Chapter XIII: Part 13

In designing a boiler for high altitudes, as already stated, the assumption is usually made that a given grade of fuel will require the same draft measured in inches of water at the boiler damper as at sea level, and this leads to making the stack height inversely as the barometric pressures, instead of inversely as the square of the barometric pressures. The correct height, no doubt, falls somewhere between the two values as larger flues are usually used at the higher altitudes, whereas to obtain the ratio of the squares, the flues must be the same size in each case, and again the effect of an increased velocity of a given weight of air through the fire at a high altitude, on the combustion, must be neglected. In making capacity tests with coal fuel, no difference has been noted in the rates of combustion for a given draft suction measured by a water column at high and low altitudes, and this would make it appear that the correct height to use is more nearly that obtained by the inverse ratio of the barometric readings than by the inverse ratio of the squares of the barometric readings. If the assumption is made that the value falls midway between the two formulae, the error in using a stack figured in the ordinary way by making the height inversely proportional to the barometric readings would differ about 10 per cent in capacity at an altitude of 10,000 feet, which difference is well within the probable variation of the size determined by different methods. It would, therefore, appear that ample accuracy is obtained in all cases by simply making the height inversely proportional to the barometric readings and increasing the diameter so that the stacks used at high altitudes have the same frictional resistance as those used at low altitudes, although, if desired, the stack may be made somewhat higher at high altitudes than this rule calls for in order to be on the safe side.

The increase of stack diameter necessary to maintain the same friction loss is inversely as the two-fifths power of the barometric pressure.

Table 54 gives the ratio of barometric readings of various altitudes to sea level, values for the square of this ratio and values of the two-fifths power of this ratio.

TABLE 54

STACK CAPACITIES, CORRECTION FACTORS FOR
ALTITUDES

_______________________________________________________________________ | | | | | | | Altitude | | R | | R^{2/5} | | Height in Feet | Normal | Ratio Barometer | | Ratio Increase | | Above | Barometer | Reading | R² | in Stack | | Sea Level | | Sea Level to | | Diameter | | | | Altitude | | | |________________|___________|_________________|_______|________________| | | | | | | | 0 | 30.00 | 1.000 | 1.000 | 1.000 | | 1000 | 28.88 | 1.039 | 1.079 | 1.015 | | 2000 | 27.80 | 1.079 | 1.064 | 1.030 | | 3000 | 26.76 | 1.121 | 1.257 | 1.047 | | 4000 | 25.76 | 1.165 | 1.356 | 1.063 | | 5000 | 24.79 | 1.210 | 1.464 | 1.079 | | 6000 | 23.87 | 1.257 | 1.580 | 1.096 | | 7000 | 22.97 | 1.306 | 1.706 | 1.113 | | 8000 | 22.11 | 1.357 | 1.841 | 1.130 | | 9000 | 21.28 | 1.410 | 1.988 | 1.147 | | 10000 | 20.49 | 1.464 | 2.144 | 1.165 | |________________|___________|_________________|_______|________________|

These figures show that the altitude affects the height to a much greater extent than the diameter and that practically no increase in diameter is necessary for altitudes up to 3000 feet.

For high altitudes the increase in stack height necessary is, in some cases, such as to make the proportion of height to diameter impracticable. The method to be recommended in overcoming, at least partially, the great increase in height necessary at high altitudes is an increase in the grate surface of the boilers which the stack serves, in this way reducing the combustion rate necessary to develop a given power and hence the draft required for such combustion rate.

TABLE 55

STACK SIZES BY KENT'S FORMULA

ASSUMING 5 POUNDS OF COAL PER HORSE POWER

____________________________________________________________________ | | | | | | | | Height of Stack in Feet |Side of| | | |______________________________________________|Equiva-| | Dia- | Area | | | | | | | | | | | lent | | meter|Square| 50| 60| 70| 80 | 90 | 100| 110| 125| 150| 175|Square | |Inches| Feet |___|___|___|____|____|____|____|____|____|____| Stack | | | | |Inches | | | | Commercial Horse Power | | |______|______|______________________________________________|_______| | | | | | | | | | | | | | | | 33 | 5.94|106|115|125| 133| 141| 149| | | | | 30 | | 36 | 7.07|129|141|152| 163| 173| 182| | | | | 32 | | 39 | 8.30|155|169|183| 196| 208| 219| 229| 245| | | 35 | | 42 | 9.62|183|200|216| 231| 245| 258| 271| 289| 316| | 38 | | 48 | 12.57|246|269|290| 311| 330| 348| 365| 389| 426| 460| 43 | | 54 | 15.90|318|348|376| 402| 427| 449| 472| 503| 551| 595| 48 | | 60 | 19.64|400|437|473| 505| 536| 565| 593| 632| 692| 748| 54 | | 66 | 23.76|490|537|580| 620| 658| 694| 728| 776| 849| 918| 59 | | 72 | 28.27|591|646|698| 747| 792| 835| 876| 934|1023|1105| 64 | | 78 | 33.18|700|766|828| 885| 939| 990|1038|1107|1212|1310| 70 | | 84 | 38.48|818|896|968|1035|1098|1157|1214|1294|1418|1531| 75 | |______|______|___|___|___|____|____|____|____|____|____|____|_______| | | | | | | | | Height of Stack in Feet |Side of| | | |______________________________________________|Equiva-| | Dia- | Area | | | | | | | | | lent | | meter|Square| 100| 110 | 125 | 150 | 175 | 200 | 225 | 250 |Square | |Inches| Feet |____|_____|_____|_____|_____|_____|_____|_____| Stack | | | | |Inches | | | | Commercial Horse Power | | |______|______|______________________________________________|_______| | | | | | | | | | | | | | 90 | 44.18|1338| 1403| 1496| 1639| 1770| 1893| 2008| 2116| 80 | | 96 | 50.27|1532| 1606| 1713| 1876| 2027| 2167| 2298| 2423| 86 | | 102 | 56.75|1739| 1824| 1944| 2130| 2300| 2459| 2609| 2750| 91 | | 108 | 63.62|1959| 2054| 2190| 2392| 2592| 2770| 2939| 3098| 98 | | 114 | 70.88|2192| 2299| 2451| 2685| 2900| 3100| 3288| 3466| 101 | | 120 | 78.54|2438| 2557| 2726| 2986| 3226| 3448| 3657| 3855| 107 | | 126 | 86.59|2697| 2829| 3016| 3303| 3568| 3814| 4046| 4265| 112 | | 132 | 95.03|2970| 3114| 3321| 3637| 3929| 4200| 4455| 4696| 117 | | 144 |113.10|3554| 3726| 3973| 4352| 4701| 5026| 5331| 5618| 128 | | 156 |132.73|4190| 4393| 4684| 5131| 5542| 5925| 6285| 6624| 138 | | 168 |153.94|4878| 5115| 5454| 5974| 6454| 6899| 7318| 7713| 150 | |______|______|____|_____|_____|_____|_____|_____|_____|_____|_______|

