Read Ebook: True Stories of the Great War Volume 2 (of 6) Tales of Adventure--Heroic Deeds--Exploits Told by the Soldiers Officers Nurses Diplomats Eye Witnesses by Miller Francis Trevelyan Editor

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Among the parts of the piston which rapidly wear away because constant lubrication is difficult, is the connection with the piston-rod . It is important that the bearing at the piston-pin be formed of two parts which can be adjusted to take up the wear. The pin itself should be of case-hardened steel. For large engines, some manufacturers have apparently abandoned the practice of locking the pin, by set-screws, in flanges cast in one piece with the piston. Indeed, the piston is often fractured by reason of the expansion of the pins thus held on two sides. It seems advisable to secure the pin by means of a single screw in one of the flanges, fitting it by pressure against the opposite boss. The use of wedges or of clamping-screws, introduced from without the piston to hold the pin, should be avoided. It may happen that the wedges will be loosened, will move out, and will grind the cylinder, causing injuries that cannot be detected before it is too late. The strength of the piston-pin should be so calculated that the pressure per square inch of projected surface does not exceed 1,500 to 2,850 pounds per square inch. It should be borne in mind that the initial pressure of the explosion is often equal to 400 to 425 pounds per square inch. Some manufacturers mount the pin as far to the back of the piston as possible, so as to bring it nearer the point of application of the motive force of the explosion. Other manufacturers, on the other hand, mount the pin toward the front of the piston. No great objection can be raised against either method. In the former case the position of the rings will limit that of the pin.

The number of these rings ought not to be less than four or five, arranged at the rear of the piston. It is to be observed that makers of good engines use as many as 8 to 10 rings in the pistons of fair-sized motors.

Piston-rings of gray pig-iron can be adjusted with the greatest nicety in such a manner that, by means of tongues fitting in their grooves, they are held from turning in the latter, whereby their openings are prevented from registering and allowing the passage of gas. As a general rule, a large number of rings may be considered a distinguishing feature of a well-built engine. In order to prevent a too rapid wear of the cylinder, several German manufacturers finish off the front of the piston with bronze or anti-friction metal in engines of more than 40 to 50 horse-power. It is to be observed, however, that this expedient is not applicable to motors the cylinders of which are comparatively cold; otherwise the bronze or anti-friction metal will deteriorate.

For the same reason, the cylinder and its casing should be independent of the frame. In many horizontal engines, the cylinders overhang the frame throughout the entire length, by reason of the joining of their front portions with the frames. Although such a construction is attended with no serious consequences in small engines, nevertheless in large engines it is exceedingly harmful. Indeed, in most modern single-acting engines, the pistons are directly connected with the crank-shaft by the piston-rod, without any intermediate connecting-rod or cross-head. The vertical reaction of the motive effort on the piston is, therefore, taken up entirely by the thrust of the cylinder, which is also vertical . This thrust, acting against an unsupported part, may cause fractures; at any rate, it entails a rapid deterioration of the cylinder joint.

The sum of the projecting surfaces of the two bearings should be so calculated that a maximum explosive pressure of 405 to 425 pounds per square inch will not subject the bearings to a pressure higher than 425 to 550 pounds per square inch.

Furthermore, fly-wheels should be nicely balanced; those are to be preferred which have no counter-weights cast or fastened to the hub, the spokes, or the rim. The system of balancing the engine by means of two fly-wheels, mounted on opposite sides, is used chiefly for the purpose of equalizing the inertia effects. Special engines, employed for driving dynamos, and even industrial engines of high power, are preferably fitted with but a single fly-wheel, with an outer bearing, since they more readily counteract the cyclic irregularities or variations of speed occurring in a single revolution . If in this case a pulley be provided, it should be mounted between the engine and the outer bearing. The following advantages may be cited in favor of the single fly-wheel, particularly in the case of dynamo-driving engines:

The third bearing which characterizes the single-fly-wheel system, is but an independent support, resting solidly on the masonry bed of the engine. The bearing with its independent support is sufficiently rigid, and is not subjected to any stress from the crank at the moment of explosion, the reaction of the crank affecting only the frame bearings. With such fly-wheels, reputable firms guarantee a cyclic regularity which compares favorably with that of the best steam-engines. For a duty varying from a third of the load to the maximum load, these engines, when driving direct-current dynamos for directly supplying an electric-light circuit, will insure perfect steadiness of the light; and the effectually aperiodic measuring instruments will not indicate fluctuations greater than 2 to 3 per cent. of the tension or intensity of the current. The coefficient of the variations in the speed of a single revolution will thus be not far from 1/60.

