Tests of a
Jacobs-Shupert Boiler

W. F. M. GOSS

sod. aks

4d

eens
4 ae iy

 
Cornell University Library
TJ 642.G67

ONT
3 1924 004 616 839

engr
‘hes rs

of a

JACOBS-SHUPERT BOILER

in comparison with a

RADIAL-STAY BOILER

A Report submitted to

Mr. A. F. HUSTON

President of the Jacobs-Shupert United States Firebox Company

Coatesville, Pennsylvania

by

W. F. M. GOSS, D. Eng.

Dean of the College of Engineering, University of Illinois
Champaign-Urbana, Illinois

Published by
JACOBS-SHUPERT UNITED STATES FIREBOX COMPANY

Coatesville, Pennsylvania

9:12
Copyright, 1912
Jacogs-SHupert Unrrep States FirEBox COMPANY

Coatesville, Pennsylvania
II.
IIT.
IV.

V.

VI.
VII.

VIII.

IX.

CONTENTS

PAGE

. LETTER or TRANSMITTAL : ’ : : : ; : é : 7

INTRODUCTION : ; : ; : ; ‘ , 3 : : : 9

A Brier Story oF THE DEVELOPMENT OF THE LOCOMOTIVE BOILER : > A

Toe Mopern Raprat-Stay Borer 3 g : ‘ ‘ : : . 15
THE JACOBS-SHUPERT BOILER AND SOME OF THE ADVANTAGES WHICH HAVE

BrEn CLAIMED FOR IT , : 3 ‘ : : s 3 : io

Tue JAcoBs-SHUPERT BOILER IN SERVICE. ; ; ; ; ‘ . 85
PRoGRAM OF TESTS AND A DESCRIPTION OF THE MEANS EMPLOYED IN CARRY-

ING IT OuT 4 ; ; 3 : : : ’ : : 4 we 39
Tuer RevativE VALUE or Frresox HEATING-SURFACE AND OF TUBE HEATING-
SuRFACE AS DETERMINED BY TEstTs oF Aa TyPICAL JACOBS-SHUPERT

Borer AND A TypicaL Rapiau-Stay Borer : . : . 52
EVAPORATIVE TESTS OF A JACOBS-SHUPERT BOILER AND A NORMAL RapIAL-

Stay Borter . 5 : : ; 5 ; . 5 , oho

. Tue Brick Arcu as A Factor In BorterR PERFORMANCE : F , no G

. Low-water Tests AND THEIR RESULTS : : : . : : - SOL
. Some Facts with REFERENCE TO THE CIRCULATION OF WaTER IN LOCOMOTIVE

BoiLers . ; : 3 é ; ; F : : . 5 . 118

. EXPERIMENTAL Meruops AND OBSERVED AND COMPUTED RESULTS . . 131

. A SUMMARY . ‘ ; : : p ; : : : : : . 164
I. Letter of Transmittal

Mr. A. F. HUSTON,
President, Jacops-SHUPERT United States Firebox Company,
Coatesville, Pennsylvania.

Dear Sir:
In obedience to your direction, transmitted under date of August 24,

1911, I have approved the designs and superintended the construction of
two locomotive boilers identical in their general dimensions and differing
from each other only in the fact that one was fitted with a Jacobs-Shupert
firebox and the other with a radial-stay firebox. I have since subjected
these boilers to an elaborate series of tests. I transmit herewith a report
of the methods employed, of the results obtained, and of the conclusions

reached.
Respectfully submitted,

W. F. M. GOSS.

CHAMPAIGN-URBANA, ILLINOIS,
July 31, 1912.
II. Introduction

1. The Jacobs-Shupert United States Firebox Company, in under-
taking the manufacture and sale of a new type of steam boiler, early deter-
mined to conduct an elaborate series of tests as a preliminary step in the
development of its business. There had already been numerous tests
designed to disclose the behavior of various details entering into the
construction of the boiler, and there were already one hundred and sixty-
nine locomotives having Jacobs-Shupert boilers in successful operation.
In addition to these significant facts, the Company desired for its own
information and for the information of boiler users in every field of
service, to make of record a correct and comprehensive statement of the
merits of the new type of boiler. A tentative program of tests was
drawn up and its execution was intrusted to the undersigned, who as
expert in charge was given a free hand in the working out of the details.
It is the purpose of this report to present a full statement of the work
done and of the results obtained.

2. For the purpose of gaining some understanding of the behavior
of the Jacobs-Shupert boiler in service, a trip of inspection was made to
a number of roundhouses and shops where locomotives equipped with
such boilers were being handled. An account of this inspection is set
forth in Chapter VI of this report.

3. In cooperation with Mr. Charles Ducas, the able Technical Man-
ager of the Jacobs-Shupert United States Firebox Company, the elaborate
series of tests which has now been concluded, was planned. The tests
have involved the construction of two modern locomotive boilers, differing
from each other only in the fact that one was fitted with a Jacobs-
Shupert firebox and the other with a radial-stay firebox. Both boilers
were built to the general dimensions of a certain standard of the Atchison,
Topeka & Santa Fe Railroad. The firebox employed in the construction
of the Jacobs-Shupert boiler was not especially made for the test, but by
permission of the Santa Fe was taken at random from a number of similar
fireboxes under construction for that Company. No radial-stay firebox
for a boiler of the dimensions selected was available, and as a conse-
quence one was especially constructed, its overall dimensions being made
to agree accurately with those of the Jacobs-Shupert firebox. Each
boiler, as first constructed, was partitioned off into two compartments by
an extension of the back tube-sheet in all directions to the outside shell
of the boiler. The tests made when the boilers were thus equipped per-
mitted a separate determination of the heat transmitted by the firebox
heating-surface and by the tube heating-surface (Chapter VIII). The
performance of the boilers thus equipped was determined when oil and
coal respectively was used as fuel. This work having been completed, the
partitions were removed and the boilers subjected to such reconstruction

9
INTRODUCTION

 

as Was necessary to make them normal to conditions of service. Tests
were then made to establish the performance of the two normal boilers
(Chapter IX). This accomplished, each boiler was subjected to a_ test
of strength under low-water conditions with results which are set forth
in Chapter XI.

4. While one important purpose of the several chapters which follow
is to discuss and summarize the results obtained, a most interesting and
promising field of study is supplied by the unembellished numerical data
derived from the tests. These are presented complete, with a full descrip-
tion of the methods employed in obtaining them, as Chapter XIII. Not
only does this chapter contain the commonly presented facts concerning
the performance of the two boilers tested, but it also presents for most of
the tests the results of a complete heat-balance. By reference to the
tables of this chapter, therefore, the student of steam engineering will
find material for comparisons involving many factors which do not appear
in the more descriptive chapters preceding.

d. It will interest those who have occasion to follow this work to know
that it is stated by the officers of the Jacobs-Shupert United States Fire-
box Company that the entire capital for its business has been supplied by
the Lukens Iron & Steel Company. It has been remarked as of more than
ordinary significance that this Company, having so much at stake, and
understanding perfectly that adverse results might have meant the clos-
ing up of a business, should have fearlessly acquiesced in the plans of
the Firebox Company, whereby a single expert was authorized to under-
take the comparative tests and was given a free hand in carrying them out.

6. In the execution of its program of tests, the Jacobs-Shupert United
States Firebox Company is indebted for substantial assistance to many
different agencies. Chief among these is the Lukens Iron & Steel Com-
pany upon whose premises all the work was done. The organization of
men and the equipment of this magnificent establishment being at all
times available, greatly facilitated the progress of the work. Whatever
the need, whether for rough labor, for skilled labor, or for materials, it
was always supplied practically on demand. The interest in the tests
which was manifested by Messrs. A. F. and C. L. Huston, President and
Vice-President, respectively, both of the Lukens Iron & Steel Company
and of the Jacobs-Shupert United States Firebox Company, permitted
no desire of the expert in charge to go unsatisfied.

7. The United States Bureau of Mines, in recognition of the signifi-
cance of the tests, has cooperated in the work so far as circumstances
would permit.

8. The undersigned finds pleasure also in acknowledging his personal
indebtedness to Mr. P. C. Haldeman, Master Mechanic of the Lukens
Iron & Steel Company, to Mr. A. M. Baird, Master Boiler Maker, and
to his personal assistant, Mr. J. F. Butler. W. F. M. G.

CHAMPAIGN-URBANA, ILLINOIS,

y 31, 1912.
July 31, 10
Ill. A Brief Story of the Development of
the Locomotive Boiler

9. The boiler is the locomotive’s primary source of power. However
efficient the details of its engine, they can be effective in the development
of power only when furnished with an ample supply of steam. This must
come from the boiler. The boilers of early locomotives were small and
inefficient and the problem of improving them as it has presented itself
to succeeding generations of designers has been beset with difficulties.

10. An early form of locomotive boiler was a plain cylindrical
structure containing a single flue. At one end of this flue a fire-door was
attached, and inside the fire-door, grate bars were arranged. At the other
end an elbow was added to connect with a vertical stack. By this arrange-
ment the stack was in front of the boiler, not on it. When the locomotive
was operating, the elbow and a considerable portion of the stack were
commonly red-hot. An improvement consisted in fitting the boiler with
a return flue which brought the stack and fire-door at the same end, and
which provided more heating-surface, a longer flameway and lower stack
temperatures than were possible with the earlier design. The famous
“Puffing Billy,” a locomotive which did effective service for many years,
was provided with a boiler thus constructed. Obviously, the power
developed by such an arrangement could not be great, and the commer-
cial success of the locomotive awaited the advent of a boiler having greater
capacity. This came when George and Robert Stephenson designed and
constructed the multitubular boiler for their famous locomotive
“Rocket.” This boiler had a plain cylindrical shell fitted with twenty-
five 3-inch copper tubes extending from end to end of the boiler. At the
front-end a smoke-box was attached which discharged into the stack. At
the back-end a box-like fixture was added to constitute the firebox. The
superior success of the “Rocket” over that of previously existing locomo-
tives was due largely to the fact that its boiler gave an abundant supply
of steam.

11. The “Rocket’s” boiler fixed the general lines to be followed in
the building of locomotive boilers for many succeeding years, but it did
not completely solve the problem of the firebox construction. That detail
was destined to take on many forms in pioneer days, and it is one which
has been the subject of much debate and change in more modern times.
The first tubular boiler having a self-contained submerged firebox, seems
to have been that of the locomotive “Planet”? built by the Stephensons
for service on the Liverpool and Manchester Railway in 1830. The fire-
box was rectangular in plan. While the Stephensons subsequently devoted

11
TESTS OF A JACOBS-SHUPERT BOILER

themselves to the development of this form of construction, others built
fireboxes which were circular in plan, crowned by a hemispherical dome,
a form well chosen to resist the stresses imposed by the internal pressure
of the boiler. In the process of developing such structures, however,
practice came gradually to rely for strength less upon form and more upon
stays by the use of which a structure weak in form could be held in place.
A firebox rectangular in plan being desirable, other forms gave way to this
plan. The stability of the sides and ends of all such fireboxes was secured
by the use of stay-bolts connecting the inside and outside sheet. The
support of the crown-sheet proved a more difficult matter. For many
years it was provided for by the application of crown-bars running over
the crown-sheet either longitudinally or transversely, the latter being the
more common arrangement in this country. The crown-bars were metal
girders of such form as to permit them to extend across and above the
crown-sheet while receiving their support from feet bearing on the upper
edges of the side-sheets. A series of such crown-bars served as lines of
support for the crown-sheet which was held up by suitable rivets or bolts.
The crown thus supported was in effect carried by the side-sheets, and
while this type of construction proved serviceable for many years and is
still used in small boilers, the time came when in the development of the
American boiler it had to give way to something better. As the dimen-
sions of fireboxes increased, the crown-bars became enormously heavy,
and the load which they imposed upon the side-sheets became so great as
to complicate the problem of firebox maintenance. In this emergency a
part of the load was for a time removed from the side-sheet by carrying
heavy sling stays from the crown-bars to the outside shell of the boiler,
but the relief thus obtained was only partial, and the size of boilers con-
tinued to increase. For a time and to a very limited extent in this
country, the crown-bar boiler was followed by the Belpaire boiler, a design
in which all portions of the firebox are stayed, and in which the outside
of the boiler is so formed as to permit all stays to connect sheets which are
parallel. But the real successor of the crown-bar boiler has been the
radial-stay boiler, in which the crown of the firebox is curved to a form
which will permit its being held up by stays extending to the outside shell
or wrapper sheet. The lines of the stays extended do not necessarily
radiate from any single point, but their arrangement suggests such a
possibility; hence the term “radial stays.’ As compared with the Bel-
paire, the radial-stay type presents greater difficulty to be overcome in
making an analysis of the stresses which are set up in its several parts
by the presence of internal pressure, but it is lighter and probably on the
whole equally satisfactory. The radial-stay firebox of the present day
may have either one of two forms. It may be “wide,” in which case the
side-sheets extend in a straight line from the mud-ring to the curved
portion of the crown-sheet, or it may be “narrow,” in which case the side-
sheets extend vertically for a short distance above the mud-ring, then
12
DEVELOPMENT OF THE LOCOMOTIVE BOILER

 

curve outward and finally back again to meet the curvature of the crown-
sheet. In either case, stay-bolts closely spaced connect the side-sheet
with the outside sheet of the boiler.

12. Practice has developed many embellishments in the construction
of this form of firebox. First, it has found that longitudinal stresses
imposed upon the tube-sheet make it desirable to have a certain element
of flexibility locally about the tube-sheet, and hence instead of inserting
rigid radial stays at this point, two or more rows of sling stays are used.
The design of these is such that while giving adequate support to the
crown-sheet they offer no resistance to the movement referred to. A
second embellishment is to be found in the use of button heads on the
firebox end of some or all radial stays. The design of these heads is such
as to provide a broad bearing for the plate upon the head of the stay, a
connection which is altogether stronger than is obtained by merely screw-
ing in the straight stay and heading it. Practice has also developed
certain forms of flexible stays for use in the water-leg and higher up in the
boiler. These devices are such as to permit some change in the angular
position of the stay without imposing transverse stresses upon it at points
near the outside sheet. These and many other embellishments in its design
have permitted the radial-stay boiler to perform a service which as meas-
ured in power output per unit weight is superior to that of any type
previously employed in locomotive service, and it is this fact which
chiefly has resulted in the wide use of the type. But the necessity for
certain of these embellishments and the practical difficulties which
are experienced in maintaining the modern radial-stay boiler suggest
deficiencies in the fundamental principles underlying its design and the
time will doubtless come when the large sized radial-stay boiler will
entirely give way to something that is scientifically more sound. The
promise of such a consummation is to be seen in the recently developed
Jacobs-Shupert boiler which was first put in service in 1909. This type
of boiler has in the past three years been subjected to extensive use and
to elaborate laboratory tests, with results which as to maintenance cost
and strength are entirely complimentary to the new design.

13. The Jacobs-Shupert boiler in its external form follows the general
lines of the radial-stay boiler, of which it is to be regarded as a logical devel-
opment. It differs radically from its predecessor in the structural charac-
teristics of its firebox and in the means employed for supporting it. The
Jacobs-Shupert firebox provides an element of longitudinal flexibility which
the firebox of the radial-stay boiler does not possess, and thereby eliminates
strains due to expansion which must be met by the rigid sheet of the
radial-stay boiler. It makes no use of stays in side-sheets or crown, and
hence abolishes completely a fruitful source of trouble which is always
present in the radial-stay type of boiler. The support of the side-sheets
and crown is secured by means of rivets submerged in the water-space
of the boiler, no one of which can be exposed to the direct heat of the

13
TESTS OF A JACOBS-SHUPERT BOILER

 

furnace. As a consequence, the strength ofthe Jacobs-Shupert boiler
under low-water conditions as compared with that of the radial-stay boiler
is vastly augmented. A fuller description of this latest type of locomotive
boiler is presented as Chapter V, and an account of its performance con-
stitutes the subject of Chapters VIIT to XIV, inclusive.
IV. The Modern Radial-Stay Boiler

14. The radial-stay boiler has constituted an important factor in the
development of the modern high-powered American locomotive. For a
score of years the locomotive designer has endeavored to secure larger
boilers. In working out this purpose, the machinery of the locomotive
has been lightened, steel has been substituted for cast-iron, and to insure
the exclusion of unnecessary weight, the design of every detail of mechan-
ism has been subject to the closest scrutiny. All that has been gained
through the better design of machine parts has been utilized by giving
increased weight to the boiler, but here again no unnecessary material
has been allowed. In the design of the boiler, the effort has been to secure
maximum heating surface for minimum weight. It is in the development
of this general conception that the radial-stay boiler has been brought to
its present-day standard. It has given the American locomotive greater
steaming capacity and power than have been possessed by the locomotives
of any other country. Whatever may be the future of the steam locomo-
tive, the history of the art will not fail to give an important place to the
radial-stay boiler.

15. However great the success of the modern radial-stay boiler, it
must be admitted that under present-day conditions involving high
steam-pressures and large firebox areas, it is a structure which is exceed-
ingly susceptible to deteriorating influences. The difficulties appear
chiefly in the firebox which as usually constructed is made up of five plates
of steel; namely, two side-sheets, the tube-sheet, the door-sheet, and
the crown-sheet. The side-sheets are usually flat plates of steel which are
in the neighborhood of five feet wide and which may be nine or ten feet
in length. As these plates must transmit heat from the furnace to the
water of the boiler, they can not be heavy and they are usually three-
eighths of an inch thick. Under modern conditions of operation, how-
ever, they must be so supported that they will resist a pressure of 14 or
15 tons per square foot. This is accomplished by the introduction of
stay-bolts which tie the side-sheet to the outside sheet of the boiler.
The construction is well shown by Fig. 1, which is a view of the
water-leg of a firebox from which the barrel and throat-sheet have
been removed. Obviously, there is no provision in the design of such a
side-sheet for taking care of local expansion, and as a consequence the
effect of such expansion can only find expression in bringing about a
change of stress within the sheet itself. The result is that different por-
tions of the side-sheet behave in different ways. They change their
position with reference to the outside sheet of the boiler, causing stay-
bolts to loosen, to become leaky, and in the zone of greatest movement,
finally to break. This fact was recently emphasized by Mr. F. A. Delano,

15
TESTS OF A JACOBS-SHUPERT BOILER

President and Receiver of the Wabash Railroad, a high authority in
railway mechanical matters, who in the course of a recent address,* said:

“A modern locomotive boiler has from 1,200 to 1,500. stay-bolts,
between 4 and 5 in. apart, on all sides of the firebox. Under the law,
five broken stay-bolts are sufficient to condemn an engine. This means
that a locomotive boiler must be more than 99 per cent. perfect to meet
approval; and yet it is safe to say that no high-pressure boiler can be
cooled down and reheated
again (as it must be for
each washing out) with-
out breaking at least this
number of stay-bolts.”’

Not only does trouble
arise from the presence
of stay-bolts, but the
sheets themselves gradu-
ally bulge between the
stay-bolts, and under un-
favorable conditions of
service they deteriorate
rapidly. Fig. 2 shows a
patch which in the proc-
ess of making repairs
has been applied to a
bulged side-sheet. The
appearance of the patch
itself and especially of
the patch bolts which
hold it in place, suggests
the difficulties that must
be met in maintaining any
flat sheet under the con-
ditions of service to which
a side-sheet is exposed.

; 16. The crown-sheet
Fic. 1—Firebox showing a heavy deposit of scale at the. Hee f
junction of the stay -holts and firebox sheets, and the 12 the radial-stay type o

corrosion of the stay-bolts. Scale formation is also boiler is usually curved.

S. hese conditions are : :
shown around the flue ferrules Thes ad S ease he iitsandian
similar to those found in most locomotive boilers : :
working under average water conditions. common with the side-

sheets it must stand up
under a pressure of approximately 15 tons per square foot, or a total load
for a modern crown-sheet of 1,000 tons or more. Support is given the
crown- -sheet by the radial stays which tie it to ‘ie outside shell of the

 

 

*An address given before th the Commercial Association of the State of Michigan,

Detroit, April 17, 1912.
16
MODERN RADIAL-STAY BOILER

boiler, and which having considerable length permit some freedom of
movement in the sheet under them. Consequently, the crown-sheet is
more durable than the side-
sheets, but it nevertheless
suffers deterioration as an in-
direct cause from expansion
and contraction stresses. Fig. 3
shows a crown taken from ser-
vice, in which the plate is more
or less bulged between stays,
and in which the dark spots
indicate pitting or local corro-
sion of the plate. Fig. 4 is a
view into the water-space over
the crown-sheet of a_ boiler
from which the barrel has been
removed. It indicates the size
and the spacing of the stays. Fic. 2.—Patch on side of firebox showing the wear

 

is A : on such patches. The patch is, in general, in
Four front rows were sling- good condition, but the bolts at the rear end
stays, and these had been re- have started working down, and there are indi-
moved prior to taking the pic- cations of cracks near the calking edge.

tures. Figs. 5 and 6 show a

similar view of a boiler with all the stays still in position. The illustrations
well show the obstructions which are presented to the free movement of
water over the crown-sheet, and the ease with which sediment or scale
may collect upon certain portions thereof in this type of boiler. Fig. 7
shows a bulged and leaky crown-sheet from the fire-side.

17. The back tube-sheet
is one difficult to maintain
in the radial-stay boiler. If
its tubes leak they must be
rolled, and the gradual process
of rolling extends the tube-
sheet upward with the result
that the forward end of the
crown-sheet gradually becomes
bent upward and the fillet of
the tube-sheet itself not infre-
quently expands above the

level of the crown-sheet. Fig.

Fic. 3—Crown-sheet showing pitting and cor- Gichowethisnce i the flleeor
rosion resulting from scale accumulation. This

box was removed on account of this pitting. the tube-sheet. One result of

this extension is a gradual de-

generation of the upper portion of the tube-sheet itself. Thus in Fig. 5 is to be

seen a series of irregular cracks extending all around the top not far from the
17

 
TESTS OF A JACOBS-SHUPERT BOILER

 

Fic. 4.—Crown-sheet showing the corrosion at the points where the bolts pass through
it. This box was removed on account of the corrosion of the crown-sheet.

 

Fic. 5.—Water side of back flue-sheet showing cracks in the flange caused by the crimping
action, resulting from the vertical movement of the sheet. This firebox was removed
because of the pitting of the crown-sheet around the radial stays and crown-bar bolts.

18
MODERN RADIAL-STAY BOILER

 

point of its connection with the crown-sheet. Figs. 8, 9, and 10 show the
degeneration of the tube-sheet resulting from stresses induced by the
distortions already referred to. These illustrations are in nowise peculiar,
but on the contrary, may be taken as entirely typical of the difficulties
to be met in the maintenance of all large radial-stay fireboxes.

18. The forces at work within the structure of the radial-stay firebox,
which ultimately bring
about its ruin, are, under
service conditions, always
present, but the careless
handling of the locomo-
tive or the necessity for
using a muddy, foaming
or scale-producing water
hastens its deterioration.
Careless handling may
expose the firebox to sud-
den changes of tempera-
ture which may result in
leaks; the use of muddy
or scale-producing waters
may result in the deposit
of solids on the sheets and
lead to local overheating;
and the use of foaming
waters may operate in
various ways to deprive
the plates of the protec-

tion against overheating

which they are designed Fic. 6.—Back flue-sheet showing the deteriorated con-
ve dition of its flange, which has resulted from the con-

to have. In other words, tinually recurring strains.

where the conditions are
all favorable to longevity, the radial-stay boiler must be tenderly handled,
and under conditions which are normal through large sections of our
country, it is kept in service only as a result of constant attention. The
radial-stay boiler is everywhere expensive to maintain, and its need of
attention requires the locomotives to spend much time in the roundhouse,
which might otherwise be given in service at the head of a train. It is
customary on most roads to have a boiler maker go over the boilers after
each trip, and on many roads the conditions are such that he must always
do some work on them. Now a boiler that must be fixed after each brief
period of service is to be compared with a highway bridge which must be
mended after each passing vehicle—it serves an immediate purpose, but
it leaves much to be wished for.

19. Finally, the radial-stay boiler is weak, as have been all its prede-

19

 
TESTS OF A JACOBS-SHUPERT BOILER

 

cessors, under low-water conditions, and when failure occurs, the results
are likely to be disastrous. A study of the radial-stay construction will
suffice to reveal the explanation. The support of the crown-sheet is such
that any local yielding imposes additional stress upon adjacent parts,
and as these fail, the affected zone is extended, the process proceeding
with such rapidity that the pent-up water and steam in the boiler is
released with explosive effect. This is well illustrated by Fig. 11, which
shows almost the whole crown to have come down together with a con-
siderable portion of one side-sheet. The explosive effect of such a failure
is apparent. A Committee of the American Railway Master Mechanics’
Association, reporting at the convention of the Association in 1910, gives

   

Fic. 7—Photograph showing the bulging of crown-sheet between stay-bolts.

results of an inquiry concerning the number of boiler explosions, failures,
and casualties to employees and others. The report was based on
responses received from 157 railroads owning and operating 43,787 locomo-
tives. The committee reports that during the period from June 1, 1905,
to November 1, 1909, there were 246 firebox explosions resulting in the
loss of 127 lives, and 2,499 fireboxes damaged by overheating, resulting in
142 deaths. More than 98 per cent. of these failures are said to have been
due to low water. This statement makes it evident that low-water
conditions are matters to be reckoned with, and that a boiler which is
inherently weak when the water is low is at a disadvantage as compared
with one which is less affected by overheating.

20. The explosion of locomotive No. 2538 which occurred four miles
south of Yoncalla, Oregon, on April 4, 1912, may be accepted as typical
of recent disasters. The accident in question occurred on the Oregon &
California Railroad which is operated by the Southern Pacifie Company.

A report of the accident as formulated by the chief inspector of locomotive
20
MODERN RADIAL-STAY BOILER

 

Fic. 9—Top of flue-sheet showing patch. This patch was made necessary by the crimping
action of the flue-sheet described in connection with photographs previously shown.
TESTS OF A JACOBS-SHUPERT BOILER

boilers of the Interstate Commerce Commission presents the following
facts:

The locomotive was of the consolidation type and at the time that it
exploded was engaged in helper service on a south-bound train of 40 cars
weighing altogether 1,605 tons. Three freight engines were coupled to the
train, the road engine No. 3203 at the head and two others No. 2538 and
No. 2194 between the caboose and the train. It was the boiler of 2538
that failed. The exploding boiler was blown clear off the frames of the
locomotive, breaking or pulling out the expansion plates attached to the
firebox, shearing cylinder saddle-bolts and breaking the saddle. It passed
over three box-cars, apparently lighting on an oil-tank car, from which
it rolled off to the right side and landed on the bank of an 8-foot cut at a
distance of approximately 218 feet from the point where the explosion
occurred. The engineer and fireman were both killed. The report con-
tinues: “At the time of the accident, the train was ascending a grade of
$4.48 feet per mile at a speed of 10 to 12 miles per hour. The accident
occurred on a tangent 627 feet south of a left-hand 8° curve. The eleva-
tion of the right-hand rail of this curve was from 319 to 3°q4 inches for a
distance of 198 feet in the center of the curve. Our inspection disclosed
the fact that almost the entire crown-sheet, with the exception of a portion
of the left back corner, was overheated. The overheated portions of the
sheet extended 4 inches below the highest part of the crown-sheet at the
right front corner and one inch below at the left front corner. At the
right back corner it was about on a line with the crown-sheet, while there
had apparently been water on the left back corner. So far as could be
ascertained by our inspection, the injectors, safety-valves and steam-gauge
were in good condition.”

The report concludes with the opinion that the accident in question was
the result of overheating the crown-sheet due to low water. With the
efforts of the inspector to fix the responsibility for the low water, the
undersigned is at present not concerned, but he wishes especially to call
attention to the fact that the crown-sheet came down as soon as any
considerable portion of it was bare and before it was entirely uncovered.
The modern firebox has so little power of resistance in the presence of low
water that the fact that any part of the crown-sheet is bare is commonly
accepted as a cause sufficient to explain a firebox failure.

21. It is obvious that any boiler, however satisfactory when
properly handled, which possesses such enormous power of destruction
when carelessly or imperfectly managed, always presents a certain element
of danger. In stationary practice, progress in the art has produced certain
types of boilers which in case of failure do not act with an explosive effect.
In these so-called “safety boilers,” the heating surface is subdivided so
that a failure, if one occurs, is limited to a comparatively small detail; a
break down can not easily become progressive. A failure is merely a blow-
out. There is no explosion, and no damage is done beyond that of the
affected part. There is no wreckage, and there are ordinarily no casual-

ties. In this respect the design of the stationary boiler occupies a much
99
MODERN RADIAL-STAY BOILER

 

 

Ic. 10.—Top of flue-sheet showing a patch which has been properly applied, but which
has itself become cracked as a result of strains.

EOL

SOEs

SAWS

c
PTL
wrrrrrry ty yt)
YT TELE hh
veeaaad

 

Fic. 11.—Crown-sheet failure in which most of the crown and a porlion of one side-sheet
were blown away, the stays retaining their places in the out-sidesheet.

23
TESTS OF A JACOBS-SHUPERT BOILER

higher plane than that occupied by the locomotive boiler. The locomotive
service is in need of a boiler possessing the elements of safety which are
to be found in existing types of stationary boilers.

22. These well-known deficiencies of the radial-stay boiler are not
rehearsed for the purpose of obscuring its merits, but that our devotion in
fostering it may not be permitted to blind our eyes to its frailties. No
one who considers the progress of the past can assume for a moment that
our present-day practice is final. The radial-stay boiler has had its pre-
decessors and they have disappeared, and no one can doubt that the
radial-stay boiler itself is but an embryo predecessor of a type which must
soon be revealed.
V. The Jacobs-Shupert Boiler and Some
of the Advantages Which Have
Been Claimed for It’

23. The term Jacobs-Shupert boiler as hereinafter used implies a
boiler having a Jacobs-Shupert firebox. This firebox is more than a
mere modification of pre-existing forms; it is entirely new in its contour,
in the means which are employed for its support, and in the fact that it
is made up of a considerable number of comparatively small plates. A
Jacobs-Shupert firebox may have the same overall dimensions as a radial-
stay or a crown-bar firebox; that is, it may be designed to respond to all
of the limitations which must be observed where other types of fireboxes
are used. On the other hand, indications are not lacking to show that
the dimensions of the Jacobs-Shupert boiler may be extended to limits
which are hardly possible in the case of the radial-stay type.

24. The contour of the Jacobs-Shupert firebox as shown by any
longitudinal section is not dissimilar to that of the corrugated furnaces so
long and so generally used in marine service. It is shown by Fig. 16.
The firebox is supported in part from the shape which is given the several

 

* As a matter of historical interest, the following brief account has been abstracted
from a very full and interesting statement prepared by Mr. H. W. Jacobs. The conception
of a sectional firebox having submerged seams originated
with Mr. F. W. Shupert while Foreman of Boiler Makers
at the San Bernardino Shops of the Santa Fe Railway.
He availed himself of an early opportunity to discuss the
matter with Mr. H. W. Jacobs,
and in April, 1906, a model in tin,
having the sections run longitu-
dinally, was made (Figs. 12 and
13). In August of the same year,
chiefly through the activities of
Mr. Jacobs, the first model hay-

Fic. 12—Model No. 1. Shupert’s ing transverse sections extending
original design of firebox. View , ; ‘
showing arrangement of stays in from mud-ring to mud-ring was

first model. March, 1906. constructed (Figs. 14 and 15).

This and subsequent models were Fic. 13.—Model No. 1.
exhibited by Mr. Jacobs to various people who were likely to on oe ee
be interested, and from whom he expected to get useful sug- ing arrangement of lon-
gestions, often with results which were discouraging to him. ea ee
But in the spring of 1907, he had succeeded in developing the 1906. ,
idea to a point where he was ready to apply for a patent. A
very complete model to scale, constructed to show the practicability of the design, was
exhibited a year later and won many friends for the new device. Encouraged by Mr.

25

  
TESTS OF A JACOBS-SHUPERT BOILER

 

elements entering into its construction and in part by stay-sheets extend-
ing between the sections and the outside shell of the boiler. There are
no sling stays in the boiler, and stay-bolts are used only in the door-sheet
and tube-sheet.

25. The sides and crown of the Jacobs-Shupert firebox are composed
of a series of channel sections made up from long, narrow, flat-sheets
which, having been heated, are pressed into shape by a special hydraulic
flanging machine (Fig. 17). A flanged section is shown by Fig. 18. Stay-
sheets are fitted between every two adjacent sections and find their sup-
port in the sections of the outside wrapper of the boiler. The two
adjacent sections of the firebox and their stay-sheet are fastened by
through rivets. The process of riveting is shown by Fig. 19, and a
firebox with all the inside sections in place by Fig. 20. The sections
have a uniform width of 9°s inches over flanges and the stay-sheets are
*< of an inch thick, so that each stay-sheet and its accompanying section
cover the construction of a 10-inch length of firebox. A firebox having
ten sections is, therefore, 100 inches in length, and one having 13 sections
is 130 inches in length. The stay-sheets connect the sections of the fire-
box with similar sections which form the outside wrapper of the boiler,
the construction of which is well shown by Fig. 21. To provide for circu-
lation in a horizontal direction, the stay-sheets are pierced with openings
of liberal size (Fig. 22) and as all stay-sheets of a given boiler are made
from the same templet, these holes line one with another. The door-

 

J. W. IKkendrick, Third Vice-President of the Santa Fe Railway, the late W. F. Buck,
Superintendent of Motive Power, under date of September 2, 1908, formally authorized
the building of a locomotive embodying the Jacobs-Shupert
firebox. Many engineers of distinction inspected the boiler of
this locomotive while it was in process of construction, and
in the spring of 1909, it was described by a number of techni-
cal papers. The locomotive
with the new boiler made its
trial trip on April 9 and went
into regular service April 20,

 

1909. It was subjected to an
Fic. 14. — Model No. 9, @Xhaustive series of road tests
Jacobs-Shupert firebox. conducted by Mr. H. B. Mac-
View showing arrangement
of stays as applied in later
model, August, 1906. the railroad company to order

, Se i
Farland. Its success encouraged ceemeetintiee tie ed

 

more fireboxes. In January, Hae 18 NA hank
IG, v.—i0del INO. 2. Jacods-

1911, the interests of the inventors and pioneer promoters Shupert firebox. View showing
were taken over by an organization incorporated as the arrangement of transverse unit

rs ee ‘ ‘ ‘ : sections in later model. August,
Jacobs-Shupert United States Firebox Company, A. F. 1906.

Huston, President; H. W. Jacobs, First Vice-President;
C. L. Huston, Second Vice-President, and Joseph Humpton, Secretary and Treasurer.
In July, 1912, G. H. Pearsall and C. B. Moore were made Vice-Presidents in charge of
sales. This company, having offices in New York and Chicago and works at Coatesville,
Pa., is now responsible for the manufacture and sale of the new device.

26
ADVANTAGES OF THE JACOBS-SHUPERT BOILER

 

 

 

 

Fira. 16.—View of joint between firebox sections and stay-sheets.

 

Fig. 17.—Horizontal hydraulic press for flanging channel sections at works of Jacobs-
Shupert United States Firebox Co.

Q7
TESTS OF A JACOBS-SHUPERT BOILER

 

sheet (Fig. 23) and the back-sheet of the firebox are stayed to each other
in the usual way. There are stays also in that portion of the tube-sheet
which is below the tubes. A throat-sheet (Fig. 24) connects the special

 

Fic. 18.—Mhiddle inside channel section

partially completed.

construction of the Jacobs-Shupert
boiler with the barrel which in all
respects 1s normal.

26. In fitting up the stay-sheets
and the inside and outside sections
of the Jacobs-Shupert boiler, all rivet
holes are drilled from standard tem-
plets, so that the process of assembling
parts is more like that of assembling
a machine than that of putting together
the several parts of the boiler. This
impression is heightened by the fact
that in the mill a long reamer is run
through half the flanges of a completely
assembled firebox, and then, working
from the opposite end, through the
other half. All rivets are driven in
reamed holes, and rivets in the same
horizontal course line with each other
perfectly. The mud-ring is in nowise
different from that employed in a nor-
mal boiler. The method of connecting

the sections with the mud-ring is shown by Fig. 25,* and a view of the in-
terior of a completed firebox by Fig. 26.

27. It has been said that objections have been made to the Jacobs-
Shupert boiler because of the number of rivets it contains, but before urg-
ing such an objection one should consider that a rivet which is well placed
and well driven is a very reliable fastening, and that there are no rivets
in the side-sheets or the crown of the Jacobs-Shupert firebox where the

presence of such fastenings
would be most objectionable.
The fact that there are no seam-
rivets in the firebox, and that
all the rivets made necessary
by the special construction of

*The latest fireboxes of the
Jacobs-Shupert design have what is
claimed to be an improved joint be-
tween the inside sections at the mud-
ring. In this new joint, the lapping
of the sections over each other at the
mud-ring and around the bottom of

 

Fic. 25a.—Details of butt-welded joint at mud-ring.

28
ADVANTAGES OF THE JACOBS-SHUPERT BOILER

 

the Jacobs-Shupert boiler are either entirely in the water-space or on the
outside of the boiler, suggests that the service to be met by them is similar
to that imposed upon the normal shell-rivet. Shell-rivets commonly give
no trouble. Moreover, the number of rivets in the Jacobs-Shupert boiler is
not greatly in excess of the combined number of rivets and stays in older
types of boilers. For example, a comparison of the drawings of the two
boilers described in Chapter VII, the heating-surface and external dimensions
of which were designed to be exactly the same, shows that the number of
rivets, stays, etc., for all that portion of the boiler back of the center of the

throat-sheet is as follows:
Jacobs-Shupert Radial-stay

 

Fras Le gee Peepee ert etd in rete Sars rue ze Meee eareten 320 312
Connecting inside and outside sections and stay-
sheets (11 sections, 12 joints).................. 2,520
As fastenings for longitudinal stays.............. 176 164
Patch bolts in door-sheet.............000.000000. 44 44
Stay-bolts in tube-sheet and door-sheet............ 368 366
Rivets in firebox seams...............0000000 cee. 180
Seam-rivets in outside wrapper.................... 373
Radial-stays, crown-bar stays, and stay-bolts not 1,196
including those in tube-sheet and door-sheet aml
so tala yt err ee ar ete eet A 3,428 2,635

Reduction in firebox rivets and stays in contact
with fire by Jacobs-Shupert construction—
1, 196-366-180 — 368.0422 ee cee ese 1,374
Increase in number of riveted fastenings involved
by Jacobs-Shupert construction—
oA S12 GOOG ae Prt SNe ae ee ne Met ee eer eee 793

 

 

the stay-sheet, is eliminated. This new style joint is shown by Fig. 25a. Adjacent
inside sections are butt-jointed from the point where the stay-sheet ends to the bottom
of the mud-ring and this butt-joint is welded by means of the oxy-acetylene method.
Fig. 255 is a view of a Jacobs-Shupert firebox having the butt-welded joint shown in
Fig. 25a. This firebox is one of several in service on the Lehigh Valley Railroad.

