The Iron Age 1909-02-04: Vol 83 Iss 5

THE Published every Thursday Morning by David Vol. 83: Neo.'s 5 IRON Williams Co., New York, Thursday, February 4, 1909. AGE 14-16 Park Place, New York. $5.00 a_Year, including Postage, Single Copies, 15 Cents Reading Matter Contents........ page 438 Alphabetical Index to Advertisers ‘* 286 Classified List of Advertisers = 275 Advertising and Subscription Rates ‘* 462 REED F. BLAIR & CO. PRICK BUILDING, PITTSBURG, PA. STANDARD CONNELSVILLE COKE FOUNDRY FURNACE CRUSHED The original and only Genuine ‘*STILLSON WRENCH ”’ is manufactured by WALWORTHIMEG. CO., Boston, U. S. A. And bears their registered Trade-Mark THE BRISTOL COMPANY o MANUFACTURERS OF u) The Wm. H. Bristol Electric Pyrometers Hie For High Temperatares THE BRISTOL CO Waterbury, Conn. There’s More Money in Samson Spot Cord |) Than there is in Cheap Grades. Samson Cordage Works, Boston, Mass. oe ee . 66 rT Cleveland City Forge and Iron Co., Cleveland, 0. tae TrTruUunRN BU OC HE I oe] GE eins BROS. Maspeth, New York, N. Y. SOFT COAL. Pillin & Crane: Real Estate Trust Bldg., Phila. TNE Ge | yEmpire Building, New York MADE IN AMERICA and THE BEST IN THE WORLD THE LUFKIN RULE CO.,, Saginaw, Mich., U.S.A. New York London, Eng. Windsor, Can. ir METAL SHEETS A natural alloy of nickel, cop- SHOT SHELLS AND HARD HITTING —__waterbun, Com. WATER TUBE > Jenkins Bros. are heavy and strong. easily kept tight, and as all parts are renewable, they are practically in- destructible. Always insist on getting, not “Jenkins ”—but JENKINS BROS; they alone bear our Trade Mark, and are guaranteed. send you our Catalog ? JENKINS BROS., NewYork, Boston, Philadelphia, Chicago “Swedon” Cold Rolled Steel ca A or THE AMERICAN TUBE & STAMPING COMPANY SEE 2 (Water and Rail Delivery) Li aedies ds of car loads of U. M. C. shells were shipped during the last venead season to the quail sections. There was a tremendous and popular UMC demand. Carry UMC shells and be hunted up by sportsmen who prefer the best. Arrow and Nitro Club loaded with Smokeless powder and New Club loaded with black powder, The Union Metallic Cartridge Co.. AGENCY: 313 Broadway, New York Babcock a Wilcox Co., 85 Liberty Street, New York She 1IBOILERS ace pase 61 There Are No Losses---All Is Gain No T i m e Lost Nails is S hoes a Customers ‘ Money «6 FOR HORSESHOERS WHO DRIVE “CAPEWELL” NAILS MADE BY The Capewell Horse Nail Company Hartford, Conn. Valves They give good satisfaction to thenser. They are May we BRipGsPort, Oonx. phan 2 per and iron—practically non- erosive and non-corrosive. AMERICAN SHEET AND TIN PLATE COMPANY Frick Building, Pittsburgh, Pa. See our ad on page 17 New York: 115 Bank St. Chicago : ANTI MAGNOLIA ,,**"), METAL The Standard Babbitt of the World We manufacture everything in the Babbitt Line. 7 > wicnouis METAL co. Fisher Building. Montreal: 31 St. Nicholas St. THE IRON AGE SSSSSSNSSNSSSSSSSSSSSSASN/ Py 4 CC (SHEET |The Plume & Atwood Mfg, Co. we contro {IBRASS} ">, | Pum & Avent Mie, Ca Sheet and Roll Brass, Wire, SHEET | Rods, German Sliver and Brass oe COPPER} ROD Goods In great variety. FOLLANSBEE eT ecm oaks: eames Branch Offices STEEL GERM — “ee tim kineietill SHEETS SILVER | wre [ANTIMONY aan “A. S. P.’* Brand BRIGHT LOW BRASS, SHEET BRONZE, (English Star) CHARGOAL SEAMLESS BRASS AND COPPER |C. W. Leavitt @ Co., Agents TIN PLATE TUBING, BRAZED BRASS AND | ———— “HEARTH BRONZE TUBING: s: : « + SCOVILL MFG. co. OPEN H BRASS, GERMAN SILVER, TO FINISHING Waterbury Brass Co. Sheets, Rolly, Wire, and DEPARTMENTS WATERBURY, CONN. Brass Shelly, Cupt Hinges, Button ; idence, R. 1. — %9 John St.. New York Provieenes Special Brass Goods to Order Bridgeport Deoxidized Bronze WATERBURY, CONN. FOLLANSBEE & Metal Co Depot: BROTHERS {| swoacronr, con, || COM PANY Phosphor > Deoxidized HenrySouther Engineering Co. Pittsbu rgh HARTFORD CONN. Composition, Yellow Brass and Alumi-| Consulting Chemists, Metallur- num Castings, large and small gists and Analysts. Complete Physical Testing Laboratory. Expert Testimony in Court and Patent Oases, All under our own supervision Matthiessen & Hegeler Zinc Co. SMELTERS OF SPELTER AND MANUFACTURERS 256 Broadway, SHEET ZINC AND SULPHURIC ACID NEW YORK. Special Sizes of Zinc cut to order. Rolled Battery Plates. Small tubing in Brass, Copper, Selected Plates for Etchers and Lithographers’ use. oa i is taanename ait ae, Steel, Aluminum, German Silver, Stove and Washboard Blanks. &c. Sheet Brass, Copper and Ger- man Silver. Copper, Brass and INOS FOR LECLANSHE BATTERY. German Silver Wire. Brazed and Seamless Brass and Copper Tube. en eee eee Copper and Brass Rod. 7 GERMAN SILVER ~w ~< In Sheet, Wire, Rods, Blanks and Shells ‘‘Search- Light ‘ NICKEL ANODES GAS Bicycle Lanterns BRASS, BRONZE, COPPER in all forms Send for Cisculars and Electrotypes. \, THE SEYMOUR MFG. CO., Seymour, Conn. po The BRIDGEPORT BRASS CO. ease ee ee BRIDGEPORT, CONN. HENDRICKS BROTHERS —_ || = tices pettos, tentwey ane Sheet anadBar Copper, Copper Fire Box Plates|~—___ and Staybolts, Wire and Braziers Rivets Fr PHOSPHOR-BRONZE Ingot Copper, Block, Tin, Spelter, ¥, ay Lead, Antimony, Bismuth, Nickel, etc. Doe e. TMMETAL Co. 49 CLIFF STREET - - NEW YORK'™” “x° ne oe en Se THE IRON AGE New York, Thursday, February 4, 1909. The Greatest Steel Plant in the World.—ll. The Power Plant at the Gary Works of the Indiana Steel Company, Subsidiary of the United States Steel Corporation. In no other department of the Gary Works have the designing engineers departed farther from the beaten paths of standard practice than in the electrical power plant. the plant itself, but also in the manner and extent of ap- Not only is this true as respects the equipment of plication of electricity as a motive force for the driving of both main and auxiliary mill machinery. It should be borne in mind that at the time the plans for this plant were drawn, prior experiments in the use placed, the engines that have later rendered good service at the South Chicago Works of the Illinois Steel Com- pany, and of which these are practically duplicates, were only then being erected and were not started until some months thereafter; also that the experience afforded by the Pittsburgh was limited to a similar equipment in Edgar Thomson mills at a few preliminary tests, the installation having just then been completed. Four of the gas engines in the Gary clectric power stations are Fig. 1.