Kent's Stack Tables--Table 55 gives, in convenient form for approximate work, the sizes of stacks and the horse power of boilers which they will serve. This table is a modification of Mr. William Kent's stack table and is calculated from his formula. Provided no unusual conditions are encountered, it is reliable for the ordinary rates of combustion with bituminous coals. It is figured on a consumption of 5 pounds of coal burned per hour per boiler horse power developed, this figure giving a fairly liberal allowance for the use of poor coal and for a reasonable overload. When the coal used is a low grade bituminous of the Middle or Western States, it is strongly recommended that these sizes be increased materially, such an increase being from 25 to 60 per cent, depending upon the nature of the coal and the capacity desired. For the coal burned per hour for any size stack given in the table, the values should be multiplied by 5.

A convenient rule for large stacks, 200 feet high and over, is to provide 30 square feet of cross sectional area per 1000 rated horse power.

Stacks for Oil Fuel--The requirements of stacks connected to boilers under which oil fuel is burned are entirely different from those where coal is used. While more attention has been paid to the matter of stack sizes for oil fuel in recent years, there has not as yet been gathered the large amount of experimental data available for use in designing coal stacks.

In the case of oil-fired boilers the loss of draft through the fuel bed is partially eliminated. While there may be practically no loss through any checkerwork admitting air to the furnace when a boiler is new, the areas for the air passage in this checkerwork will in a short time be decreased, due to the silt which is present in practically all fuel oil. The loss in draft through the boiler proper at a given rating will be less than in the case of coal-fired boilers, this being due to a decrease in the volume of the gases. Further, the action of the oil burner itself is to a certain extent that of a forced draft. To offset this decrease in draft requirement, the temperature of the gases entering the stack will be somewhat lower where oil is used than where coal is used, and the draft that a stack of a given height would give, therefore, decreases. The factors as given above, affecting as they do the intensity of the draft, affect directly the height of the stack to be used.

As already stated, the volume of gases from oil-fired boilers being less than in the case of coal, makes it evident that the area of stacks for oil fuel will be less than for coal. It is assumed that these areas will vary directly as the volume of the gases to be handled, and this volume for oil may be taken as approximately 60 per cent of that for coal.

In designing stacks for oil fuel there are two features which must not be overlooked. In coal-firing practice there is rarely danger of too much draft. In the burning of oil, however, this may play an important part in the reduction of plant economy, the influence of excessive draft being more apparent where the load on the plant may be reduced at intervals. The reason for this is that, aside from a slight decrease in temperature at reduced loads, the tendency, due to careless firing, is toward a constant gas flow through the boiler regardless of the rate of operation, with the corresponding increase of excess air at light loads. With excessive stack height, economical operation at varying loads is almost impossible with hand control. With automatic control, however, where stacks are necessarily high to take care of known peaks, under lighter loads this economical operation becomes less difficult. For this reason the question of designing a stack for a plant where the load is known to be nearly a constant is easier than for a plant where the load will vary over a wide range. While great care must be taken to avoid excessive draft, still more care must be taken to assure a draft suction within all parts of the setting under any and all conditions of operation. It is very easily possible to more than offset the economy gained through low draft, by the losses due to setting deterioration, resulting from such lack of suction. Under conditions where the suction is not sufficient to carry off the products of combustion, the action of the heat on the setting brickwork will cause its rapid failure.

It becomes evident, therefore, that the question of stack height for oil-fired boilers is one which must be considered with the greatest of care. The designer, on the one hand, must guard against the evils of excessive draft with the view to plant economy, and, on the other, against the evils of lack of draft from the viewpoint of upkeep cost. Stacks for this work should be proportioned to give ample draft for the maximum overload that a plant will be called upon to carry, all conditions of overload carefully considered. At the same time, where this maximum overload is figured liberally enough to insure a draft suction within the setting under all conditions, care must be taken against the installation of a stack which would give more than this maximum draft.

