Beruflich Dokumente
Kultur Dokumente
OPERA1"'OR'S GUIDE
Construction, Operation, inspection, and Maintenance
of Steam Boilers, urith 310 Typical Steam Eng1:neer' 8
E xamination Questions and A nswers
BY 1\
HARRY M . _ING, Ju.
S iter I n.wetoT Commis.ioned by the National B oard of B oiler a,14
P re8Stlre V •• sel T1187)eclor8, and by Code States; Licen8ed Chicf
I'iJngill.eer; .If ,mhcr of l.hc Am rican Society of
M echa1lical En(lineer.
UNDP! Sf / FAO
IjSIWiI£s ,..gwaCf NO. ..
UIRAlif
UNDP I SF I ~AlJ
FISHER IU ~NQ. , .
LIBRARY
·tf~1 !F ' FAO
nSHERIE:5 ~ CT NO. 70
LUUtAIH
COPY RfOHT , 1940, BY THE
M CGRAW-HILL BOOK CO~IPANY, JN C.
22 23 24 25 - MP - 10 9 87
60510
PREFACE
The purpose' of thiR book i. to supply a modern handbook
sp cializing on boilers and boiler equipment.
The chapter on construction should be of especial int.erest. to
thr cadet boil",!, inspector, to the operating engi neer illterestrd in
li cense examinations, and to t hose wishing to know mOl" of
standard shop practices. Methods arc shown for calculating
safe pressures for many types of boiler.
Succreding chapters drs('l'ibp inHtallation, design, and dis-
tinct.ive featurr,.; of a widp vari<,ty of boiler from the common firt--
tube' t.ypes to t he high-pressure steam j.wm·ratOJ·s in t.hi~ country
ILnd abroad.
A chapt.er on appliances and auxiliaries att.f'mpts j,o give thr
reader a picture of qllipment ne('rRRary for saff', economical
boiler operation. This is followed by a chapter on plant manage-
ment, which includ H persollnrl problems, wag~' incentives, and
hourly shift Rchedulrs usrd in many plants. The concluding
chaptrr covers many opprt1iing problems of a wide varirt,y of
equipment and t heir pl'actic:al .olutions.
An effort has been mad to make the text sufficiently non-
technical to benefit the man I:ltarting at the foot of the ladder and
yet contain information that will interest and be of value to t he
man at the top.
The questions and answers at the end of many chapters are
based on each common type of boiler and the plant equipment,
described in the chapt,PT. They are typical of tho e asked in
examinations for firem >n's, engineers', and boiler inspectors'
licenses by various states. The author disapproves of so-call!'d
"trick" questions, but some, reprrsentative of t hose occasionally
asked, are included.
The author grat,efully acknowledges the generous cooperation
of the many manufacturers and individualR who have aide.d in
the preparation of this book.
In addition to the photographs whose sources are acknowledged
throughout the pages, greatly appreciated data have been
v
VI PREFACE
received from the American Iron and Steel Institute; thE' Bab-
cock and Wilcox Co.; Besler Systems; Brown, Boveri & Co.
Ltd.; Cleaver-Brooks Co.; Combustion Engineering Company,
Inc.; Crane Co.; The Dow Chemical Company; E lliott Com-
pany, Fostpr Wheeler Corporation; E. KE'pJer Company; Lukens
Steel Company; Morehf'ad Manufacturing Company; Riley
Stoker Corporation; Siemens, Incorporated; and from Vitkovice
MinE's, Steel and Iron Works, Corp.
Special ment.ion is made of the courtesies extended by Powel',
F. A. Annett and S. A. Tucker, associate editors, and L. N.
Rowley, assistant editor; and by FredE'ri ek G. St.raub, R '!search
Associate Professor of Chemical E nginpE' ring, University of
Illinois; Paul R. Sidler, E lecLl'i al Engineer; Arthur ,J. H erseb-
mann , agent in United States for Vit ko"i ce Mines, Strel and IrOIl
Work. , Corp.; and E. R Doherty, an authorit y 011 s(;eam-hoi!pt'
design and inspection .
HARRY M. SPRING, JH.
CANTON, MA SS .
March, J 940.
CONTENTS
PAOI!I
PREFACE . . . . .. . V
CHAPTER 1
GENERAL CONSTRUCTION AND STRESS CALCULATIONS . 1
QUESTIONS AN!) ANSWERS . . . . . . . . . . . . 47
CHAPTER Il
FIRl!:-TUDE BOILERS . 55
QUESTIONS AND ANSWl!:RS . •.. .. 83
CHAPTER III
W ATERTUBE BOll,ERS (STRAIGHT TUDE) 90
QUESTIONS AND ANSWERS 110
CHAPTER IV
WA'I'ERTURE BOILERS (BENT TUDE) 114
Qm<:S'rlONS AND ANSWEJ~S . . . . 138
CHAPTER V
W ATERTUBE BOILERS (BENT TUB E)- SPECIAL SERVICE AND
EUROPEAN . . . . . 141
CHAPTER Vl
BOILER ApPLIANCES AND AUXILIARIES 160
QUESTIONS ANI> ANSWERS . . . . . . 217
CHAPTER VII
BOlLER-PLANT MANAGEMENT . . . . . . . . . . 222
vii
('ON TENTS
CHAPTER VIII
PROBLEMS OF PLANT OPERATION 237
QUESTIONS AND ANSWERS . . . 299
INDEX . . .. . . . 343
•
ABBREVIATIONS AND SYMBOLS
A or a area
A.S.M.E. Am ri<',u1 Society of Mechanical Euginccr~
A.S.T.M . American Socict,y for Te~t.ing Materials
B.D. blowdoll'll or blowback as applied to safety valve operation
B.P. bursting pr('~sure
l3.t.n . British thermal unit
B.w.g. BirminghalJJ wire gage
C carbon
C " ,,0118(11.U\,
Gil. calcium
°C. degn'!' "entigrade
,!c. cubit! {'entimeLer
c.i. cast iron .
em. centimeter
CO carbon monoxide
CO, carbon dioxide
COdl', t.he A.S.M.E. Power Boil~r Code
eu. cubit·
Cu copp r
C.~.lt . cross-sectional area, in square inches unless otherwise stated
d diameter of ltn opening unless otherwise defined
D diameter of a shell or drum
E Youl1g's modultls of clasti 'ily = unit "tress dividc,d 1,.1' ullit
~traiu (29,000,000 for at,eel)
eff. efficiency
KL. clu."tic limit
ali' . degree Fahrenhcit
F.B. firebox qUldit,y a8 IlppJied to Blecl
]i'e iron
fig . flange qUlllity as applied;O steel
F.S. factor of safpty
ft. foot
gal. gallon
gr. pcr gal. grain por gallon (concentration)
g. per min. gallon per minut,e flow
H hydrogen
H,O W!.Ltcr
hp . hors(>.power
hr. hour
H .R.T. hoiler horizontal-ruturo tubular boijpr
B.S. wat,er h(>a t iug ~ lIrface
ix
x ABBREYIA1'IONS ANT) SYMBOLS
Si s ili con
SiO, silica
SO. sulphat.(:'
sq . square
st.el. standard
I t.hi ckness, in in ehes, un less o t.h(ml'ise stated
'1' th i ckll CS~ , in s ix(c('nths or flIl inrh
temp. tcrnpcmtul'C
T .S. tensile s tr('flp;t h
\' vanadium
v:r. boii('1' vcrticni t ubullll' hoiler
w.i. wrougjJl iron
yd. ynrd
y .]>. yield point
pel' cent
foot
incl'
BOILER OPERATOR'S GUIDE
CHAPTER I
GENERAL CONSTRUCTION AND STRESS CALCULATIONS
,,
,,
60 w
Flo. l.- Lollgitudin"l vo. circumferential ske".ca imposed o n" cyliudrical ehell by
internal prossuro.
~
A B
D
FIo. 2.- (a) Cylinder r upture. (b) projected ..rea exposed to pre88ur .
P -_ 55,000 X
30 2 X 0.5 -_ 1,833 Ib . pel.sq.
. 'm.
Then we have
p = T .S. X t (1)
• R
which is the foundation of the formula for calculating the safe
pressure of a boiler shell.
From Figs. 3a and 3b, it is obvious that failure will occur
at the weakest part. If the cylinder is not seamless and has a
ri veted or welded joint along its longi t udinal axis, t his seam is
considered to be t he wc'. akest part (unless t here is a, defect in
the cylinder).
/ /00 %
, - strength
(0) (b)
FlO. 3. - (a) Seaml es" cylinder; (b) cyUn der with longi t ud iml] seam .
p = T.S. X t X % (3)
F .S. X R*
•o _ 55,000 X 0.625
24- X 0.94-2 = 1,349 Ib . per sq. lU.
. B.P ,
Dividing by tbe F.B. 5, w e find tbat tbe safe working pressure of the shell
will b 269 Ih. per sq. in . If it is desired to ob tain the maximum allowable
working pressur . without calculat ing the bursting pressure, formula (3) may
be used.
It should be remembered that all examples for safe working
pressures give a value that is based on the construction only.
Often the condition of the boiler may be such that a lower
maximum pressure is essential for safety. The condition should
be determined by an authorized boiler insp ctor, and his recom-
mendations should be followed. Typical calculation methods
for deteriorated vessels are mentioned in Chap. IX.
Riveted Seams.- The five most common types of riveted seam
are shown in Figs. 4 to 8.
The single-lap-riveted seam is used largely for circumferential
Reams or for straight seams in stayed plates. It has seldom been
used in late years for the longitudinal seam of a steam boiler,
although it was not uncommon during the last century.
GENERAlJ CONSTRUCTION ANT) STRESS CALCULATIONS 9
The strength of the solid plate, step J, its considered 100 pel'
cent. Then, the weakest value as found by step 2, 3, 01' 4 is
used in the following ratio, X being the
efficiency of the seam in percentage, ba:;ed
on the weakest part: 100 is t.o X, as
strength of solid plate is t,o strength of
wcakcRt. part,
or,
100 strength of solid plate
X = strength of weakest part
Transposing,
x _ 100 X strength of weakest part
- strength of solid plate
GENERAL CONSTRUC7'ION AND S TRESS CALCULATIONS 11
I A slide rule has been used and may be used in calculations of problems
involving measurement, though it cannot be used in arithmetic problems.
Accuracy within much closer than 2 per cent is unnecessary, for this is the
usual limit of accuracy in practical measurements in many linear dimensions.
12 ROl LER OPERATOR'S GUIDE
P X t X '1'.8.
2. Strength of the net section of plate, I'ivd holes in t.lw outer
row being deducted.
(P - d) X t XT . '.
3. ,t,rengt,h of all rivets in shear, two dOli hie and one single
shear.
N X SX.a+nXsXo
4. Strength of the net section of plate in the inner row, plus
strength of outer rivet in single shear.
(P - 2d) X t X T.S. +n X 8 Xa
5. t rength of the net section of plate in the inner row, ylus
cnlshing st.rength of the strap in front of the outer rivet.
(P - 2rl) X t X T .R. +n X b X d Xc.
GENERAL CONSTR U('7' ION AND TRESS CA L('ULATIONf' 13
OTE: Tb e st.rap is considered in crushing, rather tban tibf' plR t,e, for t,h~
$trap is not so thick,
6. Crushing strength of the plate in front of the inner row
rivets plus the crushing strength of the strap in front of the
outer rive!..
NOTE: The plate is considered in crushing at the inner row, rather thnll
the straps, for the combined tpickness of two straps exists at, this point,.
NXdXtXc+nXbXdXc
7. Crllshing strength of the plate in front of the inner row
rivets plus the shearing 8t.rength of the outer rivet.
nXdXtXc+nXsXa
Example.-A longitudin al ~eam iH hlltt Ilnd douhlr strap, double riveted.
IIJld has 5 I y 2 ~ in. pitch, '].16 in, thick shell plate, f.nd 55,000 lb. p T sq. in,
T,S'i butt st raps lire eacb ~i 6 in . thick, a nd rivt't hol os % in. diam~t,er.
Find the efficiency.
]. 5 X 0.4375 X 55,000 = 120,313
2. (5 - 0.75) X 0.4375 X 55,000 = 102,000
3. 2 X 88,000 X 0.442 + 1 X 44,000 X 0.442 = 97,300
4. (5 - J .5) X 0,4375 X 55,000 + 1 X 44,000 X 0.442 = 103,500
5, (5 - 1.5) X 0.4375 X 55,000 + J X 0,75 X 0.3125 X 95,000 = J06,S(W
6. 2 X 0.75 X 0,4375 X 95,000 + 1 X 0.75 X 0,3125 X 95,000 = 84,612
7. 2 X 0.75 X 0.4375 X 95,000 + 1 X 44,000 X 0.442 = 81,600
81,600 X 1~ = 6800/,
120,313 . 0
4. Strength of net sect.ion of plate, between rivet holes of 8l'l:ond row pluB
shearing strengt,h of outer rivet, (single shear).
(7 - 2 X 0.9375) X 0.5 X 55,000 + 1 X 44,O()O X 0.690 ~ 171,300
5. Strength of net B('etion of pl>l(,1) b(~ twee n rivet I1OIe8 of R",:ond row plus
crushing strength of strflp ill front. of outer rivet.
(7 - 2 X 0.9375) X 0.5 X 55,000 +1X 0.9375 X 0.375 X 95,000 =
174,400
6. Crushing strength of plate or strap in fron t, of lLU rivets.
4 X 0.9375 X 0.5 X 95,000 +1 X 0.9375 X 0.375 X 95,000 = 211,400
4.. Strength of nct seM.i(ln of plate between rivet holes of se<,onrl row, pluH
sbclJ.ring strength of outer rivet (~i!lgl l' Hhcar).
(15 - 2 X J ) X 0.625 X 5ii,Ooo +I X 44,000 X 0,7854 - 481,450
5. Strength of net section of plat£' hetween rivet holes of third row, plus
shearing strength (s injl;l<, ) of two rivets in second and one in outer row.
(J5 - 4 X 1) X 0.625 X 55,000 +3 X 44,000 X 0.7854 = 482,000
6. Strength of net section of plate botwecn rivet, holes of second row I plus
<>n1shing strength of strap in front of outer rivet"
(15 - 2 X 1) X 0.625 X 55,000 +J X 1 X 0.4375 X 95,000 = 488,430
7. Strength of net section of plate between rivet holes in tlte third ro\\,
plus crushing strength of the stmp in frollt. of two ,·iv('t.s in the second and
one in the outer row .
(15 - 4. X 1) X 0.625 X 55,000 +3 X J X 0.437fi X 95,000 = 502,300
8. Crushing strength of the plate or strap in front of all rivets.
Plate Strap
8"5("(x Oji25" ')(95~OOO + nd"'X'O:'437K'x"'iiKooo - fi99,ISO
9. Crushing strength of the plate in front of the third and fourth rOw
rivets, plus the shearing (single) strength of the three rivets in t.hp outer two
rows.
8 X 1 X O.62fi X 95,000 +
3 X 44,000 X 0.7854 = 578,670
481,250 X 100 = 933 01
515,600 . 10
FfG. 9. -Rolling mill for making steel plate. This is a 206-in. mill, the largest.
in the worl d. It can handl ingots weighing up to 90.000 lb. lind is d"ivan by "
20,OOO-horsopower duplex, twin tandem compound steam engine. Tbe plate
shown is finished eX(' pt for straightening to remove t he wavilless ; and lay-i nl'
out and .h Ming tl) Rio". (Courtay, Luke118 Stefl ('amra1l1/.)
Fla. lO. -The same rrdU as shown in Fig. Q. This particular photograph shows
a slab in proccs" of hnvinll scale removed by meuns of salt. It may b seen us it
is thrown onto the slab. (Courtes y, Luke", Steel CompallY.)
they are held tog ther in position by tack bolts and the holeil
drilled or reamed to full size.
Whenever two or more plates are tacked together for drilling
or reaming holes, it is important that the plates should be sepa-
rated for removal of all chip or burrs before final riveting.
The location of the rivet holes is specified thoroughly by the
Code. Paragraph P-183 of the A.S.M.E. Power Boiler Code
reads in part:
I Though "subpunching" of rivet holes is a requirement in many states,
recent fatigue tests on riveted seams indicate that ther is little or noiliing
gained thereby.
1 BOILER Ol'ERATOR'S GUIDE
FIG. 12.- Multiple drill having a capacity of fiftY-BOven l>i' 6-in. drills shown
drilling rivet holee in a boiler plate. (CourtUf/, Raey Stoker Corp.)
GENERAL CONSTRUCTION AND S TRESS CALCULATIONS 19
The diameter of a rivet hole is usually ']16 in. plus the thickness
of the plate in sixteenths of an iuch. Thus a %-in. plate would
be likely to have lU s-in. rivet holes. The rivet diameter, before
driving, is VI 6 in. less than that of the rivet hole , except wher>
machined rivets are u ed. Thus, a difference of 732 in. is CUB'
20 BOlLE Ii. OPEltATOLl'S GUIDE
FIG. 14.-- .'\ planer preparing the odges of boiler plate for welding of longitudinal
aeams. (Courtc81/ , Comlru«tion Enuin.eering Co ., Inc.)
FlO. IS.- Examining weI dod soamB of an H.R.T. boilor by mOanS of X-ray.
(Co1trte8'Y, Eri City Iron Work8.)
FIG. 16.-A (urnt,ce for stros! reli eving welded boiler drums and pressure vesscls
(CclUrte8,), t:nmhu.'i"n Enyineeriny Co., I nc.)
weight of the hammer should be ] lb. for ' 0 in. in arum thickne~s
up to a limit of 10 lb. Following the hammer test, the hydro-
static pressure is rai 'ed to twice the design pressure and held
there while the seams are examined for leaks or other visible
deIe'ts.
Any defect in the weld ·xceeding standards prescribed by
the A.. M.E. Code requires chipping out, rewelding, and a second
stress relieving and radiographic examination. This is followed
by a hydrostatic test as described.
A boiler joint, welded, stress-relieved, and tested according
to Code specifications, is allowed an efficiency of 90 per cent.
GENERAL CONSTRUCTION AND STRESS CALCULA TIONS 23
FlO. 17.- (a) Crack in welded Ream of 3~-in. boiler plate as shown by radio-
graphic film. (b) Radiographic pioture of same H otion of sonm as in Cal, afte r'
chipping out defective 8cction and rewelding. (Courtesy, Comb"stio1l Engineer-
ing Co., Inc .)
Wbere the pitch between the tube boles is equal (Fig. 18),
the efficiency is equal to
p-d
P
where p = pitch,
or longitudinal di st~nceR between holes, in
inches.
d = tube-bole diame1,er, in inches.
-ct1.PW~$-
• ed In fo hole.
" Tubes equally spqced_
Oouble srrop, _ \ 8j."aparf lonqifuC/iml/y
double rive 'fed --.... ~
/ongifudinal -----Ooubling plate
seam 720/0
erfi'ciency
, (t)
or
8.25 - 4.0625 = 50701
8.25 . /0
Using formula (3) t.o find the pressure based on t h~ longi tudinal seam, w~
hav('
1. P -- -
55,000 X 0.75 X 0.72 _ 2 '-11
- 24 X .5 - .,. , I. per
.
Rq. Ill.
Using formula (3) to find t h!, pressurr bnsecl on the tube ligament, we hit""
2. P =- 55,000 X (0.75
2~ -
+ 0.5) X 0.507
- ~
2891b
. per sq.
.
lll.
FlO. 21.-Scully diagonal stay as usod for staying the fiat segment of the head,
.. bove tubes, in borizontal fire-tube boilers. (Courteey, Erie City Iron Work • .)
palms shall line up with the .%2-in. ofi&ct holes in the shell, the
stays are heated to expand them this amount. While hot, the
palms are riveted, and, on cooling, the stays contract enough to
provide proper tension. Some shop do not take the trouble to
heat the stay t o line up the boles but "stretch" the stay into
position with a driftpin.
NET AREAS OF STAY BOLTS
(12-V threatls per inch, a rea of ~1 6-in. telltale holes being deducted)
N ct cross-scc-
Allowa ble load
Size of stay bolts, Outside dia.m eter tional !l rca of
at 7,500 lb. stress
in. of stay bolt, ill . bottom of thread ,
per sq. ill.
less 0.0276 sq. in.
------- -- -
~ 0 .7500 0.21l1 1 ,953
1~6 0 .8125 0 .324 2,425
:l-B 0 .8750 0 .391 2,935
1716 0 .9375 0.467 3,498
1 1.0000 0 .548 4 ,105
1316 J .0625 0 .635 4, 765
" 1~ 1.1250 0 .728 5,455
1~6 1 .1875 0 .827 6,205
IX 1.2500 0 .933 6,993
171 G 1.3125 J .045 7,833
1 ~8 1 .3750 1.163 8 ,71 8
1})6
1~
1,4375
1.5000
I 1.285
1.416
9 ,640
10,623
I
Mo t codes allow 11. lllaximum st.ress of 7,500 lb. PCI' sq. ill . on stay bolt.~ .
Multiply liN ttr<'1l. by 7,500 for moximum allowll.hle load .
--------- b
/ : ; Segm(mf fo ' '1_
L~t}._b~"§!PXf!...d_ __ .::~
00"00000000
0000000000
000000000000
000000000000
000000000000
000000000000
0000000000
0000000000
O@O@O
1<'10 . 2:l.-Area to stay a bove tubes in H.R.T. boilor . Front tuoo shoet of
hol'izon tal fit'c-tube boiler.
NOTIt: TJw "egmt.>nt ubove the tul1f'fII 0 11 Illt' rpl\r I IIIit' ~ht'f't u ll lu~ll y rNlu irNt id('utit'nl
~tllyjl}g .
A 4{25 - 3 - 2)2
= 2 36 - 3) _ 0608
3 25-3-2'
A = 875 eq. in.
The total load on 18 braces will be A, the area in square inches, times Lh"
pressure per square inch acting on this area. The resistance to this load is
the total number of squa re inches of brace metal t imes its maximum allo\\"-
able uni t stress, or 18 X 0.785 X 8,550.
Thus,
"'-
"'-
\.
( liak AlJglfl irons
?Il Through- fo -head braces / Brace eye_-/"'T;{~ riveted io
b=1=b==~=========--====='i5':iiTIl? rllar l ube-
_ I she¢.
Fronf end of each brace (usually fwo braces) i-(" / ~
upsef and fhreaded, fJasslng fhrough fran I - Brace ~
fube-sheelon each side of manhole, tube -sheet pin-'-r
supported by braces w/fh a washer and ........-- Ir'-
nu t Inside and oufslde on each brace
}M.:a:n:h=:o~/e~Tn:r.=me~~r.~/V.~::~f§~/~r~_~~;~jJ~~f"~
__ __
Manhole
I
---- II" --,..l "Sfee/ ring shrink
I f"if
Shaded areas represenf
m efal removed I Olmens/ons g/ven are ror
parf/cular example only
Showing RosiNono'"
manhofe rrame //
,,"/'0 ----t, ---.0. . . . ,"
dveiholes inre-
sp'ed to longifl/din - I
/ 0 .
0 "\
0 1 neufral a x is / 0 0 \
I \
FIG. 25.-FirsL spinning oporation fOI" flanged fwd dished hend shown in Fig. 26.
(CQurt esy, Luken. SteP{ ComlJulIY.)
FrG. 26.-Final spinning operation on Il Banged and dished head. While the
partioular head shown is not used Jor 0. boHer, the operation is similar. The head
shown has finished dimen8ioll.8 204~ in. outside diameter. by 1% in. thick, and
weighed 21,000 lb. (Courtoey, LukeM Sted Company.)
