The Iron Age 1931-07-09: Vol 128 Iss 2

THE IRON ESTABLISHED 1855 NEW YORK, JULY VOL. 128, No. COWDRICK FTER graduation from the University Kansas, Mr. Cowdrick engaged newspaper work and editor, and later joined the Colorado Fuel Co., becoming assistant the president. Since 1923, with headquarters New York, has been active industrial relations work. author two books: History the United and “Manpower and has written magazine articles and delivered addresses eco- nomic and labor subjects. © THE LONG-RANGE OUTLOOK INDUSTRIAL RELATIONS EDWARD COWDRICK VERY major business depression the his- tory the United States has exerted pro- found and far-reaching effects upon the conditions wage earners. 1837, 1857, 1873, 1893, 1907 and 1921, hard times weighed with extra severity upon those who had sell their labor glutted markets. with this generalization uniformity con- ditions different depressions ends. detail the effects upon labor varied widely. the panic 1837, for example, unemployment wrecked em- bryonic union movement and turned what was left away from collective bargaining and toward political agitation. sent thousands former wage earners across the mountains and down the Ohio search new homes and new careers. The depression 1873 was followed accelerated growth the Knights Labor and the appear- ance numerous revolutionary philosophies and economic heresies. The collapse 1893, with its monetary cations, led temporary alliance between discon- tented farmers and unemployed wage earners. | % was characterized Populism and the free silver crusade, with ultimate triumph for the gold stand- ard, high tariffs and the “full dinner pail.” the business decline 1921 and that through which the country now passing, the sit- uation has included new factor—the modern theory and practice personnel management. ob- serving the vicissitudes personnel management these two successive depressions and the years between that can best establish bench marks which project our survey least short distance into the future. Personnel Work 1921 and 1930 1921 there was much scrapping industrial relations work and high rate vocational casual- ties among industrial relations workers. and 1931 labor policies generally have been main- tained and the turnover among personnel directors and their associates has probably been greater than among other supervisory and staff employees. The reasons for this contrast are not hard find. The half-dozen years 1920 saw rapid and often ill-considered development administration, sometimes under the direction inexperienced and indifferently qualified men. Lack cooperation between these specialists and the line executives was intensified the theory then widely held that industrial relations should the responsibility separate department, more independent the operating organization. 1921 personnel administration had not had time rid itself the imperfections incident its youth. was looked upon many companies handy target for the efficiency man’s axe when drastic economies became necessary. Business revival the years beginning with 1922 brought new growth industrial relations prac- tice, with more experienced administrators and with better understanding its purposes and its proper place the industrial organization. Per- sonnel management came looked upon staff function, with direct responsibility for the carrying out labor policies lodged with the line executives. This new philosophy facilitated cooper- ation and understanding between operating officials and directors industrial relations. Services Labor Managers Depression not surprising, therefore, that, when depres- sion once more blighted the nation’s industry, man- agers leaned heavily upon relations spe cialists for counsel and aid meeting the problems arising the maintenance labor. Mor: over, the importance personnel coun- sel was enhanced the fact that this depression more than ever the past emplovers have exerted themselves far possible preserve the jobs, the earn- ing power and the economic status the wage earners. forecast may safely based upon this experience, may confidently pre- dict that personnel administration has become permanent part industrial 80—The Iron Age. 1931 other depression has industry done such excellent job distributing work and maintaining workers’ income. Manage- ment, with new conception the eco- nomic importance labor’s earnings, has leaned heavily its personnel departments meeting the problems arising from cur- tailed operations. There has been such scrapping in- dustrial relations work characterized the 1921 depression. the contrary, person- management and that the functions will increase rather than diminish the next decade. Probably will continue, identified with the staff rather than with the line, and its more important duties will advisory rather than executive. the same time likely be- come still further professionalized, with ever more exacting requirements knowledge and experience its practitioners. Increasingly will aided science and research. will also have the ad- vantage what appears likely steadily growing interest labor administration the part chief executives. Problems Coming Years With personnel administration thus fortified the industrial organization, what are some the . nel administration has held its place in- dustry and promises gain importance the coming decade. With the revival business activity there will increasing emphasis both cost reduction and expansion consumer pur- chasing power. Wage systems, the author says, will scrutinized search methods which earnings and output may increased simul- taneously. ‘onditions which will confront the months and years immediately ahead? Just now the most troub- lesome labor problem unemployment, and seems probable that this problem will persist, least for time, after the passing the current business depression. The story industrial progress since about 1924 gives little reason hope that return normal business activity will mean immediate absorption the entire labor reserve. seems likely that for time after business recovery has become complete there will appreciable amount chronic unemployment, with the entire labor force the country required only times abnormal activity, even then. The degree this