 

Fic. 25b.—Interior of Jacobs-Shupert firebox with butt-welded mud-ring joint. Lehigh Valley Railroad.
29
TESTS OF A JACOBS-SHUPERT BOILER

The method of riveting sections and stay-sheets has been shown by Fig.
19. Many rivets may be driven in the time that is required to set one
stay-bolt, and a rivet in a reamed hole once driven requires no attention,
while a stay-bolt must be constantly inspected and frequently worked
upon. The elimination, therefore, of 1374 firebox stays in return for the
addition of 793 through rivets, is a matter which, from the standpoint of

Ba

‘
“a
is]
9
)
y
9)
%
j
cs

~ PECL TOY y
ow Ss

Rene

 

Fic. 19.—Method of riveting together the channel sections and stay-sheets by means of
gap riveter.

construction and maintenance, has much to recommend it. Obviously,
while the Jacobs-Shupert construction does increase the number of rivets,
there is no corresponding increase in maintenance cost or hazard; the
change amounts to the displacement of a troublesome device by one of
the oldest and most reliable fastenings employed in the arts.

28, A number of advantages possessed by the new form of firebox
are at once apparent. Most obvious, perhaps, is the presence of an ele-
ment of flexibility which is introduced by the combination of curved sec-
tions. In this respect the Jacobs-Shupert firebox is comparable with the
corrugated furnace to which reference has already been made. Any

30
JACOBS-SHUPERT BOILER

THE

OF

ADVANTAGES

 

“ESS

Ae

sss. SSS

 

al firebox ready for the application of the outside sections.

ction

se

hupert

Fic. 20.—The Jacobs-S

poe editestn we ee

ee ee

rw)

Scie Tee SS ee ee

ie

aioe

CA ial es

erat a Ne Oe

Che ie
Salas ee Pag ee

 

Fig. 21.—-The completed Jacobs-Shupert back end ready for application to boiler shell.

31
TESTS OF A JACOBS-SHUPERT BOILER

strain due to longitudinal expansion is taken care of with the least chance

of injury to the structure.

Pips

7
[
20,

9900

 

00

0900099999095

 

0

 

o00 500

 

[
i

3—Removable Stays
4—Removable Stay Pins

o000000009000009000
09009005

= 070: OG) 'O

    

Fic. 22.—Stay-Sheet.

  
   

1—Inside Channel Section Rivet Holes
2—Outside Channel Section Rivet Holes

The effect of this provision must be beneficial

in reducing the cost of repairs and
in increasing the life of the boiler.

29. The presence of the cor-
rugated surface within the firebox
adds somewhat to the extent of the
firebox heating-surface as compared
with the surface presented by a nor-
mal firebox of the same overall
dimensions. The extent of this
increase in the case of the boilers
described in Chapter VII is 11 per
cent.

30. The fact that the Jacobs-
Shupert firebox has no stay-bolts in
the sides and crown removes an
important source of difficulty. With
no stay-bolts there can be, of course,
no leaky bolts to calk, no broken

bolts to replace, and no spots inherently weak when the water drops a little

low. The rivets joining
the several sections mak-
ing up the firebox struc-
ture are not inside of the
firebox. They can not
be seen from the firebox
and they can not be
affected by the direct ac-
tion of the heat from the
firebox. They are above
the crown in the water
space of the boiler at a
distance sufficiently far
from the heating-surface
of the firebox to be un-
disturbed by any condi-
tion that may arise within
the firebox. These fea-
tures place the design of
the Jacobs-Shupert boiler
upon a plane which, from
a purely mechanical point

EAE oD

 

Fic. 23.—Looking toward door-sheet of Jacobs-Shupert
firebox during process of assembling.

of view, is essentially higher than that which is occupied by the normal
radial-stay boiler. The fact also that in the manufacture of these boilers,

32
ADVANTAGES OF THE

the principle of interchangeability is

JACOBS-SHUPERT BOILER

employed, establishes a standard

of workmanship which has never before been reached in the construction

of large boilers. This superior work-
manship will not in the long run in-
crease the cost.  Interchangeability
in machine construction has operated
to improve the quality of the machine

and also to reduce its cost. Similar
results will ultimately follow the

adoption of interchangeability in boiler
construction. In the manufacture of
the Jacobs-Shupert firebox, machinery
is used instead of men. Each oper-
ation is simple and yet the result is pre-
cise. There is no drifting of holes and
no local heating of plates which have
been set in their places in the boiler.
The result of the new process is a
boiler accurately made, substantially
put together, and comparatively free
from initial strains.
the methods of com-
bined to be
sarried, and provide an inexpensive

The design and
manufacture
permit repair parts

procedure in maintenance.
31. The Jacobs-Shupert — boiler
judged by the standards of good de-

 

Kia. 24.—Straight throat-sheet showing
jig bolted in place ready for drilling
rivet holes.

sign is obviously less susceptible to the weakening influences of low-water

conditions than the radial-stay boiler.

In the Jacobs-Shupert boiler the

Inside Channel
_/ Section 7

Throat Sheet rae
Stay Sneet cE 1 ali |

   
 

         
  
   

Outside Chanuel Section

Fic. 25.—Method of lapping the joints
and making the connection at the
mud-ring.

fastenings which must be depended
upon to hold up the crown are so far
removed from the heat as to be com-
paratively unaffected; whereas, in the
radial-stay boiler they are actually in
the fire. Its superiority in this respect,
while apparent as a matter of design,
has now been abundantly demonstrated
by the results of tests under low-water
conditions, described in Chapter XI.
32. As a safety device, the Jacobs-
Shupert firebox derives from its sec-
tional form the same advantage which

the water-tube boiler derives from the subdivision of its heating-surface

into tubes of moderate size.

If for any reason, such as the occurrence of

low water or the accumulation of scale, the firebox fails, the worst thing

oO
33
TESTS OF A JACOBS-SHUPERT BOILER

which can happen is the blowing out of a single section. In this case the
plate will “pocket,” and the rent will be small. The result will not be an
explosion, but merely a discharge of steam and water into the firebox

 

Fic. 26.—Looking toward crown of Jacobs-Shupert firebox.

which extinguishes the fire and relieves the boiler from pressure without
doing serious injury to life or surrounding property. The Jacobs-Shupert
boiler may, in fact, properly be characterized as a “safety boiler.”
VI. The Jacobs-Shupert Boiler in Service

33. Having agreed to make a study of the Jacobs-Shupert boiler, it
became desirable for the undersigned to make use of such sources of infor-
mation concerning this new type of boiler as were open to him. One
conspicuous source was to be found in the one hundred and sixty-nine
locomotives having Jacobs-Shupert boilers, which were in service along
the line of the Santa Fe Railway. It was determined, therefore, as a
preliminary to the more scientific aspects of the study, to make a trip of
inspection for the purpose of ascertaining the behavior of the boilers as
they were to be seen when in service on that road. In carrying out this
purpose, Inspections were made late in November, 1911, at the Argentine
shops near Kansas City, at the principal shops of the road in Topeka,
Kansas, at the roundhouse at Newton, Kansas, and at the roundhouse
and shops at Clovis, New Mexico, at each of which points a considerable
number of Jacobs-Shupert fireboxes were handled. A Mallet-compound
fitted with a Jacobs-Shupert firebox was also ridden on the division west
of Clovis.

34. The Argentine roundhouse was found to be handling twenty-
five Jacobs-Shupert fireboxes. Most of these at the time of my visit were
out on the road, but two were found in such condition as to admit of inter-
nal inspection. These were the boilers of locomotives Nos. 1485 and 1494.
Both locomotives were equipped for using oil fuel, and both were reported
as having been in service about a year. The sections of the firebox of
locomotive No. 1485 were in perfect condition, and nothing could be found
either upon them or upon the joint between them and their stay-sheets
to indicate that they had ever been worked upon subsequent to their in-
stallation. Some calking had been done in the joint between the forward
section and the tube-sheet and work had been done on the tubes, but the
structure of the firebox was in excellent condition. The presence of brick-
work common in oil-fired locomotives prevented a close inspection in the
vicinity of the mud-ring, but no indication of leaks at that point could be
discovered. Locomotive No. 1494 was found in a similar favorable
condition. Its tubes were tight and all parts of its firebox perfect. The
boiler had just been washed out, and it was possible by inserting electric
lights through the washout holes to see a good deal of the water side of the
sections. They were found evenly coated with a thin scale, presenting
no signs of rust, of pitting, or of other forms of local deterioration. In
this roundhouse also the interior of the firebox of locomotive No. 1460 was
examined. This locomotive is in all respects similar to those already
described, except that it is fitted with a radial-stay firebox. It was in

the same service as those previously examined, was being fired with oil
35
TESTS OF A JACOBS-SHUPERT BOILER

as were they, and was said to have been in service for about twenty
months. The tubes and a good many stays widely distributed over the
firebox were leaking slightly, but the firebox was otherwise in good condi-
tion. The boiler was cold and a boiler maker was inside calking stay-
bolts. Oil firing is likely to be hard in a locomotive firebox, and this boiler
was older than the Jacobs-Shupert boilers previously examined, but after
making all allowances, one could not escape the impression that in their
resistance to the deteriorating influences of service, the Jacobs-Shupert
fireboxes were disclosing superior qualities.

35. At the Topeka shops there was an opportunity to inspect the
oldest’ Jacobs-Shupert firebox in service. It was on the Santa Fe type,
locomotive No. 917. It had been in heavy service, oil-fired, for a period
of two and a half years and was at the time of inspection undergoing
heavy repairs. The necessary work on the boiler had been completed,
but work on the machinery was still in progress. An examination of the
firebox showed that some small cracks in the upper part of the tube-sheet
had been plugged in the course of service repairs. The repeated rolling
of tubes had had the usual effect of extending the tube-sheet upward,
and the firebox section attached thereto had rolled up with it without
injury. The firebox of this boiler was a large one, it being made up of
thirteen sections. As a result of overheating, due doubtless to accumula-
tions of scale, small pockets had formed on the first six of them, counting
from the tube-sheet back. At the time of inspection these had been
heated and set back in the process of repairing, and as some small trans-
verse cracks had appeared, the oxyacetylene flame had been used to add
metal and to weld up the defects. The area of surfaces on the several
sections which had been thus treated varied from a half inch to two inches
in diameter. By this simple process a damaged crown had been made
entirely good. The sections were in perfect form and it was said that the
boiler had been subjected to a hydrostatic test of 350 pounds. These
facts are important as disclosing the ease with which the new type of fire-
box, after suffering damage, may be repaired. At the Topeka shops I
inspected also the interior of the firebox of locomotive No. 3009, a new
Mallet-compound which went into service only three months previous to
my visit. This locomotive was in the shop after having been in a head-
end collision. Its firebox is the largest in service, being made of fifteen
10-inch sections, making its length 150 inches. The condition of this
firebox was perfect.

36. The Pecos division of the Santa Fe is equipped for its freight
service with forty or more very heavy Mallet-compounds. All of these
have Jacobs-Shupert fireboxes. They are fired with coal and work heavy
trains over long grades. The feed-water is alkal, and it is necessary to
cool, empty and refill all boilers after every round trip. Locomotive No.
1162 was ridden from Clovis to Blacktower. The train consisted of 42
loaded cars and a caboose. The atmospheric temperature was about

36
JACOBS-SHUPERT BOILER IN SERVICE

 

freezing, and the entire distance was up a 0.6 per cent. grade. In a five-
mile run the engine had accelerated its train to a speed of 25 miles an hour.
The rate of firing during this portion of the run was not far from 5,000
pounds of coal an hour. The steam pressure which was 210 pounds at the
start, increased during the first five miles run to 225. These conditions,
I understand, are typical of those which determine the service which must
be withstood by the Jacobs-Shupert firebox in the Mallet-compounds of
the Pecos district.

37. At Clovis, a division point in the Pecos district, an inspection
was made of the interior of the fireboxes of two of these locomotives, No.
1158, which went into service nineteen months ago, and No. 1162, which
has been in service about one year. No. 1158 had been in the roundhouse
but a short time and was in the process of being cooled off. No. 1162
was cool, and the boiler maker was giving attention to three tubes which
showed slight leaks. With this exception, both fireboxes were in perfect
condition. No sign of a leak could be discovered about the mud-ring or
between the sections or elsewhere within the structure of the firebox.
Taking advantage of the fact that the construction of the Jacobs-Shupert
firebox permits every part of the water side of the crown-sheet in a boiler
ready for service to be closely inspected, a process impossible of execution
in a stayed firebox, the water-space of No. 1162 was carefully examined.
The tubes of the boiler presented rust spots or incipient pits, due doubt-
less to the nature of the feed-water used, and at rare intervals similar
spots appeared on the sections of the firebox. Except for this, the water
surfaces were perfect. There was no evidence of localized rust-spots on
the sections of the firebox. At Clovis also a stay-bolt firebox on the bal-
anced compound passenger engine No. 530 was inspected. This boiler
was reported to have been in service about one year. Many of the stay-
bolts had been worked upon and many had lost their heads. The stay-
bolts along the lower portion of the side-sheets were seeping and the plate
was beginning to bulge between stays.

38. The inspection at Clovis ended the detailed examinations of fire-
boxes. The five days’ experience on the line of the Santa Fe justifies the
following conclusions:

1. The construction of the Jacobs-Shupert firebox admits of easy and
thorough inspection.

2. The Jacobs-Shupert firebox gives no trouble by leaking at the
mud-ring. Not a single case of a leaky mud-ring could be found.

3. The fireboxes give no trouble by leaking between sections.

4. No indication could be found of grooving or cracking at the fillet
or in any other part of the sections making up the firebox.

5. The fireboxes examined, while very large, appear to resist perfectly
the pressure imposed, which in all cases was above 200 pounds.

6. The firebox structure of a Jacobs-Shupert boiler after a year of
service in a district of alkali water, appeared as though new, while that

37
TESTS OF A JACOBS-SHUPERT BOILER

of a radial-stay boiler in the same service for the same or a lesser length of
time presented unmistakable evidences of degeneration.

7. Evidence was not lacking to prove that minor defects, such as
those which may arise in a Jacobs-Shupert boiler from accumulation of
scale or because of low water, are easily repaired.

Since the inspection of the undersigned, that is, since November,
1911, it has been reported that defects have appeared in some of the older
Jacobs-Shupert boilers. These have arisen from a faulty arrangement
of longitudinal stays. In the boilers affected the back head is braced by
comparative short stays secured to certain of the outside or wrapper-sheet
sections. The sections being curved are not well suited to meet the loads
imposed by the stays, and it is not surprising that some of them have
suffered. The obvious remedy is to be found in extending all longitudinal
stays through to the throat-sheet or to the barrel of the boiler. By so
doing, they will be removed from all connection with the sections. I
understand that the present practice of the Jacobs-Shupert company
provides for this change in construction.

38
VII. Program of Tests and a Description
of the Means Employed in Carrying it Out

Program of Tests

39. For the purpose of determining the performance of the Jacobs-
Shupert boiler as compared with that of a radial-stay boiler, an elaborate
series of tests was outlined. The outline embraced the following provisions:

The boilers to be tested were to be designed for locomotive service
and to be identical in their general dimensions. They were to differ from
each other only in the construction of the firebox and in the means
employed for supporting it. One boiler was to be equipped with a
Jacobs-Shupert firebox and the other with a radial-stay firebox conforming
to the best present-day practice.

A laboratory was to be provided in which the two boilers could be
erected and equipped with all apparatus necessary for testing. The tests
specified were to be grouped into three series designated as Series A, B,
and C, respectively.

Series A was planned to disclose the relative amount of heat absorbed
by the fireboxes and by the tubes of the two boilers under similar condi-
tions of operation. To facilitate these tests, it was proposed to have the
boilers constructed with a partition separating the water space into two
compartments, one of which was to include the firebox surface and the
other the tube surface. In carrying out the tests, these compartments
were to be separately fed with weighed water. Not less than three tests,
one at low power, one at medium power, and one at high power, were to
be made upon each boiler. It was believed that the results would serve
to establish the relative value of a unit area of firebox heating-surface as
compared with that of a unit area of tube heating-surface, facts which
American engineers have long desired to know, and that they would dis-
close the difference, if any, in the heat-absorbing capacity of the two
fireboxes tested.

Series B was to be made up of tests of normal boilers. The boilers
which had served in the tests of Series A were to undergo such reconstruc-
tion as might be found necessary to the removal of the partitions. This
accomplished, there would be available for the further work a normal
Jacobs-Shupert boiler and a normal radial-stay boiler. Each boiler was
then to be subjected to a series of evaporative tests for the purpose of
establishing its evaporative efficiency and capacity under different rates
of power. In addition to data usually secured in boiler testing, it was
proposed to make of record such information as might be possible concern-
ing the circulation of water within the two boilers. The purpose of this
series was to secure an accurate measure of the evaporative performance of
the Jacobs-Shupert boiler and of a normal radial-stay boiler.

Series C was planned to disclose the relative strength of the two
boilers under low-water conditions. In preparation for the tests of this
series the boilers were to be removed from the testing laboratory and set
up with everything necessary to their operation in a location where their

39
TESTS OF A JACOBS-SHUPERT BOILER

explosion would result in no harm to surrounding property. Adequate
provisions were to be made for the safety of observers. The boilers were
to be operated, the supply of feed-water was to be cut off or so controlled
that the firebox would be uncovered, and the low-water conditions were
to be continued until failure occurred.

The tests contemplated by this outline have now been entirely carried out.
It is the purpose of the present chapter to present in detail a description
of the boilers and of the apparatus and methods employed in testing them.

Design of the Boilers

40. The boilers tested are shown in their general dimensions by Fig.
27. Drawings showing the detailed construction of both boilers are pre-
sented as Figs. 28 to 36, inclusive. The firebox-end of the Jacobs-Shupert

7 2) ha = ©
| |

IIH

10 ”-_

 

 

 

RADIAL-STAY BOILER

Fic. 27.—General construction of test boilers.

boiler was taken at random from a lot which were under construction
for a railroad company. No effort was made to have the particular one
chosen stronger or better than the others which were going through the
shop. In its dimensions and in the specifications which controlled in its
construction, it conformed to the requirements of the railroad company

in question. The boiler complete was made by the Jacobs-Shupert United
40
PROGRAM OF TESTS

 

 

 
 

 

JOAN, 84----sooedg penby oF ,00I—

UI F190 ION erp Ff SPOaTY XOG-aayT

nbg. 86

 

t 84601

—sooedg penbg-0f—001

|

     
            

 

01S

  
      

 

MU EGSle— —

        
              

IID) papjaas na

: | | SABg Madd JT S901
af skeqg madoguT 91 4. seg

VED 18 “06 ‘SPANL

‘IgTIog ylodnyS-sqoove Jo SULMBIP [eIaUaD—'gz ‘DI

  
    

OCG

soquy;s

        

yysuay Papjam wWrog

“RTP iG 068 “SPADE

 

41
TESTS OF A JACOBS-SHUPERT BOILER

 

States Firebox Company at Coatesville, Pennsylvania. In order to secure
a radial-stay boiler of the same general dimensions as the Jacobs-Shupert
boiler, it was found necessary to build one especially for the tests. The
order was executed by The Baldwin Locomotive Works, subject to the
specifications and standards of the same railroad to which the Jacobs-
Shupert fireboxes were being supplied.

41. In addition to the inspection of the railroad company, both boilers
were built in the presence of a personal representative of the undersigned.
All materials employed were subject to the usual inspection and test, and
a record of these tests is in the possession of the undersigned. Reports
were received daily as the work progressed. The whole purpose was to
secure two boilers, each of which should be entirely representative of the
type it was designed to represent. The purpose was to secure a normal
Jacobs-Shupert boiler and a normal radial-stay boiler.

42. The dimensions of the boilers are as follows:

Jacobs-Shupert Radial-stay

Boiler Boiler
Type of boilefssicacs2e4c04g0chinsannacsgaaeasae Pxtendéd Extended
wagon top wagon top
Dratt-appliances: a seaadus pelea ee eee ae See Fig. 7. See Fig. 44
Grates, oil burner, brickwork, brick arch......... See Figs. See Figs. 45
and Ue and 46
Boiler Shell—
Diameter at front-end........................ 70” 70”
Diameter at throat............0.0......0.0-. 8376" 8374"
Tubes—
ING ber ase ice ea Pe ore rg ee ae ihe ey 290 290
Renee ee nee nie 19/2" 18/2”
TDA MOTE cece, We eae oa pee a ee Pardee ee ees Ql” Quy”
Firebox—
Length; insid@a.cee. ten 7 teens 3 cede eect aeees 9' 154” 9/1146"
Wadthicinside@re <as\edan neem annie etka toa a aes 6’ 43.4" 6’ 444”
Depths: inside.escc/ cca eee Ae ete dee od, 6’ 145” 6/ 223”
Grate area, square feet..................0-... 58.14 58.07
Heating Surface—
Side- and crown-sheets, projected area.......... 146.2 146.6
Side- and crown-sheets, developed area, used in
all:computations: .4 cvsos bes 4084 se cdaaen ees 168.0 146.6
Back tubessheets cin stoke ices ot pote iar ain 28.9 Q7.5
Door-sheetiaus; eosin aero aces Somme ae 33.9 32.6
"Potalehrebowss socks ca bey see eee ee 230.8 206.7
Tubes... Bris las CROHNS Vince Gone GET ENN 2759.0 2759.0
Ter pe an be Succi ie be teat un necna et ae ea 18.6 18.6
‘Total: Darrell 25.06 ioe Ven tee eae eas ees 2777.6 2777.6
Total boiler. . : Sat aoe: 3008.4 2984.3
Distribution of heating- surface applicable to tests
of partition boiler (Series A)—
Side and crown-sheets...........00.0000 000055 168.0 146.6
Door-shee tes ssce pies ees Maes ye een a ene 33.9 32.6
Total surface effective in transmitting heat to
firebox ends. .ca54cegeae Hasek Sino een 201.9 179.2
ET ib Gate oe ea ieee ee eo ae ane ae 2759.0 2759.0
Front tube-sheet.........0..000 0000 ce eee eee 18.6 18.6
Back tube-sheet. . are 28.9 Q7.5
Total surface effective in "transmitting heat to
barreleeNnd otinccre sean ata o oe seen sees 2806.5 2805.1
PROGRAM OF TESTS

Jacobs-Shupert Radial-stay
3 Boiler Boiler
Ratio of total firebox surface to surface effective

in transmitting heat to firebox-end............. 1.14 1.15
Thickness of Boiler Sheets—

DIMOKE= DOK ae oriwee to wees ledaah ge tuwnea eu ae Ye" Vy”
Dell omit ring eva ceaews ae seer whet Be oe Hy”
Shell, front section...................0--00.. 34" 4”
Shell, middle section......................0.. aa’ agi!
Shell, ‘back sectionc. 6:45 cece oe ccen ey ean eae 1" 1"
Shell, throat-sheet............0... 00.00.0000. 14" i"
Shell, front flue-sheet........................ 1” Vy"
Firebox, crown-sheet.............0..00200005- 3g" ve
Firebox, side-sheets.........00..00..00 000000 3" Se
Firebox, back sheet, inside.................... 34" 3"
Firebox, back sheet, outside.................. 3" 3
Firebox, outside wrapper sheet................ Vy" Ye"
Firebox, section, stay-sheets.................. 34"

9 ff g lt

Firebox, back flue-sheet.................00...
Firebox Sections—

I
cc

4

|

INUIT Eee ar owe sere eo tne es hie Redeinsred se aro es 11
Wid tivo carpets antes rach ccc Meee glace teen ae coh 10”
Boiler Stays—
Crown-bars, number....................00--. Q
Crown stays, diameter...................000-. Wy”
Button head, stays, rows................0000. 10
Crown bolts, diameter....................0.. lly
Stay-bolts, diameter...................00.05. es
Rivets, Size—
Bolershellve were ee ete tet te eee Wy" Wy”
HirebOxs 1Nside yee d vaehiay hous ee he seromelis ethene 34” 34”
Firebox, outside. ..........0c0000sccceeeceues 1 1
MEU rin eee be eh en ed aah ache Me MELE he tate Let Leh

43. In Series A each boiler was divided into two distinct compart-
ments by the introduction of a partition between the firebox and barrel.
The partition was simply a back tube-sheet extended as a single flat plate (Fig.
30) to the wrapper-sheet and mud-ring, and riveted in place between the fire-
box and barrel. These partitions in position as they appear from the
barrel of each boiler are shown by Figs. 37 and 39. In Series B the regu-
lar flue-sheet was employed, which necessitated the removal of the parti-
tions. This was readily accomplished in the Jacobs-Shupert boiler by
cutting openings through the partition with oxyacetylene flame, thus
transforming the partition into a flue-sheet normal in form for this type
of boiler. Fig. 38 shows this flue-sheet viewed from the barrel of the
boiler as used in Series B.

44. The removal of the partition in the radial-stay boiler was a more
difficult matter. In this boiler the back tube-sheet was connected with
the side-sheet and crown of the furnace through the introduction of an
angle-iron, and it extended to the outside shell of the boiler and was
secured thereto between an angle on one side and the throat-sheet on the
other side. To make a satisfactory job it was found necessary to remove
the whole sheet. The rivets between the firebox and the angle were cut,
and the acetylene torch was used to cut out the sheet just inside of the

43,
TESTS OF A JACOBS-SHUPERT BOILER

 

shell, leaving the construction in the form shown by Fig. 40. A new tube-
sheet was thus inserted as shown by Fig. 41.

44a. In retubing the boilers after the reconstruction of their fireboxes,
all tubes were welded into the firebox tube-sheet. This was done in antici-
pation of the low-water tests (Series C) which were to conclude the experi-
mental work. This precaution was taken because low-water sometimes
allows the tube-sheet to be forced off the tubes with the result that the
failure is a tube-sheet failure. It was the particular purpose of the low-
water tests, which were anticipated, to subject the crown of the firebox to
conditions so severe as to bring about its failure, and it was thought best

  
 
   

Detail of
» Bottom Edge

 

 

 

 

  
 
  
  
  

  
 

 

 

 

 

 

 

 

 

  
 

 

 

 

   
    
 

 

 

 

 

 

 

 

 

 

 

 

 

 

       
 
  
      
      

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

«

 

 

 

 

 

 

ae

All rivets 74 dia,
iF Holes

|

 

ayaper Ta

 

 

SW e2
ae as of Flue Sheet
ae |

Naee yt
je AOS Me sy iy | Ee Located to suit
Ic q a <4 i | \ Cou k
1316" Hk 4 | KEDAA ao — He tei
L ! [ei 5S
al s \ —Hht KPa 4 \_
2 i] ill Pe :
2 i] iil) Roe pp FO
le it See Tes eo
| | i ice ) 314" high fe
| | | | 15 M4 a i] ar
| | ! Se 1 V7) al 3, /
| | con oA fy Ee a / | Be —<—+
|) iL aea SO AS NOs the
| | ! rg S et &| Enlarged a :
ai] | i” Z| Section at
| | a on A-A | (j(j.% a
| 2
| | Se
|
x |
| i
j (
Is
|
:
*

 

 

 

 

 

 

 

 

 

2 Vhreads ki, & Ly
2 |. Taper, 4 in} |
ae Vee |
a Mel a 4 é i
| OA} | (500 rag Bq ual Spaces—43 1434
i [LL =-t a a5 5-2-5 5-H OOO, OO OT)
| 8 BEBEIS eratgtala tg ahs eiareretete L iE

 

   
  

          
 
    

eee,

 

244" Taper Tap
Re&

 

Outside web,
eae Taper 4" in 12

Fic. 30.—Detail drawing of extended back tube-sheet forming partition between fire-
box and barrel.

44
OF

PROGRAM

TESTS

 

Po

 

 

 

O5 6050
OOSON G2
Solar

e SoOGo

2

o

S

xt ny DG OE

= GORO <O

St 5) eid

aE
808

OF
OOLDLPOLO,
| ADE Dt

5474" 16 EqualSpaces

Oe:

we

o
A)

6-0-0 -0-C-6-0-0-0-EF
m1

-C-0-0

-9-0-€

 

9514
¢ Sheet Cut to this line and Scarfed to suit
——

 

oot
. Be

5
-0-0-C

  
 

 

 

,
L
ww
5
*
Front
| The
L
Da
ae
ti

 

 

All Rivets 74” dia,

All Rivet Holes /" dia,

Fic. 31.—Detail drawing of back tube-sheet, Jacobs-Shupert boiler.

  

a oO
o 94 BML Spaces —o-

    
 

COO 0-00-05

‘0-0 -0-C—0c-p-9 |

        
 
  

Oo 0 |

  

 

oN

r

=

 

    

 

 

2 eee

 

  

 

Fic. 32.—Detail drawing of back head, Jacobs-Shupert boiler.

om)
TESTS OF A JACOBS-SHUPERT BOILER

to take every precaution to prevent this process being interfered with
by a premature failure of the tube-sheet. The advantage which might
accrue if the practice of welding the tubes were more general is to be seen
in the fact that throughout the tests of Series B which followed the refit-
ting, the tubes were always tight. The resistance of the welded tubes to
overheating under low-water conditions is referred to in connection with
Chapter XI in which the low-water tests are described.

The Arrangement of the Laboratory

45. The boilers having been completed, they were installed in a tem-
porary building erected to receive them on the grounds of the Lukens
Iron & Steel Company. They were erected side by side and each was
equipped for testing independent of the other. The general arrangement

 

 

    

 

  
 

hk
£
~

17

 
  
  

 

ht [esrvtsisy Bod [TS
LET TT be

atl rays
302.i}g Equal Spaces..'61" 0 He ar ae

 

 

   

 

     
 

69/6" in 27 E

 

   

 

 

 

 

 

| Lay off Holes from Mud

 

    

 

61 —

 

 

   
 

 

Fic. 33.—Detail drawing of throat-sheet, Jacobs-Shupert boiler.

of the boilers and their accessory apparatus as installed when oil was used
as fuel is shown by Fig. 42. A similar view (Fig. 43) shows the arrange-
ment as installed when coal was used as fuel. The piping for one of the
boilers is shown by Fig. 44, the detailed arrangement of brickwork neces-
sary to oil-firing by Fig. 45, and the arrangement of dampers and. brick-
work for the coal-fired tests by Fig. 46. A series of photographic views of

the laboratory are presented as Figs. 47 to 56, inclusive.
46
PROGRAM OF TESTS

 

46. The boilers were erected on concrete piers. The pier at the fire-
box end was given a flat surface and was a foot larger all around than the
mud-ring. Four cast-iron pedestals (Fig. 44) served to support the mud-
ring of the boiler 12 inches above the surface of this pier. When oil was
used as fuel, the necessary brickwork was built up from the pier (Fig. 45),
and when coal was used as fuel, the space between the mud-ring and the
pier was filled with steel sheets to serve the purpose of an ash-pan (Fig.
46). Dampers in these sheets supplied means for controlling the draft.

47. To permit the boilers to be operated under conditions common

 

|
Fic. 34.—Detail drawing of front tube-sheet, Jacobs-Shupert boiler and radial-stay boiler.

in service, they were equipped with a normal front-end arrangement and
stack, except that the usual netting was entirely omitted. A normal
exhaust pipe and tip was fixed to the bottom of the smoke-box, and suit-
able outside piping was provided to convey the steam generated by the
boiler to the lower end of the exhaust pipe. This arrangement provided
for a delivery of most of the steam generated through the exhaust tip,
and the steam thus discharged gave rise to the usual draft action. The
control of the draft was provided for by a valve in a 7-inch pipe (Figs.
49 and 52) which served, in the course of the tests, the purpose of the
usual locomotive throttle. As the steam passing it was reduced from the

pressure of the boiler to that of the exhaust pipe, it constituted an excel-
AT
TESTS OF A JACOBS-SHUPERT BOILER

lent point of observation from which to secure data concerning the quality
ofjthe steam discharged. The addition of a gage and a thermometer made
the whole arrangement serviceable as a calorimeter. Steam in excess of
that required to produce the necessary draft conditions was discharged

   
  
  

  
  

Keyl

DET |

yo

WAN,
{g

H

 
   
 

 

 

     

 

  
      
  

    
 
 

 

   

w
>
3 ©
wn 2
5 a
=| S
Te &
| on
z it
an |
& |
a or Yap
= AN | ge
| aD pS) <
Back Head)
Door, |e
Q

   

 

    

24 Equal Spaces 24%

 

 

 

 

 

 

 

 

 

 

  

=O OE Or LO ay OO
0-986 - 6-8 -___-- ——____——..

S Gaels,
oo

    

   
 
 

 

 

 

-—o91g2@ Equal Spaces. us
Fic. 35.—Detail drawing showing back head and section of radial-stay firebox

from a 3-inch blow-off pipe or was discharged by the safety-valves. The
boilers and connected steam-piping were well covered with asbestos cover-
ine. In all of these respects the equipment of the two boilers was
@.
identical. .
48. The laboratory as described by the preceding paragraphs served

In its operation, a staff of eight mic

for all the tests of Series A and B. io
, acting under the immediate supervision of Mr. J. F. Butler.

were employed
48
PROGRAM OF TESTS

 

 

 

 

   

         
   
  

| f eat kta |

linge fel /
The last 3 Threads nearest the Head |

tu be slightly larger in diameter ~

 

 

yi"
f°? 12 Threads

 
   

+2 Drilled Holes

   

No

 

Turned Steel Bolts

 

J

|

Ng” 4g

 

aa”
a

|

\"

Me Sony we >

Fig. 36.—Details of staying, radial-stay boiler.

49
TESTS OF A JACOBS-SHUPERT BOILER

 

 

Fic. 37—Photograph of partition in Jacobs-Shupert boiler from barrel of boiler. The
ele 5 ] . I . . .
partition separated the water space in two compartments for obtaining data in regard
to relative capacity and efficiency of firebox and flue heating-surface. Tests Series A.

 

Fic. 38.—Back tube-sheet in Jacobs-Shupert boiler as used in Tests Series B, viewed from
the barrel of the boiler. The partition was converted into this tube-sheet by Scutting
openings with the oxyacetylene flame.
PROGRAM OF TESTS

49. While the tests of Series A and B were in progress, an investiga-
tion was conducted by Mr. George L. Fowler, concerning the movement
of water within the boilers, the results of which are given in Chapter XII
entitled “Some Facts with Reference to the Circulation of Water in Loco-
motive Boilers.” At the conclusion of the tests of Series A and B, the

>

 

Fic. 39.—Photograph of partition in radial-stay boiler from the barrel of the boiler as
used in Tests Series A. Firebox-sheets and wrapper-sheets were attached to partition
by means of angle-irons.

boilers were dismantled, the covering upon them was removed, and they
were transferred to the ground selected as a site for the low-water tests
(Series C). An account of the re-equipment of the boilers for the low-
water tests, a description of the tests and the results obtained from them
constitute the subject of Chapter XI of this report.
VIII. The Relative Value of Firebox
Heating Surface and of Tube Heating
Surface as Determined by Tests of a
‘Typical Jacobs-Shupert Boiler and
a Typical Radial-Stay Boiler

50. Many years have passed since any effort has been made to estab-
lish by experimental processes the relative amount of heat absorbed by the
firebox and by the tubes of a locomotive boiler. In the meantime, boilers
have greatly increased in size and they have been so changed in their pro-

 

Fic. 40.—View in radial-stay boiler from barrel looking toward door-sheet after partition
had been removed following conclusion of Tests Series A. A regular flue-sheet was
applied for Tests Series B.

52
VALUE OF FIREBOX HEATING-SURFACE

 

portion that no measure of a quarter of a century ago can now be accepted
as applying to present-day practice. With the hope of making a contribu-
tion which would be of interest to the engineering profession, it was early
arranged that the tests to be undertaken by the Jacobs-Shupert United
States Firebox Company should include such a determination. In carry-

e000

eee

@
e
°e
-@
@
°
&e
@
@
&
@
@

 

Fic. 41.—Photograph in radial-stay boiler showing flue-sheet and staying of firebox previous
to start of Tests Series B.

ing out this purpose, both the Jacobs-Shupert boiler and the radial-stay
boiler as initially constructed were partitioned off by an extension of the
tube-sheet to the outside shell of the boiler. This partition separated the
interior of the boiler into two compartments. The compartments were
connected only through the medium of the steam piping, the arrangement
of which was similar to that of two boilers connected to a common steam
header. In the process of testing, both compartments received heat from
a single source; namely, the interior of the firebox, but each compartment
was fed from a separate supply of weighed water, and its output of steam

was dealt with as though it had been a separate boiler. The details of
53
BOILER

JACOBS-SHUPERT

A

OF

TESTS

 

(VY SeL9S) *$}89} pory-[lo oy} TOF posuvsre sv sioplog Surmoys ‘ATOyLAOGL’] SUISAT, JO WOLDS pUL SUOTVASTO ‘UL[|—*sF “OL

dang lo adiqyt

SS =

oysaluy wos} —
el

7 MOUIIAO IO = re ate o
= = ae

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

—— 0,0 ———- —

 

     

 

 

 

aes

 

 

 

 

“1
KS ISVS
| ae
g ro | | anyon”
addy AL EH VO Jou OL
J Z i
a S
& &
a
&

 

 

 

pug WoT PAS

 

 

 

 
se
4
4

SURFACI

=
i

HEATING

FIREBOX

OF

4
4

VALU

 

(‘q7 putw  solog) *s]s0] porY-[ROD OF posuvavy sv SIo[loq SULMOYS ‘ATOPVIOGL’T Surjsoy, JO UOLes puv suOT]VAdo ‘UL[I— ESF “PMT

 

 

 

 

 

 

 

 

 

   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

    

 

 

 

 

 

 

 

 

 

dy ‘adhd
| act
| ,
Ls
es
~0;29—— = eae
5 ,
i é adic as alte
Se 9 J y fs ~,
a> ‘ ae \
=| 8) i
}4-— AY ;
ar oak : fi :
Voi CT
SSS ©
| ayqoau,
= $5
a 4
& ee
adt,g SUL dtd b fey
uy YET & e
ym
ee
He el © Hs
} Uda af
eh adhe

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

55
BOILER

PERT

JACOBS-SHU

A

OF

TESTS

 

UMOYS JOY] YPLM [RoUapT sva Jeplog Avys-perpel
oy} Jo yuowdmbo oyy, “suryse} IoJ syuetosuvare soyyo pue suidid surmoys ‘replog yaodnyg-sqoove JO_LWOTVAIO [RIOUI)—" FF YT]

  

umd, 346

AATB aqo|D oun
By Jay 0 PAS a

Ll

 

 

 

  

(eo ee

 

=< $10} 99 [UTA O.LP-M OIA G-10.J— 9 og
——————————— 8S

 

a}01900,)

 

 

 

 

 

 

 

 

a! |

&
AABN AQOD AC

56
x-SURFACE

HEATIN(C

OF FIREBOX

VALUE

LLG |
|

“Jon sv posh SUAL
[BOO Uo AM S]}so} 10} SYXOGOAY ul LOMAYOLIG pue stoduiep jo JUSWISULLLY- —OF “OTL

 

 

ina

 

Layer
[eee fesse Sa] ea]

)

LI eat
[eee]

HH

 

 

e

 

\ /

 

 

‘pou su posn SUA [lo UdT S}So} AOj SUXOQ OI, Ut SHOMAOLLG jo JUOUOSULALDY- Op DIO]

Ssuruodg¢ LW

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

JOOS LOOP SPALMO] GULLOO]
‘JOoT[S LOOP apISuL JO pRaTTR
9 WOTOOS ASOASTRATT,

 

 

 

 

 

 

 

 

 

 

 

 

 

SaAUdIdg loo] Jo
SLLO.M- OLE

JO WOlooy [LUTPNyLSTOrT

 

I e—f SV_f

= OUT oO} fey ty al |

|__| 1

dh F 5 4
= | e & |
1 x yf |
| A
| ” tres | =
AT yt Tol pet ETO ;
| i — 489 - :

 

57
RT BOILER

7
Hy

JACOBS-SHUPI

A

Ts OF

\
4

nn
ri

 

‘sorplovy ysoy pure surdid jo yuswasuvse
‘soATRA-LjoFeS PUL SYoRIS svoqe spooy ‘sIaflog Jo UOTPWoOT Surmoys ‘AIOJVIOGL] Sutse} JO TOW} JO MATA JRIIUaH— pF “DIA
4 f : : ; I ! ! ae

.

