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Boiler Construction in Detail

plate and plates

BOILER CONSTRUCTION IN DETAIL.

The drawing or design of the boiler is worked out in the draughting room, as explained later under the head of Boiler Design.

Ile draught shows the general arrangement of the boiler, together with complete detail drawings, from which the materials are ordered. These materials are plates, rods for stays, rivets, stay bolts, tubes, steel bars, angles and channel bars for stiffening, etc.

In some boiler shops it is customary to lay the boiler out on a large blackboard full size, thereby checking the drawing. In ordering plates the blank forms are filled out in the following manner: Messrs. John Blank Co : Please furnish us with the following Steel Plates, Ultimate Tensile Strength, 60.000: Elongation. s per cent : The dimension which runs in the direction the plate is to be bent is given first. The plates are marked as per order blank, and this serves to identify the plate when the occasion arises. When ordering any odd shape, a sketch with dimensions must be placed in the column headed " Remarks." In ordering plates, allow for trimming, particularly in the case of irregular shapes. Rivets are sold by the pound, regardless of their shape or size. Round and flat iron may be ordered by the running foot. Manufacturers publish tables showing weight of rivets, round iron, etc., with which they furnish boiler makers.

Boiler Construction in Detail

Boiler shops are equipped with the following tools: plate rolls, plate planers, shears, drill presses, punches, countersinking machines, flanging machines, hydraulic and steam riveters, and a compressed-air system for operating pneumatic machines, such as calkers and chippers. They also have machine shops for doing such machine work as is required for fittings, furnace fronts, etc., and a system of cranes for handling and transporting material. In connection with the above is a storeroom of sufficient size, a forge shop, and an engine and boiler for supplying the shop with the power necessary to operate it.

In boiler-shell work drilling has entirely displaced punching, and to-day all holes are drilled. Punching is cheaper than drilling, but it is more injurious to the plates and not as accurate. It is easy to see that drilling rivet holes, even if twenty are being drilled at once, is done with less strain on the plates than when done by a multiple punch forcing several holes at once. The force required to punch a plate gives the best idea of the harm done to the plate. Experiment shows that the resistance of a plate to punching is about the same as its resistance to tensile tearing. Suppose this to be 50,000 pounds per square inch ; then the force required to punch the plate is the area cut out times the shearing strength, or d X pi X t X 50,000.

In which formula d = diameter in inches and t = thickness in inches.

For a hole inch in diameter in a 1/2-inch plate, the force will be X 3.1416 x x 50,000 = 58,900 pounds.

If the force required to punch one hole is 58,900 pounds, the force required in punching several holes by means of a multiple punch is enormous.

A good, ductile plate is but little injured by punching ; but if of a hard, steely nature, it is likely to be seriously injured. For this reason wrought-iron plates are usually punched and steel plates are drilled. On the whole, a drilled plate is somewhat stronger than a punched plate for any kind of joint.

Some boiler makers punch the rivet holes slightly smaller than the desired size and then ream them out. By this process the injured metal around the holes is cut away. Another method to overcome the injurious effects is to anneal the plate after punching.

The ordinary process of annealing consists of heating the plate to red heat, and then allowing it to cool slowly. By this means, bard and brittle iron or steel is made soft and tough. While the metal is hot, the surface becomes oxidized. For most purposes this 'scale of oxide in not harmful, but in some cases it must be removed. As this is expensive, a process of annealing in illuminating gas has been devised. The action of the gas is to reduce the oxide without altering the properties of the piece. The results obtained from annealing depend upon the kind of iron or steel, the temperature to which it is raised, and the rate of cooling. It is a great advantage to all steel of over 64,000 pounds per square inch in tensile strength, but softer steels are little better for the process.

After the shell plates are planed to correct shape and the holes drilled or punched, they are put through the bending rolls and bent into a cylindrical shape, the amount of curvature being determined by a template made for the purpose. Plates arc usually sheared to size, and then the edges planed with a slight bevel to facilitate calking. In the meantime the heads are being flanged by a hydraulic flanging machine ; when the flange is completed, the head is put on the platen of a boring mill and turned so as to exactly fit into the shell. In some shops it is customary to punch or drill only a few holes in the shell and flange of the head, these holes serving to take bolts for holding the parts together. The back head plate is bolted into the rear course of plating, and the parts thus assembled are hoisted up to drill if the plates, etc., have not been previously drilled or punched, otherwise to the hydraulic riveter.