The Iron Age 1914-01-15: Vol 93 Iss 3

THE IRO Hh | | | Established 1855 New York, January 15, 1914 Vol. 93: No. 3 The Machinery Palace at San Francisco Details of the First Structure to Be Completed— The Use of Wood for Columns and Trusses a ia 7a Fea- HE first exhibit ; | structure to be i completed on the ; 625 acres constituting the Panama-Pacific In- ternational Exposition grounds at San Francis- is the palace of ma- chinery, which stands clear of scaffolding and complete in its magnifi- cence. It is not only the first to be finished; it is also the largest building at the exposi- tion, and likewise the largest wooden structure intheworld. Indeedthere is said to be no record in history of architec- ture of any wooden building’s ever having been erected as large as this. Its outside dimen- sions are 368 x 968 ft.; s area is 369,000 sq. ft. and its volume is 38,- 000,000 cu. ft., while its hight averages 103 ft. with a maximum of 135 This magnificent cost exactly $659,- 6 > and is placed at the disposal of machinery manufacturers for the housing of their lucts during a period nine and a half | ths, in which time | | ture and eye strain reduced. } ln nan This color has been n Ve f/f ae adhered to throughout the exposition, and in- volves the magnificent main group of eight ex- hibit palaces which oc- cupy a central position. This central group of palaces covers a space 2756 ft. long and 1250 ft. deep, with three in- terior courts. These, with their extensions, have been developed longitudinally north and south in such a manner as to produce a maxi- mum diversity of effect and to afford the greatest sheltered areas around the palaces whose walls are the wallsof thecourts. It is immediately to the east of the group of eight exhibit palaces that the palace of ma- chinery stands, balanc- ing on that side the pal- ace of fine arts, which is to the west of the main group. In architectural com- position the palace of machinery is Roman and there is evident in- | fluence on the mind of the designer of the old J Roman baths. The dec- EL) Joesee anata world will gather in parr oF ONE OF THE WOODEN COLUMNS AND THE TRUssEs OF Ation is classic in form Francisco, In the Machinery Palace at the Panama-Pacific Inter- but modern in expres- | *} ° “7 + +s 2. nile the machinery national Exposition, the largest building ever constructed S10N, suggesting ma is of wood it as- entirely of wood, all of the arch trusses and columns were chinery and the marvels the appearance of completed on the ground and then hoisted into position. The }: palace, which is 967 ft. in length and 137 ft. high, is con lid permanency structed of wooden trusses. of invention. The prin- From the ground the point cipal feature in its in- ‘ . s . 2G e@ colu ’ 101 rt : ch : of connection of the four arch trusses to th lumn is 1 terior arrangement is _the medium of ft Each of the arch trusses weighs 5 tons ar d the columns h hed ‘al imitation Traver- 98 tons each. The trusses are 75 ft. in length from center tnree arcnea aisies or marble, which was to center of span and are made of wood, no metal being used bays, 75 ft. wide and ised successfully by i. Denivelle on the upper part of the Pennsyl- Railroad station in New York. It is tinted to | cream color and thus the glare resulting vast structural areas of white is avoided 189 101 ft. high, running through its entire length of 968 ft. On each side of the main structure there are side aisles, 70 ft. wide, covered with shed roofs 41 ft. high to the soffit of the trusses. Three transverse aisles of the same Fi ee Se sal . 1 . j £2 hea R Brae ae a® ta 190 width as the longitudinal aisles and 132 ft. divide the area formally. Adjoining the palace of machinery will be the gas and fuel building in which will be generated the power for the use of exhibitors requiring steam for use in connection with their displays. An effort is now being made that appeals strongly to such manufacturers of minor devices as feel that the expense accompanying an individual exhibit requiring the services of an attendant or attendants is irksome. These are invited to group their displays, provision being made, of course, that competing devices be not grouped together, and the slight expense divided among the several companies so exhibiting. Such inventions and de- vices as fuse cut-outs, accessories to boiler and steam engines, valve gears, governors, methods and appliances for testing and recording the perform- ance of engines, turbines, boilers, condensers and their auxiliaries lend themselves to most interest- ing exhibit displays. A group of all of the Diesel and heavy oil engines, a number of which will be directly connected to direct-current generators, will be employed for exposition uses and will be in- stalled on an exhibit basis. Other groupings are being made of packing, gaskets, lubricants, lubrica- tors and all electrical apparatus. A 5000-kw. steam turbine auxiliary plant will be established on the grounds to provide against the most remote possibilities of an interruption in the power which is being provided by the local electric power company. This power for the ex- position is from the hydroelectric system of the Pacific Gas & Electric Company. Supplementing this, however, the company has installed in San Francisco a 60,000-kw. plant from which power could be delivered to the exposition instantly in case of any unanticipated interruption. Still fur- ther bulwarking the exposition’s security in a con- tinuous supply of power, will be this 5000-kw. steam turbine auxiliary plant which it is probable will be placed on an exhibit basis. The floor of the machinery palace is designed for a load of 200 lb. per sq. ft., and there is ade- quate foundation firmness to insure rigidity against the stress of any exhibit that may be placed. The fire protection is complete. A double deck sprinkling system on the roofs, with overhanging sprinklers, capable of throwing a sheet of water on the walls from the eaves and interior sprinklers, of adequate number and size, will complete the protection against fire afforded to the exhibitors whose space in this magnificent palace will be given free by the exposition authoriies. The exposition is to be of contemporaneous