—The Electrie Power Station of the Indiana Steel Company, Containing 17 Allis-Chalmers Twin Tandem Gas Engines, Direct Coupled to 2000 Kw. Generators, Each Unit Being of 4000 Hp Chalmers Twin Tandem Gas Engines Not Shown. of furnace gas engines in this country afforded scant precedent for their adoption, especially upon a scale so extensive and important as was here proposed. As is well known, substantial progress in the utilization of furnace gas as a fuel for gas engines had already been made in Europe, especially in Germany, where the results achieved were such as to justify the hopes entertained for its growing ascendancy as a practical source of power, but owing to the existence of different conditions on this side, in fuel, ore and methods of operation, new problems were Recent developments in this direction, however, have been rapid, and it is not perhaps generally realized that the principal plants of this type now successfully working have proved their right to recognition as reliable and efficient prime movers since the plans for the Gary plant were drawn. presented which had not yet been fully solved. The boldness and courage of those responsible for this unprecedented undertaking will perhaps be better ap- preciated when it is understood that at the time it was finally decided to place chief reliance upon gas engines, and even up to the time orders for the machinery were Capacity. —— This Installation Also Includes Eight Allis being tried out this week; and in view of the fact that gas blowing engines have been supplying blast to furnace stacks 11 and 12 for the past three weeks, carrying the load with creditable ease and regularity, the results are expected to be highly satisfactory. The Power Station, The electric power station is located between blowing engine houses Nos. 2 and 3, and the open hearth fur- naces, at a point midway of the line of blast furnaces. It rests on a massive foundation of concrete composed of a 5-ft. sublayer of cement underlying the whole structure at the lake level, forming the separate foundations supporting the ponder- from which rise monolithic columns ous weight of individual engine and generating unit. Within this building, which is 966 ft. long by 115 ft. wide, is housed the equipment comprising power stations Nos. 2 and 3, the former occupying the south and the latter the north half of the building. These stations are de- signed to serve the first two units of the plant, or the first eight blast furnaces, and all of the electrically op- 374 THE erated equipment connected with them including the rail mill, billet mills and shops. By the construction of most massive foundations, unsparing pains were taken to guard against vibration and to secure the firm and steady movement of machinery. The power house is constructed with walls of red ‘brick, carrying a trussed steel roof, covered with heavy galvanized corrugated steel, and has 42 23-ft. bays. Ample head room for the operation of the two 50-ton Morgan electric traveling cranes, serving the entire floor, is provided in a clearance of 85 ft. from floor to roof. For a distance of 10 ft. the floor and interior walls are finished with white enamel brick with a surfacing of red pressed brick above that point. The proximity of the power station to the blast furnaces and the gas holders from which the purified fuel gas is supplied to the en- gines simplifies the piping system and shortens the dis- tance of travel; the plant is also centrally located with respect to the distribution of current to the various mill motors. The Engines and Turbines, An interior view of the central station is shown in Fig. 1, from which may be gained some idea of the im- posing character of its equipment, and its remarkable power producing capacity. The installation consists of 17 horizontal twin tandem double acting gas engines, de- signed for a speed of 83 1-3 rev. per min.; 15 of these engines are arranged for direct coupling to alternating current generators, while the remaining two are fitted for connection to direct current generators. The former are 25 cycle, 3 phase, 6600 volt machines, and the latter deliver current at a pressure of 250 volts. The twin en- gine units have a rating of 4000 hp., and the generators 2000 kw., but for the purpose of assuring ample power, they have been constructed with a view to carrying con- tinuously a.30 per cent. over-load. Near the center ofthe building are installed two Gen- eral Electric Curtis steam turbines of 2000 kw. capacity each for auxiliafy service in case of emergency. These units were the ‘first installed, and pending completion of the gas engines have been used for generating current for lighting and for operation of cranes and construction machinery, running in parallel with the gas engines in the South Chicago plant. The gas engine units, which were built and furnished by the Allis-Chalmers Company, are not materially dif- ferent from the type regularly constructed by that com- pany, but they are said to be the largest engines ever built to operate on blast furnace gas. They differ only from those built for the Illinois Steel Company, and now in service at South Chicago, in that the cylinders are 2 in. 42 x 54 in. for the latter. the most impressive features from an engineering point larger in diameter, being 44x54 in., as against Aside from their massiveness, of view are remarkable simplicity of design, solidity of construction and quiet operation. Being called upon to sustain the rapid fluctuation incident to steel mill service, it is essential that they should have reserve capacity to handle overloads with the same ease and freedom from vibration that characterize their operation under normal conditions. That they are able to meet these require- ments has been demonstrated in a practical way when, under rapid changes of load they turned their centers as quietly as the slow running Corliss machine. In the construction of the engines the aim has been to concentrate strength at the points of critical stress, and, though exceptionally rigid and heavy throughout, the frame, cylinders and tie pieces are especially heavy. It is in the frame that the principal difference between European and American design is observed. Standard IRON AGE February 4, 1909 practice abroad favors the double throw crank, while this frame is designed for a side crank, which, in spite of the heavy stress transmitted to the frame by this form of construction, has, even in the largest sized engines, been as successfully provided for as in standard steam engine | ~ z =< = © £ = o o SETTLING TANK 1 C.L. No. @ ENGINE TUNNEL FROM NEW OIL STORAGE TO GRAVITY TANK LUBRICATING SYSTEM ~< Plan of the Power House, GRAVITY TANK 2,560 GALLONS VENT 4" PIPE OVERFLOW 4" INLET ir 6 ‘PIPE 4 PIPE Longitudinal Section. Fig. 2.