industrial maladjustment and the probable pe- riod its duration are questions that defy predic- tion. Its ultimate cure depends upon events and forces that yet are obscure. Even moderate extent unemployment will once raise questions the length the work- ing day and the working week. Recent ence with short-time work has strengthened many managerial minds the sentiment favor the five- day week, and even the six-hour day has gained support from sources which command working periods are permanently shortened, ques- tions the use leisure will once press for solution. this subject industrial management has given somewhat scant attention the past. will have think more about the future. Business depression late has greatly increased the interest employment guarantees and unem- ployment compensation. Several company and inter- company plans have attracted wide attention, and efforts employers and employees protect the economic security wage earners have met with yeneral approval. Whatever may the extent unemployment remaining after business recovery, likely that the interest employment guarantees and unemployment compensation will continue and that important developments this field are looked for the nearby future. this whole sub- ject directors and their principals are certain devote much thought and effort the next few years. Increasing Labor Stability Along with greater less degree chronic unemployment there likely steady increase labor stability. This seeming paradox really pre sents inconsistency. the contrary, unem- ployment and labor stability react upon each other, each serving both cause and effect. When there labor surplus the worker who has job take care hold it, and this very tenacity job holding tends perpetuate the surplus lessen- ing the number vacant positions into which job less workers may absorbed. may therefore expect see—as have seen for the last two three constant widening and deepening the gap which separates the man with job from the man without job. Some the important consequences this con dition are social rather than industrial. the side purely labor relationships likely lead the following results: 1.—Managers will demand constantly higher grade employees. This will lead increased at- tention the selection, placement and training earners and supervisors. 2.—The steadiness and efficiency labor will in- crease, and, consequence, other things remaining equal, the productive power and the earning ability the individual worker will rise. This will bring greater economic stability among the wage- earning population, 3.—Personnel administration will concerned more and more with the so-called financial including schemes for savings and inrestment and contributory pensions and insurance. average age working forces will rise. This will result mounting costs pensions, life insurance, and sickness benefits. Other Labor Policies Increased attention demanded the conditions growing out unemployment and stability labor Sy 4 a will not necessarily de- tract from fundamental policies rate setting, employment procedure, employee representation, union- management cooperation, and the rest. the con- that all sides person- nel management will developed and strength- ened. Whatever may the trend wage levels dur- ing the next few months—and this connection well remember that American employers have already done better job maintaining wages than was ever done before major depression—there little doubt that the whole subject compensa- tion will bulk large the personnel programs the near future. Reviving business activity will not relax the pressure for efficiency and low costs, while the same time the importance consumer pur- chasing power will further emphasized. Wage systems will scrutinized search methods which earnings and output may increased simul- taneously. former years, when many companies the industrial relations man was looked uron wage setting and administra- tion were sometimes thought have little relation each other. Already there has been decided change the attitude management toward this subject. most the larger companies the indus- trial relations directors, not always actually control the rate-setting machinery, work close cooperation with and are consulted all matters affecting earnings the workers. Further prog- managers who are not already familiar with the principles wage determination and rate setting will well acquire that familiarity without delay. Growth Employee Representation Among the labor policies which suffered severely 1921 but which held their places 1930, one the most prominent employee Few, any, representation plans have been reported abandoned during the present depression, while some new ones have been established and some old ones have been enlarged. Employee representation like its younger half-brother, union-management cooperation—has been found more rather than less valuable both workers and management pe- riod declining business and necessarily reduced labor forces. has provided means for mutual interchange views and information and for con- sultation and joint action determining Modern methods cooperation probably are more firmly established American industry than ever before and their importance likely policies. increase the next few years. 82—The Iron Age, July 1931 passing the current business de- pression will not see the end unem- ployment and its related problems, accord- made, that being ing Mr. Cowdrick. Questions short- ened working periods, employment guaran- tees and unemployment compensation are the offing, well important conse- quences arising from marked increase the stability labor. Among sively exacting require- ments the man-power engineer, which ref- erence already has been able see labor policies from the economic and financial well from the humanitarian statistician pected able least comprehend the find- ings those specialists and apply them the determination and administration the industrial relations plans his company. Much progress has already been made this respect. pension ad- ministration—to mention only one feature per- sonnel program—many companies have made enor- mous advances beyond the old practice paying annuities out current earnings and trusting some future good fortune