Such a design involves fine workmanship and speaks well for the construction of the whole engine. Moreover, it enables the bearings to be brought nearer each other, reduces to a minimum that part of the crank-shaft which may be considered the weakest, and permits a rational and exact counterbalancing of the moving parts, such as the crank and the end of the connecting-rod. The best manufacturers have adopted the method of fastening to the cranks balancing weights secured to the brackets, especially for high-speed engines or for engines of high power. The projecting surface of the crank-pin should, as a rule, be calculated for a pressure of 1,400 pounds per square inch.

In gas as well as in steam engines, designs are to be commended which shield the delicate mechanism from strains and stresses that are likely to destroy its sensitiveness, as is the case in the automatic cut-off of the Corliss steam-engine.

Governors should be provided with means to permit the manual variation of the speed while the engine is in operation.

For small motors, one of the most widely used admission devices is that of the "hit-and-miss" type. As its name indicates, this admission arrangement allows a given quantity of gas to enter the cylinder for a number of consecutive intervals, until the engine is about to exceed its normal speed. Thereupon the governor cuts off the gas entirely. The result is that, in this system, the number of admissions is variable, but that each admitted charge is composed of a constant proportion of gas and air.

The governors employed for the "hit-and-miss" type are either "inertia" or "centrifugal" governors.

Inertia governors are less sensitive than those of the centrifugal type. They are generally applied only to industrial engines of small power, in which regularity of operation is a secondary consideration.

Centrifugal governors employed for gas-engines with "hit-and-miss" regulation are, as a general rule, noteworthy for their small size, which is accounted for by the fact that, in most systems, merely a movable member is placed between the admission-controlling means and the valve-stem . It follows that this method of operation relieves the governor of the necessity of overcoming the resistance of the weight of moving parts, more or less effectually lubricated, and subjected to the reaction of the parts which they control.

In engines equipped with variable admission devices for the gas or the explosive mixture, the governor actuates a sleeve on which the admission-cam is fastened . Or, the governor may displace a conical cam, the reaction of which, on contact with the lever, destroys the stability of the governor. These conditions justify the employment of powerful governors which, on account of the inertia of their parts, diminish the reactionary forces encountered.

The centrifugal governor should be sufficiently effectual to prevent variations in the number of revolutions within the limits of 2 to 3 per cent. between no load and approximately full load. Under equivalent conditions, the inertia governor can hardly be relied upon for a coefficient of regularity greater than 4 to 5 per cent.

The manner of a governor's operation is necessarily dependent on the admission system adopted. And the admission system varies essentially with the size, the purpose of the engine, and the character of the fuel employed.

"Indicated" horse-power is a designation applied to the theoretical power produced by the action of the motive agent on the piston. The work performed is measured on an indicator card, by means of which the average pressure to be considered in the computation of the theoretical power is ascertained.

The "effective" or brake horse-power is equal to the "indicated" horse-power, less the energy absorbed by passive resistance, friction of the moving parts, etc.

The "effective" work is an experimental term applied to the power actually developed at the shaft. This work is of interest solely to the engine user.

In a well-built motor, in which the passive resistance by reason of the correct adjustment and simplicity of the parts, is reduced to a minimum, the "effective" horse-power is about 80 to 87 per cent. of the "indicated" horse-power, when the engine runs under full load. This reduced output is usually called the "mechanical efficiency" of the engine.

"Nominal" horse-power is an arbitrary term in the sense in which it is used in England and America, where it is quite common. The manufacturers themselves do not seem to agree on its absolute value. A "nominal" horse-power, however, is equal to anything from 3 to 4 "effective" horse-power. The uncertainty which ensues from the use of the term should lead to its abandonment.

