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Laying out for Boiler Makers and Sheet Metal Workers

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''^^,^^^ % ^' :-^m^, %,_ / ;. ^^ » O-V ^ "ft fe' i Laying Out for Boiler Makers and Sheet Metal Workers A Practical Treatise on the Layout of Boilers, Stacks, Tanks, Pipes, Elbol^s, and Miscellaneous Sheet Metal Work OVER 425 ILLUSTRATIONS NEW YORK THE BOILER MAKER I 7 Battery Place t907 ^ ,^^^ afl \^ LIBRARY of CONGRESS UiicUu«>y neceived sEh 27 lyo^ cL»\Sf r\ XXc, No, Reprinted from Copyrighted, J 9 07 3 a J i r) X PREFACE This book has been compiled for the purpose of giving the practical boilermaker the information necessary to enable him to lay out in detail different types of boilers, tanks, stacks and irregular sheet metal work. While the work of laying out, as it is carried on in the boiler shop, requires considerable technical knowledge in addition to that gained by a practical mechanic in the course of his experience in the shop, yet a complete mastery of such subjects as geometry, mechanics and similar branches of elementary mathematics is not essential for doing the work. For this reason no attempt has been made to present these subjects separately from a theo- retical standpoint. The practical application of certain of the principles involved in these subjects is, however, very important, and this has been explained in a practical way in connection with different jobs of laying out which form a part of the every-day work in every boiler shop. Only those lay- outs which are of immediate material use to boilermakers are described, and as far as possible the minor details are given so as to make each problem complete. The first two chapters explain the methods of laying out by orthographic projection and triangulation, since these are the two principal methods used in solving any problem in laying out. A few simple problems are given in each case from which the application of the methods to more compli- cated problems rnay be learned. The chapters which take up the detailed layout of different types of boilers give not only the methods for laying out the actual boiler but also the rules for determining the size, shape and strength of the different parts. These computations are given more in detail in the case of the plain tubular boiler since the problems involved in this case are general and may be applied to almost " any other type of boiler. ' v — TABLE OF CONTENTS CHAPTER 1. PAGE THE SUBJECT OF LAYING OUT. Squaring up a Plate—Plane Surfaces—CyUndrical Surfaces- Cylindrical Tank—Open Tank—Intersection of Cylinders—A Cylindrical Coal Chute —Angle Iron Rings—Conical Surfaces—Intersection of Cone and Cylinder at an Angle of 60 Degrees—Conical Surfaces Where the Taper is Small—90-Degree Tapering Elbow 7 CHAPTER II. TRIANQULATION. Definitions—Truncated Oblique Cone— Circular Hood for Stack—A "Y" Connection 25 CHAPTER III. HOW TO LAY OUT A TUBULAR BOILER. Factor of Safety— Riveted Joints—Treble Riveted Lap Joint—How to Ascertain the Lap—Circumferential Seams—Butt Joint with Inside and Outside Straps—Thickness of Butt Straps—Welded Joints—Effect of Punching Steel Plate—Size of Shell Plates—Size of Heads—Specifications for Boiler Steel Layout of Tubes—Holding Qualities of Flues—Collapsing Pressure of Flues—Direct Bracing—Methods of Fastening Braces—Strength of Braces—^Area of a Segment Indirect Bracing—Size and Number of Rivets in a Brace—Size of Brace Palm—Forms of Braces—Brace Pins—Steam Domes—Domes Braces—Dished Heads—Manholes Suspension of Boiler—Layout of Sheets of Completed Boiler—Details of Longitudinal Seams—Piping and Fittings—Main Steam Outlet—Safety Valve—Dry Pipe—Blow-oflf Pipe—The Injector—The Check Valve—The Feed Pipe—The Feed Water Pump Water Gage and Test Cocks—Steam Gage—High and Low Water Alarms—Damper Regulator 31 CHAPTER IV. HOW TO LAY OUT A LOCOMOTIVE BOILER. Steam Domes— Dome Liner—Front Tube Sheet —Shell Plates—Gusset Sheet—Firebox Back Sheet—Firebox Tube Sheet—Firebox Side Sheet—Firebox Crown Sheet—Mud-Ring—Water Space Corners—Fire Doors Outside Firebox Sheets—Throat Sheet—Top Throat Sheet—Back Head—Belpaire Firebox Crown Sheet—Smokebox Liner—Smokebox Connection—Smokebox Exten- sion—Smokebox Front Door—Deflecting Plates—Netting Door—Stack—Lagging Boiler Mountings—Tubes and Piping 65 ——A TABLE OF CONTENTS — Continued CHAPTER V. PAGE HOW TO LAY OUT A SCOTCH BOILER. Arrangement of Furnaces—Side Elevation—Arrange- ment of Tubes—Back Connections—Stay Tubes and Plain