—The Power House.—This Building Is 966 Ft. Long and 115 Ft. Wide and the Sections Shown Above Are Typical of the Entire Construction and Arrangement, practice. The stress to which the jaw is subjected is unusually severe, and, in addition to a form of casting insuring maximum strength, this part is further strength- ened by two steel tie bolts, carried above the shaft, of sufficient size and strength to sustain their full propor- tion of the load without appreciable elongation; this re- February 4, 1909 THE inforcement is designed to eliminate bending stresses in the frame at this point. The lower half of the engine frame, weighing approx- imately 90 tons, is buried in the foundation, thus bring- ing the rods on the valve gear and other working parts near enough to the floor level to be easily accessible, which contributes much to the convenience of handling. As will be observed in the plan drawing, Fig. 2, the engines are set crossways of the building, with the cylinders on the east side nearest the source of fuel supply. Each twin tandem unit occupies a floor space of 44x70 ft. The cylinders are 44 in. in diameter by 54 in. stroke, and the crank pins are 20 in. in diameter. A flywheel 23 ft. in diameter weighing 200,000 lb. is mounted on a shaft 30 in. in diameter at the bearing. ‘ The water cooling system includes hollow pistons and rods into which the water is introduced at the center and flows forward to discharge in the frame for the front piston and backward to dis- charge in the tail guide for the rear piston, each piston having a separate supply to provide for dismantling and cleaning. The rods are made in two parts, joined to the central slide, the rear half going out at the back of the engine and the other half going out through the front, which for convenience is made open at the top. The valve gear, which is of the standard Allis-Chal- mers type, is located between the engines comprising the twin tandem set, and is thus concentrated so that the valve mechanism of both parts may be simultaneously ob- served by the engineer. This arrangement merely follows out the general scheme of reducing to a minimum the number of attendants required to handle the equipments. Ignition System, The ignition system consists of electrically controlled ignitors which are so arranged that the time of ignition may be regulated by a single hand wheel, and is supplied by direct current at 80 volts. Duplicate independent ignitors are provided at each end of the cylinder to in- sure prompt firing of low heat value gas, and also to avoid the danger of shutdown due to short circuit. From the motor generator set, which furnishes current to the electrically operated ignitor, the entire ignition system is a most carefully designed and solidly built apparatus. The smooth running of the engines under highly variable loads is further guaranteed by the constant compression under which it operates. The engine is started from any position by means of an air starting device which con- sists of a small poppet inlet air valve at each of the cylinder ends. This valve is actuated by the lay shaft, and air is admitted to each cylinder in turn at what under heat propulsion would be the working stroke. Since the high compression carried prevents the engine from stopping on a dead center, this arrangement guarantees prompt starting without the use of a turning gear. Even a tandem engine could be started in this manner, but twin tandem gas engines are, as before observed, posi- tively started from any position. A very complete oiling system furnishes lubrication for all wearing surfaces, including the main bearings, slides, crank and crosshead pins, and the cylinders are lubricated by carefully timed admission of cylinder oil fed through sight feed oil pumps. Crossing over from the gas holders in full clearance above intervening tracks, the gas mains supplying the engines are- carried along the east wall of the building. Feed pipes leading to the engines enter the building on a level with the main and drop down beneath the floor where connection with the engines is made. Running parallel with the station house upon the same side, beneath the ground level, is a tunnel 12 x 9 ft.. into which the exhaust is carried. The tunnel vpens at each end into a steel stack 9 ft. in diameter by IRON 375 AGE 92 ft. high. By this means the noises are effectually deadened and the odorous gases disposed of. Alternating Current Generators, The alternating current generators are of a type developed by the makers for use with gas engines. The laminated stator core is housed in a heavy box yoke de- signed to allow free circulation of air around all parts, and the core punchings are held in place by means of dovetails, while the grmature windings are placed in open siots in the periphery of the stator core. Wedges hold the coils in place, and replacement in case of -damage is greatly facilitated by the open slot construction. The field poles are mounted on a cast iron spider, and are so arranged that they can be removed; the exciting coils are of copper strip, wound on edge. The revolving fields are of special construction with field poles of solid cast steel, bolted to a heavy cast iron spider; they can also be readily removed in case it is necessary to get at a field coil. The field windings are held in place partly by the projecting pole tips and partly by brass rings running completely around the rotor on each side and fastened to the top of the poles by long