34 BOlLER OPERATOR'S GUIDE
The met.al removed from the shell is shown in the shaded areas, and iM
]7 X 0.5 + 4 X 0.9375 X 0.5 '" 10.375 sq. in. Let us selcct a framE>
W = 9 in. wide. (Unless given in a problem, either the length or the
thickness must be assumed.) Then both sides will have a total length for
the cross-sectional area (C.8.a.) oi 18 in., and the required thickness will be
10.375/ 18 = 0.576 in.
Now, as 10.375 sq. in. of shell plate WIIS removed, this represents a total
T.S., of 10.375 X 55,000 = 570,625 lb. Since the strength of rivet metal in
single shear is 44,000 lb. per sq. in. 570,025 / 44,000 = 12.97 sq. in. of rivets
in single shear is required in each side of the center lille, for one side is con-
sidered as an ancbor whereas the oth r side actively resists failure. Then,
because 1 ~ a-in. rivets arc to be used and the area of one rivet is 0.690,
12.97/ 0.690 = 18.7, or 19 rivets are required OIl each side, plus the 2 in the
neutral axis; or a total of 19 X 2 + 2 = 40 rivets is required.
P = 70,000 X 0.5
4.165 X 42 ~
200 lb .
. p r sq. m.
I
90
,..... 80 24 "chord
CIC /
..... 70
a..
~ 60
to
'S 50
\
.,
.240
\
""0
~ 30
l\.
20 0 I 2
" 3 4
Height of BumpCb)
FIo. 27.-Radiu8 gage for dished heads.
ing the radius of the dish. The formula used in plotting the
curve was
Lugs or h angers, when used t o support Q, boiler of any ty pe, shan bl:'
properly fitt d to the surfaces to which th ey are attached.
Where it is impracticable to use rivets, studs wi th not less tha n
10 threads per inch may be used . In computing the shearin g Btre~scs ,
the area at th e bottom of th e thread shall be used. The shearing and
crushi ng strcssc on t he rivets or studs used for attachin g t he lug or
brackets shall not exceed 8 por cent of the strength given in Pars. P-15
and 1'-10.
On the assumption that steel rivets are used, the rivets are in single shear ,
and the maximum allowable stress = 44,000 X 0.08 = 3,520 Jb. per sq. in.
The load on each hanger will be (30 X 2,000)/4 = 15,000 lb.
Then, since the cross-sect,ional area of a %-in. rivet hole is 0.601 sq. in.,
15,000/ (3,520 X 0.601) = 7.08; th refore, eight rivots would be used in
each hanger, arranged in two circumferential rows of four each or staggered
so that not more than two per hanger would fall in the same longit.udi nal
line.
sectional area of 1 sq. in. each. What is the resulting stress lIet up in the
braces? The total pressure is 10 X 10 X 100 = ]0,000 lb., and the total
brace area supporting this load is 2 X 1 = 2 sq. in. Therefore,
\0,000/ 2 - 5,000 lb. unit stress set up in the bra.ces by the 100 lb. per sq. in.
steam pressure.
From this exa.mple comes the formula
nXaXs=AXP
or
8-. -
A xP
-
nXa
., (4)
P - 3 X 10
0.8 X 7,500 ISO Ib .
X 10 - . per sq. m.
When the length of the furnace does not exceed 120 times the
thickness of the furnace sheet,
p = 51 5
[(18.75 X T) - (J .03 XL))
where the length exceeds 120 times the thickness of the plate.
4,250 X '/"
p = L X D
The reader should consult the Code for mor complete specifica-
tions for unstayed furnaces, for it gives details not permitted by
the space or intent of this boo .
If a furnace does not meet requirements for an unstayed unit,
one of the following three methods of support may be used.
1. A corrugated furnace may be used (Fig. 50). A common
type of corrugated furnace is known as a. "Morrison" furnace.
40 BOILER OPERA7'OIl'S GUIDE
Furnace
Ourside sheer
wrapper
sheer
FlO. 29 .-BTlLcing by stay bolt.
o o o
Note: Area "A" Is supported by i"ofa staybolf
areach corner, so one sfotybolf '{I the center of
this area would be of' equivalenr stren(Jth
FlO. aD.-Area s upported by stay bolt.
Stay bolts are allowbd a maximum unit stress of 7,500 lb. per
sq. in. The size of the stay bolt must b sufficient to enable it,
safely to withstand the load imposed by the pressure (Fig. 30).
It will be seen readily from Fig. 30 that the area enclosed by
42 BOILER OPERATOR'S GUIDE
the two pi(,ches less the area of t.he tay-bolt hole, as shown in
t.he dotted line, is supported by one stay bolt.
Enmple.- One-inch stay bolts are pitched 5 in. between horizontal
rows by 6 in. between vertical rows. A ~ 6-in. telltale hole is drilled in
clLch stay bolt. What is t,he maximum allowable pressure based on the
Ht.rength of tbe stlLy bolts?
From the ta.ble giving net area.s of stay bolts (pa.ge 28) the net cross-
sectional area of each stay bolt is 0.548 sq. in. By formula (4),
p n X a X8
- A
P - 1(5X X
0.548 X 7,500
6) _ 0.548 =
1391b .
. por sq. m.
Note that the minimum cross-sectional area of the stay bolt is deducted
from t.he product of the pitches to get A .
In order to obtain the diameter at the root of the threads of a stay bolt
having 12 sharp V threads per incb, subtract 0.1443 from the outside
diameter. The area at the root of the threads is then, of course, the root
diameter squared times 0.7854.
p = n (5)
~1l2 X 6'
p - J39
- 5.a9 in. max. pitch
Here it will be seen that the 6-in. pitch is too much for la9 lb. per sq. in.,
and therefore the formula should be transposed and the maximum safe
preBBure for the 6-in. pitch calculated.
p _ CT'.
p'
112 X 6' .
p ~ -- 6'- = 112 lb. per sq. m.
= [220 X T2J2
L PXR
where L = pitch, in inches.
T = furnace-sheet thickness, in sixteenths of an inch.
P = maximum allowable working pressure, in pounds per
square inch.
R = outside radius of the furnace, in inches.
The A.S.M.E. Code allows the longitudinal pitch to equal the
circumferential pitch in case the result as found by this formula
calls for a lower value. If the outside diameter of a circular
furnace exceeds 38 in., the maximum pitch in either a circum-
ferential or longitudinal direction should not exceed 1.05 X p
as found in formula (5) .
Steam Domes.-A dome is constructed usually on the top of
locomotive fire-tube boilers, and is optional on other types of
fire-tube boiler, to insure sufficient room for dissociation of much
moisture from the steam. Comparatively dry steam should
• This formula and a. complete list of constants for this formula a.re given
in Par. P-l99. A.S.M.E. Power Boiler Code.
l\ 1887
44 ROlLER OPERATOR'S GUiDE
The edges of the tube holes are chamfered about 716 in. after
the holes are drilled so that there will be no sharp edges to cut
into the tube when it is expanded.
Tube holes arc fini hed 732 in. larger in diameter t han the
outside diameter of the boiler t ube, except in the tube sheet of
fire-tube boilers. Through this, {,ubes must be drawn during
retubing, and therefore its holes a re fini shed H6 in. larger in
diameter su as to permit a tube that is coated with seale to be
removHd without dumage to the t.ube sheet.
FlO. 31.- Boilor-tube bending nllwhine used for prepul'ing tube. for many t.ypes of
w"lcrtubc bniler.. (ClIl/rt esy. Rilty Stoker ClI'rp. )
2. A ~- in . plat,e is Rupportc:>d by stay bolts :1i in. diameter at the root of tIlt'
thread and pit,ohed 5 by 6 in. Will t,his support 200 lh. p<>r Aq. ill. steam
pressure? Explain the method.
Anb. Net cross-sect.ional area of 3ij-in. stl'Y bolt. = 0.419 sq. in. 'fbt'
area of plate supported by this bolt is (5 X 6) - 0.419 - 29.581. Ii I'
maximum unit stress of 7,50(, lb. per sq. in. is "lInwed,
0.419 X 7,500
29.1)8 1 =
]0"1I Ih • pflr .
Aq. 1Il . max. AII OWIL hIe preSRIITl'
lIy (:Illculatinp; thl' ,L1lnwllblc pr\lA~m(' bn.Red Oil the platp st ifTn esH,
P = 120 X s'
6i = 213 I),. per sq. in. mlLx. 1L110l",.I>I .. preRHIII·(·.
(Here, poor design may be suspected. The stay bolt is much to() lilJ,l ,'
for the safe pressure based on the plate stiffness; that is, an lmll('C('"~,"· 1I .1 ·
thick pIa te has been used. )
3. A }1o-in. plate is to carry 150 lb. per sq. in. What is the maxillllllll
allowable pitch of stay bolts?
2
Ans. 112150
X 7 "" 6 .03 i
p - D.
4.. (a) A boiler drUID is 40 in. diamet,er; tensile strength is 55,000 Ih. per
sq. in., plate thickness U in., factor of safety 5. What is the Ili axillllllll Hafe
working pressure? (b) If the pressure is increased 10 per 'ont, what i~ tllIl
F.8.? (c) li corrosion cause a general reduction in thickness of 7!1 ill ,
what is the maximum safe pressure?
Am. (a) (No data Ilore given for the longitudinal seam, and so tIlls must,
be a8Bumed . In such cases the method is checked for being correct, fOI
the answers will vary according to the assumption.) Assume a quadruple-
riveted butt-IInd-doubJe-strap longitudinal seam having an efficiency of
94.0 peT cent. Then,
P -
55,000 X 0.5 X 0.94 258 Ib .
20 X 5 - . per sq. m.
48 BOlLER OPERATOR'S GU//)E;
(b) 258 X 1.10 = 284 lb. per sq. in . T ransposing the formula and solving
for the factor of Bufety, we h l1 ve
(c) A red uction in t hilOknpss of 7B in. wiJI be 25 per cent, which will leave
75 per oPnt of the solid plate. Since this i below the effi cien cy of the
longitudinal ""ali (94.0 per "ent.), t he maximum safe pressure should be
r(~dl:ced ItS follows:
6. Name three kinds of Ilugl!' brar!' (for segment of tube sheet over t ubes
ill H.H.. T. boilers not px(~eed ing 36 ill. diameter or JOO lb . per SCJ. ill. mfLx i-
mllm pre[;sure).
A n.. Angle iron s, channelu'ons, T irons.
6. In a boiler sho jJ, wl:y should you exltmin(' pUll chiogs from rivet holes in
boiler plat.e?
A 1IS. To sec if t he allowable tolerances worc exceeded . If t he plate docs
not. ~c()ed X G in. thickness, t he holes may b e pun ched to within U in. of fu n
diameter. If the plate exceeds ~ I G in. t hickn ess, the holes may be punch ed
not over 3i in. less t h!Ln full size.
7. How aro tube holes made?
Ans. They may be punched to not over ~ in. leas than finished diameter
IlllU finished 1..j lluLchining. They are ofien cut wit h a. pilot drill anrl l'otating
cut t.cr.
8. How far ~honl d the calking edge of a longit.udinal Bcam be f rom the
(lentcr of t he nen l'Pst row of rivets?
A1I.. Not les~ than l ~ or mo re than J % X ri,'et-hole diameter.
9. (a) How mueh larger than a flJ'e t ube maY.!:'Hl tube hol e be? (II) Row
much hll'g~r for a water tub!'?
An. . (a ) l,<J2 ill. lIlrgr r diameter at th!' fif(l cnd. Yt G in. at. the opposite
('nd. (b) 732 in . for iiber end.
10. How are the ellos of s hell pIn.tes, and butt. straps, formed for the longi-
t udmal seam?
Ans. They should bd formed by rolling or pressing, and not by blows.
11. What is the required size of the pin in double shear, passing through
the eye of tht'ough-to-head braces, below the tubes of an H .R.T. boiler?
Am. At loast 75 per cent, of t he net. cross-sectional area of th body.
12. (a) A steam drum 36 ill. diam eter, X 6 in. thiok and of 55,000 lb. per
sq. in. T .S. has a longit udinal seam, double-lap-riveted and having 71.5 per
cent efficiency. This drum has a ligament with an efficiency of 42 per cent.
What is the maximum safe pressure? (b) Assume the same drum has a
<toubls-riveted butt-and-double-strap longb llrlinA.l Realn havin c: a.n crficiency
"r 82 per cent. Also, assume that a ;!i-in. dvublrng plate is riveted over the
li~alllent. What is the tnll.xDtl1lm safe pressuret
GENJiJRAL CONS1'lWCTION AND STRESS CALCULATIONS 49
But over 100 lb. per sq. in. is not allowed on a lap seam, so the pressure woule.'
be limited to 100 lb. per sq. in.
Since the latter value is the lower, this is the maximum safe pressur('.
lS. What are the maximum- and minimum-size openings for a blowdown
cormoction in a power boiler?
A7Is. Maximum, 2~ in. Mininlum, 1 iu.
14. (a) When may cast-iron headers be used? (b) When UHty mall eable-
iron headers be usee!?
Ans. (a) If the prc~surc does not exceetl J(j0 lb. per sq. in. "nd (,he ('ross-
sectionrd area falls wit.hin 11 7- by 7-ill. rectangle. (b) If the prcss ur~ dol'S
not exceed 350 lb. per sq . iu., and t.he cross-sectional are•• falls wit hiull 7- hy
7-in. rectangle.
16. What objection is then' t.o shell pJates of all H.R.T. boiler exceedinj!.
% in. 11t the girth sealTIS, !Iud whnt sho uld be don' if thl'Y do?
Am. The combined thickness of me!.al 1t (.he Scalfl might cause thu ur'
side to overheat and crack. It is requir d that plates over % in. thick he
machined down to 110(. ovor ~ j 6 in. wit,b a radius at least I in. al the edge of
machining at girth RcaIDS.
16. What is the limit (.0 a shell or drum of uniform thickness being truJy
circu lar?
Ans. One per cent, based on difference b etween inside alld outside
diameter.
17. How should tubes be expanded whon there is a reinforcing plate?
A7I8. If the plate is calked on the outBid , the tub(~~ ~hould be expandrtl
into both the shell and reinforcing plat(lB 80 that the tubes will aid in holding
both together.
18. When maya lap-riveted longitudinal Beam be used in a shell over 36 in.
diameter?
Am. When the shell is in II section stay-bolted as a furna e sheet.
19. What are t,hree major requirements of weld !nuta! for boilers?
A 718. (1) A tensile strength not less than that of tho bailor plate. (2) A
minimum elonglttion of 20 per cent in 2 in. (3) A specific gravity of at
least 7.8.
20. (a) What is of extreme importanc . in external observation of a finished
wold ? (b) Why?
Ans. (a) That there shall be no valleys or grooves at the center or edges
(undercutting) of the weld. (b) A groove causes a "notch" effcet and
stress concentration that may result in cracking. Also, the flill tili 'kness 01
plate may not be attain d in the weld.
50 BOILER OPERATOR'S GUIDE
21. What is the minimum corner radius for an unstayect dished hell.d!
Ans. Not less t.han three limos the thinkneBB when measured on the con-
cave side, but lD no case less than 6 per cent of the inside dtameter of the sheJl
or drum to which the bead is to be attached.
22. How much may the knuckle of a dished head be thinned in forming?
A.ns. Not over 10 pCI' cent.
23. Is any motal removed in calking a seam?
AtM. The ttmount is negligible.
24. Are all tubes in a bent-tub boiler flared?
Ans. No. A few ill the bottom of t he upper drum~ are usually beaded to
provide for drainage. A few in the top of the lower drums ore li.kewiHe
hettded to prevent air pocketing when the boiler is being filled .
25. When is 1\ manhole required in the front tube sheet below the tu hes in
ILR.T. boilers?
Ans. When th!NJoilcr is 48 i.n. diamct,or or larger.
26. When is a manhole required a.bov!' the tuhes of a horizontal fire-tube
hoiler?
Ans. If externally fir d, for boilers 40 in . diameter or over j if internally
fired, for hoilers 48 in. diameter or over.
27. (a) Whl1t, is tho minimum fl\ce width of a manhole flango for a gasket
bearing surfare? (b) What eO\lld bo done if the flange were only :h' 6 in .
lhi~?
A 118. (a) I (6 in . (b) A steel ring is sbrunk OHto the fll1nge, and t no
double face mMhined 'for a hearing $urfl\ce.
28. 1'\ame four ways of supporting a circular furnace subjected to externfl l
pressure.
An8. It lUay be (1) self-supporting, (2) stay-bolted, (3) corrugated, or (4)
equipped with Adamson rings.
29. How does tho fiber run in boiler plate when the shell is completed?
Am. It, runs circumIerentially, in the long axis of the plate as it waR
rolled.
30. How is a circular manhole plate 17 in. o.d. placed in a forged drulll
with a IS-in. manhole in the head?
Am. The manhole plato is placed in tbe drum before the ends are tapered
to finiahed shape, for at that time the opening in the head is much larger
th"n 17 in.
For information on the following questions and answers, refer to Appendix .
31. What is a laminated boiler plate?
A 118. One that contains a stratum of slag, rolled in by accident.
32. What harm does a lamination do?
Am. It is an insulator that prcvents free conduction of heat. If the
plate i~ in a high-temperature zone, a blister may result due to overheating
of the plat,e on the fire sid of the lo.mination.
33. What type nnd grade of steolnre required for boiler plates under pres-
Attre (non-alloy, non-hi gil-tensile-strength steel)?
Am. Open-hearth firebox steel if the plate is to be • .:posed to the
productls of combustion. Open-hearth fio.nge steel if not.
U. Is the actual tensile strength stamped on the plate?
GENERAL CONSTRUCTION AND STRESS CALCULATIONS 51
sizes up to about 250 boiler hp. The inherent reasons for these
limitations are that the diameter of the shell increases with
capacity in order to accommodate a larger number of tubes.
The thickness of the shell must be increased for higher pressures,
or for greater diameters at the same pressure. Practicallimita-
tions for diameter are about 96 in. and about % in. fol' shell
55
56 BOlLER OPERATOR'S GUIDE
~~ftt~~~~,.... ,/
the flow of hot gases into the real' ends of th tubes and to prevent
the area of the tube sheet located above the water level from being
contacted by the hot gases.
The arch should come low enough (,0 protect th tube sheet in
the steam space, but it should allow sufficient clearance above
the top row of tubes at the middle to permit installation of a
fusible plug.
The rear arch is supported uRually by Reveral c.i. arch bars
(Figs. 33a and 33b).
Side Walls.- The boiler side walls are usually of red brick. An
air space is provided sometimes betweell these walls and the
furnace firebriok walls. The important point, is for the furnace-
lining walls to be anchored to the side wall" flO that the lining will
not collap e. The furnace lining may be of firebrick or of fire
clay installed in plastic form and baked hard. The lining is
carried up with a clearance for the "closing-in-line" with the
boiler shell (Fig. 33b). Here again, a semiplastic, heat-resiRtant
material is used to allow for free expansion of the boiler without
abr~sion of the shell. A v ry important purpose of this cloRing-
in-line is to prevent the hot gases from coming in contact, with
the lugs or brackets, longitudinal seams, or any part of the boiler
at or above t he lowest safe water Ie el where damage by over-
heating might occur.
Thus, the front of the H.R-T. boiler may be considered
anchored, whereas the boiler is free to expand to the rear,
unrestricted on both sides or at t he rear end.
Pitch.-The H.R-T. boiler should be installed with a pitch of
1 or 2 in. to the rear to allow any s diment that settles to work
toward the roar, wher it may be removed t.hrough the blowdown
line. If sediment coll cts on the bottom of the shell and is not
removed or if accumulations of loose scale collect, overheating of
the shell may occur and serious damage may result.
The one exception to the rule for pitching toward the rear will
he found in a few installations that burn su pended fuels (pul-
verized coal, oil, or gas) at high ratings. The most intense
heat is at the rear of the setting (Fig. 34). Here, difficulties
may be experienced from overheating of the blowdown line.
Such installations may be changed so that the boiler will pitch
toward the front. A blowdown connection is installed at the
hont end.
FIR'E-TUBE BOILERS 59
If the boiler is pitched toward the rear, its pitch ma.y be
measured by damming the lower half of the rear end of a tube
with clay and filling the tube with water until it just starts to
Blow- /,..-
down '
I<=>
, 1 Tle-rod-
,
4'-6/1 ..... ~ .. - I
cracks may develop in the walls and they may collapse ulti-
mately. Buckstays Me cast-steel or cast-iron columns set in
pairs, one on each side of the boiler, and spaced every 4 to 6 ft.
along the length of the side wallR (Fig. 35). The bases of these
buckstays hould be buried at least 3 in. in the concrete floor and
the upper ends should extend slightly above the top of the boiler.
A tie rod with a turnbuckle should connect the top ends of each
pair of buckstays, tying them toget,her rigidly across the boiler
t.op.
Battery.-When two Or more H.R.T. boilers are installed in
battery and supported by the brick walls, it is not unusual for
the division wail (the wall between and supporting t.wo boilers)
to become overloaded as it deteriorate!'>. This eff ct, may result
in gradual decomposit.ion and crushing of the brick or bulging
Blowdown pad,'
81owdown pipe----
FIG. 36.
of the wall. The foundation of the wall may settle, too. The
result is that one or bot,h boilers supported by the wall will
" roll" or set.tle on one side.
This condition may he checked by a level across the top of the
tub s or across two straightedges or lengths of pipe in the front
('nds of two tubes in the same horizontal row. Even a slight
settling may be serious, for the distance is muhjplied in the stearn
piping from the boiler. S rious stresses may be set up in thE'
pipe or fittings, and failure under pressure may reBult. Chronic
troubles with gasket leakage in the main stearn lines are often
an advance warning of this trouble.
Blowdown Connection.-The blowdoWD pip carulOt be merely
screwed into the shell, for there would not be a sufficient number
of threads in contact to give proper support. Instead, a pad is
riveted to the bottom of the sh 11, and the blowdoWD pipe is
screwed into this pad (Fig. 36).
The minimum size of blowdown pipe for boilers over 10 hp.
(100 sq. ft. of heating surface) houJd be 1 in. A minimum size
of % in. is permitted by most states for boilers of less than tbis
P1RE-7'UBE BOILERS 6]
M-Fronf encl
of' boiler
Or.Y-sheet-- ,
Firing clocr:
Ashpif
cloor---
FlO. ::l7.- Flush-front Betting for H.R.T. boiler.
• Some boiler manufacturers use the outside cliamet.er wh ther tbe (uhf' ie
fire- or watertube.
64 BOlLER OPERATOR'S GUIDE
LOCOMOTIVE BOILER
A great many horizontal firebox boilCl's are modifications of the
railroa.d locomotive (Figs. 39 and 40). Although thi type of
• See cha.rts for determining hea.ting surface in Appendix.
PIRE-1'UBl!J BOILERS 65
.c
:;;"
.
'Ii'"
o
~
66 BOILER OPBRA1'OR'S GUIDE
boiler may be ideal for a mobile power plant, a for rail service,
it has some limitations in stationary service. These points are
mentioned in the follomng sections.
Advantages.-l. It may be constructed at a reasonably low
cost.
2. Its comparative compactness per unit of capacity mak es it
ideal for a portable unit or for use with low headroom.
3. Absence of practically all blickwork and masonry reduces
eost of installation.
4. It is semiportable because of item 3. 11, may be moved
!\ud set up readily in different locations.
5. Tube replacement is a comparatively easy matter.
6. All tubes may be the same size; thus, one spare tube \dl
replace any tube that may fail.
Disadvantages. -For certain l'equiremen ts:
1. Some water space are difficult to clean.
2. The shape and dimensions of the firebox are set by t,he boiler
design and cannot be changed to meet the requirements of
different fuels.
3. Omng partly to item 2, the maintenance costs may be high!'!'
than for the H.R.T. boiler.
4. Owing again partly to item 2, the over-all efficiency of the
boiler may not be so great with high ratings as for some othe!'
types.