take care accruing liabilities. Industrial Relations Programs Future all industrial relations work the next few years may expect see continuation the recent tendency see the personnel program whole. Labor management has advanced far the stage which representation plan safety program elaborate system “welfare work” was considered sufficient solve the problem employer-employee relationships. Already con- sidered good practice, contemplating the adoption specific personnel policies, view them parts complete labor program which each separate scheme should adjusted each the others and the whole. Further progress this respect will far adding the already impressive accom- plishments personnel administration American industry. — & > ) gst CUPOLA MELTING BRASS MAULAND Metallurgist, International Harvester Co., Chicago practice the International Harvester Co. melting brass cupola, using fuel running per cent more fixed carbon, described this article, which based paper the author the annual convention the American Foundrymen’s Association. The cupola small, lined down in. inside diameter, and operated low-blast pressure and low air volume. The lining monolithic silicon- carbide cement with backing firebrick and insulating brick. Alloys melted are 85-5-5-5 and 80-10-10 compositions. Principal loss the first zinc and the second, lead. Castings manufactured are largely carbureters and bushings. Some these, being light, are poured temperature high 2300 deg. APID and economical melting, ease and abil- ity get hot metal, low melting loss, ab- sence heat and noise, and absence fumes except when tapping are some the advantages derived from cupola melting brass. Ability melt efficiently borings, turnings, spillings, skimmings, washings and insulated copper wire another favorable consideration. For two and half years have been melting in., down in., operated low- blast pressure and low air volume, using fixed car- bon fuel The metal and coke charges are weighed scale situated the floor level near the cupola and are elevated and dumped into the cupola mechanical charging arrangement having skip hoist and operated from the floor level. The molten metal tapped into crucible hung trolley from overhead monorail con- necting with pouring cranes which serve all mold- ing floors. this way molten metal taken from the cupola molds direct without transfer. The operator occasionally ascends platform located the charging door level observe the progress melting poke down the charge, poking down being necessary only when long gates other bulky materials are used the charge. The cupola air blast system equipped with volume meter and pressure gage. The slag hole located the side the cupola and the charging apparatus the rear. The section the cupola from the bottom door foot two above the melt- ing zone lined with 2-in. monolithic silicon- carbide refractory backed course firebrick and course Sil-o-cel brick for insulation. Ordi- nary firebrick used above the melting zone. For the monolithic lining, from 400 550 silicon-carbide cement required. This lining good for three weeks more, depending the ton- nage melted and the care taken daily patching. The life the firebrick and insulating brick backing approximately one year. Patching takes one hour labor every morning, the bad spots the bide cement. After the tap hole and breast are fixed up, the bottom door swung into place. The bottom door permanently lined with fire- brick. The space between the wall the cupola and the firebrick the bottom door partially filled with molding sand and then mixture fireclay and ground firebrick. This done through orening the back the cupola, which then closed from — the outside two cupola blocks. The bed charge coke ignited and brought incandescence natural draft through the open tuyeres. The blast put few minutes before the first charged. About min. later the metal ready tap. The metal charges usually consist alloy ingots, returned scrap and sprue and returned borings. They naturally vary with the class castings made. When light castings are be- ing produced which there considerable machin ing, the proportion returned borings and sprue used higher. Two alloys are generally melted, either the 85-5- 5-5 the 80-10-10, both. When changing from one alloy the other, all the metal the cupola melted and drained out before the second alloy charged. try, course, run one alloy long foundry conditions permit. When melting the 85-5-5-5 alloy, the princip The Age, July (Concluded led on page 136) > GOOD GOOD LIGHTING INVESTMENT HERBERT CHASE Consulting engineer, Forest Hills, that factories without windows sky- lights are beginning make their appear- ance, executives who stop consider how undependable daylight are coming see more clearly than ever the advantages really good artificial lighting system. not ex- pected, course, that plants built take advan- tage natural light will shut off entirely. But more evident than ever that the shop that tries “get with inferior artificial light imposing upon itself serious handicap, for workman can expected his job most efficiently unless can see perfectly. Plants that are making the most money given capital investment today are those which are working this investment hardest using the equip- ment which the investment has purchased the great- est possible number hours day. This involves, course, least two and often three shifts day, and plant with such schedule can possibly without first-class artificial lighting system. Since such system essential maximum efficiency any case, idle place much reliance upon nat- ural lighting. Aside from its unreliability, one the chief dis- advantages natural light that its intensity va- ries constantly. During parts most days likely bright produce glare, and during other parts provide insufficient illumination. addition, parts most shops never have adequate natural light. Moreover, daylight not costless, some assume. costs much money keep windows and sky- lights clean, well provide and adjust shades 300-watt incandescent lamps with reflectors, spaced 10-ft. centers, give lighting intensity foot-candles this shop the Arrow Head Steel Products Minneapolis. Iron Age, July 1931 \ \ 3 day, Since nat- dis- Va- uate S, as sky- ades illumination