TABLE 56

STACK SIZES FOR OIL FUEL

ADAPTED FROM C. R. WEYMOUTH'S TABLE (TRANS.
A. S. M. E. VOL. 34)

+----------------------------------------------------+ |+--------+-----------------------------------------+| || | Height in Feet Above Boiler Room Floor || ||Diameter+------+------+------+-----+--------------+| || Inches | 80 | 90 | 100 | 120 | 140 | 160 || |+--------+------+------+------+------+------+------+| || 33 | 161 | 206 | 233 | 270 | 306 | 315 || || 36 | 208 | 253 | 295 | 331 | 363 | 387 || || 39 | 251 | 303 | 343 | 399 | 488 | 467 || || 42 | 295 | 359 | 403 | 474 | 521 | 557 || || 48 | 399 | 486 | 551 | 645 | 713 | 760 || || 54 | 519 | 634 | 720 | 847 | 933 | 1000 || || 60 | 657 | 800 | 913 | 1073 | 1193 | 1280 || || 66 | 813 | 993 | 1133 | 1333 | 1480 | 1593 || || 72 | 980 | 1206 | 1373 | 1620 | 1807 | 1940 || || 84 | 1373 | 1587 | 1933 | 2293 | 2560 | 2767 || || 96 | 1833 | 2260 | 2587 | 3087 | 3453 | 3740 || || 108 | 2367 | 2920 | 3347 | 4000 | 4483 | 4867 || || 120 | 3060 | 3660 | 4207 | 5040 | 5660 | 6160 || |+--------+------+------+------+------+------+------+| +----------------------------------------------------+

Figures represent nominal rated horse power. Sizes as given good for 50 per cent overloads.

Based on centrally located stacks, short direct flues and ordinary operating efficiencies.

Table 56 gives the sizes of stacks, and horse power which they will serve for oil fuel. This table is, in modified form, one calculated by Mr. C. R. Weymouth after an exhaustive study of data pertaining to the subject, and will ordinarily give satisfactory results.

Stacks for Blast Furnace Gas Work--For boilers burning blast furnace gas, as in the case of oil-fired boilers, stack sizes as suited for coal firing will have to be modified. The diameter of stacks for this work should be approximately the same as for coal-fired boilers. The volume of gases would be slightly greater than from a coal fire and would decrease the draft with a given stack, but such a decrease due to volume is about offset by an increase due to somewhat higher temperatures in the case of the blast furnace gases.

Records show that with this class of fuel 175 per cent of the rated capacity of a boiler can be developed with a draft at the boiler damper of from 0.75 inch to 1.0 inch, and it is well to limit the height of stacks to one which will give this draft as a maximum. A stack of proper diameter, 130 feet high above the ground, will produce such a draft and this height should ordinarily not be exceeded. Until recently the question of economy in boilers fired with blast furnace gas has not been considered, but, aside from the economical standpoint, excessive draft should be guarded against in order to lower the upkeep cost.

Stacks should be made of sufficient height to produce a draft that will develop the maximum capacity required, and this draft decreased proportionately for loads under the maximum by damper regulation. The amount of gas fed to a boiler for any given rating is a fixed quantity and if a draft in excess of that required for that particular rate of operation is supplied, economy is decreased and the wear and tear on the setting is materially increased. Excess air which is drawn in, either through or around the gas burners by an excessive draft, will decrease economy, as in any other class of work. Again, as in oil-fired practice, it is essential on the other hand that a suction be maintained within all parts of the setting, in this case not only to provide against setting deterioration but to protect the operators from leakage of gas which is disagreeable and may be dangerous. Aside from the intensity of the draft, a poor mixture of the gas and air or a "laneing" action may lead to secondary combustion with the possibility of dangerous explosions within the setting, may cause a pulsating action within the setting, may increase the exit temperatures to a point where there is danger of burning out damper boxes, and, in general, is hard on the setting. It is highly essential, therefore, that the furnace be properly constructed to meet the draft which will be available.

Stacks for Wood-fired Boilers--For boilers using wood as fuel, there is but little data upon which to base stack sizes. The loss of draft through the bed of fuel will vary over limits even wider than in the case of coal, for in this class of fuel the moisture may run from practically 0.0 per cent to over 60 per cent, and the methods of handling and firing are radically different for the different classes of wood (see chapter on Wood-burning Furnaces). As economy is ordinarily of little importance, high stack temperatures may be expected, and often unavoidably large quantities of excess air are supplied due to the method of firing. In general, it may be stated that for this class of fuel the diameter of stacks should be at least as great as for coal-fired boilers, while the height may be slightly decreased. It is far the best plan in designing a stack for boilers using wood fuel to consider each individual set of conditions that exist, rather than try to follow any general rule.

One factor not to be overlooked in stacks for wood burning is their location. The fine particles of this fuel are often carried unconsumed through the boiler, and where the stack is not on top of the boiler, these particles may accumulate in the base of the stack below the point at which the flue enters. Where there is any air leakage through the base of such a stack, this fuel may become ignited and the stack burned. Where there is a possibility of such action taking place, it is well to line the stack with fire brick for a portion of its height.

Draft Gauges--The ordinary form of draft gauge, Fig. 35, which consists of a U-tube, containing water, lacks sensitiveness in measuring such slight pressure differences as usually exist, and for that reason gauges which multiply the draft indications are more convenient and are much used.

An instrument which has given excellent results is one introduced by Mr. G. H. Barrus, which multiplies the ordinary indications as many times as desired. This is illustrated in Fig. 36, and consists of a U-tube made of one-half inch glass, surmounted by two larger tubes, or chambers, each having a diameter of 2½ inches. Two different liquids which will not mix, and which are of different color, are used, usually alcohol colored red and a certain grade of lubricating oil. The movement of the line of demarcation is proportional to the difference in the areas of the chambers and the U-tube connecting them. The instrument is calibrated by comparison with the ordinary U-tube gauge.

In the Ellison form of gauge the lower portion of the ordinary U-tube has been replaced by a tube slightly inclined to the horizontal, as shown in Fig. 37. By this arrangement any vertical motion in the right-hand upright tube causes a very much greater travel of the liquid in the inclined tube, thus permitting extremely small variation in the intensity of the draft to be read with facility.