5. There arc practical constructional limits for pres ure and
rapa<:ity which may not meet requirement. t
6. Exposure of the firebox plates to radiant heat may lead to
bulging under certain adverse conditionR.
7. In practice, it is UnAble to carry high overloads ,vithoui
being d mag d by overheating.
Gas Flow.- The flow of gases in the locomotive boiler is
straight through the tubes alld out. Unless quite long t ube are
used, the gas exit temperature may be comparatively high at
high ratings with resultant loss in efficiency.
General Details.-A study of Fig. 41 should be made to become
familiar mth the names of the different sheets of boiler plate used
in constructing the locomotive boiler. It is customary in con-
structing the looomotive boiler to rivet or weld the firebox
1 The maximum pressure for which these boilers are manufaotured com-
monly is about 300 lb. per sq. in. at this time.
FIRE·TUBE BonERS 67
rr==1l
"..
>.
!
~
"i
.
.c
E
"Q
>"
"
«i
.t
~t
co.c
"_ w
>~
cu ::l
"_<n _g..
-0-
.,."
0
~
"Q
~
~
~0
0
"Q
"Q"
"!j
::>
.
0
..c
b
.;
~
"Q""
"!l"
.
"
..c
.'"
]'"
~ ~ "~"
~ ">cu_ a
0
13 0
I... +cj"
~ el
se
L<..~
""".;
------ {;
68 BOILER OPERATOR'S GUIDE
Mucirlng "
Wafer/eg --~ Furnace ",
,,
Ours/cleor
wrap'per -
sheet ~
I
Huclring'
seam
FIG. 42.- 'Vuter-log bottom. fimbox-lYlJe boiler •• '" lld rinlt style.
steam generation starts. Then the upper enns of the t.ubes may
be "cooled" by steam.
Capacities and Pressures.-The maximum practical capacity
of the vertical tubular boiler i about 300 boiler hp., and t he
maximum usual pressure is in the neighborhood of 200 lb. pel'
sq. in. The higher capacities are obtained generally oy use of
a large number of ~mall diameter tubeR.
Advantages.
1. Thc cost of construction is comparatively low.
2. A minimum area of floor space is required.
3. The tubes are all th sam size, one tube for a spare being
thus suffioient for any repla ement.
4. The boiler is seU-contained, requiring litt] or no brickwork.
5. The boiler is semiportable because of item 4. It can be
moved and set up readily in dH'fer nt locations.
Disadvantages.
1. Limitations as to capacity and pressur may not meet
reqnirement .
FIIlE-7'1 HIl' ROlLER. 75
2. The internal furnace has fixed dimen ions which cannot be
altered to meet requirements for a change in fuel. (Brick exten-
sions-"Dutch ovena"-may overcome this disadvantage to a
certain extent.)
3. Limitations in furnace volume
make operation at ratings of over
about 125 p r cent impractical.
4. A comparatively high heac1-
room is required.
5. With the straight-shell type of
boiler, tube maintenance may be
high un d e r abnormal operating
conditions.
Gas Flow.-The products of com-
bustion are not turned by bnffleR in
these boilers but pass straight up
through the t ubes to the flue OJ'
breeching.
Blowdown Connection and the
Water Leg.-At least one blow-
down connection at least 1 in. diam-
eter, but not over 2)1' in. , should
be provided in t he lowest part of
the water leg. The shell is rein-
forced at the point of connection,
usually with a riveted pad, 1'0 as (.0
provide t he proper numb J' of
threads for th blowdown pipe.
The water leg i an ideal poin t T .}"IG. 4 .-Submorgod-buad \ ' .
fu'o-tu be boiler. The upper
for sludge to settle, and any ac- tube sh oet is below tho normal
level. «('0"rl.• 81/. Jame.
cumulation that builds up to the Lwater ofTd &: Co.)
area exposed to the fire usually
causes overheating and serious damage to the furnace sheet.
For this reason, it is well to provide at least two blowdown con-
nections in the larger diameter boilers. These connections
should be at widely separaten points so as to provide th most
effective means of sediment removal.
Sometimes an endless chain i installed in the bottom of the
water leg. When the boiler is opened for cl aning and the hand-
hole plates are removed. this chain is pulled around t.o r.onvey
76 BOILER OPERATOR'S GUiDE
J Boilens of this type have the lower tube sheet flanged in 80 that the
riveted 8f!8Jn will be protect ed against, overheating.
78 BonER OPERATOR'S GUIDE
FIG. 49a.- Scokh marine boiler. Longi tudinal seotion . (Courte.lI, The Hodoe
Boiler Work•. )
FIG. 49b.- Scotch marine boilol'. Half front olevation Illld cross soction through
furnace. (Courtesy. 'i'he BodO" Boiler Work •. )
Fla. 50.- Leffel 'cotc b Boilor-Portable (a Dry-back type) the circulating tube
oonnecting the top and bottom of the corrugated furnace should be noted. This
i8 used in those Leffel uni ts of 50 H .P . and larger to faciJitu,!o circulation , thus
increasing efficiency and eliminatinj:: alup:gi sb circulation below the furnaoe.
(Court.SII. The Jame8 Leffel ,f' Company.)
back marine type in that the gas flow is diverted back into the'
rear end of the tubes by a brick arch instead of a crown sheet.
The Scotch bruler may be by far the largest, in diameter of any
fire-tube boiler, being built up to about 15 ft. diameter. Since
the area of the segment of heads above the tubes is large, diagonal
stays are usually preeluded because of the great number that
would be required. Instead, it is customary to use a smaller
number of head-to-head through-stays of 2 to 3 in. diameter.
In boilers of large diameter, it is the praotice to use more than
one furnace. Two, three, or even four furnaces are used in the
large boiler of this type.
FIRE-T UBE BOILERS 81
Gas Flow.- The path of the products of combustion is simple.
It passes to the rear through the furnace or furnaces to the rear
combustion chamber. H ere the flow is turned hack by the rear
arch or crown sheet into the t ube' where the flow is to the front
and out into the smokebox and the stack breeching.
Setting.-The Scotch boiler is elf-supporting. The bottom
of the shell rests in two or more cast-il'on cradles. The dry-back
type require a firebrick lining in the rear combustion chamber
and a firebrick arch. The wet-btLck marine type may dispense
with all brickwork exeept a small bridge wall in t he furnaces to
support the rear of grates when used.
There j . a pitch of 1 to 2 in. to t he rear so that sediment may
work back to th bJowdowll for removal.
P iping Connections.- The blowdown line is connected by
screwing into a riveted pad on the bottom of the shell near the
lower end.
The steam and safety-valve nozzles are on the top of the sheU,
as with other horizon tal fire-tube boiler. It is sometimes con-
sidered ~est to have t he stenm outlet at the front, for the hottest
gases entering the l'ear ends of t he tubeR cl),use the most violent
ebullition of steam bubbles at the rear. Since the water surface
at the front end is somewhat calmer, it is claimed by some t hat
drier steam results.
The feed-water pipe enters through a boiler bushing at the
upper front part of the shell or through the top of the front head
as in the R.R. T. boiler. It discharges near the middle or is
carried down below the furnace by an illternal pipe.
The water-column connect.ions are the same as in t he H.R.T.
boiler, the team line being connected from the top of the front
head or shell and the water connection from the lower part.
The lowest safe level for the lowest visible part of the gage
glass is 3 in. above the highest part of the crown sheet for the
wet-back marin!> type of boiJer. For the dry-back type, it if'
3 in. above the top row of tubes.
Circulation.- The water rises between the tubes, usually
faster at the rear half than in front. Because the shell plates are
exposed to room temperature, the water travels downward
alongside the shell and completes the cycle.
Owing to the large diameters of some of these boilers, it is
difficult to bring the water up to steaming temperature in a cold
82 BOILER OPERATOR'S GUIDE
7S. Why, inRLcad of through-to-head stays, are diagonal staya not used
below t,hc t.ubes, as above tho tubes, to brace the tube sheet? .
Am. Because there is USUI\lly insufficient room for the proper number
without placing them too close together or using sizes larger than is prac-
t.ical. Also, they would tend to hold 10080 scale and sludge and prevent its
free movement to the blowdown.
74. How much space should there be in front of the boiler in planning
installation?
Am. Sufficient room for replacement of tubes.
76. If on looking in the furnace the bottom of the shell is found to be
bulged, what should be done?
Am. The boiler should be shut down immediately and then inspected
by lin authorized boiler inspector. His recommendations should be followed
before returning the boiler to service.
'16. Why are boilers over 72 in. diameter required to be supported by the
outside-suspension type of setting?
Am. Because the weight of the larger boilers may be in excess of the safe
load on brickwork. Crushing or buckling of the walls might result from the
load of a large boiler full of water.
84 BOILER OPERATOR'S GUIDE
TV. What are two dangerous condit ions offered by a weakened rear arch?
Ana. (1) If t he arch collapses wholly or in part, t he upper part of the
Tear tub" sheet mtly become overheated and damaged. (2) Anyone walking
on top of the arch may cause it to collapso, and he will fall through to a horri-
ble death.
78. What precaution is required with a fiush-front-set H.R.T. boiler?
Ans. The front arch protects t h dry-sheet an d front bead seam from
damage by overheating. This arch should be kept in goot! ()ondition.
79. Why should the hole in the brick wall th rough which tbe blowdown
pipe passes be inspected?
An8. To sec that t he pipe is not resting on the bottom of t he opening.
If it does, it is an indication that t ho boiler is probably settling and that it
may not have sufficient clearance to allow frell expansion and cOlltraction.
80. Would loose bricks lying in the fu'ebox be of any interest? If so,
why?
Am. They might be from the losing-in lin e or from some point where
they are supposed to protect part of the boiler from overheating. Al so,
they might be from a poin t where their lOMs wo ul d wea ken t he walls.
81. Name three poin ts wh erp brickwork should protect t he boiler front
overheating.
Arl8. The rear arch, the closing-in-line along t ho sides of the shell, and
the front arch in the fiush-front-sei boiler.
82. How and under what condi tions may t.he segments of the hends " hovp
the tube dispense with dingonal or thl'ough-stuY8?
A.na. In boilers not exceeding 36 ill. d iam eter or 100 lb. pCI' "q . in. 1l1I1xi.·
mum allowablp. pressure, the segm ents m tLy he hraced by st.iffening witl,
channel irons or angle irons (riveted bnck to back) ri vetor] to the i ube sheet"
The specifications for structural form sbould comply with Code rules.
83. What dangers are there in settling of the boiler foundation or sup-
porting walls?
Am. Severe stresses may b e Bet up in the piping (collnections to the
boiler) or in the boiler itself. The brickwork protecting parts from over-
h eat ing may be dislodged. Sludge may settle at the hot end of the boil er
and cause overheating and damage. If serious, the walls may become
weakened and collapse.
M. What is the maximum height of the fire line ?
Am. Below the lowest safe wat r level.
86. What is the lowest safe water level ?
Am. One in ch above t he top row of tubes.
86. What is a strongback?
Ana. It is a bar bolted to the tube sheet to prevent the sheet from buck-
ling when the stays are put in tension before the tubes are installed.
87. If the boiler is pitched forward slightly, what should be done ?
Am. Unless the installation was designed in this way with the blow-
down in front, the boiler should be reset with tho proper pitch toward the
real' as soon as possible. In the meantime, the boiler should be shut down
frequently and the manhole or bandhole in t he front head below the tubes
removed . All sediment should be washed out. The frequency of t hese
washoUts depends upon t he rapidity with which sediment aooumula.tes.
FIRE-TU BE B OILERS 5
88. What is the rlifference in a through-brace and a through-to-heacl
brace? Where.is each used? Why?
Am. The through-brace has wfishers and nuts on each end. The
through-to-head brace has nuts and washers on one end; the other end is
forged into an eye that is held clear of the rear head by a pin or other con-
struction. The through-stays may be used above t he tubes, for the reo.r
outside nuts are protected from burning off by I he rear arch.
Tbe tbrough-to-hclicl braces a re used below the tubes where the rear eons
have to be protected from t he high-temperat,ure gases.
89. If a fusib le plug is used, wh ere should it be IO(ll1tcu?
A 11,8 . Ncar t he center line of the rear tube sheet not less than 1 in. above
t,he top row of tubes.
90. In AilS. 89, why near t he cent er line?
A 1\8. BHcause this is the highest part of the rear arch (unlcss Ii " fl at "
'1reh is usecl ), nnd this extra space is often Iwcdod for use of a wrench.
91. How lllay I.he maxiIIlulJl pr llHure for whir:h t hl' boil or is COJ:lstru ctNI
be discovered '/
Ans. From Ih (' standard st"m ping on t.h" fron t, tube ~ h eet above the
I,ubcs.
92. Where is th p Illud drum on nn H.R.T . boiler?
Ans. There j~ no mud drum.
93. How may t ht' proper height of 11 water column be r.hccked?
Ana. Filll,he hoil er wi th wa,tel' to a level 3 in. "bove th e top row of tubes
at their higheHt end (usually the frout). The water column should b 11t II
level where water JURt Ahows in the bottom of the gage glass. Or th(· height
of a water column may he "her'ked by measurem ent from any common point
of elevation.
94. Why do the fl at scgmcIl LS of the tube shccl,s or heads rCl] illre bracing?
A 1\8. Because internlil pressure tends to bulge these arelLs outward in to
a semispherical shape.
LOCOMOTIVE BOILERS
The soot and ashes should then be blown '~nd swept clear of all tubes, shell
plates, heads, and seams 11nd every accessible external surface.
The blowdr)wn valve should be shut if any otber boilers feed this line.
The manhole, hand hole p lates, and inspection plugs sbould then b · removed.
All loose deposits of sludge or other sediment, should be washed out. The
blowdown valve shou ld b opened only wilen it is certain that there is no
pressure in tbe line and no Olle inside the boiler. Attached scale or oil
deposits should be loft for t he inspector to see.
A hoiler properly p!"epltred for inspection should be cool, clean, and dry.
It is adv islLbl' t,o attach a red tag marked " Man in boiler" to the steam,
blowdown, feed, and fncl valves and a lso to t he manhole plate wbenever any-
one is in the boiler.
129. How nre d iagonal stays instftll d?
Am. Wben t he crowfoot is against tbe head, tile holes in t he shell should
l>e 80 placed lhnt the holos in the palm of the stay are about 7!l2 in. shy
of lininp; up . Often, t he crowfoot is bolted to the h<'.l1d, and t.he shell Or
palm holes ''''l' marked off and drilled to moet this r ·quiremcnt. The crow-
foot is then ri vel;ed to t h() hear!. The stltY is elongated 80 that. the shell and
palm hol es lin e up. This effect may be aceomplishcd by beating, but !~
driftpill is of ton sl()up;cd in onc hole to serve the purpo~e. The palm is
riveted in pORition, and the stay becomes in tension to support the head.
Diagonnl stays are installed before t he t uues arc. The tube sheet JOust b('
hold from buckling by a strongback un til the tubes IIr() pu t in.
130. May f\ slIfety-valve nozzle or steam nozzlo be inserted flush ,· n.1
butt-welded to the boiler shell ?
A 118 . Yes, if all requirements for fusion-weld ed I oilers arc met.
131. Briefly, what arc these requiroments?
Ans. The joints sho uld be fu sion-weld ed by certificd wclders. They
should be Bubj eoted to stress relicving, radiographic examination, and a
hydrostatic and a hammer test l>y an a uthorized inspecto r.
132. Of what valu is a steam dome?
A 118. It is d signed to give drier steam, and it adds very slightly to
the steam-storage capacity of the boiler.
133. How large a steam dome IDIl.Y be used?
Am. A stoam dome may be as Il1rge as 0.6 X the shell diameter unless
t he dome h ead or shell is stayed fully to the neutral shoet of the boiler
ehell. In the latter case, the dome may not excced 0.8 X the boiler-shell
diameter.
134. How should a dome be attached to t he boiler shell?
Am. If the dom e is 24 in. diameter or over, it should be double-riveted
or doublc-full-fillet-welded. If under 24 in. diameter, it should be double-
full-fiUet-weld ed, or sin gle-riveted unless the dome diameter X the maximum
pressure in pounds per square inch exceeds 4,000. Double riveting is then
required . If the double full-fillet welding is lIsed, the weld m ust meet all
specifications for f usion welding except that the X-ray examination may
be omitted.
186. Where and whY' are drain holes required in a steam-dome installation?
FIRJ<J-TUBE BOILERS 89
Ana. A drain is required on each side of the dome in t.he lowes t part of
the neutral sheet so that condensate will not collect and possibly cause
corrosion.
136. Maya dome hllve a lap-riveted longi tudinal seam?
Ans. Yos, if t he dome is under 24 in. diameter nnel the max-imulD working
pressure is calculated with 8 as a fllctor of Rafety.
137. What other types of seam in Question 136 ma.y be used?
Ans. But t-aud-doub le-strap, or butt~welded if all mquircmcuts for
fusion welding art' com plied with.
138. Wlutt prceautioJlR sh()uld be t"t.k(Jn before entering a boiler shell?
A1l8. If th(' b lowclown ent.pr8 a rl)mmon line wi th other hoi lorH in opern.-
tiol1, i1, mu st he (wr1ain thl1t all vfdvc~ on t he line to the open hoiler aT('
(·loserl. If other uoiJers are operl1ting on t he salUe stel1m bCltd('r, both stop
valves must. 1)(' dOsed and the drip valve between them open. Any other
vILlves OIl lin os wldor pressure le,.d ing t:o the boiler must he cho(,kcd. The
('np;in"'~r in chlLrge And t.hl' op('rHlor on (lut y Illust be t.old thHt 80tn~O n ~
iH J,!;oi )( g in ~ id e. A r spollsihl l' P CI'KO I1 should hI' Htationerl itt the manhole
or I' l1t'" II(''' doors while anyone is inside !'he boiler.
139. \Vhlli docs an inspector do in followinp; the ~onstruction of II boiler
through the shop 'f
Am. On t hH first visit, 11(' t']l eck~ tl!p ('1H'Uli<:nl and physielll propurties
of t he st,eel from t.he mil l t,est r port s to R('U if they m",p( Codf' r('quire men t~.
He t hen checks the mdt and Sll\b number" on (h('s(' reports wit.h Ill(' numhers
stamped on the ph,tcs to identify t llPlO . 'rhe shop st.l1ndiug is checked to
seE' if t he shop is authorized to cOllstruct boilers for t he state iuto which
t.he boiler is to be carriod " nd instfillcd. The platt's are CXamill()d for finy
visible defects, as Rcars, gouges, or lam inaLions. The tltickness of the plllt('R
is gllged, a tolerance of 0.010 in. under thl1t specified bciug all owed . Th e
design of the proposed boiler ,is checked to Bce if it meets ode specificatiorlN.
A second visit iR made to check methods used for riveting or welding, PT('-
paring calking 'dges, rivet. boles, t ube holos, nnd assembling t.he boiler.
A third visit is made on com pl etion to view a hydrostat ic !'est and examin e
t he geneml workmanship j if th boi ler has been completed satisfactorily
in accordan ce with Code specifications, t,he boi ler is stamped and the manu-
facturer's data sheets are signed by the inspeotor .
CHAPTER III
WATERTUBE BOILERS
i A•
nozzl es 011 each dl'Um. The safety valves are connected dU'ectly
to their nozzles, wh rca: t he steam pipi11g connects into a
crossover connection which ties the steam nozzles of all drums
t.ogeth r.
The blowdown connection is made by a. £lang d pipe joint at
the lower middle of t he mud drum. If more t han one steam
drum is used, necessitating a long mud dl'Um, two or more blow-
down connections are common. These are equally spaced along
the bottom of the mud drum.
LongitUdinal Box-header Types.- Tbe box-header type of
watertube boiler differs from the sinuou -header types dealt with
so far ill that only two headers are used, one front and One rear.
Figure 56 shows a typical header and tb names of the aheet,s.
96 ROlLER OPF:ftATOR'S GUfDE
Tube-cClp she~f
"Trough sheef
Flo, 56,- Box-hoader section,
pipe enters usually through the top of the drum and discharges
toward the rear into the front end of u. trough-shaped cylinder
(Fig. 58). The front end of this is open for feed water to enter
the boiler water after it makes a reverse turn at the rear blind
~nd of the mud drum . A blowdown is connected from the blind
head, passing through the rear head of the boiler drum, and is
used to remove solids deposited in the mud drum.
The customary method of supporting the Heine boiler is to
suspend the front end and to support the rear end by short steel
columns under the rear box header.
/ Feedwafer inlef
+
Rear end"
of Heine
boiler drum
__ Handhole
forc/ean -
ouf
FlO. 59A.
100 BOILER OPERATOR'S GUIDE
tive feature the fact that the front and rear box headers are both
flanged and Iiveted directly to the drum, the tub s being thus
parallel to the bottom of the steam drum. When the boiler is
installed in its setting, the drum or drums are then inclined the
same as the tubes.
The Murray boiler is suspended by four sling bolts, each with
an eye at the bottom end through which is a bolt pin in a riveted
pad (8 e Fig. 60).
WATER7'UBE BOILERS 10]
FIG. 61.- Murray wate,·tubc boiler. A iongitutlillul th"co-drul11 boi ler wit'h bux
bcaders. (Collrte.y , i'lll rrau iron Works omJI(1I1II.)
But this height may not give sufficient furnace volume for
desired combustion conditions. It becomes necessary then to
increase either the lengtn Or thc width of the furnace. It is often
impractical to carry the length of the furnace beyond a definite
proportion of the boiler's length. The dimension of furnace
width then become of interest.
With longitudinal-drum boilers, the number of drums must bn
increased as the setting is made wider. This is expensive, for the
drums are the most costly part of the boiler. But with a cross-
drum boiler, the width of the furnace may be increased to any
desired limit wjt,h one steam drum merely by constructing a
proportionately longer drum. Thip feature is the great advan-
tage of the ross-drum boiler.
Disadvantages.- There arc but two f atures of the cross-drum
boilers that could be listed under this classification. However,
they are not disadvantage if the boiler is designed for the given
service requirements.
A typical 500-hp. standard eros -dmm boiler installation and
lungitudinal-drum boiler installation will show uHually one Irum
for the former and two or t.hree drums for the latter. Ob,riously,
the steam and water storagc capacity of the latter j.~ considerably
greater. Consequently, there may be more pre!:lsure fluctuation
in the cross-drum type with variable loads unless the R p(> e ifict~
t.ions are design d for thi type of service. A l::trger drum diam·
eter may then b used to give greater s~orage capacity.
The second disadvantage is that some provision must be made
to compensate for the JOngitudinalligament of tube holes in th ,
drum. These are r quired for the row of horizont,al circulating
t ubes and the vertical row of downcomer nipples.
A heavier drum thickness is ometimes required at, these !Sec-
tions, or a doubling plate l is used, in order to maintain the
strength of the drum. However, this additional expen. e is much
more than offset by the savings effected by eliminating additional
drums
Springfield Boiler.-The standard Springfield boiler (Fig. 63)
is a modern ero s-drum type of boiler. It is of the sinuous-header
type, but each bend of the header and each tube cap include a
group of four tubes (Fig. 64).
The front end of the standard pringfield boiler may be
supported by sling bolts from each front header to overhead
I Deecribed in Chap. I.
104. BOILER OPERATOR'S GUIDE
channel irons set back to back, and the rear end is supported by
several cast-iron cradles und r the mud drum. This type of
setting is used for low- and moderate-capacity units. It will
be noted (Fig. 63) that the steam drum is somewhat forward
from the rear headers. Inclined downcomer nipples are thus
required for this type of Springfield boiler.
FlO. 63.- pringfield we.tertube boilor. A cross-drum type with sinuous (sec-
tional) headers. (Courteay, S,>ri.noficld Boiler Company.)