 

sari
VALUE OF FIREBOX HEATING-SURFACE

the process may be perfectly
apprehended by reference to
the explanatory notes and the
tables of Chapter XIII.

51. The location of the
partition was such that the
heat transmitted by the tube-
sheet of the firebox was de-
livered to the barrel-end of the
boilers, and the evaporation
from this portion of the firebox
was weighed in with that of
the tubes. The observed data
(Cols. 37 and 38) give the a
actual weighings of water fed — Fic. 48—Photograph showing water-glasses and
to each portion of the boiler, gage-cocks arranged for Tests Series A. These

show water-levels in firebox and barrel when
the same were separated by partition.

 

and all items involving water
evaporated, which follow in the
tables, are deduced from these values, being based upon the observed
results referred to the actual surface which was effective in bringing about

 

Fic. 49.—Photograph of forward end of test boiler showing main steam discharge pipe and
controlling valve, the 3-inch relief pipe to atmosphere above it, and the electric pyro-
meter for indicating the temperature of smoke-box gases.

59
TESTS OF A JACOBS-SHUPERT BOILER

 

 

Fig. 50.—Two calibrated water tanks on left and fuel-oil weighing tank on right as arranged
for Tests Series A. Water was supplied independently to the firebox and barrel by
means of the separate water tanks.

\ 4

 

Fic. 51.—Another view of fuel-oil weighing tank on platform and receiving tank below.
After the oil was weighed it was discharged into the receiving tank from which it was
ted directly to the burner by gravity. ;

60
VALUE OF FIREBOX HEATING-SURFACE

 

 

 

Fic. 52.—Photograph showing draft-gages in front and behind diaphragm, gas sampler
for flue gases, and steam gages and thermometers in discharge pipe. The large valve
served a double purpose, namely, that of regulating the draft, and with the apparatus
behind it, as a throttling calorimeter. There were other calorimeters nearer the boiler.

 

Fic. 53.—Photograph showing firing platform of one test boiler. Scales in foreground
are for weighing ashes. Scales for coal are located near door of laboratory not visible
in picture.

61
TESTS OF A JACOBS-SHUPERT: BOILER

the result. The deduced values covering the firebox performance have been
obtained by multiplying the evaporation actually obtained by the ratio of
the total firebox surface to the
firebox surface effective in pro-
ducing vaporization in the fire-
box-end of this boiler. The
small increment, which by this
correction is added to the ob-
served evaporation of the fire-
box, is in the deduced results,
subtracted from the observed
evaporation of the barrel. The
effect of this correction is merely
to credit to the firebox and
debit to the barrel the heat
Fic. 54.—View at front of firebox, showing steam transmitted by the back tube-

and oil pipes to fuel-oil burner. Gage shows sheet. These statements are,

pressure in steam line. of course, applicable to both

boilers.

52. In the operation of the boilers constructed and equipped as
described, a series of conditions appeared which, while unexpected, were
interesting. It was found after starting fires under coldjboilers that the
firebox-end of the boiler would begin
to make steam while the barrel re-
mained comparatively cold. The
steam thus generated by the firebox
passed through the piping to the cooler
steam space of the barrel, where

 

much of it condensed. As a result,
the water-level of the barrel would
gradually rise and the water-level in
the firebox-end would fall. The prog-
ress of these changes soon made it
necessary to blow off water from the
barrel, and to feed water to the firebox-
end. This action operated greatly to
prolong the process of getting the
boiler into action. After the barrel
began to make steam, both com-
partments performed normally as two
boilers of a single battery, the qual-
ity of steam delivered from each Pye. 55 —Valve for controlling fuel-oil

 

being practically of the same value. supply to burner under boiler. A
li is obvious that the action as micrometer adjustment and calibration
; 1s rious the ac =

: : of valve provided a very delicate regu-
scribed had nothing to do with the lation of oil used during tests.
62
VALUE OF FIREBOX HEATING-SURFACE

differences in the design of the two boilers, but was a result of the manner
in which they were fitted up for the test in hand. The action occurred
in connection with both boilers. It was completely overcome by adding
a 2-inch emergency pipe connecting a washout hole in the bottom of the
barrel with a washout hole in the water-leg of the firebox. This connec-
tion permitted, during the process of warming up, the firebox-end to be
supplied with water from the barrel-end, and it established a channel for
circulation which was found to be necessary to normal action. The pipe
in question was provided with two valves and a drain between so that
the circulation could be effectually stopped after both parts of the boiler
were gotten into action.

53. The record of injector action for the two compartments, when the
evaporation for the whole boiler equaled 25,000 pounds of water per hour,
will be of interest as suggesting the constancy with which the conditions
of the tests were maintained. It is as follows:

 

 

 

BARREL FIREBOX
INJECTOR WATER INJECTOR WATER
LEVEL see eee Sekt Ae ee LEVEL
| ABOVE | ABOVE
ON OFF IN ACTION CROWN ON OFF IN ACTION CROWN
CLOCK CLOCK TIME IN SHEET CLOCK CLOCK TIME IN SHEET
TIME TIME SECONDS INCHES TIME TIME SECONDS INCHES
8-15 8-16 60 514 8-16 8-17 40 6.0
8-18 8-19 65 8-20 8-21 35
8-21 8-22 50 8-23 8-24 40
8-24 8-25 50 8-25 8-26 40
8-26 8-27 40 8-28 8-29 35
8-29 8-30 55 8-31 8-32 30
8-32 8-33 50 8-33 8-34 30
8-35 8-36 50 534 8-36 8-37 30 5%
8-37 8-38 55 8-38 8-39 30 |
8-40 8-41 50 8-42 8-43, 30 |
8-43 8-44 55 8-45 8-46 30 |
8-46 8-47 50 8-47 8-48 30
8-48 8-49 55 8-49 8-50 30
8-50 8-51 50 8-52 8-53 30
8-53 8-54 55 5 8-55 8-56 30 5.0
8-56 8-57 50 8-58 8-59 30 |
8-59 9-00 55 9-00 9-01 30
9-01 9-02 50 9-03 9-04 30
9-04 9-05 50 9-05 9-06 30
9-07 9-08 55 9-08 9-09 30
9-09 9-10 50 9-11 9-12 30
9-12 9-13 55 9-14 9-15 30
9-15 9-16 50 41% 9-17 9-18 30 56
9-18 9-19 55 9-20 9-21 30
9-21 9-22 50 9-24 9-25 30
9-23, 9-24 50 9-26 9-27 30
9-25 9-26 55 9-28 9-29 30
9-27 9-28 50 9-30 9-31 30
9-29 9-30 55 9-34 9-35 30
476 ene ana ne 51g

 

 

63
TESTS OF A JACOBS-SHUPERT BOILER

 

54. The tests upon the partitioned boilers are referred to throughout
this report as those of Series A. Nine tests were made with oil as fuel,
five upon the Jacobs-Shupert boiler and four upon the radial-stay boiler.
These were followed by twelve tests, during which coal was used as fuel,

 

Fic. 56.—Cinder trap over stack of boiler.
Samples taken in four positions.

six upon the Jacobs-Shupert boiler and six upon the radial-stay boiler,
The results of all tests are given in detail by the tables of Chapter XIII.
A summarized statement of the more significant facts developed is as
follows:

Series A. Oil Fuel

55. Numerical values which are of especial interest are presented in Table
1, and a diagram showing the percentage of the total heat absorbed by
the firebox as Fig. 57. The points plotted in this diagram include all
results as obtained from both the Jacobs-Shupert boiler and the radial-
stay boiler. Referring to Table 1, it will be seen that each pound of oil
burned resulted in the evaporation of from 15.9 to 13.2 pounds of water,
the amount diminishing as the rate of power is increased. The thermal
efficiency of the Jacobs-Shupert boiler under low rates of power may
exceed 80 per cent. and even under high rates of power it is above 70 per
cent. It can be shown that when the Jacobs-Shupert boiler is made to
evaporate 20,000 pounds of water an hour, it will generate 14.14 pounds
of steam for each pound of oil burned. It can be shown also from data
to be presented later in this chapter that at the same rate of power it will
generate 8.3 pounds of steam for each pound of Dundon coal burned, so
that a comparison of the results here presented, with others which are to
follow, makes one pound of oil in locomotive service equal to 1.7 pounds
of high-grade bituminous coal.

56. With reference to the distribution of work between the firebox
and the tubes, Fig. 57 shows that the fraction of the total heat transmitted
which is taken up by the firebox is greatest when the rate of power is low
Thus, when only 800 pounds of oil are being fired per hour, 54 per cent. of
the total evaporation is from the firebox surface, whereas when 2,200

64
E

SURFAC

\
=

HEA TIN ¢

BOX

\
4

FIRE

EK OF

‘
4

VALUI

 

 

 

  

 

mae
TI
LLL
89° §I

 

spunod
TOA
AO
aNna0da
Nad
ILVUOdVAA
ATVALNDA

 

 

 

XOHWFUIA
NI
NOLLVUOdVAA

TVL
LO
“INGO Wad

 

1s '6
Loh
66°24
Slt
69°6
66°6
16°9
63° L
06°86

89

spunod
IVLOL

 

In’¢
98'S
LE F
00°6
66°9
oS
OL F
TL F
60°76

4g

spunod
LORRI EL

 

 

9g

spunod
NOPMAILA

 

MAOH NAd AOVAMAG ONILVAP

 

OF AUVAdDS uda
LVUOdVAW LINATVALNOOT

IC LAR
TaN4d TlO—V SalMgs

68L°L]
O89'TS
FSS'TS
OOF OL |
966'86
69866
8°06
LEO TS
OFL TT

 

bg

spunod
TYLOL

LEST
TSLOL
LFL‘OI
OFS'G
OLLI
9STSI
O¢O'TL
60S TI
FONE

eg

spunod
TAMU EL

NnOy Wad
NOLLVUOdVAG, LNATVAINOG

oT6'IT 90LS
9F6 ‘OL OFF
SEL‘6 OST
TIED O6L
906°TL LILG
S89'TL CLS
LOG'6 668'T
Sor Ol SOFT
969 96L
Sg ST
spunod
xodaul
spunod
4wnoH
udd
TIO

YALA
40 SAHONI
WOVUHdVIG

fo
INOW NI
LaAvad

 

u-6-V
U-8-V
ULV
w9-V
f[-¢-v
f--V
{-$-V
f-0-V
{-1-V
e iB
T ~
LSaL
dO NOIL
-YNDISaG
TESTS OF A JACOBS-SHUPERT BOILER

 

 

 

 

 

S
oe in
te leas
ration in Firebox—

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

| | :
a 7 Stes reer oe | a ar >
S|
ee ee |_| ae
= |
om | |_|
2 ee ye re real eg eld
£8 7 | /
Bi el eae camel ee eat |
( = | | | | |5 Jacobs—Shupert Boiler
+2 | xy Radial Stay Boiler
Z eee
| | | | Oil |Burnea per Hour—Pounds
500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200

Fic. 57.—Ratio of evaporation in firebox to oil burned per hour. Test Series A—Oil Fuel.

pounds of oil are fired per hour, 40 per cent. of the total transmission 1s
through the firebox. This statement shows that the proportion of the
whole work done by the firebox is not only surprisingly large at its maxi-
mum, but that it continues to be large under all conditions of operation.
Translating the facts presented by these values given into measures which
are more readily recognized, and expressing them in round numbers, it
may be said that when served with 2,200 pounds of oil per hour:

The Jacobs-Shupert boiler will evaporate 40,000 pounds of water per
hour. Of this amount, 16,000 pounds will be evaporated by the firebox
and 24,000 pounds by the barrel.

The whole boiler will develop 1,200 horse-power, of which amount
nearly 500 horse-power will be developed by the firebox.

The average rate of evaporation per foot of heating-surface per hour
for the whole boiler will be 9.78 pounds.

The average rate of evaporation per foot of heating-surface per hour
for the firebox will be 49.59 pounds, and for the barrel 6.47 pounds.

The ratio of heat absorbed per foot of heating-surface by the firebox
to that absorbed per foot of tube heating-surface is as 7.6 to 1.

57. While the tests show the efficiency of the boilers when fired with
oil to be high, and while the results are very consistent, they can not be
accepted as constituting a basis of comparison which admits of a high
degree of refinement. This fact arises from difficulties encountered in the
maintenance of a satisfactory fire. The burning of oil in large quantities
within the firebox of a locomotive boiler presents a problem which has not
yet been perfectly solved. In the case of the boilers experimented upon,
the burner, the brickwork, and all other provisions affecting combustion
were made to agree with the practice of large railway corporations having
hundreds of locomotives oil-fired. The undersigned believes that the
results obtained at the testing plant were probably as satisfactory as any
which are obtained upon the road, but it was impossible in the mainte-

66
VALUE OF FIREBOX HEATING-SURFACE

 

nance of the fire to prevent deposits of soot upon the heating-surface. The
practice of thoroughly cleaning the heating-surfaces before starting fires,
and of afterwards doing nothing to them during the progress of the test,
resulted in abnormally high smoke-box temperatures and in the accumu-
lation of considerable quantities of soot which was required to be removed
at the end of the test. All results obtained under this practice were finally
discarded. Later recourse was had to sanding the tubes, a practice com-
mon on railroads. At regular intervals during the progress of the test a
scoopful of sharp sand was carefully distributed through the door into
various portions of the furnace in such a manner that the particles would
be taken up by the draft and carried through the tubes, cleaning them as
by a sand-blast process. While this practice gave cleaner tubes, it did not
clean the firebox, and an attempt was made to reach this portion of the
heating-surface by using an air-blast with sand. As a result of these
efforts systematically applied, the results obtained are fairly consistent,
but since it is known that the performance of the boiler was more or less
affected by the presence of soot, and since it can never be certain that
the extent of this defect was constant for all the tests made of record, the
results can not he accepted as constituting a measure of the relative per-
formance of the two fireboxes, which is satisfactory from a scientific point
of view. For this reason, also, no attempt has been made to elaborate,
through a complete heat balance, the computations of the oil-fired tests.

Tests of Series A with Coal

58. The more essential facts developed by these tests are set forth
in Table 2. This table includes the results of twelve tests, six
upon the Jacobs-Shupert boiler and six upon the radial-stay boiler. For
each boiler, two tests were made with Scalp-Level coal and four with
Dundon coal. The Scalp-Level coal burns with a short flame. Its analy-
sis (coal as fired) is as follows:

Per cent.
ISAS CAT DOL cats. baie eid fos. Ge ue ess ae he ew ele 75.90
Volatile: matters assoc ue lose deat states, VIORADS
IMIGISUUTE Ss Acs oaies eh ectece cheese ut sans ate kt ND tae eas 2.15

The Dundon coal is a long-flame gas coal. Its analysis (coal as fired) is
as follows:

Per cent.
Fixed carbon............ eT eI ee: her nen ae, ADL OS
Volatile matter.............00. 000000000 cece eee .. 84.34
IVI OIS tree tacts cote tear tiny Mere Goce vosns aeons 3.38
PAIS Tie mtn a epee ctae te ed Rerntieh eaten Pisce aout teetuee thas eet 12.74

59. The results show that under low rates of power either boiler will
give an evaporation of more than 10 pounds of water per pound of coal.

For the whole series of tests the evaporation is normally above 8 pounds
67
R

\
4

BOLLE

RT

\
4

4

SHUPI

JACOBS

A

Ok

TS

iS

k

T

 

 
 

 

 

 

 

 
 

 

98° 1S sec lL StS /  geotrE rFe'Sa | GOOTTT | SSF | uopund ro YU-oll-V
oe SS 66°11 9¢e°8 FLL ES esLso GBC TT | Sa uopun( Lb Y-ILI-V
o9'$ 0S OF 6L'S8 cae LOE FS G8OFL Sts'6 cEse uopund ; “Ls Y-OLI-V
| ‘ A a | 3 i :
666 10°68 ols T6°¢ | 19lte | LeF'or FSL'L SIF PaeT aes ||| tee U-6OI-V
OF OL to OF 60'¢ OLS 88°06 SOO'SL = 0898 688'9 FSET | pet dreog | TT U-80I-V
ses 66° SF CO F IL'6 C6 TS SOL FL | seerk | €o@'L | ToL | uopun(y | oT U-LOI-V¥
68°24 60°96 SF Il FO'S SL ae ese'ts | OFSS Ss GEOCST 666° uopund L'9 £-901-V
ss's FS°SE LLTL SF's a6 1¢ | Sores |  gaF'ga oS6'1L S8o'F uopund | Gok £-¢01-V
6E°8 Lo 8S T'S Teg LO OF 6L9°C6 | GE8TST 968'6 066% uopund | OF {-FOI-V
FLOL S§°¢S ors 06°¢ LL’ S& 8a6'°CS 6LE'9L 6T6'8 S6TS PAvT dpeog tF f-S0I-V
6L°8 FL St TLE 697% 60°08 | OS6FI 906°L TT69 G39'T uopun(d FT {-201-V
96°01 96° OF as F 10's F996 FIC TL 696°8 6TL'9 Foe PavT dpeog or f£-101-¥
- J == 7 = ae
ro gg 8g 4g 9g bs | eg 6g To | 9T | ST T
= | = |
spunod spunod spunod spunod spunod spunod
spun IVLOL TWaHHva NOAA TWLOL TAnuvVa NOAA
qaqa sv | = HaALVM
IvVoOO aad > - = = - - oes dO S@HONI ISGL
AW ALSTON" . Gana: | TV¥0O | WOVUHA ‘ao
at vad T¥OO AO -vid NOLL
NOLL MAOW UAd AOVAUDAS ONILVaAH wnoy uaa qaqa aNIn 0 : -YNDISad
-VuUOd VAT | fi0 aul auvaog ad NOILVUOdVA IN@TV ALND | AMOLSIOI LNOUT NI
LNGTV NOILVUOd VAY LNATVALAOD - LAV
-ATIDG |
Z FIVeL

TaNA TVOO—V Saluas(SLsaL

68
VALUE OF FIREBOX HEATING-SURFACE

 

of water per pound of coal. A comparison of the performance of the whole
boiler when delivering a definite amount of power, shows that the thermal
efficiency is from 8 to 10 per cent. less when coal is fired than when oil is
used as fuel.

60. The percentage of the total heat absorbed by the boiler, which
is taken up by the firebox when the fuel is coal, is shown diagrammatically
by Fig. 58. The points plotted upon this diagram fall into two series of
groups. The first located by double circles represents all results obtained
with Dundon coal, both from the Jacobs-Shupert boiler and the radial-stay
boiler. The second located by single circles represents results obtained
with the Scalp-Level coal. Neither boiler was equipped with the brick arch
during these tests. It is interesting to note that the short-flame coal is
at a distinct disadvantage as compared with the long-flame coal in giving
up heat to the firebox. When Dundon coal is used as fuel, the percentage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T zl ouG
(sea ome rae lf ee a L | = eo shh |
| —s Dundon Ceal
| | aearah a eer
ee | | 22 see eee eee
| | |< A a el =
| | Scalp |Level|Coal 5 Oe] |
| || | g |
) | | | & 3
a | > 2 sal
ee el Eas
(ee es ae eee pee hh ~ An | peers |
ia | | rt | | | 9°0 dacobsoshinert Hore) |
Lo "| | omen | | my oy Radi Stay Boiler _ ||
See | ee
2 a | |
cS | asi Dry Chal per Ho w—Pounds | |
1000 1200 1400 1600 ‘eh 2000 2200 2400 2600 2800 3000 3200 3460 3600 3800 4060 4200 4400

 

 

 

Fic. 58.—Ratio of evaporation in firebox to coal burned per hour. Tests Series A—Coal

Fuel.

of the total heat absorbed by the firebox varies from a little less than 50
to a little more than 30, depending upon the rate of power, the percentage
diminishing as the power is increased. When Scalp-Level coal is used,
the percentage is about 8 less than when Dundon coal is used.

61. If we assume the Jacobs-Shupert boiler to be evaporating 20,000
pounds of water per hour, the percentage of the total heat absorbed by the
boiler which is taken up by the firebox, is as follows:

Per cent.

Wihen- orl ismisedkas: fuel: siacats Choe tas de pee ea ea we 42
When long-flame bituminous coal is used as fuel. ....... 42
When short-flame coal is used as fuel... .............0... 35

This suggests the possibility of the existence of some relation between the
oo u

percentage of total heat which is absorbed by the firebox and the charac-

ter of the fuel. For example, it may be that the substitution of anthracite

for bituminous coal would operate to reduce the total work done by the
69
TESTS OF A JACOBS-SHUPERT BOILER

 

firebox below 35 per cent. The explanation is perhaps due to a changed
condition in the tubes rather than in the firebox. It may be that the freer
burning coal deposits less soot in the tubes and permits them to absorb a
larger proportion of the total heat delivered.

62. It will be of interest to note that with Dundon coal when the rate
of combustion equals 4,341 pounds per hour, which is near the highest
reached in firing the partitioned boilers:

The Jacobs-Shupert boiler will evaporate 35,405 pounds of water per
hour, of which amount 11,982 pounds will be evaporated from the firebox
and 23,423 pounds from the tubes.

The whole boiler will develop 1,026 horse-power, of which amount
304 horse-power will be developed by the firebox.

The average rate of evaporation per foot of heating-surface per hour
for the whole boiler will be 11.77 pounds.

The average rate of evaporation per foot of heating-surface per hour
for the firebox will be 51.92 pounds, and for the barrel 8.43 pounds.

The rate of heat absorbed per foot of heating-surface by the firebox
to that absorbed per foot of tube heating-surface is as 6.15 to 1.

A Comparison of the Performance of the Two Fireboxes

63. The Jacobs-Shupert firebox and the radial-stay firebox were
designed and constructed to have the same over-all dimensions. The
heating-surface of both fireboxes, as measured by their projected areas, is
substantially the same and is equal to 206.7 feet. But the curved form
of the sections of the Jacobs-Shupert firebox gives a developed area which
is greater than that of the plain surface of the radial-stay firebox. The
developed area of the surface of the Jacobs-Shupert firebox is 230.8 feet,
an increase over the surface of the radial-stay firebox of 11 per cent. This
increase in the heating-surface of the Jacobs-Shupert firebox is an incident
in the development of its design. The purpose of giving the sections of
the firebox the shape they have is not primarily that greater heating-
surface may be secured, but that a satisfactory structure may result.
Nevertheless, a question as to the effect of this increase in heating-surface
upon the amount of heat absorbed by the firebox, is one of some impor-
tance, and its determination constitutes one of the questions for which
the present series of tests was instituted. The results upon this point, as
set forth in detail by Chapter XIII and as briefly reviewed in the short
tables presented herewith as Tables 1 and 2, are not conclusive. While
results of individual tests may be selected which will show a considerably
higher percentage of the total heat absorbed to have been taken up by the
Jacobs-Shupert firebox than by the radial-stay firebox, their effect is neu-
tralized by the possibility of other comparisons involving results believed
to be equally reliable. The fact as developed by the results of 20 tests
seems to indicate that the difference in absorbing capacity of the two
fireboxes tested is not sufficient to be established by carefully conducted

boiler tests. Heat transmitted by a locomotive firebox is chiefly the
70
VALUE OF FIREBOX HEATING-SURFACE

result of conduction and convection; radiation probably plays but a small
part. Transmission by conduction is a function of differences in tem-
perature. If in the case in hand, a plane in the water space above the
crown-sheet is considered as receiving the heat and a parallel plane in the
firebox below the crown-sheet as the source of heat supply, the amount of
heat transmitted will theoretically be independent of the form of the
metallic crown-sheet between. Again, the convection currents have a
clear sweep over certain exposed portions of the firebox sections, but do
not reach other portions which are between the sections. It is not unlikely
that considerations such as these account for the results which have been
obtained. These statements apply only to the fireboxes. The results
which have been derived from the boilers as a whole are next described.
IX. Evaporative Tests of a Jacobs-Shupert
Boiler and a Normal Radial-Stay Boiler

G4. At the conclusion of the tests described in the previous chapter,
the boilers were reconstructed to such extent as was necessary to secure
the removal of the partitions, which in the previous work separated the
firebox-end from the barrel. A statement of the means employed in
bringing about this result will be found in Chapter VII. The reconstrue-
tion accomplished, there was available for the further work a normal
Jacobs-Shupert boiler and a normal radial-stay boiler. Tests upon the
normal boilers were first run using Scalp-Level coal as fuel and without
the presence of an arch in the firebox. This series was followed by two
tests in which Dundon coal, a long-flame gas coal, was used. After this,
the brick arch was added to the firebox and the program of tests prac-
tically repeated. The details of the process may be perfectly apprehended
and the results obtained easily understood by reference to the explanatory
notes and the tables of Chapter NHI. The tabulated statement Table
3 presented herewith covers the more important results which were
obtained from the entire series. A summary is as follows:

Results of Tests without the Brick Arch in Firebox

65. These are represented in Table 3 by tests 201 to 302, inclusive.
The series includes five tests of the Jacobs-Shupert boiler and four
tests of the radial-stay boiler when fired with Scalp-Level coal, and
one test of each boiler when fired with Dundon coal. The efficiency of a
locomotive boiler is highest when the power developed is least. For
example, referring to the first test (201), it will be seen that when the
Jacobs-Shupert boiler was fired with 1,315 pounds of moisture free coal per
hour it—

(a) Evaporated 15,293 pounds of water per hour.

(b) Evaporated 5.08 pounds of water per square foot of heating-
surface per hour.

(¢) Evaporated 11.01 pounds of water per pound of coal.

(d) Developed 443 horse-power.

(e) Developed an overall efficiency of 71.86 per cent.

(f) Developed an efficiency, excluding the grate, of 79.75 per cent.

66. The precise effect produced by increasing the load upon a boiler

is well shown by the values of the heat balance for the several tests run
ie
 

oa
WM
x
=
Z
on

PI

VAPORATIVE

‘
Hy

BOILER I

ATIVE

OMPAR

Y

(

 

10°49
SF oo
OL GL
oL' 08
46°19
ol 19
0g gL

8° sl

96°09
96° LE
66° FE
LO LE
If 99
L664
96 G¢
96'8¢
96°69
19° 1k

GL°6L

O4

ALVUo
ONIGONTONGA
LONGIOISAL

 

 

TS o9 848 SI | 699'T SL’ 61 cs SIT 6gs'9
L8°8¢ T3'8 66 | 860'T 10ST | 9L' 28 690°¢
or LO To OL | rs 898 FOOL T& 0¢ 966%
og 9k OL TT | 49 Str alg IL 66 166'1
06° L¢ 6L°8 | 06 00ST 16° a1 | 69 SOL L88'¢
9L°9¢ 6F'8 | 66 | COST 61ST 18 T6 986°¢
GL 69 49°01 | TS | TS8 SL OL L6°0¢ 99'S
o8 FL LPIL | 9°9 | SoP lo¢ 90° F6 L96'T
XOdsaYdIA NI HOUV HLIM
SO 6S | 60°8 | 66 | L8o'1 48° FT S8ETF 66°76 PSPS
Fo 9S 69h | LG LOFT GS OL L19°0¢ oL OTT 1s9°9
Go GE 182 Fo | 600'T Lo tL FOP OF I& &6 LOF'S
79 FS 86'8 6G | F601 L6° FL SCOTT 08 6 LOE
96°69 Fo'6 o's TTS cL 6 SOT'6S 9F oS TOS
69'9L 89 TI 6°9 S&F 10'¢ OSO FL TO 66 | o8o'L
TF 0S 19k 66 | S66‘T 86ST OLO'SF PL TIL FISD
00 6G LhLek 66 | ces‘l 6 ST CFO OF se ror | 066°¢
66° 8¢ 6'°8 96 | 8ST 8o'ST | F966 69°S8L LOPE
46°69 19 6 os 696 | 66 OL | 198°OS 8ST’ 09 GIFS
98° TL | TOIL | 89 STP 80°¢ | 660'S1 oP FG 6861
| Se eee [eee eS = Z|
xXOdddIA NI HOUV LNOHLIM
69 v9 69 6g 8g | bg SS TS
—— ooo — —__—_-—____— | — —=—— a =
‘ | spunod |
aauld Fault | qqaowaga “MH Wad spunod = spunod spunod
Pacrctunel eno ‘aH OL agqdo 1s AMA sovaras | Leese estes
ee : mTOVaUAS ‘dH ONILVORH MNoOH uma | “AMY! aNOH umd
AO NO EUs ONMEVGH NaTIO’ LVDS UTI | NoivuodvAa | (LL OS MEd | oS gaa

NOILVUOdVAG
INATVALNOD

TvYOO aad
Guy OLsIoWw

dO OLLVU | NOILVHUOdVAG, LNATVAINOT

| DNATVAINOT

AUOALSIOW

 

€ 1921
SLTNSAY AO ATAVL GASNAGNOD
yoary wmoynwM pue yUM—g SelIeag s}say

| uopunqdg

” ”
” ”
” ”
” ”
. ”
” ”

uopun(d
” ”
a ”
” ”
” ”
” »

Jar] djrog

9T

TWOO
AO
aNIM

f-10s-@
U-LOT-2
U-90t-
U-S0t-a
{-TOF-@
£-S0F-2
{-c0f-@
£-LOF-@

U-o0s-a
f-106-a
U-606-4
U-s0e-d
U-L00-2
U-900-2
{-£06-4
{-t00-@
{- 600-€
{-G00-d
f-1L0e-d

LSaL
AO
NOILYNDISAG
TESTS OF A JACOBS-SHUPERT BOILER

with Sealp-Level coal. For example, tests 201, 202, 204, and 205 repre-
sent in the order given an increased rate of power. A statement of con-
ditions and results is as follows:

 

SRESt mum DET 395004 Sak iawn eas a aye ea 201 202 204 205
Pounds of coal fired per hour............ 0.4 1,389 3,419 5,930 16,314
Thermal units for each pound of coal:
(a) Absorbed by water in boiler........... 10,687 9,327 7,532 7,388
(b) Lost by moisture in coal.............. 48 34 37 33
(c) Lost by moisture in air............... 49 53 114 64
(d) Lost by hydrogen in coal............. 486 497 500 514
(e) Lost by smoke-box gases.............. 1,979 2,731 3,992 4,675
(f) Lost by incomplete combustion........ 78
(g) Lost by cinders passing up stack....... 153 851 —- 1,078 1,012
(h) Lost by combustible in ash............ 1,187 679 291 185
(t) Lost by radiation and unaccounted for . 205 547 881 783
Total B. T. U. per pound of coal........ 14,872 14,719 14,425 14,654

By comparing the values in the horizontal lines, the changes resulting
from changes in the rate of power may be seen. First, it will be observed
that the number of thermal units absorbed by the water in the boiler
becomes smaller with each succeeding test. The loss thus sustained is
accounted for by the increased amount of heat which goes off with the
smoke-box gases and in the form of combustible material which passes out

of the stack as cinders.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

yf 67. The evaporative
He a rt performance of the boil-
Ei eee tee ers in terms of pounds
= Ho | of coal fired per hour is
Pe rt Bunlion Coa shown by Fig. 59. In
8 7 ae this figure the double
Sy TAM] :
le circles represent tests
= with Dundon coal and
ae the single circles tests
I 1 with Scalp-Level coal.
4-8 g15 Tests upon the Jacobs-
2 E ele tee Shupert boiler are indi-
a % | ox Radial Stay Botlel cated by the plaincircles,
oe | while the tests on the
ae | Polnds of Coal, Moisture Free, per Hour | radial-stay boiler : oon
1000_| 2000 | 3000 | 4000 | 5000 | 6000 indicated by combined
Fic. 59.—Water evaporated per pound of coal. Tests circles and crosses. The

Series B. Without arch. diagram represents all
results obtained. Tests
301 and 302 were run with Dundon coal, all others with Scalp-Level coal.

The long straight line represents the tests of the Jacobs-Shupert boiler when
T4:
COMPARATIVE BOILER EVAPORATIVE TESTS

using Scalp-Level coal, with a maximum error which is less than 3 per cent.
and an average error which is less than one per cent. It will be seen that
the line also represents fairly well the results obtained from the radial-stay
boiler, which are marked by crosses. Dundon coal gives a higher evap-
oration than Scalp-Level coal. A parallel line is drawn through the two
points representing the results obtained from the two boilers when fired
with Dundon coal.

Results with a Brick Arch in the Firebox

68. Upon the completion of tests 201 to 302, inclusive, described in
the preceding paragraphs, both boilers were equipped with firebox arches
supplied and installed by the American Arch Company. Thus equipped,
tests 401 to 501, inclusive, were run. A detailed description of the arches,
together with a discussion of their effect upon boiler efficiency, is reserved for
another place (Chapter
X). The present pur-
pose is to consider the
results in their relation
to the two boilers

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tested. = TH |-Sealp Level Coal
69. A summarized 118 ——
statement of the actual — [10 = 4
values appears in Table loz sal. ip ee
3 and the comparative ps 2 ie
performance of the two |*=
boilers is set forth by eae
Fig. 60. In the latter ae
figure, the long straight |_ 5 3
lineisdrawntorepresent | 3 Sa
as nearly as possible the /+¢ AG
points shown by circles, {3 BS see beseunerh Ealler
which are those of the |, = ol acacia a
Jacobs-Shupert boiler “é
when fired with Scalp- {1 as)
Tevel-coal. Te seill he 0 | Pounds of Coal, Moisture Free, per Hour

1000 2000 3000 4000 5000 6000 7000

seen that the line also . :
: Fic. 60.—Water evaporated per pound of coal. Tests Series
represents fairly well B. Withearc:

the points located by

crosses, which indicate results obtained from the radial-stay boiler. The
crosses fall lower than the circles which determine the location of the
line. Only one test representing Dundon coal is of record in this
group, and this (501) is a test of the Jacobs-Shupert boiler at the highest

rate of power developed during the series. In this test, the firing
75
TESTS OF A JACOBS-SHUPERT BOILER

was at the rate of 6,553 pounds of moisture free coal per hour. This
rate of firmg resulted in:

A rate of combustion equaling 119.38 pounds of coal per foot of grate
per hour.

An evaporation of 57,564 pounds of water per hour, or the equivalent
of 19.13 pounds of water per foot of heating-surface per hour.

The development of 1,669 boiler horse-power, or the equivalent of
one boiler horse-power for each 1.8 foot of heating-surface.

An evaporation per pound of coal, notwithstanding the high rate of
power developed, of 8.78 pounds of water.

The maintenance of an overall boiler efficiency of 65.34 per cent., and
of the boiler, exclusive of the grate, of 67 per cent.

70. It is unusual for boilers to be driven to such rates of power. At
the Purdue locomotive testing plant, as a result of its first fifteen years of
operation, the highest rate of evaporation made of record was 14.45 pounds
of water per foot of heating-surface per hour, obtained August 7, 1905, by
the use of Youghiogheny coal. At about the same time the report of the
Pennsylvania Railroad Company of the St. Louis tests was issued, by
which it appeared that the New York Central locomotive No. 3000 had,
while on the testing plant, been forced to a rate of 16.34 pounds per foot
of heating-surface per hour, which was the maximum for that celebrated
series of tests. It is in comparison with these record-breaking perform-
ances that the rate of 19.13 pounds obtained for the Jacobs-Shupert boiler
at Coatesville is to be considered. So far as the undersigned is informed,
it represents the highest rate of power to which any locomotive boiler has
been driven.

71. The conclusion to be drawn from the tests of Series B concern
evaporative efficiency and capacity. The results show that the Jacobs-
Shupert boiler and the radial-stay boiler, under all the various conditions
of the tests, operate at practically the same efficiency. There are indica-
tions that under very high rates of power the Jacobs-Shupert boiler has
some slight advantage.

72. Two boilers of the same efficiency will generate equal amounts of
steam for equal quantities of fuel consumed. Relative steaming capacity
is in the case of such boilers a matter of relative coal-burning capacity.
The superior strength of its firebox allows the Jacobs-Shupert boiler to be
fired to very high limits of power without injury. Its strength thus
becomes an indirect factor in extending its capacity. In this respect, the
capacity of the Jacobs-Shupert boiler excels that of the radial-stay boiler.
X. The Brick Arch as a Factor in Boiler

Performance

73. The tests of Series B afford an excellent basis from which to deter-
mine fie value of a brick arch in a locomotive firebox. Some of these
tests, Nos. 201 to 302, inclusive, were run w ith no arch; the others, Nos.
401 to 501, inclusive, were run with an arch. They involve both the
Jacobs-Shupert boiler and the radial-stay boiler. Sealp- Level coal was
used for some of these tests and Dundon coal for the others.

74. The arches used in these tests were, as previously noted, supplied

  
    
 

Note- See that arch tubes are spaced 40" apart

C.to C.at a point 60" from flue sheet
along the tubes ee

 

 

 

   

Section A-A

 

 

 

eae (oy —

eae 109¢"——

Fic. 61.—General_ drawing of brick arch as applied to Jacobs-Shupert firebox. Tests

Series B.
b | Wy >

(iy /

ele

 

Section A-A

« —i61—

 

a |
>

 

 

 

 

Fic. 62.—General drawing of brick arch as applied to radial- ey firebox. Tests Series B.
V7
TESTS OF A JACOBS-SHUPERT BOILER

 

and installed by the American Arch Company. They were substantially
the same for both boilers, but the curvature of the firebox sections of the
Jacobs-Shupert boiler made necessary some slight differences in design.
The arch as installed in the Jacobs-Shupert boiler is shown by Fig. 61,
and as installed in the radial-stay boiler by Fig. 62.