The gauge is first leveled by means of the small level attached to it, both legs being open to the atmosphere. The liquid is then adjusted until its meniscus rests at the zero point on the left. The right-hand leg is then connected to the source of draft by means of a piece of rubber tubing. Under these circumstances, a rise of level of one inch in the right-hand vertical tube causes the meniscus in the inclined tube to pass from the point 0 to 1.0. The scale is divided into tenths of an inch, and the sub-divisions are hundredths of an inch.

The makers furnish a non-drying oil for the liquid, usually a 300 degrees test refined petroleum.

A very convenient form of the ordinary U-tube gauge is known as the Peabody gauge, and it is shown in Fig. 38. This is a small modified U-tube with a sliding scale between the two legs of the U and with connections such that either a draft suction or a draft pressure may be taken. The tops of the sliding pieces extending across the tubes are placed at the bottom of the meniscus and accurate readings in hundredths of an inch are obtained by a vernier.

EFFICIENCY AND CAPACITY OF BOILERS

Two of the most important operating factors entering into the consideration of what constitutes a satisfactory boiler are its efficiency and capacity. The relation of these factors to one another will be considered later under the selection of boilers with reference to the work they are to accomplish. The present chapter deals with the efficiency and capacity only with a view to making clear exactly what is meant by these terms as applied to steam generating apparatus, together with the methods of determining these factors by tests.

Efficiency--The term "efficiency", specifically applied to a steam boiler, is the ratio of heat absorbed by the boiler in the generation of steam to the total amount of heat available in the medium utilized in securing such generation. When this medium is a solid fuel, such as coal, it is impossible to secure the complete combustion of the total amount fed to the boiler. A portion is bound to drop through the grates where it becomes mixed with the ash and, remaining unburned, produces no heat. Obviously, it is unfair to charge the boiler with the failure to absorb the portion of available heat in the fuel that is wasted in this way. On the other hand, the boiler user must pay for such waste and is justified in charging it against the combined boiler and furnace. Due to this fact, the efficiency of a boiler, as ordinarily stated, is in reality the combined efficiency of the boiler, furnace and grate, and

Efficiency of boiler,} Heat absorbed per pound of fuel
furnace and grate } = ------------------------------- (31)
Heat value per pound of fuel

The efficiency will be the same whether based on dry fuel or on fuel as fired, including its content of moisture. For example: If the coal contained 3 per cent of moisture, the efficiency would be

Heat absorbed per pound of dry coal × 0.97
------------------------------------------
Heat value per pound of dry coal × 0.97

where 0.97 cancels and the formula becomes (31).

The heat supplied to the boiler is due to the combustible portion of fuel which is actually burned, irrespective of what proportion of the total combustible fired may be.[54] This fact has led to the use of a second efficiency basis on combustible and which is called the efficiency of boiler and furnace[55], namely,

Efficiency of boiler and furnace[55]

Heat absorbed per pound of combustible[56]
= -------------------------------------- (32)
Heat value per pound of combustible

The efficiency so determined is used in comparing the relative performance of boilers, irrespective of the type of grates used under them. If the loss of fuel through the grates could be entirely overcome, the efficiencies obtained by (31) and (32) would obviously be the same. Hence, in the case of liquid and gaseous fuels, where there is practically no waste, these efficiencies are almost identical.

As a matter of fact, it is extremely difficult, if not impossible, to determine the actual efficiency of a boiler alone, as distinguished from the combined efficiency of boiler, grate and furnace. This is due to the fact that the losses due to excess air cannot be correctly attributed to either the boiler or the furnace, but only to a combination of the complete apparatus. Attempts have been made to devise methods for dividing the losses proportionately between the furnace and the boiler, but such attempts are unsatisfactory and it is impossible to determine the efficiency of a boiler apart from that of a furnace in such a way as to make such determination of any practical value or in a way that might not lead to endless dispute, were the question to arise in the case of a guaranteed efficiency. From the boiler manufacturer's standpoint, the only way of establishing an efficiency that has any value when guarantees are to be met, is to require the grate or stoker manufacturer to make certain guarantees as to minimum CO_{2}, maximum CO, and that the amount of combustible in the ash and blown away with the flue gases does not exceed a certain percentage. With such a guarantee, the efficiency should be based on the combined furnace and boiler.

General practice, however, has established the use of the efficiency based upon combustible as representing the efficiency of the boiler alone. When such an efficiency is used, its exact meaning, as pointed out on opposite page, should be realized.

The computation of the efficiencies described on opposite page is best illustrated by example.

Assume the following data to be determined from an actual boiler trial.

Steam pressure by gauge, 200 pounds. Feed temperature, 180 degrees. Total weight of coal fired, 17,500 pounds. Percentage of moisture in coal, 3 per cent. Total ash and refuse, 2396 pounds. Total water evaporated, 153,543 pounds. Per cent of moisture in steam, 0.5 per cent. Heat value per pound of dry coal, 13,516. Heat value per pound of combustible, 15,359.

The factor of evaporation for such a set of conditions is 1.0834. The actual evaporation corrected for moisture in the steam is 152,775 and the equivalent evaporation from and at 212 degrees is, therefore, 165,516 pounds.

The total dry fuel will be 17,500 × .97 = 16,975, and the evaporation per pound of dry fuel from and at 212 degrees will be 165,516 ÷ 16,975 = 9.75 pounds. The heat absorbed per pound of dry fuel will, therefore, be 9.75 × 970.4 = 9461 B. t. u. Hence, the efficiency by (31) will be 9461 ÷ 13,516 = 70.0 per cent. The total combustible burned will be 16,975 - 2396 = 14,579, and the evaporation from and at 212 degrees per pound of combustible will be 165,516 ÷ 14,579 = 11.35 pounds. Hence, the efficiency based on combustible from (32) will be (11.35 × 97.04) ÷ 15,359 = 71.79.[**should be 71.71]

For approximate results, a chart may be used to take the place of a computation of efficiency. Fig. 39 shows such a chart based on the evaporation per pound of dry fuel and the heat value per pound of dry fuel, from which efficiencies may be read directly to within one-half of one per cent. It is used as follows: From the intersection of the horizontal line, representing the evaporation per pound of fuel, with the vertical line, representing the heat value per pound, the efficiency is read directly from the diagonal scale of efficiencies. This chart may also be used for efficiency based upon combustible when the evaporation from and at 212 degrees and the heat values are both given in terms of combustible.