brass screws. This con- struction combined with the solid poles gives a large damping effect, prevents hunting and aids in securing parallel operation. Direct Current Generators, The direct current generators, of which there are two, while designed with particular regard for this service, con- form in all essential features to the Allis-Chalmers stand- ard engine type machine. They supply current for the operation of the ore bin, ore bridge and unloader motors. Owing to the area covered by the ore yards, and the length of transmission lines necessary to carry D. C. current to their extreme limits, two substations equipped with two motor generator sets of 500 kw. each, have been installed at either end of the yards and near the dock walls. The one at the north end is temporarily located near the deck on a line with the No. 12 furnace, but will eventually be moved on to the north end of the yards when. the proposed additional furnaces are built. Remote control Cutler-Hammer field rheostats and field switches are used in connection with the generators. The controlling apparatus, which is located in the basement, is placed as near as possible to the generators, and is operated from the bench board installed in the power house gallery. These rheostats are designated as “eross head” type; they are actuated by vertical motors, and are provided with automatic devices which insure the stopping of the motor at either limit of the cross head travel; or, in other words, when all resistance has been cut in or cut out of circuit. In addition to the automatic control means are provided for operating these field rheostats by hand in case of damage to the motor. A very complete oil filtering system is installed in the basement with pipe connections extending to all of the stationary machinery requiring lubrication. This equip- ment consists of water separators and three large oil set- tling tanks, having facilities for draining the sediment into the sewer. System of Control, In the system designed and furnished by the Western Zlectric Company for the remote control of the electrical apparatus in the power plant is seen a remarkably com- plete and modern installation which, in point of extent and adaption to the service required, is perhaps the most notable of its kind in operation. Located on the gallery extending along the west side of the building are two control boards of the bench board type, in which the con- trol is centered. A view of the one in No. 3 station is February 4, 1909 Q RI Fa av ae td Fig. 3.—Control Switchboard in Which the Control of the Power System Is Centered. 2 seen in Fig. 3, the other, in No. 2 station, not yet fin- They are 9 divided into three sections; on No. 3 station board, the ished, being of similar style and equipment. first, containing 12 panels, controls two D. C. generators, the storage battery, the rotary converter, the boosters and rotary exciter set with carbon regulator; section 2, with nine panels, handles the exciter set and seven A. C. generators, and from the 11 panels of section 3 are con- trolled nine D. C. and nine A, C. feeders and a 22,000-volt line, running and the South Works, This section also controls a tie line for tying together these stations with future ones when completed. between Gary Chicago The bench boards in No. 2 station are likewise composed of three sections, which, beginning with the first, control, respectively, the exciter sets, the A. C. generators, and the A. C. board is furnished with a field ammeter, three A. C. am- meters, an indicating wattmeter, and an A. C. volt meter feeders in this power house. The generator for each of its 10 panels; volt meter plugs are thus done away with. The bench board is substantially constructed with an- gle iron frame work, with instrument and bench panels of slate. It is arranged with removable sheet steel sections in the sides and rear. so that easy access can be had to The test panels, which constitute a special feature of the board, All small wiring from the instruments and the various transform- the interior for repairs, testing and inspection. are located inside and are thus easily reached. ers and switches in the station terminates on these panels where each individual circuit can be tested out without disturbing the system. Indicating instruments are of the horizontal edgewise pattern with black finish, and are mounted on the top panels of the bench board. Control switches for operat- ing the oil switches, circuit breakers, field switches, rheo- stats and governors are mounted on panels, and are pro- and green the open or closed position of the switches which they con- trol. There each A. C. gen- erator or feeder connecting with either of the two sep- vided with red lamps, which indicate are two oil switches for arate bus bar systems, and to prevent these switches from being closed at the same time, their control mechanism is interlocked by an ingenious mechanical device. generators, the rotary converter and synchronous motor are designed to The control switches for the A. C. operate in conjunction with an automatic synchronizer. The bus bar and oil switches are encased in compact white enamel brick compartments, the bus bar structure being of double deck construction with generator switches floor, feeder switches Current for regulating 6600 volt generators passes through one set of three Wagner core type cur- and Westing- house reserve current inverse time limit relays are taken located on the engine room with directly above on the gallery. from the purposes three phase, rent transformers, and the switch board care of in like manner by two sets of two each Wagner type current transformers. Fig. 4 shows the positive and equalizer breakers for the exciter and negative breaker, the negative breaker be- ing mounted on the panel facing the other way. Being of double construction with positive apparatus on one side and negative on the other, the possibility of a short cir- February 4, 1909 ‘ cuit on the D. C. switchboards, when repairs are being made, is eliminated. The bus bars are all of laminated copper supported on insulators, and the generator leads of 350,000 C. M. protected by paper insulated, lead coy- cables are laid on a construction in