James Tayler Milton and Joseph Gregory Horner

“ Much of the corrosion which occasionally occurs has been traced to the action of the oxygen of the air which enters the boiler in solution in the feed-water, and the best practice now provides for the delivery of the feed into the boiler at such positions that the air evolved from it as it becomes heated passes direct to the steam space without having an opportunity of becoming disengaged upon the under-water surfaces of the boiler. ”

“ Welding fills a large place in boiler work, but it is that of the edges of plates chiefly, predominating over that of the bars and rods of the smithy. The edges to be united are thin and long, so that short lengths have to be done in succession at successive “heats.” Much of this is hand work, and “gluts” or insertion pieces are generally preferred to overlapping joints. But in large shops, steam-driven power hammers are used for closing the welds. Parts that are commonly welded are the furnace flues, the conical cross-tubes and angle rings. ”

“ As all the excess air has to be raised to the same temperature as that of the really burnt gases, it follows that an excess of air passing through the fire lowers the temperature in the fire and flues, and therefore lessens the heat transmission; and as it leaves the boiler at a high temperature it carries off some of the heat produced. ”

“ Desirable qualities are that the arrangements of the furnaces should be such that a reasonably perfect combustion of the fuel should be possible, and that the heating surfaces should be capable of transmitting a large proportion of the heat produced to the water so as to obtain a high evaporative efficiency. Further, the design generally should be compact, not too heavy or costly, and such that the cleaning necessary to maintain the evaporative efficiency can be easily effected. ”

“ But in modern boiler shops little hand work is ever done; instead, plates 4 ft., 6 ft., or 8 ft. in diameter, and fire-box plates for locomotive boilers, have their entire flanges bent at a single squeeze between massive dies in a hydraulic press. In the case of the ends of marine boilers which are too large for such treatment, a special form of press bends the edges over in successive heats. The flanges of Adamson seams are rolled over in a special machine. A length of flue is rotated on a table, while the flange is turned over within a minute between revolving rollers. ”

“ Three furnaces are the most usual practice. Each furnace generally has its own separate combustion chamber. In four furnace boilers, however, one chamber is sometimes made common to the two middle furnaces, and sometimes one chamber is fitted to each pair of side furnaces. In double-ended boilers furnaces are fitted at each end. In some cases each furnace has a separate combustion chamber, but more usually one chamber is made to serve for two furnaces, one at each end of the boiler. ”

“ The lower front box of each element of the boiler proper is connected to a horizontal cross-tube of square section, called a “feed-collector,” which extends the whole width of the boiler. When the boiler is not in use, any element can be readily disconnected and a spare one inserted. The lower part of the steam-chest is connected to the feed-collector by vertical pipes at each end of the boiler, and prolongations of these pipes below the level of the feed-collector form closed pockets for the collection of sediment. The tubes are made of seamless steel. ”

“ Another chamber is formed between the first and second sets of tubes. The feed-water enters the back upper drum, and must pass down the third set of tubes into the lower drum before it reaches the other parts of the boiler. Thus the coldest water is always where the temperature of the furnace gases is lowest; and as the current through the lower drum is slight, the solid matters separated from the feed-water while its temperature is being raised have an opportunity of settling to the bottom of this drum, where the heating is not great and where therefore their presence will not be injurious. ”

“ Flanging occupies a large place in boilermaking, for end-plates, tube-plates, furnace flues, &c., but is scarcely represented in bridge and girder work. Plates are bent to cylindrical shapes in boilermaking, for shells and furnaces, but not in girder work. Welding is much more common in the first than in the second, furnace flues being always welded and stand pipes frequently. In boiler work holes are generally drilled through the seams of adjacent plates. ”

“ Amongst the essentials are a receptacle capable of containing the water and the steam produced by its evaporation, and strong enough continuously to withstand with safety the highest pressure of steam for which the boiler is intended. Another essential is a furnace for burning the fuel, and a further one is the provision of a sufficiency of heating surface for the transmission of the heat produced by the combustion of the fuel to the water which is required to be evaporated. ”

“ At times when less than the normal supply of steam is required for the engine more than the average quantity of feed-water is pumped into the chamber, and the excess accumulates with its temperature raised to the evaporation point. When an extra supply of steam is required, the feed-pump is stopped and the boiler is fed with the hot water stored in the chamber. ”

“ These last in stationary boilers usually consist of valves kept in their seats against the steam-pressure in the boiler by levers carrying weights, but in marine and locomotive boilers the valves are kept closed by means of steel springs. One at least of the safety-valves is fitted with easing gear by which it can be lifted at any time for blowing off the steam. Blow-out cocks are fitted for emptying the boiler.
Openings must always be made in boilers for access for cleaning and examination. When these are large enough to allow a man to enter the boiler they are termed man-holes. ”

“ Hand-riveting has mostly been displaced by hydraulic and pneumatic machines, with resulting great saving in cost, and the advantage of more trustworthy and uniform results. For boiler work, machines are mostly of fixed type; for bridge and girder work they are portable, being slung from chains and provided with pressure water or compressed air by systems of flexible pipes. ”