75. The evaporative efficiency of the boilers with and without the

arch is well shown by Fig. 63. In this figure the points shown as triangles

 

 

 

 

 

 

 

 

 
 
  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

|
12> arial SS a T q
eam Te . |

= ee |
1.6 Se Sal ee ee

v | yA. . With Arch-Scalp Level |

fy ee roa ieee Sel == | (ea
Peer a hea bel (eal

| Without Arch-Sealp Level 7 JN _ | , With Arch-Dundon

2S eee

5 SScclesst ;

a | | ASS = e| ~]
Qh = | eth aes % oe
og gz, Without Arch. = = .

sa 2 | Dindon— ~ Re
mS a tlie st eo) | | — SS
2 | | | E 4 |

© | 3a
Ope alee ee j i ae

ey i ll aa ie.

bE) Ss) a | Tests Without Arch | |
5-3-7 pt Ht ~—|

| | | 9) 9 | Tests With Arch | |
4 eee ail al =

z | ii
3s\— t— |

Lf | | | | |
jo el | Ss eae
Rn | |

S | |

Au | | —
0 Pounds of Coal, Moisture me per Hour
1000 2000 3000 4000 5000 6000 7000

Fic. 63.—The effect of the brick arch in firebox on efficiency.

represent tests (Nos. 201 to 302, inclusive) without the arch. Nine of
these tests were run with Scalp-Level coal, five on the Jacobs-Shupert
boiler and four on the radial-stay boiler. The long dotted line drawn
through this group of points may be accepted as representing the per-
formance of both boilers without the arch fired with Scalp-Level coal.
Similarly, the points located by squares represent results from both boilers
with the arch. Six of these points represent tests with Scalp-Level coal,
and the long full line may be accepted as fairly representing them. The
addition of the arch raised the performance of these boilers from that
represented by the dotted line to that represented by the full line, an
increase of 0.6 of a pound in the amount of water evaporated per pound
of coal. For example, assuming the boilers to have been fired with 6,500
pounds of Scalp-Level coal per hour, they will evaporate 7.35 pounds of
water per pound of coal without the arch and 7.95 pounds of water per
pound of coal with the arch, a gain of 8 per cent. Comparisons involving
lower rates of combustion lead to smaller gains when these are expressed
as a percentage of the evaporative efficiency. In the light of these experi-
78
THE BRICK ARCH IN BOILER PERFORMANCE

 

ments, it is fair to say that the addition of an arch in the firebox of loco-
motives using Scalp-Level coal, results in increasing the efficiency from 5
to 8 per cent.

76. The points representing tests with Dundon coal are three in num-
ber. One representing the Jacobs-Shupert boiler and one the radial-stay
boiler without the arch are shown on Fig. 63 as triangles enclosed in

-204-J/B

U yun For 924

a yunted| For|881

Due-to-€o
Ash|291 to le
e td Comb le
in Stack Cinders
1078

Due|to C ble

AL

Due to Escapin
83958

C

o-Hydr«
in 480
Due toM ure

e to Hyd n 1¢ to Moistu
in Coal in Coal 31
e to

ea
a
aa
—
oH
TN
oO
=
qa

0
in| Air jtt4
ue-to—Me

in|Coal 37

ND

Absor b
Boiler;

Absor vy
Boiler 7535

T|UNITS PER |PO

1500-—
|

|
Total Heat Units 14427

 

otal Heat Units
14
Fic. 64.—Comparison of heat balances of representative tests with and without arch.

circles, and one representing the Jacobs-Shupert boiler with the arch as a
square enclosed in a circle. A short dotted line is drawn through the two
points representing the two tests without the arch, and a short full line
through the one point representing the test with the arch. The differ-

ence in the location of these lines measures the effect produced by the
79
TESTS OF A. JACOBS-SHUPERT BOILER

arch. It represents an evaporation of one pound of water. Thus, when
6,500 pounds of Dundon coal are fired per hour, the boilers without the
arch will evaporate 7.7 pounds of water per pound of coal, and with the
arch, they will evaporate 8.7 pounds of water per pound of coal. This
means that with Dundon coal the addition of the arch resulted in increas-
ing the evaporative efficiency to the amount of 12 per cent.

77. The results of the heat analysis for two tests at substantially the
same rate of power, one with the arch and one without it, are presented as
Fig. 64.

78. The difference in the effect produced by the arch in connection
with the two grades of coal is doubtless to be found in differences in the
manner in which the coal burns. The Sealp-Level coal has only half the
volatile matter of the Dundon coal. The benefits to be derived from the
presence of an arch—the longer flame way, the better mixing of gases, and
the conserving of high furnace temperature—are all matters which affect
its combustion favorably, but the long-flame Dundon coal being in greater
need of these advantages, naturally profited most by the presence of the

<

 

arch.

80
XI. Low-Water Tests and Their Results

79. One of the principal advantages claimed for the Jacobs-Shupert
boiler is that of increased safety. This claim has been based upon the
fact that its firebox is made up of comparatively small sections, that the
rivets joining the sections are entirely in the water space of the boiler,
where even under low-water conditions they can not be exposed to the
direct action of the heat, and that there are no stays in side-sheets or
crown ending in the firebox. If low water occurs and the crown-sheet
becomes overheated, the parts most affected are the curved portions mak-
ing up the center of the sections, that is, the portions of the plates most

 

Fic. 65—The Jacobs-Shupert boiler on the way to low-water testing grounds over the
industrial tracks of the Lukens Iron & Steel Company. Note its size as compared
with that of the boiler of the mill locomotive.

remote from the joints. The excessive heating, therefore, comes at a
point which, by the design of the boiler, is best able to withstand it. It
is, of course, entirely conceivable that even under these conditions the
overheating may proceed to a point which will result in a failure of the
sheet, but it has been claimed that even in such an event, a single section
only will fail, that the plate will pocket and blow out through a compara-
tively small opening, and that the effect of the failure will be entirely
local. These assumptions, if true, make the Jacobs-Shupert boiler a safety-
boiler in the same sense that the modern water-tube boiler, so much used
in stationary service, is a safety-boiler. If the action described actually
takes place, there can be no explosions of a Jacobs-Shupert boiler such as
occur in the case of a radial-stay boiler when the crown-sheet comes down.
The confidence with which the claims for safety were put forth had been

greatly strengthened by the results of a test of a large Jacobs-Shupert
. : 81
TESTS OF A JACOBS-SHUPERT BOTLER

boiler which was made at Topeka, Kansas, in the fall of 1910. These
tests were most carefully conducted by Mr. H. B. MacFarland, and the
results as reported by him completely sustain the assumption above
stated. But notwithstanding the confirmatory evidence thus supplied, the
officers of the Jacobs-Shupert company early expressed the desire that
such tests be included in the series to be conducted by the undersigned,

 

Fic. 66.—Setting of Jacobs-Shupert boiler for low-water test. View shows concrete piers
and the substantial supports under the boiler.

 

Fic. 67.—Setting of radial-stay boiler for low-water test. View shows the substantial
concrete piers and supports identical to those under the Jacobs-Shupert boiler.
82
LOW-WATER TESTS AND THEIR RESULTS

 

Fic. 68.—General view of testing ground, showing location of boilers with reference to
each other, the shelter for the operating staff, the elevated fuel-oil tank, and the large
display board for indicating to guests in the pavilion the water-levels and steam pressures
during tests.

and these were, as a consequence, specified in the original outline. This
provided that at the conclusion of the evaporative tests, the results of
which have already been presented, both the Jacobs-Shupert boiler

and the radial-stay boiler
JACOBS-SHUPERT should be tested to complete

RADIAL STAY
: \S BOILER failure under low-water condi-

BOILER |X S

  
  
  
    
  
  
   

tions if that should be prac-
ticable.
80. The boilers have al-
214’ Water Line - 215” Water Line ready been described (Chapter
ta Oll Lane “Ye Oildane VII). Both were of the same

general dimensions, and both
were designed for a working
pressure of 225 pounds. As
has been previously stated,
the firebox-end of the Jacobs-
Shupert boiler was selected at
random from a number of
similar fireboxes under con-
struction at Coatesville on the
order of a railroad company.
There was nothing special
about it. It was, however,
fitted up under the scrutiny
/Fuel Oil Pump of a personal representative
i ree of the undersigned. It was

no stronger or better than the
Fic. 69.—Ground plan of testing field. others of the same lot.

o
v

 

 

 

  

3 Water L

Cperating Shelter i! i: y"Steam Line

Fuel Oil Tank :
Dispiay Board for Guests
TESTS OF A JACOBS-SHUPERT BOILER

 

81. The radial-stay boiler
was constructed under the spec-
ifications of the Santa Fe rail-
way by the Baldwin Loco-
motive Works under the
scrutiny of a Santa Fe in-
spector. It was inspected also
by a personal representative of
the undersigned, whose daily
reports cover progress made
and include — certificates — of
analyses and of tests made by
him, or in his presence, of the
materials entering into the
construction of the boiler.

 

Fic. 70.—The shelter for operating staff in low- These, however, are not im-
water tests, consisting chiefly of a Jacobs- portant to this presentation,

Shupert firebox behind an embankment of .
timber and dirt. Located about 200° feet except so far as they concern

from boiler. the details which failed under

the low-water tests, and this

report need not be cumbered by a full record of such statements. Those

facts which are most pertinent will be set forth in connection with the
discussion of the results of the low-water tests.

82. Preparations for the low-water tests received careful attention.

 

Fic. 71.—View of Jacobs-Shupert boiler in position after low-water test, showing water,
oil and steam pipes. valves and connections, the three pops and special water-glasses
and gage-boards.

84
LOW-WATER TESTS AND THEIR RESULTS

An extensive fill made up of refuse from the mill of the Lukens Iron &
Steel Company, extending up the valley of a small stream for a distance
of several thousand feet, remote from habitations, supplied an acceptable
ground. The fill was traversed by railway tracks over which the mill
locomotives and cars were constantly operating. Fig. 65 shows the
Jacobs-Shupert boiler on its way to the testing-ground. The upper sur-
face of the fill was fairly level, and at the point chosen for the setting of

 

CastIron =_2——~‘0j] Burner Port ‘ Oil Burner
Pedestals AirPortsBack Wall Supply Pipes to
Oil Burner

 

Fic. 72.—General arrangement of oil burner and fixtures and brick arch in test boilers in

low-water tests.

the boilers it extended to a width of approximately 200 feet. Each boiler
was set on two concrete piers, one under the firebox approximately 10 feet
square, and the other under the barrel of the boiler of much smaller
dimensions. These are well shown by Figs. 66 and 67. The location of
the boilers with reference to each other and to surrounding features of the
landscape is shown by Fig. 68, and the general layout of the equipment by
Fig. 69. A substantial shelter for those conducting the tests, consisting
principally of the firebox-end of a Jacobs-Shupert boiler, was established
200 feet from the nearest boiler (Fig. 70). In the rear of this shelter an
oil-tank was erected at such a height as would serve to deliver fuel-oil to
the burners under the boilers by gravity, and a small pump near the tank
served to take oil from a works tank-car which could be switched to an
adjacent track to this service tank. The Jacobs-Shupert boiler with its
connected piping, gage-boards, etc., is shown by Fig. 71. The radial-
stay boiler was similarly equipped. The boilers were fed with water by
means of an independent steam-pumping plant located on the bank of the
stream below the fill. A shelter was provided for the attendant of this
plant. A main feed line was laid directly from the feed pump to the
operators’ shelter, at which point it branched to each boiler, a valve in
each branch within the shelter permitting a control of the feed during the
progress of the tests (Fig. 69). The oil-supply pipe also branched at the
shelter, and each branch was provided with valves permitting control at
that point. These oil-valves, however, were not used except to shut off
85
TESTS OF A JACOBS-SHUPERT BOILER

 

the supply of oil when the boiler being supplied went out of commission.
The location of the oil-burner, the design of the brickwork and other
details of furnace arrangement are shown by Fig. 72. The draft which
during the low-water tests was supplied in the same manner as in the evap-
orative tests, that is, by dis-
charging steam from the boiler
through a normal exhaust
pipe and tip, could be con-
trolled from the shelter. This
was accomplished by having
a ratchet-wheel (Fig. 73) fit-
ted to the stem of the 7-inch
valve in the steam-delivery
pipe, and two levers carrying
dogs to engage the ratchet-
wheel. The action of one
lever served to open the valve,
while that of the other closed
it. Either lever could be op-
erated by pulling a wire at
the shelter, a counterweight
serving to return the lever to
its initial position. It had
been planned originally to ob-
serve the steam pressure and
Fig. 73.—Draft regulator for controlling the steam water-level by means of water-

flow through exhaust-pipe of boiler during glasses and gages located
low-water test. By means of wires the draft =
could be controlled from the operating shelter.

 

within the shelter, but the
possibility of errors appearing
in apparatus extended so far from the boilers resulted in a determination
to take these readings from apparatus immediately affixed to the boiler.
To make this possible two small telescopes were mounted on the top of the
operating shelter, by the use of which observers could read with greatest
ease the graduations and figures on the steam-gage, and observe accurately
the level of the water in the water-glass. One of these glasses is to be seen
in Fig. 70, and the instruments to be observed in Figs. 74 and 75.

83. Elaborate provisions were made for the comfort and conven-
ience of official guests. Upon the hillside above and to the rear and at
a distance of 600 feet from the nearest boiler, a pavilion (Fig. 76) was
erected having seats under roof for 300 guests. A telephone connected
the guests’ pavilion with the operating shelter, and a large display board
was erected to serve in keeping the guests at all times informed as to the
steam pressure and the water-level within the boiler under test. Adja-
cent to the guests’ pavilion was a refreshment booth from which lunch
could be served to guests arriving by morning trains. <A specially con-

86
LOW-WATER TESTS AND THEIR RESULTS

 

structed shelter for the accommodation of a moving-picture machine was
located on the hillside at a distance of approximately 300 feet from the
boilers. The opposite side of the valley, at distances from the boilers of
1,500 feet or more, supplied an abundance of room for those citizens of
the town and vicinity who might desire to witness the tests. Provisions
were made for effectively policing the limits of the testing-ground as thus
defined.

84. Thursday, the 20th of June, the day set for the tests, was ushered
in under a clear sky. The boilers which in anticipation of the day had,
after careful internal and external inspection, been declared clean and in
perfect order, were early under steam. Guests arriving in the middle of
the forenoon were given an opportunity to see all parts of the testing plant,
and later by the courtesy of Messrs. A. F. and C. L. Huston, were con-
veyed on a tour of inspection
through the extensive works of
the Lukens Iron & Steel Com-
pany. To facilitate such in-
spection, a number of mill cars
were fitted with wooden
bodies having longitudinal
seats for the accommodation
of guests. These cars in trains
of two or three were moved
rapidly from point to point
over the entire works and also
between the works and the
boiler-testing ground. Ladies
accompanying guests_were es-
pecially provided for in the
mean time at the home of
Mrs. A. F. Huston. Soon
after noon the company began
to assemble in the visitors’
pavilion, and by one o'clock
it was filled to overflowing.
The townspeople lined the op-

ia
ON ad a eS

a oe he
hed, See ee ae

 

Fic. 74.—Photograph of boiler head of Jacobs-

posite bank of the valley and Shupert boiler, showing special water gage-
all the country-side assumed glasses and gage-boards for indicating the

; . water-level in boiler during low-water tests.
a holiday aspect. The ground Readings were made from shelter by means
about the boilers had been of telescopes.

cleared of all but the expert

and his immediate assistants. "The two boilers which were to be tested
were both in action. The roar of their exhaust completely drowned the
sounds which otherwise {would have filled the valley. Soon after one

o'clock a telephone message received at the operating shelter from the
87
TESTS OF A JACOBS-SHUPERT BOTLER

 

Visitors’ pavilion announced the arrival of the last. train bearing invited

guests. The fire under the radial-stay boiler was immediately
suppressed and the steam blast) was shut off. The Jacobs-Shupert

boiler, the first to be tested, was brought under conditions which had
been carefully predetermined. The valve controlling the discharge
of steam from the exhaust tip was carefully adjusted until the draft-
gage connecting with the front-end indicated 6 inches of water. The
oil supplied the fire was next adjusted to give as heavy a fire as could be
sustained by this draft without black smoke. Preliminary tests had shown
that this condition of draft
and fire with the boiler’ in
question could be relied upon
to evaporate approximately
30,000 pounds of water per
hour, or 10 pounds of water
per foot of heating-surface per
hour. This condition is not
the maximum to which the
boiler could be forced, but was
accepted as representing that
which under road conditions
would be regarded as a heavy
normal load. Upon the report
from the attendants that the
predetermined conditions had
been secured, a committee of
three engineers consisting — of
Mr. Charles Ducas, Mr. J. F.
Butler, and Mr. P. C. Halde-
man were requested to inspect
carefully the boiler as it was
then operating and to report

 

Fic. 75.—Photograph of boiler head of radial- to the undersigned whether all
stay boiler showing special water gage-glasses conditions were in accordance

and gage-boards for indicating the water-
level in boiler during low-water test. Readings
were made from shelter by means of telescopes. or ten minutes this committee

with the program. After eight

returned to the shelter, report-
ing that all conditions, including the draft, the fire, the water-level, the
steam pressure, ete., were as stated, whereupon it was announced from
the shelter that the tests would begin.

85. The organization at the shelter was as follows:

Charles Ducas. Time-keeper. It was Mr. Ducas’ part to call out

a warning and to give a signal at 30-second intervals. Mr. Ducas also

made the necessary changes in the display boards, which served to indicate
88
LOW-WATER TESTS AND THEIR RESULTS

 

to the guests the condition of steam pressure and water-level after each
observation.

J. F. Butler. Observer of water-levels and checker of steam-gage
readings at Telescope A.

P. C. Haldeman. Observer of ga
levels at Telescope B.

A. M. Baird. Assistant in immediate charge of boiler operation.

H. S. Coleman. Log keeper.

W. Seachrist. Valve operator within the shelter.

W. F. M. Goss. Expert in charge.

86. The test of the Jacobs-Shupert boiler began at 1.48 p.m. Upon
signal from the time-keeper, observations were reported and noted upon
the log in the following order:

(a) Water-level
(b) Steam pressure
(c) Number of pops blowing.

ge readings and checker of water-

5

After these entries were complete, the check readings were announced.
By observing this order of procedure there was never confusion, though
the time interval between observations was short. The expert in charge
had before him a plotted diagram with the 30-second intervals marked off
as abscissee, and upon which he noted the water-levels as ordinates so
that the history of the tests at any particular moment was completely
under his eye. All changes in the setting of valves was in response to ver-
bal direction from the expert in charge. The procedure thus described
was persisted in without interruption until the test was terminated. The
water left the crown-sheet at 1.49% p.m., and its level steadily declined
for 34% minutes when it had fallen to the bottom of the special water-
glass 25% inches below the crown-sheet. The steaming capacity of the
boiler declined as the water-level fell. In the beginning, besides the steam
passing out of the exhaust pipe, a large volume was discharged by the
safety-valves, but with the fall of water-level the amounts thus discharged
diminished until the valves ceased to open. The pressure then declined,
the blast became less effective, the draft weakened, and the fire became
smoky. Twice the throttle opening was increased to stimulate the draft,
but the pressure ran down the more rapidly. Fifty-five minutes after
the beginning of the test upon the Jacobs-Shupert boiler, the water-level
had fallen to a point where the barrel of the boiler was less than one-fourth
filled, and the capacity of the boiler to generate steam had so diminished
that the draft conditions with which the test started could no longer be
maintained. The oil supply had not been changed and an enormous cloud of
black smoke issued from the stack. When the steam pressure had fallen
to 50 pounds, the low-water test of the Jacobs-Shupert boiler was ended.
It had been boiled nearly dry and no failure had occurred.

87. Immediately upon the termination of the test of the Jacobs-
Shupert boiler, fire was restarted under the radial-stay boiler. Approxi-
mately half an hour was required in which to bring this boiler to a condi-

89
TESTS OF A JACOBS-SHUPERT BOILER

tion of operation identical with that which defined the operation of the
Jacobs-Shupert boiler. The conditions when secured were announced,
the test was started, and the record kept in precisely the same way as had
been previously done. When the water had fallen in the water-glass to
a point which was 14’ inches below the crown-sheet, 17° minutes after
the water had fallen to the level of the crown-sheet, the spectators heard
above the steady roar of the exhaust a loud report and saw a great cloud

 

Fic. 76.—The guests’ pavilion erected on the hillside about 600 feet from nearest boiler
and some of the 500 guests. Telephone communication with operating shelter and
the display board served to keep the guests informed at all times of conditions in

the boilers.

of steam, rolling out in all directions from the neighborhood of the mud-
ring, quickly envelop the entire boiler and_ its immediate surroundings.
Every one understood that the test of the radial-stay boiler under low-
water conditions was over and that the boiler had failed.

88. Among those who witnessed the tests as invited guests were many
distinguished practising and consulting engineers, railway officials, college
professors and scientists, a committee formally appointed by the Master
Boiler Makers’ Association, and others having interest in the event.
Those from the City of Coatesville and vicinity, who occupied positions
of advantage along the opposite side of the valley, were estimated by
the newspapers of the city as from eight to ten thousand.

89. The arrangements incidental to the reception of special guests,
the policing of the grounds, and the handling of the crowd were all under
the immediate direction of the officers of the Jacobs-Shupert United States
Firebox Company and of the Lukens Iron & Steel Company.

90
LOW-WATER TESTS AND THEIR RESULTS

 

90. A detailed study of the tests supplies a more accurate definition
of what occurred. A copy of the log of the test of the Jacobs-Shupert
boiler is presented herewith as Table 4, and a copy of the log of the test of
the radial-stay boiler as Table 5. Prior to the beginning of the tests, a
tentative curve showing a proposed rate at which the water-level should
be allowed to decline was drawn, and an attempt to parallel this curve in
the actual test led to the feeding of both boilers for brief intervals in the
early part of the test. It soon became apparent, however, that the actual
curve would run above the assumed curve, and consequently no feeding
was employed except in the early part of the test. In the Jacobs-Shupert
boiler the feed was on for a total of 244 minutes during the first 5 minutes
of the test, after which the whole process was simply one of boiling away
the water contained by the boiler. In the radial-stay boiler the feed was
on 2 minutes during the first 7 minutes of the test only. The fall of the
water-level in both boilers is shown graphically by Fig. 77. In the execu-
tion of the tests, the main purpose was to secure a rate of fall in the water-
level which should be substantially the same for both boilers. The degree
of success in meeting these requirements is well shown by Fig. 77. This
figure also shows the steam pressure for both boilers throughout the tests.
It will be seen that both boilers lost water at substantially the same rate
for the first 2214 minutes of the test. At the end of this time, the radial-
stay boiler had failed, but the Jacobs-Shupert boiler continued in opera-
tion without diminution in the amount of oil burned for 3014 minutes
longer. The radial-stay boiler failed in less than 18 minutes after the
water was observed at the crown-sheet level. The Jacobs-Shupert boiler
was operated 53 minutes after the water was observed at the crown-sheet
level.

91. The water-levels entered upon the logs Tables 4 and 5 are those
actually observed from the water-glass attached to the back-head of the
boiler. The water column in the water-glass, however, was presumably
heavier than the mixture of water and steam within the boiler, and conse-
quently the surface of the water inside of the boiler must have been some-
what higher than the level observed upon the glass outside. The differ-
ence between the observed and the actual water-level within the boiler is
not easily estimated, and no attempt has been made to establish the actual
water level within the boiler, except as it was made apparent at the close
of the test by the color effects upon the heating-surface. It should be
clear, however, that the surface of the water within the boiler did not fall
below the level of the crown-sheet at the instant which the observations
indicate, and that the actual decline in the boiler for all portions of the
test lagged a little behind the record of the observed results.

92. Many of those who witnessed the tests received the impression
that the Jacobs-Shupert boiler did not steam as freely as the radial-stay
boiler. Two causes operated to give rise to such an impression: First,

it is true that during the first 6 minutes of the test of the Jacobs-Shupert
91
TESTS OF A JACOBS-SHUPERT BOTLER

LOW WATER TESTS—SERIES C

Log of Boiler Conditions During Test
Table 4 JACOBS-SHUPERT BOILER

TIMI MINUTES FROM LEVEL OF WATER STEAM NUMBER BOILER

30 SECOND TIME WATER WAS ABOVE OR BELOW PRESSURE OF POPS rr
INTERVALS) AT CROWN SHEET CROWN SHEET GAUGE, LBS. BLOWING WATER

  

 

 

   

1.48 pom. ahs 1” Above 295 3 On
1.4815 oe igo 220 2 Off
1.49 ot Ls se 220 2 On
1.4914 le 14" Below 220 2 Off
1.50 an | 1 See 220) Q "
1.5015 11, ie 290) ) a
1.51 RAs Tee = 220 2 On
1.51)5 Ql, eee es 290 2 a
1.52 ee 220 2 S
1.5216 Sle ee 220 2 Of
1.53 134” 215 1 fi
1.5316 415, 134” * 215 ] =
1.54 Oe hs. 38 220 2 a
1.5415 51 : 223 3 ¢
1.55 23 s 228 3
1.5515 61, ee ees bese 228 3 i
1.56 Sige «88 228 3 i
1.5615 T6 Lie 223 3 Ks
1.57 “6 hy 228 3 3h
1.5719 Sle 3 229 3 a
1.58 oe 1 229 3
1.5814 916 y Qage 3

1.59 ees # 222 3 .
1.5914 1016 ee 229 3

2.00 a5 e 229 3 or
2.0014 111, 7 222 3 :

201 ria . 0 2

2.0114 121% 220 Q

2.02 a 220 2 =
2.021, 1316 es 220 Q a
2.08 a 220 2

2.0314 144% es 220 2 ea
2.04 : 220 Q |
2.0415 1514 ts 220 Q | ee
2.05 ane ® 220 2 ce
2.0515 1616 ‘ 218 Q ee
2.06 s 218 Q es
2.0615 171% ce 220 Q

207 | i. 220) 2 fe
2.0715 181¢ ‘ 220 2 ae
2.08 ane 1308 OY 215 1 | of
2.0814 191¢ 13144" © 220 2 as
2.09 ee 1314" “ 220 2 a
2.0915 2014 13144" “ 220 2 is
2.10 Aare 13144” © 215 1 ss
2.1015 211, mee 218 2 8
er eh 15) 220 2

2.1115 291, 1534" “ 218 Q :
2.12 ep 1Ge fee 218 Q t
2.121, 231¢ 1615" 220 Q
2.18 . ee Tat Q15 ] ss
2.1315 241¢ Lie 220 2 | a
2.14 te Ine 215 1 s
2.1415 Q51¢ 1sly” Q15 | 1 | :
LOW-WATER TESTS AND THEIR RESULTS

 

TIME
(30 SECOND
INTERVALS)

15
16
1614
17
1715
18
1816
19
1915
20)
2015
oe
Q115
99 -

991

92

2.2316
Q 4

DW www WwW ww WW WW WH WW

wr
Nw

t
oO

a

a
é

2,94)

D125

é

t
wo

t

we
wo
oe
Ww

So
we
oO

©
wo
we

2.4116

2.42

2.4216
Test Stopped

 

93,

LOW WATER TESTS—SERIES C (Continued) Table 4
MINUTES FROM LEVEL OF WATER STEAM NUMBER BOILER
TIME WATER WAS ABOVE OR BELOW PRESSURE OF POPS FEED

CROWN SHEET | GAUGE, LBS. BLOWING WATER
oe 19” Below 210 1 Off
2616 ly” 208 0 i

a 20 tee 210 0

6 PIU RE Sr 208 0 y

ee 20%" " 205 0 a
2814 2" 200 0 .
ans Oe 200 0 a
291% gag 200 0 a
rae DO a a 200 0
\% QQle”" 200 0 es

igs OSes 197 0 .
31l¢ QB ss 195 0 ~
css 2334" | 195 0 fs
3216 DAL eS 190 0 BS
ee Wy" « 190 0 .
331% Qe" 187 0 as
OF ieee | 187 0 od

| Bw" 185 0 S

ie herr torencne 185 0 H

é lee ce eer 185 0 ee
ee fe ee 180 0 2
3616 Wier ten, 178 | 0 “
aoe Lea here a 175 0 2
Tete alii were eer eee 170 0 ce
cs leeMmeReirie nce ae: 167 0 “s
35 Ae We ere ew se 163 0 oS
A) ey yee ee ys 155 0 i
20cm | CMS REE Nears 150 0 “
aes 0 Af ee tae 145 | 0 -
AO Ue tienes tne 143 0 “¢
ewe ME Ce ys Deh 140 0 es
seca alll) entrants serio 130 0 i
Neen la Pee hee rere ace 125 9 se
4216 ett aoe: 120 0 ie
ee en Mee Cr ene 118 0 “
ASU em R Beart cnc ae 105 0 ss
aS Rete een ica at eas: 103 0
441 hae cc eer 100 | 0 ‘4
| “se

457g en |e ene cena eee 95 0 iB
at ed crater cer eete 90 0 sg
461% | mera ce eater te 89 0 a
rth) =o iets Garnckteaces Reyer 90 0 ee
A UE eM Cer Aa acyogee rss 88 0 “
aus, Pe Mik Moenaistedsl scion miccew.s9 80 0 ae
AS UG |e ime eet ee aes 77 | 0 io

Caress sts aioesn ei 75 0 i

GomnI|| EEK pete tee ae 73 0 af

OR ee eee 70 0 ef
DO ame ees ane muncr eres 70 0 s
ee ieee ee: 65 0 es

Cagle RATE 60 0 ee

Pe RRM ieee es 57 0 ss
52 ean Rete eee | 55 0 ee
Pe ie ee Rete een seas es 53 0 cc

316 35’ (Est.) 50 0 “
Table 5

TIME

(80 SECOND
INTERVALS)

ow oo ©

oo

es

eo oo 8

eo

eo

eo

eo

oo

eo

 

 

35 PM.

3516

36
3616

oot

e112

71s
38
3814
39
3916
40
4015
+1
411
42
4216
43
4316
Ad

4415

AS

4515

46

4615
47
4714
48

3.4815
49

4915

30

i ee ee

rSTS OF A JACOBS-SHUPERT BOILER

LOW WATER TESTS—SERIES C

Log of Boiler Conditions During Test
RADIAL-STAY BOILER

 

MINUTES FROM LEVEL OF WATER NUMBER BOILER
TIME WATER WAS ABOVE OR BELOW OF POPS FEED
AT CROWN SHEET CROWN SHEET GAUGE, LBS. BLOWING y

2M

 

214" Above 230 3 On
Ble 233 ‘ s
Og 230 3 Off
gy 223 3 “
Vi 220 2 i
1 rr 223 2 ne
| Wg 225 3 | e
| 1 ss 228 3 | fs
Sears 230 8 |
| age 230 3 e
14” Below 230 3 a
eeeon EE 230 £ On
| Wye 233 3 Off
AUB 8 230 | 3 On
| Wy" 230 3 | Off
| ry se 230 3 er
| ayy 228 3 fe
gly” 230 3 i
| 307 « 230 8 -
| gy" 230 3 "
Bore Ne 230 3 es
ayy” 230 3 a
4g” 230 3 #
Sot 38 230 3 _
54" 233 3 Ee
| Gwe a 233 3 -
| 6lo" 233 3 «
He ew oft 230 3
Ww" 233 3 e
gag 233 3 “
ee ee 233 3 ‘
Sys 233 3 i
gig" 233 3 f
sy" 233 3 cs
Oi tine OE 233 3 fe
gigi es 233 3 di
LO Ae Se 233 3
104" “ 233 3
Tvs <2 233 3 He
lig” 233 3 ss
wi 233 3 ss
1234” “ 233 3 es
Saat ne 233 3 a
13%" “* 233 3 :
| wage 233 3 :
| air 228 3 53

| Boiler Failed

94
LOW-WATER TESTS AND THEIR RESULTS

wn) Sheet Leve

RADIAL STAY BOILE

Crown| Sheet _

st
==:

‘Ol

heet Fail

nch

JACOBS-SHUP

4
2
>
_.
4
H
ovo
y
x

ing on Water Gauge

JRADIAL STAY) BOI

\OBS-SHUPERT BOILE ‘al
| aoe | |
i \

/Probable| Water Level
at End-of Test, -
35” below Crown

Sheet

 

10 20 30

Fic. 77.—Water-levels and steam pressures in boilers during low-water tests.
TESTS OF A JACOBS-SHUPERT BOTLER

 

boiler, the excess of steam generated over that required to produce the
draft was successfully discharged by two safety-valves, whereas through-
out the corresponding period the three safety-valves of the radial-stay
boiler were always open. An explanation of this action is to be found in
the fact that the Jacobs-Shupert boiler was not so well supplied with water
at the start, and as shown by the record was fed liberally during the first

 

 

K
\

[+

|

MN
=

N

 

 

J

nches

        
 

io
nel

SY

i

4

N\

10

 

[: Firebox
feo

Banvel-y

sheet, I

srown' ss

Total Boiler

 

pe
> ' fron Cr
at Et rae St
| [ens | se ane
Theron =
| |
|
Ly
Deity

40

Distance fre

Gol]

Iie, | ame eae eee feral ne at as |
| | Thousand Pounds | | |
6 $8 10 12 14 16 18 20 22 24 26

10 }—

 

to
he

Fic, 78.—Calibration of Jacobs-Shupert boiler, showing water capacity at various levels.

few minutes of the test. Second, another condition which influenced the
spectator grew out of the fact that the test of the Jacobs-Shupert boiler
endured for 32!5 minutes longer than that of the radial-stay boiler. The
spectator was naturally more impressed by the conditions prevailing dur-
ing the last half hour of the test than by those prevailing during the earlier
portions thereof. He knew that the water-level was steadily receding,
failure seemed imminent, and he was in the attitude of expectancy. His
condition of mind and the fact that during this interval the quantity of
steam discharged steadily declined, accounts for the impression referred
to. Such an impression so far as it has reference to that portion of the
test of the Jacobs-Shupert boiler which is comparable with the entire
period of endurance of the radial-stay boiler finds no justification in the
records of the tests.

93. The fact that after nearly a half hour of operation without feed,
the delivery of steam from the Jacobs-Shupert boiler diminished as the
test proceeded is to be accounted for in several ways: First, as the heating-

96
LOW-WATER TESTS AND THEIR RESULTS

 

surface of the boiler became bared, its evaporative capacity necessarily
diminished; second, with heating-surface bare, the steam delivered became
superheated and the safety-valves were called upon to handle a reduced
weight of steam, each pound of which carried away an increasing amount
of heat; third, as the heating-surface became bare, the heat of the furnace
was in part absorbed in raising the temperature of the metal of the boiler,
not only the firebox and the tubes, but indirectly through the increased
temperature of the steam within the boiler, the shell, and all parts to
which the steam had access. Heat could not be taken from the firebox
to raise the temperature of the steam and to increase the temperature of
metallic parts of the boiler and at the same time evaporate as much water
as was possible before these new avenues of heat absorption appeared.
The working out of this process and the fact that the test of the Jacobs-
Shupert boiler proceeded until 78 per cent. of the water it contained had
been evaporated, explains the significance of the observed action.

94. As already stated, it was the purpose in the case of each boiler to
start under conditions which would insure the evaporation of approxi-

10

\

wn Sheet

Firebox | |
10 I

Barrel =

&
2
o
HH
vo
y
a

60.

bee ae ol
Thee Pounds

aoe
16 18 20 22 24 26

 

9
a

Fic. 79.—Calibration of radial-stay boiler, showing water capacity at various levels.

mately 10 pounds of water per foot of heating-surface per hour. This is
equivalent to a total of 30,000 pounds per hour. It has just been shown
that at whatever rate the boilers may have been started, the output in the
form of water evaporated must have steadily declined as the test pro-

ceeded. It would be interesting to know what was the rate of this
97
TESTS OF A JACOBS-SHUPERT BOILER

 

decline. Data for such an inquiry are supplied by the known weight of
water contained by the boiler for every surface-level and the observed
rate at which the surface-level receded. An attempt to make use of these
data leads to inconsistencies resulting, no doubt, from unavoidable errors
in observation caused by the surging of the water in the gage-glass. But
however inaccurate, the results of such an investigation are not without
interest, and brief reference may therefore be made to them.

95. The calibrated water capacity of the Jacobs-Shupert boiler is
given by the lower curve of Fig. 78, and that of the radial-stay boiler by
the lower curve of Fig. 79. The curves are practically the same for both
boilers. The rate of fall in water-level during the low-water test. is
recorded in the logs of the tests Tables 4 and 5. From facts thus avail-
able, computations have been made as follows-:

96. Concerning Rate of Evaporation, Jacobs-Shupert Boiler:

POUNDS OF WATER MINUTES DURING

|
: : EQUIVALENT TO POUNDS OF DY
EMO Ee DROP IN WATER WATER Sea
ER LEVEL FOR FIVE-MINUTE PER HOUR | aera
INTERVALS | §
eeu cick —— areas ee

1:48 to 1:53 1,300 | 15,600 2.5

1:53 to 1:58 2,000 24,000 0.0

1:58 to 2:03 875 10,500 0.0

2:03 to 2:08 2,825 | 33,900 0.0

2:08 to 2:13 1,700 | 20,400 | 0.0

2:13 to 2:18 1,875 22,500 | 0.0

2:18 to 2:23 | 1,325 15,900 | 0.0

The boiler feed-valve was open during one-half of the first interval
embraced by those computations. The weight of water fed, if it were
known, should be added to the value given in the second column. It is
known that the rate of feed more than equaled the rate of evaporation
so that the actual rate of evaporation during this interval must have been
more than double 15,600 pounds. At 2:23.5 the water passed below the
bottom of the gage-glass which was 25.5 inches below the crown-sheet.
The calibration curve (Fig. 78) shows that there was then a little more
than 10,000 pounds of water in the boiler, which when filled to the middle
gage-cock, contains 30,000 pounds.
97. Concerning Rate of Evaporation, Radial-stay Boiler:

POUNDS OF WATER EEL eee

. fas as EQUIVALENT TO POUNDS OF RGR pee

PIVE-MINOTE DROP IN WATER WATER SS UREN ORE
INTERVALS LEVEL FOR FIVE-MINUTE PER HOUR au

INTERVALS WAS OPEN
a ALS

3:35 to 3:40 1,600 | 19,200 1.0
3:40 to 3:45 1,800 21,600 1.0
3:45 to 3:50 1,800 21,600 0.0
3:50 to 3:55 2,200 | 26,400 0.0
LOW-WATER TESTS AND THEIR RESULTS

 

  

CL hg Ve

Fic. 80.—Photograph of Jacobs-Shupert firebox after low-water test, showing brick arch
in place and in perfect condition. The light spot on flue-sheet at center of crown-sheet
is the visible record of the only leak observed in the firebox after the test.

Fic. 81.—The center portion of the Jacobs-Shupert firebox after the low-water test. The

sections shown in the photograph received the most severe overheating and were badly
scaled and discolored. The line of demarcation is seen clearly on the right side-sheet.

99
TESTS OF A JACOBS-SHUPERT BOILER

It will be seen that the values deduced for the first two intervals are
affected by the introduction of feed-water. The weight of water fed
should, of course, be added to the value in the second column. At 3:5734
the boiler failed. It contained at the time of failure something more than
14,000 pounds of water.