the ered concrete basement. All small Wiriug is done with double braid rubber covered wire run in conduit. Wiring. Not the least in importance in this great system of electrical power and its adaptation to steel mill uses is the arrangement and construction of the overhead trans- mission lines. From two large steel distributing towers, supported on one side by latticed girder steel poles and on the other by beams fastened to the west wall of the power house, the lines diverge to the rail mill, open hearths and other plants served by current. In the foreground of Fig. 5, the tower leading from No. 2 station is seen, the second appearing in the distance further along the building. Current at a pressure of 6600 volts is carried from the station up to these towers by \4 in. by 5 in. copper bars, where all wire connections are made outside of the station. For this equipment 20,000 Ib. of copper bars was required, while for the entire transmission system there has already been used over 500 tons of copper. In accord with a consistent policy of guarding against con- tingencies that might interfere with the continuous oper: ation of every part of the works, due provision has been made in the wiring plans against stoppage of current from line troubles. To this end wires capable of carrying a heavy overload are used and are strung in two divi- sions on the poles, so that in event of a breakdown on one Fig. 4.—The Position and Equalizer THE IRON sreakers AGE A a | “i side, the other has suflicient capacity to carry the load temporarily. It will be noted that the double poles are spaced far enough apart to clear a standard freight car; this was done for the reason that when the plans were drawn the trackage lines were not all definitely located, and to forestall the possible necessity of running between them this precaution was taken, Each of the standard poles is fitted to carry 48 No 0000 7-strand cables on each head, or 96 on both, and they range in hight from 50 to 75 ft. to the bottom cross arms. The latter are inserted through and are held in place by steel brackets, and can be withdrawn when nec essary without the removal of bolts. In fixing the dis- tance between wires on poles, the outside limit of good practice has been followed, with the result that the in- sulators are set 18 in. to 20 in. apart and spaced in staggered lines from top to bottom. Because of the loose, of the cement foundations for the poles. sandy character soil, it was necessary to use These are set 9 ft. 6 in. deep, and imbedded in them are eight 2-in. bolts by which the base of the upright is anchored to the top above the ground. An ingenious color scheme in the outside, as well as inside, wiring has been introduced to facilitate the locat- ing of trouble. Under this plan each phase is run out on insulators of a certain color, blue, white and green being chosen, respectively, for the three phases. Thus, when the lineman locates trouble he is able to imme diately inform the central station on what phase it is found, and much time is saved that would otherwise be spent in tracing the leak or break back to its source. A high tension line, transmitting current at 22,000 volts, for the Exciter and Negative Breaker 378 connects this plant with that of the Illinois Steel Com- pany at South Chicago, affording means of running these plants, and the intermediate one of the cement works at Buffington, in parallel. This line enters the Gary power house near the north end, where it is supported on a special tower. Extreme care has been taken to prevent the possi- bility of contact with this dangerous voltage, especially in its passage through the plant. Three heavy porcelain Locke insulators mounted on machined steel pins bolted to a cast iron base plate are top braced by a cast brass The wire is brought in from the right through a groove run- plate across the top te which they are cemented. Ng UL Bibi Fig ning longitudinally across the top plate, and after being looped around the anchor piece at the left is clamped down in the groove with yoke bolts; the station connec- tion is made with the projecting plate surface at the extreme left. At the end of the line is a set of Westinghouse electric lighting arresters which are connected to the line by a type switch. Machined steel pins are used for mounting the insulators in order to secure the requisite strength in a minimum diameter, thereby widening the air space between the pin and the rim of the insulator bowl, and so reducing the opportunity for leakage losses. All of the insulators on this and other lines are unusually horn heavy, and are rated for two-thirds more current capacity THE IRON AGE February 4, 1909 than is usually carried. The insulated copper wire prin- cipally used ranges from one million circular mills for the D. C. circuits down to half this size for the A. C. circuits, while the bare wires are No. 0 on D. C. and No. 0000 on A. C. circuits. Storage Battery. Equalizing and supplementing the effective force of the generative system is a large storage battery in- stalled in a two-story brick building 47 x 87 ft., located adjacent to the north end of the power station. This in- stallation, supplied by the Electric Storage Battery Company, is commensurate in size with the plant of which it is an adjunct, and is designed to be kept = Pe ae elie ae "| ee date cf | Lee) Flea aa rae bad St ai teliaten aeidadal z: 5.—The Towers and Transmission Lines Taking Current from the Power House for General Distribution, charged as nearly as possible to full capacity. The sur- plus power generated during periods of light load is charged into batteries to be drawn upon when service demands the.