“ For a high efficiency, completeness of combustion of fuel must be combined with sufficient heating surface to absorb so much of the heat produced as will reduce the temperature of the funnel gases to nearly that of steam. ”

“ It is generally considered that the amount of excess air required is nearly equal to that theoretically necessary; experience, however, tends to show that much less than this is really required if proper means are provided for ensuring an early complete mixture of the gases. ”

“ Where water tubes are used they are made of seamless steel.
Boiler Accessories.—All boilers must be provided with certain mountings and accessories. The water-level in them must be kept above the highest part of the heating surfaces. In some land boilers, and in some of the water-tube boilers used on shipboard, the feeding is automatically regulated by mechanism actuated by a float, but in these cases means of regulating the feed-supply by hand are also provided. In most boilers hand regulation only is relied upon. ”

“ The boilers are generally internally fired, the furnace plates being surrounded with water and forming the most efficient portion of the heating surfaces. On leaving the furnace the products of combustion are led into a chamber and thence through flues or through numerous small tubes which serve to transmit some of the heat of combustion to the water contained in the boiler. ”

“ Where corrosion is feared it is usual to fit zinc slabs in the water spaces of the boiler. Experience shows that it is better to make them of rolled rather than of cast zinc, and to secure them on studs which can be kept bright, so as to ensure a direct metallic contact between the zinc and the boiler-plate. The function of the zinc is to set up galvanic action ”

“ The speed of travel is so regulated that by the time the remaining parts of the fuel reach the back end the combustion is nearly complete. It will be seen that the fire becomes thinner towards the back, and too much air is prevented from entering the thin portion by means of vanes actuated from the front of the boiler. ”

“ But actually so much is involved that subdivisions of tasks are numerous; the operations of templet-making, rolling, planing, punching and shearing, bending, welding and forging, flanging, drilling, riveting, caulking, and tubing require the labours of several groups of machine attendants, and of gangs of unskilled labourers or helpers. Some operations also have to be done at a red or white heat, others cold. To the first belong flanging and welding, to the latter generally all the other operations. Heating is necessary for the rolling of tubes of small diameter ”

“ For the shell plates and for long stays, a quality having a tensile strength ranging from 28 to 32 tons per sq. in. is usually employed, and for furnaces and flues, for plates which have to be flanged, and for short-screwed stays, a somewhat softer steel with a strength ranging from 26 to 30 tons per sq. in. is used. The tubes of ordinary land and marine boilers are usually made of lap-welded wrought iron. In water-tube boilers for naval purposes seamless steel tubes are invariably used. ”

“ In bridge work each plate or bar is usually drilled or punched apart from its fellows. Boilers, again, being subject to high temperatures and pressures, must be constructed with provisions to ensure some elasticity and freedom of movement under varying temperatures to prevent fractures or grooving, and must be made of materials that combine high ductility with strength when heated to furnace temperatures. Flanging of certain parts, judicious staying, limitation of the length of the tubes, the forms of which are inherently weak, provide for the first ”

“ When steam is being raised, the super heater is flooded with water, which is drained out through a blow-off pipe before communication is opened with the steam-pipe. In large boilers of this type, two steam-chests are placed side by side connected together by two cross steam pipes and by the mud drum. Each, however, has its own separate feed supply. The largest boiler made has two steam chests 41/2 ft. diameter by 251/2 ft. long a grate surface of 85 sq. ft., and a total heating surface of 6182 sq. ”

“ They are fed with sea-water, and means are provided for blowing out the brine produced in them when some of the water is evaporated. The heat required for the evaporation is obtained from live steam from the boilers, which is admitted into coils of copper pipe. ”

“ Brickwork baffles compel the furnace gases to take specified courses among the tubes It will be seen that the space between the boiler front and the tubes form a large combustion chamber into which all the furnace gases must pass before the enter the spaces between the tubes ”

“ To punch or drill holes singly is too slow a process in the best practice, and so machines are made for producing many holes simultaneously. Besides this, the different sections of boilers are drilled in machines of different types, some for shells, some for furnaces, some peculiar to the shells or furnaces of one type of boilers, others to those of another type only. ”

“ The upper and lower parts of the tubes between these fitting portions are then cut away, the side portions only being retained, and the end is termed a “lanterne.” A small water-circulating tube of thin sheet steel, fitted inside each generating tube, is open at the lower end, and at the other is secured to a smaller “lanterne,” which, however, only extends from the front of the header to the diaphragm. This smaller “lanterne” closes the front end of the generating tube. ”

“ Hundreds of bracing bars for bridges and girders will be cut off all alike, and drilled or punched from a templet bar, so that they are ready to take their place in bridge or girder without any adjustments or fitting. ”

“ This is the system almost universally adopted in war vessels, and it is used also in some fast passenger ships. The air pressure usually adopted in large vessels is that corresponding to a height of from 1 to 11/2 in. of water, whilst so much as 4 in. is sometimes used in torpedo-boats and similar craft. ”