[Graph: Evaporation from and at 212° per Pound of Dry Fuel against B.T.U. per Pound of Dry Fuel

Fig. 39. Efficiency Chart. Calculated from Marks and Davis Tables

Diagonal Lines Represent Per Cent Efficiency]

Boiler efficiencies will vary over a wide range, depending on a great variety of factors and conditions. The highest efficiencies that have been secured with coal are in the neighborhood of 82 per cent and from that point efficiencies are found all the way down to below 50 per cent. Table 59[57] of tests of Babcock & Wilcox boilers under varying conditions of fuel and operation will give an idea of what may be obtained with proper operating conditions.

The difference between the efficiency secured in any boiler trial and the perfect efficiency, 100 per cent, includes the losses, some of which are unavoidable in the present state of the art, arising in the conversion of the heat energy of the coal to the heat energy in the steam. These losses may be classified as follows:

1st. Loss due to fuel dropped through the grate.

2nd. Loss due to unburned fuel which is carried by the draft, as small particles, beyond the bridge wall into the setting or up the stack.

3rd. Loss due to the utilization of a portion of the heat in heating the moisture contained in the fuel from the temperature of the atmosphere to 212 degrees; to evaporate it at that temperature and to superheat the steam thus formed to the temperature of the flue gases. This steam, of course, is first heated to the temperature of the furnace but as it gives up a portion of this heat in passing through the boiler, the superheating to the temperature of the exit gases is the correct degree to be considered.

4th. Loss due to the water formed and by the burning of the hydrogen in the fuel which must be evaporated and superheated as in item 3.

5th. Loss due to the superheating of the moisture in the air supplied from the atmospheric temperature to the temperature of the flue gases.

6th. Loss due to the heating of the dry products of combustion to the temperature of the flue gases.

7th. Loss due to the incomplete combustion of the fuel when the carbon is not completely consumed but burns to CO instead of CO_{2}. The CO passes out of the stack unburned as a volatile gas capable of further combustion.

8th. Loss due to radiation of heat from the boiler and furnace settings.

Obviously a very elaborate test would have to be made were all of the above items to be determined accurately. In ordinary practice it has become customary to summarize these losses as follows, the methods of computing the losses being given in each instance by a typical example:

(A) Loss due to the heating of moisture in the fuel from the atmospheric temperature to 212 degrees, evaporate it at that temperature and superheat it to the temperature of the flue gases. This in reality is the total heat above the temperature of the air in the boiler room, in one pound of superheated steam at atmospheric pressure at the temperature of the flue gases, multiplied by the percentage of moisture in the fuel. As the total heat above the temperature of the air would have to be computed in each instance, this loss is best expressed by:

Loss in B. t. u. per pound = W(212-t+970.4+.47(T-212)) (33)

Where W = per cent of moisture in coal,
t = the temperature of air in the boiler room,
T = temperature of the flue gases,
.47 = the specific heat of superheated steam at the atmospheric
pressure and at the flue gas temperature,
(212-t) = B. t. u. necessary to heat one pound of water from the
temperature of the boiler room to 212 degrees,
970.4 = B. t. u. necessary to evaporate one pound of water at 212
degrees to steam at atmospheric pressure,
.47(T-212) = B. t. u. necessary to superheat one pound of steam at
atmospheric pressure from 212 degrees to temperature T.

(B) Loss due to heat carried away in the steam produced by the burning of the hydrogen component of the fuel. In burning, one pound of hydrogen unites with 8 pounds of oxygen to form 9 pounds of steam. Following the reasoning of item (A), therefore, this loss will be:

Loss in B. t. u. per pound = 9H((212-t)+970.4+.47(T-212)) (34)

where H = the percentage by weight of hydrogen.

This item is frequently considered as a part of the unaccounted for loss, where an ultimate analysis of the fuel is not given.

(C) Loss due to heat carried away by dry chimney gases. This is dependent upon the weight of gas per pound of coal which may be determined by formula (16), page 158.

Loss in B. t. u. per pound = (T-t)×.24×W.

Where T and t have values as in (33),

.24 = specific heat of chimney gases,

W = weight of dry chimney gas per pound of coal.

(D) Loss due to incomplete combustion of the carbon content of the fuel, that is, the burning of the carbon to CO instead of CO_{2}.

10,150 CO
Loss in B. t. u. per pound = C×--------- (35)
CO_{2}+CO

C = per cent of carbon in coal by ultimate analysis,

CO and CO_{2} = per cent of CO and CO_{2} by volume from flue gas analysis.

10,150 = the number of heat units generated by burning to CO_{2} one pound of carbon contained in carbon monoxide.

(E) Loss due to unconsumed carbon in the ash (it being usually assumed that all the combustible in the ash is carbon).

Loss in B. t. u. per pound = per cent C × per cent ash × B. t. u. per pound of combustible in the ash (usually taken as 14,600 B. t. u.) (36)

The loss incurred in this way is, directly, the carbon in the ash in percentage terms of the total dry coal fired, multiplied by the heat value of carbon.

To compute this item, which is of great importance in comparing the relative performances of different designs of grates, an analysis of the ash must be available.