FIG. 64.- H ader section from Springfiold boiler. (CourtCIIY, SprinoficUJ. Boue>
Coml)(Lnll·)
FIG. 66A.- The Babcock and Wilcox two-stago furnace boiler. This boiler i~
one of two built for "n Eastern utility . Its design pressure is 14 5 lb . per sq.
ill., its maximum conti"uou8 caplloity is 615,000 lb. steam per hr .; its totalst.earn
temperature i8 925°F. (Courte.l/, The Babcock and Wileo", ComllUnl/.)
IF A TER7'(] BE BOlLERS J09
F I G. 68. -The Wickes vertioal watertu be boiler. (Cou rtllll1/. The W ickllll B oiJ,.,
CO?n1IO. n ll .)
The tubes are pitched equally and far enough apart to per-
mit replacement of a tube in the middle of the tube bank. Or
the tubes may be spaced elo 'el' in group of two, with a lane of
sufficient distance between the groups to permit a tube to pass
through .
STIRLIN G BOILERS
The Stirling boil er (Fig. 72) is one of the fir t types of bcn t-
t ube boiler to comr into common use. Stirling boilers similar to
the boiler shown in the figure and built over for ty years ago may
be found till opera ting efficiently . An int,el'CI'l ting point is
that the origin al design was so nearly correct, ('ven as l'egal'dH
modern practice, alld wad so far in ad\'an 'c of its time t hat it has
been necessary to make bu t few cballges t.o enable it to k ep t.he
title of being an execcdingly effici ent stf\am generator.
There are three steam drums and one mud drum in this boiler,
with steam equ alizing tub's, as shown, between 1.he midd le and
rear .lteam drums and between the fron t and rear steam drUID".
Equa (i zers between the front a nd middle drum are omitt d, fot'
the fl ont rOW8 of generating t.ube. ' exposed to t he radiant ht'at
oj t he fire discbarge steam and water into the fron t drum \O\1th
con sid ~l'abJ e turbulence at high ratings. Since the main steam
line is ·)onnected to the top of the middle drum, wet steam might
be prorluced if the equalizers were carried to that vicinity from the
possibly turbulent steam and water space of the front ell·um.
Water-circulating tubes connect the frOUL and middle steam
drums below th e water lin e; th se are omitted between t hc
middle and real' drums. Th e rear rows of generating tubes con-
necting the middle drum deviate from the middle bank of
generating tubes to ioin the rear bank of generating t ubes
between the rear steam drum and the mud drUID. This arrange-
ment makes for positive circulation throughout the boiler,
'!specialJy at high ratings.
Gas Flow and Baftling.-The products of combustion sweep
upward between the front bank of generating tubes, over the
top of the front baffle and downward in the second pass. The
second pass includes part of the generating tubes connected to
t he middle steam drum. In some of the older installations, the
" middle" suspended baffle divided these generating t ubes, all of
which formed t he middle tube bank. But, in the latest type
118 BOILER OPEllA7'OR'S GUIDE
hown, the real' rows of t he tubes pass behind the bafflc into the
rear t ube bank.
FIG. 72.- The modorn Stirling boiler shown with convection superheater.
(Court6&lJ, The Babcock and Wilcox Companlf.)
development is the baffle against the back of the rear tube bank.
This prevents the gases from making a sweep toward the duct in
t.he rear wall and by-passing the upper ends of the rear tube
bank.
Baffles are provided between the three steam drums for the
full width of the setting; they are located below th lowest safe
water level. They protect the longitudinal seams and that part,
of the drums above the water line from being contacted and
overheated by high-temperature gases.
The bridge wall is cH,rried up and closed-in-line against the
front of the mud drum, just below the front row of tubes. Thus,
the fire and gases are prevented from sweeping under the mud
(ll-um and therefore causing overheating of the longitudinal
Ream and short-circuiting thc first and s cond passes.
Feed-water Entrance and Circulation.- The feed-water pipc
pnters through the top of the rear stea.m drum or through the
upper rear part of its manhole head. Feed water discharges into
a long trough riveted or welded along the rear part of this drum .
It then spills over the front of the trough to enter the boiler-
water circulation.
The water circulates downward through the rear bank of
tubes to the mud drum, and supplies the middle and front banks
. of tubes through which it rises to the respective steam drums.
It circulates from the front to the middle steam drum through
the short circulating tubes, thus tending to equalize the water
level in these two drums. As the rear rows of tubes from the
middle drum pass back to join the rear tube bank where lowel
gas temperatures permit a downward circulation, the water level
in the middJe and rear steam drums tends to equalize through
the mud drum.
The mud drum is large in diameter, and all the riser and down-
comer generating tubes are remote from its bottom. Sediment
is deposited here, for this section is not disturbed by rapid cir-
culation. The blowdown connects into a forged-ste I fittinl!;
riveted or welded to the bottom of the mud drum. In the case of
large boilers with long mud dr ms, more than one blowdown mH\y
be provided.
Steam Nozzles.-It is customary to install the safety-valve
nozzles on top of the rear steam drum, whereas the main st am
nozzle is connected to the top of the middle steam drum. An
120 BOILER OPERATOR'S GUIDE
internal collecting pipe or dry pipe for the main steam line is
optional, but with good water conditions the baffling of the
steam-equalizing tubes is uwally sufficiently efficient for the
dry pipe to b dispensed with.
The extremely large water surface, which disengages steam
bubbles, is another important factor in producing dry steam from
these boilers.
Flo. 74.- Babcock and Wil cox low-head watortubo boilor. A three-drum
t.ype using bent tubes and adILPt,ed {or low headroom . (C(J1IrtMI/, Thr lJ'L{Jc(Jck
a"d Wilcox ('omprMJ/ .)
RILEY RP BOILER
This boiler (Fig. 75) if; a modification of the ullit described
a.bove. It is designed especially for installation in existing space
and is built in capacities of about 500 to over 2,000 hp.
This if; a three-pass boiler using plate type step baffies in the
second and third passes. The step baffies cause the gases to
zigzag back and forth between the tubes on t heir downward and
upward path, high heat transfer and evapora,tion rates per unit of
heating surface being the result.
Tb front head r has a series of handholes or tube caps through
which the tube,' may be rolled, turbined, and inspected. In spite
of the compact tube arrangement, the tubes are so ized and
lVATER1'UBE BOILER (BE1I' 'l'-7' IT 81?) 125
pi.tched t~at it is possible to removl' fl.ny tube for replacement
WIthout dIsturbing other tubes.
."
;
""g
.<::
til"
I.
'"...
_ _ _ _ _ _ _ _ _ _ _......I ci:
.......__..........;.......:._ _ _ _ ~
"
INTEGRAL-FURNACE BOILER
A successful development in the eros '-drum type of bent-
tube boiler in the Babcock and Wilcox integral-furnace boiJer
(Fig. 76). This is an extremely flexible unit, because of the large
amount of beating surface exposed to the radiant heat of the
126 HOfLER OPERATOR'S GUIDE'
Fro . 78.- A Wiekes t hree-drum watertube boi ler with intcgrnl water-eDDied
bridg and front wall s. (Courtuy. The Wicku B oiler Company.)
The latter supplies water to the radiant and front bank of gen-
erating tubes and t.o the lower headers of the three waterwalls.
The water-and-steam mixture rises in these tubes, returning to
the upper drum . Here, an efficient baffle system separates the
moi ture from the steam, returning the water to circulation.
Capacities.- Up to the pre ent writing the VU steam generators
have been built for outputs ranging from 20,000 to 200,000 lb.
steam per hr. and for pressures of 150 to 700 lb. per sq. in.
Support.- AIJ headers and pressure parts of these boilers are
suspended by the steel structurb which forms thc casing frame .
Thus, free expansion is provided.
WICKES THREE-DRUM BOILER
A late type of three-drum boiler (Fig. 78) makes usc of a
water-cooled bridge wall and front wall. The method of sup-
port and waterwall connection are shown in the figure. This
type of boiler possesses many of the desirable featurf's of multi-
drum boil ra wi t hout the expense of more drums. It should be
noticed t.hat the front waterwall header is mounted un springs-
a desirable method of supporting the weight of the headers and
still permit ting free expansion of the tubes.
THE LARGEST BOILER
The largest boiler in the world built to date (Fig. 79) is a Com-
bustion Engineering bent-tube type, which at first glance appears
to be two three-drum boilers in the same setting. This unit is
designed to generate 1,000,000 lb. st eam per hr. at 1,385 to
1,425 lb. per sq. in. and at 925°F. It is not unlikely that the
design capacity may be exceeded by a considerable amount, for
the design incorporates all practical methods of obtaining high
capacity at high efficiency.
The firing is by pulverized coal, tangentially from each corner
of the dry bottom furnace. The heating surface of the boiler
is 20,800 sq. It., to which is added a waterwall of 19,863 sq. ft.
Additional capacity is provided by two Eleseo fin-tube econo-
mizers, each with a heating surface of 12,925 sq. ft. Air pre-
heaters, too, are used, of the Ljungstrom regenerative type.
THE TWIN-FURNACE BOILER
A recent development by the Foster Wheeler Corporation is
the twin-furnace boiler (Figs. 80a and 80b). This boiler iR
130 HOlLER OPERATOR'S GUIDE'
FIG. 80b.-Seotional .ide elevation of the twin-furnaoo boiler shown in Fig. 80a.
(Court"'II . Fo.ter Wh.eler Corporation.)
FIG. Sl.- Itiley ItO boil or. A longitudinal-drum low-hoad bont-tube wutertube
boiler with intogral watorwalls. (Courtesy. Riley Stoker C<>T1).)
The steam drum is carried for the full length of the setting, roof
tubes and upper horizontal headers for the side-wall tubes being
thus eliminated.
The feed water enters through the front head of the upper
drum, as shown in the figure, and travels through an internal
feed pipe extending to the rear part of the drum . From here,
FIG. 83.- Wiukes type A watertube boiler. A three-drum bent-tube unit with
di\';ded g(18 flow . (Court 811. The Wick .. Boiler Company.)
drum, and upward through the fron t tubes of the main bank.
Circulation through the waterwall is, of course, upward. The
wall tubcs are suppli d by nipples connecting t he waterwall
headers with the lowcr drum .
}'IO. 84. -A Wi okes typo A watertu b boiler enclosed in it. st.eel C!lSi nll. (Collr-
tesy, T he Wicke. BOI:I.~r COtn1JUTlU.)
WIens TYPE A
Am. It is when the boiler is idle 0 1' operating at low ratings. At high
ratings, the water level in t.he drum supplying the downcomer tu! CA i oft,en
lower than that in the other drums.
185. Name three met.hods of supporting the upper drums of brnl-tIlhf'
boilers (cross type).
Am. , ( 1) U bolts around each cnd of the drum s aud ti!'d Iu overhracl
cross beams. (2) Cast or forged L pads attached t" each h ead a nd re~t ing
on eross bealllA. (3) Cast cra dles under each en d of t he drllms Ilud r('~t in~
(Ill cross beams.
186. ror what rca.'ons are ben t tuucs used in Stirling t.ype uuil"J'!<?
A ns , To allow for expansion and contrl1ction. To permit I uhc rcplace-
OIt'nL Tr> allow tubes to cnter dr um s perp0ndiculnl' 10 surfaf'(' tangent,
To nilo\\' fl exibility in design.
187. How are Stirling type boilers designed ill regard to t,lIh(' IllTIlflf!t' Il H'1I1
to allow removal and replacement of tubes?
An.~. Th e tube may hI' pitched eq ually fli' a grcatl'l' spacin g I hall thr
tube diam('t.er, or th" t.ubes may b(' grouped in I wos with closer pitch in tlu
pairs and th e wide piLch between lh e pairs.
188. What is the purpose of u bridge wall in a Hlirling boiler?
Ans. It protects tho mud drum from exposure to the direcI, h at of tho
fife.
189. What might, happen if 1he Stirling bridge wall coll.tpscd?
An8. The longitudinal seam might be overheat,ed aud damaged.
190. Wllat is t he usual diameter of a tirling-boi!E'r mud drum in J'p.lal ion
to steam-drum dilLmcter? Explain your answer .
Ans. The mud drum is often about 4 to 10 in. larger in ciialllE'ter t hnn
the steam d l·um. The tube_ from a;! t.hree steam drullls euler tht' mild
drum .
191. Are tuhes flared or beaded in bent-tube boilers? Explain yo m
answer.
Ans. A nuulber of tubes in the bottom of each upper drum a r(, beaded in
order to permit complete drainage of the boiler. A number of tUbes ill t be
top of each lower drum are beaded in order to eliminate air puckets when t ho
boiler is fill ed . The l'eru ailling tuhcs are {hued, there is nothing t,Q bp ga in f'cl
by beading them.
192. What is usually the weakest part (from t he yi('wpoint of constnu'-
tion) of a bent-t,ube boiler?
Am, The tube ligamcnt.
193. How many courses are there in bent-tube boiler drum s? Explain
your answer.
Am. One, because a girth scam would unnecessaril y interfere with the
tube ligament. Also, different-lengt h tubes wou ld be required for each J'O,," ,
194. Where is the manhole in bent-tube boiler drums ?
Ans. In at least OIlP. head of each drum .
195. Where arc braces used in bent-tube boilers?
Ana. It is not customary to use braces in modern bent-tube boilers.
196. Wha.t is the purpose of circulating and equalizing tubes in belli -tube
boilers?
140 BOlLER OPERATOR'S GUlDE
Ans. Circulating tubes (,OUllt'ct tbe wa t,or space of adjacent steam drumR
(usually at the SRmc level) and aid in cquRlizn.tion of water level. Equaliz-
ing tubes connect, the st,eam spRee of such d rums t,o equalize the steam
pressure.
197. In rive l.ed drums of bent-tube boilers, why is it customary to select
n. longitudinal seam of com pn.ratively low efficiency (45 to 75 per cent),
whereas, in ~traight- tuh(' type~, longi t udinal SL'U I1l S are d esig:ned usually
with n.n c ffi cien c~' of R!; 1'0 95 pel' Cf'Llt?
AnR. Becnus!' thr bpl1t-tu hc type bas a t ube-lign.men t efficiency below
55 per cl'nt usua lly, whcrcn.s the straight-tube t y pe has no ligamcut. It
would be a waste of money to ch!Rip:1l a ri veted longitud in a l seam of higb
('ffirimlCY when t he press ure Oil t he boiler was limi ted b~' t he tuhe ligament .
198. Wltat is t he diJIe l'e ll r~ hC't"'PC'n fL mud drum in a Sti rling nnd in "'
st,raight-tuue type boill'l'?
Am. A St.irling mud drum is on!' of the main drums in the circulatory
syst,rm. In Rtl'a igh t-t,ulw boilers, lhe mud drum may h(~ It trough in the
ijteum drum (Hoi li e boil er) or an ("xtC'Tl1 a l hox at t he bot. t,om of the headenl
(as in t he Bobro('k .lnd Wilcox hoiler ).
199. W1Wl't· ILre Lhe hlowdown ('OfUl cctions on bcnt-tube boilers, n!lcl how
many !\re there?
Ans. In t.he hotLon. of t hE' lowost, or lllud , drum , One or more, depenrl-
ing on the length of t h(' drums.
200. Why u.rc circulftting t uhes bent in 'tirling type boilers ?
An8. To permit, rephw(,lfHll1t Rnd [I,lIow for expansion.
201. WhR,t is t ill' diffl·rclI ('p het'\V(' f'n t hA tuhf' "heet ill IL bent-t,ube boiler
and in an H,R.T. hoil'r?
AnB. In the bent,- tube boi ler, the t,uh ' Abact, is t bu.t portion of [,he drum
into which the tubes arc rolled, I n th e H.R.T, boiler, the tube sheet j, H
f1 ut head.
CHAPTER V
180
1l, 160
~
cs
140 /
r: /(
;1 20
VI
:;;100 L
0..
:i 80
V
/ :--l-
t:>
III
:l
60
40
I
f-""
v
-
H-
--
ct'- 20 V
o
0.. 0
I r-
~ U470 490 510
-2 ~50 530 550 570 590 610 630 650 670 690 710 730 750 770
Te mperc>tu.-e, Deg. F.
FIG . 90. -Vowtherm A. vupor-pl'e. UI' O curve. (CourtIJllY. The D ow Chemirol
Com pany. )
be shown for leaks that bot Dowtherm might find . The most
satisfactory test for Dowthel'm boilers is to int roduce ammonia
gas into the system at a preSSUl'e of up to about] lb. per sq. in. 01'
to fill the boiler half full of aqua ammoniae. Ail' pressure at
about 50 per cent of tho rated boiler pressure i . then appli d. A
lighted sulphur candle or a dilute hydrochloric acid swab is passed
FlO. 92.-8team boiler unit (1400-1b. series type) using Dowtherm fol' incUrect
suporheating and reheating of steam. (Court~y. The Dow Chemical Companv.)
Kg.perhr"
,,/I ..... ~
8J25.J;. : 12
l.i4ofm. 247"C. I
(/91/b.~r sq.in,
51fW Fj
o<..J
~ o.+..;.;..;
~ ;...;;;..;.;..;..;;..;.;.;.;.... ~,
(4464. c.)
"Engineering"
Flo. 94.-Loeffler boiler heat diagram. (Courte.y. Pro/es.or E. Joo. e. Tech"';"",1
UniwerBity. Berlin.)
pressure for Loeffier boilers, the design of the appliances for these
boilers is interesting.
A multiple-disk safety valve (Fig. 96) was designed for di -
charge of 100,000 lb. ,team per hr. at ] ,900 lb. per sq. in. and
932°F. This valve is in a solid icrged-st.ecl block, and six 0.86-
in. opening valvl'H arc ufied from the one supply . Thl' de .ignel'H
thought gage glasses unsatisfactory at over 1,500 lb. per Rq. in.
and dev loped an electrical water-level indicator (Fig. 97). To
pr vent coliap e of the float, it is filled with a liquid that evap-
orate at operating temperatures and creates an internal pressure
commensurate with the external pressure. The style of pine
joint was developed by Dr. Loeffier (Fig. 98). A pressur -tight
seal is effect d by drawing up the stud nuts until a slight deforma-
tion occurs in th mfltal-to-metal contact between the point of
\;he male flange and t.he cone of the female flange.
iM BOILER OPERATOR'S GUIDE
}<~IO . 9 .- Pipe joint. Edge of inner cene is deformed by pre8lJUre thue producing
" bermeti c seal.
bO
' .... ,.."..
~
~.. .e ~ ..:
.. e ci. .
~
~
co
I:>. 3 " ..;.,..
..
..Q
IE ..:
~ ~
.; " "". .," I:>.
to
Ii
3 "".." I:>. .,...: .
.;
.,co .. :5"... 08'" to
'
co"
to I:>.
... 8
]"
~
..Q
.
8-
., .
.3 " .9 ..: "3 '~ ca~ "
. ~B <- OJ
:;3
i " E
8
8 ~
..
~ ~ r:.lI> 0 ~ .1)8 t3 ri: (5 r.." r.]8 .s I:!l"
'S0
C/)
_---Wafer pre-
-- --- heater
--- --Auxiliary
surrace
Trcms/fion
secfion - ---
_ '- - - Thrqttling
deVIce
~
.;r-- ===!=!~~;;;;;;~§in - --Superhearef
Sup;;hea fed- ,Radiant -heat
steam outlet " absorbing
section
~ Wafer inlet
;; iii
Wafer .' Wet sfeom ' Superheafed steam
Fl .. IOO.- Benson hoiler with liuxiliary bCI1tinl( HurfaCQ.
]5 BOlLEN OPERATOR'S GUIlJE
D = W
1.55 X P X D
For "f'atH at other ang;les,
lr
A = 50 X P
wherc D == inside diameter of va)v!' seat, in inches.
W = discharge apacity, in pounds per hour.
P == popping prf'ssure, in poundf'\ per square inch absolute
(gag pressure +14.'1 at sea level).
L == v(~ rtical lift of valve disk, in inches at 3 % excess
pressure.
A = relieving area, in square inches = 7r X D X L X sine
of seat angle.
The A.S.M.E. Code specifies that at least one safety valve
shall be set at or below the maximum allowable working preS8ure
166 ROlLER OPERATOR'S GUIDE
and that the rest of the ,'alves shall range from 3 per cent above
to within 10 per cent of the highest pressure at which any valve is
set. It is poor economy for all safety valves to pop at once; if
there is a few pounds differential on the setting, the fireman 'will
have warning to check his fires when the safety valve set at t,h~
lowe t pres ure blow '.
Water Columns, Gage Glasses, and Gage Cocks.- The gag!'
glasR and gage coclu; are essential applianCI'R for indirating the
J!' lO. l07.- Refleot,ing-typo gnp:e glass. ,md safety water column with high- and
low- water ,,[nl'm whistles. (CQ ll r (C8Y, The Reli"'lcc Ga.uge Column 0.)
level of the boil I' water. The water column (often omitted in
railroad and marine practice) is installed betw en t he gage glass
and the boiler. It serve to eliminate excessive fluctuations of
water-lev I indication in the glass due to rapid boiler cil'culation
or ebullition and thus act,s as a steadying medium.
Mirrors (Fig. 107) are sometime' U ' d where, because of
extremely hi b levation, gage glasses are not visible from the
BOlLER A1JIJLJANCES AND AUXiLiARIES 167
lip ·l'lltiug" tioOI'. Other styles of .glass mak(-' llse of remolt' gag't' -
glass indicators (Fig. 108) which may be IO('.fl.tNi a1 thf' operating
floor level.
The gage-glru s conncctions between the gla s and the water
('.olumll (or boiler if the column is omitted) hould be at least
~ in. , and a draoin Yalv(' or cock 'honld be provid d in the bottom
FlO. IOg.- Tandem mounted blowdoWll valves. (Court' sv, Ya;",all-Warino CQ. )
FlO. 112.- Gate valve, nOll- FlO. 113.- Gate valve (out-
rising stom. (Courtesy, The side screw and yoke), rising
Chapman Valve Mig. 00.) stem. (OourteBY, The Chap-
man Valve MI(J. Co.)
and side plug, the valve and seat may be ground to a new face
when worn. Also, all of these parts are renewable.
Check valves for very high pressures are usualJy of forged
st eel and of the piston type (Fig. 115). A globe valve and check
valve may be combined in one unit for feed-water attachment to
a boiler drum h ad (Fig. 116).
A nonretum valve (Fig. 117) is used sometimes as a stop valve
on the main steam line next to a steam boiler. The function of
In the outside type (Fig. 118), the tin core is tapered, with the
large end at the threaded end of the casing that is exposed to
pr S 'ure. This type is installed from the fire side (as in most
boilers). The inside plug (Fig. 119) is installed from the pressure
FIG. 120.- Door latch for w!\tertube boiler. (Courte8V. Erie Cit1l Iron Work,.)
sid and has the large end of the tapered tin core at the hexagon
end so that pressure will not blow the core out.
Fusible plugs are seldom used for pressures above 250 lb. pel'
sq. in. Below this pressure, they are required in but few locali-
ties. The author strongly recommends their use with the
BOILER APPLIANCES AND A UXILIARIES 175
a
d
(B)
FIGs. 122A and B .-Original Bourdon gage .
m Boiler wafer
mJ Boiler steam
53 Boiler feed water
FlO . 124.- Bailey feed-water regulator. When the regulator is placed in oper-
ation, the steam in the upper portion of tho inlier generator tube B causes part of
the wa tor .hOWD (in the closod system) s urrounding that, portion of the genel'atol'
t.uoo to flash into steam. The resulting increased pressure in the gonerator BOts
like [\ piston forcing the wator down out of tho generator until its water level is
the same as thut in pipe B. Tho wator forced out of t he gonerator passes into
the 8ylphon on the regulator valve, expanding it aDd compressi ng the valve spring
a proportionate amount. (Courte8Y, Bail l'/ii Meter Company .)
control valve. As the water level rises, the tube cools, contracts,
and closes the feed-water valve.
