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LONDON: iJublisfjcti bu tijc institution, 25, (JUKAT GEORGE STREET, WESTMINSTER, S.W. [Tklegkams, " LvsTiTUTioN-, LoxDON." Tki.ki-hone, " 3oai."j 1887. [7'Ae riijhi nf Publication and of Tramlalion is reserved.] ADVEETISEMENT. The Institution as a body is not responsible for the facts and opinions advanced in the following pages. tOKPON: PKIKTEP BY WM, CtOWES AND SONS, LIMITED, STAMFORD STREET AND CHAKING CB08B. THE INSTITUTION OF CIVIL ENGINEERS. Sect. II.— OTHER SELECTED PAPERS. )S8. (Paper No. 2444.) "Iron and Brass Foundries, Point St. Oharles Works, Grand Trunk Eailway of Canada." By Frederic Lumb Wankltn, Assoc. M. Inst. C.E. • (Abstract.) These foundries were specially designed to meet the requirements of two-thirds of the Company's entire system, and to supply cast- ings to all departments, and not solely to tno locomotive and wagon works. The annual capacity of the iron foundry is 3,000 tons of cast- ings, that of the brass foundry 200 tons. The main body of the foundry is cruciform, 200 feet from north to south, and 200 feet from east to west, with a span of 60 feet and height of 18 feet from the level of the floor to the top of the walls. The building is heated by steam pipes capable of maintaining a uniform temperature of 64^ in the coldest weather. The brass foundry occupies a space of 60 feet by 30 feet in the north end of the building. A line of rails of the standard gauge of 4 feet 8 J inches leads from the main line into the building. The cupola house is situated in the south-west angle of the main building. Its main dimensions are 31 feet 7^ inches by 20 feet by 20 feet high. There is a light iron stair at one corner for the use of the furnuce-men and a hoist for lifting up the charges of fuel and metal. The building is ventilated by annular ventilators passing through the roof round the cupola stacks, similar to those used round the funnels of steam-ships. There are two cupolas, made of boiler-plate, |- inch thick, 5 feet in diameter, in five parallel courses, 1 3 feet 9 inches high to the top of the fifth course ; the sixth course is conical, 3 feet 6 inches, con- tracting from 5 feet in diameter to 3 feet 3 inches at the base of the stack, which is also of boiler-plate, ^V ii^ch thick, built in thirteen parallel courses, 35 feet high, and 3 feet 3 inches in diameter. Each is fitted with a drop bottom. The lining is parallel from the sole-plate to the flare contracting into the stack, of double fire-brick. The course next to the shell, or 4 WANKLYN ON IRON AND BRASS FOUNDRIES. [Seloctwl outside lining, ia of plain firo-bricks, 9 inches by 4J inches by 2^ inches thick, placed on edge, tlie small ends down, and backed with about Jl inch of sand to keep tlieni oil" the rivet-heuds in the seams of the shell. The inner lininj^ consists of segmental iire- bricks of a superior quality, 9 inches by 4^ inches by 4^ inches thick, and moulded to a radius of 1 foot lOg inches, the diameter of the cupola inside the lining being 44 inches. The flare is lined with one course of specially moulded segmental fire-bricks, inches by 3^ inches by 2^ inches thick and 1 foot HJ inches radius, as is also the stack throughout its entire length with bricks 9 inches by 3i inches by 2h inches thick and of 1 foot 4 inches radius, the dia- meter of the stack inside the lining being 31 inches. The bricks arc set in thin fire-clay mortar, consisting of refractory sand and Jersey fire-clay; great care being taken to break the joints of the inner and outer linings, and to make them as thin as possible. A lining, such as the one just described, will last ten months, used daily, before any of the inner lining bricks require renewing. The first to burn out are those in the zone of fusion about 20 inches above the tuyeres. The repairs are carried out without disturbing the rest of the lining ; angle-iron rings riveted inside the shell support the lining at three points. The blast is delivered into an annular ■wind-chest 1 foot 8 inches by 9 inches. Sight-holes are provided in elbows fitted with covers glazed with thick glass and mica or talc, a ^-inch air space being left between the glass and mica, which is on the inside, preventing the glass from being cracked by heat. The tuyeres are five in number, circular, 5^ inches in diameter in one belt, 1 foot 5^ inches from the sole-})late to the centre of the tuyeres, and 3 feet apart. The charging hole is 2 feet 3 inches by 2 feet 8 inches, placed 10 feet 9 inches above the sole-plate. It is fitted with cast-iron doors, which are lined with fire-brick, and