character, rather than historic. Exhibits of products antedating 1905 in construction will not be reviewed for award, and on account of space limitations the displays must be selective in char- acter. Precedence will be given to those applica- tions which contemplate exhibits having distinc- tive features from an engineering or educational point of view. Already applications are on file covering two- thirds of the available space in the palace of machinery. The final allotment of space will be made early in 1914, so that prospective exhibitors are urged to hasten with their proffered exhibits, remembering that this exposition will have a greater representation in visitors, official and oth- erwise, from the Latin-American countries of South America than ever attended any previous exposi- tion, and the Orient is made a neighbor by the Panama Canal, which event the exposition will cele- brate mightily. high THE IRON AGE January 15, 1914 ST. GEORGE TRANSFER BRIDGE Interesting Use of Screws, Gears and Sheaves for Raising Heavy Loads The recently completed freight transfer brid; of the Baltimore & Ohio Railroad, at St. Ge borough of Richmond, New York City, afford interesting example of the application of scr: worm and spur gears, sheaves and counterwei: for raising and lowering heavy loads. This road has no direct entrance to New York City or to any of the freight terminals on the west bank of the Hudson River. The passenger traffic is handled over the tracks of the Central Railroad of New Jersey, but the freight trains leave the main line at a point about 16 miles west of the termina! at Jersey City and the line runs directly across coun- try to the southern end of Elizabethport, crossing Arthur Kill on a long, high-level trestle and draw- bridge into Staten Island. From this point, the tracks of a local steam road, the Staten Island Rapid Transit Railway, are used to St. George. The trains as run into the St. George yard are broken up and run over freight transfer bridges upon car floats for lightering to various points in New York Harbor. The old type of bridge, which was in service at St. George, was a track platform on a pontoon. This arrangement is open to the objection that silt will get under the pontoon and prevent it from moving with the difference in, the level of the tide, but this is not as serious as the Water Find of the Apron with the Two Sets of Cou eights The Two Houses Containing the Raising é Mechanism Are Shown at the Top of th Iengraving with the Control Room Between ry 15, 1914 ne caused by the ice in the winter season fills the slip and either prevents the car float entering at all or else lodges under the pon- nd raises it out of line. Another objection is ar floats which are more heavily loaded on de than on the other are hard to handle, and ne cases an hour or more is lost before the finally docked and the cars run off. Witha ) overcoming these objections, the engineers bridge department of the railroad developed type of transfer bridge, which is modeled one erected several years ago at the com- large freight terminal at Locust Point, Bal- Harbor. bridge at St. George is double tracked and ts of two parts, which are known as the and the apron, the former being 85 ft. long. mounted on trunnions at the shore end, while uter one is supported by cable counterweights, h carry 90 per cent. of the dead load. The re- nder of the dead load and the entire live load supported by four screws having an external eter of 81% in. and a length of 29 ft. Three these screws are shown in one of the engravings, gether with one of the two 50-hp. motors, which ised to drive them. The power is transmitted the motors through the pinions and large gears shown to a longitudinal shaft. On shaft in front of each of the screws is a which meshes with a worm gear that is tened to the trunnion and saddle of each screw. the trunnion is mounted a bronze nut, having a ead 27 in. long. This nut is rotated by the m gear and drives the screw to raise and lower bridge. These screws are capable of lifting ridge, together with two trains of fully loaded through a hight of 15 ft. A thrust roller ng is provided to take care of the load on the vl THE IRON AGE 191 screws and is designed to carry a load of 275,000 lb. The apron, which is 30 ft. long, is hinged at the inner edge to the bridyge and is supported at the outer end by cables and a double system of counter weights arranged on endless cables. A view of the counterweights and a portion of the system of wire ropes is presented in one of the engravings. The cable from the rear counterweight, which is the upper one in the engraving, passes over motor driven drums in the house directly above. It then passes around an equalizer sheave which carries the apron and upward and over a second large sheave and drum to a pick-up counterweight which is shown resting upon the floor of the tower which is its normal position when not in operation and guideways are provided in the tower for alignment during operation As the name indicates, this View in the Bridge House Showing Three of the Four Screws Employed to Adjust the Level of the Bridge counterweight is made up of a number of sections which are picked up automatically according to the train load passing over the apron as the level is lowered and are dropped back in place as the apron rises. The drums which are shown in the interior view of the apron house are motor driven through a reduction gear, having a ratio of 4 to l, a por tion of this gear being shown in the lower right corner. These drums are used to set the apron at the proper level to meet the incoming float, the power being transmitted from the horizontal shaft through a worm cut on it to a worm gear, which is shown inclosed at the left. The worm gear shaft has a pinion cut solid on it which meshes with a large spur gear attached to the drum. The cable passes around the rear drum shown back of the worm gear housing and down to the counterweight and up and over the large drum at the right. This cable passing from one drum to the other is shown in this engraving. . ee i od im eeinge herent a ee oe tashe 5 * a ss 22 wis *. Se ; A ‘va 192 THE IRON AGE After the float has been fastened to the apron the fluctuations