@xpenditure of unusual power, and the load fluctuations aré thus taken care of without impos- ing unnecessary Strain upon the gas engine generators. As here constructed, the storage battery consists of two series of cells, each series containing 125 cells of the chloride accumulator type; each cell is composed of a lead lined tank measuring 68% by 24% in. by 32% in. high, in which are placed 73 type R plates 185 in. square. These two series of cells are adapted to operate on a 250-volt bus, and when connected in parallel are capable of furnishing an output of 17,280 amperes at the regulat- February 4, 1909 THE ing rate. Provision has been made for increasing the capacity of this installation by the addition of two more series of cells, which will take care of stations Nos. 1 and 4 when built. The battery is arranged to regulate the fluctuations of both the A. C. and D. C. loads, the former charging through a split pole rotary converter, having a continu- 2000 kw. The special feature in the design of this machine consists of the division of each ous capacity of pole into three parallel sections, with separate windings on the three sections, so arranged that the distribution of the magnetic flux over the armature surface may be varied to bring about a variation in the ratio between the A. C. and D. C. In this way the A. C. voltage may be maintained constant, while that of battery voltage of the machine. the D. C. is varied automatically to cause the the D. C. circuit, which is connected directly across brushes to charge and discharge into the A. C., and so relieve the A. C. generators of the load fluctu- ations. The automatic control of the fields of this converter is effected by means of a special A. C. and D. C. exciter, whose armature is connected to a series of transformers in the A. C. circuit by slip rings, and also to the field windings of the converter by commutator and brushes. The battery is also connected to the D. C. bus by means of two direct current boosters of sufficient capacity to handle the fluctuations of the D. C. load. These boosters are automatically controlled by a carbon regulator, which A second split pole converter of size and type identical with the first wili be installed soon after the plant is completed. All of the switching apparatus for operating the storage battery, the converters, the boosters and the exciters is of the distant control type similar to that furnished for the other electrical equipment of the plant. controls the field of the booster exciter. Boilers. Since the use of steam is limited to the driving of two steam units in each of the blowing engine stations, the two Curtis turbine generating sets in the electric power station and the driving of hydraulic pumps, the boiler plant is naturally relegated to a position of minor importance. As a source of reserve power, however, to be called into action in case of need, a total capacity of 6400 hp. has been installed. The batteries comprising this equipment are housed in two separate buildings of steel construction, located in line with and on either side of the gas scrubbers. Each uf these buildings contains 16 units of 400 hp. each, No. 2 fouse being supplied with Sterling and No. 3 with Rust water tube boilers. Furnace gas fuel is used for firing, the supply being taken off from the primary washers, from whence it is piped into a large main extending the full length of each boiler house. A firing bed of coal is maintained in the furnaces, and because of the compara- tively small quantity of this fuel required it is hand stoked. SS SS Eee The Pocahontas Collieries Merger Sustained.—An important judgment in favor of the Pocahontas Consol- idated Collieries Company was rendered by the United States Circuit Court of Appeals at Richmond, Va., Jan- uary 16, affirming the decision of the lower court, declar- ing valid the merger of the Pocahontas Collieries Com- pany in the Pocahontas Consolidated Collieries Com- pany, Inc., effected July 1, 1907, under the Virginia cor- poration act. The decision is important in that it is the first large merger that was made under the act named, which act is also sustained by this decision. The officers of the company are: Isaac T. Mann, president; Charles $S. Thorne, first vice-president; Jenkin Jones, second vice- IRON AGE 379 president; James E, Jones, general manager. The New York office is at 30 Pine street. The company has 11 coal mines in the Pocahontas region and about 3000 coke ovens. Its stockholders are located not only in the States of Virginia and West Virginia, but in Pennsylvania, New York and the New England States. cctapeascaiiiailaasincaaaainies The Economy Drill Sockets and Sleeves. To restore to usefulness taper shank drills, the tangs of which have been broken or distorted, the Standard Tool Company, Cleveland, Ohio, is making the Economy short sockets and sleeves shown in Figs. 1 and 2. These are similar to the regular sockets and sleeves on the mar ket, but with the slot for driving lower down and of larger dimensions. To provide a new tang to fit these sockets the Economy tang gauge is used. By slipping it over the shank of the Fig. 3. The Economy Drill Sockets and Sleeves and Manner of Prepar- Fig. 1. Fig. 2 Fig. 4. ing Broken Tang Drills for Use in Them. broken drill as shown in Fig. 3, a new tang can be marked of the correct size and position, which is then shaped either by milling, planing, filing or grinding. The new tang is heavier and stronger than the old one, as will be seen in Fig. 4, and insures an accurate and powerful drive. The shanks of the Economy sockets and sleeves are made of regular dimensions and will fit the spindles of all the leading makes of power drill presses. —xainaicnilaeliliabananniniagsis I’. L. Melville, 192 Front street, New York, is placing on the market a preparation successfully used for some time in protecting machinery and finished iron and steel against corrosion. It is known commercially as Anti- Rust, and is especially recommended for coating exposed surfaces during transportation and while in warehouses and warerooms. This product is semiliquid in form, easily applied and not affected by changes of tempera- ture. It is readily removed from the surface treated without resorting to the use of benzine or other cutting agents. Anti-Rust has given good results under all man- ner of severe tests, notably in the protection of iron from the corroding influence of salt water and in long continued open air tests. Another tunnel under the Hudson River, between New York and Jersey City, was pierced through on January 27. It is one of the two tubes which will have their ter- minal at Cortlandt street, and makes the fifth tunnel under that river. Within 60 days the other tube will be pierced through, and it is expected that both will be ready for train service by July 1. 