carried on a cast-iron frame bolted to the shell. The blast enters the wind-chest at two points directly opposite each other, placed between the tuyeres and not opposite to any one of them. The main blast-pipe leading from the cupola-house to the engine- room is 24 inches in diameter, made of galvanized iron No. 20 B. W. G. ; all seams and joints are riveted and soldered to ensure their being air-tight. This i)ii)e is provided with weighted valves opening outwards, which prevent the pressure in it exceeding 1 6 oz. per square inch. The blast is supplied by two No. 8 Sturtevant fans. The pressure -"-aries irom 8^ to 9 oz. The fans and other niacliinery are driven by an ordinary high-j)ressure engine ; the cylinder lias a bore of 12 iuclics and length of stroke of 30 inches, indicating ^ Papers.] WANKLYN ON IRON AND BRASS FOUNDRIES. ^^ 30 IIP. Tho steam for tho ongino and for heating purposes ih snppliotl hy two boilers of the locomotive type, 1 1 feet 7 inches in extreme lengtli, and 4 feet 2 inches in diameter. Tho dimen- sions of tho fire-boxes inside are 5 feet 4 inches by 6 feet 3 inches by 3 feet 9 inches. The main chimney is of Y',j-ii»ch plate 3 feet in diameter at the base, tapering to 2 feet 6 inches at tho top, and it is 02 feet high. There are two core ovens, ^vith flues loading into tho main boiler-house chimney. They are buil. of brick, air spaces being provided in the walls to prevent their cracking. The roofs are of iron plate, stiffened with old rails, and covered with a cement mixture of clay and asbestos fil>re about inches thick; this is found to keep the heat in well, and does not crack. Tho general core oven is 18 feet by 8 feet G inches by 8 feet high. The other core oven is 20 feet by 10 feet by 8 feet high. The entrance is 10 feet by 8 feet. The door is of iron plate, lifting upward between guides, and balanced. The space above the core ovens is used for storing iron patterns. There are four cranes in the building, one 8-ton and one 4-ton of 25 feet radius, and one 2-ton and (mo 1-ton of 20 feet radius. Very light hand-work is moulded on benches. The moulds are made in movable or " snap " flasks, and do not require any flasks round them when being cast, the adhesion of the sand being in itself sufticient to resist the pressure of the molten metal. This method of moulding is very econorucal ; a good bench moulder will turn out forty to fifty moulds per day. The charging hoist in tho cupola house is capable of lifting 2 tons, and is run by simple worm and wheel gear with straight and crossed belts, one fast and two loose pulleys. Tho power to work it is transmitted from the main shafting running through the engine-house by an ordinary tarred 4^-inch hempen rope, running cast-iron V-pulleys 6 feet in diameter; tho bottom of the groove in the pulleys is filled with india-rubber. This rope runs outside the building, exposed to all weather, and lasts on an average ten months. Tho rest of tho machinery consists of: a sand-grinding and loam- mixing mill, two rattlers or fettling drums 50 inches long, one of them 48 inches, the other 24 inches, in diametei-. The larger of these is mounted on friction rollers, and is built into a woo jn chamber lined with sheet iron ; the dust coming from the castings being cleaned in the mill is exhausted from this chamber, and blown out of the building. The sinaller drum is placed outside tlie ciii)ohi-liouse, and is used exclusively for separating the iron from the cinders and slag dropped out of the cupolas, which often 6 WANKLTN ON IRON AND BRASS FOUNDRIES. [S«lected amounts to 8 or 10 cwt. Oao vibratory sand-si ftor; one hay- baiul making machine; a doiiblo-whuolod emory grinder for drcHsing fina and gatea ; one Bmull vortical and one wmall hori- zontal drill ; a machine for breaking pig-iron ; thu' macliine enabloH the furnace-man to break pigs into pieces 8 or 10 inchoe long; large pieces of pig thrown into the cupola do serious injury to the lining, crushing and bruising t}ie bricks, and tliey aro also apt to scaffold or hang ; it therefore pays to break the pigs into small pieces ; a drop-weight and polo '60 feet high for breaking up large pieces of scrap, &c. The largest ladles uued hold 6 tons of metal ; all ladles from 40 cwt. and U])wards are geared, and ladles over 1 cwt. capacity are fitted with malleable-iron removable lips. The brass foundry is divided from the iron foundry by a brick wall 8 feet high, surrounded by an iron rr.iling, 4 feet high. The moulding sand in this department is contained in L- ^o trou^as over Avliieh the moulders work. These troughs nre placed