The other losses, namely, items 2, 5 and 8 of the first classification, are ordinarily grouped under one item, as unaccounted for losses, and are obviously the difference between 100 per cent and the sum of the heat utilized and the losses accounted for as given above. Item 5, or the loss due to the moisture in the air, may be readily computed, the moisture being determined from wet and dry bulb thermometer readings, but it is usually disregarded as it is relatively small, averaging, say, one-fifth to one-half of one per cent. Lack of data may, of course, make it necessary to include certain items of the second and ordinary classification in this unaccounted for group.

TABLE 57

DATA FROM WHICH HEAT BALANCE
(TABLE 58) IS COMPUTED

+------------------------------------------------------+ |+----------------------------------------------------+| ||Steam Pressure by Gauge, Pounds | 192 || ||Temperature of Feed, Degrees Fahrenheit | 180 || ||Degrees of Superheat, Degrees Fahrenheit |115.2|| ||Temperature of Boiler Room, Degrees Fahrenheit| 81 || ||Temperature of Exit Gases, Degrees Fahrenheit | 480 || ||Weight of Coal Used per Hour, Pounds | 5714|| ||Moisture, Per Cent | 1.83|| ||Dry Coal Per Hour, Pounds | 5609|| ||Ash and Refuse per Hour, Pounds | 561|| ||Ash and Refuse (of Dry Coal), Per Cent |10.00|| ||Actual Evaporation per Hour, Pounds |57036|| || .- C, Per Cent |78.57|| || | H, Per Cent | 5.60|| ||Ultimate | O, Per Cent | 7.02|| ||Analysis -+ N, Per Cent | 1.11|| ||Dry Coal | Ash, Per Cent | 6.52|| || '- Sulphur, Per Cent | 1.18|| ||Heat Value per Pound Dry Coal, B. t. u. |14225|| ||Heat Value per Pound Combustible, B. t. u. |15217|| ||Combustible in Ash by Analysis, Per Cent | 17.9|| || .- CO_{2}, Per Cent |14.33|| ||Flue Gas -+ O, Per Cent | 4.54|| ||Analysis | CO, Per Cent | 0.11|| || '- N, Per Cent |81.02|| |+----------------------------------------------+-----+| +------------------------------------------------------+

A schedule of the losses as outlined, requires an evaporative test of the boiler, an analysis of the flue gases, an ultimate analysis of the fuel, and either an ultimate or proximate analysis of the ash. As the amount of unaccounted for losses forms a basis on which to judge the accuracy of a test, such a schedule is called a "heat balance".

A heat balance is best illustrated by an example: Assume the data as given in Table 57 to be secured in an actual boiler test.

From this data the factor of evaporation is 1.1514 and the evaporation per hour from and at 212 degrees is 65,671 pounds. Hence the evaporation from and at 212 degrees per pound of dry coal is 65,671÷5609 = 11.71 pounds. The efficiency of boiler, furnace and grate is:

(11.71×970.4)÷14,225 = 79.88 per cent.

The heat losses are:

(A) Loss due to moisture in coal,

= .01831 ((212-81)+970.4+.47(480-212)) = 22. B. t. u., = 0.15 per cent.

(B) The loss due to the burning of hydrogen:

= 9×.0560((212-81)+970.4+.47(480-212)) = 618 B. t. u., = 4.34 per cent.

(C) To compute the loss in the heat carried away by dry chimney gases per pound of coal the weight of such gases must be first determined. This weight per pound of coal is:

(11CO_{2}+8O+7(CO+N)) (-------------------)C ( 3(CO_{2}+CO) )

where CO_{2}, O, CO and H are the percentage by volume as determined by the flue gas analysis and C is the percentage by weight of carbon in the dry fuel. Hence the weight of gas per pound of coal will be,

(11×14.33+8×4.54+7(0.11+81.02)) (-----------------------------)×78.57 = 13.7 pounds. ( 3(14.33+0.11) )

Therefore the loss of heat in the dry gases carried up the chimney =

13.7×0.24(480-81) = 1311 B. t. u.,
= 9.22 per cent.

(D) The loss due to incomplete combustion as evidenced by the presence of CO in the flue gas analysis is:

0.11 ----------×.7857×10,150 = 61. B. t. u., 14.33+0.11 = .43 per cent.

(E) The loss due to unconsumed carbon in the ash:

The analysis of the ash showed 17.9 per cent to be combustible matter, all of which is assumed to be carbon. The test showed 10.00 of the total dry fuel fired to be ash. Hence 10.00×.179 = 1.79 per cent of the total fuel represents the proportion of this total unconsumed in the ash and the loss due to this cause is

1.79 per cent × 14,600 = 261 B. t. u.,
= 1.83 per cent.

The heat absorbed by the boilers per pound of dry fuel is 11.71×970.4 = 11,363 B. t. u. This quantity plus losses (A), (B), (C), (D) and (E), or 11,363+22+618+1311+61+261 = 13,636 B. t. u. accounted for. The heat value of the coal, 14,225 B. t. u., less 13,636 B. t. u., leaves 589 B. t. u., unaccounted for losses, or 4.15 per cent.

The heat balance should be arranged in the form indicated by Table 58.

