and produce a faster and more stable flow which enhances the cooling of the tubes and keeps to acceptable levels both their individual temperatures and the temperature differentials between adjacent tubes of different passes.

The differences in temperature of the fluid discharged from the upper output ends of the several tubes of each pass are equalized by connecting all of these ends to a “mix header” manifold extending around the outside of the furnace walls to receive the fluids and mix them together before feeding them to the “downcomer” conduits. The lower ends of the downcomers are similarly connected to another “mix header” which is connected to the lower input ends of the tubes of the next pass. In boilers having successive passes arranged one above the other in the furnace walls, the outlet and inlet mix headers are positioned adjacent one another at an intermediate level opposite the juncture of the two passes.

The furnace walls are not self-supporting but are hung from an overhead support, with the weight of the lower passes being carried through a coplanar web welded to the upper passes. To distribute the load stress at the juncture between upper and lower passes over welds of greater length, which are under shear stress rather than tensile stress, the upper end portions of alternate tubes of the lower passes overlap for a short vertical distance the lower end portions of alternate tubes of the upper passes.

The up-up circuitry with intermediate mix headers was employed by Babcock in its “UP-9” boiler for the Tanners Creek Station of Indiana Michigan Power Co. and its “UP-12” boiler for the Hudson Station of Public Service Gas & Electric. In each installation, the tubes of the two vertically coextensive passes in the lower portion of the walls were “interlaced,” with the individual tubes of the two passes in alternating positions around the periphery of the combustion chamber. This was done, in the apparent belief that it would avoid the high stress concentrations which would be created at welded junctions between side-by-side panels or groups, each made up of a number of parallel tubes of the same pass, so that an entire panel tends to expand as a single unit.

On April 13,1965, Babcock filed an application for patent, Serial No. 447,669, on this circuitry in the names of Frendberg and another Babcock engineer, Harold J. Dungey.

*795

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Bluebook (online)
512 F. Supp. 792, 210 U.S.P.Q. (BNA) 232, 1981 U.S. Dist. LEXIS 9536, Counsel Stack Legal Research, https://law.counselstack.com/opinion/foster-wheeler-corp-v-babcock-wilcon-co-nysd-1981.