CENTIMETERS

UipW

A SELECTIVE MICROFILM EDITION PARTV (1911-1919)

Thomas E. Jeffrey Senior Editor

Brian C. Shipley Theresa M. Collins Linda E. Endersby Editors

David A. Ranzan Indexing Editor

Janette Pardo Richard Mizelle Peter Mikulas Indexers

Paul B. Israel Director and General Editor

Sponsors

Rutgers, The State University of New Jersey National Park Service, Edison National Historic Site New Jersey Historical Commission Smithsonian Institution

A UPA Collection from

LexisNexis-

7500 Old Georgetown Road • Betlicsdu, MD 20814-6126 Edison signature used with permission ofMcGmw-Edison Company

Thomas A. Edison Papers

Rutgers, The State University of New Jersey endorsed by

National Historical Publications and Records Commission 18 June 1981

Uitgcrs, The State University of New Jersey, New Brunswick, New Jersey.

The original documents in this edition are from the archives at the Edison National historic Site at West Orange, New Jersey.

ISBN 978-0-88692-887-2

THOMAS A. EDISON PAPERS STAFF (2007)

Director and General Editor Paul Israel

Senior Editor Thomas Jeffrey

Associate Editors Louis Carlat Theresa Collins

Assistant Editor David Hochfeldcr

Indexing Editor David Ranzan

Consulting Editor Linda Endersby

Visiting Editor Amy Flanders

Editorial Assistants Alexandra Rimer Kelly Enright Eric Barry

Outreach and Development (Edison Across the Curriculum)

Theresa Collins

Business Manager

Rachel Weisscnburgcr

BOARD OF SPONSORS (2007)

Rutgers, The State University ofNcw Jersey Richard L. McCormick Ziva Galili Ann Fabian Paul Clemens

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National Park Service

Maryanne Gerbauckas Michelle Ortwein

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EDITORIAL ADVISORY BOARD (2007)

Robert Friedel, University of Maryland Louis Galambos, Johns Hopkins University Susan Hockey, Oxford University Thomas P. Hughes, University of Pennsylvania Ronald Kline, Cornell University Robert Rosenberg, John Wiley & Sons Marc Rothenberg, Joseph Henry Papers, Smithsonian Institution Philip Scranton, Rutgers University/Hagley Museum Merritt Roe Smith, Massachusetts Institute of Technology

FINANCIAL CONTRIBUTORS

Wc thankfully acknowledge the vision and support of Rutgers University and the Thomas A. Edison Papers Board of Sponsors.

This edition was made possible by grant funds provided from the New Jersey Historical Commission, National Historical Publications and Records Comm.ss.on and The Nat.ona Endowment for the Humanities. Major underwntmg has been provided by the Barkley Tund, through the National Trust for the Humanities, and by The Charles Edison Foundation.

We are grateful for the generous support of the IEEE Foundation the Hyde & Watson Foundation, the Martinson Family Foundation, and the GE Foundation. We acknowledge gifts from many other individuals, as well as an anonymous donor; the Association of Ed son Illuminating Companies; and the Edison Electric institute. For the assistance of all these organizations and individuals, as well as for the indispensable aid of archivists, librarians, scholars, and collectors, the editors are most grateful.

A Note on the Sources The pages which have been filmed are the best copies available. Every technical effort possible has been made to ensure legibility.

PUBLICATION AND MICROFILM COPYING RESTRICTIONS

Reel duplication of the whole or of any part of this film is prohibited. In lieu of transcripts, however, enlarged photocopies of selected items contained on these reels may be made in order to facilitate research.

EDISON GENERAL FILE SERIES

1919

Edison General File Series 1919. Edison Portland Cement Company (E-19-24)

This folder contains correspondence and other documents relating to the business of the Edison Portland Cement Co. (EPCCo). Among the items for 1 91 9 is a 23-page report by consulting engineer Cornelius C. Vermeule on "Remodelling Steam Plant by Stages," bearing numerous annotations by Edison. Other correspondents include retired EPCCo president Walter S. Mallory; vice president Harold M. Scott, who resigned in September; and Martha M. Darling, a relative of Edward A. Darling, the Stewartsville mill manager who was killed in a plant fire in 1903.

Approximately 50 percent of the documents have been selected. The unselected material includes routine company correspondence, other letters not relating to EPCCo business, and documents pertaining to a phonograph presented to an "old reliable steam engineer," George Kaufman.

January 20,1919.

Dear Hr. liallory:

I am Borry to report very poor results' in our searoh for -Niool prisms. On Thursday and Friday last I had an expert go over to Hew York, and visit every instrument maker to try and pick up even. an odd. one if he could, hut we had absolutely no success. lie tells me that there is a great demand for them, bjit there is none to he had at any of the places that he visited. He is a man who knows exactly how to look for such a thing, as he was connected with the D. S. Naval Observatory for many years and. is well acquainted with opt j cat subjects

In addition to this, we have had another one of our men, Ur. S. G. 'Warner, telephoning and per-, sonally making inquiries in other Cities, but thus far ho has only been able to pick up one Hiool prisms and that would not be very good because it is so old that the Canada balsam i3 very much discolored. The only thing we could do would be to try and dissolve the balsam and reoement it, but as you know this might be considered precarious.

I have written to quite a large number of the concerns in different localities, but up to'this time have not received -any replies that givos any on-' o ouragement whatever. I wrote a s.peoial letter from Ur. Edison to John A. Brashear of Pittsburgh; They are- very warm personal friends, und if there is any . one man that oould obtain something that ho wanted from Ur. Brashear, Ur. Edison is the man. We received a reply that the' Brashear plant is tied up for all of this year on special Government work and they could not take on an item from outside under any circumstances.