In installing a motor, the determination of its horse-power is a matter of grave importance, which should not be considered as if the motor were a steam-engine or an engine of some other type. It must not be forgotten that, especially at full load, explosion-engines are most efficient, and that, under these conditions, it will generally be advisable to subordinate the utility of having a reserve power to the economy which follows from the employment of a motor running at a load close to its maximum capacity. On the other hand, the gas-engine user is unwilling to believe that the stipulated horse-power of the motor which is sold to him is the greatest that it is capable of developing under industrial conditions. Business competition has led some firms to sell their engines to meet these conditions. It is probably not stretching the truth too far to declare that 80 per cent. of the engines sold with no exact contract specifications are incapable of maintaining for more than a half hour the power which is attributed to them, and which the buyer expects. It follows that the power at which the engine is sold should be both industrially realized and maintained, if need be, for an entire day, without the engine's showing the slightest perturbation, or faltering in its silent and regular operation. To attain this end, it is essential that the energy developed by the engine in normal or constant operation should not exceed 90 to 95 per cent. of the maximum power which it is able to yield, and which may be termed its "utmost power". As a general rule, especially for installations in which the power fluctuates from the lowest possible to double this, as much attention must be paid to the consumption at half load as at full load; and preference should be given to the engine which, other things being equal, will operate most economically at its lowest load. In this case the consumption per effective horse-power is appreciably higher. Generally, this consumption is greater by 20 to 30 per cent. than that at full load. This is particularly true of the single-acting engines so widely used for horse-powers less than 100 to 150.

In some double or triple-acting engines, according to certain writers, the diminution in the consumption will hardly be proportional to the diminution of the power, or at any rate, the difference between the consumption per B.H.P. at full load and at reduced load will be less than in other engines. It should be observed, however, that this statement is apparently not borne out by experiments which the author has had occasion to make. To a slight degree, this economy is obtained at the cost of simplicity, and consequently, at the cost of the engine. At all events, the engines have the merit of great cyclic regularity, rendering them serviceable for driving electric-light dynamos; but this regularity can also be attained by the use of the extra heavy fly-wheels which English firms, in particular, have introduced.

Of such automatic devices, the first that shall be mentioned is a combination of pipes, provided with cocks, by the manipulation of which, a certain amount of gas, drawn from the supply pipe, is introduced into the engine-cylinder. The piston is first placed in a suitable position, and behind it a mixture is formed which is ignited by a naked flame situated near a convenient orifice. When the explosion takes place the ignition-orifice is automatically closed, and the piston is given its motive impulse. The engine thus started continues to run in accordance with the regular recurrence of the cycles. In this system, starting is effected by the explosion of a mixture, without previous compression.

Some designers have devised a system of hand-pumps which compress in the cylinder a mixture of air and gas, ignited at the proper time by allowing it to come into contact with the igniter, through the manipulation of cocks .

These two methods are not absolutely effective. They require a certain deftness which can be acquired only after some practice. Furthermore, they are objectionable because the starting is effected too violently, and because the instantaneous explosion subjects the stationary piston, crank, and fly-wheel to a shock so sudden that they may be severely strained and may even break. Moreover, the slightest leakage in one of the valves or checks may cause the entire system to fail, and, particularly in the case of the pump, may induce a back explosion exceedingly dangerous to the man in charge of the engine.

These systems are now almost generally supplanted by the compressed-air system, which is simpler, less dangerous, and more certain in its effect.

The elements comprising the system in question include essentially a reservoir of thick sheet iron, capable of resisting a pressure of 180 to 225 pounds and sufficient in capacity to start an engine several times. This reservoir is connected with the engine by piping, which is disposed in one of two ways, depending upon whether the reservoir is charged by the engine itself operatively connected with the compressor, or by an independent compressor, mechanically operated.

In the first case, the pipe is provided with a stop-cock, mounted adjacent to the cylinder, and with a check-valve. When the engine is started and the gas cut off, the air is drawn in at each cycle and driven back into the reservoir during the period of compression. When the engine, running under these conditions by reason of the inertia of the fly-wheel, begins to slow down, the check-valve is closed and the gas-admission valve opened, so as to produce several explosions and to impart a certain speed to the engine in order to continue the charging of the reservoir with compressed air. This done, the valve on the reservoir itself is tightly closed, as well as the check-valve, so as to avoid any leakage likely to cause a fall in the reservoir's pressure.