in level due to the loading or dis- charging of cars are taken care of by the pick-up counterweight, as has been explained. It is possi- ble to adjust the apron to correspond with any change in the level of a float which comes in heavily The Drums Used to Adjust the Level of the laden and listed as one side is toggled fast to the apron and then the level of the other side is ad- justed by either paying out or taking up the cable operated by the drums, there being two sets of drums, one on either side of the apron, geared to- gether and a sufficient number of laps of cable around the drums to prevent slippage. The general design of this structure was origi- nated by the bridge department of the Baltimore & Ohio Railroad, while the details of design were prepared by the Earle Gear & Machine Company, Philadelphia, Pa., which manufactured all of the operating machinery and supervised the erection. The steelwork used was fabricated and erected by the Fort Pitt Bridge Works. The bridge has been in service for almost one year and has given satis- factory service under some severe operating con- ditions. Record Year in British Shipbuilding The British shipbuilding industry turned out a greater tonnage in 1913 than ever before in its history. Estimates cabled to this country indicate that 933 war and merchant ships of 2,186,607 gross tons were launched from private yards in the United Kingdom during the year, a record which is not likely to be exceeded in 1914 from present in- dications. Swan, Hunter & Wigham Richardson, for the second year in succession, lead the list of builders with a record output. Their total is 22 vessels of 107,636 tons. Sir W. G. Armstrong, Whitworth & Co. come next with 9 vessels of 99,333 tons and William Gray & Co. take third place with 18 vessels of 86,000 tons. In marine engineering John Brown & Co. stand first, with 239,000 i. hp. to their credit. January 15, 1914 Power for Electrodeposition of Metals A symposium on the power problem in the elect ro- lytic deposition of metals was held on January 9 at the Engineering Societies Building, 29 West Thirty- ninth street, New York City. The meeting, which was held under the auspices of the American Institut ; Electrical Engineers, wa joint one with the New York section of the American E|\ec- trochemical Society and the New York members of the ical Engineers. Dr. C. 0. Mailloux, president of the In- stitute, presided, and papers were presented dealing with the problem from the stand- points of the three industries represented. The first paper, by Law- rence Addicks, superintendent of the United States Metals Refining Company, dealt with the problem from the view- point of the electrochemist. This referred to a copper re- fining plant as typical of this general class of electrolytic processes and discussed the limitations imposed by pres- ent practice upon the amper- age, voltage and kind of cur- rent used, the separation of Apron circuits, the high load factor, the use of steam for warming the electrolyte and the size of plant installed. H. E. Longwell, mechanical engineer, Westing- house Machine Company, dealt with the mechanical side of the problem and pointed out that a steam plant of the geared turbine type was the best suited. The exhaust from the auxiliaries, he suggested, could be used for heating the electrolyte, and he estimated that 40 per cent. of the steam required for generating the current could be supplied by waste heat boilers, which, however, were only run six days a week and necessitated the use of reserve boiler equipment to carry the plant over the week end. The geared turbine plant was in his opinion better than the combination plant employing recip- rocating engines, and such a plant could be built for a cost of $75 per kilowatt. The electrical side of the problem was discussed by F. D. Newbury, division engineer, Westinghouse Electric & Mfg. Company. He favored a combined alternating-current turbo-generator and converter unit for the power supply as economical, reliable and flexible, especially where large units and long transmissions are required. In the discussion following the papers one of the speakers pointed out that the efficiency on partial loads favored the use of reciprocating engines. Another speaker spoke of depositing the metal rapidly to eliminate the necessity for heating the electrolyte and stated that the cost of heating operated against electrolyte temperatures above 135 deg. F. He also pointed out the brittle, rough deposit that accompanied an accelerated rate. The Deforest Sheet & Tin Plate Company, Niles, Ohio, has increased its capital stock from $400,000 to $600,000, in order to provide for the expansion of its business. Blast Furnaces of the Reading Iron Company How the Old Plants Were Modernized —Extensive Ore Storage and Han- dling Facilities—Concrete Ore Bins ;conomy in operation has become a matter of vital importance to Eastern blast furnace inter- est The competition of the Central West, Lake e and Southern furnaces and the possibility of entry of foreign pig iron as a factor in the Eastern market, in combination with other condi- tions, have produced a situation which demands that Eastern furnaces be thoroughly modernized nd equipped with labor saving devices. Eastern furnace plants, built in recent years and plants that been modernized are, for the most part, well prepared to meet competition and low prices. On House Engine HHHH | Cast UVES | = (Stig y “Furnace ; on mS , coke Bin, SOT p A fe a TT dl ) Se See eee ee y eB Eee EE Made d alate lel et ile and unloading the winter’s ore supply during the summer and autumn are very important elements in the cost of operation. At the Crumwold plant, the extent of the ore yard was somewhat limited by local conditions. By reference to the plan shown in Fig. 1 it will be seen that a railroad track is provided on each side of the storage yard, one track being located on the extensions of the piers carrying the stock bins and the other being placed at ground level on the oppo- site side of the yard. Generally, ore is unloaded on the tracks next the bins and distributed in the Fig. 1—General Plan of Crumwold Furnace Fig. 2—General Plan of Keystone Furnace Plant the other