Tubes^Shell Plates—Butt Straps—Circumferential Seams—Manholes—Locating Butt Straps—Through Stays Boiler Saddles—Ordering Material—Laying Out Shell Plates—Front and Back Heads —Tube Sheet—Back Heads of Combustion Chambers—Wrapper Plates—Furnace Fittings—Uptakes—Boiler Mountings—Specifications for a Typical Three-Furnace Boiler : 105 CHAPTER VI. REPAIRING LOCOMOTIVE AND OTHER TYPES OF BOILERS. Renewing a Set of Half-Side Sheets, Half-Door Sheets, Front Flue Sheet and Smokebox Bottom—Applying Back Corner Patches, Back Flue Sheet, Backing Out Rivets and Repairing Cracked Mud- Ring—Renewing a Set of Radial Stays, Broken Staybolts and Flues—Applying a Patch on Back Flue Sheet, a New Stack, Bushings Between Staybolt Holes and Straight- ening a Bulge in the Firebox—Stationary Boilers—Two-Flue Cylindrical Boiler Vertical Fire Engine Boiler—Water Tube Boilers—-Babcock-Wilcox, Stirling, Yarrow, Nest Coil Semi-Flash Boilers 139 CHAPTER VII. THE LAYOUT AND CONSTRUCTION OF STEEL STACKS. Size of Stack—Guyed vStack—Self- Supporting Stack—Base Plate—Anchor Bolts—Lining—Fancy Top—Stability—Thick- ness of Shell Plate—Calculations for Stack 191 Feet High by 10 Feet Diameter—Bell- Shaped Base 157 CHAPTER VIII. MISCELLANEOUS PROBLEMS. A "Y" Breeching—A Tank 85 Feet in Diameter by 30 Feet High—Offset from a Round to an Oblong Pipe—A Four-Piece 90-Degree Elbow With Large and Small Ends on Each Course—Bottom Course of Stack—A Simple Method of Laying Out Ship Ventilating Cowls—Intersection of a CyUnder and Elbow by Pro- jection—A Copper Converter Hood—A Hopper for a Coal Chute by Triangulation— 90-Degree Elbow—A Flue and Return Tubular Boiler with Drop Leg Furnaces A Lobster Back Boiler—A Dog House Boiler 165 FLUE AXn RETURN TUBULAR BOILER IXSTALLED OX THE UXITED STATES REVEXUE CUTTER PERRV. II FEET 6 INCHES DIA^EETER BY 1/ FEET LONG, STEAM PRESSURE 60 POUNDS PER SQUARE IXCH. THE SUBJECT OF LAYING OUT The work of laying out in a boiler shop consists of first while, in certain cases, rtiles can be given for this, the most determining from blue prints or drawings the true size and successful man will have to depend upon his experience shape of the plates, bars, etc., of which an object is to be for this knowledge. For this reason every layer out should constructed, and of then marking out on the material itself to be a practical boiler maker, and have a thorough understand- readily these dimensions the lines on which it is to be cut and shaped. ing of the boiler maker's trade, as he will then more This necessitates on the part of the layer out a knowledge of some of the more common problems in plane geometry, such as are ordinarily used in drafting; a knowlerdge of that part of descriptive geometry which deals with the development of the surfaces of solids of all kinds ; and an intimate knowledge of the behavior of the material which is used in the construc- tion, when it is being punched, roMed, flanged, etc. J The work of a layer out is similar in many respects to that of a draftsman, except that it is done to a much larger scale, with coarser instruments, and upon iron and steel instead of paper. While some of it is merely copying what the drafts- FIG. 2. —MEASURING WHEEL. understand when such allowances should be made and how much they should be. Most of the tools and instruments used by a layer out in his work are well known to a boiler maker and need little ex- planation. The lines are drawn in with chalk or soapstone pencils. Long, straight lines are snapped in with a chalk line. Short ones are drawn in with a steel straight edge. Circles are drawn with trammels, or, as they are more commonly called "trams," a sketch of which is given in Fig. i. FIG. I. —TRAMMELS. F. man has already worked out, yet the layer out must know how to construct accurately the common geometrical figures and figure out their dimensions, as he often has to work out in de- tail what the draftsman indicates only in a general way. He >i CO must know how to find the development of the surfaces of all kinds of solids, because most of the drawings of the various objects made in a boiler shop give only the dimensions of the completed article, showing the plates, angles, etc., after they A B have been bent or forged to the required shapes. From these I „: dimensions the layer out must find the exact size and shape <I of every piece of material when laid out flat, so that after it cut out and shaped by these lines it will be of ex- has been FIG.
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