In the second case, which applies particularly to engines of more than 50 horse-power, the charging pipe connected with the reservoir is necessarily independent of the pipe by means of which the motor is started. The reservoir having been filled and the decompression cam thrown into gear, starting is accomplished:

THE INSTALLATION OF AN ENGINE

In the preceding chapter the various structural details of an engine have been summarized and those arrangements indicated which, from a general standpoint, seem most commendable. No particular system has been described in order that this manual might be kept within proper limits. Moreover, the best-known writers, such as Hutton, Hiscox, Parsell and Weed, in America; Aim? Witz, in France; Dugald Clerk, Frederick Grover, and the late Bryan Donkin, in England; G?ldner, Schottler, Thering, in Germany, have published very full descriptive works on the various types of engines.

We shall now consider the various methods which seem preferable in installing an engine. The directions to be given, the author believes, have not been hitherto published in any work, and are here formulated, after an experience of fifteen years, acquired in testing over 400 engines of all kinds, and in studying the methods of the leading gas-engine-building firms in the chief industrial centers of Europe and America.

An engine should be supplied with gas as cool as possible, which condition is seldom realized if long pipe lines be employed, extending through workshops, the temperature of which is usually higher than that of underground piping. On the other hand, pipes should not be exposed to the freezing temperature of winter, since the frost formed within the pipe, and particularly the crystalline deposition of naphthaline, reduces the cross section and sometimes clogs the passage. Often it happens that water condenses in the pipes; consequently, the piping should be disposed so as to obviate inclines, in which the water can collect in pockets. An accumulation of water is usually manifested by fluctuations in the flame of the burner. In places where water can collect, a drain-cock should be inserted. In places exposed to frost, a cock or a plug should be provided, so that a liquid can be introduced to dissolve the naphthaline. To insure the perfect operation of the engine, as well as to avoid fluctuations in nearby lights, pipes having a large diameter should preferably be employed. The cross-section should not be less than that of the discharge-pipe of the meter, selected in accordance with the prescriptions of the following table:

GAS-METERS.

The records made are exact only when the meters are installed and operated under normal conditions. Two chief causes tend to falsify the measurements in wet meters: evaporation of the water, the failure to have the meter level.

Evaporation occurs incessantly, owing to the flowing of the gas through the apparatus, and increases with a rise in the temperature of the atmosphere surrounding the meter. Consequently this temperature must be kept down, for which reason the meter should be placed as near the ground as possible. The evaporation also increases with the volume of gas delivered. Hence the meter should not supply more than the volume for which it was intended. In order to facilitate the return of the water of condensation to the meter and to prevent its accumulation, the pipes should be inclined as far as possible toward the meter. The lowering of the water-level in the meter benefits the consumer at the expense of the gas company.

Inclination from the horizontal has an effect that varies with the direction of inclination. If the meter be inclined forward, or from left to right, the water can flow out by the lateral opening at the level, and incorrect measurements are made to the consumer's cost.

During winter, the meter should be protected from cold. The simplest way to accomplish this, is to wrap substances around the meter which are poor conductors of heat, such as straw, hay, rags, cotton, and the like. Freezing of the water can also be prevented by the addition of alcohol in the proportion of 2 pints per burner. The water is thus enabled to withstand a temperature of about 5 degrees F. below zero. Instead of alcohol, glycerine in the same proportions can be employed, care being taken that the glycerine is neutral, in order that the meter may not be attacked by the acids which the liquid sometimes contains.

In the matter of accuracy of measurement there is little, if any, difference between wet and dry meters. The dry meter has the merit of measuring correctly regardless of the fluctuations in the water level. On the other hand, it is open to the objection of absorbing somewhat more pressure than the wet meter, after having been in operation for a certain length of time. This is an objection of no great weight; for there is always enough pressure in the mains and pipes to operate a meter.

In many cases, where the employment of non-freezing liquids is necessary, the dry meter may be used to advantage, since all such liquids have more or less corroding effect on sheet lead and even tin, depending upon the composition of the gas.

Although these devices are constructed in different ways, the underlying principle is the same in all. They comprise a metallic casing, containing a flexible diaphragm of rubber or of some fabric impermeable to gas. Suction of the engine creates a vacuum in the casing. The diaphragm bends, thereby actuating a valve, which cuts off the gas supply. During the three following periods the gas, by reason of its pressure on the diaphragm, opens the valve and fills the casing, ready for the next suction stroke.