hand, plants that have not been remodeled are necessarily operating in good times at a consid- erable disadvantage, while in bad times they can- not be operated without a loss. The Reading Iron Company’s blast furnace plants are located at Emaus and Reading, Pa., the former being known as the Crumwold furnace and the latter as the Keystone furnace. These plants were originally built as “barrow hand-filled” fur- naces with vertical hoists. Realizing the situation ‘orth above, the company decided some years to modernize both plants. The general arrange- nts of the Crumwold and Keystone plants are vn in Figs. 1 and 4 respectively. THE ORE STORAGE YARDS One of the most important auxiliaries of a fur- plant, particularly in the East, is an ample ore storage yard. The advantages of transporting 193 yard by means of a self propelled crane equipped with a “grab” bucket. The unloading track as well as the tracks over the bins, are so graded that, after unloading, the cars are dropped by gravity to the tail track indicated. In filling the bins, ore is taken from the stock pile by the crane and either dis- charged directly into the bins or into a drop bottom car which is in turn transferred over and dumped into the bins. During the larger part of the year, a considerable quantity of the current ore supply is discharged directly into bins on its arrival at the lant. At the Keystone plant, the ore storage yard, while much the same as the Crumwold yard in prin- ciple, is much larger in capacity. The plan shown in Fig. 2 and the elevations Figs. 3 and 4 indicate that three elevated railroad tracks extend through- out the length of the storage yard; any one or all of these tracks may be used for unloading ore or e+ pment ge ‘~ 194 THE IRON AGE 22 22 22 22 ae wt TROT for loading cars to be transferred over the bins. All tracks are carried by steel girders resting on reinforced concrete piers, the track next the bins being supported on extensions of piers forming part of the bin construction. While the self-pro- pelled crane of the “‘whirly” type has been adopted for both plants, the design and arrangement is such as to permit the installation of a bridge trav- eling crane. THE BIN SYSTEMS Various designs of stock bins have been de- veloped from time to time embodying the use of wood, steel or a combination of both. These de- signs are all, however, subject to serious objections arising from the decay of wood and the corrosion of the steel. At the plants under discussion, the entire equip- ment of stock bins and trestle piers are built of reinforced concrete, the only wood entering into the construction being the maple linings of the bins proper, which is so installed as to be capable of easy renewal. There is thus provided a bin system January 15, 1°14 hale i al iH | | | Te Nee NO g Elevated Tracks which is practically indestructible, does not decay, require painting or expensive renewals. The first example of the use of reinforced concrete for bins was at the plant of the Richard Hecksher & Sons Company (now Alan Wood, Iron & Steel ¢ pany) and was described in The Iron Age for Ju 25, 1907. This plant and the plants under discus C. Roberts & Co., Philadelphia. The ore and stone bins are of the double type with a railroad track supported by steel girders over each row. The Crumwold plant is equipped with eight ore bins and four stone bins, while at the Keystone plant there are provided 16 ore bins and eight stone bins; in both instances the row of bins next the ore yard is devoted to ore. The sec tions of the bottom of ore bins adjacent to the gates, are made of cast iron plates containing pipe coils through which steam is circulated in the winter to prevent freezing. An electrically operated bottom dump transfer car, equipped with scales, transports the ore and limestone from the bins to the skip hoist. The bin Fig. 6 Design of Bins, Showing Their Construction y 15, 1914 ? ; > >| > > ; 7 a} “ i ke: % Pg + yf ? 4 + A é 72 a 2 an Sat seth 2S > t 3 3 ; > 2° g . > ° Stein es i ig Design of Sts Bins ire of the pivoted type arranged to be oper- a lever carried by the transfer car, thus ng the expense and complication of a separate and operating apparatus for each gate. ne coke bin of large capacity discharging di- y into the skip cars, is provided at each plant. oke may be delivered to the bin on any one or all of three overhead tracks. The coke on its way to the skip cars passes over screens, the braise fall- ng into a pit located under the coke bin. This pit extends beyond the coke bin a distance sufficient to enable the braise to be taken out of the pit by a bucket and traveling crane located on the outer track over the coke bin. 195 7 re c @ Mi ale 1 Pe ( The general design of the stock bins and the relative position of the stock transfer car are shown in Fig. 5. The design of the bins is further illus trated by Figs. 6 and 7 FURNACE CONSTRUCTION Both furnaces are equipped with double skips furnace charging and apparatus of the type. The hoisting equipment in each case con sists of Otis steam engines located at ground level The starting levers for the hoist engines, the con- trol of the bell cylinders, the bell indicators and the furnace sounding apparatus are all located in the hoist engine house. Roberts Fig. 7—Design of Bins, Showing Transfer Car 196 The furnaces proper are constructed with steel shells supported -on cast iron columns; the-bosh cooling equipment consists of a combination of cooling plates and spiral water trough surround- ing the larger portion of the bosh. Crumwold furnace is 75 ft. high with a bosh diameter of 16 ft. 1 in. and a hearth diameter of 10 ft. Keystone furnace is 79 ft. high with a bosh diameter of 18 ft. and a hearth diameter of 12 ft. The stove equipment at the Crumwold furnace is being replaced by three Roberts stoves of the three pass type; while the stove equipment at the Key- stone furnace consists of four Massick & three pass stoves built some years ago. Cooke POWER PLANT No additions, except electric generators and en- gines, have been made to the power at either plant. At the Crumwold furnace the power equipment con- sists of 1500 hp of boilers; two blowing engines having 84 in. diameter Southwark air cylinders by 84 