380 THE Republic Iron & Steel Company Statement. The Executive Committee of the Republic Iron & Steel Company bas made a report in the past week of the earnings of the committee in the second six months of last year, with financial statement for December 31, 1908. It says that while the net profits shown are for a period of six months, actual operations cover five months only, as manufacturing was suspended during July, 1908, on account of labor adjustments at the Northern plants, and due to the miners’ strike in the South, full operations there were not resumed until November 8, 1908. Allow ing for the period of time and percentage of capacity employed, the appropriations and charges for repairs, re construction and depreciation, it is stated, have been maintained at the maximum, and are as follows: Maintenance and repairs......... hace wee ae el ..- $401,856.91 Depreciation and reconstruction...........+.+.e+. 193,382.93 rn. asa eG so 6d e O56 Oe hie be deem an eh 74,604.22 NN ee ee ee eC OT Tee 41,641.00 PL Aca whe Rew a eee jrabdeaees send aee a $711,485.06 After deducting all charges, the net earnings applica- ble to dividends for the period ending December 31, 1908, are $782,330.31. This sam, added to the surplus reported in the last annual report, brings the total amount of the surplus fund as of December 31, 1908, to $5,481,857.27. Net cash assets (exclusive of $206,000 of first mortgage bonds, held in the treasury, purchased in advance of sinking fund requirements, not due until October 1, 1909), now stand at $7,197,357.68, or an increase since the date of the last annual report, July 1, 1908, of $483,537.05. The statement of income and surplus for the six months ending December 31 is as follows: Net earnings from operations after deducting $401,- 856.91 for maintenance and repairs............$1,231,647.54 Interest and dividends on investments, less interest eer (shaw obs Coed nee eid bh ase aoe 27,307.42 Total profit for the six months..............$1,258,954.96 Less appropriations for improvements Ny ORR. a 6 an soe ecccdecseswe $193,382.93 Extiuzguishment fund............ 74,604.22 —-- - 267,987.15 Net profits for the six months............... $990,967.81 Deduct interest on first mortgage 5 per cent. bonds 208,637.50 DBurpias for Che Wik MOtRS. . i. o.c cece cesses. $782,330.31 RE GUGEGS BE DUR 1, BOOB io ccc kienwvccsvecsvcs 4,699,526.96 Net surplus carried to balance sheet. . ..$5,481,857.27 The balance sheet December 31, 1908, is as follows, with comparison with the end of the last fiscal year, June 30, 1908 : Assets, June 30, 1908. December 31, 1908. Cost of properties with additions of six WE a hr ke bs se oes vw o's ye CORRE T4 BEE 008,280 Other investments (Potter ore, &c.)... 965,336 863,336 Cash deposited with trustees for re demption of notes and bonds.. 2,895 2,895 SOE coon ig ce ea ig 5,327,781 4,547,999 Ore contract payments (ore at Lake 0 ee ee ee eee 689,756 800,906 Accounts and bills receivable......... 2,829,624 2,368,248 SN cag ea Ose pails oe hob ae > 218,645 667,963 Deferred charges (mine work)........ 747,389 715,294 RMR AeA ti wee lS oe $64,862,600 $63,964,830 Liabilities. Common eek... 6c... s ccesevsnivees cs S27,10L,000 $27,191,000 eS er ri eee er eee 20,416,900 20,416,900 First mortgage gold bonds........... 8,275,000 8,546,000 Potter Ore Company bonds.......... 342,000 345,000 Mineral extinguishment fund......... 781,342 706,738 Furnace relining fund............... 80,749 54,707 Fire and accident insurance fund..... 246,523 237,812 NT MOE in gil oi 178,780 95,850 Sn SS ha Sn ae ws eae eos 1,652,414 1,362,025 Ore contract balances................ 49,718 96,335 oe el ee a 62,880 103,365 ee OCU Cia saws RbWee sees 103,437 106,825 Pn, PN «sc sebwebbeheess - selaw dc *2,746 Profit and loss surplus.............. 5,481,857 4,699,527 POS caic wi nin s se eeees nnn ds seen BER OSL SD * Unclaimed preferred dividend. The report says that operations in the second half of 1908, as compared with normal periods of activity, averaged approximately as follows: Finishing mills and factories, 55 per cent.; stee] works, 70 per cent.; blast IRON AGE February 4, 1909 furnaces, 66 2-3 per cent. ‘The unfilled orders on hand compared with June 30 were as follows: Finished and Semifinished Products. WE MEE ND catia ik ins 16d cee aan AIO eee ow eS 283,743 net tons. December 31, 1908......... Perrrrrerr rere Fe a: TR SR Hares eli eine ia lanes oe aw oh Gin od wa 107,297 net tons. Pig Iron. PUG By, WU o's vob ou dined wn sin des ees 0's 0 6 sep nO eens cons. RINE Sate: JUDE» ine oa ne ered Gea w'Se ie . 89,934 gross tons. To ictal oh ech ib ed to Mw 30,738 gross tons. In conclusion, President John business booked A. Topping says: * Your promises some improvement to opera- tions, but your Executive Committee were of the opinion that under present unsettled business conditions it was wise to defer action on resumption of dividends, even though your earnings and net assets suggest the pro- priety of dividend payments at this time. In the interim, however, your property will be further improved and your cash reserves strengthened by accumulating profits.” ———-~»~»-e—_—_ The Retirement of Frank Dickerson. Frank Dickerson rounded out his 10 years of service with the American Sheet & Tin Plate Company February 1, and on that day announced his retirement. During that time he has been head of the sales department of this company in New York City, both previous te its absorption by the United States Steel Corporation in April 1, 1901, and since that date. Mr. Dickerson has devoted his business life to the sheet and tin plate trade first as an importer of foreign products and later as a manufacturer and sales manager of the domestic article shortly after that came to be a pronounced factor in the trade. After his graduation from Yale in 1871 he en- tered the office of his father, who was a tin plate im- porter. In 1875 he was one of the organizers of Dicker- son, Van Deusen & Co., New York City, who for a nunm- ber of years were important importers and jobbers of tin plate. Later the business changed to the jobbing of tin plate, sheet iron and metals, which business is still