Part 1

Transcriber’s Notes:

Underscores “_” before and after a word or phrase indicate _italics_ in the original text. Equal signs “=” before and after a word or phrase indicate =bold= in the original text. Small capitals have been converted to SOLID capitals. Illustrations have been moved so they do not break up paragraphs. Typographical and punctuation errors have been silently corrected.

YOUNG ENGINEER’S GUIDE.

BY J. V. ROHAN,

RACINE, WISCONSIN.

PRICE: Cloth Bound, $1.00. Leather Bound, 1.25.

COPYRIGHT, 1894. BY J. V. ROHAN.

All rights reserved.

INDEX.

PAGE. Ascending Hills, 150 Automatic Oiler, 79

Banking Fires, 162 Babbitting Boxes, 188 Belting, 165 Blower, 55 Blow-off Valve, 105

Calking Flues, 52 Check Valve, 107 Cleaning Flues, 53 Compression Grease Cup, 108 Compound Engines, 189 Connecting Rod, 67 Crank, 68 Crank-Pin, 69 Cross-head, 66 Cross-head Pump, 91 Crossing Bridges and Culverts, 156 Cylinder Cocks, 107

Descending Hills, 154 Differential Gear, 115 Duties of Engineers, 13

Eccentrics, 73 Eccentric Strap, 73 Eccentric Rod, 74 Ejector, 97 Engine Frame, 67 Engine Stalled, 155 Exhaust Nozzle, 55

Firing With Coal, 160 Firing with Wood, 159 Firing with Straw, 159 Foaming, 156 Friction Clutch, 116 Fusible Plug, 56

Gauge Cocks, 106 Gearing, 113 General Information, 170 Governor, 76

Heater, 96 Heating of Journals, 141 Hints to Purchasers, 9 Horizontal Tubular Boiler, 15

Injector, 83

Jet Pump, 97

Knocks or Pounds, 137

Laying Up a Traction Engine, 163 Link Reverse, 69 Link, 72 Locomotive Boiler, 16 Low Water Alarm, 57

Packing Piston and Valve Rods, 143 Piston and Rod, 62 Priming, 157

Questions with Answers concerning Boilers, 30 Questions with Answers concerning Engines and Boilers, 119 Questions with Answers for Engineers applying for License, 195

Return Flue Boiler, 18 Reversing an Engine, 130 Reverse Lever, 72 Rules and Tables, 226

Safety Valve, 101 Setting Plain Slide Valve, 144 Setting Slide Valve of Reversing Engine, 147 Setting Valve Duplex Pump, 150 Steam Cylinder, 61 Steam Chest, 63 Steam Engine, 60 Steam Gauge, 98 Steam Pump, 89

Testing Piston Rings and Valves, 136 Throttle, 88 Traction Engines, 112

Valve, 64 Vertical Boiler, 22

Water Tube Boiler, 24 Water Gauge, 104 Work-shop Recipes, 186 Woolf Valve Gear, 74

_INDEX OF ILLUSTRATIONS._

ENGINES. E. P. Allis & Co., Milwaukee, Wis., 21 J. I. Case Threshing Machine Co., Racine, Wis., 26, 29, 224 Gaar, Scott & Co., Richmond, Ind., 36 Nichols & Shepard, Battle Creek, Mich., 49 J. I. Case Engine Co., New Britain, Conn., 58 M. Rumely Co., LaPorte, Ind., 71 Minneapolis Thresh. Machine Co., Minneapolis, Minn., 111 Advance Thresher Co., Battle Creek, Mich., 129 Watertown Engine Co., Watertown, N. Y., 135 Frick Co., Waynesboro, Pa., 153 Armington & Sims Engine Co., Providence, R. I., 168 The Geiser Manufacturing Co., Waynesboro, Pa., 178 The Ball Engine Co., Erie, Pa., 193 A. W. Stevens & Son, Auburn, N. Y., 203

BOILERS. S. Freeman & Sons Manuf’g Co., Racine, Wis., 15, 16, 17, 22 J. I. Case Threshing Machine Co., Racine, Wis., 19 The Stirling Co., Chicago, Ill., 25

FITTINGS. Thomas Prosser & Son, P. O. Box 2873, New York City, 52 Frontier Manufacturing Co., Buffalo, N. Y., 54 The Lunkenheimer Co., Cincinnati, O., 56, 89, 104, 106, 107 J. I. Case Threshing Machine Co., Racine, Wis., 75, 90, 116 The Gardner Governor Co., Quincy, Ill., 76 The Detroit Lubricator Co., Detroit, Mich., 81, 82, 83 American Injector Co., Detroit, Mich., 84, 87, 97, 98 Battle Creek Steam Pump Co., Battle Creek, Mich., 93, 94 The Ashcroft Manuf’ct’g Co., P O Box 2803, N. Y. City, 99, 100 E. B. Kunkle & Co., Fort Wayne, Ind., 101, 102 Chas H. Besly & Co., Chicago, Ill., 109

PREFACE.