in. stroke and the usual outfit of pumps, elec- tric engines and generators. The Keystone furnace is equipped with 2000 hp of boilers; two blowing en- gines having air cylinders 76 in. diameter by 48 in. stroke; two blowing engines having air cylinders 84 in. diameter by 60 in. stroke and the necessary pumps, electric engines and generators. British Galvanized Sheet. Trade A cablegram in The Iron Age of December 18, 1913, announced the formation by the British gal- vanized sheetmakers of an association based on regulation of output. London journals point out that the failure of the old association in 1910 was caused by outside competition rather than by internal dis- sension. Conditions have improved lately. The export trade in particular has ex - panded greatly, espe- cially to India, Ar- gentina and Aus- tralia. The total ex- ports for the 11 months to December 1, 1913, amounted to 700,540 tons, an in- crease of about 100,- 000 tons over those for the same period in 1912. It is evident that 1913 made a new record. It is be- lieved, however, that any undue advance in British export prices will bring on competition, par- ticularly from the United States. The alloy Tantiron is a special grade of cast iron made in England and very high in silicon. It has special resistance to corrosion and is therefore recom- mended for use in pipes and fittings in chemical works and other places where acid attack is the chief con- sideration. It is said to be very brittle and so only suitable for small castings. The Railway Supply Manufacturers’ Association will hold its annual convention and exhibit in conjunc- tion with the Master Car Builders’ and the American Railway Master Mechanics’ Associations, on Young’s Million Dollar Pier, Atlantic City, N. J., June 10 to 17. THE IRON AGE January 15, 1914 Threading Machine for Large Pipe A new 16-in. pipe threading and cutting-off chine has been brought out by the Williams Company, Erie, Pa. This is known as the No, ¢ heavy type machine, and while many of its genera] features are similar some changes have been mace in its design as compared with the company’s No. 5 heavy type, 12-in. machine. This machine h capacity for pipe ranging from 7 to 16 in. in d eter and it is of very heavy construction throug The dies are set with a lead screw instead cam lever as in the smaller machine referre The die head rests on a sliding carriage th: moved backward and forward by a machin rack and pinion operated by a handwheel on the front of the machine. The carriage has a travel ; 36 in. and the die head can be brought up to the gripping chuck. In cutting off the pipe instead of being steadied by a scroll chuck is supported by two universal V-guides. The cut-off is mounted on one of these guides and is operated by a handwheel. The YV- guides and cut-off slides are fitted with gibs to take up wear. The hollow spindle through which the pipe passes rests in a strong headstock, which is firmly bolted to the head of the machine and dowelled to prevent it from getting out of line. The bodies of the three-jaw gripping chuck at the end of the spindle are steel forgings fitted with tool steel inserts for the grips so that in case of wear the entire jaws do not have to be replaced but only the grips. The chuck jaws are operated by a hand lever. The spindle has four changes of speed that are secured through gears controlled by two levers in front of na- i A A Recently Developed Machine for Threading and Cutting Off Pipe Ranging from 7 to 16 In. in Diameter the machine. The upper lever operates a friction clutch on the driving gears for stopping the ma- chine. The gears are of coarse pitch, machine cut and extra heavy. The bed of the machine is unusually heavy and, instead of being mounted on legs as in the lathe type, rests on the floor. The machine is driven by 10-hp. constant-speed motor. It occupies a floor space of 544 x 18 ft. and weighs 1400 lb. The American Shipbuilding Company, Cleveland, Ohio, has taken a contract from the Kelly Island Lime & Transport Company for a sand steamer to be deliv- ered next spring. The boat, which will be built at the Lorain yards of the company, will be 175 ft. long and 38 ft. wide. \ecident Prevention Work and Results A Brief Statement of the Activities of the National Metal Trades Asso- ciation—Some Preventive Measures BY WILLIAM H. DOOLITTLE rding the results to be obtained from ac- yrevention work we have good reason to be ic. The industrial world is growing safer. tlated statistics of injuries in the indus- ints in the United States bear out this While no well-informed person takes d that all accidents where the human ele- a factor may be there is a pro- tendency toward ill proper preven- measures before any accident as entable. National Metal rades ASsSociation, for several been giving special ttention to industria! safety, is now continuing the campaigu with great vigor. Every plant in the association member- ship is regularly in- spected and the working conditions which affect the personal safety of the operatives are noted and commented on by the as- sociation’s official safety whi has ler with Provision to Guard the Belt on the In- taking Side r, these comments with suggestions for ‘terment of conditions being afterward con- n a written report and transmitted to the the firm. Great interest is manifested heads of manufacturing establishments in eports and nearly all of the recommenda- ‘e put into practice. addition to inspecting the plants of its National Metal Trades nspector, Association. Safety Method of Piling Shafts 197 members, ia conducts industrial safety meetings in different parts of the country Addresses, illustrated by picture pli opticion views, are given and the industrial safety exhibit is used to instruct the individ One of the the association ivs and stere ial workmen. accompanying illustrations shows a safe method of piling round shafts as _prac- ticed in the plant of the Cincinnati Milling Machine Company, Cin cinnati. Square sticks, in the opposite sides of which half round depres sions have been sawn, are placed between the layers of shafts, thus in- suring stability and safe- ty. Another view is one taken in the plant of the Brown & Sharpe Mfg Company, Providence, R. I., and