The Bailey r gulator repres nts the thermostatic-hydraulic
type (Fig. 124). An inclined thermostatic tube is used This
tube is surrounded by a iacket having fins to dissipate heat to
the atmosphere and make it rapidly responsive to temperature
changes within the thermo tatic tube. The jacket contains
water which through a closed piping system connects with a metal
bellows on top of the feed-water controlling valve. A spring
BOILER APPLIANCES AND AUXILIARIES 179
Blow-orr - - / /
- - Lower flexible tube
o, , ,
3
! , ,
G 9 IZ
I , , I , ,I
Sc Cf Ie) Inches
F'IG. 126.-Morehet,d boiler feod. (Court esy. Morehead JIIa .,ujllcturi"(J Co.)
When the water valve is opened, water flows through it into the ooiler
reeding system.
When the end of the dip pipe is closed by the rise of the boiler water
level, steam is trapped in the tank and the upper connections to the.
tank. This steam condenses, and boiler water rises into the tank .
When full, this tank is heavier than the counterweight and conse-
quently moves downward, and the valve is closed.
The boiler water level then begins to fall and, as 800n as the end of
the dip pipe is un covered, the steam goes up to displace the water in the
tank, which gravitates to boiler water level. The counterweight moves
the tank upward, and the valve is opened again. The gate valves
shown in the figure are essential and must not be omitted. They are
used when it becomes necessary to blowout sediment that may accumu-
late in the flexible tubing.
To blow down, close both valves, and open the union in the lower
flexible tube. Open upper gate valve, and allow steam to blow through
the flexible tubes. Close the union, and reopen both gate valves.
Caution . Do not twist the flexible tubing.
Since operation depends upon the condensation of steam in the tank,
it is necessary in starting the apparatus to open the pet cock above the
tank to veot all air. Close it again when air has been expelled by the
steam pressure.
The Morehead valve may be connected also to the steam
supply of a boiler feed pump. In such cases, a small by-pass
around the valv may supply sufficient steam to keep the pump
operating very slowly at all times when thi is desired.
Feed-water Heaters.-Feed-water heaters arc used to bring
feed water nearer tothe temperature of the boiler water. Each
10°F. rise in feed-water temperature increases the over-all boiler
efficiency about 1 per ccnt owing to savings in fuel that would
have been required to heat t he boiler water an equal amount.
An added advantage is that temperature stre ses in the boiler
may be avoided by feeding water at higher temperatures.
Two general classes of feed-water heater arc used: open and
closed types. The open heater is sometimes classed as a "direct-
contact" heater in that the water and steam mix, and the closed
heater is sometimes termed an "indirect" heater because the
steam and water are separated by tubes and the water is heated
by conduction.
Under these classifications, the direct-contact heater has two
definite subdivisions, namely, the standard open hep.ter and the
Deaerating heater.
BOILER APPLIANCES AND AUXILIARIES 181
~
'5 c 10 f-- t- -i---+-- - t - -!--1I--t*-i
l·g
]g Wl--+--+--+--~~---r--I-~
~~
] 0 3060 80
u::
Fro. 128.- Theoretical and praotical suotion for water at variuus
temperatures.
D
reedwafer
heater
FIG. 129 .-Hei~ht q_{ feed-water heater above pump suotion depends upon water
temperature.
-Heafing
frays
_{*fi~:01~-~-;JJlt~~~
- - ...
Deaerafed wafer fo
boi/er- reed pump
FlO. la:-l.- Dillgrammat.ic arrangement. of deael'ating heater. (Court.BY . Elliott
Compan1/.)
FIG. 140.- Scyon-stnp;o boilor feed pump, Jersey Contral Power & Light Com-
pally. (CotIrtesy, Worthinoton P"mp and Machinery COr1).)
Live steam
FIG. 144. -Mol'cbead return trap.(CQUTtC8Y. Morehead lIfan1lfacturi711l
Company.)
The return trap (Figs. 143 and 144) is used to return con-
densate to a steam boiler without thc aid of a pump or injector.
It is located about 6 ft. abov th boiler. Conden ate is fed by
gravity or under pressure from another trap into t he body of the
return trap. The body is vented automatically so that the trap
chamber will not become air-bound. The trap body is mounted
on pivots and balanced against an xternal counterweight Oll
the lever arm. AB the chamber fills with water, the increased
BOILER APPUANCE ANn A(!XILIARIES 197
PRESSURE
MOREHEAD LlOUIVATOR
~
~I W
:1'10 . 146.- I llvorted-huckot stearn trap. (a) Tmp closed, ill coming .teuIl'
under tho Uout buoys it up, ke ping the outlet closed. (b) Trap open, incomiul!
condon.nte has filled t h e Uoat, permitting i t to .ink and ope n the outlot. (COUT-
t eall, The (.',.ane Company.)
.,E
~
.j
"
of:'"
~
ill
."
."
..
""
"
:;l
~"
jI.
~
202 BOILER OPERATOR'S GUlDE
BOILER APPLIANCES AND AUXILIARIES 203
The oil pressure i" varied by a pilot valve the po ition of which is
determined by the exit. steam pressure. The regulating system
shown in the figure can reduce and desuperheat over 1,000,000
lb. steam per hr. from 1,200 lb. per sq. in. at 900°F. to 260 lb.
p~r sq. in. at 600°F.
Oil burners are divided into two distinct classes: mechanical
atomization and steam atomization. Oil burners operate by
producing a fine mist by atomization of the oil as it is pumped to
the burner. The finer tbis Rpray a it is produt' d, the more
readily will it igllite and attain complete combustion. Con-
versely, a "heavy" (poorly atomiz >d) spray causes poor com-
bustion and heavy carbon deposits.
1,800
1,600 /
~
;1;400
/
<./) /
t0..1,200 /
/
:1 /
i',oOO
::>
III
~ 800
V
I-
0..
/
~ €lao /
o
ID
400 /
./
V
200 ....
o
200
._.
- I-'
300 400
Tempero+ure, Deg . F
500 600
the oil pump and the first shu toff valve in t he discharge line to
the heater. The discharge of t his r lief valve may be piped back
to t h ' oil storage tank for cleanliness. A second oil-presFmrr.
reli f valve houla b installed at the outlet from t he h eater, for,
when valves arc clos d, expansion may create excessive pre ures.
The condensate from the heater should b drained to waste
unless a well-lighted and frequently observed gage glasR is on the
trap body or oth I' suitable means of oil detection are employed
(see Chap. VIII). One cannot be too careful with this inRtalla-
tion, for a split tube in the oil heater might. allow th fuel oil to
BOILER APPLIANCES AND AUXILIARIES 205
pass into the fced-water system, flooding the inside of the boilers
with oil, an extremely hazardous condition.
Superheaters.- Each pres ure of saturated steam has a corr -
sponding temperature (Fig. 152) . Heat added to the dry steam
at this pre 'surc is known a R " uperheat" and results jn a higher
6U alld 72) and absorbs its heat from t he gas flow. The conVf>C-
tion type iR usually made up of a number of clements (Fig. 154)
expanded at aeh nd into inlet and outlet headers.
Though uperjwatcrH Ill" used more often with watertube
boilers, they arc soml'time,' used with fire-tube boilers. One type
~uspendcd around the rear end of th H.R.T. boiler is shown in
Fig. 155. Thf'Y are almost always used in locomotive boilers
for railroad service and consist of U tubes installed inside a
number of large diameter fire tubes or flues (Fig. 40).
onstant temperature of uperheated steam is the desire of
mo, t designers, for a steam turbine is designed for the particular
1 The deterioration of high-spe d turbine blades caused by inlpingement
Two purposes are ' rved by the waterwall: (1) Added heating
'iurface and boiler capacity ar secw-ed. Revamping and adding
waterwalls to an exi ·ting boiler may even double its capacity.
(2) Maintenance of the refractory wall protected is reduced
greatly. Thi protection of refractory walls is extremely impor-
tant when high combustion rates are desired. The practical
combustion rate i about 18,000 to 25,000 B.t.u. per cu. ft. fur-
nace volume per hr. when bar refra'tory walls are exposed to
the furnace. But combustion rates of 40,000 to 200,000 B .t.u.
BOILER APPLIANCES AND AUXILI ARIES 209
pel' cu. ft. per hr. have been attained without difficulty with all
refractory sW'faces protected by waterwalls.
The circulation of water is upward t hrough the wall t ubetl
exposed to radiant heat. These tubes are supplied by water
t.h!'ough hfl}Ldel'tl connected by piping from one or more of the
1"1(1. 15 .- ,,' utol·wall tubes f1t burner ports. (Courttl8l1. COmQu8tion Enqinecri11Q
C 07nT)f11111. l11c.)
boiler drulUs and located outside of the boiler setting (Fig. 157).
1'h supply system is known a ' the" downcomer."
In laJ'gl' boilers using pulverized coal, oil, or gas burners, the
watcl'waU tube may be bent around t he burne!' ports (Fig. 1.'i8).
A row of waterwaU t ubes may face a bridge wall and at the same
time form the bottom row of generating tubes (Fig. 159).
Blowdown valves are required for each header at the bottom of
I~ series of watcrwall tubes, for the same reasons that the boiler
it elf 11 ds them. Sediment accumulation in a header supplying
wall tubes might cause interruption of circulation, with conse-
quent overheating and failure of t he tubes.
BOILER APPLIANCES A N D AUXILIARIES 211
FIG. 159.- Springfield watertube boiler with water-cooled bridge wnll. (Cour-
t e8V. Sprinofield B oiler ('0.)
FIG. J60. -Bnile.v stud-tubes. ourte81J. Th:e Ba.bcock a.nd Wilcox Company.)
the tub s (~gainst tho corroRive or abrasive effocts of the fuel bed
(Fig. 161) .
Pulv rized coal is much llii d in firing boiler of 500 hp. up
to the highest capaciti s built. T\\'o systems are in common us :
the entral-bin syst,emi and the uni.t, Or dir ct-filing, system.
The central-bin system is used in a Dumb r of larg uti.lity
st am stations and may be cOllsidered ru a storage battery for
fuel, being charged when the load is light Ilnd drawn upon during
heayy loads. Pulverizer are usually m tor-driven and require
an appreciable amount of power. In the central system, the
pulveriz rs operate during early morning hours whep tb station
BOILER , lPPLI ANCE1:3 AND Ar XILIARTES 213
FlO. 161. -Taylor stoker with water-oooled side walls. (Courte8Y. American
Enoinemno COml){lny.)
214 BOILER OPERATOR'S GU10M
peak load on the station, th pulv rizers are iJle and I ave that
much more gen rat d energy available to m et peak load
d mand. The table type pulverizer (Fig. 162) i. often used
with central systems.
The unit, or dir ct-fired, system operates as its name implies.
The pulverizer opemt s continuously to supply the burners
BOILER APPLIANCES AND AUXILIARIES 215
FIG. 164.-R iloy Atritl\ unit p\ll\"~";zer. (Cmll·lr.", Ril ey Sioker Corporation.)
Am. The open heater brings low-pressure steam in direct contact with
t he water and operates at or slightly above atmospheric pressure. The
closed feed-water heater consists of shell and tubes with indirect contact
between steam and water and may operate at high pre88ure.
229. What is the main difference in the purpose and function of a deaerat-
ing and an o}Jen feed -w6.ter heat.er?
Am. The open heater reduces oxygen content by heating th e feed water
to about 212°F ., venting thc contents Itt atmospheric pressure. T he
deaerating heaLer removes practically all oxygen by heating the feed water
witb steam of about 30 Ih. p er sq. in. or high er. Its shell is vented at
pressure, through a vent condenser Md vacuum pump.
230. What applil1nces would you recommend 011 an economizer?
Am. Pressure gage, rolief v!Livc, blowdown valve, inlet and (Jutlet
water thermomoters, inl ot and out.lcL gas tempemt.ul'l' indicators or record ra.
231. How is normal scale formaLion removed from evaporator tubes?
Am. By ahodding, rCRlIlting from forced expansion and contraction of
Lhe tubes.
232. What arc t he "uvlLnt"g('~ .UlU th., cli 8,,(lvl1ntago~ of motor- and steam-
driven feed-water pumps?
Am. A motor drivo rcd uces the ILlUount of RtCfl.m piping and is preferred
usually when the ffled-wILter h eatinll; system secures steam bled from the
main generating Lurbine. The steam drivc ia not n,ffpcted by loss of elec-
trical circuits as would be tho motor. At least one sleam-driven feed pump
is almost always installed for this emergency. BLeam units may exhaust
to a feed-water heater.
233. How doeR an illject,or foroe water Hgainst boiler prC~8un' whell it
uses steam at the Bam(> pressuro?
An8. "Because of t he restricted arc .. of t hl' llozzlp, high velocity carri es
the drops uf water SO t hat their momentunJ (lnllR(>~ flo w into the boiler.
234. What is IL stAam trap, and where should YOll expect to find one in a
hoiler in 'Lallation?
AtloS. It is lL devi(:o dCRign ed to remove co nd c l1 ~a(.e from steam space with
minimulll l.o8s of tpltm. A stearn trap is very often u sed on pockets 01'
~e pl\rators of steam lin es.
236. What is t ho purpose of a pressure-reducing or pres8ure-regulaLing
valve? Where might you fiud one?
Ans. It serves to reduco an available pre88ure to a lower, constant,
desired pressure. A stcam lin e operating at 400 l b. per sq. in. for power
generation has to supply a branch line to a beater shell designed for 75 lb.
per sq. in. A reduding valve would be installed on such a line and sct to
maintaiu beat,er pressure within tbe prescribed limits.
236. What are two essentitl.l appliances used in conjunction with th e
reduccd-pre88ure side of the regulator? Explain your answer.
Ana A pressure gage and a safety valve. The former is req uired to
check tbe operation of the regulator, the latter to protect the low-pressure
equipment aganst ex essive prCBBure should the regulator fail.
237. What are two services performed by waterwalls?
Ana. 'They increase boiler capacity and reduce refractory tnRintenance.
BOILER APPLIANCES AND AUXILIARIES 221
~60r-~---+~----~+-----~~~~
c
QI
'0
t40r-----~------~------_+------~
UJ
e~ 20 I-------I-------+-------!-------I
o
Shift A is then off from 4:00 P.M. of that Saturday until 12 mid-
night Sunday, when t hey work 12 midnight to 8: 00 A. M . through
to the following Sunday. Then they are off until 8:00 A.M.
Monday, returning to start the original schedule.
Many plants that employ a number of operating engineer<;
find it necessary to have at least one spare man, or "floating "
operator. This man should be capable and trained to fill in allY
shift vacancy due to iilnes , absenc " or vacation periods. Dur-
ing normal conditions, he may be absorbed in a maintenance or
t.est schedule.
It should be a strict rule in shift work that no operator should
leave his station to prepare to go home until his relief operator
INSERT PLUG
The monthly operating cost or the function performed by the old unit
might be $175 whereas for the new unit it is estimated at $150.
The net saving in operating cost would then be $25 per month, or the new
unit would be written off the books in 3 years.
If the expected life of the new unit were 15 years, it could be
amortized wi t h a definite saving, and immediate installation of
this replaccment unit would be strongly recommended.
More complex itE'ms than mere amortization enter the picture
of fixed charges, such as interest, in urance, and taxes; but oft n
Lhese are more t han balanced by savings in operating cost
po. sible when modern equipment is substituted for obsolete
equipment.
In the design for installation of new or replacement boiler-plant
equipment, it is well to submit the blueprints, proposed plans, and
specifications to the plant engineer for comments or approval.
He should know the" ins and outs" of the plall t, its general setup ,
and its peculiaritiets, whereas the designer or consultant, lacking
familiarity with the particular plant, may unintentionally slip on
an important item. Many costly errors may be eliminated by
close cooperation of the de igner or consultant and the chief
engineer.
Insurance of boilers is an important item usually handled by
t he company executives, but one on which t he chief engineer is
sometimes call d for consultation.
Insurance should be twofold in scope. It should be designed
(,0 be an adequate bond to give financial reimbursement for any
possible accid nts, and it should carry with it an inspec tion
service that will make it possible to reduce accidents to a mini-
mum. This service should be expected, also, to point out any
conditions in the boilers, overlooked by the plant personnel, that
might b corrected to reduce operating or maintenance costs.
Two general types of boiler insW'ance may be written. One
covel'S damages. caused by explosion or ruptur of any part of the
boiler proper under pressure, and the other reimbur es the user
for los of production due to outage of equipment operated by the
boiler in case of uch an accident. The former is known as
"e}..'plosion coverage," and the latter is classed as It use and occu-
pancy coverage."
Many states reqwre that steam boilers operating over 15 lb. per
sq. in., and not under federal control, should be inspected by a
BOILER-PLANT MAN AGEM ENT 23J
...
ct:I000 O O t - - l t ) -
00 aO"': 00 00 00 oO U)
cn ...
...
(')co~~cn~
~
.. '"
00
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00 ... 0 0 0 0 0 0
.
'"
------- ------~~----------------------------~-----
c.10lt')OOC))IQO
o
O~MOO~-OO
"" ....
I.¢ 1(,) .....
o'" ,~
... • 0'11'- •
, r)oO_;~oO«>oOoci ' " ('Q 0) lI:) - 0-
- 00•
CJ)"!fI .....
'"
r.C~~0>~
~
~O>Q)(O
_C'I ~ .... _ "'-
"'ao
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....I-''OO ., f:
O ..... ('Q IQ~!eC!:
'" ""...
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... . ,0,1' .
g:;~~~~g!~ Q) . ... 0> .........
~OOO> .....
10 .....-00
• ....
'" '" ~
_..... _
00
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-IT
BOILER-PLANT MAN A GEM EN7'
~:~:g
~~;;~
......
M~_tt')
f-..tt')~
.....
Cl?l()-~
~-ooao
'"......
"'Ol
"''''
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.....
-00
'"'"'" "''''
o
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00
-C- - -.- . - - -.
234 liOlLEl? OPERA TOR 'S GU Tnrc
Pump
Mooke _ _ •
Boiler Feeol Service
A'1Ie _ . Cost new
No.2
I
Serio I No. Type
Ma ior Reoairs Minor RepairS Inspection and Tests
Date Tvpe Cost Dote Tvpe Cost Oat.! Type os·~
---
FlO. l7l .-Card indexing for maintenanoe program .
Even the smallest plant can effect a system that will give thiH
information in an alphabetical card-index file that can be pur-
chased for less than $1 (Fig. 171).
Safety.- Large plants sometimes employ a "safety" engineer
whose duty is to see that all hazards are reduced to a minimum,
to educate the per onnel to be safety-minded, and to select
educational material on safety for posting. Obviously, t~.\)
small plant cannot afford such a specialist. But the samG ideas
of safety can be developed among a smaller personnel at a propor-
tionately lower cost. Such a program supplies another instance
of how spending ten dollarS may save hundreds.
No matter how small a plant may be, a bulletin board should
be included in its equipment. If employee's compensation
236 BOILER OPERATOR'S GUIDE
To treat ihe CUUS is of an cxplo 'ion in more detail, boiler def cts
contributing to an explosion inc Iud cracking, improprr design
or construction for the operating pl'essur , and defective matcrial
Uf'led in construction. Most of these should be disclosed by
compet · It inspection.
Appliance defects most likely to cause an explosion are safety
valves of defective de 'ign or in improper setting or condition.
Defecti\'e installation, de 'ign, or condition of water-level-indicat-
ing equipment constitutes a similar hazard. Pressure-gage
inaccuracy may lead to such accidents, as may failure of feed-
watcr quipm nt. Defective blowdown cquipment resulting
in fouled internal surfaces of the boiler have caused explosions.
Internal surfaces may be fouled from other sources to such an
extent that explosions may be cau ed, as mentioned later in
this chapter. An analysis of improper operation would include
PROBLEM OF PLANT OPERATION 239
I
FlO . J74.- Remnin8 of boilorhouBe dil'e~Uy nfter' explosion of boiler' in Fig. 173.
(Fig. 174) and killing fiv e perSOlls. This cxpJo 'ion was dlle to
low water. Bmatl boilers, indeed, must often be cons! CJ~cI
more hazardous than tho e in large plants, owing to their frequ en t
laclC of competent attendance. However, close adherenco to
A.S.M.E. Code standards for construction and care of power
boilers, and a hio-h grad of opera tion and inspection will pra-et;
cally eliminate possibility of accidents of this nature.
The following paragraphs 011 the effects of improper water alld
overheating all deal with conditions that roay lead to an explosion
if neglected.
240 BOILER OPERATOR'S GUIDE
so that it will take several hours or longer to fill the boiler with
warm watcr. In this manner the kerosene floats on the water
surface and tends to soak into the scale as it rises. Draining
Fro. 1761>. -Inside of boilor in Fig. 176a dirootly after oponin handbole under
tubes, sbo\\'ing pilo of 10080 scalo wbich dropped from tubes and causod bulge.
(Rod on bottom is hoe inserted to removo scale.)
--reedwater to boiler
Fro. 177.- 0il dotcttor tank.
70,000 lb. per sq. in., and the drum is designed for 262 lb. per sq. in. maxi.
mum working pressure based on an F.S. of 5. Corrosion and pitting have
reduced the average thickness ~ in. in large areas (Fig. 179). What is the
safe pressure?
P _ T .B. X t X %
R X F.B.
0.5 - 0.125 = 75'"
0.5 10
FlO .
....
~ ..
181.-Boil er failure due to ernbl'ittlcmeut. (COIu·l eB/I. Un'iver.it71 0/ Jllinoi.
Pro/, F. a. Straub, )
FJO. 1 2.-Under a butt strap in8ido nn ornbl'ittiod drum. 500-hp. boiler. (Cour-
tUJI. UniverBil1l of Illinoi8. Prof. P. G. Straub.)
butt straps (Fig. 182) or under the laps of the plate in riveted
scams but are rare in welded drums. The embrittling action is
actual ly a mic!'Oseopic form of corrosion between the grain
boundal'ie of the metal.
The exact cause and l' medy Jar all cases of embl'ittlement are
not determined as yet. A number of America's for most authori-
ties are giving thi problem their ttention. The one thing that
they have agreed on to date is that t he job i. still unfinished .
The action of embrittlement is shown in the accompanying
photomicrographs (Figs. 1 3 aod 184) of an affeeted boiler. The
crack i intel'cry. talline, whereas a fatigue crack is transerystal-
252 BOILER OPERATOR'S GUIDE
Hof blowdown
/Apporfl"oning
)f valve.~
De .F.
Boi/er- ~=~)
I pump
feed -- .
r-
- /%,.,., .
r-~~~e
I-
~ 35 000
:f '
.t
I-
~ 30,000 1\ , I
t:i 25,000 I
a;
c:'
2 20, 000
~
~ 15, 0 00
1\ +
-i-
.!: !\
~ 10, 000
I\. I
o
......
~
en 5,000 ..... ....
o
o 100 200 300 400 500 600 700 BOO
Suspend ed Solids , Pads per Million
FlO. 187.-Criti cal conoentration value a nd t ho rob tion betweon d issolved and
suspendod solid •.
PSp cialJy dangerous. There is a critical poin t limiting t hese
concentrations in any given boi1:>r iIl ' taliation .
The curve of F ig. 187, obt ailled from tests Ort a 3,000-sq. ft.
longitudinal-drum watertube boiler operating a t 200 per ccnt
rating, 'hows th poillts at which carry-over occw·s with varying
concent rations of dissol ved and suspended solids.
Soap or oth l' organic matter in boiler water is particularly
undesirable. Evcn t hough present in very small quantities,
thes substanccs which enter the boiler through contamination
of t he feed-water supply by certain types of engille oil or sewage
often produce foamillg.
PROBLEMS OF PLANT OPERATION 25g
H. R. r boiler
011
burner
"
.I!'ru. 190.-Ors..t appo.ratu8 tor aoalyzing flu" gase8. (CourtUJ/, The Bay.