Some two years ago the author commenced collecting memoranda of mechanical and practical information pertaining to the care and operation of steam engines and boilers, with a view of forming a systematic digest.

Being an employee of the J. I. Case Threshing Machine Co. for a number of years my attention was called to the constant inquiry for a book of this description from young men mechanically inclined and those running farm engines and small steam plants.

By repeated assurance that there was great need for such a work, and by ready and valuable assistance from personal friends and experts in mechanical engineering, I have considered it advisable to publish a practical guide for young engineers.

The aim has been to place the information contained in the book in the most simple and compact form, and while it is not intended for the education of the more advanced engineers, the instructions given will be found practical in the operation of steam plants of any size. It is more especially intended for the instruction and guidance of young men learning to run engines, and those operating farm engines and small plants, whose experience has been limited.

After carefully considering the mode of presentation, it was thought best to adopt the form of a catechism, with the questions and answers so set forth as to resemble an ordinary conversation; also to illustrate and give a minute description of the construction and function of the different parts used in the building of engines and boilers.

While the greater part of the information is new, parts have been compiled from Power, Roper and other mechanical papers and books, simplified to meet the required aim, for which due acknowledgement is here given.

J. V. ROHAN. Racine, Wis., 1895.

Young Engineer’s Guide.

HINTS TO PURCHASERS.

In selecting an engine of whatever style, or for whatever purpose it is very important to get not only a good one, but one that is of the proper size. Do not entertain the mistaken idea that it is best to have a larger engine than is required (so that it will do its work easily), as an engine which is too large for the work required is very wasteful both of fuel and water. An engine always gives the best results when it has a fair load.

In the selection of a farm or traction engine you should look carefully to the arrangement of the driving gear, the manner in which the engine and the traction wheels are attached to the boiler, the convenient arrangement of the throttle lever, reverse lever, steering wheel, friction clutch lever, independent pump (if used) and injector for easy operation from the footboard, as the easy control of all these parts by the engineer saves much time and annoyance and in many instances may prevent accident which might prove disastrous to both life and property.

Always purchase a boiler with sufficient capacity to allow a small margin beyond its ordinary requirements. Be sure and have the boiler or boilers properly set so that the best results may be derived from the fuel burned. Many good boilers are condemned because they do not steam well on account of bad setting.

If a locomotive style of boiler, see that it has a large fire box (well stayed) and a sufficient number of flues to allow of easy firing and good combustion of the fuel without being obliged to use a forced draft.

If a return flue boiler see that the main flue is of sufficient size and of the required ⁵/₁₆ inch thickness of material; also that it has a mud drum and from four to six hand-holes (the more the better) both top and bottom for the purpose of keeping the boiler free from scale and becoming mud burnt and unsafe.

Remember there is no advantage in carrying low steam pressure in boilers as it is more economical to carry high pressure rather than low. The average boiler pressure should be about 80 lbs. per square inch, which is not too high for safety, nor too low for economy of fuel.

The purchaser must use his own discretion as to the style of engine he prefers, a horizontal or vertical, side or center crank, as all styles are extensively used with equally good results. It is purely a matter of preference depending, of course, largely upon space or room available for stationary engine.

Do not make the mistake of deeming that any kind of a foundation will answer for a stationary engine. It should be built by a skillful mason in every case and hard brick or stone and cement used in its construction. The best is always the cheapest in the end.

An engine or boiler should never be put in a dark corner or damp cellar, rather place them when possible in dry well lighted rooms and so arranged that every part can be reached when necessary without trouble or delay. Walls and floors should be kept clean and a good supply of oil cans, wrenches, waste and whatever tools are needed should be kept in their proper places.

The purchaser of a traction engine should see that it has a Friction Clutch as an engine with a clutch is much more practical, convenient and safe to handle upon the road than one without a clutch. The matter of brackets, braces, gearing, traction wheels, axle, the manner in which the engine is mounted upon the boiler should be well considered as there are many kinds and styles, all of which have their merit “more or less.” Your own judgment should be used as to the style wanted after thoroughly studying the various kinds.