illustrates a neat and effective way of guarding the intake side of a wet grinder belt. Unprotected belts on wet grinders have many serious accidents. The third view: comes from the machine shop of caused Gears of Old Lathe Protected. Note Door to Permit Changing Gears Deere & Co., Moline, Ill. The strong and substan- tial home-made guards, covering the gears of an engine lathe, are fairly typical of hundreds of others which the company has installed in different parts of the works. Mention might also be made of a belt-shifting device developed by the R. K. LeBlond Machine Tool Company, Cincinnati (illustrated in The Iron Age, December 25, 1913). Se 198 THE IRON AGE STAGGERED ROLLING MILL GEAR A Gear 23 Ft. in Diameter with Three Rows of Teeth in Six Sections What is probably the largest steel gear of its kind was recently shipped by the Mesta Machine Company from its works at West Homestead, Pa., to the Inland Steel Company at Chicago. This gear is different from ordinary practice, as the teeth are staggered in three sections. It will be used for driving a sheet mill, and it will be possible to obtain a single-stage speed reduction from the motor to the mill by using it. The number of teeth in the gear, which is almost 23 ft. in diameter, is 154, and there are 20 teeth in the pinion, which is 35 in. in diam View of the Gear in a Planing Machine Showing the Method of eter. The face width of the gear and pinion is 38 in. and the circular pitch is 54% in. The drive is subjected to axial motion, and for that reason it was decided to use a spur gear, herringbone gears not being considered because of the unequal pres sures that would be exerted on the side of the tooth face. The speed at which the gears travel is 2000 ft. per min., and to meet this requirement the gears were carefully cut, the teeth staggered and the drive arranged to run in an oil bath. The gear is composed of six parts, the central rim segments of the teeth being carried by the gear center, which includes the arms, etc. The two halves of the gear are bolted together and the sep- arate rims fastened to this by bolts running through the side of the central casting. The machining of the gear was an interesting operation. The gear teeth were cut on a specially designed planing machine which was built by the Mesta Company. It is stated that for large work it was found that the old style of crank-operated January 15, 19}4 machine was too yielding, and as a result special machine was designed, in which the to driven directly by a heavy lead screw receiv; power from an adjustable-speed reversing e motor. After the rough casting had been anneal: joints at the hub and rim of the central port the gear were planed, after which they were d»j!Jeq and reamed and the two halves bolted together next step was to place the wheel in the pit where the center was turned down to the corree; diameter and the surfaces where the rim segments were to rest machined. The main gear was they removed from the lathe and the rim segments, which had lugs cast on them to aid in holding the work on the faceplate, machined. In this opera- tion one segment was bolted to the faceplate and Cutting the Teeth of All Three Sections Simultaneous turned up, after which it was reversed and the other side machined to size, and the segment turned to the correct diameter. The surface of the seg- ment resting on the main gear was also machined at this time. The next step in the process was to bolt the rims securely to the main gear center with all the teeth in a straight line across the face. The teeth were next planed through the center and bot! side sections simultaneously, the final cut being taken on the gear without removing the tool during the entire cutting operation. The mating pinion was machined in a simila! way. When all the teeth were cut the bolts were taken out and the two side sections shifted in rela- tion to the central one to give the proper amount of stagger. An indicating micrometer was used for doing this work with a view to eliminating an) variation from the exact dimensions. After the teeth of the pinion were properly staggered those of the gear were set to match the pinion. A set 0! holes was then drilled through both rims and the 15, 1914 the gear, and after being reamed, machine re inserted. hipping the gear it was separated into the parts. It was pointed out that the installa Triple Mill Used for a Inland Steel Gear to Be of the Staggered Tooth Drive at the Plant Company Sheet tion of this gear will be a simple operation, as it is built up of six parts, all of which were fitted together at the plant with machine bolts before ship- ping. It is expected that it will not be necessary to disturb any of the machinery already installed n setting this gear in place. December Increase in Idle Cars In the half month ended January 1 the net sur- is of freight cars in the United States and ada increased from 101,545 to 188,850. The greatest increase was in coal cars, of which 72,535 were unused January 1, as against 36,435 on De- I 5 One year previous there was a net of 17,058 cars as against a shortage De- ber 15, 1912, of 34,882 cars. The average of cars continues to increase and there heavier loading of available equipment. At ne time gross earnings confirm the substan- line of traffic. mn » 7 er iv. reported from Pueblo, Col., that the strike long been in progress at the plants of the Fuel & Iron Company is substantially broken. maller working force can take care of demand was the case when the strike started. While some time before the works reach their former the results of the strike are satisfactory to iny from many standpoints. Griffith, Canton, Ohio, representing the Union Tin Plate Company, and his chief engineer, on, Youngstown, Ohio, have been investigat- tions at the company’s plant at Marietta, Ohio ry to beginning operations. It is stated that to be placed in operation as soon as it can hape. THE IRON 199 AGE An Improved Upright Drilling Machine The use of a gear box and a dial for regulating the feed changes is a feature of an improved design of positive feed vertical drilling machine brought out by the W. P. Machine Rochester, N. Y. There are three changes ranging from 0.007 to 0.017 