Corporation.)
than the rate at which cooler water can be supplied from its
lower end. A stcam pock t, serious overhcating, and failure of
the tube usually Te ult. Water t ube' are also au c ptible to the
same results of flam e impingement 118 those mentioned with
r ference to fire-tube boilers (page 270).
A reduction in thickness, due to erosion by particles of burn-
ing carhon and of fly I18h, will result if flame impingement con-
BOILER OPERATOR'S GUIDE
a
Combusfion chamber
•O . • 0
0•0• 0 0• 0
• °0•• 0 0
• • •• •
0 0 0 0
0
(b)
CombusTion chClmber rlue
• 0 . 0 ~ O 0 •
.~
· 0
•
0
• 0
•
o
-=>
.", 0
•
0 ••
0 0
• o 0
• 0
0
0 ••
• (c)
Legend
• Carbon molecule ~ Carbon monoxide (CO)
o Oxygen molecule ~ Carbon dioxide (C02)
FIo. 193.- (11) Good combustion. All ILvailable oxygen molecules have pairod
up with carbon moleoule! to form a high percentage of CO.. (b ) Poor combU!l-
tioD. Tbere ha.a been an inadequate number of oxygen molecules to supply a pair
for each carbon molecule. The C (carbon) molecules. unattaohed. denote smoke.
For good oombustion. inorease the air supply (c) Poor combustioll. Fluo 1M
show8 both unattached oxygen and carbon molecules although there is an abun-
dance of each. Tbis indicates lack of mising in furnace (turbulence) . Furnace
design. proportions. or the Bame oharacteristios require ohanging.
If CO and no 0 appea.rs in the flue gases, this fa.ct indica.tes
that insuffici nt oxygen was supplied the combustion chamber to
PROBLEMS OF PLANT OPE'RATION 267
allow the C molecule to acquire the second 0 moleculeneccssary
(or complete combustion (Fig. 193b) . On tbe other hand, if
CO is found in the gases with 10 per cent or more 0, lack of
flame t urbulence for proper mixing is often indicated . The 0
molecules were there, but they did not meet the C + one 0
molecules in time to unite at combustion temperatures (Fig. 193c) .
In operating oil, pulverized-coal, or gas burners, t he primary
air should be adjusted so that the flame will start just far enough
from the burner tip for its burners not to overheat. The second-
ary air should t hen be controlled so t hat a "clean" fire will
result and maximum CO 2 will be obtained. A clean fire means
one maintained at as neal' "incandescent" heat as possible
for load carried, and up to such praetieallimits as safe refractory
temperatures. This objective is accomplished by reducing the
secondary air to just above t he point where t he fire looks yellow-
ish and smoky.
Oil fires sometimes pulsate or flu tter to t he extent t hat the
entire boiler setting may vibrate. This effect may be traced
usually to a pulsating oil-burner pressure resulting from a
reciprocating oil pump. Usc of an air-cushion chamber usually
:solves this problem.
The method of ignition is an important item in the use of
suspension fuels. 1 An adequate torch or auxiliary-burner flame
should be applied to wit hin 1 or 2 ft. in front of t he burner before
fuel flow is started. The secondary-air supply should be practi-
cally cut off, and the primary air reduced so that a "rich " fuel
mixture results. If ignition does not occur within about 15 scc.,
t he fuel should be cut off, and the ignition extinguished. Thc
furnace should be scavenged by full draft for several minutes
before attempting ignition again.
Burners should never be lighted by t he heat of the refractory or
from the flame of a burner. Use the igniter. Furnace-gas
explosions may result if these igniting precautions are neglected.
Ignition stability is important to safe burning of suspension
fuels. Coal of low volatile (gas) content is sometimes unstable
when pulverized and when operation is at low loads. Oil-
burner instability can be traced usually to a clogged oil Bystem
or to improper oil temperature.
oot should be blown after thc firebox has cooled, if steam OJ' air
js available. Otherwise, if flame stabiljty is affected, the burncrs
should be set at their lowest point with a lean mixture, land
secondary air and draft should be high enough to carry soot
deposits to the stack.
The inherently limited combustion volume of internally fired
boilers and the requirements of fuels such as wood-waste prod-
I High primary air-low fuel rateR.
270 BOILER OPERATOR'S GUIDE
Burner
.,
the rate of firing, and just how low the water gets. A popular
fallacy is that adding water t.o an overheated boiler causes an
explosion, but experiment.s abroad and by a large railroad in
this country have proved otherwise. However, an overheated
boiler should b cooled gradually by extinguishing the fire and
leaving a.11 valves as they are. Competent inspection for damage
is then essential.
If the boiler is a type with a crown sheet over the firebox or
combustion chamber, such as a locomotive or Scotch marine type,
a rupture of the crown is almost inevitable if the water drops
below t he level of the crown heet, for the bared metal Boon
272 BOILER OPERATOR'S GUIDE
Ogee j l/Somefirnes
(reverse)- ... (iP' ~ cracks here
fkmqe ~ ~!d!:::!:!:!:!::Io:!::!!db!::l:l,,- ~
~ ~
~ ~
~ ~
~ ?1
~ ~
FIG. 201.-0geo crncks in Manning boiler.
FlO. 202.-Cracked flango in lower tube sheot of vertical t ubular boiloo·. Rmall
black dot l~ hole drilled to meaaure depth of crack.
Fro. 204.- Section of longitudinal lap-riveted seam ; . Iots cut ill p late to detect
sourc'e of leakage.
F,O. 205.-Soction of a girth seam showing whero fi,'o cmcks may oncnr and how
to repair t horn .
orfube
/ \~
Flared end
'"
F======;===~~ ~ / Tube-cap
Tube .;:' hole
~==~~==~~~t
rolls ex-
pand and flare tube
in one operation
FIG. 208 .- Abovc, expanding tub" end for ueading: oeuter, beaded tube end;
below, expand ing and fl a ring tube !l8 in watertubo boilers. (Courte81l , Th_
Gustav Wiedeek e Co.)
between the tube and the tube hole. The tube is then expanded
against this ferrule.
It is nee sary sometimes to weld ends of a water tube, as with
circulating tubes to a header which is being renewed . Th e edges
280 BOILER OPERATOR'S GUIDE
ne....1I_0I
.,..... eo.,u
nlt(·ooor
FIG. 209.-Vertical Jire-tubo boiler.
Steam protects the upper ends of tubes in vertical fire-tube
boilers from burning. During starting up periods, a low fire
should be maintained until several pounds pressure is attained,
or else overheating-may damage the tube ends. Sometimes dur-
ing the starting periods these boilers are filled with water to the
top to protect the tube ends. The water level is blown down
after steam generation starts.
It may be of much value to keep a record of replacements of
tubes, stay bolts, etc. A method used in one plant of identifying
the tubes is shown in Fig. 209.
PROBLEMS OF PLANT OPERATION 281
FlO. 210. -J ncking ffLbricnted pnt ch into position for ri veting 00 trough nt
bottom of box honder in wntertubo boiler .
not burned. One of the most concise codes for proper design of
riveted patches, reprinted in the Appendix by the cowiesy of
Mr. Joe Kunschik, Commissioner of Labor, is that of the Texas
Department of Labor, Bureau of Boilet· Inspection.
Collapse of a front arch under a box header of a watertube
boile!' sometime.' permits Damr impingement to cause a bulge in
the" trough I 011 t,he botLom of t he header. Figure 210 shows
a fabricated pal eh lwing i!l:talled for rivpting to repair such
damage to a 400-lh. boi[(')·.
Handhole rings are required to strengthen edges of handholes
deteriorated badly by external corrosion. This corrosion i
caused usually by leakage past the gaskpt. Th elliptical ring
is of the same thicknes.' fl. the ~hrrt, ftno it. .. hould overlap the
IHandhole cy>ening
.FlU . 211.- Ncw scat for h andhole plate.
Fro. 212.- Flellible stay-bolt installation. Tbe threaded end of tbe stay bolt is
usually upset so tbat tbe diameter at root of threads will not be lesa tban the
body diameter.
,,
:.4'w . 214 . Bt\cking up furnace .beet of vCl'li ct\1 ,"b,,!tll' t,oi ler fOi' (hidng bac·k
bulge.
Feed-wafer
@ connecfion
" Mud
ring
shell expands, it carries the lower part of the heads and brace
attachments with it, stretching the brace far beyond th ir yield
point. Thus, when the shell ron tracts, the braces have been per-
manently elongated and will bow. The direction of this bowing
j often upward (but may be in any direction).
A slight bow need J10t be repaired. If t he braces are bowed
badly, they should be taken out and straightened. If they arc
elongated so mUI',h t hat, a fult numh<:,r of t hreads is not in ~,ontact
with the inside nut, DeW braces should be installed.
D = l ~(
where )fro = cubic feet of steam fl ow per minute.
D = requil'eu diameter 01 pipe, in inches.
F = pc rl1li ~s ibl c Htmull- {lo w veloci(y, in feet per minute.
To select I.L proper pipe si7.c for 12,000 lb. sat llrated stetun per br. at 300 lb.
per sq. i.ll., first find the density for the pros8ure from tile stenlll tables. P'll'
300 lb . pressure, it is 0.67 lb. per cu. ft. i therefore,
12,000
0.07 = 17,910 cu. H. per hr. or 208 1I. f t. per min.
2S
'"
Q)
.s:::
E20 ~----+-----~-----1~~f-~--~~--~~-----1
t:
+
'f
.-15
...J
c
o
I/)
CIO
8.
x
LJJ
Fto. 219.- Mcllu radius of expansion bend in inches. (Data by coltrtcsy of the
Crane Company.)
8ii-f'
pressur:e or8/a :(:i I
per sq. tn. \ I
*
"
returns from backiug up the return line in case the steam valve
is olosed (Fig. 221).
In installing steam piping from a boiler, all essential or emer-
gency steam lines, such as for feed-water pump, fire pumps,
and station auxiliary drive lines, should be connected directly to
the boiler or to the main steam line between the boiler and stop
valves. Thus it is pos ible to operate this equipment without
subj ecting the main piping to pressure. Stop-valve require-
ments for su h direct lines are the same as those for the IllJj;1l
stearn line if other boilers tie in with them.
PROBLEMS OF PLANT OPERATION 291
Use of a number of short-radius 90-deg. bends in steam lines is
undesirable when the flow through them is of a pulsating nn,ture,
for the reaction of the piping may set up severe stresses and even
cause the boiler to pulsate and wreck its setting. Wide-sweep
bends are the proper design for such installations.
Drainage of piping at all low points is essential. Traps are
desirable for automatically serving this purpose. A pocket of
water in piping may be pichd up by steam flow, and its momen-
tum on a sharp turn may result in rupture of the fitting.
Cold-water piping often sweats in humid weather, and dripping
water may be undesirable. As a preventive, the piping may be
Sfecrm line
---- .... ~
~ / Abouf
....:t.,,4,...--.. .
12"t 1
--r I I
I I
I I
I ~~----~--~--------~
I Condensafe refurns by gravi y
Sfeam - __
supply Open Tee
wafer
heafer
expansion and contraction serves to shed surface Beale from the coils
The scale drops to the bottom of the shell and passes out the blowdown.
During operating hours, periodic tests on the evaporator (Fig. 223)
shouln be made to determine concentration and proper time interval~
for blowing down. Maximum allowable concentration will, of course,
vary with the type of evaporator, pretreatment of make-up water, and
such other factors as llIay be present in the individual casco
Good results in tbe removal of scum and other surface impurities
from the water will be had with the use of a surface continuous blow-
down . This should be tapped into the shell at the average water level.
In one installation the surface blowdown line consisted of a ~f -in. pipe
having a ~ -in. orifi ce. Thi.' line may discharge into any waste vacuum
line having a higher vacuum than that which may occur in the evapora-
tor. Suitable discharge points for this line may include condenser tail-
water piping, ~ ulilp-well pump suction, generator air-cooler tail-water
pipillg, etc.
A high -pressure single-effect evaporator should be equipped with at
least three pressurr gages. Olle gage should be calibrated higher than
the maximum Rtealll jJl'e~~ ure to the coil and should be counecteu at the
RUPl1ly end of this <loil. TWI) compouuu pressure gages I'Ihould be
connected, one tappe,[ intu th vapor outlet from the sheU and the other
tapped directly into the top of the shell or the Rafety-valve nipple.
'ollllDon practice for the past few years has becn to install an intemal
purifier within the evapoJ'l1tor to remove allY l:!Olids in the entrained
water. Tbe pressure dilfer ntial Ahown by the readings of the two
compound gages will show the pre sure drop across this purifier. In
spite of all such precautions, carry-over by foaming is still experienced
occasionally. Much of this has been eliminated by installing a rec-
tangular baffle plate of sheet steel in a horizontal position midway
between the water level and the purifier bottom. This plate haa an
area of 50 to 75 per cent of the water-surface area.
If, after some time, a pressure differential of greater than 10 per cent
of the maJo.imum operating shell pressure is shown, it will be necessary
to clean out the purifier. This may be done by removal from the shelJ
and scraping by hand, but this is a long tedious job in large evaporators
and is usually unnecessary.
It has been found that most of the solids which encrust the purifier
surfaces are soluble in hot water, and so an easy method of cleaning the
purifier is aa follows: The float valve on the water supply is blocked
open, filling the evaporator with water, and the float is left blocked in
this position. The valves on the vapor discharge and blowdown lio.es
are closed. Steam is then passed through tbe coils, and the water in
t,he shell is allowed to boil about 15 min. During this boiling out, a
131-in. line frc.!.D thp. evaporator side of the vapor-discharge gate i ~
296 BOILER OPERATOR'S GUIDE
opened to the sump. AB the water boils out of this line, carrying dis-
solved impurities to the sump, fresh water is constantly admitted, the
purifier being kept under water. The shell should then be drained,
refilled, and boiled out a second time. Then it may be drained, refilled
to the correct operating level, and placed in service.
Many are the methods that are used in blowing down, but one very
effective one is given. Steam-supply and vapor-discharge valves are
closed. The make-up water line is shut off, and higb-pressure steam is
admitted to the shell by a special ;!i-in. lin tapped into the top. As
soon as the shell pressure builds up to ab('ut 50 per cent of the safet:v -
valve setting, the blowdown valves are opened. An indication that
the shell is empty will be a sudden drop in the positive pressure reading
of the two compound gages. Tbis is caused by a loss of the water seal
on the blowdown line and the sudden release of steam through it . A
small quantity of water is then admitted to the shell to flush it out, and
this is then blown out. The tlvaporator is then filled 'with water to the
correct operating level and placed in service ill the usual manner. In
lUling the shell, water should be admitted by a by-pass of large diameter
around the meter and float valve in order to cause maximum coil
cooling and contraction.
An evaporator should be drained and refilled in thi8 manner after
standing idle for over 8 hr. Otherwise, the action of tbe water on the
scale will have raised the concentration to such a value as to cause
probable carry-over through foaming.'
SBJety-val ve care in t,he operating schedule should include
frequ ent periodic tests of safety valves. In boilers of moders.f.e
pressure, the va.lve should be lifted by its lever at least cnce each
day of operation and the pressw'e should be raised t,o the popping
point to test the safety valves at least once each week of opera-
tion. If the safety valve does not blow at its set pressure, the
lever should be tried at that pressure, for the spindle may be
stuck slightly in its bushing. If the valve is not freed or if it
does not blow at its set pressure on several subsequent trials, the
boiler should be shut down at once for safety-valve overhaul.
If the spindle becomes sticky in operation owing to soot
binding in the bushing, free use of kerosene and repeated lifting
of the Jever may free it. Cleanliness is a big point in safety-valvE>
maintenance, and soot and dust accUDlulations should not be per-
mitted on t he safety-valve mechanism. Lubricating oil should
'H. M. Spring, Jr., Power, September, 1933 . .
PROBLEMS OF PLANT OPERATION 297
not be used on the spindle, for it may collect dust and cause
gummy deposits.
Owing to the cutting action of high-pressure steam, daily tests
of safety valves set at over 500 lb. per sq. in. may not be advisable.
The manufacturer and local boiler authorities should be con-
sulted on t his point, but it is seldom wise to II.llow more than a
week to pass between tests except on superheater safety valves.
If the safety valve b lows at a lower pressure than normal,
according to the pressure gage, the gage should be te ·ted. If the
gage i correct, the gage piping should be blown out to be sure
that it il:! clear. If the safety valve then blows at too Iowa pres-
sure, it may be adjusted by a compet.ent person, taking extreme
care that plenty of clearance is left between the spring coils when
the valve is wide open. 1t is always best to check the boiler
pressure at two different, point::; on thE' boil r to eliminate thf'
possibility of incorrect prCHsure iudication. Any considerabl e
deviation from normal operation of safety valves should receive
immediate competent attention.
Safety-valve escape pi} es may become dogged with sediment
owing to leaking safety valves. The periodic test should dis-
close this condition. Leaking safety valves should be reground ,
never tightened by adjustment to SLOp leakage.
Water-column and gage-glass behavior i · affected directly by
operating procedure. Obstructed connection· arc dangerous
and may cau ·e fal se water-I vel indicati:m. If the upper con-
nection to the gage glass is ob ·tructed, the glass will fill rapidly
to the top after blowing down either the column or the glass,
although a test by the try cocks shows normal water level.
Sometimes the connection may be freed by opening and closing
the shutoff valve repeatedly. If it cannot be freed, the boiler
must be shut down for clearing the line.
An obstructed steam connection to the water column is rare
but exceedingly dangerous. The water will go rapidly to t he top
of the glass on blowing down either the glass or the column, and
the try cocks, too, will sbow a falsely high level. Tbe only way
to detect this condition, if suspected, is to shut off the lower
connection to the column and open t he drain. If no flow results,
the upper connection is obstructed, and the boiler should be
removed from service at once. If no shutoff valve is provided
298 BOlLER OPERATOR'S GUIDE
llli3. Two identical boilers operate in the same plant with the same feed
water. Blowdown from each is t.he same. More Reale forms in one boiler.
Why?
Am. Evaporation must be greater in t.he boiler having the most scale.
2114,. A watertub bo.iler is scaled heavily. What should you recommend?
Am. Removiog the scale Illcchauicfllly by t urbining the tubes and
scaling (chipping) the drum surfaces if necessary. Kero 'ene saturation or
caustic boiling may b benefi(·ial. After Lhc boiler is clean, treat men t. of
the feed water should be il1(,orporaterl 01' C()rrectod to pl'ov(mt sCl1le fOrIIlIltion .
266. Can a tube turbine cause damllge 10 a tube? How?
Am. Yes, if forced or held in one position too long.
266. What care should be exercised in changing feed-water treatment or
Iced-water source of supply? Explain.
Am. If scale of any quantity is present, it may be loosened suddenly
and precipitated ont,o hot surfllces where it wm cause overheating or damage.
The change sho uld be made u,s gradually flS possible, and the boiler opened
very often for inspection during and directly following change.
267. Is a tube tu rbin e used to remove scale mechanically froln fire t ill es?
If not, what is used?
Am. No. A tuhe rattler or vibrator is used.
268. Of what benefit Ui a coating of oil on internal surfaces of a boiler?
Expla.in your answer.
Am. None. It. is exceedingly dangcrous. Oil is a heat insulator and
thus may produce dangerous overbeating of affected surfaces.
269. What is the most common so\!rce of oil in boilers?
Am. Use of contaminated condensate returns from reciprocating steam
equipment.
260. How might fuel oil get into a boiler when oil burners arc used?
Am. By failuro of a t ube or coil in a fuel-oil steam hoating element wilen
the condensate is returned to the feed-water s,Ystem.
261. If the pH of water is 6.5, what may be said regarding alkalinity?
Am. The water is acid.
262. What is pitting (briefly), and when is it serious?
Am. It is a localized form of internal corrosion acti ng to deteriorate t,he
boiler surfaces. It may b serious if active and is serious if the pits are
extensive Rnd closely spaced.
263. What is a protective coating used for in a boiler?
Am. It is a very thin coating used to prevent direct contact of boiler
water !lgainst the boilor surfaces. Internal corrosion and pitting may thus
be redured.
264.. What is galvanio action?
Am. It is an electrolytic Bow between dissimilar metals in a boiler,
resulting in localized deterioration.
266. Is internal corrosion more serious in a drum having a quadruple-
riveted longitudinal seam than in one having a lap seam 7 Explain your
answer.
A'I'l~. It is more serious with a quadruple-riveted boiler because a smaller
p(>r entage d terioration would bring the resultant strength of the drum
]J low the st rength of the longitudinal seam of rugh efficiency.
PROBLEMS OF PLANT OPERATION 301
288. What causes most external corrosion?
Am. Sulphur (S) in soot, coal, or ash, and moisture.
287. What objection is there to burying piping under the boiler Roor?
Am. External co rrosion may progress unnoticed to a dangerous point.
268. What is erosion, and what is the most common causo of it in a boiler?
Am. It is the wearing of surfaces by abrasion. It is usually caused by
impingement of ~oot and ash particles.
269. What causes priming 11nd foaming?
An,q. A high water level plus sudden demand for steam may oa\lSc prim-
ing. High concentration" oI solids, or organjc mf1tter may causo foaming.
270. Whut hu.rm may priming and Iouming do?
Am. Priming may cuuso rupture of stcl\m piping or wreck turbines or
engines. Foaming may make it impossible to tell t.h corre(:t water level
in the boiler. It !Day cause severe wear of pipe fittings, valves, and steam
equipm(mt.
271. What shou ld YOII recommend for priming and foaming?
An.~. Cllrrying a lower water level (but in safe range) and a higher
pressure up 1.0 "afc limits for the hoiler, to reduce priming. Blowing the
boiler down more frequcl1tJy, to reduce concent,mtion causing foaming.
272. What harm mR.Y be euused by flame impingement?
Ans. Locl11izcd overheating nnd damage to boiler part.s exposed to
ref rltctory.
273. What is the external indic!l.t.ioll of low wal.er and overheating in !.
boiler other than possible distortion, cliS(lolomt.ion, and leakage?
Ana. The soot would be burned oft' of affected surfaces.
274. Which is the mor(' serious, a lap crack or a fire ('mck? Where muy
each be found?
Ana. A lap crack is more serious. l ,ap cl'l1!'ks arc found in longitudinal
lap-riveted seums. Fire eracks Jrmy I e found in the lap of rivete(1 8 !LmS
exposed to rudi!1.nt, heat as in H.R. T. girth seams and firebox-boiler furnace
seams.
276. How may lap cracks be repai red?
Ans. 0 repairs are allowod other than an ntiro now courso of boiler
plate. Otherwise, the boiler is condemned.
276. Should YOll advise repairs to n fir£' crack extending from a rivet hol e
to the calking dge? If so, how shou ld tho r puirs be made?
Ana. Only if leakage occurs. Then remove tho rh'et and the two rivet.s
on either sid e. Yoe out crack, and electric-weld. Ream rivet holes, and
drive new rivets.
277. The ogee (r verse) flange of a Manrung fire-tube boiler is cracked
17 in. circumfercntially. Whnt type of repairs would be in order?
Am. A new ogee flange or a new boiler.
278. What is grooving? Where is it found?
Am. It is a localized form of corrosion in highly stressed areas, suoh as
thoso adjuccnt to a riveted scam or in the knuckle of a dished-head flange.
279. When is it dangerous toO weld fire cracks?
Am. When they extend over 3 in. bcyond the lop into the sclid plate, or
when they extcnd from rivet hole to rivet hole.
280. Name four oauses of failure in tube.~ of watertube boilers.
302 BOILER OPERATOR'S GUIDE
Am. (1) Sca.le, (2) oil, (3) low water, (4) flame impingement.
t81. What is safe-ending, and why is it used?
Ana. It is cutting off and replacing ends of fire tubes that have become
eroded or corroded till they are too thin for safe use. A short length of new
tube is welded to the cut end of the old tube.