TABLE 58

HEAT BALANCE

B. T. U. PER POUND DRY COAL 14,225

+----------------------------------------------------------------------+ |+--------------------------------------------------------------------+| || |B. t. u.|Per Cent|| |+--------------------------------------------------+--------+--------+| ||Heat absorbed by Boiler | 11,363 | 79.88 || ||Loss due to Evaporation of Moisture in Fuel | 22 | 0.15 || ||Loss due to Moisture formed by Burning of Hydrogen| 618 | 4.34 || ||Loss due to Heat carried away in Dry Chimney Gases| 1311 | 9.22 || ||Loss due to Incomplete Combustion of Carbon | 61 | 0.43 || ||Loss due to Unconsumed Carbon in the Ash | 261 | 1.83 || ||Loss due to Radiation and Unaccounted Losses | 589 | 4.15 || |+--------------------------------------------------+--------+--------+| ||Total | 14,225 | 100.00 || |+--------------------------------------------------+--------+--------+| +----------------------------------------------------------------------+

Application of Heat Balance--A heat balance should be made in connection with any boiler trial on which sufficient data for its computation has been obtained. This is particularly true where the boiler performance has been considered unsatisfactory. The distribution of the heat is thus determined and any extraordinary loss may be detected. Where accurate data for computing such a heat balance is not available, such a calculation based on certain assumptions is sometimes sufficient to indicate unusual losses.

The largest loss is ordinarily due to the chimney gases, which depends directly upon the weight of the gas and its temperature leaving the boiler. As pointed out in the chapter on flue gas analysis, the lower limit of the weight of gas is fixed by the minimum air supplied with which complete combustion may be obtained. As shown, where this supply is unduly small, the loss caused by burning the carbon to CO instead of to CO_{2} more than offsets the gain in decreasing the weight of gas.

The lower limit of the stack temperature, as has been shown in the chapter on draft, is more or less fixed by the temperature necessary to create sufficient draft suction for good combustion. With natural draft, this lower limit is probably between 400 and 450 degrees.

Capacity--Before the capacity of a boiler is considered, it is necessary to define the basis to which such a term may be referred. Such a basis is the so-called boiler horse power.

The unit of motive power in general use among steam engineers is the "horse power" which is equivalent to 33,000 foot pounds per minute. Stationary boilers are at the present time rated in horse power, though such a basis of rating may lead and has often led to a misunderstanding. _Work_, as the term is used in mechanics, is the overcoming of resistance through space, while _power_ is the _rate_ of work or the amount done per unit of time. As the operation of a boiler in service implies no motion, it can produce no power in the sense of the term as understood in mechanics. Its operation is the generation of steam, which acts as a medium to convey the energy of the fuel which is in the form of heat to a prime mover in which that heat energy is converted into energy of motion or work, and power is developed.

If all engines developed the same amount of power from an equal amount of heat, a boiler might be designated as one having a definite horse power, dependent upon the amount of engine horse power its steam would develop. Such a statement of the rating of boilers, though it would still be inaccurate, if the term is considered in its mechanical sense, could, through custom, be interpreted to indicate that a boiler was of the exact capacity required to generate the steam necessary to develop a definite amount of horse power in an engine. Such a basis of rating, however, is obviously impossible when the fact is considered that the amount of steam necessary to produce the same power in prime movers of different types and sizes varies over very wide limits.

To do away with the confusion resulting from an indefinite meaning of the term boiler horse power, the Committee of Judges in charge of the boiler trials at the Centennial Exposition, 1876, at Philadelphia, ascertained that a good engine of the type prevailing at the time required approximately 30 pounds of steam per hour per horse power developed. In order to establish a relation between the engine power and the size of a boiler required to develop that power, they recommended that an evaporation of 30 pounds of water from an initial temperature of 100 degrees Fahrenheit to steam at 70 pounds gauge pressure be considered as _one boiler horse power_. This recommendation has been generally accepted by American engineers as a standard, and when the term boiler horse power is used in connection with stationary boilers[58] throughout this country,[59] without special definition, it is understood to have this meaning.

Inasmuch as an equivalent evaporation from and at 212 degrees Fahrenheit is the generally accepted basis of comparison[60], it is now customary to consider the standard boiler horse power as recommended by the Centennial Exposition Committee, in terms of equivalent evaporation from and at 212 degrees. This will be 30 pounds multiplied by the factor of evaporation for 70 pounds gauge pressure and 100 degrees feed temperature, or 1.1494. 30 × 1.1494 = 34.482, or approximately 34.5 pounds. Hence, _one boiler horse power is equal to an evaporation of 34.5 pounds of water per hour from and at 212 degrees Fahrenheit_. The term boiler horse power, therefore, is clearly a measure of evaporation and not of power.

A method of basing the horse power rating of a boiler adopted by boiler manufacturers is that of heating surfaces. Such a method is absolutely arbitrary and changes in no way the definition of a boiler horse power just given. It is simply a statement by the manufacturer that his product, under ordinary operating conditions or conditions which may be specified, will evaporate 34.5 pounds of water from and at 212 degrees per definite amount of heating surface provided. The amount of heating surface that has been considered by manufacturers capable of evaporating 34.5 pounds from and at 212 degrees per hour has changed from time to time as the art has progressed. At the present time 10 square feet of heating surface is ordinarily considered the equivalent of one boiler horse power among manufacturers of stationary boilers. In view of the arbitrary nature of such rating and of the widely varying rates of evaporation possible per square foot of heating surface with different boilers and different operating conditions, such a basis of rating has in reality no particular bearing on the question of horse power and should be considered merely as a convenience.

The whole question of a unit of boiler capacity has been widely discussed with a view to the adoption of a standard to which there would appear to be a more rational and definite basis. Many suggestions have been offered as to such a basis but up to the present time there has been none which has met with universal approval or which would appear likely to be generally adopted.

With the meaning of boiler horse power as given above, that is, a measure of evaporation, it is evident that the capacity of a boiler is a measure of the power it can develop expressed in boiler horse power. Since it is necessary, as stated, for boiler manufacturers to adopt a standard for reasons of convenience in selling, the horse power for which a boiler is sold is known as its normal rated capacity.