98. The conclusion of the low-water test as applied to the Jacobs-
Shupert boiler found that boiler undisturbed and apparently ready for
service. After having boiled nearly dry, when its steam pressure had
fallen to 50 pounds, the test was terminated by shutting off the blast and

 

 
    
   

Deep Blue Coty Sey,

ee ie

 
 
  

 

on

/ ) \
9
or

p. XL

   

 

 

Vv

 

 

 

 

 

Fra. 82.—Discoloration of firebox sheets from overheating—Jacobs-Shupert boiler. Sec-
tion through firebox section No. 5.

the fuel supply. An hour later, after the test of the radial-stay boiler had
been completed, an inspection, through the door of the Jacobs-Shupert
boiler, disclosed portions of the brick arch still sufficiently heated to glow.
A description of a detailed inspection of this boiler which was made later
is as follows:

99. The Jacobs-Shupert firebox, as photographed through the door
after the test, is shown by Figs. 80 and 81. In both of these views the
brick arch is seen to be wholly undisturbed and in perfect condition.
Later, this arch was removed and the boiler was turned on its side to

facilitate inspection. When in this position, the photographs shown by
100
LOW-WATER TESTS AND THEIR RESULTS

Figs. 83 and 84 were taken. A well-defined line of demarcation was
found to run around the firebox approximately 34 inches below the stay-
sheet calking line in the crown of the firebox. The line presented waves as it
passed the convolutions of the several sections, its maximum and minimum
limits being those shown by Fig. 84. Portions of the sections below this
line were soot covered and normal in appearance. Higher up and in more
exposed portions of the firebox the sections had the color and appearance
of freshly heated steel. The more highly heated portions were flecked

 

Fig. 83.—View of forward portion of Jacobs-Shupert firebox after low-water test, showing
first five sections and flue-sheet. Above the line of demarcation the steel is of dark
blue color, and the surface scaled from intense overheating. The blue shades off into
reddish brown, and lower down into sooty black.

with scales, resulting from oxidation (Fig. 81). Between the portions
which were soot covered and those which bore the appearance of freshly
heated steel was a belt approximately 5 inches in width which was gen-
erally reddish brown in color shading off into the black which was below
and into the freshly heated steel above (Fig. 82).

100. The firebox was made up of eleven sections. <A critical examina-
tion of these, taking them in order beginning with the forward section,
resulted as follows: The first section was found to show the color of newly
heated steel on the curved portion, the effect being most striking on the
lower side (Fig. 83). This color did not anywhere extend entirely around

to the stay-sheet. A few scales of oxidation only were found on this
101
TESTS OF A JACOBS-SHUPERYT BOILER

 

section. The five successive sections, all of which appear in Fig. 83, were
found to be similar except that each succeeding section bore evidence of
increased heating effects. The hottest sections in the whole boiler were
five and six, and these sections, as well as section seven, gave evidence of
having been highly heated on the sides as well as in the crown. Sections
five and six were thickly covered with scale (Fig. 81). Section eight was
found to have only a portion of its area the color of newly heated steel,
and sections nine, ten, and eleven were found to be, within the heated zone,
entirely of the reddish brown color (Fig. 84).

101. Those most affected disclosed a curvature which drops one-half
inch more than that which was originally given them. The change in
contour, while not entirely regular, disclosed no evidence of a disposition
to develop pockets or to local failure by blowing out. The final contours
of the section were accurately outlined by means of templets made from

 

Frc. 84.—Rear portion of the Jacobs-Shupert firebox after low-water test. Discoloration
of last four sections and door-sheet from overheating is clearly shown.

the sheets. Facsimiles of these templets are shown for all eleven sections
in Figs. 85 to 95 inclusive. In these figures the side contours were taken
94 inches on either side of the center line of the firebox. It is note-
worthy that, notwithstanding the high temperature to which this firebox
was subjected, the color of newly heated metal nowhere extends around
the section to a stay-sheet, nor was there any point on the calking edge of

the stay-sheet which had been heated beyond that temperature which
102
LOW-WATER TESTS AND THEIR RESULTS

 

results in the reddish brown color. Nothing in the appearance of the sec-
tions or of the stay-sheets indicated the presence of the least leak through
the crown.

10la. The back tube-sheet as shown in Fig. 83 was found to disclose
a clearly defined water-line, which is 3114 inches below the crown. The
color of the greater portion of the area of this sheet is that of freshly
heated metal. For two or three inches above the clearly defined water-
line and for six or more inches around the edges of the sheet it was red-
dish brown. The tube-sheet was found to retain very nearly its original
shape. On either side of the center and near the middle of the heated
zone, where in the design of the boiler there is a considerable area unsup-
ported by tubes, the plate was bulged to the extent of one-fourth inch. At
the crown of the tube-sheet, as shown by Figs. 80 and 83, a small leak had
developed. The joint at this point is made by riveting the first section
of the firebox to the tube-sheet with a copper calking strip between. It
is at the crown of this joint that the evidence of the leak appears. This
leak, the only one to be found in the firebox, was slight. It could not have
interfered with the normal operation of the boiler.

1016. Within the highly heated area of the tube-sheet, shown in Fig.
83, are 188 tubes. Naturally the upper tubes were most affected by the
heat to which they were exposed. Four of the tubes were found to have
collapsed just inside of the tube-sheet, 14 others, making 18 altogether,
were found pulled apart inside of the sheet. The weld between the tube
and the sheet was not disturbed in any case. It is probable that,
except in the case of those which collapsed, the actual rupture of these
various tubes occurred in the process of cooling after the test had been
finished. All other tubes were intact so far as their contact with the
back tube-sheet is concerned. All those within the heated zone were found
deflected downward, the deflection varying from a comparatively small
amount to an amount equal to the diameter of the tubes. The tubes
which at the conclusion of the test were below the water-line remained in
their original straight condition.

102. The door-sheet of the firebox (Fig. 84) was not greatly affected
by the conditions imposed by the test. No distinctly marked water-line
appears upon this sheet, though the upper portion had the mottled red-
dish brown and black appearance. ‘There was no distortion of this sheet
and no evidence of leaking stay-bolts.

103. The arch tubes (Figs. 80 and 81) were not disturbed or affected
by the test, and the arch at the conclusion of the test was, as already
noted, in perfect condition. The mottled appearance of the arch tubes
in some of the photographs results from a disturbance of the soot which
covered them.

104. A review of these conditions discloses the fact that so far as the
firebox construction is concerned, the boiler at the conclusion of the test

was in condition for operation.
103
Front

 
 

TESTS OF A JACOBS-SHUPERT BOILER

SECTION No. 1

 
 
   
    
 
 
 
   

Final Contour /
/
Pr /
Oviginal>~ f
: ed : /
Contour = /
‘ ==,
Ro ee es eee ee eee /
me ON 8 SSS SSeS i
e 7
SN
ie rs
Original Ss.
~
Contour ~
MA
los
S
aa)
Left Side
pe oe
Original - 2S

Contour,7
7

Front

  
 
 

Fic. 85.—Change in contour of firebox sections as a result of exposure
during low-water tests.

Illustrations are about six-tenths full size.

    
 

SECTION No. 2

— Final Contour

  
   

S
See Ne
Original ~~2y
Contour

  

Baek

ea Left Side

  

Fic. 86.—Change in contour of firebox sections as a result of exposure
during low-water tests.

Tllustrations are about six-tenths full size.

104
LOW-WATER TESTS AND THEIR RESULTS

     

SECTION No. 8

  
  

   

aA
Pees »

Original S\

Contour

   

   
   

>»
Tee

Original’.
\

 
 

Contour
z ‘
= =
Final Contour —, 2 R Seo) Gare
Left Side

    

Fic. 87.—Change in contour of firebox sections as a result of exposure
during low-water tests.

Illustrations are about six-tenths full size.

   
  

    
 
 

SECTION No. 4

ae 2p
Original ~SX
Contour

   
  

 
    

ight Side wees /

Back

Front

  
 

Final Contour

   

Fic. 88.—Change in contour of firebox sections as a result of exposure
during low-water tests.

    

Illustrations are about six-tenths full size.

105
TESTS OF A JACOBS-SHUPERT BOILER

 
   
 
     
 
   
     
   
 
   
 
    

SECTION No. 5

~ ieee \
Originals,
: PG
Contour ~\_

Front

Back

Original ~~
<A 7
be a
Contour,

Fic. 89.—Change in contour of firebox sections as a result of exposure
during low-water tests.

Illustrations are about six-tenths full size.

SECTION No. 6

—Final Contour
SN

‘ 5 he
Original” >~._
Contour

4 N,
Original >._
Contour ><

Front

Back

Left Side

Fic. 90.—Change in contour of firebox sections
during low-water tests.
Illustrations are about six-tenths full size.

106

as a result of exposure
LOW-WATER TESTS AND THEIR RESULTS

 
   
 
   
  
   
     
     
       
 
    

SECTION No. 7

 
 

7
Original ~
Contour

Original SS —Final Contour
Contour ~~

~ ba
=I as
) o
m =
Original
-

Contour~,

Fig. 91—Change in contour of firebox sections as a result of exposure
during low-water tests.

Illustrations are about six-tenths full size.

SECTION No.

 

\ a cia (sa
\\ Original "~\y
Contour

 

ear S
Original’y |

Contour

1 4
a 3
oS =
S os
Ho AA

et eee) 8 = =

Left Side
ee aS
Original 3-7 a
Contour” A- Final Contour &
7
/

Fic. 92.—Change in contour of firebox sections as a result of exposure
during low-water tests.
Illustrations are about six-tenths full size.

107
TESTS OF A JACOBS-SHUPERT BOILER

   
 
    
 
 
 
 
  
   
 
    

SECTION No.

Original *\S
Contour

eee
Originals
Contour

~
4 ‘4
a 4
2 o
4 =

eH FQ

Final
Contour,

Fria. 93.—Change in contour of firebox sections as a result of exposure
during low-water tests.

Illustrations are about six-tenths full size.

SECTION No. 10

ee
Original > ~_

Contour

  
     
 
 
   

Right Side

ee S
Original > _
Contour

Center of Crown

Left Side

 

Fic. 94.—Change in contour of firebox sections as a result of exposure
during low-water tests.
Illustrations are about six-tenths full size.

108
LOW-WATER TESTS AND THEIR RESULTS

 
   
 
   

SECTION No. 11

    
 
    

ers
Original >. _
Contour es

Right Side

  

Se
Original
5 ES
Contour
Center of Crown

Front

Back

    
 
  

Left Side

Original »,-
Contour,”

Fic. 95.—Change in contour of firebox sections as a result of exposure
during low-water tests.

Illustrations are about six-tenths full size.

105. The radial-stay boiler failed under the low-water test. Its
appearance at the moment of failure is shown by Fig. 96. The force of
the explosion was sufficient to raise the rear of the boiler, to blow out the
tile brick arch, to blow out the cast-iron pedestals, to disrupt the brick-
work under the boiler, and to scatter fragments of all of these over an
area a hundred feet or more in radius. The diagram (Fig. 97) and the
photographs (Figs. 98 and 99) show well the distribution of débris. The
boiler itself was lifted from its foundation and was moved forward a dis-
tance of about 8 inches, the rear swinging to the right, as shown by Figs.
100 and 101. As the front-end of the boiler slid forward on the support
under the barrel, an extra heavy blow-off pipe was sheared.

106. The radial-stay boiler failed by the pocketing of a considerable
section of the crown of the boiler (Fig. 102). This section embraces 188
crown-stays and stay-bolts. The button-headed stays failed by the stays
breaking inside of the sheet and the flat-headed stays pulled through the
sheet. The length of the damaged portion as measured longitudinally
extends from the first row of stays, counting from the front-end of the
firebox to the twenty-first row. In the first row the sheet pulled away
from a single stay and in the twenty-first row from three stays. A plan
of the crown-sheet and a profile of the pocket, the formation of which
resulted in failure, are shown by Fig. 103. The sheet itself was found

not to have ruptured or cracked, and, so far as could be determined, no
109
TESTS OF A JACOBS-SHUPERT BOILER

 

button-headed stay pulled through the sheet, though the holes in the sheet
(Fig. 104) are in many cases considerably elongated in direction of the
maximum movement of the plate. The contents of the boiler were dis-
charged through the openings vacated by the stay-bolts, the aggregate
area of which has been found to be approximately 186 square inches.
107. A considerable portion of the undisturbed area of the crown of
the firebox was found to be mottled blue and black, giving evidence of
some scaling from the effects of heat. The brightness of the color, how-
ever, had been affected by the discharge of steam from the firebox. The
button heads of the undisturbed stays in the vicinity of the pocketed sec-

 

Fia. 96.—The radial-stay boiler at the moment of failure. Escaping steam and water
through the ruptured crown-sheet mingled with the smoke from the stack and formed
a cloud several hundred feet in height completely enveloping its surroundings.

tion showed the same variegated blue, black and white. This effect,
however, was practically confined to the zone occupied by the button-
headed rivets and to the forward two-thirds of that zone. There was a
slight change in the superficial color of the plate between the eighth and
ninth row of stays on the left-hand side of the boiler, suggesting that below
the ninth row of stays the effect of overheating was nil.

108. Both side-sheets with their staying were in perfect condition, no
evidence of leaking stay-bolts appearing.

109. The door-sheet with its stays was found in perfect condition.

110. The tube-sheet was found in perfect form and the tubes appeared
110
LOW-WATER TESTS AND THEIR RESULTS

 

to be as secure as when originally welded thereto. Only a few tubes,
variously estimated from nine to eighteen in number, seemed from their
color to have been involved by the overheating. No tube was found
which had been sufficiently heated to sag. The very small portion of the
tube-sheet which was overheated may be seen from Fig. 104.

111. The arch tubes had been forced somewhat downward by the

 

175ft—_—_—_
15°
1. Piece of Arch Brick 9. Draft Door
2. Fragment of Brick from Side Wall 10. ee
3. C. I. Pedestal 11. Fragment Arch Brick
4. Iron Pipe Stand 7’-6” long, 2’ E. H. 12. “ Brick
flanges on ends 13 “
5. ©. I. Pedestal ;
6 «4 “ 14.
7 oe oe 15.
8. 14 Pig Iron (leaned against door) 16. Oil Boiler Piping

Fic. 97.—Diagram showing distribution of débris by explosion of radial-stay, boiler.

discharge of steam from the crown-sheet (Fig. 105), and the right-hand
tube had been distorted sufficiently to develop a leak in the tube-sheet.
112. The simple character of the failure of the radial-stay boiler per-
mits our interest in the design and in the characteristics of the materials
used in working out the design to be centered upon two things. These
are the crown-sheet and the radial stays. The crown-sheet was manu-
factured by the Lukens Iron & Steel Company. A sample for test cut
from this sheet and examined prior to the construction of the boiler gave

the following characteristics:
111
TESTS OF A JACOBS-SHUPERT BOILER

 

Fic. 98.—Photograph showing the radial-stay boiler after the low-water test and the dis-
tribution of débris over a radius of 150 feet.

 

Fic. 99.—Another view of the radial-stay boiler after the low-water tests, showing effects
of the explosion.

112
LOW-WATER TESTS AND THEIR RESULTS

 

Fic. 100.—The radial-stay boiler after the low-water test. The explosion caused a for-
ward movement of eight inches and a side movement of eighteen inches, the rear end
swinging to the right on the front support as a pivot.

 

Fic. 101.—Another view of the radial-stay boiler after the low-water test, showing final
position of boiler after its failure. In the foreground will be observed the supporting
pedestals, one of which was broken.

113
TESTS OF A JACOBS-SHUPERT BOILER

 

Mite i leisy wea thar ee tru ey aes te Dyas ike aces inane Ser teen ye Tere N= 1957
Ultimate strength, pounds per square inch................... 66,970
Klogationy per Céitas e453. paves wa tie. ees weer esaaenasase. — 20200
Carbon;, per cents d cca ceodue pees nay a Reatghe teed ealtar oA Eslohees .16
Manpanese.permeentf5.5 iin fans dae ato vere ate eek nei ome bate 42
Phosphorus peiCemtte anes cee e meeit eh eg Rea aan 02
Sulphur, per cent......... get Se ne re Ree he Mt Ge Hane O24

The fact that this sheet in coming down did not crack is in itself evidence
of the high quality of the material.
113. The dimensions and design of the radial stays are shown by

 

ee ee Se ee ee Oy ot SNe” pat

 

Fic. 102.—Photograph of radial-stay boiler, after low-water test, showing the failed crown-
sheet. A large pocket was formed in the forward right side of the crown-sheet, the
sheet pulling away from 188 crown-stays and stay-bolts. The button-head stays
failed by heads breaking inside of sheet and the flat-headed stays pulled through the
sheet.

Fig. 106. These stays were manufactured of Taylor stay-bolt iron and
the record of the tests is as follows:

Markie, Shue es ae pee ey eee ee ey Pay lorstay-bolt
DDraane ber chtn asec ene ter cme etek net che econ yh eck A 1.003
INTO hs 2 gees wae wiry ey sous snail me Be Us re A atten et eae ta NG .790
Breaking strength, pounds......................2205. 38,200
LLESS: PEr SG UArE INCH vase seg A eae eS 48,400
Original: length, anchés. 34.45 2h4f0edes oy ata ena ea 8.
Length after breaking, inches................0..0205. 10.72
Blongation, percent ina cisicinaes Paes A Seok SR 34.00

114. These statements will suffice to show that in the selection ot
materials and in working out the construction, the radial-stay boiler was
not inferior to the highest standards prevailing in such matters. The fact

114
 
  

pug «ey

puy yuo.

Oo

 

18 19

15 16 17

18 14

a
aol
ol
we
o
m

9

              

pormnfuug <uarddy 34 43 ”
polis a a s ”
pINd 4 = TOTUTIOD

painfurug Afjuetvddy ay ”

poring a ” a ” ”

pong ‘s}[og Avg proyy UO NG sooUudT

 

 

 

 

>

x

©
mK
e

Fria. 103.—Plan and profiles of pocket in crown-sheet of radial-stay boiler.

5
TESTS OF A JACOBS-SHUPERT BOILER

 

Fig. 104.—A close view of the pocket formed in crown-sheet of radial-stay boiler in the
low-water tests. The sheet was not cracked or ruptured, and the tube, side and door-
sheets were uninjured, all of which is conclusive evidence of the high quality of material
and workmanship entering into the construction of this boiler.

 

Fic. 105.—Photograph of radial-stay boiler after low-water test, showing pocket in crown-
sheet. The arch tubes were disturbed and forced downward.

116
LOW-WATER TESTS AND THEIR RESULTS

 

that the failure of the boiler was not more disastrous is to be accounted
for in the superior character of the materials and workmanship employed
in its construction.

115. The preceding description of the breaking down of the radial-
stay firebox is significant in that it confirms the experience in practice on
the road. The firebox tested was new; there was no accumulation of
scale upon it. It had not been weakened by strains induced by long

Crown Bars

 

  
 

 

 

a \

 

fe i

<1"

Ciown Bolts

Extra strong
\ a ey, Hydraulic Pipe
s a5 28g EJ © lor Thimbles
ee =
as

List
| an 7! (8)
ne 5" (S) :

 

 

 

 

 

Radial ne

 

 

 

 

 

 

 

 

Fic. 106.—Crown bars, crown bolts and radial stays used in radial-stay boiler.

service, and it had every chance to present the maximum resistance to
failure to be expected of that type of construction which it represents.
The facts show, however, that when, through the receding of the water-
level, the heated zone had extended downward sufficiently to include the
upper portion of the crown and to take in only the upper rows of the
tubes, this firebox, new and in perfect condition, possessing material
advantage over the average radial-stay firebox in service, failed.
XII. Some Facts with Reference to the
Circulation of Water in
Locomotive Boilers

116. The motion of the water within a locomotive boiler in response
to the energy transmitted to it in the form of heat, is known to have an
important bearing on the up-keep and life of the boiler. Tt is known also
that the water always rises from the heating-surface, and that upward
currents thus stimulated must be compensated for by downward currents
in other portions of the boiler. But the downward currents are secondary
and are probably less stable and less direct than the initial currents which
rise. In the complicated passages of a locomotive boiler, these secondary
currents may take various directions and move with various velocities.
Their strength and direction have been the subject) of much loose
speculation.

117. It has been urged, for example, that the presence of the stay-
sheets which enter into the construction of the Jacobs-Shupert boiler,
retards the circulation, and that they are, therefore, objectionable. Such
an objection must be based upon the assumption that the stay-sheet is
deficient in the openings it presents as channels for the fore and aft move-
ment of water, and as these openings possess considerable area, 1t must
be assumed also that the fore and aft currents are tremendously vigorous.
Each of these assumptions is susceptible of rather careful examination.

118. The stay-sheet of a Jacobs-Shupert boiler consists of a com-
paratively thin plate extending from the firebox to the shell of the boiler.
From the mud-ring upward it is pierced at regular intervals with ports
which are approxtmately 3 inches square. The bridge between the ports
is normally 3.5 inches in width. Actual dimensions taken from the stay-
sheet of the Jacobs-Shupert boiler which was tested, show the port loca-
tion and area to be as follows:

Port No. 1, center 2.0’" above mud-ring, area 11.0 sq. in.

DS et 9.0" 8.3 i
ee ae 3, oe 15.5” se ee “ee 8.6 we oe
oe SAG OE SOO (i SS iy 2 SOEs
me he re FOB bs SE fa He SOROS
ia ee Osea 35.0” ba ra i Oe ee
pe Re AG, ee SAUER a Sa a en al OnLy he ie:

Be Oey ee 48.0” bs A se SOLD.

Saat Pose es 54.5" - ee = 109"
LOS 62.5" a cf “16.5%
eee SIN 68.77 ef mi “18.0%
Portarea in water-leg of one side.......... 11.38)"
Total area of ports in water space of boiler... ..223.6 °

118
CIRCULATION OF WATER IN BOILERS

 

These ports are entirely in the water space. Above them are others
much larger which are in both the water and steam space. Assuming,
then, that vigorous longitudinal currents are to be provided for in the
water-leg of a locomotive boiler, the design in question provides a portage

 

 

 

 

 
    

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

<(i{i7¢—-——h-

yy

(HE = — =Ih-

(i—-— il) 2 =
1 = Sa
a 2
| = fe

{_—ay*

{ii - — TM}

SU peel es Lt

Ee |
Radial-Stay Boiler. Jacobs-Shupert Boiler.

Fig. 107.—Horizontal section of water-leg of radial-stay and Jacobs-Shupert boilers.

 

 

 

 

 

 

 

Radial-Stay Boiler. Jacobs-Shupert Boiler.

Fic. 108.—Vertical section of water-leg of radial-stay and Jacobs-Shupert boilers.

which, under a head as small as a hundredth of a foot, will suffice to pass a
volume of water equal to that contained by the boiler in about 70 seconds.
119. A discussion of this question so far as it relates to the Jacobs-

Shupert boiler, usually leads to comparisons between that type of boiler
119
TESTS OF A JACOBS-SHUPERT BOTLER

and the radial-stay type, and the fact that in the radial-stay boiler there
are obstructions to the fore and aft movement of water is often neglected.
It may be that thickly-set stay-bolts impede the free fore and aft move-
ment of water as much as stay-sheets. The clear space between the stay-
bolts is greater than the port openings in the stay-sheets, but there are
two and a quarter courses of stay-bolts where there is one stay-sheet.
Fig. 107 presents a horizontal section
of the water-leg of the two types of
boilers. It shows in’ plan the ob-
structions which in each type of boiler
impede the horizontal movement of
water. Fig. 108 presents a similar
comparison of vertical sections. While
it is clear that the largest: openings
are in the radial-stay boiler, the
differences are not great. This state-
ment is emphasized by a comparison
of photographic views of actual boilers
(Figs. 38 and 41).

120. Thus far the argument has

 

been addressed to those who insist

upon the presence in the water-leg of Fic. 109.—Crown-sheet of Jacobs-Shupert
boiler, showing smooth, unobstructed,
finely curved surface for ascending
or less horizontal in direction. Leav- currents of water.

ing this question for a moment, it will

be of interest to observe the superior advantages presented by the Jacobs-
Shupert boiler in facilitating the movement of water in a vertical direction.
The water space about a Jacobs-Shupert firebox presents broad unob-
structed channels, permitting freedom in the vertical movement of water,
which have no counterpart in the stay-bolt boiler. Differences in dimen-
sions are shown by the drawings presented as Fig. 107, which are to scale.
A better understanding of the excellence of the surface over which the
ascending currents sweep is given by Fig. 109 which is a view over the
crown of a firebox section between two stay-sheets. In the radial-stay
construction, an area similar to that shown would present two rows of
stay-bolts extending out from the sheet which in the Jacobs-Shupert con-

the boiler of strong currents more

struction presents a smooth, unobstructed, finely curved surface.

121. The paucity of facts available concerning the movement of water
about the firebox of a locomotive boiler led to an early determination on
the part of the Jacobs-Shupert company to undertake an experimental
study of the matter. In the development of its plans the well-known
consulting engineer, Mr. George L. Fowler, was retained to conduct the
proposed investigation. Mr. Fowler entered upon the work with enthu-
siasm. He skilfully devised a method of procedure and he designed and
secured the construction of special apparatus which he afterward used at

120
CIRCULATION OF WATER IN BOILERS

 

 

 

JACOBS— RADIAL JACOBS — RADIAL
SHUPERT STAY SHUPERT STAY
1” from Inside Face of Side Sheet 3" from Inside Face of Side Sheet
15% Hole No.3 No.3
~! Velocity-Ft. per Sec, 9 s >
ai wo a 9:
No.8 @No.7 No.8 “bNo.8 No.7 No.8
R 2
S ai “ 0,
e 0.79 e09 te ee
of Nol? No.12 @— eNo.12 0.12@¢
\
2" from Inside Face of Side Sheet 4” from Inside Face of Side Sheet
aS LS
SE No.3
é
mr wD
| a 8 >
No.8 en 3b ¢. 5 8
No.8, @No.7 oO. é oO. No.
ont oO tof 0. oN oO
¢ G
>
ge 0.75 0.46
No.12% No.12 <— No.12@—

Fic. 110.—Diagram showing velocity of mixture in feet per second in different portions of
water-leg.

the testing laboratory in Coatesville. Mr. Fowler assumed the responsi-
bility for all that he undertook to do and is entitled to all the credit for
the results achieved. What he did and how he did it is all described in
his report, a brief summary of which is presented in the succeeding para-
graphs. A complete transcript of Mr. Fowler’s report concludes this
chapter.

122. In preparation for Mr. Fowler’s work, the water-leg, both of the
Jacobs-Shupert boiler and of the radial-stay boiler, was drilled with fifteen
holes regularly located at points chosen for exploration. The holes were
filled when not in use by a l-inch pipe plug (Fig. 112). It is to be
regretted that in the time allowed for the work actual observations
could only be taken at holes 3, 7, 8, and 12 of the Jacobs-Shupert boiler
and at holes 3, 8, and 12 of the radial-stay boiler. By the methods
employed by Mr. Fowler, and fully described by him in the report which
follows, an exploring tube with an opening at right angles to its axis was
connected with a suitable manometer gage. This tube was inserted at
the point to be investigated. By turning the exploring tube on its axis
and observing the indications of its gage, the direction of the flow could
be ascertained. The tube was inserted through a stuffiing-box and _ its
initial end could be made to occupy any position along the line of its
axis between the firebox sheet and the outside sheet of the boiler. The
results as to direction are shown graphically, and as to velocity, both
graphically and numerically, by Fig. 110. Concerning the inconsistencies

12]
TESTS OF A JACOBS-SHUPERT BOILER

 

which are here apparent, Mr. Fowler ealls attention to the fact that ‘the
records of the angle of flow must not be taken as positive or fixed.’ The
observations for direction of flow were not taken simultaneously with those
for velocity. The fact is, as Mr. Fowler himself makes clear, that the
work he has done is to be accepted only as the beginning of a solution of a
very complicated problem.

123. It should be very clear from these statements that no useful
result will follow an attempt to compare values obtained from the Jacobs-
Shupert boiler with corresponding values from the radial-stay boiler.
Neither as to direction nor velocity of flow are the values given absolute
or comparable. Since all circulation is in response to the application of
heat, the velocity of flow and for some points in the boiler, the direction
also must depend upon the rate of power at which the boiler is operating.
Since, also, the introduction of cold water must tend to suppress upward
currents and stimulate downward currents, a full interpretation of any
set of values must specify whether the injector is in operation or other-
wise. Observations to determine the precise characteristics of the cir-
culation, to possess comparative value, must be taken when all of these
controlling conditions are maintained. Mr. Fowler’s observations upon
the radial-stay boiler were made during the progress of efficiency tests
Nos. B—405—R, B—406—R, B—407—R, B—502—R, the results of
which are elsewhere reported. His observations on the Jacobs-Shupert
boiler were made after the boiler had been transferred to the site of the
low-water tests, where it was especially operated for his work. The fact
that Mr. Fowler makes no attempt to connect the results he observed with
the rate of evaporation or with any other factor which could be accepted
as a measure of the activity of the process within the boiler, is an indica-
tion that he regarded the data which it was possible for him to secure in
the time allotted, as insufficient for such a purpose.

124. But notwithstanding the limitations which must be placed about
them, Mr. Fowler’s results constitute a distinct contribution to the sum
of knowledge and are of tremendous significance. They show, for exam-
ple,”"almost a complete absence of any fore and aft movement of the water.
His conclusion upon this point is as follows:

“T think that if this matter were to be examined to a finality, it would
be found that there is a regular slow movement from front to back, broken
throughout the whole course by violent agitation and innumerable cross
currents, but that in no place are these currents torrential nor is the steam
movement itself very rapid.”

That is, Mr. Fowler finds no evidence to show that the water at the
bottom of the boiler is pushing backward and in the upper part forward.
His observations seem to sustain the very rational assumption that enough
water passes back from the barrel to the water-legs of the boiler to make

good that which the firebox evaporates, and no more. Since the firebox
122
CIRCULATION OF WATER IN BOILERS

evaporates from 30 to 50 per cent. of the water handled by the boiler, a
similar percentage of the total feed must, in the case of the Jacobs-Shupert
boiler, find its way through the ports in the forward stay-sheet. Some of
this water is evaporated before the second stay-sheet is reached. With the
passage of each section, the backward flow diminishes until at the last
stay-sheet only enough passes to supply that which the last section
evaporates. Obviously, an aggregate port area of 1°5 square feet is quite
sufficient to pass from 30 to 50 per cent. of the water which the injector
delivers through a 2-inch or a 2'%-inch pipe.

125. The conclusion that the fore and aft movement of water in a
locomotive boiler is no greater than is necessary to convey from the front
of the boiler, where it is delivered, that portion of the feed which is to be
evaporated by the heating-surface which is farther back, is amply con-
firmed by the experience gained in running the evaporative tests of Series
A. It will be remembered that in these tests, both the Jacobs-Shupert
boiler and the radial-stay boiler were fitted with a water-tight partition,
absolutely closing off the barrel of the boiler from the firebox end. In
this case, whatever circulation there was in the barrel could only involve
barrel water, and whatever circulation there was in the firebox end could
only involve the water of that end. Obviously, there was no chance here
for the longitudinal movement of water, and yet, under these conditions,
not the least difficulty was experienced with either boiler in working the
rate of evaporation up to more than 10 pounds of water per foot of heat-
ing-surface per hour, that is, to a rate of power which upon the road
would be regarded as normal.

126. All this should make clear the fact that the ports in the stay-
sheets of the Jacobs-Shupert boiler have a very minor function to per-
form. Not only are they, as now designed, entirely sufficient, but the
thermodynamic performance of the boiler could not suffer in any way if
they were reduced to a small percentage of their present area.

127. The full report of Mr. George L. Fowler is as follows:

New York, June 12, 1912.
Pror. W. F. M. Goss, Urbana, III.

Dear Str—In accordance with instructions received from you in your
letter of October 3, 1911, I have made an investigation into the rapidity
of the circulation of the mass of the liquid at a number of points of each
of the two boilers which you have been testing for the Jacobs-Shupert
Firebox Company.

The apparatus used for this purpose was designed to measure the
velocity and direction of flow as well as the quality of the mass of the
liquid at different points of the water-leg of the firebox. It is shown dia-
grammatically in the accompanying print. The principle of its operation
is that of measuring the impact of the flow of the mass in the water-leg
upon the mouth of a Pitot tube, by means of the elevation of a liquid
heavier than water in a U-tube, and afterward determining the quality of
the liquid, that is, the proportions of contained water and steam by means

123
TESTS OF A JACOBS-SHUPERT BOILER

of samples led off into a barrel calorimeter. The Pitot tubes were
inserted in the firebox at the points where it was desired to make the
measurements, and could be moved to and fro through suitable stuffing
boxes so that the opening could be placed at any point between the two
sheets. At the same time it was revolvable so as to be turned to face in
any direction. The construction of the apparatus in detail was as follows:

The Pitot tube G (Fig. 111) was inserted in the water-leg and was con-
nected by means of the flexible pipe C with the top of a water-glass F.
From the bottom of the water-glass F another flexible tube B ran to the bot-
tom of the water-glass E; while from the top of the water-glass E, a third
flexible tube, A, ran to a point in the firebox below the water-line. The
flexible pipe B and the two water-glasses formed a U-tube which was filled

 

 

 

 

 

Fic. 111.—Apparatus for measuring boiler circulation.

to the center of the glasses with tetrachloride of carbon that was colored red
and whose specific gravity is exactly 1.6. It was evident that, with connec-
tions to the boiler as shown, the liquid will stand at the same height in each
of the two glasses so long as the pressure above the tetrachloride of carbon
in each leg remains the same, but if the pressure on either leg exceeds that
of the other, the tetrachloride in the leg of the higher pressure will be cor-
respondingly depressed. This increase of pressure was secured by turning
the Pitot tube, and when it faced directly into the stream, it would pro-
duce the greatest pressure at the top of the glass F, with a corresponding
depression of the tetrachloride in that leg.

For convenience of entering the boiler fifteen holes were drilled in the
side of the firebox. They were in three rows, five in a row and numbered,
for the sake of identification, as shown in the accompanying print Fig. 112.
The Pitot tubes were used; those holes not occupied being plugged.

124
CIRCULATION OF WATER IN BOILERS

 

After a reading had been taken, the valve H was closed and the valve
I opened. This cut the pressure off from the top of the water-glass F,
and allowed the mixture of steam and water entering the Pitot tube to
flow into the water partially filling the barrel calorimeter K, when from the
temperature ranges before and after the admission of the liquid from
the boiler together with the pressure existing at the time as read from the
steam gage, it was possible to determine the percentage of steam and
water entering into the mixture as it existed at the mouth of the Pitot
tube in the water-leg. From this the specific gravity of the mass could
be calculated.

Then with the head produced by the difference in the levels of the
tetrachloride of carbon and the specific gravity of the liquid whose impact
caused that difference of level, the velocity of the liquid can be calcu-
lated. This is the method followed in all of my observations and which
are tabulated on the accompanying sheets. (Tables 6 and 7.)

>) n A 0 A rn A

 

ARIE

 

 

 

 

5 4 3 2 1
° ° ° ° °
10 9 8 7 6
° ° ° °
15 14 13 12 11 |—
° ° ° 3 Oo

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fic. 112.—Side elevation and section of firebox showing location of holes for circulation tests.

The heat (B. t. u.) given is for that above 32 degrees Fahr. The
column headed “Angle of Flow,” indicates the observed angle at which
the mass was moving at the time of the observation. It is measured in
the direction of the movement of the hands of a watch starting with 0
for the vertical downward movement. Then 90 degrees would be hori-
zontally from the front to the back; 180 degrees vertically upward, and
270 degrees horizontally from the rear to the front.

The “Specific Gravity of the Mass” denotes the specific gravity of
the combined mass of steam and water.

The “Velocity of the Mass” is the velocity which a mass of the corre-
sponding specific gravity would have to have in order, by its impact on the
mouth of the Pitot tube, to cause the difference in the level of the tetra-
chloride as observed.

The “Velocity of the Steam,” given in the last column, is the velocity
that steam of the pressure existing in the boiler at the time of the observa-
tion would have to have in order to cause the observed difference in the
levels of the tetrachloride.

125
TESTS OF A JACOBS-SHUPERT BOILER

These velocities are calculated on the basis of the elevation of a mass
Whose specific gravity is 0.6, for this reason. The specific gravity of the
tetrachloride is 1.6. The 1 is balanced by the superincumbent weight of
water in each leg of the U-tube, leaving only the .6 to be moved by the
impact on the Pitot tube.

In handling the apparatus and making the observations here recorded,
the differences in level of the tetrachloride were first observed. Then
water and steam were blown through the piping, leading to the calori-
meter, sufficient to heat it, after which it was turned into the barrel for
the measurement of its heat values.

The records of the angles of flow must not be taken as positive and
fixed. The figures given are for the approximate average inclination of
the flow. As a matter of fact it shows every evidence of constant varia-
tion, sometimes through angles approximately 45 degrees for the higher
velocities, and this together with other general indications have led me
to the opinion that there is much agitation in a boiler, with comparatively
little circulation or progressive movement of the water. I think that if
the matter were to be examined to a finality it would be found that there
is a regular slow movement from front to back, broken throughout the
whole course by violent agitation, and innumerable cross currents, but
that in no place are these currents torrential nor is the steam movement
itself very rapid, while in some places there is a true circulation, that is,
the water follows a definite path returning to a previous position. An
example of this is found in the tests at hole 8 of the radial-stay boiler on
June 4. At one inch from the inside sheet there was an upward flow of
1.71 feet per second; at two inches the flow was still nearly vertical; at
three inches there was a neutral point at which no movement could be
detected; while, at four inches or near the outer sheet, there was a vertical
movement downward. The same thing is observable with the Jacobs-
Shupert firebox at holes 7 and 8, but without the indication of a neutral
zone devoid of flow.

There are some peculiarities in the observations that I cannot attempt
to account for because of the limited data. For example, in the observa-
tion at hole 12 of the radial-stay boiler, the three records of the third, show
a constantly increasing percentage of steam in the mixture from the inner
sheet to the outer. This is checked by the observations on the fourth,
except that the one at four inches from the sheet, which is farther out than
that of the third, shows a falling off as the outer sheet is approached.
This same condition, though not so markedly, appears in the Jacobs-
Shupert boiler at hole 7.

As for the general character of the water movement, there is, in the
radial-stay boiler an entire absence, so far as my observations went, of
eddy or reverse currents. The movement is either vertical or back from
front to rear, whereas in the Jacobs-Shupert firebox, with the general
movement the same, there was one hole where the movement was from the
rear to the front, evidently due to eddies set up by the stay-plates.

In calculating these velocities corresponding to the heights, I have
taken it that these heights or differences of level vary as the impinging
mass and that the squares of the velocities vary inversely as the mass.

