Part 4

The advantage of a pure water, which does not deposit scurf, is so great for the supply of boilers that it is always worth while to go to considerable expense for obtaining it; or to take some steps for purifying the feed water as much as possible. If it is only mud mechanically suspended, which would deposit by gravity on the bottom of the boiler, frequent use should be made of the blow-off apparatus. If the impurity is light enough to be carried to the surface in the form of scum, the blow-off apparatus should discharge from the surface of the water as well as from the bottom. If the impurity is chemically suspended in the water, some one of the many substances which form the refuse from various manufactures, and which may contain suitable ingredients, should be used to counteract the effect of the impurity. Common soda will answer the purpose perhaps better than anything else. It must not be forgotten however that the blow-off apparatus must afterwards be used more frequently, to rid the boiler of the foreign matter, or the mischief will be increased. In marine boilers, constant attention is necessary to get rid of the saline deposit; and in stationary boilers using impure water an equally systematic attention is needed to get rid of the earthy deposit.

* * * * *

Perhaps no cause of explosion is oftener mentioned than shortness of water, and this is not unfrequently coupled with turning on the feed suddenly into an overheated boiler. Many explosions have been attributed to this cause, when closer investigation would have revealed some far more probable reason. For instance, shortness of water was stated as the cause of the explosion, at Abercarn in 1865, of a single-tube boiler with a very large flue tube, which collapsed upwards from the bottom. The top of the tube and the sides of the shell had not the slightest mark of overheating, although exposed to the flame of three furnaces, one of which worked through the tube, and the others on each side of the shell. In this case the cause of explosion was clearly the weakness of the tube, and not shortness of water. It is erroneous to suppose that if a boiler runs dry, or if the feed is turned into a red-hot boiler, there must necessarily be an explosion. If a boiler unconnected with any other runs rapidly empty, from the breaking of the blow-off pipe or any such cause, it will simply get red-hot and sink out of shape upon the fire, as may often be seen, but no explosion would happen. If the water only falls gradually, as it would if the feed were turned off and evaporation continued, the parts exposed to the fire would get overheated as the water left them. If the subsidence of the water were very slow, those parts might get red-hot, and so much softened and weakened as to be incapable of bearing the pressure, when an explosion would take place, as at Smethwick, in the present year, where the flues were set above the water line, as shown in Fig. 74.

If however the water were turned on again before the overheating had gone so far, and the feed pipe were, as usual, carried down to nearly the bottom of the boiler, the water would gradually creep up the heated sides and cool the plates, the heat of which would not be sufficient to cause greater evaporation than the ordinary safety valves would carry off. The danger would not arise so much from the excess of steam generated by the heat accumulated in the heated plates of the boiler, as from the injury and strain that would be caused to the plates by the undue expansion and sudden contraction, especially as this action would take place on only a portion of the boiler. A singular case, bearing on this point, may be mentioned. A four-furnace upright boiler, like that shown in Fig. 44, happened to run so nearly empty, through the accidental sticking of the self-acting feed apparatus, that the level of the water sank to the top of the hemispherical end forming the bottom of the boiler. The feed apparatus then became released of itself, and, the feed being turned full on, the water gradually rose until the whole occurrence was only discovered by the leaking at the seams that had been sprung, which caused so much steam in the flues as to stop the working of the furnaces. The overheating had been sufficient to buckle the plates, and in one place a rupture had almost commenced; but there was no explosion. By way of direct experiment upon this point, boilers have been purposely made red-hot and then filled with cold water, without causing explosion.

It has been supposed that boilers sometimes explode from overheating without the water level being below the usual point, or without the accumulation of scurf previously alluded to, but simply by the rapidity of the evaporation from an intensely heated surface causing such a continuous current of steam as to prevent the proper contact of the water with the heated plate. Such has been the cause assigned for the explosion of a three-furnace upright boiler at Birmingham in 1865, shown in Fig. 75. A piece of plate about 3 ft. by 1-1/2 ft. was blown out of the side, at a place where an enormous flame impinged continually. The plates had first bulged out, and then given way in the centre of the bulge, each edge being doubled back and broken off. There was no positive evidence as to the water supply; but the crown of the centre tube, which was much above the bottom of the part blown out, remained uninjured.