without glare deep shadows unques- tioned aid economical production work. Examples are given the author show how properly designed system may result enough saving pay for the equipment less than year. contends that, however good natural lighting may be, adequate artificial system nevertheless necessity. when these are required prevent glare. Then, too, much heat escapes through glass windows and sky- lights winter, and thus increases the cost heat- ing. factories are built take maximum advan- tage natural light, they must either single- story structures must sacrifice much otherwise useful area light-wells. either case they cover more ground than necessary and this tends in- crease overhead, especially where land values are high. Speed and Accuracy Thrive Good Lighting Workmen often not realize how much poor lighting slows their work increases the number errors they make, but carefully kept cost sheets are almost sure tell the story. The saving realized through good lighting may appear small, but usually the shop which the aggregate small economies considerable proves most efficient, other conditions the plant are the same. Partly for these reasons many the most mod- ern shops not only have the best artificial light- ing, but make use constantly, matter how good the light may be. established fact also that certain kinds artificial light, espe- cially that from the mercury vapor arc, make pos- sible see better than daylight. Defects and scratches polished surfaces, for example, invis ible daylight, are readily seen the approximate- single-colored mercury vapor light. For this and other reasons such lights are used both for inspec- tion and other work throughout many shops. Shadows are important their effect upon see- ing conditions. This another reason why natural light unsatisfactory. usually comes from one side only, thus leaving the far side work shadow. avoid this effect, rows lights often Despite the large window area this grinding department the Lapointe Machine Tool mercury vapor lights, some them very close the windows, are used supplement daylight even bright days The Age, July <a 4 m Both mercury-vapor and incandescent lights help give good illumination and avoid shadows the radio assembling department the Philadelphia Storage Battery Co. parallel the windows, back far enough illuminate work that otherwise would shadow. Good diffusion light tends soften elimi- nate shadows; consequently important see that artificial light well diffused. Well-designed reflectors help diffusion and also help shield the direct rays light from the eyes. effect they make the light source larger and this itself pro- motes diffusion. Without proper reflectors the mod- ern clear-glass incandescent lamp neither efficient nor satisfactory other respects, for its concen- trated source produces excessive glare and the shadows casts are hard and sharp. Proper re- flectors minimize, they not completely elimi- nate, these disadvantages. They are, however, much less consequence the mercury vapor light, for with the source large and low intensity low liancy,” the lighting engineer puts it. Yet the total quantity light can made great with any other artificial source. Because the large source, the shadows casts are neither sharp nor dark, and the direct rays the light are much less trying the eye than are the direct rays from concentrated source. Powerful Should Not Concentrated Glare another factor having nounced effect upon seeing ability. Any one who doubts this fact need only try read when facing strong light which shines directly into his eyes over the top the page. will find this most trying and eye-tiring procedure. Yet countless shops workers are required equally close work hr. day, week after week, under precisely this condition. small wonder that their efficiency impaired. 86—The Iron Age, July 193] Bright sunlight entering window which the worker faces often produces this condition. present also whenever intensely bright artificial light comes within the line vision, sure when improperly shaded incandescent lights are employed. Most drop lights produce glare. Even when shaded from the eyes the user, they are shine into the eyes other workers produce trying reflections from polished oily sur- faces. well designed lighting system makes use unshaded incandescent lights. And even windows through which glaring sunlight enters should have some means for modifying directing the light that does not enter the worker’s eyes true, however, that window shades require fre- quent adjustment and are likely impair seeing conditions bays not adjacent the windows. But this one more reason for not placing too great dependence upon natural light and for providing adequate artificial lighting system. First-class artificial lighting really very in- expensive tool. many, not most, shops its total cost runs less than 5c. day per worker, including per cent annual depreciation, per cent interest investment and cost current, clean- ing, maintenance, and all other charges. Consequently, even very small saving, resulting from less lost time, reduction waste, increase output, decrease accidents, amply warrants the moderate investment required. addition, the greater satisfaction and better health workers and the accompanying decrease lost time and labor turnover, characteristic well-lighted shops, should not overlooked. Generalizations based measured savings resulting from improved lighting are likely — misleading, but there doubt that many such savings are realized. The following examples, taken from data compiled engineers the Nielsen Co., may not typical, but they are sig- nificant what can accomplished some cases. Definite Savings Traced Good Lighting placed lighting system which gave average intensity foot-candles, with one similar type but foot-candles, and better distribution light the working surfaces. The total in- cluding derreciation, interest, lamp renewals and power, amounted $2,380 year, about twice the former cost. one metal-working department the increased cost was $428 year, day per man. The labor turnover decreased from 6.37 per cent 2.78 per cent month, representing saving about $100 year cost hiring and training new men. addition, the men were greatly