continued by the firm. The retirement of Mr. Dickerson is not a sudden idea, as for several years he has looked forward to traveling for pleasure and recreation. While it is true that he will maintain an office for the trans- action of his own personal business, this will in no wise be connected with the iron trade in which he has so long been identified with a prominent branch. Mr. Dickerson’s business life has seen curious changes in the tin plate trade. When he commenced business, in 1875, all of the tin plate used here was imported, and amounted that vear to 1,672,863 boxes of 112 lb. each, valued at about $6 per box. Now, the domestic production of tin plate amounts to over 11,000,000 boxes, and reached a total of nearly 13,000,000 boxes in the boom year. ——_9--@——_—_——_ Convention for Saving Life and Property Lost Through. Accidents. The coming convention of the American Anti-Accident Association is to be held in Y. M. C. A. Hall, 215 West Twenty-third street, New York City, on the afternoon and evening of Thursday, February 11. The following programme has been arranged: ifternoon Session. ‘“‘Hoodlumism in Holiday Observance,” by Mrs. Isaac L. Rice, president of the Society for the Suppression of Unnecessary Noise, New York City. “Our Shameful Lead in Railroad Accidents and the One Sure Method of Checking It,” by Edward Bunnell Phelps, editor American Underwriter, New York City. ‘Fire Wastes Through Carelessness,” by C. M. Goddard, President National Fire Protection Association, Boston, Mass. “The Child, and Accidents of Our Unbridled Laxity,”’ by Thos. D. West, president of the American Anti-Accident Associa- tion, Sharpsville, Pa. Evening Session. ‘Museum of Safety and Sanitation,” illustrated with lantern slides, by Dr. William H. Tolman, director of the Museum. ‘Industrial Accidents and the Inventors,” by Joseph J. O’Brien, member of International Congress of Inventors, Wash- ington, D. C. ‘Safety Devices in the Machine Shop and Manufacturing Establishments,” by Prof. John E. Sweet, Syracuse, N. Y. ““Wage Workers’ Accident Insurance and Compensation Fra- ternity,”” by Thos. D. West. February 4, 1909 Standard Punches, Dies and Couplings. BY C. C. SWIFT, CLEVELAND, OHIO. y shop that operates a punching machine uses punches, dies and coupling nuts of some description. The tools might have been of some known standard when the machine was purchased, but the question is are they still standard? It is likely where companies make their own tools that each succeeding lot differs slightly from the previous lot, so that in the course of a few years the tools become special for that machine. When a company oper- ates more than one punching machine and the above con- ditions prevail, the result is not merely continued annoy- ance, but the added expense of having a stock of tools for each machine, It is far better to arrange the machine to hold standard tools, so that the couplings, punches and dies used on one machine can be used on any other ma- chine of like capacity in the shop. In doing this it is Every advisable to adopt a standard which will permit the widest range of punching at the least cost. In other words, the most economical system is the one that re- quires the least number of punches, stems and coupling THE IRON AGE 381 ery for punches, dies and couplings. While it would be of untold advantage to have a single standard, so that where a shop is equipped with several different makes of punches, the same couplings, dies, &¢., could be used on all. This is a condition which could only be brought about through the adoption of some standard by an association which is influential, not only in the boiler making, but also in the structural bridge and sheet metal working shops all over the country, and is not likely to come to pass for some time. The illustrations are taken from the stock list pub- lished by the Cleveland Punch & Shear Works Company, Cleveland, Ohio, and show the manner in which this com- pany has brought about standardization in its punches, dies and couplings. The punches shown are representa- tive of a range suitable for punching holes from 1 up to 15-16 in. in diameter. A shank of the size at the left is used for diameters from \ to 9-16 in.; the second from 52 to % in.; the third from 138-16 to 1 1-16 in., and the fourth from 14% to 15-16 in. The third fits the coupling nut shown directly above it, the shank of the punch being 1-64 in. less than the bore of the nut. The sleeves shown above the first and second punches fit them as bushings, adapting them to be used with the coupling nut over the t . , ’ . ~, 10 TH'DS PER INCH - Le pean ee « ee eo rl eee K L SS \ = : a X zk } | \. | i ————— | x 4 | =). \ Nees + | a \ t 2 \ y ~ Punch Dimensions of Shanks, Couplings and Nuts to Shear Punch nuts to accomplish a wide range of punching, it being un- derstood that the punches are made with the smallest amount of steel necessary, and that they conform to ac- cepted designs. Unquestionably a company building punching machin- ery, and thus in close touch with requirements of such tools, should know what the trade desires. Punches are subjected to sudden and excessive shocks, and the ability to harden and temper them properly is an art acquired only by long experience. In purchasing standard mate- rial, not only can a lower price be obtained, due to the fact that such tools are made in large lots, but immediate delivery can be had, which generally means a great saving. In standardizing it is necessary to design a punch stem that will permit the use of an economical punch, and at the same time give wide range of punching. Punches made of %4 in. stock, 114 in. long, are the cheap- est that can be made for punching 7-16 and 9-16 in. holes, but if it is desired to punch 11-16 or 13-16 in. holes a new stem and coupling nut would have to be used. If, how- ever, a stem was designed to hold an economical 13-16 or 15-16 in, punch, a punch made out of say, 1%4 in. stock with a special arrangement for holding the smaller punches in the same coupling nut would accomplish the desired result. At present there are some half dozen different stand- ards established by different builders of punching machin- Works Company’s Standard. Holes Rang