A somewhat similar case was that of a large horizontal boiler at Kidderminster, the tube of which collapsed in 1865, as shown in Fig. 76. It was heated by four furnaces, one of which worked into the tube, one under the bottom, and one on each side; and all the furnaces worked into the same end of the boiler. The tube was found to have partially collapsed at that end, and the top had dropped 11 inches. This was repaired in the first instance, but was afterwards again found injured by overheating, although not so seriously. It is very probable that the extremely rapid ebullition from the sides and bottom, from which the steam had to pass up the narrow space between the tube and the shell, produced such a foaming that very little solid water could reach the top of the tube where it was exposed to extreme heat.

Many explosions have been attributed to deterioration of the iron through long use, as in an explosion at Durham in 1864, and another at Haswell, near Sunderland, 1865, where the boilers had worked constantly for 25 and 30 years respectively. When an explosion arises from the failure of a plate which has not been properly welded in rolling, there is no question that it was unsound when put in, and escaped notice; but when the plate that fails is found to be brittle and of bad iron, the fault is rather attributed to the effect of working than to original bad quality. Of course this is not always the case, as the injury done to plates by overheating has been already explained. Pieces of plate have in some cases been erroneously pronounced to be deteriorated by work, which have been taken from situations in the boilers where they were not exposed to any action of fire that could cause overheating; and therefore in reality the injury could only have taken place when the boiler was being made, by burning the iron in bending it to the required shape. A frequent cause of fatal injury to boilers is injudicious repair, whereby the crossing of the seams is destroyed, as in the explosion at Wolverhampton in 1865, previously referred to and shown in Fig. 36. Moreover the edges of the old plates, already tried by the first rivetting and the subsequent cutting out of the rivets, are frequently strained again by the use of the drift to draw them up to the strong new plates; and many a seam rip is thus started which ultimately causes explosion.

Many explosions have been caused by the want of proper apparatus for enabling the attendant to tell the height of the water and the pressure of the steam, and also by the want of sufficient apparatus for supply of feed water and escape of steam, or by the failure of one or other of these; but such explosions can only be referred to generally in the present paper. The mountings on a boiler are usually so open to observation, and the importance of having them good and efficient is so universally acknowledged, that much remark is not needed. Mention has already been made of the sticking of self-acting feed apparatus as a cause of mischief, and similar failures of floats and gauges have constantly happened; but this should by no means be considered to condemn self-acting apparatus, either for assisting in the steadiness of working, or for giving warning of danger. The apparatus however should be relied on for assistance only; and an attendant cannot be called careful who leaves a boiler dependent on such apparatus without watching. The self-acting principle has been seen by the writer applied in a novel and useful way in a recording pressure gauge, which proved the more interesting as it had shown the actual pressure of steam at the time of the explosion of one of the boilers with which it was connected.

Among the numerous boiler explosions that have been attributed to over-pressure through deficient arrangements for escape of steam, in many cases the safety valves have been placed on the steam pipes in such a manner that the communication with them was cut off whenever the steam stop-valve was shut, which is just the time when the safety valves are most wanted. Safety valves are too often found needlessly overweighted; and it is believed that many boilers are constantly worked with safety valves so imprudently arranged and weighted, that they could not carry off all the steam the boilers would generate without a very great increase of pressure.

* * * * *

It is concluded that enough has now been said to show that boiler explosions do not arise from mysterious causes, but generally from some defect which could have been remedied if it had been known to exist. It only remains therefore to consider what is the most ready and efficient way to discover the true condition of a boiler. It has been maintained that this end is best accomplished by what is called the hydraulic test, in which a pressure of water is maintained in the boiler for a given time at a certain excess above the working pressure. This test is undoubtedly useful so far as it goes, and is perhaps the only one that can be applied to boilers with small internal spaces, such as locomotive boilers, not admitting of personal inspection over the whole of the interior; and it is also admirable for testing the workmanship of a new boiler. But on the other hand the conditions of a boiler at work are so different from those which exist during the hydraulic test, that this alone cannot be depended on; for old boilers have been known to stand this test to double their working pressure without apparent injury, although known to be dangerously corroded. The difficulty also of seeing or measuring the effect of the hydraulic test upon large boilers set in elaborate brickwork is so great that little practical benefit has resulted in many cases.