along the wall, under the large windows, and down the centre of the shop. The pot holes or furnaces are placed along the west wall, occupying a space 1 9 feet 3 inchesi by 9 feet 3 inches ; they are seven in uuml)er, six of the ordinary type, 1 foot 6 inches in diameter, and 2 feet 5 inches deep, lined with segmental fire-bricks, 1 foot 7 inches by 41 inches by 6J inches thick and 9 inches radnis, and are large enough to admit 80-lb. crucibles. The seventh is Fletcher's patent furnace. All funiaces are provided with a forced blast of about C oz. pressure, as well as the natural draught from the chimney. The tops of the furnaces are level with the floor ; there is an ash-pit in front of the furnaces, 3 feet wide, 4 feet 5 inches deep, covered with a strong wrought-iron grating. The flues all lead into one chimney of Y^-i^ch plate, 3 feet 3 inches at the base, tapering to 2 feet 6 inches at the top, and 40 feet high, lined with fire-brick for about one-third oi the way up. The hot gases, before entering the chimney, pass round and heat the core- ovens, which are of iron plate fitted with suitable shelves. At the side of the building opposite the furnaces is a coal bunker, cajiable of holding 7 tons of coal. The coal is carried from this bunker to the fires in a swing- bucket, travelling on a rail overhead. There is also a double emery wheel and rattler for dressing and cleaning castings. These and the fun are driven by a diagonal engine, having a cylinder 8 inches by 10 inches. The cost of foundry materials in Montreal, in 1886, was as under : — PapcM.] WANELYN ON IRON AND BRASS yODNJRIBS. 7 Iron Focndrt Material. x. s. d. Scrap iron per groBB ton (2,240 Iba.) 2 6 8 rig iron, " Lnngloan," No, 1 . . „ „ 4 5 7 „ " Huiumcrlco." ... „ „ 447 „ " Anierioan," ... „ „ 4 A Afi Coko, Reading and I'ittsburg Mining Co., per not ton (2,000 lbs.) I 10 Coal, Lehigh anthracite lump pur groHH ton 1 10 2 .. .. egg size .... „ 142 „ Steam, Lower Province Canadian . . „ 15 10 Moulding sand, Canadian „ * 2i „ „ American „ 14 7 River ,, for eorc-iiinking .... ,, 5 10 Fire-clay, Scotch, ground, in bugs .... "^r 100 lbs. 3 4 „ American, in lumpa per net ton 2 1 8 Rad clay , pc Kf^sa ton 7 8^ Fire-brick, Scotch ' „ 1,000 4 9 7 „ American, \o. 1 „ 27 10 .. » i. J. 2 „ 11 5 Lumber per 1,000 *" < t 3 2 <5 Flour for core-making per lb. 1 Sea-coal facing per net ton 2 13 4 Curbonizod lead facing „ 9 7 Powdered charcoal „ 10 10 5 BuAsa FocNDUY Matehial. I. d. Scrap brasa per lb. 5 Ingot copper „ G M tin „ 10} Cake zinc „ If Pig lead 1} Antimony „ 5} Crucibles, GO Iba. capacity each 8 11} Cost of Labour. — Foreman, £177 Is. Sd. per annum; moulders, lOd. to Id. ; core makers, Sd. to 7jrl. ; furnaceman, 7\d. ; carpenter, C)^d. ; engino-man, r»^^, ; fitters, 6\d. to 5^77 „ castings produced 2,411,!)18 7SJ „ mill scrap 300,404 !)| „ defective casti.^gs .54, MO ij „ excess after filling moulds 187,737 oj „ Waste i08,i)(;4 aj Total amount of fuel used 411,548 li)s. Ilatio of fuel to irou melted 1 to 7J. Total number of melts 248 ,, time in melting charges 2(33 l)ours. Averngo weight of each melt 0,77.5 ll)s. Ratio of pig iron to scrap ] to 3. General Statement showing the Working of the Brass Foundry fro.m January 1st to OcTjiiER 30tl'., 1885 : — Per cent, of Ills. iiii'tal.s iiieitij. Total metals molted 358,410 „ castings produced 315,342 88 „ excess after filling moulds 18,1G2 ,5^ „ gutes 21,557 0^ „ waste H,S5S J Total amount of fuel used 433,(J1S lljs. Kiitio of fail to m"tals melted 1', to 1. Ratio of scrap metals to ingot niotals 3.Mo 1. The couiiunnicatioii is illustrated by a general plan n{" tlio works, Plate 4. LUNDON: I'ltlNTKll liV W.M. CI.OV, ES AND SONS, LIMITi;!), STAMli>rili .STIIKI.T AND I'!)A1{IM, ('U().',,s, RAND TRUNK RAILWAY OF CANADA PI.AI K . 4- ^[37 j;^^- J COAL laUNKCR CUPIOARD. .If.- - Y' ;i .;■,' /■■,■<■/ I lu.ii . so 7n no ttioKv/ THlK- KF.i.r, i H >N, I'll EmMiiPBi-w.Vol, LXaXVIII. Sw^ioji [S86-e7. F.n.t 1 ]]. 'ill on An£) ss] POINT ST CHARLES WORKS. G ^mrnimA w/wM -1!^^ / / r \ WALL CRANE I TON., fM^M^mm^ - -^ / \ 8 TON CRANE . J IRON FROM AS. ^.^ IKI/i"N. PK.!,'^ Mmutes rt [ivr.^"lm>'"t^ ul The Inslifiitii^n i^r -r/ INT ST CHARLES WORKS. GRAND TRUNK RAILWAY OF CANADA PI.ATK . 1. I I 'fm^ v^;^'- mm fmm^^ CUP»0«l»D . "-% ^^i^^ i / wm^L a TON CBANE. / TRACK SCALES. -f— *a 4- TON CRANE . ^-■^-"■rr-r^ Y^iWMWA ■sr.:V„--r>.->Jxrgr\\xr.; .■-■-:■■ ■r\'v,-.;rA- SAND HOUSE. '^^p^ ^:^'«v^ --J-' '^ »Av^^T' I ■-'" ■■''' '.' o<> so in Ml -li) iiloy,rl 'lin.-K >.l The liislidiiii-n .; i-il HnojiiPef,'.;, V"J. 1,XaXVIII. Sessioii k^ tno^WniiU * rtcitj, J ,: •