Do not make the too common mistake of thinking a cheap engineer is the man you want. The engine and boiler are important factors in the success of your business and no matter how simple and strong they may be it will pay you to put them in charge of a competent engineer who is capable of taking the proper care of them. For a small plant, or traction engine, it is not necessary to have the highest grade of ability, as there are several grades among engineers; but it is better to pay a suitable man for competent and faithful work than to pay for what may happen through the neglect or incompetency of one whose only recommendation is that he is _cheap_.

Do not be deceived by imposters claiming to be first-class engineers, who, the first thing they do, to substantiate their claims, alter the engine in some way that only deranges it. Be watchful of this and see that such men do not tamper with the valves and adjustments of the engine, which are always set properly before it leaves the factory.

DUTIES OF ENGINEERS.

The duties of an engineer are of much more importance and require a better knowledge of the operating of machinery than is generally understood. The responsibilities that rest upon him are very great; this applies to all engineers, but more especially to inexperienced men who take charge of small plants or farm engines, whose knowledge of machinery and the dangers connected with the improper handling of it, is limited. The proper management of boilers and engines is of as vital importance to prevent accident as their proper construction; as they are liable to get out of order and become unsafe unless the engineer is sufficiently informed to know what precautions should be taken under any and all circumstances that might prove disastrous.

Not only should an engineer be ever on the alert to guard against accident, but he should also be capable of keeping the engine, boiler and appliances in good condition, as the life of the machinery depends largely upon his competency and the faithful performance of his duties.

An ENGINEER:

Should be sober.

Should be industrious.

Should be careful.

Should be faithful to his charge.

Should keep his engine and its surroundings neat and clean.

Should keep his engine running smoothly without knocks or pounds.

Should learn to let “well enough” alone.

Should never attempt experiments unless he knows what he is about.

Should have a place for everything and keep everything in its place.

Should show by the quietness in running and appearance of the engine in his charge that it is properly cared for.

Should constantly endeavor to expand his mind as to the management, construction and care of boilers, engines and their appliances.

Should carry this book in his pocket for reference as it contains much valuable information and in a time of need may save much time and expense, or even prevent a catastrophe.

Boilers.

HORIZONTAL TUBULAR BOILER.

Q. How is a horizontal tubular boiler constructed?

A. It has a cylindrical shell, with heads riveted at each end, in which are placed a large number of tubes, 4 inches or less in diameter. It is set in brick work, with the furnace at one end, beneath the shell. The products of combustion pass under the boiler its full length and return through the tubes or flues to an up-take at the front end. It is furnished with a man-hole beneath the flues, and hand-holes for cleaning, and generally has a steam dome.

Q. What are the advantages of a horizontal boiler?

A. It is simple in form, easy to construct, requires bracing only on the flat heads, which are sustained their greater part by the tubes, generates a large amount of steam for the space occupied, and is not difficult to keep clean with fairly pure feed water.

LOCOMOTIVE BOILER.

Q. How is a locomotive or fire box boiler constructed?

A. The ends of a cylindrical shell are continued straight down upon the sides, and enclosed to form a rectangular structure in its lower portion and conformed to the curvature of the cylindrical shell at the top. In the rectangular portion is secured a fire box, separated from the sides and ends by water spaces called “water legs,” and having its top which is called the “crown sheet” about the center of the cylindrical shell. An opening is formed in both sheets in rear end of the fire box door frame. The cylindrical shell has heads riveted at both ends. These heads have numerous flues open at both ends put in. All the flat surfaces are stayed to each other at suitable intervals, and the crown sheet is stayed from the shell. The fuel is thrown in through the door at the rear, and the products of combustion are conveyed to further extremity through the tubes or flues. It is furnished with hand-holes for cleaning and a steam dome. There are two different styles of fire boxes on Locomotive Boilers, the round bottom fire box in which the water circulates under the grates, and the square open bottom fire box. Both kinds are used extensively.

Q. What advantages have the locomotive or fire box boiler?

A. It is entirely self-contained, generates steam very rapidly, is economical in space, and needs no elaborate foundation.

Q. What disadvantages has the locomotive or fire box boiler?

A. Expensive first cost, and difficulty in cleaning, especially where impure feed water is used.

RETURN FLUE BOILER.

Q. Describe the construction of a Return Flue Boiler?

A. It has a cylindrical shell, with heads riveted at each end, in which are placed a large main flue, and a number of small flues or tubes, open at both ends. The top row of flues is placed below the water line. One end of the main flue is used for the fire box, into which the fuel is thrown through door at back end and the products of combustion pass forward through this main flue to an ample smoke box in front end, and return through the smaller flues or tubes to smoke box at rear end, which is connected to the smoke stack. They are generally supplied with steam dome and mud drum, and are used extensively in the construction of traction engines where straw is used for fuel. They are also furnished with several hand-holes placed in proper places for cleaning the boiler.