It is believed by the writer that the surest way to ascertain the true condition of a boiler is to examine it at frequent intervals in every part, both inside and outside; and as this can only be done when both the boilers and the flues can be readily entered, it is specially important that facility for examination should be made a consideration in selecting a construction of boiler. Permanent safety should be considered as an element of economy, in addition to its still higher importance in reference to the preservation of life.

ON THE CONCLUSIONS DERIVED FROM THE EXPERIENCE OF RECENT STEAM BOILER EXPLOSIONS, BY EDWARD B. MARTEN, MEM. INST. M.E., EXCERPT MINUTES OF PROCEEDINGS OF THE MEETING OF THE INSTITUTION OF MECHANICAL ENGINEERS, AT NOTTINGHAM, 3RD AUGUST, 1870, THOMAS HAWKSLEY, ESQ., VICE-PRESIDENT, IN THE CHAIR. BY PERMISSION OF THE COUNCIL.

The records of Steam Boiler Explosions in recent years are very numerous, as the increased attention drawn to the subject in this and other countries has placed far more information at disposal; and the experience of the last four years, since a former paper was read by the writer on the subject of boiler explosions, has confirmed the opinion then expressed, that all boilers, however good in original construction, are liable in the course of time to get into bad order and explode. The particulars of the explosions during this period are given in the Tables appended to the present paper, which show the number of explosions due to each cause in each class of boiler, distinguishing those of the United Kingdom from those in foreign countries. An analysis is also given of the explosions in the last four years, showing the causes of explosion of each form of boiler; and also a summary of the causes of explosion under the three general heads of--(1) faults in construction or repair: (2) faults in working which creep on insidiously and unnoticed: (3) faults which might be seen and guarded against by careful attendants. Nearly all of the faults in these three classes would have been detected by periodical examination.

* * * * *

In the case of Cornish, Lancashire, and other boilers with internal flues, the faults of construction which have caused explosions have been weakness in the tubes, combustion chambers, ends, domes, or manholes; and explosions in these, as in other classes of boilers, have also resulted from external or internal corrosion, shortness of water, undue pressure of steam, and scale or mud on the boiler plates.

In plain cylindrical boilers, and others without internal flues, explosions have resulted from the boiler ends being made flat, and also from frequent repairs producing seam rips, especially in boilers having the plates arranged lengthways instead of in rings.

In marine boilers, weak flues and weak ends have also led to explosion, in addition to the other causes mentioned above.

Locomotive boilers have in two cases exploded in consequence of the strains thrown upon them by their being used as a frame for the engine.

Other explosions have resulted from want of stays, and from too much heat impinging on some particular part; and in domestic boilers from freezing of pipes under pressure.

* * * * *

Altogether the total number of explosions in this country that have been recorded during the past four years has amounted to 219, which may be classed under the following heads:--

Faults of construction or repair 95 Faults to be detected only by periodical examination 62 Faults which should be prevented by careful attendants 54 Extraneous or uncertain causes 8 --- Total 219 ---

By these 219 explosions 315 persons were killed and 450 injured.

The following are the particulars of the construction of the 219 exploded boilers:--

Cornish, Lancashire, or other boilers with internal flues 84 Plain Cylindrical boilers or others without internal flues 54 Marine boilers 12 Agricultural boilers 11 Locomotive boilers 10 Furnace-upright boilers 8 Crane boilers 6 Rag steamers, &c. 6 Balloon and Elephant boilers 5 Domestic boilers, &c. 16 Not sufficiently described 7 --- Total 219 ---

The causes of these 219 explosions may also be classed as follows:--

Worn out, corroded, or burnt plates 89 Undue pressure, overloaded valves, intentional or from carelessness 25 Bad construction, defective fittings or stays, or want of repair 69 Shortness of water, formation of scale or mud, or external flues set too high 28 Extraneous or uncertain causes 8 --- Total 219 ---

Sketches are given of the most instructive examples of boiler explosions during the last four years, which are sufficient to explain themselves, with a brief reference to their special features.