You will observe that the percentages of steam are less in the
Jacobs-Shupert boiler than in the radial-stay. From the dates you can
determine the probable rates of evaporation in the radial-stay, from your

126
BOILERS

WATER IN

OF

CIRCULATION

 

S186
19° G6
OL 86
Ss"
00°
00°0
elit
o0'¢
60'S
6L°8
6L'L
00°
og
40°
00°L
Tg'2
6F OL
0074
£9" 06

anooags
udd
“La NI
WVaQLS
40 ALI
-OOTHA

 

98°3 |

LO's)
093]
LBS |
co"
00°
6h
OF

 

-OOTHA

TEC”

0&6"
LPG"
086°
St6"
186°
St6"
6F6"
F96"
L96°
086°
618°
L¥8°
866"
S68"
0g8"

SSVIL
0
ALIAVUD
O1ldIogdds

 

oF

So
o

mm HO OD 0
Dro hr

oa OS™ Ww
9 Oo Oo HH
eo

2

+
mo

oH
a
=

“ST

SSVIL

WVaLS
20
GOVINO
“und

 

 

SIo

S06
S16
066
O16
OTS
S06
£06
S06
OLT
Ost
066
SST
O6L
066
006

“Sat
auos
“Saud
uadtTiow

 

O8T

O8T

GLI
&6
06
06
06
O8T
ool
OST
gg
06
06
LPT
O8T

MAOTA

@IONV

 

 

 

 

 

 

LLE | SLE‘OL | 9°23 FOL | SLES
O1F | OTSST | 0°88 901 | 0098
BF | SELSLT | (0° OF Bal | 9° E8E
SIF CFOS | OFF | S1ssI | O0' 988
FOP «| F6S'6L | 9° 8h G31 | 0° 886
FF BESTS | OBS | 28s | O' BRE
ost FOS | O'S | S{8BI_ 0° 00F
OIF | segs | O'S¢ Sst | 0°96
COF SIFOL | SOF | S{8IL | 9 OTF
OOF | SIFIT | ¢°83 | %00T | ¢'98s
oss =| FOL'SE | 9°68 8IL | 0 998
SOF =| oFS‘SE | 9 FF OIL | ¢'9LE
L6F =| SoT‘ss | g'0¢ G3L | 0 SbF
ELE | OSGLT | O'8E FIL | O FSF
lf | F90‘8L | OFF | 24SLL | O'8FF
SLE | OFG‘EL | 9 6% 901 | 0° 09F
G6F | SLEGI | ¢' 68 FIL | 0° OFF
ae ‘AL ‘a eanvil ‘UHYa | ‘SaT
“AL ‘a IVLOL AO “dW WHSIAM
LADITM
uagtTiog WOU UALAWNIUOTVYD
9 1981

 

 

(ss | 0088
9L 0'8Ts
88 g 1S
88 0° FE
98 ¢ 66
88 0°98
88 0° 8S
98 O° LFS
68 0° 9L8
8L 0°89
88 ¢ 91g
98 0° BES

S18 9 FOS
68 0° 91F
a8 0° F0F
ws S 18t
8L | $ 00F

“MHVA “SaT

“dL LHOIGM

UALV AL

241-K1

T

a
XN
oN

CoE Eats o Le

7 90 \g0 SCO

mat SO NAS
PN AN IN AN o@\ oo EN AN

SQHONI
‘qano-n
NI

 

dINdITt
40 |

 

LHW |

e418
818

&

S@HONT
‘LOGHS
@dIsNri
Wout
GONV.
-sIa

manne

ol
ol
ol
ol

@IOH
10 ‘ON

 

WATIOd AVLS-TVIGVA NI NOILVTNOUID AO SNOILVAYASAO AO STIV.LAG

 

 

» IFC) ”
WV ¢FS | goung
» 616 ”
» POT 3
‘Wd 0€'T | *
» PRIT a
» OO ”
» OOTT ”
|
» 8 °OT) ”
WY ST'6 | Foune
» 96S » é
xn
Wdtoe! cas
WY ¢§ oune
|
aw | ava
R

\
4

BOILE

RT

\
4
4

SHUPI

S

ACOBS

J

 

 

 

 

 

 

    

 

0 | ‘ ag : at f ee We
99° | 616 sol O61 0 SOF SOLsI 00 SIL ¢'FLE +6 o TTS 4 é & > SBI] a,
o6 L68" ¢'6 O6L | OGT LEF II@FI «6¢te | SIL ¢ FSS cs 0 aes My I g » O66T) 45
66 oo6 CF 008 0 90F LOFLI (0 SF | OoL Iss 798 ¢° 86s y t L » OOCI] ,,
lL o96" OF Cle 0 OOF EsSFlL fos | OIL | O' 98s 68 o' 6TS oo g L » S@Tl] 4
GL Lt 69 Were O61 St LOST 0 SF | eq8ll 0° S68 8 0° 0¢s SE é L 3 (ROSTER | cy,
as SL 6o'1 $96" 6S 0% OST 10F 868'FS 089 OTT 0 90F ¢9 O° FTE 4% | I L wv CF oT soune
18°F ct 196 CF fso | SIE SOF OLe6T SLE | Sat 0 0LE 8 gees , fF & ra APSE Se) es
66°8 o16 PF COL cL 696 OOL6L =o FS | CIL 0°86 8L ¢ Sts 4 é él » Ose 3
6°11 alt £6 ae C2B C&S Slt loset = g LE oIL = ¢ 186 18 0 FFE Se I ol 3. OS *
60° OI 16 £16 C3 Ole 0 686 OSS'OT LaF BOL | OOF FTLL gees | Tt + 8 oUF | 3s
co'¢ L¢ OT6 s¢ G06 0 80T OLS FL ¢°96 | SOL ¢'F9S 9b | osss | 28 | § 8 3 Of | ss
es +9 OL6 Ld coe | (O9T 08 esV'IL 0 6B | FG TBOL OO 8%E FB 0668 | va é ae ee
a0 TL st Sts Sol OLT | OST 1¢t 9OO'SL 0 BF OIL O'8LE Lh 018s iy I 8 Wad (OE | Zounr
=
ae ‘uud SSVIV wae sat ee en wavy eas sae ea ei came taane | |
“La NI ‘La NI IO IWYaLS quas Soe : aes | IVLOL Soave a | “dNGL [aoe ‘d WAL | eHOTAL Irs NI e ACISNT a@10H | sie | ae
IVVaLS SsvIv ATIAVED: : 10 “said aTONY ia a —| Se see 2 aa dInNdIT Wout 40 °ON | i. |
JO XLT HO ALI OMIOddS % INFO YaATIOd iO GONVL |
“DOTHAN “udd | Uuavog Woy YALAWINOIWY MLV AL LHSIGH | -sId
£1921

YATIOd LYAMNHS-SHOOVE NI NOILWTNOUID JO SNOILVAYASAO AO STIVLAG

128
CIRCULATION OF WATER IN BOILERS

other tests with the Jacobs-Shupert the evaporation is estimated to have
been about 12 pounds per square foot of heating surface per hour. And
the boiler was being fed with water at a temperature of about 70 degrees
Fahr. The rate of movement, too, was more rapid with the radial-stay
than with the Jacobs-Shupert, but in both cases the movement was so slow
that no criticism can be offered as to the checking of the flow by the stay
plates of the Jacobs-Shupert firebox. Evidently, from the rate of flow
and the percentage of steam contained in the water, there was ample
opportunity for the water to come back and completely fill the leg.

Incidental to this, I observed that a change in the rate of steam flow
through the exhausting pipes would have its effect on the velocity of the
currents in the water-leg of the firebox. The opening of the safety-valve,
for example, would increase the speed at once. While when the pressure
was being raised, the water seemed quite stagnant.

In order to ascertain the likelihood of there being a straight flow of
cold water from the front to the rear over the top of the foundation ring,
a thermometer was placed at the back lower corner of the Jacobs-Shupert
firebox on the eighth, when being driven as already indicated and using
feed water at a temperature of about 70 degrees Fahr. When the boiler
was at work under 215 pounds’ pressure the observed temperature at this
point was 380 degrees Fahr., or only 13 degrees below the boiling point at
that pressure. This indicating either a circulation through hot portions
of the boiler before reaching the back end of the water-leg, or an agitation
of the water en route and its mingling with quantities of steam or hot
water by which its temperature was raised.

The tests cannot be regarded as conclusive because of their meager-
ness, but they indicate that neither the water nor steam velocities of a
locomotive firebox are high, and that the opening in the stay-plates of
the Jacobs-Shupert firebox are quite sufficient to admit the water in ample
quantities to all parts of the water-leg.

Finally I wish to suggest that many of the seeming inconsistencies of
these observations may be attributed to the interval of time between them.
This ran for fifteen minutes to forty-five minutes in which there was ample
time and opportunity for such changes to occur in direction of flow and
rate of evaporation as to fully account for the actual changes observed.

Respectfully submitted,

(Signed) Geo. L. Fow rer.

129
AIT. Experimental Methods and Observed
and Computed Results

128. There is presented in this chapter as Tables 8 to 30, inclusive,
the full exhibit of observed and calculated results derived from the evapo-
rative tests. Series A (Tables 8 to 19) consists of 21 tests, and for each of
these the water and steam record is presented separately for the barrel and
the firebox end. Series B (Tables 20 to 30) consists of 19 tests. This
gives a total of 40 tests reported. The facts associated with these tests are
presented under 125 headings. Each of these column headings bears a
number, and throughout the text, whenever tables are used, any given col-
umn number always refers to the same heading.

129. In general the methods employed have been those outlined by
the code for conducting boiler trials of the American Society of Mechanical
Engineers. The observed data tabulated have been corrected in so far as
necessary in accordance with calibrations of the instruments in question.
The Steam Tables of Marks and Davis have been employed.

130. That no one may be in doubt as to the significance of any item
given, the tables are preceded by concise explanations of the manner in
which the values of each column were obtained. This is as follows:

Table 8, Tests Series A, and Table 20, Tests Series B

General Conditions

131. Column 1. Designation of Test.—This column appears upon
each of the tables as a cross reference. The first term of this designation
indicates the series to which the test belongs, the second, the number given
the test, and the third, the boiler upon which the test was made. Thus,
the designation for the first test reported upon Table 8 is A-1—J, which
indicates that this test belongs to Series A, has been given the laboratory
number 1 and was conducted upon the Jacobs-Shupert boiler.

Column 2. Date of Test.

Column 3. Duration of Test, Hours.—In general it was sought to
have the duration of oil-fired tests such as would result in the consump-
tion of from 4,000 to 6,000 pounds of oil. In like manner it was sought
to have all tests during which coal was used of such duration that approxi-
mately 10,000 pounds of coal would be burned. For the low and medium
power tests, it will be noted that from 8,000 to 11,000 pounds of coal were
burned. For the high power tests, it was found impossible for a single
fireman to handle to the best advantage more than 6,000 or 7,000 pounds
of coal at the necessary rate of firing. On this account it was deemed

130
METHODS AND COMPUTED RESULTS

 

advisable to limit the tests to such a length as would permit one fireman
to work through an entire test. For high power test No. B-209-R, only
3,672 pounds of coal were fired. This test was closed at the end of 40
minutes on account of injector trouble.

Column 4. Power.—This column will be of service in indicating
approximately the load carried by the boiler. For Series A, the terms
“Low,” “Medium,” and “High” indicate approximately an equivalent
evaporation per square foot of heating-surface for the entire boiler per
hour of 4, 7, and 10 pounds, respectively. In like manner for Series B the
same terms indicate rates of 5, 10, and 15 pounds of equivalent evaporation
per square foot of heating-surface per hour.

Column 5. Furnace.—This column appears only upon Table 20
relative to Series B, indicating whether or not the firebox was equipped
with a brick arch. During Series A the fireboxes were without arches dur-
ing all tests. A description of the arches as installed during Series B wil]
be found in paragraph 74, page 77.

Column 6. Barometric Pressure, Pounds per Square Inch.

Column 7. Boiler Pressure, Gage, Pounds per Square Inch.—During
Series A the boiler pressure was recorded b oth for the firebox end and the
barrel end of the boiler. In all tests, however, the average values for the
two portions of the boiler were found to be the same and are so recorded,
The location of the gages and arrangement of piping showing the method
by which the pressure was equalized between the two ends of the boiler
are shown in Figs. 47 and 48, pages 58 and 59.

Column 8. Temperature of the Laboratory, Degrees Fahr., is the
average of observations taken upon an ordinary dry-bulb thermometer at
10-minute intervals.

Column 9. Temperature of Laboratory by Wet-Bulb Thermometer,
Degrees Fahr., is the average of observations taken upon a stationary wet-
bulb thermometer at 10-minute intervals.

Column 10. Temperature of Outside Air, Degrees Fahr.

Column 11. Temperature of Smoke-Box Gases, Degrees Fahr., was
determined by means of thermo-couples, the location of which is indicated
in Fig. 49, page 59.

Column 12. Draft Back of Diaphragm, Inches of Water.

Column 13. Draft Front of Diaphragm, Inches of Water.—For the
high power tests of Series B mercury manometers were used to determine
the draft in front of the diaphragm. In all other cases water manometers
were used in making draft determinations. Fig. 52, page 61, shows the
location of draft gages in connection with one of the boilers.

13]
TESTS OF A JACOBS -SHUPERT BOTLER

 

Table 9, Tests Series A, and Table 21, Tests Series B
Fuel

132. Column 14. Total Oil Burned, Pounds.—The oil used was
obtained from the Sun Company, Marcus Hook, Pennsylvania, and has
been referred to as “close cut.” It is stated that it had been specially
treated for the removal of sulphur. Its analysis is given in Table 16, page
152. Oil was delivered to a weighing tank set upon platform scales from
which it passed to a calibrated storage tank and thence by gravity to the
oil burner. Figs. 50 and 51, page 60, show the arrangement of the
oil tanks. The amount of oil burned, as shown by the calibration of the
storage tank, was recorded every 20 minutes.

Column 15. Oil per Hour, Pounds = column 14 + column 3.

Column 16. Kind of Coal.—Two kinds of coal were used during the
lests, Sealp-Level and Dundon Gas coal. The Sealp-Level coal was
mined in Cambria County, Pennsylvania, and may be described as a short
flame coal. The Dundon Gas coal, a long flame coal, was mined at Widen,
West Virginia, on the line between Clay and Nicholas counties. For
those tests marked “hand-picked”? lumps from 2 to 3 inches in diameter
and larger were used, the larger lumps being broken to size suitable for
firing. For test No. B-406-R coal which had been left from previous tests
was run over a 14-inch screen, thus removing a large portion of the very
fine coal which would otherwise have been unduly large for this particular
test. Upon Tables 15 and 26, pages 148 and 159, will be found chemical
analyses of the coal employed, and upon Tables 17 and 28, pages 150 and
161, will be found their calorific values.

Column 17. Coal as Fired, Total, Pounds.—All coal fired was weighed
on platform scales and distributed to the storage bins, two in number.
The fireman drew his supply from one bin for the check period of twenty
minutes. At the end of that time any coal remaining was weighed back
and the bin credited with same. The supply was then drawn from the re-
maining bin for the next check period. In this way each bin was in service
every alternate twenty minutes. Fig. 53, page 61, shows the arrange-
ment of scales for weighing coal and ash. As each coal barrow was brought
into the building a shovel of coal was taken from it and deposited in a con-
tainer. At the end of the test this sample was mixed and quartered, one-
quarter being placed in a shallow iron pan and covered. Weighings of this
sample before and after drying gave determinations as to accidental mois-
ture. After the accidental moisture determination had been made _ the
sample was again mixed, crushed and quartered until a suitable sized
sample was obtained which was placed in an air-tight container and for-
warded to the chemical laboratory.

Column 18. Coal as Fired per Hour, Pounds, = column 17 +

column 3.
METHODS AND COMPUTED RESULTS

Column 19. Coal as Fired per Square Foot of Grate per Hour,
Pounds, = column 18 + grate surface, square feet.

Column 20. Moisture Free Coal, Total, Pounds, = column 17 x (1 —
(column 80 + 100)).

Column 21. Moisture Free Coal per Hour, Pounds, = column 20 +
column 3.

Column 22. Moisture Free Coal per Square Foot of Grate per Hour,
Pounds, = column 21 + grate surface, square feet.

Table 10, Tests Series A, and Table 22, Tests Series B
Fuel (Continued)

133. Column 23. Total Ash, Pounds.—The ashes were drawn from the
ash-pan from time to time as the test progressed and weighed at the con-
clusion of the test. A shovel full of ashes was taken from each barrow
load after being weighed and placed in a container. This gross sample
was then mixed, crushed, and quartered until a suitable sized sample
remained which was forwarded to the chemical laboratory for analysis.

Column 24. Total Stack Cinders, Pounds.—A portion of the stack
cinders was collected by means of a spark-trap the nozzle of which
extended over the stack. The position of this nozzle, which was deter-
mined by a graduated quadrant, permitted collecting sparks from four
representative portions of the outflowing stream. The weighed portions
so collected were used as a basis for the determination of the total sparks
emitted. Fig. 56, page 64, shows the arrangement of the spark-trap as
attached to the stack.

Column 25. Moisture and Ash Free Coal Fired, Pounds, = column
17 x (1 — ((column 80 + column 83) +100)).

Column 26. Moisture and Ash Free Coal Fired per Hour, Pounds, =
column 25 + column 3.

Column 27. Moisture and Ash Free Coal Consumed, Pounds, =
column 25 — (column 23 x column 100 + 100) — (column 24 x column
99 + 100).

Column 28. Moisture and Ash Free Coal Consumed per Hour, Pounds,
= column 27 + column 3.

Column 29. Per Cent of Ash in Terms of Moisture Free Coal, =
(column 23 + column 20) x 100.

Column 30. Per Cent of Stack Cinders in Terms of Moisture Free
Coal, = (column 24 + column 20) x 100.

Column 31. Steam Used by Oil Burner, Pounds.—The amount of
steam used by the oil burner was determined by, passing it through a cali-
brated orifice placed in the line leading to the burner. The drop in pres-
sure at the orifice was determined by means of suitable pressure gages.

Column 32. Steam Pressure, Atomizer of Oil Burner, Gage, Pounds per

Square Inch.—The average of observations taken at 10-minute intervals.
133
TESTS OF A JACOBS-SHUPERT BOILER

 

Tables 11 and 12, Tests Series A, and Table 23, Tests Series B

Boiler Performance

134. Column 33. Temperature of Feed-Water, Firebox, Degrees Fahr.

Column 34. Temperature of Feed-Water, Barrel, Degrees Fahr.

Column 35. Temperature of Feed-Water, Degrees Fahr. All recorded
feed-water temperatures are averages of observations taken at 10-minute
intervals.

Column 36. Water Fed to Boiler, Corrected, Pounds.

Column 37. Water Fed to Boiler, Corrected, Firebox, Pounds.

Column 38. Water Fed to Boiler, Corrected, Barrel, Pounds.

Column 39. Water Fed to Boiler, Corrected, Total, Pounds.—The
water fed to the boiler was measured in calibrated tanks provided with
overflows to insure uniformity in filling. Four measuring tanks, two for
each boiler, were used, each of which was supplied with a feed-water tank
from which the injectors drew their supply. The arrangement of tanks is
shown in Fig. 50, page 60. Each injector, of which there were four, had a
separate measuring and feed-water tank. Observations were taken upon
the heights of water in the feed-water tanks every twenty minutes, making
possible the determination of the amount of water fed to the boiler for this
interval. The overflow from each injector was received in a barrel and
returned to its feed-water tank. During the tests of Series A with the
partitioned boiler, one injector with its measuring and feed tanks supplied
the firebox end of the boiler with water while another injector with its
complement of tanks supplied the barrel end. The values given in columns
36, 37, and 38 have been corrected for leaks, which in the majority of tests
amounted to nothing and in the other tests were very small and for differ-
ences of water-level and steam pressure in the boiler at the beginning and
end of the tests. All tests were so conducted as to make such differences
and therefore the corresponding corrections as small as possible.

Column 40. Water Fed to Boiler, Adjusted to Include Back Tube-
Sheet as Part of Firebox, Firebox, Pounds.

Column 41. Water Fed to Boiler, Adjusted to Include Back Tube-
Sheet as Part of Firebox, Barrel, Pounds.

Column 42. Water Fed to Boiler, Adjusted to Include Back Tube-
Sheet as Part of Firebox, Total, Pounds.—Upon page 42, paragraph 42,
will be found information relative to the heating-surface for firebox, barrel,
and total for each of the two boilers. Where the term heating-surface
appears in the following expressions it is expressed in square feet. The
partitioned boiler as actually tested was so arranged that the heating-
surface of the back tube-sheet was necessarily included as a part of the
heating-surface of the barrel instead of as a part of the firebox heating-
surface. In order that all results relative to evaporative performance
which are affected by the division of the boiler into firebox end and barrel

134
METHODS AND COMPUTED RESULTS

end may be based upon the firebox heating-surface which includes the back
tube-sheet and upon the barrel heating-surface which does not include the
back tube-sheet the following assumption has been made: The equivalent
evaporation per square foot of heating-surface of the back tube-sheet was
equal to the equivalent evaporation per square foot of heating-surface of
the remaining part of the firebox. In accordance with this assumption,
column 40 = column 37 + (column 37 x heating-surface of back tube-
sheet + (heating-surface of firebox — heating-surface of back tube-sheet)),
column 41 = column 38 — (column 87 x (heating-surface of back tube-
sheet + (heating-surface of firebox — heating-surface of back tube-sheet))
x (column 47 + column 48)), and column 42 = column 40 + column 41.
It will be evident that the differences which exist between corresponding
values in columns 39 and 42 are due to the slightly different conditions
which existed for the firebox end and barrel end as to feed-water tempera-
ture and quality of steam. All tabulated results relating to evaporative
performance may be calculated either from columns 37, 38, and 39, taking
into account the assumption made above, or may be calculated somewhat
more readily from columns 40, 41, and 42.

Column 43. Quality of Steam, Firebox.

Column 44. Quality of Steam, Barrel.

Column 45. Quality of Steam. The quality of steam was, in all
cases, determined through the use of throttling calorimeters and the
results are averages of observations taken at 10-minute intervals.

Column 46. Factor of Evaporation.

Column 47. Factor of Evaporation, Firebox.

Column 48. Factor of Evaporation, Barrel—The factor of evapora-
tion for a given test is the ratio of the heat supplied in producing a pound
of steam from average feed-water temperature to average boiler pressure
under average conditions of quality to the heat of vaporization of water
at 212 degrees Fahr. Expressed algebraically this becomes,

qt+ar—h
970 .4

where q = heat of liquid for average test conditions.

x = average quality of steam.

r = latent heat of vaporization for average test conditions.

h = average heat in feed-water above 32 degrees Fahr.
970.4 = latent heat of vaporization of water at 212 degrees Fahr. and

14.7 pounds pressure per square inch.

Column 49. Equivalent Evaporation, Firebox, Pounds, = column 47
x Column 40.

Column 50. Equivalent Evaporation, Barrel, Pounds = column 48 x
column 41.

Column 51. Equivalent Evaporation, Total Pounds.—In Table 12
Series A this column = column 49 + column 50. In Table 23 Series B

this column = column 36 xX column 46.
135
TESTS OF A JACOBS-SHUPERT BOILER

Column 52. Equivalent Evaporation per Hour, Firebox, Pounds, =
column 49 + column 3.

Column 53. Equivalent Evaporation per Hour, Barrel, Pounds, =
column 50 + column 3.

Column 54. Equivalent Evaporation per Hour, Total, Pounds, =
column 51 + column 3.

Column 55. Equivalent Evaporation by Firebox, Per Cent of Total,
= (column 49 + column 51) x 100.

Column 56. Equivalent Evaporation per Square Foot of Heating-
Surface per Hour, Firebox, Pounds.—The values in column 56 were cal-
culated in accordance with the expression ((column 37 x column 47) +
column 3) + ((heating-surface of firebox — heating-surface of back tube-
sheet). These values are also equal to (column 52 + heating-surface of
firebox).

Column 57. Equivalent Evaporation per Square Foot of Heating-
Surface per Hour, Barrel, Pounds, = column 53 + heating-surface in the
barrel.

Column 58. Equivalent Evaporation per Square Foot of Heating-
Surface, per Hour, total Pounds = column 54 + total heating-surface.
For Series A these values are also equal to ((column 37 x column 47) +
(column 38 x column 48)) + (column 3 x total heating-surface).

Table 13, Tests Series A, and Table 24, Tests Series B

Boiler Performance (Continued)

135. Column 59. Boiler Horse-power Developed = column 54 + 34.5.

Column 60. Ratio of Heating-Surface to Boiler Horse-power Devel-
oped, Firebox, = firebox heating-surface + (column 52 + 34.5).

Column 61. Ratio of Heating-Surface to Boiler Horse-power Devel-
oped, Barrel, = barrel heating-surface + (column 53 + 34.5).

Column 62. Ratio of Heating-Surface to Boiler Horse-power Devel-
oped = total heating-surface + column 59.

Column 63. Equivalent Evaporation per Pound of Fuel as Fired,
Pounds, = column 51 + column 14, for all tests reported in Table 13
in which oil was used as fuel, and = column 51 + column 17, for all tests
in which coal was used as fuel.

Column 64. Equivalent Evaporation per Pound of Moisture Free
Coal Fired, Pounds, = column 51 + column 20.

Column 65. Equivalent Evaporation per Pound of Moisture and Ash
Free Coal Consumed, Pounds, = column 51 + column 27.

Column 66. B.t.u. Absorbed by Boiler per Pound of Oil = column
63 x 970.4.

Column 67. B.t.u. Absorbed by the Boiler per Pound of Moisture
Free Coal Fired = column 64 x 970.4.

136
METHODS AND COMPUTED RESULTS

 

Column 68. B.t.u. Absorbed by the Boiler per Pound of Moisture
Free Coal Consumed = (column 70 x column 103) + 100.
Column 69. Overall Efficiency, per cent.—This is the ratio of the heat
units absorbed by the boiler to the heat units fired,
= column 66 + column 101 for all tests reported in Table 13 in
which oil was used as fuel,
= column 67 + column 103 for all tests in which coal was used as

fuel.

Column 70. Efficiency of Boiler and Furnace Excluding Grate, per
cent.—This is the ratio of the heat units absorbed by the boiler to the heat
units which may be considered as rising from the grate, = (column 65
x 970.4) + column 104.

Table 14, Tests Series A, and Table 25, Tests Series B
Smoke-box Gases and Air Supply

136. Column 71. Gas Analysis, CO, per cent. by volume.

Column 72. Gas Analysis, O., per cent. by volume.

Column 73. Gas Analysis, CO, per cent. by volume. The gas analyses
were made with the Orsat apparatus and are averages for continuous sam-
ples. Fig. 52, page 61, shows the position of the gas sampling tubes.
Where insufficient data regarding gas analyses or data that were obviously
In error were secured these have been omitted from the tabulations.

Column 74. Gas Analysis, N, per cent. by Volume = 100 — (column
71 + column 72 + column 73).

Column 75. Dry Gas per Pound of Carbon Consumed, Pounds, =
(4 x column 71 + column 72 + 700) + (3 x (column 71 + column 73)).

Column 76. Dry Gas per Pound of Moisture Free Coal Fired, Pounds,

= (column 75 xX column 85).

Column 77. Air per Pound of Carbon Consumed, Pounds, = column
74 + (.33 x (column 71 + column 73)).

Column 78. Air per Pound of Moisture Free Coal Fired, Pounds, =
column 85 x column 77.

Column 79. Ratio of Air Supplied to Theoretical Requirement =
column 74 + (column 74 — (3.77 x column 72)).

Table 15, Tests Series A, and Table 26, Tests Series B
Chemical Analysis—Coal

137. The chemical analyses and determinations of calorific values for
oil, coal, ash and stack cinders were made at the Pittsburgh laboratory of
the United States Bureau of Mines. For the tests during which oil fuel
was used one composite sample made up from separate samples for each

test was analyzed and reported upon. For the tests during which coal was
137
TESTS OF A JACOBS-SHUPERT BOILER

 

burned one sample each of coal, ash, and stack cinders were submitted for
each test, proximate analysis being made for each sample submitted and
calorific determinations being made for all coal and stack cinder samples.
Ultimate analyses were made for one sample of Scalp-Level coal and for one
sample of Dundon coal. From the ultimate analyses submitted by the
chemist an ultimate analysis was calculated for the coal of each test upon
the basis of its ash and sulphur as shown by the proximate analysis for that
sample and upon the assumption that the hydrogen, carbon, nitrogen, and
oxygen bore the same quantitative relation to each other in all samples,
namely, that shown by the single ultimate analysis.

Column 80 to 89, inclusive, Chemical Analyses, obtained from the
report of the chemist.

Table 16, Tests Series A, and Table 27, Tests Series B
Chemical Analyses—Stack Cinders—Ash—Oil

138. Columns 90 to 98, inclusive, Chemical Analyses, obtained from
the report of the chemist.

Table 17, Tests Series A, and Table 28, Tests Series B

Calorific Values

139. Column 99. Per cent. of Combustible in Stack Cinders = column
91 + column 92.

Column 100. Per cent. of Combustible in Ash = column 95 + column
96.

Column 101 to 105, inclusive, Calorific Values by Oxygen Calorimeter,
B.t.u., obtained from the report of the chemist.

Column 106. Calorific Value per Pound of Ash, Estimated, B.t.u.,—
for all tests during which Scalp-Level coal was burned column 106 =
column 104 x (column 100 + 100) x 0.912 and for all tests during which
Dundon coal was burned column 106 = column 104 x (column 100 +
100) x 0.945. The constants 0.912 and 0.945 appearing in these expres-
sions were determined in the following manner. Upon examination of the
calorific values submitted by the chemist for stack cinders it was found
that the combustible contained in those cinders had a heating value uni-
formly lower than the combustible in the coal from which the cinders orig-
inated. In the case of the Scalp-Level coal tests the average calorific value
of the combustible in the stack cinders was found to be 91.2 per cent. of
the combustible in the coal. In the case of the Dundon coal tests the
corresponding figure was found to be 94.5 per cent. These figures were
employed in the above expression for computing the calorific value of the
ash, thus assuming that the combustible in the ash was of substantially
the same calorific value as the combustible in the stack cinders.

138
METHODS AND COMPUTED RESULTS

Table 18, Tests Series A, and Table 29, Tests Series B
Heat Balance—British Thermal Units

140. Where insufficient data have been secured or data relative to
gas analyses have been omitted the corresponding heat balances have also
been omitted. The reliability of data relative to flue-gas analyses is not
comparable with that of other portions of the data. Heat balances for
all tests during which coal was burned for which sufficient data were
secured are presented notwithstanding the fact that some of the results
are obviously inconsistent.

Column 107. B.t.u. per Pound of Moisture Free Coal = column 103.

Column 108. B.t.u. absorbed by Boiler per Pound of Moisture Free
Coal = column 67.

Column 109. Loss Due to Moisture in Coal, B.t.u., = (column 80 +
(100 — column 80)) x ((212 — column 8) + 970.4 + 0.47 x (column 11
— 212)).

Column 110. Loss Due to Moisture in Air, B.t.u., = ((grains mois-
ture per pound of air) + 7,000) x column 78 x (0.47 x (column 11 —
column 8)). The number of grains of moisture per pound of air was deter-
mined by means of psychometric tables and the data given in columns 8
and 9.

Column 111. Loss Due to Hydrogen in Coal, B.t.u., = (column 84
+100) x9 x ((212 — column 8) + 970.4 + (0.47 x (column 11 — 212)).

Column 112. Loss Due to Escaping Gases, B.t.u., = 0.24 x column
76 x (column 11 — column 8).

Column 113. Loss Due to Incomplete Combustion, B.t.u., = (column
85 + 100) x (column 73 + (column 71 + column 73)) x 10,150.

Column 114. Loss Due to Stack Cinders, B.t.u., = (column 24 +
column 20) x column 105.

Column 115. Loss Due to Ash, B.t.u., = (column 23 + column 20)
x column 106.

Column 116. Loss Due to Radiation and Unaccounted for, B.t.u., =
column 107 — (column 108 + column 109 + column 110 + column 111
+ column 112 + column 113 + column 114 + column 115).

Table 19, Tests Series A, and Table 30, Tests Series B

Heat Balance—Percentages

141. Column 117. Heat Absorbed by the Boiler, per cent., = (column
108 + column 107) x 100.

Column 118. Heat Loss Due to Moisture in Coal, per cent., = (col-
umn 109 + column 107) x 100.

Column 119. Heat Loss Due to Moisture in Air, per cent., = (column

110 + column 107) x 100.
139
TESTS OF A JACOBS-SHUPERT BOILER

Column 120. Heat Loss Due to Hydrogen in Coal, per cent., = (col-
umn 111 + column 107) x 100.

Column 121. Heat Loss Due to Escaping Gases, per cent., = (column
112 + column 107) x 100.

Column 122. Heat Loss Due to Incomplete Combustion, per cent., =
(column 113 + column 107) x 100.

Column 123. Ieat Loss Due to Combustible in Stack Cinders, per
cent., = (column 114 + column 107) x 100.

Column 124. Heat Loss Due to Combustible in Ash, per cent., =
(column 115 + column 107) x 100.

Column 125. Heat Loss Due to Radiation and Unaccounted for, per
cent., = (column 116 + column 107) x 100.

140
METHODS AND COMPUTED RESULTS

GENERAL CONDITIONS
TESTS SERIES A
Table 8

| TEMPERATURE—DEGREES

 

 

| FAHRENHEIT Dusne
DESIGNA- he | MORE “ETRIC, | eae | LABORATORY | |
nen OF | OF | POWER | Sonn |,8UR& |—— a ; BACK FRONT
case | Eee || tae pee SUR [ume | oe ware| Ge, | Pee [Ore Ona
a ew (eka AIR GASES | ins. of | ins. of
MOM- MOM- water water
| | | ETER | ETER
1 2 3 | 4 | 6 7 8 | 9 10 TT ||) xd 13
A- LJ | 3-18-12} 5.00 Low 14.6 216.4 | 72.0 70.9 68 455 | 1.2 1.5
A- 2S | 3-12-12) 3.67 | Medium 14.5 210.4 53.6 Site 37 566 | 1. 2.6
A- 3-3 | 3-20-12) 4.00 | Medium 14.6 | 215.2 57.9 | 56.6 61 562 | 2.0 3.0
A- 4-J | 3-11-12) 3.00 High 14.5 212.2 | 50.0 49 4 37 730 3.2 532
A- 5-J | 3-20-12} 3.00 | High 14.6 215.0 | 59.0 | 58.8 60 | 642 | 4.0 6.5
A- 6-R | 3-13-12; 5.00 Low 14.4 216.4 57.8 57 3% 49 473 0.9 1.2
A- 7-R 3-12-12) 3.00 Medium 14.5 211.7 | 49.5 eaten) “ee 598 | 2.0 2.8
\— 8-R , 3-16-12) 4.00 Medium 15.1 217.6 54.9 Ravin 44 582 2.0 2.6
A- 9-R | 3- 8-12) 3.00 High 14.3 214.8 53.0 52.3 41 O74 4.0 6.1
A-101-J | 3-29-12) 6.00 Low 14.3 217.6 68.6 oe ok 67 529 0.6 L.2
A-102-J | 4-— 3-12) 5.00 Low 14.5 215.1 47.0 46.0 49 562 0.8 1.3
A-103-J | 3-30-12) 3.83 Medium 14.7 217.0 49.9 47.9 50s} 44
A-104-J0 0 4- 3-12) 3.00 Medium 14.5 |) 214.1 42.6 Atos. ly) cade 581 | 2.1 4.2
A-105-J_ | 4- 1-12) 2.00 High 14.6 | 215.2 64.0 mane 59 617 | 3.2 7.3
A-106-3 | 4- 5-12, 2.00 High 14.7 Q14.0 | 56.1 49 4 55 639 | 3.3 6.7
A-107-R | 4— 4-12) 5.00 Low | 14.8 216.8 51.3 45.3, 46 602, 0.9 1.8
A-108-R | 3-28-12) 7.00 | Low | 14.6 | 217.0 61.5 61.2 59 499 | 0.6 1.1
A-109-R | 3-27-12) 4.00 Medium 14.6 215.6 | 56.9 55.8 57 | 572 | 1.9 3.4
A-110-R | 4— 2-12} 3.33 Medium 14.2 216.5 65.6 62 568 | 1.6 SA
A-IILER | 4-11-12) 2.00 | High | 14.6 | 214.7 | 54.2 | 54.2 50 | «G18 3.9 77
AHR | 4 #12 2.00 | High | 14.8 214.2 56.1 | 48.9 51 615 | 3.2 6.4

 

141
TESTS

OF

A JACOBS-SHUPERT BOILER

 

| OIL

 

DESIGNA-
TION |
OF TEST |

 

TOTAL | PER HOUR

pounds pounds
a Se
1 | 44 15
A- 1-J 736
A- 2 1,453
A- 3J | 1,399
A- 43 | 2,156
AS J | 9,117
A- 6-R 790
A- 7-R 1,504
A- SR 1,440
A- 9-R 2.106
A-101-J |
A-102-J |... feupesssi tots
A-103-J3 | aN dsAar2S Hat ee
A-104-F | o..c.. | esas.
A-105-J | .....
A-106-J | aaa eh
PUR ccce. wears
A-108-R J sees [Petes
A-109-R | oweces | ween
A-110-R........ fpovseee
BOVE |) asaee: WV (eeeea
A=1ie-K | xssaue |i) eeees

FUEL

TESTS SERIES A
Table 9

 

COAL AS FIRED MoIsturE FREE COAL

 

ror | PER SQ.FT. PER SQ.FT.