282. What would be a likely cause of leakage at the upper ends of tubes
in a vertica.l fire-tube boiler? Give repair and preventative recommendation.
A m . Overheating tbe tubes by forcing fire in starting up the boiler is a
common cause. The tube ends should be rerolled to make tight; or if the
t.ubes are damaged by overheating, tube renewal may be necessary. A low
fire should be carried until steam is raised to protect the upper ends of the
tubes, or the boiler may be filled with water until hot, then blow down to
operating level.
28S. What is an approximate limit of extension for Il. bulge in boiler sbell,
before repairs are recommended?
Am. Depth not to exceed about 2 per cent of length.
284.. What is the limit of depth of a blister before repairs or a cut in
allowable pressure are necessary?
Am. When the ratio of sound metal remaining to the total original
thickness expressed as a percentage is less than the percentage efficiency of
the longitudinal seam, repairs and / or a cut in pressure are necessa.ry.
2815. Briefly, how is a bulged shell repaired?
Am. If the depth of the bulge is not over about one-eighth its length
and the-plate is not ruptured or burned badly, the bulge may be heated and
driven back. Otherwise, it is necessary to cut out the affected Ilrea and
install a properly designed, riveted patch.
286. What is a common defect at edges of 0. handhole? Give cause,
prevention, and repairs.
Ana. Leakage from the gasket may cause cxternal corrosion to deterior-
ate the plate down to a knife-edge, giving it insufficient strength to support
t he handbolc plate. Leakage should be prevented. If deterioration does
not exceed 40 per cent of original thickness and affected IlrelL is close to hand-
hole, the plate may be built up by electric welding. Otherwise, the hole
.hould be trimmed back to sound metal and an elliptical ring seal welded
inside the shell or head.
287. How is a broken stay bolt in an empty, idle boiler detected?
Am. hcn the ends of solid-type stay bolts Me struck with a hammer, a
broken stay bolt may be detected by a dull BOund. Flexible stay bolts are
tested by removing the cap a nd using a heavy screw driver in the ball slot.
288. What docs lli!akagc from the telltale bole in a stay bolt indicate?
Am. The bolt is either broken or cracked halfway through.
289. What causes stay bolts to break, and what location is most sus-
ceptible in firebox boilers?
Am. The expansion and contraction (breathing tlCtion) in the boilers
bends the stay bolts. Fatigue may break them eventually. The upper
rows are most susceptible to breakage, for the expansion is greatest there,
the lower part of the firebox being stiffened by the riveted or welded connec-
tion to the outer sheet.
PROBLEMS OF PLANT OPERATION 303
290. How should you repair a broken stay bolt?
Am Repairs are not allowed. A new stay bolt should be installed.
291. If a. fire sbeet is badly corroded externally or internally ~ in. around
a number of sta.y bolts, what repairs would be advisable?
Am. Removing the stay bolts, drill, and tap sheets, and installing R
larger stay bolt to contact sound metal.
292. Briefly, what causes through-to-head braces below the tubes in an
H.R.T. boiler to bow?
Am. Overheating of the shell bottom causes excessive expansion anci
permanent elongation of the braces. When the shell cools and oontra tA,
the braces bow .
293. What causes steam binding of a feed pump? How should you
recognize it, and what should you do for it?
Am. Exoessive temperatures for the head pressure on the suotion am
the cause. A reciprocating pump would race, short-stroke, or hammer. A
centrifugal pump would overheat, vibrate, and operate noisily. Temporary
measures might include slowing the pump down, th rottling the water dis-
charge, and / or red ucing the water tempera.ture by introducing cold water
into the suction if necessary. Playing a stream of cold water onto the suc-
lion pipe may aid in emergencies. Permanent correction req uires greater
suction-head pressu re or lower temperature.
29(. What is a common causc of excessive feed-pump suction t,e mper-
ature?
Am. Steam blowing through into the feed-wat.er storage owing 1.0
defective traps.
296. What operating precaution should be exercised with outdoor econo-
mizers in cold weather?
Am. Freezing of the blowdown should he guarded against (lither by
use of a small line by-passing the blowdown valves or by leaving thp blllw-
down valves open slightly.
296. How are superheater tubes protected against overheating in starting
a boiler?
Am. Flooding the tubes with water is recommended for a few types.
More commonly, the Buperheater is vented t,o atmosphere by a free blow
valve until the boiler goes on t,he line, and the firing is kept at 11 low rate
until steam appears from this vent, indicating that steam cooling of the
tubes has started.
297. What happens if the lower connection to a gage glass is obstructed"
Am. Th water will return to the glM8 very slowly after blowing it
down . If the obstruotion is complete, the glass will filJ with water slowly,
becauso of steam condensation. An incorrect water level will be shown by
the glass.
298. With reference to Question 291, how should the water level be
checked 7 Outline the procedure.
A.m. By use of the try oocks. Try to remove the obstruotion by
attempting to blow down the glass with th steam connection closed. If
not succeBBful, close the connections, and remove glass. Try to run a stiff
bent, wirl' through the 10"'er oonnection aftflr opening this valve part way,
304 BOILER OPERATOR'S GUIDE
taking care to keep to ono side 80 as not to get scalded. A careful check on
the water level by t he try cocks should be maintained. If the obstruction
cannot be freed, the boiler should be shut down so that tho connection may
be dismantled for cl aning.
299. How should you know if the upper connection of a gage glass were
obstructed? WLat should you do if it were?
Am. Water would rise rapidly to the top after blowing the glass down,
although try cocks show a lowcl' true level. Proc:eed the same as for lowel
obstruotion.
300. What is tbe first th ing to do On entering a boilerroom?
A tl8. Look ftt the gage glass.
301. How should you kuow if a connection to the water column wero
obstructed?
A 118. The water in the glass would show action similar to that described
for gage-glass obstructions, but [, check on t he true level by try cocks
would be impossible if they were mounted 011 the water column. If
this condition is suspected, the boil or shou ld be shut down immediately 80
that the connections may be cleaned.
302. II the distance between the bases of gage-gl!,as stuffing boxes is 12 in.,
how long should you cut a new gage glass? Explain your answer.
Am. About 1l ~~ in. to allow for expansion.
303. Wha.t tools and materia.ls should you need to install a new gage glass
(tubular type)?
A n8. A gagc glass, a gage-glass cutter, new packing rings, a knife, 11
0
packing hook, It wrench, a wiping rag, a stick, and a pail of cold water to cool
the packing nuts.
30t . What should you do if you saw a small amount of steam leaking
through the brick covering OJ) a boiler drum?
Anll. Shut the boiler down Il.t once Il.nd have it inspected.
306. What is a hydrostatic test? How should you apply this test on 1\
boiler installed in battery with others in operation?
Ans. It is a test on [l. boiler with cool wator Il.t a pressure of up to 1 ~
times the maximum allowable working pressure of t he boiler. The test is
performed on new boilers and on boilers in the field to check major repairs or
suspected defects.
All areas to be examined should be exposed. The boiler should be filled
to the top with water at room temperature but not under 70°F. The safety
valves should bo gagged or tbe connections blanked. Both stop valves on
the steam wo should be closed and the valved drip between them open. A
t est gage should be used to check the pres.~ure. If any leakage from the drip
between the stop valves occurs, the test should be stopped and the steam line
blanked off. The water pressure should be rai.~ed slowly to not over 1 ~
times the working pressure and beld at that value long enough to make a
complete examination of the boiler and a hammer test when advisable.
Immediately after the test, the safety-valve gags or blank flanges should
be removed.
806. Wha.t is the trouble if the try cocks on the water column all show
steam but the glass is half full of water, and what should be your procedure?
PROBLEMS OF PLANT OPERATION 305
Am. The lower connection of the gage glass is obstructed. Shut the
boiler down at once, and have it inspected for possible damage.
307. Where on a boiler should you use gaskets cut from sheet rubber?
Ana. For gaskets below the water line, and temporarily only. Pre-
pared gaskets of the asbestos composition typo should replace such rubber
gaskets as soon as possible.
308. What would result from a nick (a) in the edge of 1.1 bowl of a mechan-
ical atomizing oil burner? (b) In the jct opening of a steam atomizing oil
burner?
Ans. (a) and (b) An unstable fire with pOOl' combustion and excessive
carbon deposits might result. (b) Also, flame shape and direction might b('
changed, fllLllle impingement thus being clLuscd.
309. If a safety vlLlve sticks open, what should you do?
Am. Reduce tbe firin!l; rate. Tap the top of the safety-valve spindle
sharply with a light hammer. After the valve scats, blow all dust from the
external surfaces of the slLfet,y valve, Ilnd pour some kerosene arouud the
spindle bushing. Operate t.he valve with the lifting lever until it workH
freely. If the valve will not ~eal" remove the boiler from service lLnd over-
haul the safety valve. Care should be taken to maintain proper water level
when t.he safety vltlve is blowing.
310. How should you propare ~Urfl\CeB for weldjng?
Am. Wire bnlsh and wipe them clean of !til paint, oil, rust, and scalo
deposit,s. Make sure that they Ilre dry on both sides.
APPENDIX 1
GLOSSARY OF BOILER TERMS
priming. An induction of boilor water caused by the steam Bow into the
steam line. The water lTlay be in the form of a spray or a solid body .
radiant (as 9.pplied to heat). Having the property that permits heat to be
transmitted by ra.ys similar to those of light. To absorb radi9.nt heat
an object must be in the" light" of the fire.
radiant superheater. A superheater exposed to the direct radiant heat
(Light) of the fire. See a lso superheater .
raw water. Untreated feed water.
re-lInd (v.l. See 8afe-end.
refractory. A heat-insulating materi9.l, such as firebrick or plastic fire clay,
used for such purposes 118 lining combustion chambers.
reheater. A device using highly superheated steam or high-temporat.uro
fiu e gases as a medium serving to restore superheat to partly expanded
steam. Used often between high- and low-pressure turbines.
return trap. A trap designed to discharge its condensate against boiler
pressure and feed to the boiler wjthout additional llle~ballical equip-
ment. S 'e also trflp.
safe-end (v.). To replace a doteriorat,ed end of a firo tube by cutt.ing off the
end Ilnd welding on a short longth of new tube.
safety valve. A valve that au tomatically opells when prcssure attains th"
valve setting which is adjustable. Used to prevent excessive pressure
from building up in n boiler.
safety-valve drain. A hol e at least % in. diameter rcquired through t he
body' below the valve-scat level in Sllfety valves larger thllll 2 in . diam-
eter. Used to prevent condensate from collecting at this point.
safety-valve escape. A pipe conduc.tillg stcam diseh9.rged from a 'lI,fely
valve to !l safe location.
safety-valve lifting lever. A lever by whic,h n safety vnlve may be lift,ed
from its seat.
safety-valve muffier. A silencer designed gO that it. will not cause appre-
ciable rcstriction to steam flow.
safety-valve nozzle. A fiangpd nozzle by which a safety valve is connected
to a boiler shell (ir drum.
scale. A deposit of medium to extrem e hardness occurring on water hcatinp;
surfaces of n boiler because of an undesirable condition io the boiler
water.
scleroscope. See ShOff 8clero8cope.
sectional headers. Sec boiler header.
separator. A tank type pressure vessel installed in a stenm pipe to collect
condensate to be trapped off and thus proyidjng comparatively dry
steam.
shank. The body of a rivet.
shear (v.). To cause failure of a material by the "cutting" across its longi-
tudinal axis of parallel tTl111SverSe stresses acting in opposite directious
See Figs. 233a, 233b, and 234. for cases of single and double shear .
Shore scleroscope. A device to test tho hardness of a material, perfonned
by dropping a diamond-pointed hammer from a standard height.
sUica. A scale-forming element found in some boiler feed waters.
APPENDIX 1 315
sinuous header. See boiler header.
siphon. A" pigtail" shaped pipe or a drop-leg in the piPIl leading to a
steam pressure gage, serving to trap water in t he gage and prevent its
overheating from direct contact with steam.
slag. A residue deposited by ash particles that have attained their soft-
ening temperature (1900 to 2700°F. ) depending upon t heir composi-
tion. Slag may be plastic and viscous when ho t. It hardens and is
rather porous and brittle when cool.
slicer. A slicing bar. A long steel har used for b reaking up a fuel bed in
coked or caked condition.
slug. A solid body of boiler water passed into the steam flow by priming
or picked up from a pocket of condensat.e in the steo.m line.
soft patch. A patch applied with tap bolts, with a gasket under t he patch
plnte to prevent leakage.
soot blower. A tube from which jets of steam or compressed air a re blowl1
for cleaning the fire side of tubes or other pa rts of a boil r.
specific gravity. The ratio of t he weight of a unit volum e of a material to
the weight of the same unit volum e of wa ter.
spud. A fl ange nut wrench , open at one end and pointed at the other as ..
drift pin. The pointcd end is uscd for aligning boltholes of pipe flanges.
stack. A steel "chimney."
stay bolt. A stay threaded and ri"cted over at each end , used to connect
two flat or curved pressure parts of a boiler.
steam. Water vapor produced by cvapomtion. Dry saturated stoam
contains no moisturo and is at a specific temperature for every p rcssure;
it is colorless. The white appearanoe of escaping steam is due to con-
densation at th e lowered temperaturc; it is t ho water vapor that showB
white.
stress. The internEtI resistance of a materi al to an external force changing,
or tend ing to change, the shape or position of the material. S e also
tolal stres8, unit stre88.
stress-relieve (v.) . To dissipate pent-up stresses caused by welding, by
meaUl! of heat-treatment.
strongback. A hoavy steel bar bolted to tube sheets of fire-tub e boilers
during constru ction, while braces !lre being iustalled, to prevent the
tub sheot from buckling before installation of the tubes.
subpunch (v. ). To drive a pilot hole through a plate preparatory to drilling
a larger hole.
superheated steam. Steam heated to a temperatu re higher than that
" corresponding to the temperature equivalent to the pressure.
superheater. A series of tubes exposed to high-temperature gases or to
radiant heat. Steam from the boiler passcs through these tubes to
attain a higher temperature than would be possible otherwise. This
superheated steam ensures dryn ess. See also convection superheater,
radiant superheater.
superheater header. A large-diameter (about 4- to 8-in.) thick-wallel!
tube into which a row of superheater tubes is rolled.
316 BOILER OPERATOR'S GUIDE
tack (v.). To hold edges of plate in correct position fol' rivetinjl; by (J) 8,
few scattered bolts, known as "tack bolts," placed through rivet holes
or (2) by small scattered spot welds known as "tack welds" or "stitch
welds."
telltale hole. A hole drilled into the ends of a stay bolt. The hole extends
at least 31' in. inside the inner surface of t he stayed sheets; or if tbe stay
bolt is reduced in dillmetcr at its middle portion, t he hole extends 31' in.
inside t,he point of diameter reduction. The purpose is to show leak-
age, through the telltale hole, if the stay bolt breaks or cracks.
tensile strength (ultimate). That stress which causes breaking in ten sion.
thermostatic trap. A non return trap usin g a thermostatic expanRion and
cOlltmction principl e 118 its actuating medium. See also nonretUTn
trap, trap.
titrate (v.). A chemical process used in analyzing feed water.
titration point. That point at which a solution changes r-olor when a n
indicating chemicl\1 .is introduced drop by drop.
total stress. The total resistance of a material to an external force on itH
eu ti 1'(' Cl'OSB-Aectional area in 11 plane perpendicular to the direction of
the fo rce. See also stress.
trap. A device designed to remove condensate from steam automatically,
with negligible lOBS of at.eam. See alao nonreturn trap, return trap,
thermostatic trap.
try cock. One of three valves mounted on a boiler or water colum n within
t ho visible rango of the gage glass and used to check the water level.
tube. Sec boiler tube.
tube cap. An elliptical or circular handholc plat,e used opposite the cnd of
1\ water tube in a hendor of a watert\lbe boi ler. Used for inspection,
cleaning, or tube removal.
tube rattler. A vibrating tool designed to b paa~ed thr011gh fire tubes 10
crack seal" 1 0(l~(; from the tube as a result of the vibration.
tube sheet. A flat head of a boiler or that part of a boiler drum into which
boiler tubes nrc rolled.
tube turbine. A rotating tool used with water or compressed air prcssure,
designed to he passed th rough water tubes to remove scale.
tube vibrator. See tube rattler.
unit stress. A valve expressed in pounds per square inch anci found by
dividing he total stross or force by the cross-secti.onal aroa stressed.
Set) also stress, total stress.
upset (v.), To enlarge or increase the cross-sectional area of auy part of a
metal hy forging It bl~ck to a shorter length.
valve. See check valve, gate valve, globe valve, safety valve.
washout plug. An inspection, sight,l1.nd cleanout opening, r,ircular, t hreaded
and fitted 'with a threaded pipe plug, !lond not to he used for any pipe
connection.
water column. A vertical, hollo\'I" chamber located b tween a boiler and
the gage glass fo r the purpose of steadying the water level in the glass
through the reservoir capacity of th column. Also, the cohlll1n IYUt)'
APPENDIX 1 317
eliminate the obstruction of small-diameter gage-glass connections by
serving as a sediment chamber.
water leg. That space wbich is full of boiler water between two parallel
plates. It usually forms ouo or more sides of internally fired furnaces.
water tube. A boiler tube through which the fluid under pressure flows.
The products of combustion su rround the tube.
watertube boiler. A boiler in which t he water or other fluirl flows through
the tubes and the produ cts of combustion surround the tubes.
waterwall. A row of water tubes lining a fuma.ce or combustion chamber,
exposed to the radian t hen,t of t he fire. Used to protect refractory
a nd t,o in crease capacity of t he boiler.
weld (v.). To join together two edges or surfaces of metal by the appli-
cation of hellt. See also forge-weld, fusio1l,.. weld.
wire drawing. A cuttinll; of su rfaces caused by the abrasive action of high
velocity flow under restri cted outlet.
yield point. The point at whi{lh a metal, under a mounting tensile load,
exceeds its clasl,ic limit. At the yield point the metal hecomes per-
manently deformed and will not return to its original shape or position
upon cessation of the load.
APPENDIX 2
MATERIALS
Manufacture of Steel.-The first step in the product ion of steel ;s to
extra.ct iron from the ore. This is accomplished in t.he blast furna.ce. T he
blast furnace is a vertical-tubular steel chamber hned with refractory. Tho
furnace may be 5 to 25 ft. diameter and up to 100 ft. high.
It is charged from the top with iron ore, flux, and coke. The usual flux
is some form of hmestollc.
When the" charge" is fired up, the coke burns at extremely rugh tempera-
tures-up to 3bOO°F. The iron is melted out of tbe .lre and flows to the
bottom of the furnace. Tbe flux combines with most of tbe impurities in
the molten iron and likewise flows in liquid form to the furnace bottom.
However, because the flux-slag mixture has a lower specific grll.vity than the
molten iron. it floats 011 the surface of the pool. The molten iron is tapped
off at the bottom, most of the slag content of the furnace being thus
eliminated.
The molten iron flows into molds wbere it solidifies into "pigs." Pig
iron contains a rugh percentage of carbon which causes low ductility. Con-
sequently, further refinemcnt is m: 'essnry before the physical and chemical
propertics of pig iron arc satisfactory for its use in boiler construction.
There are several methods of reducing the cn.rbou con lent of pig iron to
convert it into st e1. .
Th blast furttace (Fig. 225) is a vertical-tubular furnace lined with
refractory. An escape port is located at the top fo r discharge of gas. This
converter, or furnace, is charged with molten pig iron. and air is blown
through from the bottom. Thi oxygen in the air combines with the carbon,
sulphu r, silicon, and manganese by combustion. This process is continued
un til the greater part of these elements has burned out. The CQrrect pro-
portion of desired constituents of tho steel is then attained by careful adding
to meet chemical-content specifications.
Another process of steel manllfacture is the open-hearth method (Fig.
226). The chetuical properties of steel ml~de by tIllS process are more o.C(\U-
rately proportioned. Open-heo.rth steel is required for steam-boiler parts
under pressure. Briefly, the open hearth is a bowl-shaped container which
holds the molten pig iron. A mixture of gas and Ilir burning at high tempera-
ture is blown onto its surfaoe continuously until the carbon and other
impurities have burned out. Then the desired clements are added in correc~
proportion and amount. The advantages of the open-hearth method ar...
that less metal is lost, thero is less oxidation due to surface combustiol' and
.. IIOmewhat more accurate control of chemics,l properties is possible.
318
APPENDIX 2 319
The A.S.M.E. Powor Boiler Code requirom ents for chelllieal properties
of boiler plat e up to 4 in. thick are 8.8 follows:
FlO. 227.- Tensile testing machine. (CourtIUlY. Tiniu8 Olsen T.8tino Machin.
Co.)
Flo. 228.-Tensilo i,esting machine. (CourtUIl. Tilliu8 Olsl'1t T tsl ino MaciJin.
Co.)
Flo. :l30.-Porlfible Brinull teB ing machine. (Courtll8l1. Louis C. E1.loen Co.)
on the specimen during the test. The iutemal resistance of the material
to tension is balanced nccurately on a weigh h am hy whieh tbe readings
are obtained.
As the tension of the specimen is increased to an illeJement beyond the
elastic limi t, tho yield point is reached. The yield point is sbown by the
dropping of the weigh beam, indicating that the specimen has Mtretehed
suddenly with little or no load increa e, and it is out of proportion to its pre-
vious stress-strain relationship. The yielrl point sbould b at least one-half
the tensile strength for open-hearth hoiler-plnte steel of either flange or
firebox quality having a T.S. of 55,000 to 65,000 lb. per sq. in. A lower
yield point indicates weakness due to too great ductility.
The load is then increased un til the specimen fractures. The reading
shown on the weigh beam at that time is the ultimate tensile strength of
the material.
324 BOILER OPERA7'OR'S GUIDE
The unit tensile strength is the ultimate tenaile strength divided by the
original cross-seotional area.
Sufficient ductility is ensured by meeting Code specificationa for elonga-
tion. The percentage elongation is then com puted after fitting the two
pieces of the specimen together and measuring the distance between the
punch marks .
. The Code requires that open-hearth flange steel shall have an elongation
in all 8-in. test specimen of at loast 1,500,OOO/ T.S. per cent. Open-hearth
FlU. 232.
The weight of the weld metal hUH eonsidNflhJf' hearing on its other physi-
cal properties, and therefore the A.S.M.K Code limits the minimum specific
gravity to 7.80. The tcusilp strength of a weld must be at least equal to
the minimnm tensile strenp;th of t.be parent metal.
Equally important as the Jabomtory tests lire several checks which can
(asily be made in the field . First is the bend test of a welded sp('cimen.
Figure 232 shows a specimen being subjected to a b nd test in a vise. Prep-
aration of the specimen for this test requires that the full thickness of
the plate shall be used. A minimum width of 1 % in. is required; but if the
available force is not sufficient to bend a specimen of this width, the Code
allows it to be cut into strips, each strip being the full thickness of the plate
and each meeting the requirements of the test for the 1>1l-in. piece.
The inner and outer surfaces of the specimen a re then machined smooth
so that the reinforcement of the weld is machined off flush with the plate
and the corners are rounded off slightly. A light line is scribed along each
boundary of the weld on the surface opposite that which is to be bent back-
ward. The distance is carefully measur d before bending. The specimen
is then slowly bent until failure occurs. The Code considers the weld to be
lufficiently ductile if tbe fibers on the outside of the weld elongate lit lel).81
326 BOILER OPERATOR'S GUIDE
30 per cent before failure.. The pcrcentage elongation is calculated from the
difference between the original distance between scribe lines and the distance
at, which failure occurred.