pleased. Because their piece-work rate could (and was) cut per cent without reducing their total daily earnings, the lighting system saved the management $842 year, much more than enough pay for the installation within this period. another department,on putty-glaze conveyor line, the imrroved illumination made possible reduce the number men required, thereby effecting saving $120 day, net saving $117.65 day when the extra cost the lighting deducted—enough pay for the system every days. Consicerable savings were effected also the painting department, where the reduction labor required for touching work that formerly came through cefective, because the inability work- men see perfectly, cut net costs $1,680 year, whereas the improvements required only $600. Good Dividends Available Most Shops Not every shop can duplicate such savings, course, but unless shop has much better tha average lighting conditions faced some verse situation unconnected with working condi tions, up-to-date lighting system investment destined pay excellent dividends. For the shop which runs more than one shift, and thereby boosts its output from given investment proportion, first-class artificial light- ing system becomes prime essential. hardly less important, however, even shops designed make the mest natural light single-shift basis. For otherwise such shops cannot operate with full efficiency the year around, because the inter- mittent and undependable nature natural lighting. IMPRISONING THE X-RAY EAD provides prison walls prevent escape the benefi- cent and highly destructive ray. This X-ray room Quincy Hospital, Quincy, Mass., being Co., Everett, Mass., will accom- modate 175-kv. machine and, prevent escape the rays, will have thickness lead lining weighing the square foot. more powerful X-ray machine 900 kv., being installed the Memorial Hos- pital New York, will require 2-in. sheets 120 the square foot. space will left uncoated with lead. the lag screw heads will covered with pieces in. square. The open- ing for window, through which observations may made, will filled with lead glass. sheets walls, ceiling and floor will overlap, and joints will lapped and burned. The floor above will protected sheet lead top and extending about in. beyond the walls, there will direct route for rays escape the seam. The Iron Age, July 1931—87 OO J > a @ 4 methods have been put into effect the gray iron foundry the Lycoming Mfg. Co., Williamsport, Pa., get larger output with- out increasing the foundry area. One these consists grouping roller conveyors around Sand- slingers. The other consists making two castings identical design single flask only slightly larger than the one formerly employed for single casting. Sometimes with the same crew, sometimes with the addition one man, making crew six instead five, these changes have been put through. re- sult, one instance production 9-hr. day has been stepped from 175 castings 170 flasks, 340 castings. Similiar results are reported from the other units which this system has been put into use. This plant has two principal combustion engines for automobiles and motor boats, and boilers for heating purposes residences, apart- ments, hotels, stores, etc. running the rate about 175 200 tons iron poured each day, operating single cupola, sometimes two the four cupolas installed. Two cupolas have 96-in. shells and two have shells. They are lined respectively in. and in. One element considerable saving both time and expense lies the fact that the iron run from the 88—The Iron July 1931 GETTING MORE THE SAME cupola always from identically the same charge. Whatever changes the iron composition are desired are made additions the ladle such alloys may required for the purpose. The mix the cupola charge present run about per cent pig iron mixture several irons), per cent cast scrap from the foundry floor, and per cent steel scrap, which four-fifths consists broken rails. reported that the cost this iron the spout only about 0.9c. pound, which addi- tion for unloading charges and freight charges would make total perhaps 1.05c. This does not include overhead. This iron taken from the cupola one- ton bull ladles overhead crane. These ladles are set upon ladle stands conveniently located alongside pouring stations, and the pouring ladles are filled tilting the bull ladle through hand gear. Except for the smallest sizes for small castings, the actual pour- ing done from ladles carried overhead tramrails and handled either air hoists chain blocks. Castings Poured Conveyors HERE are four stations which engine castings are poured while conveyors. One the motor-driven, which cylinder blocks are poured. the mold- ing units, viewed from the rear. Cores approach from the left. The drag made one machine placed the con- veyor, and the cope, made another ma- chine, put upon comes past that machine. Pouring and shake-out are far right. | ‘ >. ] 4 > ~ CASTINGS FROM FLOOR SPACE the floor space devoted molding and installation roller conveyors have made possible for automotive foundry get almost twice many castings from the same floor space. the same time the crew has not been materially increased. How this has been done, connection with other changes practice facilitating greater speed operation, described here. The other three consist gravity rollers which exhaust manifolds, cylinder head castings, and other work the lighter nature are poured. planned add three more these gravity conveyor units, each with its molding machine, thus filling the length the bay which the similiar units are now lo- cated. All four these stations are served jolt ma- OLT molding ma- chines, producing the cope and drag, respective- ly. Samples the product are shown top both pages. chine, using properly tempered sand overhead hoppers, and under overhead tramrails. The latter carry not only the pouring ladle, but also air hoists for handling and turning molds. Hence each station complete unit itself, where all the operations molding and pouring occur proper, and rapid, quence. The crew functions group piecework basis, making for tramwork and for great produc tivity can had. adjoining bay the north, where the sections are cast, the larger sections are rammed and poured rollers, one casting the