in. per revolution of the spindle available, the rate in use at any particular time being clearly indicated on the dial. The back gears are thrown in and out of engagement by the move ment of a single lever. The changes made in the new machine include the lengthening out of the spindle so that the driving slot is placed below the sleeve and the increasing of the diameter and face width of the driving cone pulleys. The diameters of the different steps on the cone pulley range from 41, to 9 in. and the face is 2% in. wide. The tight and loose pulleys are 10 in. with a 3-in Davis Company, in diameter 4 Recently Developed Vertical Drilling Machine Ex with a Geared Feed face, as compared with 8 and 21% in. respectively in the older type. The net weight of the machine 720 lb. 7 Denton & Anderson, 1017 Engineers Building, Cleve land, Ohio, are successors to Denton & Flagg, continuing the business at Cleveland, Chicago and Detroit in the same offices. I. H. Denton is located at the Cleveland office: J. A. Anderson at the Detroit office; and C. FE Finley in charge of the Chicago office. They will be the direct representatives of the Ohio Seamless Tube Company, Cumberland Steel Company, Winfield Ele tric Welding Machine Company, and Dahlstrom Me tallic Door Company in its automobile specialty depart ment. The force of salesmen will be materially ir creased. “ Owing to the new run-of-mine wage basis that practically sure of adoption by the Ohio Legislature, coal miners and operators are predicting a suspension if not a strike in the spring. Large consumers are pre naring to stock coal in anticipation of thi a me The Rennerfelt Electric Steel Furnace A Swedish Invention Differing from All Other Types—Details of Construction and Operation A contribution by Axel Sahlin to the London Iron and Coal Trades Review for December 19, 1913, contains the following details of a new electric steel furnace, mention of which was made in The Iron Age of July 24, 1913: In the year 1912 Ivar Rennerfelt, a Swedish en- gineer, constructed at Hallstahammer, Sweden, an electric furnace on a principle differing from all types previously in actual operation. The trial was so successful that, within a year, a steel foundry containing four Rennerfelt furnaces was con- structed at Hallstahammer. During the period from April to November, 1913, seven furnaces have been put in operation, a number have been ordered “i | Fig. 1—A 25-cwt Rennerfelt Electric Furnace at Hallstahammer, Sweden from Sweden, Norway and Russia, and repeat or- ders are being received. “Lhe furnace covers a field which has not yet been fully, covered by any pre- vious type, viz., an economical small furnace for crucible works, steel foundries, copper smelting, glass melting, also for melting ferromanganese, ferrosilicon and pig-iron alloys, and for chemical purposes. The furnace is owned by a Swedish com- pany, the Aktiebolaget Elektriska Ugnar-System Rennerfelt. This company has its offices at No. 2, Fredsgatan, Stockholm. The general agency for Great Britain, Belgium, Germany, Austria and Hungary is in the hands of the International En- gineering Company, successors to Julian Kennedy, Sahlin & Company, Limited, 52 Rue du Congrés, Brussels, and Prudential Buildings, Sheffield. DESCRIPTION OF THE FURNACE The Rennerfelt furnace, shown in Fig. 1, is preferably built with a -horizontal cylindrical steel shell, rolling in cradles or tilted by revolving horizontal axle. It is lined with silica, carbon or magnesite brick, according to the work for which it is intended. A closely fitting charging and casting door is placed in one side or in each end of the furnace. The current is circulated by three elec- trodes, one central electrode descending vertically through the crown of the roof, flanked on either side by one horizontal, entering through the ends or sides of the furnace. These latter are adjustable longitudinally and also vertically. In ordinary prac- tice the electrodes do not come in contact with the slag or bath. The arcs are free burning. Three-phase current is passed into a transformer for Scott’s method of phase transformation, changing the entering energy into bal- anced two-phase current, and delivering one-phase current to each of the horizontal elec- trodes. A return cable con- nects the common point of the two phases with the cen- tral electrode. The currents entering through the horizon- tal electrodes neutralize one another, but the action of the returning current into the central electrode generates a field of force which deflects the arcs downward toward the bath, thus forming them into an inverted arrow head or a fleur de lis, as shown in the cross sections, Fig. 2. This form of arc has hith- erto been unknown in electric furnaces, and is one of the principal reasons for the suc- cess of the Rennerfelt fur- nace. The heat generated in the arcs is, to an exceptional extent, concentrated down upon the bath though the electrodes do not come in con- tact with either metal or slag. The hight of the arcs from the points of the electrodes to the surface of the bath can be adjusted, but is usually kept at about 6 to 12 in. Smaller sizes of furnaces are tilted and discharged by hand-lever and ratchet move- ment, larger furnaces by electric or hydraulic mechanism. OPERATION OF THE FURNACE The Rennerfelt furnace is a large crucible, and can be charged with cold or liquid metal. If cold, the metal is charged by hand into the pre-heated furnace, together with the necessary fluxes. Dur- ing the charging the electrodes are drawn back, 80 as to prevent their being injured. There is just enough ‘activity in the bath after melting to form a neutral or reducing atmosphere in the furnace. One steel-melter and two laborers, or boys, per shift can manage a furnace melting from three to six tons of steel or more per 24 hr. In the riveted steel shell is placed an insulating 200 Janu 15, 1914 THE IRON AGE 201 ning of Ye-in. asbestos board. Silica or first- na firebricks in rings are built up:against this, m the bedding for the actual inner lining. made of silica, carbon or magnesite brick, aot ings of different diameters:so as to form an ped interior melting chamber. It has not een possible to determine the life of