* * * * *

Although the importance of periodical examination as the best safeguard against explosion is generally admitted, a great number of those who make or use boilers have not at present sufficient belief in its importance to adopt this course. Boilers are still constructed or set in such a manner as to render examination next to impossible; and are continued to be worked without making it the duty of those who mind them, or of any one else, to examine every part at frequent intervals; and hence such explosions have occurred as shown in Fig. 1, No. 12, 1870, in which the original position of the boiler before explosion is indicated by the dotted lines. It is thought by many steam users that all has been done which is possible, if their boilers are the best that can be procured, and are set in the most approved way; and it is taken for granted that such boilers should last for many years, under the idea that a good boiler can never explode unless the feed is neglected. Similar boilers are often referred to as having worked safely for ten or twenty years, but it is forgotten that they may be exposed to the insidious action of furrowing on the inside or channelling on the outside, such as caused the explosions of the originally good boilers shown in Figs. 2, 3, 4, and 5, Nos. 35, 1870; 50, 1866; 46, 1869; and 25, 1870.

Much mischief arises from special classes of boilers, fittings, or apparatus, being looked upon as promising permanent safety from explosion; while the inevitable circumstance is overlooked that it is only so long as everything is maintained in good condition that safety is insured. An apparatus, for instance, for preventing explosion from shortness of water or over-pressure, however perfect for any such object, would be quite inefficient as a safeguard against explosion from corrosion, furrowing, channelling, or weak construction. It is curious to note how often it is the case that every other part of an establishment is subject to severe and perpetual scrutiny, the engines especially being overhauled with the most scrupulous regularity; while the boilers, the very source of the power and the heart of the whole business, are left to themselves for long periods, even for years, without examination; and it is too often only after bitter experience that owners have understood the need of this examination. In this, as in many other matters, experience has shown that there is no royal road to safety, and that immunity is only secured by unremitting care and constant watchfulness. It should never be forgotten that even a good boiler can explode; for however good at the outset, sooner or later the time must eventually arrive, when such wear and tear will have taken place as will result in dangerous weakness, unless the boiler is carefully and systematically attended to. Although a boiler may even last safely for ten to thirty or more years if worked slowly and with care, no confidence can be placed in a boiler which has worked so long, unless it is examined in every part.

The opinion is more general than many are aware of, that explosions as a rule are caused by shortness of water and the sudden turning on of the feed water upon red-hot plates; and the appearances of injury in the plates from fire, arising in the ordinary course of working, have been frequently mistaken for signs of overheating from shortness of water at the time of explosion, as illustrated in Figs. 6 and 7, No. 24, 1867, and No. 59, 1866. Although boilers do explode from the softening of the plates by overheating in consequence of shortness of water, yet it is very doubtful whether the turning on of the cold water at such a time is ever the cause of explosion. The feed water being always introduced at the bottom of the boiler, as in Figs. 8, 9, and 10, cannot be scattered suddenly near the overheated parts, but must rise gradually up the sides; and the boiler would have gone to pieces from the giving way of the softened parts long before the water reached them, as was the case in the explosions shown in Figs. 11 and 12, end of 1868. The experiment of injecting cold water into red-hot boilers has been carefully tried more than once, without producing any explosion.

Although it may be too much to suppose that boiler explosions will ever be entirely prevented, it is important that those who have the care of boilers should understand better what are the true causes of explosion, in order that they may know what to guard against in addition to shortness of water. This better understanding of the subject has been much retarded by the supposition that the causes of boiler explosions are beyond the comprehension of the boiler minders; and still more by the important differences of opinion among those under whom they work. Much evil has resulted from the promulgation of strongly expressed views, which have been founded upon facts but of too limited extent, and such as must become modified by consideration of the facts of a large number and variety of explosions. Mysterious theories to account for explosions have been resorted to only from want of clearer explanations.