The efficiency of a boiler and the maximum capacity it will develop can be determined accurately only by a boiler test. The standard methods of conducting such tests are given on the following pages, these methods being the recommendations of the Power Test Committee of the American Society of Mechanical Engineers brought out in 1913.[61] Certain changes have been made to incorporate in the boiler code such portions of the "Instructions Regarding Tests in General" as apply to boiler testing. Methods of calculation and such matter as are treated in other portions of the book have been omitted from the code as noted.

1. OBJECT

Ascertain the specific object of the test, and keep this in view not only in the work of preparation, but also during the progress of the test, and do not let it be obscured by devoting too close attention to matters of minor importance. Whatever the object of the test may be, accuracy and reliability must underlie the work from beginning to end.

If questions of fulfillment of contract are involved, there should be a clear understanding between all the parties, preferably in writing, as to the operating conditions which should obtain during the trial, and as to the methods of testing to be followed, unless these are already expressed in the contract itself.

Among the many objects of performance tests, the following may be noted:

Determination of capacity and efficiency, and how these compare
with standard or guaranteed results.

Comparison of different conditions or methods of operation.

Determination of the cause of either inferior or superior
results.

Comparison of different kinds of fuel.

Determination of the effect of changes of design or proportion
upon capacity or efficiency, etc.

2. PREPARATIONS

_(A) Dimensions:_

Measure the dimensions of the principal parts of the apparatus to be tested, so far as they bear on the objects in view, or determine these from correct working drawings. Notice the general features of the same, both exterior and interior, and make sketches, if needed, to show unusual points of design.

The dimensions of the heating surfaces of boilers and
superheaters to be found are those of surfaces in contact with
the fire or hot gases. The submerged surfaces in boilers at the
mean water level should be considered as water-heating surfaces,
and other surfaces which are exposed to the gases as
superheating surfaces.

_(B) Examination of Plant:_

Make a thorough examination of the physical condition of all parts of the plant or apparatus which concern the object in view, and record the conditions found, together with any points in the matter of operation which bear thereon.

In boilers, examine for leakage of tubes and riveted or other
metal joints. Note the condition of brick furnaces, grates and
baffles. Examine brick walls and cleaning doors for air leaks,
either by shutting the damper and observing the escaping smoke
or by candle-flame test. Determine the condition of heating
surfaces with reference to exterior deposits of soot and
interior deposits of mud or scale.

See that the steam main is so arranged that condensed and
entrained water cannot flow back into the boiler.

If the object of the test is to determine the highest efficiency or capacity obtainable, any physical defects, or defects of operation, tending to make the result unfavorable should first be remedied; all foul parts being cleaned, and the whole put in first-class condition. If, on the other hand, the object is to ascertain the performance under existing conditions, no such preparation is either required or desired.

_(C) General Precautions against Leakage:_

In steam tests make sure that there is no leakage through blow-offs, drips, etc., or any steam or water connections of the plant or apparatus undergoing test, which would in any way affect the results. All such connections should be blanked off, or satisfactory assurance should be obtained that there is leakage neither out nor in. This is a most important matter, and no assurance should be considered satisfactory unless it is susceptible of absolute demonstration.

3. FUEL

Determine the character of fuel to be used.[62] For tests of maximum efficiency or capacity of the boiler to compare with other boilers, the coal should be of some kind which is commercially regarded as a standard for the locality where the test is made.

In the Eastern States the standards thus regarded for
semi-bituminous coals are Pocahontas (Va. and W. Va.) and New
River (W. Va.); for anthracite coals those of the No. 1
buckwheat size, fresh-mined, containing not over 13 per cent ash
by analysis; and for bituminous coals, Youghiogheny and
Pittsburgh coals. In some sections east of the Allegheny
Mountains the semi-bituminous Clearfield (Pa.) and Cumberland
(Md.) are also considered as standards. These coals when of good
quality possess the essentials of excellence, adaptability to
various kinds of furnaces, grates, boilers, and methods of
firing required, besides being widely distributed and generally
accessible in the Eastern market. There are no special grades of
coal mined in the Western States which are widely and generally
considered as standards for testing purposes; the best coal
obtainable in any particular locality being regarded as the
standard of comparison.

A coal selected for maximum efficiency and capacity tests, should be the best of its class, and especially free from slagging and unusual clinker-forming impurities.

For guarantee and other tests with a specified coal containing not more than a certain amount of ash and moisture, the coal selected should not be higher in ash and in moisture than the stated amounts, because any increase is liable to reduce the efficiency and capacity more than the equivalent proportion of such increase.

The size of the coal, especially where it is of the anthracite class, should be determined by screening a suitable sample.

4. APPARATUS AND INSTRUMENTS[63]

The apparatus and instruments required for boiler tests are:

(A) Platform scales for weighing coal and ashes.

(B) Graduated scales attached to the water glasses.

(C) Tanks and platform scales for weighing water (or water
meters calibrated in place). Wherever practicable the feed water
should be weighed, especially for guarantee tests. The most
satisfactory and reliable apparatus for this purpose consists of
one or more tanks each placed on platform scales, these being
elevated a sufficient distance above the floor to empty into a
receiving tank placed below, the latter being connected to the
feed pump. Where only one weighing tank is used the receiving
tank should be of larger size than the weighing tank, to afford
sufficient reserve supply to the pump while the upper tank is
filling. If a single weighing tank is used it should preferably
be of such capacity as to require emptying not oftener than
every 5 minutes. If two or more are used the intervals between
successive emptyings should not be less than 3 minutes.

(D) Pressure gauges, thermometers, and draft gauges.

(E) Calorimeters for determining the calorific value of fuel and
the quality of steam.

(F) Furnaces pyrometers.

(G) Gas analyzing apparatus.

5. OPERATING CONDITIONS

Determine what the operating conditions and method of firing should be to conform to the object in view, and see that they prevail throughout the trial, as nearly as possible.