the linings in the few months during which the furnaces have heel operation, but basic linings have run 110 heat ithout requiring repairs, and acid linings are in working order after more than 174 heats. The nperature is much higher in the basic fur- at The circular form of the furnace is one of its greatest advantages. The radiating heat from the free-burning arcs is reflected on to the bath from the entire mirror-like incandescent inner sur- face of the vault. Yet the arcs are at such distance from this roof that the danger of melting the same s; minimized. The shadow of the vertical electrode has a marked protecting influence on the vulnerable portion of the vault, the area around the entrance opening for the said electrode. There is no break between the roof, side walls and bottom, all being built together in one continuous curve. Owing to the comparatively small radius of the roof the arch is exceptionally strong, and the disadvantage of ex- pansion and contraction of the lining is reduced. As the furnace is not only durable, but also small in comparison to its capacity, the cost of renewals of lining is low. To facilitate relining, the cylindrical shell is divided into an upper and a lower half, the two being bolted together when lined. THE ELECTRODES The electrodes are held with a loose fit in water- cooled, insulated phosphor-bronze boxes or holders, those for the horizontal electrodes being adjustable also in the vertical plane. They are turned to diam- eter specified, and made continuous by threaded sockets and dowels. For smaller furnaces the elec- trodes, which can be touched without shock, are fed by hand. For larger furnaces a hand-operated feeding mechanism has been added. For very large furnaces automatic feeding will be employed. The regulation is effected by gradually advancing or withdrawing the horizontal electrodes. -The ver- tical electrode need but seldom be touched. Once the ares are adjusted, it suffices to advance the side electrodes about 1 in. every hour. The consumption ' Acheson electrodes per ton of steel is less than 4 lb. REACTIONS AND RESULTS _ Results depend upon the purpose for which the ‘urnace is used. One Swedish firm employs an acid \2-cwt. Rennerfelt furnace for making the highest grade of electric crucible steel employed for cutlery, ‘aw blades and tool steel. It requires 800 to 1000 ‘W.-hr. per ton of steel made. The current supplied ‘100 kw. The stock, carefully selected, is charged cold. There is no boiling, only a slow circulation ‘the metal, permitting any small globules of slag Vhich form to rise to the surface. The atmosphere nthe melting room is slightly basic, and the for- ‘ion of gas is just sufficient to prevent the oxidiz- ig air from entering the furnace, which thus acts “4 large crucible. As compared with the crucibles, “ie economy is marked. A basie furnace of 12 ewt. capacity, with mag- te lining, is operating in a Swedish steel producing special steel castings. The ““etge is made up of cast iron and steel scrap, ore “nd ime. There are only 90 to 100 kw. of current vie, and the melting down requires about 11% ‘he duration of the heat is about 3%%4 to 4 hr. indr Owing to the high temperature maintained—some 2400 to 2500 deg. C.—sulphur and phosphorus are largely eliminated. With a working staff of four ' yu | je ain a . \ \ / \YA\ | | ad } i} Lb y UJ j 1} oy x ee ‘ f - f fj | TT Rly // er / NX 4 S< Ca } =) \ \\ Fig. 2—Cross Sections of Rennearfelt Electric Furnace men per shift, two furnaces will give an output of about 18 to 20 tons of steel per 24 hr. Experiments are under way to ascertain the actual economy arrived at by the employment of carbon brick instead of magnesite. COST OF MANUFACTURE According to experience in Sweden, one kw-year will produce: Tons In a small furnace—tool steel... ...cccccccccccccccees 8 In a small furnace—soft steel for castings............ 9 In a large furnace (estimated), refined liquid steel from Bessemer or open-hearth........... ait save een: Te In a small furnace, cast iron melted and refined........ 22 A basic Rennerfelt furnace of 12 cwt. capacity, producing 3 tons of soft steel per day, is producing liquid metal in the ladle at the following cost: Shillings per ton 1,025 kgs. scrap at 66s. per met. ton....... ie 5. Recarburizer and additions.............. 5 oa ale rad 3.10 Electrodes, 3 kw. (6.6 Ibs.), at 1s. 3d. per kg...... 3.75 So ie is eel an teak na aah wh oh Cee e aeRO es ; 10.00 Repairs and renewals... ....cc.ceceereseseees ive 5.00 Depreciation, 10 per cent......ccccccees Shari Stleat 9 2.50 PE oc cugevareddn s aaciaswe teas eveewes ss 4.00 DEE cc cktstakencdwgs .d0ekbadeacedsaaede j wie 2.00 SE 5 a occu a. @ bere RE ck Ok eke Ae 98.00 One-ninth of a kw.-year at 368...........--e02:. 4.00 Foetal cont GF GSO. oc ccvienceaadvcerscenstuts 102.00 If kw.-year cost had been 72s., cost would have been 106.99 If kw.-year cost had been 144s., cost would have been 114.00 If kw.-year cost had been 288s., cost would have been 130.00 Though it is not yet a year since the first small Rennerfelt, furnace was started, larger furnaces of up to 3 tons capacity are running and being con- structed. The principle is applicable to small as well as large units, and the 30 to 50-ton Rennerfelt electric refining furnace for steel and iron is in sight. The Norfolk & Western Railroad Company has awarded to the Virginia Bridge & Iron Company, Roan- oke, Va., the contract for the construction of the sup- ports to be used in that portion of the electrification of the railroad company’s line between Bluefield and Vivian, in the Pocahontas coal field. The amount of the contract is $100000 and work will be begun within 60 days. The power station is being constructed at Bluestone Junction on the east side of the mountain and will supply the current to be used by the electric motors. At the annual meeting of the Burt Mfg. Company, Akron, Ohio, held last week, reports showed a very satis- factory year’s business in 1913 and bright prosrects for 1914. Officers were elected as follows: President, W. F. Warden; first vice-president, H. F. Maranville; sec- ond vice-president, M. E. Knowles: general manager, J. Aca Palmer; secretary and assistant treasurer, J. Dwight Palmer; t