flask. Here, again, some the smaller units are poured two flask for the purpose increasing production the same floor space, and the same time lowering the unit cost the product. Each bay has long conveyor take the castings, after being knocked out, the cleaning section east end the building. the bay handling the motor parts this conveyor power-driven, the castings being thrown upon flat tables running level with loor. the heater bay the conveyor the foundry The Iron Age, July | = q ~ the gravity roller type and the heavy castings are handled from there separately. Castings are all run through tumbling barrels the first cleaning process. Thence they grinders over several parallel lines gravity roller conveyors. far possible the flow straight line east- ward. And castings the same similiar character are carried single line conveyor. Reaching Rough Warehouse > Sand Blast | D) & - > sand Carrouse/ Mixing Floor. | 7 the end the cleaning line, the engine castings once into the shipping dock for delivery, partly rail and partly motor truck, the manufacturing plant, one mile away. Heater castings from the cleaning division into heater storage division. Here they are machined faced and tapped. After hydraulic test they are held, 90—The Iron Age, July 1931 with boxed fittings for unit assembly, await ship- ping orders. Making Two Castings One Flask methods for making castings for the engine cylinder block have been employed, one with the block integral with the crankcase, while the other the block and crankcase are separate. one such in- Machine Shop layout the foun- dry (left), showing straight flow materials the tion the grinding and chip- ping top. Cores come from the right side, through the ovens, the molding floors. Warehouse Detail the molding units which have done much (Heaters) speed production shown next page. All three units are alike. Pouring near the upper end the oval. After shaking out, the casting thrown the conveyor, which takes the cleaning depart- ment. Casting heater sections grav- ity conveyors shown bot- tom next page. the midst core hop pers Sand Bin —— Overhead Crane stance, the integral casting weighs 270 lb. planned make two the cylinder blocks (separate from the crankcase) single flask, involving 165-lb. castings, total 330 lb. the flask. This, expected, will done with the same six men now the crew, and with production reaching approxi- mately twice the present number castings. Because = 2 j | Shay (Heaters) Grinding and Chipping \ \\} ) Storage Bins’ - ‘3 Je a 7 the extra each flask, the cost per pound will some- what lower. the meantime two crank- cases will cast single flask, and expected that the unit cost the pound will held down the present cost tegral castings for V-type engine, and for V-type 16-cylinder engine, are being planned. expected that production will begin these about the end this year. These will weigh between 360 and 400 each. The casting for one the marine-type en- gines weighs approximately 600 Use Ladle Additions the OST the iron used the straight run from the cupola, without ferroalloy addition. Some the lighter sections having thin walls, etc., such the manifolds for exhaust gases and other parts, have certain definite amount ferrosilicon added the stream goes into the ladle. This adds the fluidity the iron and permits the thin sections fill out easily. For the cylinder blocks there addition ferrochrome chrome-nickel, depending upon the specifications the particular cylinder being cast. results naturally from the cupola mix and the ladle additions that these cylinders are made very high-test iron. The Brinell hardness the bore the cylinder average about 207, against specification 196. Other parts the block run about 217 and high some portions 222. illustrate something the gain cupola pro- duction from the use single mix, may men- tioned that formerly 12-hr. cupola run gave about 120 tons, against 175 tons present. The saving time found apply not only the cupola itself, but the pouring floors, where never necessary wait more than moment two for iron. empty ladle going back the cupola for its metal carries red tag for iron which contain one ferroalloy, black tag for another, etc. there tag the ladle that means the straight iron without ladle additions. These ladle additions are all carefully measured out separate units advance, that all that necessary put them the iron fills the ladle. they are finely crushed and are poured into the stream from the spout, they be- come thoroughly mixed the iron, without segrega- tion. Better control the scrap coming back the cupola afforded these methods. Most the iron used contains such small amount ferroalloy, none all, that its effect the cupola, melting the iron for pouring, practically negligible. Hence, all goes into the cupola charge, without the necessity for segregating one kind scrap from another, and then mixing stipulated percentages. Cupola charging hand from wheelbarrows, The Iron Age, July p- TY Main Cony ne \ he it 5 > / A / i a i q q al 4 Cylinder-block molding units, showing left background the Sand-slinger filling the molds, and, right, section the carrousel which the molds are poured. drawing from conveniently located source material. overhead crane spanning the charg- ing floor, and running out into the open over two spur railroad tracks, deposits foreign scrap steel and the different grades pig iron into the respective bins. From here the metal picked and weighed wheelbarrows its way the cupola. magnet used for unloading cars. These same craneways extend over the sand-mixing department, depositing sand means grab-buckets overhead hoppers. From here dropped batches into the mixing machines, and then carried out conveyors over the hoppers, whence reaches the core makers and molders respectively. coke hopper overhead, parallel with the row cupolas and between cupolas and metal bins, has spouts intervals, from which coke can drawn into the cupola charge. Cores Made Two Floors HERE are two core rooms, one for the light work and the other for the heavy work. The light-work room the second floor and operated mostly girls. Their products are run through eight ovens, and then delivered the molding floor needed, racks cores being sent down the elevator. This