COAL TOTAL | PERHOUR|OFGRATE| TOTAL | PERHOUR | OF GRATE

| pounds pounds | PERHOUR| pounds | pounds | PERHOUR

pounds | pounds
16 17 18 19 20 | 21 22
| |

sates erases sles ah eee es lil cee eee
stalalanata | was tela sicuaaes Pena | Ske eth | ee)
eae Jovsee aE, ee ee | ee | ae
Scalp es 8,206 1,368 24.1 7,946 | 1,324 | 23.3
| Dundon 8,285 1,657 29.2 8,109 | 1,622 | 98.6
Scalp Level] 9,871 2.575 45.3 9,577 2,498 | 44.0
Dundon 9,269 3,090 54.4 8,969 2,990 52.6
Dundon 8,682 4,341 76.4 8,455 4,228 | 74.4
Dundon 8,929 4,465 78.6 8,783 4,392 | 77.3
Dundon 8,784 1,757 30.2 8,606 1,721 29. 6
Scalp Level) 10,165 1,452 25.0 10,040 1,434 24.7
‘Scalp Level) 9,888 2,472 42.5 9,672 2,418 | 41.6
Dundon | 9,677 2,903 49.9 9,449 2,835 48.7
Dundon | 8,690 4,345 T4.7 8,500 4,250 73.1
Dundon 8,542 4,271 73.4 8,275 4,138 71.1

 

 

 

142
METHODS AND COMPUTED RESULTS

 

FUEL (Continued)

TESTS SERIES A

 

 

 

 

Table 10
PER Ee «
| MOISTURE AND | MOISTURE AND | cENT CENT. STEAM
ASH FREE COAL | ASH FREE COAL OF _OF PRES-
; STACK Ee oes 48H loinpens| UsED | “aT
DESIGNATION pee CINDERS rnurs IN | BY ATOM-
nen | pounds | TOTAL oa TERMS OIL IZER
| oe mors- | yots- | pounds | BURNER
TOTAL, | Sore | TOUAU | noe: | eRag | TUES Ibs. per
pounds | pounds | POURdS | pounds | coaL ee odes
1 23 24 25 26 27 28 29 30 31 32
A= 2J | 420 | 9.5
A- 2J | 262 | 7.6
A- 3-3 285 | 7.6
A= 44 | 193 | 6.2
A- 5-J 250 | 9.4
A- 6-R 351 | 7.3
A- 7B 932 | 8.5
A- 8&R | 305 | 8.2
A- 9-R ies ee eee Repke a) Ul) etevacey Bars babetvn ace 158 4.2
A-101-J 353 112 7,511 1,252 | 7,197 1,200 4.4 1.4
A-102-J 230 68 7,365 1,473 7,279 1,456 2.8 0.8
A-103-J3 365 492 9,109 2,376 8,456 2,206 3.8 5.1
A-104-J 270 70 7 A384 2,478 7,336 2,445 3.0 0.8
A-105-J 65 93 7,753 3,877 7,670 3,835 0.8 1.1
A-106-J3 218 93 8,015 4,008 7,900 3,950 2.5 1.1
A-107-R 315 87 7,870 1,574 7,774 1,555 Oat: 1.0
A-108-R 353 208 9,436 1,348 9,078 1,297 3.5 2.1
A-109-R 292 479 9,211 | 2,303 8,675 2,169 3.0 5.0
A-110-R 256 76 8,648 2,594 8,568 2,570 a1 0.8
A-111-R 229 61 7,557 | 3,779 7,465 3,733 Date 0.7
A-112-R 404 61 7,376 3,688 7,248 3,624 4.9 0.7

 

 

 

 

 

 

 

 

 

 

 

 

 

143
TESTS OF A JACOBS-SHUPERT BOILER

BOILER PERFORMANCE

TESTS SERIES A

  

      

 

 

Table 11
TEMPERA WATER FED TO a yap

TE) PE LA ATE PE ce i BOILER Stk FACTOR OF

Fre eo Watmte he Sau Pe Bea aael EVAPORATION
DESIGNATION PART OF FI
OF — =
TEST

fone aaa Seen ee TOTAL as eo TOTAL FIRE-  BAR-  FIRE-  BAR-

Geet dees Ibs. Ibs. lbs. tbs. Ibs. Ibs. BOX REL BOX REL

1 33 384 37 388 89 | 40 41 42 43 44 47 48
A- 1-J 53.8 538.5 | 22,145 26,376 48,521. 25,315 23,195 48,510 0.998 0.993 1.2119 1.2079
A- 2-J 45.3 45.0 27,440 38,801 66,241) 31,368 34,847 66,215 0.997 0.986 1.21911.2111
A- 3-J 55.7 | 55.3 | 26,733 42,468 69,201 30,559 38,635 69,194 0.995 0.9921.2078 1.2061
A- 4-J 43.7 43.1 25,083 48,951 74,034 28,674 45,307 73,981 0.997 0.9761.2223 1.2042
A- 5-J 55.7 54.4 24,315 47,676 71,991 27,796 44,182 71,978 0.997 0.991 1.2095 1.2052
A- 6-R 46.7 44.9 24,570 26,523 51,093 28,340 22,750 51,090 0.997 0.994.1.2198'1.2190
A- 7-R 46.8 44.9 20,804 33,086. 53,890 23,997 29,896 53,893 0.996 0.995 1.2181 1.2184
A- 8-R 49.5 46.8 31,181 40,043 71,224. 35,966 35,258 71,224 0.997) 0.995,1.2173)1.2178
A- 9-R 47.6 44.5 | 25,502 43,001 68,503 29,415 39,082 68,497 0.996 0.991/1.2179 1.2164
A-101-J 56. 56.6 26,705 45,547) 72,252 30,527 41,708 72,235 0.996 0.990 1.2087 1.2034
A-102-J 54.2 54.5 25,088 33,864 58,952 28,678 30,263 58,941 0.996 0.992 1.2106 1.2071
A-103-J 52.9 | 52.4 | 24,727 55,388 80,115 28,266 51,842 80,108 0.997) 0.993. 1.21341.2110
A-104-J 55.0 53.4 | 21,319 42,392) 63,711 24,371 39,339 63,710 0.996 0.993 1.2096 1.2089
A-105-J 56.5 | 57.0) 17,371 41,369 58,740 19,857 38,878 58,735 0.994 0.993 1.2068 1.2050
A-106-J 50.8 51.6 17,387 39,333 56,720 19,875 36,846 56,721 0.994 0.995 1.2118 1.2126
A-107-h 52.4 50.3 | 25,810 35,089 60,849 29,771 31,077 60,848 0.997 0.9941,.2134 1.2129
A-108-R 56.5 54.4 32,029 54,833 86,862 36,945 49,916 86,861 0.997 0.9941.2095 1.2088
A-109-R 53.9 | 52.3 | 22,123) 57,709) 79,832 54,307, 79,826 0.998 0.993 1.2123 1.2099
A-110-R 59.0 57.0 23,604 43,979. 67,583) 27,226 40,355, 67,581 0.996 0.993.1.2056 1.2049
A-111-R 56.4 56.3 17,204 42,116 59,820 19,845 39,468 59,313 0.996 0.992 1.20861.2051
A-112-R 55.4 52.9 15,780 AIST 57,094 18,202 38,895 57,097 0.996 0.995 1.2096 1.2106

144
METHODS AND COMPUTED RESULTS

BOILER PERFORMANCE (Continued)
TESTS SERIES A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 12
BQUIY-
EQUIVALENT EVAPORATION BOUL ALENT UAT ORAZIGN) ALENT ae RQ. FT. Ty pare
DESIGNATION ORATION) BUpEagn sa OUR
“i Mon BaRReL| Toran | QRX | BARREL | romas: ereenee ox | BARREL | TOTAL
pounds | pounds ; pounds pounds pounds | pounds CENTS pounds pounds | pounds
1 49 50 51 52 53 54 | 55 56 57 58
aby oe s a fae a : | pean ee) ree eee ee ee ee |e

A- 1-J 30,680 | 28,018 | 58,698 6,136 5,604 | 11,740 | 52.27 | 26.59 2.02 | 3.90
A- 2J 38,240 | 42,205 | 80,445 | 10,428 | 11,509 | 21,937 | 47.54 | 45.18 4.14 7.29
A- 3-J 36,908 | 46,598 | 83,506 9,227 | 11,650 | 20,877 | 44.27 | 39.98 | 4.19 6.94
A- 4-J 35,048 | 54,558 | 89,606 | 11,683 | 18,186 | 29,869 | 39.11 | 50.62 6.55 9.93
A- 5-J 33,619 | 53,249 | 86,868 | 11,206 | 17,750 | 28,956 | 38.70 | 48.55 6.39 9.63
A- 6-R 34,569 | 27,732 | 62,301 6,914 5,546 | 12,460 | 55.48 | 33.45 2.00 4.18
A- 7-R 29,230 | 36,423 | 65,653 9,743 | 12,141 | 21,884 | 44.52 | 47.14 4.37 7.33
A- 8-R 43,782 | 42,935 | 86,717 | 10,946 | 10,734 | 21,680 | 50.49 | 52.96 3.86 7.27
A- 9-R 35,825 | 47,540 | 83,365 | 11,942 | 15,847 | 27,789 | 42.97 | 57.78 5.71 9.31
A-101-J 36,896 | 50,191 | 87,087 6,149 8,363 | 14,514 42.36 | 26.64 3.01 4.82
A-102-J 34,718 | 36,530 | 71,248 6,944 7,306 | 14,250 | 48.74 | 30.09 2.63 4.74
A-103-J 34,300 | 62,781 | 97,081 8,949 | 16,379 | 25,328 35.33 | 38.77 5.90 8.42
A-104-J 29,479 | 47,558 | 77,037 9,826 | 15,853 | 25,679 | 38.27 | 42.57 5.71 8.54
A-105-J 23,964 | 46,846 | 70,810 | 11,982 | 23,423 | 35,405 | 33.84 | 51.92 8.43 | 11.77
A-106-J 24,085 | 44,680 | 68,765 | 12,043 | 22,340 | 34,383 | 35.03 | 52.18 8.04 | 11.43
A-107-R 36,125 | 37,692 | 73,817 7,225 7,538 | 14,763 | 48.93 | 34.95 2.71 4.95
A-108-R 44,683 | 60,337 |105,020 6,383 8,620 | 15,003 | 42.54 | 30.88 3.10 5.03
A-109-R 30,936 | 65,707 | 96,643 7,734 | 16,427 | 24,161 | 32.01 | 37.42 5.91 8.10
A-110-R 32,824 | 48,625 | 81,449 9,848 | 14,589 | 24,437 40.30 | 47.64 5.25 8.19
A-111-R 23,984 | 47,563 | 71,547 | 11,992 | 23,782 | 35,774 | 33.52 | 58.02 8.56 | 11.99
A-112-R, 22,017 47,087 | 69,104 | 11,009 | 23,544 | 34,553 | 31.86 | 53.26 8.48 | 11.58

 
TESTS

OF A JACOBS-SHUPERT BOILE

BOILER PERFORMANCE (Continued)
TESTS SERIES A

R

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Table 13
—
ees Ne EQUIVALENT EVAP- B. T. U. ABSORBED ENCE
TO BOILER HORSE- ORATION BY THE BOILER
PowER DEVELOPED ee
[OVER ALL]| NACE EX-
oe POUND eee OF | GRATE)
DEBIGNATION Bae mia Seay OF PER Boers B.T.U. | PER CENT.
angen DEVE eounp| or | MOIS= POUND|* ‘Gp | ABSORBED] OF B.T.U,
OPED | prRE- | BAR- or | mors- | "Np. PounD saat More Sone fae
TOTAL| FUEL | TURE TURE
BOX | REL Ag. |GaRpn, || 48H OF | TURE | ppeR PER BOILER
vinup | coaL | FREE | OI | FREE | Goar, | POUND PER
Ibs. |¥IRED | COAL COAL | Con | OF FUBL | POUND
Ibs for FIRED | syppp| FIRED OE WHER
lbs. SUMED
1 59 60 61 62 63 64 | 65 | 66 67 | 68 69 70
| oes
A- 1-J 340 | 1.30 } 17.10] 8.84 | 15.96}...... | eae 15,488}. ..... eee BOG8. 4] satandes
A- 2J 636 | 0.76 6.38) 4278 | 16.10) |. 02542 Jobe PA CBI aisccvers| eraawore 3 T6385. Cl ek ee
A- 3-J 605 | 0.87 8.23 | 4.97 | 14.92 es scear ees V4 ASD coe Ala ake TORAAD IN) GS
A- 4-J 866 | 0.68 5.27| 3.48 |13.86]......)...... 13,446). ..... eaed es | 70205: | cae aes
A- 5-J 839 | 0.71 &.40| 3.68 | 13.68 jcc cccleccess WSBT Bliss heen 69.15" |) -vedee
A- 6-R B61 | 1.03 | VF 287) BQO | VST hic.e ae ale oun 3 U5 SOF les 85 erlioe lade | MOT 2) pense
A- 7-R 634 | 0.73 7.89) 4.70 | 14.55]......).... oil PAGAL TB occ czas | iain jo! iSeDoo | eae
A- 8-R 628 | 0.65 $93) 40°78 | S06. eee Vee aoa celal] LA OMB cia ccass ieee GTA |) ei tice
A- 9-R 806 | 0.60 | 6.05) 3.71 ]13.20]...... frees 12,809). 0... Kee 66.70 | .....
A-101-3 421 | 1.33 | 11.45) 7.39 | 10.61) 10.96/12.10!...... 10,636 Ree 71.62 TA.75
A-102-J3 413 | 1.15 | 13.12] 7.28 8.60} 8.79| 9.79]...... 8,526} 8,626) 62.01 62.74
A-103-J 734 | 0.89 5.85 | 4.15 9.84] 10.14] 11.48]...... 9,837| 10,595| 65.79 70.86
A-104-J 744 | 0.81 6.04] 4.04 8.31] 8.59) 10.50)...... 8,335} 8,447) 67.39 68 .30
A-105-J 1,026 | 0.66 | 4.08) 2.93 8.16) 8.38 | Qu QS anya ary 8,127) 8,215) 58.65 59.28
A-106-J 997 | 0.66 4,.30| 3.02 | 7.70) 7.83) 8.70)...... 7,597| 7,707) 55.12 55.91
A-107-R 428 | 0.99 | 12.70] 6.96 8.40) 8.58] 9.50)...... 8,323} 8,428} 60.22 60.97
A-108-R 435 | 1.12 | 11.11] 6.86 | 10.33]10.46)11.57)...... 10,150] 10,549) 68.65 71.35
A-109-R 700 | 0.92 5.83] 4.26 9.77 | 9299) WL. 14 | nos 9,696] 10,295) 64.68 68 .68
A-110-R 708 | 0.72 6.57) 4.21 8.42] 8.62) 9.51]...... 8,365| 8,442) 60.51 | 61.07
A-111-R 1,037 | 0.59 4.03] 2.88 893.) B.42)) 95589). ccose « 8,168} 8,270, 61.10 61.86
A-112-R 1,002 | 0.65 4.07] 2.98 8.19 | 8.35] 9.54]...... 8,104 8,249] 60.09 | 61.16

 

146
METHODS AND COMPUTED RESULTS

SMOKE BOX GASES AND AIR SUPPLY
TESTS SERIES A

 

 

 

 

 

 

 

 

 

 

Table 14

| Gas ANALYSIS Dry Gas | AIR RATIO

PER CENT BY VOLUME PER POUND PER POUND Sain

aaa TIGN) =} — oo

S CARBON | MOISTURE) CARBON | MOISTURE)

pounds | pounds | pounds pounds | reine
1 71 72 73 | 74 75 | 76 | 77 | 78 | 79

| _| | Sar

|

A- 1-J | 13.1 | o.1 0.0 83.8 19.2 | ae: | 19.4: | Sitcee | 1.2
A- 2-J | 13.0 | 1.2 0.2 85.6 LO SO. |i) sabiets & 1 TR gees Ll
A- 33 12.1 3.5 0.0 84.4 208% I devs [i soaeOn | cas: 1.2
A- 4J 12.4 | 2.6 0.3 84.7 LOR Wl ses | BOO wl hk ss | 1.1
A- 5-J 13.7 | 0.4 0.7 85.2 LISOe | | aveke cs 1 a ee 1.0
A- 6-R 11.4 | 5.3 0.0 83.3 QQ AO ih aha Doe Wh. fate as | 1.3
A- 7-R 10.4 5.9 0.0 83.7 QAO | lt) kena: 24.4 ] 22... | 1.4
A- 8-R 12.9 2.8 || 0.0 84.3 19%? | \) Piatto | LOBE Ti tte | 1.1
A- 9-R 12.4 2.3 0.2 85.1 198 Once Ne2025° ||) owes / 1d
A-101-J 10.1 | 8.0 0.4 81.5 23.8 | 20.4 23.5 20.2 1.6
A-102-J 9.2 7.5 0.5 82.8 25.6 | 19.7 25.9 20.0 1.5
A-103-J 7.0 11.7 0.1 81.2 34.7 | 30.0 34.7 30.0 | 279
A-104-J 12.5 | .3 O70 81.5 16.5 11.6 16.2 11.4 | 1:2
A-105-J 12.9 2.8 2.8 81.5 16.0 12.5 15.7 12.3 1:2
A-106-J VW .7% 3.2 2.0 83.1 | 18.3 | 14.2 18.4 14.3 1.2
A-107-R 7.4 11.6 0.3 80.7 | 32.1 | 24.9 31.8 24.7 | 2.2
A-108-R 9.7 8.5 0.1 81.7 95.4 | 21.7 25.3 21.6 1.7%
A-109-R | 11.9 5.3 | 0.2 82.6 20.7 | 18.0 20.7 17.9 1.3
A-110-R | 8.7 9.8 0.3 81.2 | 97.6 | 21.5 27.3 || as
A-111-R 8.0 10.8 0.4 80.8 29.5 22:3 29.2 29:.1 | 2.0
A-112-R | 9.7 8.8 0.3 81.2 | Q4.9 | 18.9 24.6 18.7 | 1337

 

 

 

 
TESTS OF A JACOBS-SHUPERT BOILER

CHEMICAL ANALYSIS—COAL
TESTS SERIES A

 

 

Table 15
PROXIMATE ANALYSIS ULTIMATE ANALYSIS
CoAL AS FIRED MoIsTuRE FREE COAL
DESIGNATION | = Ss ‘ : a
ein | MOIS- aes | RIXED | gu | ) ae carpon | NITRO-  oxyarn SUL- ee
per cent. MATTER por cent. per cent. per te per cent. Der eet per cent. per cent. \per cent.
a
1 80 | 81 82 83 | 84 85 86 87 88 89
| |

A- 1-J ; ane CA

A= 2 ie | ay | aoe

A- 3 Whe Sais | eta |

A- 4-J } .

AS BS | tl |

A- GR | | |

A- 7-R |

A- 8-R |

A-101 —J | 3.17 16.14 75.40 5.30 4. 34 85.86 | 1.33 2.30 0.69 | 5.47

A-102-J 212 36.52 | 52.39 8.98 4.81 , 77.18 1.52 6.40 0.92 | 9.17

A-103-J | 2.98 16.40, 75.86 4.75 4.37 86.46 | 1.34 2.31 0.62 | 4.90

A-104-J3 3.24 31.58 | 48.62 16.56 4.39 70.43 1.39 5.84 0.84 | 17.11

A-105-J 2.62 34.72 | 54.58 8.08 4.86 77.92 | 1.53 6.46 | 0.93 8.30

A-106-J 1.63 35.42 | 54.35 8.60 4.83 77.54 | 1.53 6.43 0.93 8.74

A-107-R | 2.03 35.61 | 53.98 8.38 4.85 Tr 1.53 6.45 | 0.90 8.55

A-108-R | 1.23 16.36 76.47 5.94 4.31 85.43 | 1,33 2.29 | 0.63 6.01

A-109-R 2.18 17.05 | 76.10 4.66 4.37 86.59 | 1.34 2.32 | 0.62 4.76

A-110-R 2.36 34.82 | 54.55 8.28 4.85 77.86 | 1,53 6.46 | 0.82 8.48

A-111-R | 2.19 34.56 | 52.40 | 10.84 4.71 75.59 | 1.49 6.27 | 0.86 | 11.08

A-112-R | 3.13 33.74 | 62.62 | 10,52 4.73 75.87 1.49 6.29 | 0.75 | 10.86

 

 
METHODS AND COMPUTED RESULTS

CHEMICAL ANALYSIS—STACK CINDERS—ASH—OIL
TESTS SERIES A
Table 16

PROXIMATE ANALYSIS PROXIMATE ANALYSIS

 

 

 

DESIGNA- StTacK CINDERS SH
= = ULTIMATE ANALYSIS
TION | mors- ee | poset. | caper mole | aS | pixep | asi ROLE
or Test | TURE  yyapppR CARBON TURE = warrpr CARBON
per cent. per cent. /P& cent. per cent. per cent. ner cent, Pe cent.|per cent.

1 90 91 92 93 94 95 96 97 | 98
A- LJ | ee er eral eee ima ee Sr eN Cena ll anton Sith gSrtensy
Ad A eer un ieee | conereatetee || Mia ern ie tncece alll Gee tall) ronan Se 8e [I reves per cent.
A- 3-3 | ROT eter el eee viocem eee Hees OMe Me tee egal ll Aton 8 Hydrogen..... 12.39
Ae Alc) lr er rN a reg | Marc eran NN tee Ra cree g Mee ate aeRO lll ee ace Al tay Carbon........ 86.85
Fee I ener nearer ase meee dpe Wty lloe apes MN ee tall ac Sulphur. ...... 0.29
(Naan O— Rall an oan noe Meek ee van cee | MG ee Abell phn ull! auetersg Water......... 0.00
A- TR | ee ee kl eer eee ee Were ea Meee ||| eee aera Sand a s2cax 2% 0.00
ACA S= Helen wera ie eet ee sees Lee re || late ea ela ta Ill owned
Resor ie INN! aaa: lReseterte mere ot nA cee ethane |) me 99.53
A-101-J | 1.22 | 3.73 | 62.80 | 82.25 | 0.85 | 3.25 | 65.28 | 31.17 egtiecea
A-102-J | 16.45 | 4.96 43.56 | 35.08 7.89 | 2.73 20.34 69.04 | ee ae oe
A-103-J | 0.42 | 2.48 | 74.83 | 22.82 | 0.21 | 2.82 | 73.42 | 24.05 | viscosity (Engler
A-104-J | 1.08 4.76 52.42 41.74 7.80 2.27 19.21. 70.72 Degree at 20° C.) 1.6
A-105-J | eave | eee pee ae ae et 8.03 2.14 20.40 69.43 | Flash Point—
A-106-J | 0.50 | 2.65 | 71.20 25.65 | 6.97 | 1.857 | 19.37 | 72.09 ees
AOR) 7.93 | 6.10 48.44 48.13 0.40 | 1.78 | 15.10 | 82.72 | tbe... 8020
A-108-R| 8.10 | 3.93 | 66.71 28.55 0.38 | 4.71 55.80 | 39.11 | Ignition Point—
A-109-R,| 0.37 | 2.74 | 72.53 | 24.36 | 0.32 | 5.09 55.14 | 39.45 | — (Pensky - Mar-
A-110-R| 0.78 | 4.45 | 42.94 51.83 | 0.53 1.86 | 15.15 | 82.46 Hiss en
A Ud Ess lige | sea es Weer earl eet | 0.827) 1.48 | 20.80°| 97.64) Gaitas nar man
A-112-R | 0.48 | 2.384 67.36 29.82 0.35 | 1.67 19.67 | 78.31 | high value . . . 10664

 

149
DESIGNATION

OF
TEST

1
A- LJ
A= 2-J
A- 3-J
A- 4-J
A- 5-J
A- 6-R
A- 7-R
A- 8-R
A- 9-R
A-101-J
A-102-J
A-103-J
A-104-J

A-105-3

A-106-J

A-107-R
A-108-R
A-109-R
A-110-R
A-111-R
A-112-R

OF A JACOBS-SHUPERT BOILER

CALORIFIC VALUES

 

 

 

 

TESTS SERIES A
Table 17

| CALORIFIC VALUE BY OXYGEN CALORIMETER

 

CALOR-

l IFIC
| PER CENT.) por CENT. | | PER VALUE
| OF COM” | of coM- I ge VER. | pounp: | 32 PER
BU Rupes senrBiis PER | aR an ars. OF me | SAD UL
STACK IN FOUND | OF COAL TURE oO sa OF stack | ‘Ty DOH
CINDERS ner OF OIL |asrrrep | FREE | AND ASH | onpers | Bas
| BeT Us | alm GORE FREE Beas | MATED]
| ee Coan | | Bru.
| | | | |
|__| = _ |—
99 | 100 | 101 102 103 104 | 105 106
} — S| eee 2a See ee Pe —=
fr ROTO S|) caeakty i) Stew ee ll Sivwteg || seein Lil ocetitg
POT OS = | asda 1) | wee. | eaves? il) ote W saiopeeics,
Ih ranted S POO ii nekte lel Gussmecan |) “aheswesx [Alle eorctx nets
|
Nea ee ILO TOSS le ecteoe | Mantra ac ti are see Ul a erie ph enawes
HELO MMOD nil esnue® | osrmmany bh a umaysee. [lll | siseeasces Ill eapeeyes
| 19,195 | waeeies || pea f omega ||! Catia We sachs
mthat SG TO5: 2/1) hada ie ees siganten |'|ll aeathees
LOSTO RAN Reece pee een Illeana elt UR le ht eee
oe ae T9A95 | sands Spas | | keke Wty Petaszeit nore ete
i6 68.48 | Peete 14,380 14,850 | 15,710 | 9,585 | 9,809
48 52 QB.0F | sc ees 13,458 13,750 15,140 6,766 | 3,299
76.76 TOtAG AN oS snaps 14,506 14,953 15,721 10,958 10,857
57.18 21.48 11,967 | 12,368 14,920 | 8,233 3,074
oe 22.54 steps, | ESMGR | 49/886" | Ts1Is: | eau. 3,217
73.85 BORO Wr) Shore 13,559 13,784 15,106 | 10,510 2,988
49.54 POs88° Pass 13,542 13,822 15,115 | 6,937 2,410
70.64 60.51 |, eesres 14,604 14,785 15,734 | 10,193 8,612
| |
75.27 60.23 | ateciae 14,663 14,990 15,741 10,701 8,645
47.39 | 17.01 | ..... 13,498 | 13,824 15,106 | 6,865 2,428
wise 22.04 | ..... | 13,076 | 13,969 | 15,085 | ..... | 3,130
69.70 21.34 |) | Jecctaecas 13,065 | 13,486 15,129 9,878 | 3,050
: i | |

 
METH

ODS

AND

COMPUTED RESULTS

HEAT BALANCE—BRITISH THERMAL UNITS

TESTS SERIES A

Table

 

| 2. T. U.

 

 

18

 

 

 

 

 

a | BT,
B. T. U. | SORBED
Saunt | nomen | (pe i
DESIGNATION ce | pee, | | onli, aie
seis | eee one “mois. | Mors- | HYDRO- | ESCAP- ao
Goal | TURE | TURE | TURE GEN ING | comBUS
| | prep |INCOAL| IN arr |INcoaL| Gases | COSY
COAL
1 | 107 | 108 | 109 | 110 111 112 113
| | ees
A- 1-J
A- 2-J |
A- 3-J |
A- 4J |
A- 6-R
A- 7-R
A- 8-R | | |
A- 9-R ah ee beoat was eee | Nahe
A-101-J 14,851 | 10,636 | 41 Salou 493 2,252 331
A-102-J | 13,749 8,526 28 29 563 2,440 407
A-103-J 14,952 9,837 41 55 519 4,029 123
A-104-J 12,368 8,335 44 518 1,503 1,273
A-105-J seme | aes Steven sda Bee Rae ae
A-106-J | 13,784 | 7,597 22 23 577 1,980 1,149
A-107-R | 13,823 | 8,323 27 32 574 3,298 308
A-108-R 14,786 | 10,150 16 49 487 2,278 87
A-109-R 14,990 9,696 29 39 509 2,220 140
A-110-R 13,824 8,365 31 560 2,587 | 261
A-111-R cond Sees Masa ahi pea 34M mie dee
A-112-R | 13,487 8,104 42 29 560 2,537 231

 

 

DUE TO
COMBUS-
TIBLE
IN
STACK
CINDERS

114

133
57
562
64
112
70
208
529
55

72

 

DUE TO
'COMBUS-
TIBLE
IN
ASH

115

436
94
414
92
T4
88
302
260
66

149

U. Loss PER POUND OF MOISTURE FREE COAL FIRED

DUE TO
RADIA-
TION
AND
UNAC-
COUNT-
ED FOR

 

116

 

528
1,605
—628

539
2,250
1,102
1,210
1,568
1,899

 

1,761

 

151
. TESTS OF A JACOBS-SHUPERT BOILER

HEAT BALANCE—PERCENTAGES

TESTS SERIES A
Table 19

PER CENT. OF HEAT OF FUEL FIRED

 

| |
DESIGNATION | TO

 

 

a TO TO a
TEST SORBED | ol pnp woeunn| HYDRO” | wscar- | INCOM’ | COMBUS | conus. | “tow
sare | IN COAL | IN ATR | aN GOT, | Ne ee | eae COUNTED,
| ——-
1 e700) ae: |) ave 120 121 | 122 12a. | «(124 «| «126
| | |
i | | |

Aaeaege y) e235 eee a Weeeree Heer lM cme atanaae 1 cece lM eeeres th eases
AS Ao-7) ||, Bees. peer eet TL) Jes con aul Piea eee n env ayapane | LAN eeaa et eciee eel Pay, ere elise
tec eey eeeeeel baa betes Wl acne, ee he Reet aa, Dy hanes.
A- 43 | ..... [i eaters Ills waecheetan (il) tacaeeers |) | eters Pl aceder ets, le theres | I che aes | Sra
A= ob Sd ltl oa aesy ites sess lili geet ts Icey seer Ld desis ESSN ante te INE RN RRC oy ktakcteeal lll rsa rants
AS 6B lll wane UP ee ceed | eiretee reap omer call (oe eC ceria a a [pa Lb eaens
AE ETT ee nan hese etn ence lta ee lectern ean bere eee ee [erences
RPE hl manta, eens Nagase tl ecern a Malla sean Py eae eee Th re UB eng oRe
Tee = IA linac eal CALL tocol Ill ante Ree wae I ery perce TH ease NID |b iets arena ME Aara Saeed Une toes eee LN Ur yas
A-101-J 71.6 GE See (It eee 3.3 15.2 2.2 09 | 29 3.6
A-102-J 62.0 02 | 02 | 4.1 17.7 | 3.0 0.4 | 07 11.7
A-103-J 65.8 0.3 | 0.4 3.5 26.9 0.8 3.7 2.8 -4.2
A-104-J 67.4 ie Sav ecreee: 4.2 12.2 10.3 05 | o7 | 48
A-105-J RE copra) ar torn |e ee ee eee ol eave eens taf Serene eran Uh ot cay
A-106-J 55.1 0.2 | 02 42 | 14.4 | 8.8 0.8 | 05 | 16.8
A-107-R 60.2 0.2 0.2 4.2 | 23.9 2.2 0.5 0.6 8.0
A-108-R 68.7 0.1 0.3 8.8) 15.4 0.6 ae Og 8.2
A-109-R 64.7 0.2 0.3 3.4 14.8 0.9 es et eC
A-110-R 60.5 0:25 | ee, 4.1 18.7 | 19 0.4 0.5 | 18.7
ASV SRe. Where md Aeeseeeaea lil Pacer lL 2A teen lctpenec IN) eat teeh teens wll aah LY plots
A-112-R 60.1 0.3 0.2 4.2 | 18.8 1.7 0.5 | Vl 13.1

 

152
DESIGNATION
OF
TEST

1

B-201-J
B-202-J
B-203-J
B-204-J
B-205-J
B-206-R
B-207-R
B-208-R
B-209-R
B-301-J
B-302-R,
B-401-J
B-402-J
B-403-J
B-404-J
B-405-R
B-406-R
B-407-R
B-501-J

METHODS

AND COMPUTED RESULTS

GENERAL CONDITIONS
TESTS SERIES B

 

 

 

Table 20
| |

| |BENRERATIEE | ber

BA- : ae eh eee || ae =
DURA- ROM- | BOIL'R| LABORATORY
"OE, Oe POWER FURNACE PRES- nee ie + aera a ee
TEST TEST SURE jlbs.per) BY | BY SMOKE j7,_ DIA-
hrs Ibs. per| sq.in.| DRY | WET | BOX | pupey| pHR'M
sq.in. | | BULB BULB | GASES | {03 of | ins. of
| | aot eas | water | water
| BTER | BTER |
2 8 4 5 6 7 8 | 9 | 11 | 12] 18

5- 6-12 7.00 Low Without Arch 14.6 215.8 71.5 66.7 497 0.8 1.6
5- 3-12 3.33 Medium Without Arch 14.7 | 210.9 74.3 | 63.7 | 601 2.9 7.8
5— 7-12 | 1.33 High Without Arch 14.5 | 171.3) 61.1 | 59.0 | 625 5.0 13.6
5-13-12 1.00 | High Without Arch 14.5 | 142.0) 69. 63.7 | 632 6.2 15.9
5-11-12 1.00 High Without Arch’ 14.6 | 161.9; 67.1 | 56.6 | 662 6.8 16.5
5-27-12 7.00 Low Without Arch 14.6 | 212.9) 80.2 | 67.3 558 | (0.8 1.3
5-28-12 3.33 Medium Without Arch 14.5 | 207.5 77.2 | 69.4 622 | 3.2 7.4
5-28-12 1.00 High Without Arch 14.5 | 176.3 84.5 72.9 620 5.5 13.1
5-29-12 0.67 High Without Arch 14.5 | 182.0 77.1 72.4 647 5.4 11.3
5- 7-12 1.00 High Without Arch 14.5 | 180.7 61.4 59.5 632 6.8 18.1
5-29-12 1.00 High Without Arch 14.5 | 182.3) 74.2 | 69.9 662 | 5.7 11.5
5-20-12 7.00 Low With Arch) 14.6 217.0. 84.1 | 71.4 S25 | 1,0 1.9
5-21-12 3.83 Medium With Arch 14.6 | 212.7) 77.4 | 64.9 | 589 | 3.9 | 8.7
5-22-12 1.00 High With Arch| 14.7 164.9| 62.9 | 59.0 | 686 | 6.9 15.8
5-22-12 1.00 High With Arch 14.7 | 157.0) 69.0 | 62.4 704 | 8.7 | 18.8
6-412 7.00) Low With Arch 14.5 | 210.8) 80.2 | 68.9 524 | 0.9 | 1.6
6— 3-12 | 3.33 Medium With Arch 14.7 205.1, 77.0 | 65.9 630 | 3.7 75
6- 3-12 1.00 High With Arch 14.7 | 171.6) 81.6 68.0 677 | 6.7 | 12.8
5-23-12 1.00 High With Arch 14.7 | 168.6] 61.3 | 58.8 | 730 HS | 22.9

 

 

153
TESTS OF A JACOBS-SHUPERT BOILER

 

FUEL
TESTS SERIES B

 

 

 

 

 

 

 

 

 

Table 21
= a . = SS ee
| COAL AS FIRED | MOoIsTURE FREE COAL
KIND _——— ee sae 5 = —————
OF | | PER SQ. FT. | | PER SQ. FT.
COAL | TOTAL PER HOUR | OF GRATE | TOTAL | PER HOUR | OF GRATE
| pounds pounds PER HOUR | pounds | pounds PER HOUR
pounds pounds
1 | 16 17 is | 19 | 20 | 21 | 22
aa — =| = = eee cena || SO = a
B-201-J Scalp Level ; 10,092 1,442 | 25.38 9,720 1,389 Q4..45
B-202-J Scalp Level 11,699 3,510 | 61.78 11,396 3,419 60.18
B-203-J Scalp Level 6,163 4,623 | 81.38 5,954 4,467 78.63
B-204-J Scalp Level* 6,098 6,098 107 . 34 5,930 5,930 104.38
B-205-J Scalp Level* 6,471 6,471 | 113.91 6,314 6,314 111.14
B-206-R Scalp Level 9,168 1,310 22.52 8,971 1,282 22.04
B-207-R Scalp Level 10,518 3,155 | 54.25 10,171 3,051 52.46
B-208-R | Scalp Level* 5,508 5,508 94.70 5,397 | 5,397 92.80
B-209-R Scalp Level* 3,672 5,508 94.70 3,618 5,427 93.31
B-301-J Dundon 6,822 6,822 | 120.08 6,631 6,631 | 116.72
B-302-R Dundon 5,611 5,611 | 96.47 5,484 5,484 | 94.29
B-401-J Scalp Level 9,929 1,418 24.96 9,571 1,367 24.06
B-402-J Scalp Level 10,096 3,029 53.32 9,521 2,856 | 50.27
B-403-3 Scalp Level* 5,593 | 5,593 98 45 5,386 5,386 94.81
B-404-J Scalp Level* 6,032 6,032 106.18 5,887 5,887 103 .63
B-405-R Scalp Level 9,571 1,367 | 23.50 9,248 1,321 22.71
B-406-R Scalp Levelt 10,133 3,040 | 52.27 9,752 | 2,926 50.31
B-407-R Scalp Level* 5,172 5,172 88.93 5,069 5,069 | 87.16
B-501-J Dundon 6,782 6,782 | 119.38 6,553 6,553 115.35

 

 

 

 

* Hand-picked. f Screened.