Other devices, which are never sold with the engine, but are rendered necessary by reason of the conditions imposed by the gas supply are sold under the name "pressure-regulators" . They consist of a bell, floating in a reservoir containing water and glycerine , and likewise actuate a valve which partially controls the flow of gas. This valve being balanced, its mechanical action is the more certain. Such devices are very effective in maintaining the steadiness of lights. On the other hand, they are often an obstacle to the operation of the engine because they reduce the flow and pressure of the gas too much. In order to obviate this difficulty, a pressure-regulator should be chosen with discrimination, and of sufficiently large size to insure the maintenance of an adequate supply of gas to the engine. Frequent examinations should be made to ascertain if the bell of the regulator is immersed in the liquid. In the case of anti-pulsators, care should be taken that they are not spattered with oil, which has a disastrous effect on rubber. Anti-pulsators are generally mounted about 4 inches from a wall, in order that the diaphragm may be actuated by hand, if need be.

The capacity of the rubber bags that can be bought in the market being limited, it is necessary to place one, two, or three extra bags in series , for large pipes; but it should be borne in mind that the total section of the branch pipes should be at least equal to that of the main pipe. It is also advisable to extend the tube completely through the bag as shown in Figs. 48 and 49.

If there be two branch pipes the minimum diameter which meets this requirement is ascertained as follows: Draw to any scale a semicircle having a diameter equal or proportional to that of the main pipe . The sides of the isosceles triangle inscribed within this semicircle give the minimum diameter of each of the branch pipes.

Sometimes engines are provided with a cock having an arrangement by means of which the gas feed is permanently regulated, according to the quality and pressure of the gas and according to the load at which the engine is to run. This renders it possible to open the cock always to the same point .

Resistance to the suction of air should be carefully avoided, for which reason the length of the pipe should be reduced to a minimum, and its cross-section kept at least equal to that of the air inlet of the engine. Since the quality of street-gas varies with each city, the proper proportions of gas and air are not constant. In order that these proportions may be regulated, it is a matter of some importance to fit some suitable device on the pipe. Good engines are provided with a plug or flap valve. Generally the air-pipe terminates either in the hollowed portion of the frame, or in an independent pot, or air chest. The first arrangement is not to be recommended for engines over 20 to 25 horse-power. Accidents may result, such as the breaking of the frame by reason of back firing, of which more will be said later. If an independent chest be employed, its closeness to the ground renders it possible for dust easily to pass through the air-holes in the walls at the moment of suction, and even to enter the cylinder, where its presence is particularly harmful, leading, as it does, to the rapid wear of the rubbing surfaces. This evil can be largely remedied by filling the air-chest with cocoa fiber or even wood fiber, provided the latter does not become packed down so as to prevent the air from passing freely. Such fibers act as air-filters. Regular cleaning or renewal of the fiber protects the cylinder from wear. In a general way, care should be taken, before fitting both the gas and air pipes, to tap the pipes, elbows, and joints lightly with a hammer on the outside in order to loosen whatever rust or sand may cling to the interior; otherwise this foreign matter may enter the cylinder and cause perturbations in the operation of the engine. Under all circumstances, care should be taken not to place the end of the air-pipe under the floor or in an enclosed space, because leakage may occur, due to the bad seating of the air-valve, thereby producing a mixture which may explode if the flame leaps back, as we shall see in the discussion of suction by pipes terminating in the hollow of the frame. On the other hand, sand or sawdust should not be sprinkled on the floor.

The water, which results from the combination of the hydrogen of the gas with the oxygen of the air, is deposited in most cases at the bottom of the exhaust-chest. It is advisable to fit a plug or iron cock in the base of the chest. Alkaline or acid water will always corrode a bronze cock. In order that the pipes may not also be attacked, they are not disposed horizontally, but are given a slight incline toward the point where the water is drained off. If pipes of some length be employed, they should be able to expand freely without straining the joints, as shown in the accompanying diagram , in which the exhaust-chest rests on iron rollers which permit a slight displacement.

The joints or threaded sleeves employed in assembling the exhaust-pipe should be tested for tightness. The combined action of the moisture and heat causes the metal to rust and to deteriorate very rapidly at leaky spots.

When several engines are installed near one another, each should be provided with a special exhaust-pipe; otherwise it may happen, when the engines are all running at once, that the products of combustion discharged by the one may cause a back pressure detrimental to the exhaust of the next.

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