room exceptionally well supplied with daylight means large windows. Underneath the larger-core room. Cores are made machines for the most part, and then run 92—The Iron Age. July 1931 through core ovens racks. The ovens, all fired with oil, are placed between the core room and the pouring bay. Racks (on wheels) are run into the oven the core-room side and, after the cores are baked, are run out the foundry side. Each oven has capacity for two racks. Much delay and confusion were done away with when these ovens were made the “through” type. Formerly each had only one door—that from the core room. Racks accumulating for baking often had moved aside make room that racks baked cores could drawn out. Then these racks had pushed through congested aisles reach passage leading the pouring bay. All this now avoided and the cores follow prac- tically straight path from core core setter. The line- the core room is, nearly may be, op- posite the point where each type core into its mold, thus aiding avoiding cross currents their flow. | FASTER AND MORE EFFICIENT GAS PRODUCERS VICTOR WINDETT Manager, gas producer division, Wellman Engineering Co., Cleveland OME years ago the gas producer art emerged from the era the hand-worked producer into that the me- chanical machine. Char- acteristics the earlier producers were low pacity, great fluctuations gas quality, high car- bon loss the ashes, high ratio manual labor heat output, and demand for the best coal had. Paralleling the developments Bessemer, Siem- ens and Wellman the manufacture steel, Wil- liam Hughes developed the first practicable and successful mechanical gas producer. This step was the essential foundation the mass production open-hearth steel. What Distinguishes the Mechanical Producer Outstanding features mechanical operation are mechanical rotation the producer body and ash pan, use plow adaptable continuous ash removal, mechanical variable-delivery coal feed, and mechanical poker. Resulting from this work were largely increased capacity and greater uniform- ity the quality gas. Additional benefits were EVELOPMENT from the hand-operated producer years ago the mechanical producer, and later the present greatly improved mechanical operation, was outlined paper read May New York, before the American and Steel stitute. Some the characteristics what may prove the future producer are brought out the ab- stract the paper here presented. particular plea made let the producer operator make the gas, fied, and the dependa- instead attempting control the operation his units from the furnace floor. high decreased labor needed, less carbon loss the ashes and lower gasifica- tion cost. Some ten years ago this producer, having reached its state high- ast development, gave way successor more suited the trend the times. Using past and untram- meled time-worn tra- Area Sq. Ft. Trend gas producer and open-hearth operation, showing steady improvement efficiency for two decades ducer gas has been gas producer art was made. The ruling condi tions governing the velopment the new roducer may summed the one expression low coal must gasi- bility must surpass the excellence predecessor and com petitors. aims were achieved the use mprovements, such discarding the revolving drum feed for one using the alloy steel double bell and ring seat, with intermediate holding chamber, similar the modern blast furnace top. Poker action was proved. Other new features used are the period- ically intermittent ash pan differential motion rela- tive the body rotation, continuous ash plowing, and the substitution power-driven air blower with independent humidification control instead the less satisfactory steam jet blowers. These improvements resulted increased capac ity decreased cost, shown, with the approx! mate aceuracy average figures, Table Experience indicates that the limit output, i without reaching maximum, fixed the ability the turbo- blower deliver air the yasification zone The capacity blower liver air sufficient for maximum gasification, irrespective the dens- ity the ash zone and zone above the air duct outlet. The value pro- The Iron Age, July 1931—93 — ‘ q q | 70 > co, 3 Cann 52 Are 2 Pe- Coy a > 200) | * ¢ Progdive 2, 0g erAr Hearth Are a Area 0 an taken customarily its figure the heat combus- tion, based chemical analysis. The figure thus se- cured that clean, washed gas deg. Such gas rarely used industry. The gas used hot with its sensible heat and loaded with highly useful combustible tar vapors, soot and certain amount dust. Analysis shows that about per cent the tar vapors and about half the soot and dust are carried into and burnt the furnace. The net dust loss only the weight the carbon the particles coke the original coal dust. making studies fuels, the proper value the heat content producer gas the sum the heat combustion the gas, tar, soot and dust actually delivered into the furnace, together with their sensible heats. high gas velocity the flues advantageous 4 decreasing tar and soot losses, high velocity Table Gas-Producer Practice Practice Underlying Earlier Work, Still Used by Present Practice Obtainable Writers Today Gas producers ots Stationary, hand Mechanical and auto- worked mati Coal feeding By hand, periodic at Continuous, mechani- variable times cal Ash removal : By hand, periodic 12 Continuous, mechani- to 24-hr. intervals cal Air delivery. By steam jet, insepa- Turbo-blower, inde- rable steam and air pendently controlled delivery humidification Fire working By hand, according Continuous, mechani- to the inclination of cal poking of fire the gas man, much carbon lost by hand poking Ash bed Unworked Periodic loosening to . f litate pflow of supply Producer zones.. Oxidation, 0 to 5 in.: Total 15 up to 30 in. reduction 30 in.; distillation 1 total, ft. in. up to 7 ft Gasification rates, Ib. Ib. Ib. Ib. 108 Ib. per sq. ft. per hour Ratio CO/CO : 5 at 28 to 40-in. fire 5 at 15-in. fire bed bed Gas velocity at off- 1.5 to 2.8 ft. a second 9.2 to 19.0 ft. a second take 1400 deg. gas Gas flow through fire 1.4 to 4.6 ec decreases condensation and precipitation due its greater carrying capacity. also provides shorter time for tar condensation consequent tempera- ture drop. disadvantage too high