The nick-break test is often used to determine the quality of a specimen
of a welded joint. The weld is nicked on the surface along its axis, and the
specimen is supported horizonttllJy !Ii each end. A sudden sharp blow is
applied downwa.rd outo the weld so as to bren.k it through. The s\lffacc of
the fracture should then be oxaminod carefull y . Thorough pen etra tion is of
prime importance. SIa.g inclusion should not be noticcable. Ga.s pocket.
should not exceed six pcr square inch, and n()nc of thesc sh ould exeeed
X o in.
Defects and Tolerances.- On e of the most importa nt I1ctlll.1 defects is
a lamination in the plate. This iH the result of It slag aocumlll n.t,ion th at.
~ Single sheOir
(01)
Boiler plafe -----
Angle Irons" ,
Boiler brace
Double sheC!r
(b) 8rcrce p/n .-
Arrows show a/recf/on oFforce (Oouble shet:¥r)'
c~using or fencl/ng to cause shear
FIo. 233.-(a) Single shoar; (b) FlO. 234.
douhl e . hoar.
escaped the refining prot1esses. When slag ia in the hot Bteel heing roll ed
in to Ii plate, it may not cow' to a Hurface so as to b e readily visiblc. In
such cases, it may be olongllted into a slag stratum Of lamination within the
plate during the rolLing process. Oncll au intern al lumination exists, it is
very difficult to detect it by practical tests unless a particular location is
suspccted.
Fortunately, improvements in refining methods have increllsed the effi-
ciency of slag removal, and plates having serious 1(1,111 inations are becoming
more uncommon. Repairs of a laminat.cd plate al' discussed in Chap. VIII.
Another defect of a much more appa rent nature is the result of a surface
InJury. Far too often, careless handling or transportation results in a gouge
or scar across the surface of a plate. The result of such a n injury is to set
up a stress concentration at that point when tho plate is in a boiler under
prell8Ure. A prolonged stress concentration may result in fatigue, cracking,
and failure. Plates that show a physical injury of more than a very minor
nature should be rejected unless the section injured is to be cut out during
fabrication.
APPENDIX 2 327
It sometimes happens that an error in the rolling mill results in a plate
being rolled too thin. A thickness of 0.010 in. below specifications ill the
tolp,rance allowed by the A.S.M.E. Code.
I
Minimum
Crushing or
tell~ilc
compressive
strength,
strengt h, lb. per
lb. per
sq. in.
sq. ill.
240 /
/
1/ /
/ /
V
ifl 55 V
~(leL
,,0~y rI~
-- - ...J- - -- - V
I! _...,V
1/ I /_
,./
/ I
I
L
V ../ 0
2 4 6 8 10 12 14
Cubic em., St"nolorci Soap Solution, ApproximOlte
Ounces Sod", Ash (N"'2C03 )pe~ 1,000 Gal.WOIter
1<'1 0. 235.-('urvos for dotermining hardness nnd weight of sodl\ ash o·cqu ired to
soHeu the water.
c
iJ '@;=u
Section through 4; kB-A'
FIo. 238.-Diamond-shaped patoh at center of sheet (insi de).
Likewise, to avoid the necessity of calking in sharp corners, a patoh may
he shortened in width to the extent that no more than four rivets will be in
a longitudinal line, as shown in "Fig. 237,
332 BOILER OPERATOR'S GUIDE
FIo. 239.- TrifmgulnJ' patch at hend of .eam and hlowotr on bottom of boiler
(outside) .
(lonstant is the figure hy which the Icnp;th shou ld be multiplied 1,0 deterl1lin~
the width.
The first thing that should be taken into consideration in proceeding with
the design of a patch ill whether all of the end stress is to be carried by the
patch or not; in other words, whether the heads are supported or unsup-
ported. In dnlms of watertube boilers, the full endwise stress has to blJ
carried by the shell plates and the patch seams wher liS in shells of H.l'l.T.
boilers some of the endwise stress is carried by the through-rods, tubes, or
flues and consequently there is less stross on the shell lind patch SCllms.
It is evident, then, that a patch in the oue case need not have the same v.';dth
for II giv n length as in th other casco In other words. different const.antl!
APPENDIX 4 333
may be used in determining the width. The two tables, F-J and F-2, that
have been prepared take in to account these two di fferen t conditions.
As the angle of a patch as laid out when fiat does not change when formed
to the curvature of the boiler, the diameter of the boiler docs not have to b"
taken into consideration in the design.
Rules for Riveted Patches.- In laying out new patches over 24 in . long,
it is recommended that they be triangular or diamond in shape, as may h~
required for the particular job, with definite straight line sides, but with the
%2 % 1 % 60 .0
~6 % 1 % 60 .0
1% 2 % 2 71 6 57 .5
7i's 191 6 2 X 56 .0
1% 2 1 7) 6 2 3-8 55 . 5
~ 1 2 ~ 52 .5
% 1 716 2X 50 .5
278 2 1 78 2 91 6 51.4
1716 1 }i 2 ~6 51.4
-
E 0.60 0.51 0.52 0 .53 0.54.
"·"1"·,,1"" "·..~t,·~ 0 . 02 0 . 63 O. 64 0 .65
0.90 .... 2 . 07 2 . 89 2 80 2.71 2 .65 2 .57 2 . 50 2A2 2.34 2 .27 2 . 21 2.14 2.08 2 . 0 1 1. 95
0.91 .... .... 2 . 94 2.86 2 . 77 2 . 69 2 . 62 2 . 54 '. 47 2 . 39 2 . 32 2.25 2 . 10 2 . 12 2 . 062 . 00
0.92 .... ... . 2.99 2 . 90 2 . 82 2 . 74 2.66 2 . 59 2 . 51 2 . 44 2 . 30 2 . 30 2.23 2.17 2 . 102 . 04
0.93 .. .. .... .... 2 . 95 2 . 87 2 . 78 2 . 70 2 . 63 2 . 56 2 . 48 2.42 2 . 34. 2 . 28 2.21 2.1 52. 08
0.94 .... .... .. .. .... 2 . 91 2 . 83 2 . 75 2 . 67 2 . 60 2 .53 2 .46 2 . 30 2 . 32 2.25 2 . 192 . 13
0 . 95 ... . .. .. .. .. .... .... 2 . 87 2 . 79 2 . 72 2 . 64 2 . 57 2 . 50 2 . ' 3 2.36 2 . 29 2 . 2 ~2 . 1'i
I I
336 BOILER OPERATOR'S GUIDE
L will give the constant C. Table I will give~. Then under Il in Table F-l
or F-2, depending upon the type of boiler to be repaired, find the consta.nt
C. Then wha.tever E is found at the left is the longitudinal or allowed effi-
ciency of the patch scsm (see Prob. 2).
Material.-Patch material shall be of firebox or flange steel depending
upon the plate it replaces. Tank steel must not be u~ed .
1"-2.-CoNSTANT C
TAllLE
Heads unsupported
Triangle or crescent shape pa.tches : C = W + L; W - C X Lj
L - W + C.
Diamond or oval: C = 2W + L; W ... C X L -;. 2; L - 21V -;. C.
0.66 2 . 20 2.061.931.801.091.501.451.351.241.14
0 . 662.302.162 . 03 l.90 1. 78 1.66 1.55 1 A5 1.34 l. 22 1.12
0 . 672.402 . 262 . 132 . 001.881. 751.641.521.431.321.21
0 . 682.502 . 362 . 232 . 101.98 1. 861.731.631.521.421.311.10
0 . 602.622 .462 .33 2.202 . 071. 95 1.84 1.711. 61 1.50 1.4() 1 . 30 1.17
; 0 . 80 ............ 3 . 463 .283 . 102 . 922 . 762.01 ~ . 482 . 302.242 . 14 2 . 031 . 921 . 83
" 0 . 81 .. .............. 3.4.03 . 203 . 032 .872 . 71 2 . 57 2 . 45 2 . 332 . 21 2 . lJ 2 . 001. 90
:g 0 . 82 . ... . ..... . .... ... .. 3 . 343 . 102 . 972.822.672 . 53 2 . 422 . 302.192.09 1. 98
'g, 0 . 83 ............ . . . ..... 3 . 46 3 . 293 . 102.932 . 782 . 632 . 50 2 . 39 2 . 27 2 . '17 2 . 00
] 0 . 84 .......... . ............. 3 . 393 . 22 S . 052. 872 . 7 52.592 . 472 . 372 . 252 . 15
280
260
/
v ./
~ L---::::
240
5
q h /
220
200 / 4 ~~
B~f-'
V
./"" ~ ~ 5 /I ...,...,... V
-+'
LI..
18"
.S
OJ
u
ti-IBO
Vl
.S 160
u
.f 140
Q)
r--- -- --
~ ~ 0 ~ -7.
./'" :::::--: ~ /- / ~ ~~V .---
~ 6"sh e
/IV V
-
----
~...
::>
J; 120 ~ ~V
L
c::-
~ ~ V -~f-' ~
-- --
v ~.'sltell -
-
en
OJ
C Ol
~ ~ v
:::::- :...-- v- ~v-
v-v
-----
;;: .!: 100
-J6"
:1:.20:!J:! 80 ~
a I-""
Q) a
4-
:::::= k--'" f-- sheUl-,:-;;
4"ft/be.,.... -:::-:-
~ 15 'ii 60 ~ ~
II) •
r:::.- ~ t:- ~
::>
.....
..c
10
III
40 ~ I=--
~~
I--- ~ ::::.. r-
e3 .,."
One 2~"ftlbe
ne z".,."be
-
t-
5 2. 0
i
10 1113 1214 15 1& 17 18 19 20 21
Length in Feet Shell or Tubes
FIG. 242.-Chart.s for finding heating surface ot boilers of n.R.T. type.
The longitudinnl senm is of the double-riveted butt-strap typo, having all
efficiency of 82 per ceut. The Safety valve is set for 1251h. pressure. What
l'1aximum pressure should he allowed on the boiler?
Referring to Table I, it shows that the norm l4l efficieucy of the patcb
seam is 57 per ceu t.
If th efficiency is not found in the table, refer to any other available table,
or determine it in the custom8ry manner, described in Pars. A-l and 2 of
the Appendix of the Texas Boiter Constnlction Code.
Divide the width of the patch W = 4 in. by the length L = 30 in . to
.find the constant C - 4 ~O - 1.60
APPENDIX 4 339
Follow down column 0.57 of Table F-l until 1.60 is found . It will be
noted that this is somewhere between 1.56 and 1.62 representmg E some-
where between 0.72 and 0.73. Ail the difference between 1.56 and 1.62 is
6 and the difference between 1.56 and 1.60 is 4, E will be 0.72 plus % of 0.001
which is 0.7266.
The pressure app roved varies directly as the seam efficiency. Accord-
ingly, P = 0.7266/ 0.82 X 125 - 110 lb.
If this allowance interferes with the operation of t he plant, the patch will
have to be replaced by a new one with proper dimensions giving a diagonal
cffi ieney of 82 per cent.
Problem S : Design of a Patch for a Watertube Boilet.- Sections of the
plate having a total length of 36 in. (measured at the pitch line) are to be
removed on each side of a. girth scam. The patch is to be diaffi()nd or oval
shape. The shell pla,te is :J'16 in. thick, and the longitudinal seam is double-
riveted butt-strap constnlCtion, having an efficicn(,y of 82 per cent. Wh at
should be the widtb of the patch for maintaining the same pressure allowance?
Referring to Table I, it shows that a single-riveted lap seam wiih :J'1s-in .
plate, l~ 6-in.-diameter rivet holc~, 2~-in. pitch, has a normal efficiency
of 56 per cent.
Referring to Table F-2, we find for E 0.82 and e 0.56 that the constant
C is 3.16.
The width W - C X L + 2
W ~ 3.16 X 36 + 2 - 56.88, say 57 in .
APPENDIX 5
BOILER SAFETY RULES*
Never Always
Never light a burner without a torch. AlwaY8 assume delayed ignition
You can't dodge a furnace blast. is going to cause a furnace
explosion. Use propElr ignition
methods.
Never attempt to light a burner with- AlwaYB allow draft to cl~ar furnace
out venting the furnaoe until clear. of gas and dust for several min-
Bu rns arc painful. u tea. Change draft conditionR
slowly.
Never fail to report unusual behavior Always consult someone in author-
of a boiler or other equipment. It ity. Two heads are better than
may be a warning of danger. one.
INDEX
A Backing sleeve, 280
Badonhalls(;n hoilor, 123
Abrasion (see Erosion ) Baffling, 92-93, 270
Absolute pressure, 1 step, 124, 127
(See also Pressure) Bailey feed-water regulater, 177- 179
Adamson ring, 39-40 (See also F eed-water regu lators)
Air-cushion ch amber, 267 Bailey stud tubcs, 126, 211, 212
Air t rapped in boi l 'r, 116 Ball-float trap, 199
A.S.M.E. st amp , 4U (See also Traps)
Angularity of stays, 30 Barrel pins, 20
Apexior, 246 Beading of tubes, 44, 116
Arch bar, 57 Benson boiler, 157-159
Area to be stayed, 29-30 cap acities of, 159
Atomization of fuel oi l, 203 flow diagram for, 157
Automatic shutoIT for gagp-glflss Hent-tuhe boi l(Jf8, 11 4-138
connection, 167- 168 (See also hoilers classifj(\d by
Automatic stoker, 21 6-217 mako, as Riley, Murray,
Taylor, 216-217 etc.)
13 Beslor I oiler, 141- 142
Bessolller converter, 318
Habcock and Wilcox \\' llLCl'tui.Je Black-liquor boiler, 142-144
boiler, 91, 94--95, 105-10G, Blast furnace, 318
142-144 Bleeder feed-water heater, 186
black -liquor Tomlinson, 142-144 (See also Feod-water heaters)
blowdoWll connection, 95 Blister, 281
circulatioll, 94 Blowback of safety valve, 162
cross-drum type, 105-107 Blowback ring, 162
equalization of water I vel in, 95 Blowdown, 169-171
feed-water connec:tioJl, 94 continuous, 254-255
fusible plug, 94 fittings, 170
gas flow, 92-93 pad, 60
gM passages, 106 pipe, 60
integral-furnace type, 125-126 expansion of, 61
circulation, 126 purpose of, 169
gas flow, 126 valves, 169-171
method of support, 126 Blowing down a boiler, 259
longitudinal-drum type, 94--95 Boiler bushing, 63
lowest safe water level, 94 Boiler compounds, 260, 26:&
piping connections. 91; Boiler tubes (see Tublls)
suspension of, 93-94- Bonus, 224-225
two-stage furnace type, 108 Bourdon tune, 175-177
343
344 BOlLER OPERATOR'S GUIDE
Feed wa.ter, hardness of, 183, 328- Foster Wheeler boilers, 129, 131-
329 133, 144-146
impurities in, 240-241 capacity, J33
inlet, 63 starting up, 133
oil in, 204-205, 243 twin-furnace, 129, 131-133
organic matter in, 253 waste-heat boiler, 144-146
oxygen in, 184 Foster Wbeeler economizer, 187-]88
temperature of, 182-J8H (See also Economizers)
testing of, 328- 329 Front arcb, 61
treatment of, 259-261 }uel-oil hoaters, 203-204
Feed-water heaters, 180-186 Furnace xplosioDs, 26
bleeder, 186 J<urnace mouth, 69
closed, 184-] 86 Fur!l!lce volum e, J06-107, 269-271
deaerating, 184-186 Furnaces, 38-43
extraction, 186 internal, 66, 75, 78-80, 82-83
open, ] 81-183 multiple, 80
protection of, 292-293 Fusible plug~, 58, 63, 71, 73, 77, 82,
testing of, 293 94
Feed-water pumps, 192- 19~ in Babcock and Wilcox boilers. 94
centrifugal, J93-19-1 clearancn for, 58
duplex, 193 design of, 173-J74
Feed-water J'l"gulators, J 7ti--180 in Economic boiler, 73
Bailey, 177- 171:1 in ll. R.T . hoilers, 63
Copes, 177- 178 in locomotive boilers, 71
Morehead,179-180 in Scotch boilers, 82
Steta, 178-179 in vertical tubular boilers. 77
Ferrules, 279 Pusion welding, 20-23
Fin tubes, 144-146
Fire clay, 58 G
Firebox, 66-6 Gage cocks, 168
boilers, 73 Gage glass, 16G--167
Fire-tube hoilers (sce under classi- rephtcement of, 298
fication as to type, as R .R.T., testing of, 297- 298
Scotch marine, (~tc. ) Gage prossure, 1
li'ire tubes, 90 Galvanic action, 247
Fires in breeching, 26 Gamma ray, 2J
Flame impingement, 26]- 264, 270 Gas flow, 92-93
Flanging of heads, 33-36 Gate valves, 171- 172
(See also Valves)
Flaring of tubes, 44, 116
Girth seam, 3, 8-9
Floor space, 73
Globe valve, 171
Flu gas analysis, 264-265 (See also Valves)
turbine, 156 Grcen economizer, 188-189
Flush-front setting, 61 (i:>ee also Economizers)
Foaming, 252-25 Grommet, 30
Foroed circulation, 81 Grooving, 245-:&46
Forcing v rtieal tubular boilers, 73 of furnace sbeets, 285-286
Forge welding, 44 Grouting, 59
INDEX 347
H Hydrometer, 254
Hydrostatic test, 22, 298-299
Hammer test, 22
Handhol es, 62, 70
repairs at, 282 Ignition of burners, 267
Hangers, 36-38 Impeller, 193
Hardness of steel, 324-:J25 Injector, 193-195
Hartford Loop, 290 Inspirator, 193-195
Header, 95-96, 104-105, 109 Insurance, 230-231
box header, 95-96, 109 Integral economizer, 190
sectional header, 91, 95, lU4 - 105, (See al80 Economizers)
107 Int<,gral-furnace boiler (Babcock and
sinuous header, 91, 95, 104-10;" Wilcox ), 125-126
107 Interdeck nipple, 106
Headroom, 75 Internal furnace, 66, 75, 78-80, 82- ·
H eads, 2 83
dished,2 (See also Furnaces)
semielliptical, 2 Internal mud drum, P8, 102
spherical, 2
Heat exchanger, 254 K
Heat-recovery boiler, 145 Keeler watertube boilers, 102, 13,~-
Heat release, permissible in furn aces, 137
270 box header, J02
Heaters, fuel-oil, 203- 204 method of support, 102
Heating surface, chart for deter- CP boiler, J35-137
mining, 338 capaci ties, J37
Heine boiler, 97- 98 circulation, 13G-J 37
baffling of, 97 Korosene, use of, in boilers, 241- 243
hollow staybolts, purpose of, 97
L
blowdown cOOllections, 98
feed-water diseharge, 97- 98 Lamination, 281, 326
internal mud drum, 97- 98 La Mont boiler, 154, 156
method of support, 98 Lap craok, 9, 275, 276
Holly Loop, 289-290 Lap-riveted seam, 26
H.R.T. boiler, 29-30, 37, 55-64 Largest boiler in world, 129
Mvantages of, 56 Leffel Scotch boiler, 80
Lifting lever for safety valve, 162
capacity, 55
Ligaments, 23-26
oirculation in, 62
Lime, usc of, in boilers, 246
olearan ce in, 57 Liquivator, Morehead, 197- 198
disadvantages of, 56 Load curves, 224
gas flow, 56 Locomotive boilers, 43-44, 64-70
rating of, 63 advantages of, 66
setting, 56-60 ditJadvantages of, 66
Hot-sbort, 320 gas flow in, 66
Huddling cbamber, 162 general details of, 66-68
Huston stay, Z7 rating of, 71
Hydraulio riveting, 19-20 water l('vel in, 70
348 bOILER OPERATOR'S GUIDE'
MacGregor stay, 27 o
Magnesium (Mg), 240
Maintenance programs, 2a4--235 Obsolescence, 229--230
Malleable iron, physicA.l pJ'Orerti('~ Ogee flange, 68, 76
of,327 cracks, 274
Mandrel,45 Oil burners, 203
Manganese (Mn ) in st.eel, 320 Oilbilt hoilN, 2-83
Manhole, 30-31, 32, 34, 62, 70 Open feed-water heo.ter, 181- l83
frame, 31- 32, 34 (See also Feed-water heate r~)
reinforcement, 31-32, 34 Open-hearth furnace , 320
Manhole riveting, 32-34 Organic mo.tter in boiler water, 253
Manning boiler, 73- 74 Orsat apparatus, 265
Massachusetts D epartment of I'llb- Overheating, 62, 73, 75-76, 261-
lie Safety lowest factor. of 264, 270-272
safety, 7 by accumulations of solias, 255
Morehead fced-wo.ter regulator, 171l- by flame impingement, 261 - 264,
180 270
(See also Feed-water regulators) of furnace in vertical tubular
Mud drum, 94, 97- 98, 102, 104, 106 boilers, 75-76
for Babcock and Wilcox watertube due to low water, 271- 272
boilors, 94, 106 by Bcale, 240-241
for Heine watertube boilers, 97- 98 of tubes in vertical tubular boilers,
for Keeler watertube boilers, 102 78, 280
for Springfield watertube boilers, of waterwall tubes, 2tO
104 Oxidation (lee Corrosion)
INDEX 349
Oxygen, 183-184, 264-267 Pressure, safe working, 6--8
for combustion, 264-267 total, I, 37
removal, 183- 184 unit, 1
Pressure gage, 175---177
P Pressure-reducing value, 199-202
Pressure regulators (see Pressure-
Palm of stay, 27 reducing valves)
Patching, 281, 285-286,330-339 Priming, 252-253
riveted, design of, 330-339 p~'otective coatings, 246--247
welded, 285-286 Apexior, 246
Personnel, 225---226 lime, 246
pH of water, 244--245 Portland cement, 247
Phosphorus in steel (P ), 320 silicate of soda, 246
Physical properties of steel, 321- Pulverizers, coal, 212-217
325,327 Foster Wheeler Tricone type, 215,
Pipe joint, for Loeffler boilel', lS3- 217
154 Riley Atrita, 216--217
Piping, 60, 250, 288-289, 291 unit type, 214--216
capacity, 288 Whiting table-roller type, 214--215
connections to boilers 50, 70, 81, Purchasing, 231, 234
90, 94, 95, 98, 119, 134
drainage of, 291 R
expansion in, 289
maintenance of, 250 Radiant heat, 56
size of, 288 Radiograph (see X ray)
support for, 288 Roar arch, 57
sweating of, cold, 291 Reinforcing strap, 25
Pitch, of boiler, 58 Relief valves, 189, 204
how to determine, 59 for economizers, 189
of stay bolts, 42-43 for fuel-oil heater, 204
of tubes, 24 Replacement of equipmont, 229-230
Plate, 5---7, 10-20, 25 Return traps, 195-198
plate mill, 15---17 Riley steam-generator boilers, 114,
preparing shell plate for rivetinl1:, 123, 124
15---20 Riley watcrtu be boiler, 114, 123-
punching of, 16-17 125, 133-135
rolling of, 15---17 RO boiler, 133-135
thickness of, 5---7, 10-15, 25 capacities, 134
Plate drill, 16--18 gas flow and baffling, 134
Plate planer, 15---16, 18 piping connections, 134
Pneumatic riveting, 20 RP boiler, 124--125
PoroQity, 22 (See also Riley steam-generator
Portland cement, use of, 247 boilers)
Pressure, I, 4-8, 37, 91 Ring oirculation , 123
absolute, 1 Rivet holcs, 19
bUl'!Jting, 4-5 Riveted seams, 8-15, 19
critical, 91 double lap, 9, 11
gage, 1 douhle-riveted b'Jtt, 12-13
350 BOILER OPERATOR'S GUIDE
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II 1887
CENTRAL INITITUT. J'867
OF FIIHfRIEI EDUCATION, BOMIAY.
Llkal1.
Form No. 3
Author Sr~, -na IWlJ'?J'If tn
Title B~\kb' ofelrofolJb a-t.t.th ,
AOCD. No. 18' rt