Q. What are the advantages of this style of boiler?

A. Large heating surface, easily repaired and cleaned, simplicity of construction and compactness.

REYNOLDS CORLISS CONDENSING AND NON-CONDENSING ENGINE.

This engine has a massive, peculiarly constructed frame, being cast in two parts. The forward part contains the main pillow block bearing, and the part in which the cross-head runs is cylindrical in shape, and has bored Guides, and large lateral openings.

The crank is a large disc plate, and the large heavy fly-wheel serves the double purpose of a drive pulley and balance wheel.

The cylinder is supplied with four valves, two at the top and two at the bottom, and directly upon the bore of the cylinder. The two at the top are the steam valves, the two at the bottom are exhaust valves, and receive their motion from a single eccentric acting through the medium of a wrist plate or vibrating disc, from which the valve connections radiate. The valve being independently adjusted, the commencement, extent and rapidity of the movement of each can be most accurately arranged. The steam valves are controlled by the Governor, which, being very sensitive to the variation of load, allows just the required amount of steam to enter the cylinder to keep up the uniform speed. The exhaust valves being at the lower ends of the cylinder, at the clearance space, the water of condensation is allowed to escape in the most thorough manner, without the use of cylinder cocks or other devices.

This style of engine is intended for all purposes, but is especially adapted to heavy and continuous work and where the conditions call for an engine capable of working under a high steam pressure, also when the work is of an intermittent character.

VERTICAL BOILER.

Q. How is a Vertical Tubular Boiler generally constructed?

A. A cylindrical fire box set into the lower part of a vertical cylindrical shell, the space between forming an annular “water leg.” An opening is formed in both sheets for the fire door. The top of the fire box serves as a flue sheet for numerous tubes or flues which extend through the closed top of the outside shell, and through which the products of combustion pass to the smoke stack. The upper portions of the tubes are surrounded by steam.

Where this style of boiler is made for marine purposes, the upper part of the tubes is submerged, and is called a submerged-flue boiler.

Q. What advantages has the vertical type of boiler?

A. Minimum floor space, portability, low cost of setting, and a wide allowable variation in the water level.

Q. What disadvantages has this type?

A. Liability to leakage in the exposed upper ends of flues where they are not submerged, deposits from impure water in the “water leg,” in small sizes insufficient heating surface, though the latter fault can be corrected by making the boiler very tall. Some of the very large vertical boilers are remarkably efficient.

WATER TUBE BOILER.

Q. How is a water tube boiler constructed?

A. The Stirling Water Tube Boiler as illustrated, has three upper or steam domes, the steam space of all of which is connected, while the water space of the two front domes is connected. All of these three domes are connected with a lower or mud drum, which is not bricked in, but is left free to expand and contract.

The three upper domes are supported on wrought iron beams, which are entirely free and independent from the brick work. The feed water enters the rear upper dome, and descends gradually to the lower or mud drum, being heated in its descent by the escaping gases to a sufficiently high degree to cause precipitation in the mud drum of all of the solid or scale bearing matter that the feed water contains. The water then in the front bank of tubes is chemically pure, and all danger of scale reduced to a minimum.

Q. What advantages have the water tube boilers?

A. One of the great advantages of this style of boilers is its distinct circulation, being up the front bank of tubes across from the front upper dome to the middle dome, down the middle bank of tubes to the lower or mud drum, and up again the front bank of tubes, and so on in circuit. It also has great steaming capacity, and is economical in fuel. Steam is taken from the middle dome.

This marked circulation is a desideratum in boiler practice, and the Stirling may be said to be the first that has accomplished it to so great a degree.

Q. What disadvantages have the water tube boilers?

A. Expensive first cost of setting them up in brick work.

J. I. CASE TRACTION ENGINE.

This engine is known as the Center Crank, Rear Gear traction. The engine is mounted on the center of boiler at the rear end, and rests upon and is securely bolted to two saddles. The rear saddle also supports the two outer bearings for the crank shaft.

The engine frame is cast in one piece, cylindrical in shape, with bored guides for cross-head, and has large lateral openings. It forms the front cylinder head at one end, and contains the two pillow block bearings at the other.

The cylinder is overhanging and self-lining.

It has the locomotive type boiler, with open bottom fire box, covered with an ash pan, and has a steam dome at front end. The outer shell of this boiler over fire box extends beyond the back head. To this extension is bolted the two brackets containing the bearings for the main axle and cross shaft.

The traction wheels are of the wrought rim steel spoke type, with high mud cleats bolted diagonally across the entire width of tire.