velocities the un- due consequent building gas pressure within the producer. This turn for given service in- creases the delivery pressure the air blower out- let, resulting increase power used for the blower operation. the case turbo-blower the air delivery curve for such pressures air and steam are customarily found routine producer operation flat that these circumstances are not serious. High Efficiencies Recently Achieved Speed gasification and resulting functions have increased from six ninefold (Table and the times gas flow through the fire bed have de- 94—The Iron Age, July 1931 creased, accordingly recent practice. sug- gested that the thermochemical activity fied this speeding through heat generation shorter time interval, similar that found blow-pipe flame. may follow, therefore, that heat losses radiation and otherwise are somewhat lessened. the case these recent high rates the quality and the thermochemical efficiencies remain the high values found lower rates working the same type gas producers, probably due the speed- ing up. What the Future May Hold Tentative studies have been made what may expected the moderately near future gas producer output, reaching gasification rate approaching tons more per producer hour, com- pared with the present high figures somewhat over tons. Special circumstances may warrant certain cases large unit one handling tons hour. will made one leap, for the reason that con- trolling the thermochemical and attendant functions producer are, present, matters empirical experimentation, rather than office and drafting room prediction and vision. this producer more like living organism than statically deter- minant machine structure. Now thought that, for the moderately remote future, the present size producer about large average demand calls for. Until the open- hearth executives fall line with the users elec- tricity, water and other energies drawing their gas, water electricity from general main flue, equipped with suitable control valves other instru- ments, open-hearth furnace will equipped with single producer. Prudence would forbid and good judgment would overule “paper” estimates the savings suggested single producer. Hence the steel industry the largest producer desirable such that normal operation two units will serve one furnace, with third for standby. two alone may sufficient, considering final costs per ton steel made per year. Should one the two down temporarily, the other could carry furnace output of, say, per cent normal. Getting Desired Results Proper coordination between gas man and fur- nace tender (whether open-hearth melter nace) may secured through the furnace man in- dicating the gas house, electric push-button lighting either blue red bulb, call for more less gas. the same time the push button rings bell call the gas man’s attention, should not looking the lights. receiving such call, the producer man responds correspondingly altering both rate air and coal delivery into the rroducers. The lag delay between the furnace man’s call and the response cut minimum. many plants customary allow the melter regulate the steam supply which actuates the | Table I—Advances Gas-Producer Operation Coal Gasification for Each Cost Operation Sq. Ft. and Total Overhead, Cost Producer Producer Kind of Gas Day, Area Coal, per Million Producer Year Tons Hourly, Lb. Ton B.t.u. Hand worked........ 1910 6.6to 15.0 Early mechanical..... 1920 20 to 30 30.0 to 40.0 0.5 0.16 Modern mechanical... 1930 40 to 90 50.0 to 95.5 0.23 0.13 blower the producer. This does manipu- lating valve, placed for this purpose the open- hearth building, with long steam line from the charging floor the gas producers. The engineer large steel works, who has designed the past few months large installation open-hearth fur- naces, deliberately planning for remote producer control from the open-hearth charging floor. Harmful consequences such design are the following nature: reasonably certain that wet steam, carrying times “slugs” water, will delivered into the producer air supply. Steam this quality chills the fire, causes low and high CO, and excessive moisture the gas. The gasifica- tion rate falls. Addition per cent moisture the gas increases the fuel cost much though the CO, content had increased 2.25 per cent. Another consequence that remote control in- duces irregularity the gasification conditions the producer. The gas man has way discover- ing that the rate air supply has been changed, ex- cept looks, from time time, through ob- servation hole into the producer. Then notes considerable change the fire level, the ap- parent gas temperature, the appearance more less incipient holes the fire. His remedies are alter, guess, the rate coal feeding (not knowing the actual rate air supply), and possibly certain amount hap- hazard hand poking. sees the fire conditions be- coming poor, and the quality the gas fall off. gas man, newly employed, soon learns that thus hopelessly handicapped, acknowledges beaten circumstances beyond his control, and contents himself with merely holding his job, accompanied with little possible from all his various bosses. Discussion Gas-Producer Paper PLEA for expert engineering supervision for the gas house was made Martin Conway, fuel engineer, Lukens Steel Co., Coatesville, Pa. Table Producer—Open-Hearth Practice Producer type....... Hand Mechl. Mech]. Hand Mechl. Mechl. Me oe” See . Hand Hand Mechl. Hand Mect Mechl. Mech! 600 594 548 477 412 42 {2s Producer per ton of steel per 4 2 3.6 0.62 1.5 1 Producer area per sq. ft. hearth area.... 0.72 0.33 0.6 0.2 thinks that should have adequate engineering care boiler plant, and correspondingly full complement recording instruments should much part its standard equipment the case steam plant. This argument the basis that gas house frequently gasifies much coal month large steam plant consumes. Cost figured out much for each million B.t.u. de- livered the furnace. This speaker suggests regulation the producer plant through the temperature the gas leaving the producer. Whenever the capacity sufficient permit, mechanical operation throughout should re- place hand firing producers. Wherever inferior fuel can used, low unit fuel cost, the initial cost special produ