154
METHODS AND COMPUTED RESULTS

FUEL (Continued)
TESTS SERIES B

 

 

 

 

 

Table 22
mores | aoe. | commune | ened ee
TEST pounds POTN OF MOIS- | OF MOIS-
pounds TOTAL PER HOUR TOTAL PER HOUR | TURE FREE | TURE FREE
pounds pounds pounds pounds COAL COAL

1 23 24 25 26 27 28 29 30
B-201-J 1,029 151 9,207 1,315 8,297 1,185 10.6 1.6
B-202-J T45 806 10,691 3,208 9,473 2,842 6.5 7.1
B-203-J 219 401 5,679 4,259 5,181 3,889 3.7 6.7
B-204—J 183 507 5,499 5,499 4,930 4,930 Oak 8.5
B-205-J 146 505 5,948 5,948 5,417 5,417 2.3 8.0
B-206-R 364 108 8,467 1,210 8,158 1,165 4.1 12
B-207-R 453 320 9,661 2,898 9,059 Q,717 4.5 3.1
B-208-R 143 219 5,072 5,072 4,805 4,805 a.7 4.1
B-209-R 109 72 3,373 5,065 3,240 4,865 3.0 2.0
B-301-J 161 111 5,803 5,803 5,662 5,662 2.4 1.7
B-302-R 138 47 4,819 4,819 4,737 4,737 2.5 0.9
B-401-J 579 130 9,134 1,305 8,666 1,238 6.0 1.4
B-402-J 370 535 9,038 2,712 8,354 2,505 3.9 5.6
B-403-J 147 278 5,004 5,004 4,647 4,647 2.7 5.2
B-404-J 61 288 5,551 5,551 5,247 5,247 1.0 4.9
B-405-R 559 73 8,776 1,254 8,317 1,188 6.0 0.8
B-406-R 401 356 9,160 2,748 8,566 2,570 4.1 3.7
B-407-R 151 221 4,715 4,715 4,445 4,445 3.0 4.4
B-501-J3 174 120 5,689 5,689 5,548 5,548 a07 1.8

 

 

 

 

 

 

 

 

1

 
TESTS OF A JACOBS-SHUPERT BOILER

BOILER PERFORMANCE
TESTS SERIES B

 

Table 23
EQUIVALENT EVAPORATION
Mower | gta OF, mprowowns] Ugg | oe one
mma PEE VATE 10 CTE Fatet EVAPORA- aes >) B. }
pounds
1 35 36 45 46 51 54 58
a acetai ie

B-201-J3 64.4 89,172 0.9970 1.2005 107,049 15,293 5.08
B-202-J 66.3 91,206 1.0000 1.2010 109,538 32,861 10.92
B-203-J 65.9 44,446 0.9999 1.1989 53,285 39,964 13.28
B-204-J 68.9 38,592 1.0002 1.1931 46,045 | 46,045 15.31
B-205-J | 66.9 | 40,147 | 1.0005 1.1974 48,070 | 48,070 15.98
B-206-R 73.8 87,788 | 0.9980 1.1922 104,662 | 14,952 5.01
B-207-R 73.1 81,366 | 0.9982 1.1924 97,025 | 29,108 9.75
B-208-R 77.3 37,629 | 0.9987 1.1868 44,658 44,658 14.97
B-209-R 74.8 23,787 0.9982 1.1886 28,269 | 42,404 | 14.21
B-301-J 66.0 | 42,220 0.9999 1.1989 50,617 | 50,617 | 16.83
B-302-R, 76.8 37,420 | 0.9979 1.1861 44,383 44,383 14.87
B-401-J 70.7 91,752 0.9995 1.1965 109,783 15,683 5.21
B-402-J 71.9 84,986 0.9996 1.1956 101,613 30,484 10.13
B-403-J 72.1 38,353 1.0007 1.1916 | 45,701 45,701 15.19
B-404-J 71.4 | 43,444 0.9995 1.1914 | 51,759 51,759 | 17.21
B-405-R 78.1 91,106 0.9980 1.1872 108,162 15,452 5.18
B-406-R V7.4 84,098 0.9980 1.1872 99,843 29,953 10.04
B-407-R 80.6 | 37,917 0.9980 1.1812 44,788 44,788 | 15.01
B-501-J3 68.3 48,164 0.9990 1.1952 57,564 57,564 19.15

156
METHODS

AND COMPUTED RESULTS

 

DESIGNATION
OF
TEST

B-201-J
B-202-J
B-203-J
B-204-J
B-205-J
B-206-R
B-207-R
B-208-R
B-209-R
B-301-J
B-302-R
B-401-J
B-402-J
B-403-J
B-404-J
B-405-R,
B-406-R
B-407-R
B-501-J

 

 

BOILER PERFORMANCE (Continued)
TESTS SERIES B
Table 24
|
| EFFICIENCY
B. T. U. —
EQUIVALENT EVAPORATION | ABSORBED BY THE | | [BOILER
RATIO BOILER | AND FUR-
OF [OVER NACE EX-
HEATING | ALL] CLUDING
SCnen ieee aaa —| PER CENT., GRATE)
| PowER To PER | OF B.T.U. | PER CENT.
BOILER 9 ABSORBED| OF B.T.U.
| “orap | HORSE- PER pombe armors | Aes pounp | BY THE | ABSORBED
POWER POUND | OF MOIS- |TURE ae POUND | or mors- | BOILER | BYTES
DEVEL- oy COAL |TUREFREE ASH FREE |,OF MOIS- legnprren| ,PER | BOILER
OPED as¥FIRED| COAL | COAL eee COAL gent BAe
| | ds | ON- a CON- ‘ a
| Me | oanoe soars SIRED SUMED ENED eae
pounds | SUMED
Se ee. ee ee za ! teas! €
59 | 62 63 64 65 | 67 68 | 69 70
<a = = ‘| | piaseaeneeti jammer a | +
443 6.8 10.61 11.01 | 12.90 10,687 | 11,860 71.86 79.75
| 953 3.2 9.36 9.61 | 11.56 9,327 | 10,526 63.37 71.51
| 1,158 2.6 8.65 8.95 | 10.29 8,684 9,528 58.29 63.96
1,335 2.3 7.55 | Ho 9.34 7,535 8,405 52.23 58.26
1,393 2.2 7.43 7.61 8.87 7,388 | 8,112 50.41 55 .36
433 6.9 11.42 11.68 12.82 11,315 | 11,740 76.62 79.37
844 3.5 9.23 9.54 10.71 9,257 | 9,874 62.26 66.41
1,294 2.3 8.11 8.28 9.29 8,030 8,476 54.64 57.67
1,229 2.4 7.70 7.81 8.73 | 7,582 7,893 52.25 54.39
1,467 2.1 7.42 7.63 8.94 | 7,407 7,593 56.54 57.96
1,287 2.3 7.91 8.09 9.37 | 7,853 7,990 59 .23 60.26
455 6.6 11.06 | 11.47 12.67 11,130 |) 11,731 74.82 78.85
884 3.4 10.07 | 10.67 12.16 10,357 | 11,205 69.79 | 75.50
1,325 2.3 8.17 8.49 9.84 8,234 8,866 56.76 61.12
1,500 2.0 8.58 8.79 | 9.86 8,532 9,028 57.90 61.27
448 6.7 | 11.30 11.70 13.01 | 11,350 11,976 76.50 80.72
868 3.4 | 9.85 10.24 11.66 | 9,935 | 10,625 67.42 72.10
| 1,298 253 | 8.66 | 8.84 10.08 8,574 9,094 58.87 62.43,
1,669 1.8 8.49 8.78 10.38 8,524 8,741 65.34 67.01

157
TESTS OF A JACOBS-SHUPERT BOILER

SMOKE BOX GASES AND AIR SUPPLY
TESTS SERIES B

 

 

 

Table 25
GAs ANALYSIS | Dry Gas AIR RATIO
PER CENT. BY VOLUME | PER POUND | PER POUND OF AIR
DESI¢ ae TION a ai ca i = | = lena oo === oe Reraaee
me | | ea aera ree
| C02 | O2 | £o | ty | SUMED FIRED SUMED FIRED Te
| | pounds pounds | pounds pounds
1 | 7 | 7 | 73 | 74 75 ve | wy | ae 79
Pr IY i eal | et at eee si : + |
B-201-J 11.0 | 81 | O1 | 80.8 22.6 19.4 | 22.1 19.0 1.6
B-202-J 98 | 92 0.0 81.0 5.5 | ie | erat | gk | aes
B-203-J | ume. Alb eek, Milk eqeaene | rec? aes | ee | Pee: | eae | ee
B-204-J 70 12.8 0.0 | 80.2 35.3 | 29.6 34.7 || 29.0 «| 26
B-205-3 6.4 12.6 0.0 ) 81.0 38.5 32.7 | 38.4 32.7 2.4
B-206-R 10.8 7.8 0.1 | 81.8 23.0 | 19.6 | 22.6 19.8 1.6
B-207-R 8.8 | 10.6 | 0.0 | 80.6 28.3 | 24.3 | 27.8 23.9 | 2.0
B-208-R | Heiss Vel eeuse ee, Will | eaeeiees Hh aeenayiaes cma lM cepa MORSE) Boke alll see
B=209SR> fi) eee Cl aavene. ill Boreas ett IPRs crater llinigteacectete alt ll eeestsyceeey ni aeecteese nll ern ee
B=30J-3. | -eecan | ees: i te See oad ha mae ew I ll Ingress LIN | cetera wi acmereteeenn ||| Peoceevene
B-302-R | 9.4 9.8 0.3 | 80.5 | 25.7 | 19.2 | 25.2 | 18.8 | 1.8
B-401-J 9.6 | 9.7 | O.1 | 80.6 | 25.7 22.3 | 25.2 21.8 | 1.8
B=402-Je pl Verctrcse Vly eaencaceny UNL eesscvers tll Linsceeae pity pememnen | tee kesAsey I Votaeegesen Niue esc 4 |, Gedarass
B-403-J Mei |) ldo 0.1 | 81.5 33.3 27.9 33.4 | 27.9 2.1
B-404-J 8.1 | 10.3 | 0.0 81.6 | 30.6 | 26.0 | 30.6 | 26.0 | 1.9
B-405-R | 10.4 8.8 0.0 80.8 24.1 0,7 93.6. | 26.2 | LL.
B-406-R | ..... |... Hh etree NT beceecerieets 1h crete ||| atitetes IW cette | I poe delaen |) vecaosaste
Bw7-R | 5.6 | 14.7 | 0.0 | 79.7 | 48.9 | 387.0 | 43.1 | 36.4 | 3.3
| 17.9 24.1 17.8 1.6

B-501-3 10.2 7.8 | O.1 |} 81.9 | 24.2

158
METHODS AND COMPUTED RESULTS

CHEMICAL ANALYSIS—COAL
TESTS SERIES B

 

 

 

 

 

Table 26
PROXIMATE ANALYSIS ULTIMATE ANALYSIS
CoAL AS FIRED MoIsTURE FREE COAL
DESIGNATION ce
TEST mots- | VOrA" | FIxep asa | HYDRO- ares NITRO- | oyygen| S8UL- | Asn
parite ah [CANE ped Glae| ue, BoE COM yoe ay DEE Ce pcaky, pe cat
1 80 81 82 83 84 85 86 87 88 89

B-201-J 3.69 16.09 75.14 5.08 4.34 85.89 1.33 2.30 0.86 5.28
B-202-J 2.59 16.46 74.92 6.03 4.28 84.85 1.32 2 OF 1.09 6.19
B-203-J 3.39 16.54 75.60 4.47 4.36 86.34 1.34 2.31 1.03 4.62
B-204-J 2.75 17.10 73.08 7.07 4.24 | 83.91 1.30 2.25 1.03 HOF
B-205-J 2.43 16.79 75.13 5.65 4.30 85.16 1.32 2.28 1.14 5.80
B-206-R 2.15 16.45 75.90 5.50 4.31 85.38 1.32 2.28 1.09 5.62
B-207-R 3.30 17.56 74.30 4.84 4.34 86.08 1.34 2.30 0.95 5.01
B-208-R 2.01 16.76 75.33 5.90 4.30 85.21 1.32 2.28 0.87 6.02
B-209-R 1.48 17.17 74.67 6.68 4.26 84.41 1.31 2.26 0.98 6.78
B-301-J 2.80 32.10 52.97 12.13 4.64 74.42 1.47 6.17 0.82 12.48
B-302-R oeT 33.75 52.14 11.84 4.66 | 74.79 1.47 6.20 O46 |W
B-401-J 3.61 16.55 75 44 4.40 4.37 86.57 1.34 2.32 0.83 4.57
B-402-J 5.70 16.50 73.02 4.78 4.35 86.12 1.34 2.31 0.81 5.07
B-403-J 3.70 16.41 73.05 6.84 4.22 83.66 1.30 2.24 1.48 7.10
B-404-J 2.40 17.38 74.66 5.56 4.29 | 84.99 1.32 Deo 1.43 5.70
B-405-R 3.37 18.10 73.60 4.93 4.34 85.89 1.33 2.30 1.04 5.10
B-406-R, 3.76 16.51 73.89 5.84 4,29 84.90 1.32 g 27 1.15 6.07
B-407-R 1.99 17.18 73.98 6.85 4.26 | 84.37 1.31 2.26 0.81 6.99
B-501-J 3.38 34.34 49.54 12.74 4.60 | 73.84 1.45 6.13 0.80 13.18

 

 

 

 

 

 

 

 

 

 

159
TESTS OF A JACOBS-SHUPERT BOILER

CHEMICAL ANALYSIS--STACK CINDERS—ASH

TESTS SERIES B

 

 

 

 

24 | 22.67

Table 27
PROXIMATE ANALYSIS—STACK CINDERS | PROXIMATE ANALYSIS—ASH
‘TION OF : ee ATILE FIXED Leo reen VOLATILE i: a a
er | pereaut. | enue | Aer ee | "pereent. | MATTER | CARBON | percent.
| | 1 — Z.
1 90 91 92 93 94 95 96 97

B-201-J | 1.05 6.13 63.30 29.52 | 0.82 | 5.42 72.95 | 20.81
B-202-J 0.51 Ze 81.76 15.21 1.13 6.67 65.82 26.38
B-203-J 0.43 2.47 84.23 12.37 | 0.65 | 6.61 61.90 | 30.84
B-204-J 0.21 2.35 85.85 1430 | 0.66 | 7.11 59.60 32.63
B-205-J 0.16 1.96 86.96 10.92 3.91 8.88 47 46 39.75
B-206-R | 3.90 6.24 58.65 31.56 | 2.97 | 6.29 59.39 31.55
B-207-R | 0.38 3.48 | 78.29 17.85 1.54 5,93 69.21 23 .32
B-208-R | 0.22 2.80 | 84.18 12.80 | 0.17 | 4.57 48 .60 46.66
B-209-R | 0.21 2.95 83.72 ele 0.68 5.87 59.48 33.97
B-301-J | 0.15 | 4.43 | 74.05 21 37 | 0.83 | B30 29 85 65.95
B-302-R. | 0.00 3.74 77.57 | 18.69 1.05 4.16 27.97 66.82
B-401-J | (0.98 5.37 62.24 | 31.46 0.51 | 9.385 | 56.21 33.93
B-402-J | 0.53 2.56 79.06 | 17.85 2.36 7.33 59.41 30.90
B-403-J 0.28 2.36 87.47 9.89 0.75 6.46 | 67.28 25.51
B-404-J 0.28 | 2.48 | 89.62 | 7.62 0.36 4.21 | $9.37 36 .06
B-405-R 0.00 5.04 56.91 38.05 0.34 | 8.20 | 65.82 25.64
B-406-R 0.00 | 2.65 | 84.65 | 12.70 0.65 | 7.31 | 63.35 | 28.69
B-407-R 0.10 2.51 82.87 14.52 0.00 6.52 | 47.30 46.18
B-501-J 0 | 39.88 | 3.38 | 3. 70.71

24 | 3.66 76.22

 

160
DESIGNA-
TION OF
TEST

B-201-J
B-202-J
B-203-J |
B-204-J |
B-205-J
B-206-R
B-207-R
B-208-R
B-209-R
B-301-J |
B-302-R
B-401-J
B-402-J
B-403-J
B-404-J
B-405-R
B-406-R |
B-407-R |
B-501-J3

METHODS

AND COMPUTED RESULTS

CALORIFIC VALUES
TESTS SERIES B
Table 28

CALORIFIC VALUE
BY OXYGEN CALORIMETER

PER CENT. | sau cunn. | = SS =
| COMBUSTIBLE Soe aE PER | er | BN ena
gare, 1h) eee |e ere | one ae
CIDER re AS FIRED ee ASH FREE Gas
| Bes U3 B. T. U. es B. T. U.
99 100 | 102 | 108 | 104 105
et ee eee —_——|- | ee
69.43 | 78.37 14325 | «14872 «15,700 9,884
84.28 | 72.49 14338 | (14.719 15,691 | 12,040
86.70 68.51 14,392 | 14,897 15,619 | 12,386
88.20 66.71 14,031 | 14,427 | 15,557 | 12,604
88.92 56.34 14,297 | 14,654 | 15,556 | 12,647
64.89 65.68 14,740 | 14,792 15,673 9,211
81.77 75 14 14,377 | 14,868 15,651 | 11,657
86.98 53.17 14,402 | 14,697 15,638 | 12,397
86.67 | 65 .35 14,298 | 14,512 15,566 | 12,330
78.48 33.22 12,733 13,100 14,969 11,176
81.31 32.13 12,958 13,259 15,088 11,594
67.61 65.56 14,340 | 14,877 15,590 | 9,652
81.62 66.74 13,996 14,841 | 15,633 | 11,648
89.83 73.74 13,970 14,506 15,615 | 12,746
92.10 63.58 | 14981 | 14795 | 15,624 13,055
61.95 74.02 | 14937 | 14897 | 15,635 | 8,867
87.30 70.66 | 14,188 | 14,737 | 15,689 | 12,469
85.38 58.82 | 14,276 | 14,566 | 15,662 | 12,195
79.88 25.91 | 12,604 | 13,045 | 15,025 11,376
| |

 

 

161

CALORIFIC
VALUE
PER
POUND
OF ASH
{ESTIMATED ]
By TU.

11,219
10,371
9,756
9,463
7,991
9,386
10,725
7,582
9,275
4,697
4,579
9,320
9,513
10,500
9,058
10,552
10,108
7,686
3,677
TESTS OF A JACOBS-SHUPERT BOILER

 

HEAT BALANCE-—BRITISH THERMAL UNITS
TESTS SERIES B

 

 

 

 

 

 

 

Table 29
ee B. T. U. Loss per Pounp oF MoIstuRE FREE COAL FIRED
BLT. U. | SORBED
| corn ner wit | | | | hi. i) i -
DESIGNATION a ae / ETRE lee | DUE TO
naa MOIS- POUND | DUB TO) DUB TO DUB TO | DUB TO PUB TO | comBus- SO Ge Theron
TURE | OF MOIs- | MOIS- | HYDRO-| ESCAP- | Qrow, | TIBLE | "rein | AND
Bont]! aera cee wy ca ares | eee OED see) AN naa
FREE | | TION |crnpERs| “58 | Caen
1 | 107 | 108 | 109 | 110 | 111 | 112 113 | 114 | 115 | 116
= ||, | —| ron 3 a
B-201-J 14,872 | 10,687 48 49 486 | 1,979 78 | 153 1,187 | 205
B-202-J 14,719 | 9,327 34 53 497 | 2,731 0 851 679 547
B-203-J Baleares pba | re eaiets- 1)" eee Dates as es
B-204-J 14,427 | 7,535 37 114 500 3,992 0 1,078 | 291 881
B-205-J | 14,654 7,388 33 G+ 514 4,675 0 1,012 185 | 783
B-206-R | 14,792 | 11,315 28 | 49 491 | 2,244 | 79 11] 381 95
B-207-R | 14,868 | 9,257) 44 | 86 507 3,180 0 307 |) 477 950
B-208-R Depeeaaietieehl ec Soca | aetel es
B-209-R | Ae oes Anes ve eae
B-301-J UL enol Rennes, oe ee Svea eee | dee ee Ser
B-302-R 13,259 | 7,853 31 78 554 Q711 | 235 99 115 1,584
B-401-J 14,877 | 11,130 47 63 490 | 2,356 | 88 131 564 8
B-402-J ee | a ae eee aa | ne | cess | aes ee ee ee
B-403-J | 14,506 8,234 52 82 | 510 4,170 | 119 657 287 | 395
B-404-J 14,735 | 8,532 31 Uh | 480 | 3,958 0 639 94 924
B-405-R 14,837 | 11,350 44 55 | 488 2,202 Oo | 70 637 -8
B-406-R nei | ieehnes ae Peon eae rete Pex eee ey.
B-407-R 14,566 | 8,574 Q7 112 |) 506 5,286 | 0 531 229 | —428
B-501-J | 13,045 | 8,524 48 56 | 565 | 2,872 75 208 98 600

 

 

162
METHODS AND COMPUTED RESULTS

HEAT BALANCE—PERCENTAGES
TESTS SERIES B
Table 30

 

PER CENT. OF HEAT OF FUEL FIRED

 

 

 

 

DESIGNATION | | | | nO 16 | | TO
AB- | TO TO =: <I] TO RADIA-
ee oo eeen | MOISTURE] MOISTURE Bea | een wea Puera | TiSLn fe rane es
BOILER | EN ACOA | GIN ATS ra coat || Gases | Coe eUe. TA ee | IN ASH | COUNTED
= | ce ee As |——— er
1 117 118 | 119 120 121 122 | 123 | 124 125
PRPS EIEE | Eras, Se en | | “es
B-201-J3 71.9 0.3 0.3 3.3 13.3 0.5 0 8.0 1.4
B-202-J 63.4 | 0.2 | 0.4 3.4 | 18.6 0.0 | 5.8 | 4.6 3.6
Peale epee tee ulinye ve eee Merce Leta Uta al Neds Eiaeeoe ae tta ceca
B-204-J 52.2 | 03 | 0.8 3.5 Q7.7 0.0 | 75 | 2.0 6.0
B-205-J | 50.4 0.2 0.4 3.5 31.9 0.0 | 69 | 1.3 5.4
B-206-R 76.5 | 0.2 0.3 3.3 15.2 0.5 0.8 2.6 0.6
B-207-R 623 | 0.3 0.6 3.4 | 21.4 00 | ge | os 6.3
B2208 Fy ners eee ileeey || bee Pee er fre eae erate Nene em ace
B-209-R i... eras lmeece ree Rea Ul eos ee gE Mliegee es ah eee Ii biaes creamed MID geet ta es
etd wales reel nue |) setae Weer tere a ll acaee ae Leesa tell eect
B-302-R 59.2 | 0.2 0.6 4.2 20.4 | 1.8 0.7 | 0.9 12.0
B-401-J 74.8 | 0.3 0.4 3.3 | 158 | 06 | O9 | 38.8 0.1
B-402-3 | ee ener Mie ae em On ONE RENIN. ce hey fey Fh Dect a Wotee th eras
B-403-J 56.8 | 0.4 0.6 3.5 28.7 0.8 4.5 2.0 Qh
B-404-J 57.9 0.2 0.5 3.3 | 26.9 0.0 4.3 0.6 6.3
B-405-R 76.5 0.3 0.4 3.3 14.8 0.0 | 0.5 4.3 -0.1
B-4062R | Goes.) dae. em | pace Ieee ent | ee eect mete
B-407-R 58.9 0.2 0.8 3.5 | 36.3 0.0 | 3.6 | 1.6 | —4.9
B-501-J. «65.3 0.4 0.4 4.3 | 22.0 | 06 | 1.6 | 8 4.6
| } )

 

 

163
XIV. A Summary

142. A Brief Story of the Development of the Locomotive Boiler (Chap-
ter IIT) emphasizes two facts, (1) that the design of such boilers has from
the beginning been subject to frequent change, and (2) that the difficul-
ties in the construction and maintenance of such boilers have always cen-
tered in the firebox.

143. The Radial-Stay Boiler (Chapter IV) is recognized as the most im-
portant detail of the modern high-power locomotive. Many embellishments
in its construction have from time to time been introduced, and present-
day designs represent a highly developed practice. But forces are always
present within the structure of the radial-stay boiler which make its main-
tenance difficult and which ultimately bring about its ruin. Like all its
predecessors, the radial-stay boiler is weak under low-water conditions
and failures, sometimes disastrous, are not uncommon. No one who con-
siders the progress of the past can assume for a moment that our present-
day practice is final. The radial-stay boiler has had its predecessors and
they have disappeared, and no one can doubt that the radial-stay boiler
itself is but an embryo predecessor of a type which must soon be revealed.

144. The Jacobs-Shupert Boiler (Chapter V) seeks to overcome some
of the defects of the radial-stay type. Its firebox construction is more
than a modification of preéxisting forms; it is new in its contour, in the
means employed for its support, and in the fact that it is made up of a
considerable number of comparatively small plates. The contour of the
Jacobs-Shupert firebox is not dissimilar to that of the corrugated furnaces
so long and so generally used in marine service. It has no radial stays and
there are no stay-bolts except in the tube-sheet and door-sheet. There
are no rivets or stay-heads on the fire side of the crown-sheet or side-sheets.
The rivets joining the several sections making up the firebox structure are
not inside of the firebox. They can not be seen from the firebox and they
can not be affected by the direct action of the heat from the firebox. They
are above the crown in the water space of the boiler at a distance sufficiently
far from the heating-surface of the firebox to be undisturbed by any condi-
tion that may arise within the firebox. These features place the design
of the Jacobs-Shupert boiler upon a plane which, from a purely mechan-
ical point of view, is essentially higher than that which is occupied by the
normal radial-stay boiler. The fact also that in the manufacture of these
boilers, the principle of interchangeability is employed, establishes a high
standard of workmanship. Interchangeability in construction operates to
improve quality and to reduce costs. In the manufacture of the Jacobs-
Shupert firebox, machinery is used instead of men. Each operation is
simple and yet the result is precise. There is no drifting of holes and no

164
A SUMMARY

local heating of plates which have been set in place in the boiler. The
result of the new process is a boiler accurately made, substantially put
together, and comparatively free from initial strains. The design and the
methods of manufacture combined permit repair parts to be carried, and
provide an inexpensive procedure in maintenance.

145. The Jacobs-Shupert Boiler in Service (Chapter VI) was made the
subject of an inspection at several division points, and on the road along
the line of the Santa Fe, where at the time of the inspection (November,
1911) a hundred and sixty-nine locomotives were in service. As a result
of five days’ inspection, conclusions were reached as follows:

1. The construction of the Jacobs-Shupert firebox admits of easy and
thorough inspection.

The Jacobs-Shupert firebox gives no trouble by leaking at the mud-
ring. Nota single case of a leaky mud-ring could be found.

3. The fireboxes give no trouble by leaking between sections.

4. No indication could be found of grooving or cracking at the fillet
or in any other part of the sections making up the firebox.

5. The fireboxes examined, while very large, appear to resist perfectly
the pressure imposed, which in all cases was above 200 pounds.

6. The firebox structure of a Jacobs-Shupert boiler after a year of
service in a district of alkali water, appeared as though new, while that of
a radial-stay boiler in the same service for the same or a lesser length of
time presented unmistakable evidences of degeneration.

7. Evidence was not lacking to prove that minor defects, such as those
which may arise in a Jacobs-Shupert boiler from accumulation of scale or
because of low water, are easily repaired.

Some months after this inspection, it was reported that defects had appeared
in the outside wrapper-sheets of some of the older boilers. The cause was
easily seen to be in a defective arrangement of some of the longitudinal
stays, and the remedy was simple. The occasion for the occurrence of such
defects is avoided in more recent designs.

146. A Program of Tests (Chapter VII) designed to disclose the per-
formance of the Jacobs-Shupert boiler in comparison with that of a radial-
stay boiler was outlined as follows:

The boilers to be tested were to be designed for locomotive service
and to be identical in their general dimensions. They were to differ from
each other only in the construction of the firebox and in the means employed
for supporting it. One boiler was to be equipped with a Jacobs-Shupert
firebox and the other with a radial-stay firebox conforming to the best
present-day practice.

A laboratory was to be provided in which the two boilers could be
erected and equipped with all apparatus necessary for'testing. The tests
specified were to be grouped into three series designated as Series A, B, and
C, respectively.

Series A was planned to disclose the relative amount of heat absorbed
by the fireboxes and by the tubes of the two boilers ander similar condi-
tions of operation. To facilitate these tests, it was proposed to have the
boilers constructed with a partition separating the water space into two

165
TESTS OF A JACOBS-SHUPERT BOILER

 

compartments, one of which was to include the firebox surface and the other
the tube surface. In carrying out the tests, these compartments were to
be separately fed with weighed water. Not less than three tests, one at
low power, one at medium power, and one at high power, were to be made
upon each boiler. It was believed that the results would serve to establish
the relative value of a unit area of firebox heating-surface as compared
with that of a unit area of tube-heating-surface—facts which American
engineers have long desired to know—and that they would disclose the
difference, if any, in the heat-absorbing capacity of the two fireboxes tested.

Series B was to be made up of tests of normal boilers. The boilers
which had served in the tests of Series A were to undergo such reconstruc-
tion as might be found necessary to the removal of the partitions. This
accomplished, there would be available for the further work a normal
Jacobs-Shupert boiler and a normal radial-stay boiler. Each boiler was
then to be subjected to a series of evaporative tests for the purpose of estab-
lishing its evaporative efficiency and capacity under different rates of
power. In addition to data usually secured in boiler testing, it was pro-
posed to make of record such information as might be possible concerning
the circulation of water within the two boilers. The purpose of this series
was to secure an accurate measure of the evaporative performance of the
Jacobs-Shupert boiler and of a normal radial-stay boiler.

Series C was planned to disclose the relative strength of the two boilers
under low-water conditions. In preparation for the tests of this series the
boilers were to be removed from the testing Jaboratory and set up with
everything necessary to their operation in a location where their explosion
would result in no harm to surrounding property. Adequate provisions
were to be made for the safety of observers. The boilers were to be oper-
ated, the supply of feed-water was to be cut off or so controlled that the
firebox would be uncovered, and the low-water conditions were to be con-
tinued until failure occurred.

147. The General Dimensions of the Boilers Tested (Chapter VIL) were
as follows:

Jacobs-Shupert Radial-stay
Type of boiler...... Ext’d wagon top Ext’d wagon top
Diameter of shell. .c.ssccce sees TO” 70"
Number of 214” tubes............. 290 290
emer tlior ties 2.2 5o4 aoe 24s 18/9” 18/2”
Length of firebox..........2.+2...- 97158" 9/1146"
Width of reboot ....4 52252244454 6/436" 6/414"
Total heating suriace. .........+... 3008.4 2989.3

148. The Percentage of the Total Heat Absorbed by the Boiler, which is
taken up by the Firebox (Chapter VILL) varies with the rate of power at which
the boiler is worked. It is affected also by the character of the fuel used.

When oil fuel was fired at the rate of 2,200 pounds an hour:

(a) The Jacobs-Shupert boiler evaporated 40,000 pounds of water per
hour. Of this amount, 16,000 pounds were evaporated by the firebox and
24,000 pounds by the tubes.

(b) The whole boiler developed 1,200 horse-power, of which amount
nearly 500 horse-power was developed by the firebox.

166
A SUMMARY

 

(c) The average rate of evaporation per foot of heating-surface per
hour for the whole boiler was 9.78 pounds.

(d) The average rate of evaporation per foot of heating-surface per
hour for the firebox was 49.59 pounds, and for the tubes 6.47 pounds.

(c) The ratio of heat absorbed per foot of heating-surface by the fire-
box to that absorbed per foot of tube heating-surface was as 7.6 to 1.

When oil is used as fuel, the percentage of the total heat absorbed that
is taken up by the firebox can be found by dividing the pounds of oil fired
per hour by 100 and subtracting the quotient from 62. Strictly speaking,
the application of this statement should be limited to those rates of firing
which were covered by the experiments; that is, to rates between the limits
of 700 pounds and 2,200 pounds of oil per hour.

When a long-flamed bituminous (Dundon) coal was fired at the rate
of 4,340 pounds per hour:

(a) The Jacobs-Shupert boiler evaporated 35,405 pounds of water per
hour, of which amount 11,982 pounds were evaporated by the firebox and
23,423 pounds by the tubes.

(b) The whole boiler developed 1,026 horse-power, of which amount
304 horse-power were developed by the firebox.

(c) The average rate of evaporation per foot of heating-surface per
hour for the whole boiler was 11.77 pounds.

(d) The average rate of evaporation per foot of firebox heating-surface
was 51.92, and for the tube heating-surface 8.43.

(e) The ratio of heat absorbed per foot of firebox heating surface to
that absorbed per foot of tube heating-surface was as 6.15 to 1.

When long-flamed bituminous coal is used as fuel, the percentage of the
total heat absorbed that is taken up by the firebox can be found by divid-
ing the pounds of coal fired per hour by 190 and subtracting the quotient
from 56. Strictly speaking, the application of this statement should be
limited to those rates of firing which were embraced by the experiments;
that is, to rates ranging from 1,400 pounds to 4,500 pounds of coal per hour.

Different fuels produce different results in the distribution of heat.
For example, assuming the Jacobs-Shupert boiler to be evaporating 20,000
pounds of water per hour, the percentage of the whole quantity of heat
absorbed, which is taken up by the firebox, is as follows:

(a When ollis:usedias fuelster i. cseu su y eens gn ney a 42%
(b) When long-flame bituminous coal is used as fuel.. 42%
(c) When short-flame bituminous coal is used as fuel.. 35%

149. Results of Evaporative Tests of a Normal Jacobs-Shupert Boiler and
a Normal Radial-Stay Boiler (Chapter TX) disclose the evaporative effi-
ciency and the capacity of the two boilers tested.

The high efficiency of the Jacobs-Shupert boiler, unaided by the pres-
ence of a brick arch is to be seen in the fact that when fired with 1,315
pounds of Dundon coal per hour it:

(a) Evaporated 15,293 pounds of water per hour.
167
TESTS OF A JACOBS-SHUPERT BOILER

(b) Evaporated 5.08 pounds of water per square foot of heating-sur-
face per hour.

(c) Evaporated 11.01 pounds of water per pound of coal.

(d) Developed 443 horse-power.

(e) Developed an overall efficiency of 71.86 per cent.

(f) Developed an efficiency, excluding the grate, of 79.

75 per cent.

The various effects resulting from operation at higher rates of power
may be set forth as follows:
Pounds of coal fired per hour = 1,389 3,419 5,980) 6,314
Thermal units for each pound
of coal:

(a) Absorbed by water in

Oller arene ee 10,687 9,327 7,532 7,988
(b) Lost by moisture in coal 48 34 oF 33
(c) Lost by moisture in air 49 53 114 54
(d) Lost by se neEe in

6 497 500 514
9 2.731 3,992 4,675

coal. re 4.
(e) Lost by cmoke hos gases 1,9
(f) Lost by incomplete

DPD

 

combustion. . aus 78

(g) Lost by cinders passing
up elev te in ae he 153 851 1,078 1,012

(h) Lost by combustion in
DS Der te ee teen ee 1,187 679 291 185

(7) Lost by radiation and
unaccounted for... . 205 547 881 783
Total Bo. leper 22. SS = ae
pound of coal... 14,872 14,719 14,4250 14,654

The evaporative efficiencies of the Jacobs-Shupert boiler and of the
radial-stay boiler were found to be practically identical.

In the matter of capacity the data show the Jacobs-Shupert boiler to
possess some advantages over the radial-stay boiler. The Jacobs-Shupert
boiler was forced without the least sign of distress to an unprecedented
rate of power. It was fired at the rate of 6,553 pounds of coal per hour
resulting in:

A rate of combustion equaling 119.38 pounds of coal per foot of grate
per hour.

An evaporation of 57,564 pounds of water per hour, or the equivalent
of 19.13 pounds of water per foot of heating-surface per hour.

The development of 1,669 boiler horse-power, or the equivalent of one
boiler horse-power for each 1.8 foot of heating-surface.

An evaporation per pound of coal, notwithstanding the high rate of
power developed, of 8.78 pounds of water.

The maintenance of an overall boiler efficiency of 65.34 per cent, and
of the boiler, exclusive of the grate, of 67 per cent.

The published records of boiler performance disclose no results of equal

significance.

SD

168
A SUMMARY

150. The Brick Arch as a Factor in Boiler Performance (Chapter X) is
always beneficial. Its effect depends upon the characteristics of the fuel.
When a short-flamed bituminous (Scalp-Level) coal was used, the addition
of an arch to either boiler tested, increased the amount of water evapo-
rated per pound of coal 0.6 of a pound; that is, assuming either boiler to
be fired with 6,500 pounds of Scalp-Level coal per hour, they will evaporate
7.35 pounds of water per pound of coal without the arch, and 7.95 pounds
with the arch, a gain resulting from the introduction of the arch of 8 per
cent. The substitution of a long-flamed bituminous (Dundon) coal will,
under similar conditions, result in the evaporation of 7.7 pounds of water
per pound of coal without the arch, and 8.7 pounds with the arch, a gain
resulting from the introduction of the arch of 12 per cent.

151. Some Facts of Interest with Reference to the Circulation of Water
within a Locomotive Boiler (Chapter XII) have been developed. The
motion of the water within a locomotive boiler in response to the energy
transmitted to it in the form of heat is known to have an important bear-
ing on the upkeep and life of the boiler, and there has been much specu-
lation concerning the direction and strength of the circulating currents.
It has been urged, for example, that the presence of the stay-sheets which
enter into the construction of the Jacobs-Shupert boiler retard the fore-
and-aft movement of water and that they are, therefore, objectionable.
As the stay-sheets are provided with widely distributed openings of large
area, such criticisms necessarily assume fore-and-aft currents which are
tremendously vigorous. ‘The presence of such vigorous currents has been
questioned. An experimental inquiry conducted by Mr. George Fowler
sustains the very rational contention that only enough water passes back
from the barrel of the boiler to the water-legs of the firebox to make good
that which the firebox evaporates. Since the firebox evaporates from 30
to 50 per cent of the water handled by the boiler, a similar percentage of
the total feed must, in the case of the Jacobs-Shupert boiler, find its way
through the ports in the forward stay-sheet. Some of this water is evapo-
rated before the second stay-sheet is reached. With the passage of each
section, the backward flow diminishes until at the last stay-sheet only
enough passes to supply that which the last section evaporates.

As the stay-sheets have an aggregate port-area below the water-line
of 114 square feet and as only 30 to 50 per cent. of the total water delivered
by the injectors must pass by them, it is inconceivable that their presence
‘an affect the circulation unfavorably.

The strongest currents which are set up in a locomotive boiler are
those which sweep over the heating-surface in a direction which in its
general tendency is vertical. These are the most important of the circu-
lating currents, and with respect to them, the Jacobs-Shupert boiler pre-
sents superior advantages, for the water space about a Jacobs-Shupert
firebox presents broad, unobstructed vertical channels which in the matter
of form and dimensions have no counterpart in the radial-stay boiler.

169
TESTS OF A JACOBS-SHUPERT BOILER

 

The conclusion as drawn from analysis and experiment, is to the effect
that with reference to circulation the Jacobs-Shupert boiler is at no dis-
advantage as compared with the radial-stay type, but on the contrary
possesses elements of distinct superiority to that type.

152. The Superior Strength of the Jacobs-Shupert Boiler under Low-
Water Conditions (Chapter XI) has been abundantly demonstrated by
experiment. In the progress of the tests each boiler in turn was put under
steam. Its draft was adjusted to give an evaporation of approximately
10 pounds of water per foot of heating-surface per hour. Upon signal, the
injectors were shut off and the delivery of feed-water ceased. Thereafter
the water-level steadily declined, but the fire was not checked. The pur-
pose was to maintain all the general conditions the same for both boilers,
and the data show that this purpose was satisfactorily achieved.

In the test of the Jacobs-Shupert boiler, the water-level receded to
the bottom of a special water-glass 2519 inches below the level of the crown-
sheet in 34 minutes after it had passed the level of the crown-sheet, but
there was no failure or serious leak. The extent of the submerged heating-
surface continued steadily to diminish and the steam-jet from the exhaust
ip which made heavy demands upon the boiler began to reduce the steam
pressure, until finally when the water had fallen nearly 40 inches below
the crown-sheet and the pressure had been reduced to 50 pounds, 53 minutes
after the water had fallen to the level of the crown-sheet, the test was
ended. The Jacobs-Shupert boiler had been boiled nearly dry and no
failure had occurred. An inspection of the boiler after the test showed
all the usual effects of overheating except that the firebox was intact.
Three-quarters of the tubes were out of water and were sagged from the
effects of the heat. Several tubes had collapsed. The crown and sides
of the firebox for half their height presented the scale and color of newly
heated metal. There was some change in the curvature of sections, but
there were no local pocketing and. no leaks between sections. The integrity
of the firebox was complete, and so far as its condition was concerned, the
boiler at the conclusion of the test might have been refilled and operated.
Probably no other type of locomotive boiler now in common use could have
withstood such a test.

The radial-stay boiler was subjected to a similar test. The condi-
tions of operation imposed were identical with those which had prevailed
during the test of the Jacobs-Shupert boiler. Seventeen and three-quarters
minutes after the water in glass had fallen to the level of the crown-sheet,
when its level was 1415 inches below the crown, the boiler failed. One-
half the crown-sheet came down. The rear end of the boiler was lifted
from its foundation and the brickwork making up the furnace construc-
tion was scattered in all directions over a radius of 150 feet. An exam-
ination of the boiler showed only the upper row of tubes to have been out
of water, and these had not been heated sufficiently to make them sag.
The lowering of the water-level had not been sufficient to allow the side-

170
A SUMMARY

sheets or the back sheet or the tube-sheet to take on evidences of over-
heating, facts which suggest the brevity of the interval during which the
crown was actually exposed, and yet in the interval, the crown of a new
boiler came down with explosive effect. The failure was complete; the
boiler had broken away from all its fastenings, property in its vicinity was
disturbed, and the boiler itself left incapable of rendering further immediate
service.

A comparison of these statements shows conclusively the superior
strength and safety under low-water conditions of the Jacobs-Shupert
boiler.

153. The General Conclusions justified by the work are to the effect
that the design of the Jacobs-Shupert boiler is the result of a carefully
studied development of preexisting practice; that the design easily admits
of a grade of workmanship difficult to attain in the construction of pre-
existing types of locomotive boilers; that those features which are peculiar
to the new construction are such as tend to reduce cost in maintenance;
that the evaporative efficiency of the Jacobs-Shupert boiler is the same as
that of a radial-stay boiler of the same dimensions; that the steaming
capacity of the Jacobs-Shupert boiler is, in general, the same as that of a
radial-stay boiler, but that it may be forced without danger of injury to
higher power; that the Jacobs-Shupert boiler presents nothing in its internal
construction which can interfere with the usual movement of water over
the heating-surfaces, and that in the matter of circulation it possesses
some advantage when compared with other types of locomotive boilers;
that the superior strength of the Jacobs-Shupert boiler under low-water
conditions permits it to endure overheating without failure for long periods
of time, where the normal radial-stay boiler quickly fails; and that where
the overheating is so severe that it can not be resisted, the result will be
a blow-out and not a disastrous explosion.