I am sorry to disappoint you, S3 I was expecting to show you a more satisfactory result.

W.H.MEADOWCROFT.

Mr . W. S .Mallory.

Edison Portland Cement Co.

8 WEST 4-OIH STREET N EW YORK

January twenty-second

4

Bear Mri Meadowcrofts

I m enclosing herewith sample of spodumene which came from ^ew Mexico*

Will you kindly deliver it to

At«T)

J? ^c. ■(Z^a^^c-

^^§Sgl

y/Cz^^^ zf^^ZZ'

ZZ2%ZZZ? J’AntA^M^

/O

' March 85,1919

Mrs. John Darling,

530 Palm Ave.,

Fresno, Cal. ,

Dear Madam:

Your letter of March 11th, in regard to the Edison Portland .Cement Co. has been received. The Company has never earned or paid a dividend, hut it is Btill operating and may do so some day.

Yours very truly,

• Edison laboratory.

A/6807.

Edison Portland Cement Co.

GENERAL. OFFICES O WEST 40TV STREET

"New York City

September 5th, 1919.

Ur. W. H. Ueadowcroft, Scoretary to Hr. Edison, Orange, Hew Jersey.

Dear Mr. Ueadowcroft j

Attached you will find request from our very good agents , the Cuba Commercial Co. for an autographed photograph of Mr. Edison for their new office in Santiago, Cuba.

We have been very anxious to build up our business in the eastern end of the Island because of the new local plant near Havana, which sooner or later, will control the major portion of the business in Havana. To the eastern end of the Island, which is the big sugar country, we can reach almost as cheaply as they, so naturally we want the maximum solicitation in that territory.

If you can accommodate us, I am sure Ur. llolanphy. President of the Cuba Commercial Company, will be very grateful to Ur. Edison for the photograph and you know that I too will appreciate this oo-operation.

[ATTACHMENT/ENCLOSURE]

leeway ^vmmercearf (fid

?twvf rr//i(t'\r./a> -y/'C>S--//-ffS.

August 26, X919 •

Edison Portland Cement Co.,

If 8 6 West 40th St.,

Hew York City.

Dear Sirs:-

Would you be good enough to send us a recent picture of Mr. Edison, for our Santiago office.

Very truly yours,

CUBA COMMERCIAL COMPANY

9nrytrl>~

™/ __

C7M^

(dli \JUed ^

dstl/'hi C(fVMyt^LA;Cl*.e^y »

fit 60 >7

d^U/ljL LJ 1 (d'O-

Edison Portland Cement Co.

GENERAL OFFICES O WEST 40TV STREET

NewYouk City

Septenfcer thirtieth 19 19.

EERSOKAL

Mr. Harry F. Miller, Edison Laboratory, Orange, NEW JERSEY.

Bear Mr. Miller:

in leaving the company tojnorrow, X want to thank you and through you Mr. Meadowcroft, Mr. Lykeman, Mr. Schultz and others at Orange who have been so courteous and kind to me during the past three years or more that I have been a member of the EDISON organization.

It is with with most sincere regret that I have tendered ny resignation, but I feel that I have been, able to leave an organization whioh is second to none in the industry, and one vho will fulfill for Hr. Edison his expectations and de¬ sires whioh I would like to do.

I am with most sincere regards,

Edison Portland (fluent («*.

I

8 West 40W St..N.Y. City

Mr. Thomas A. Edison, Llewellyn Park,

West Orange, H.J.

Bear Mr. Edison:

At the request of Messrs/ Theron I.

Orane, William H. Shelmerdine any Thomas M. Thompson, Direotors, a special meeting of/Tjhe Board of Direc¬ tors of Edison Portland CemenlrCoff^any is called to be held on Monday, October 13th, )at 10 o'olook A.M., at the principal offioevof_,tKe Company, Edison Laboratory, Lakeside Avenue, West Orange, Hew Jersey.

Mr. Stephen B. Mambert, President, states that in view of the importance of the matters to be disoussed at this meeting it is highly desirable that every member of the Board of Direotors be present.

Yours very truly.

JOL/L

IN VIEW OF THE FACT THAT IT Will NOT BE POSSIBLE FOR AH DIRECTORS TO BE PRESENT AT MEET INC GALLED FOR MONDAY MISTER MAMBERT HAS ASKED THAT THE CALL BE CANCELLED

EDISON PORTLAND CEMENT COMPANY J 0 LA HUE

Charge to EDISON PORTLAND CEMENT CO.

31 words WDO/L

TIME

11:15

remodelling steam plant by stages. I

c. C . Vermeule,

Oct.. 16, 1919.. Consulting Engineer.

gage.1,

_00|IEHI Sj_

Condensation in Steam Pipes Loss of Power Due to Low Vacuum Engine Ko. 1, Rock CruBher Engine Ho. 2, Chalk Plant Engine Ho. 3, Pine Grinding Engine Ho. 4, Coal Plant Engines 5, 6, 7, Hain Power House Power Output and Consumption, Oct. 13th Pounds of Steam per day Steam Consumption of Present Engines Oct. 13th Table of Output and Steam per day - Improvement by Stages Addition of Waste Heat Boilers only Addition of Stoker fired Boilers Table of Power needed Advantage of Electric Drive

Addition of 2,000 Horse Power Turbo-Generator Table of Steam Consumption Turbo-Generator, 4,000 Horse power Table of Steam Consumption Summary of Saving at 5,100 bbls. capacity Economy at 6,300 bbls. capacity Tables of Steam Consumption Operating Expenses per day and per bbl.

Labor saving by Stages

3

4

5

6

7

8 . 9

10

12

14

17

18 18 19

19

20 21 22

on U<XATV OAi OAca. <su

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2

2^ and no material saving is to be made in this. I am of the opinion that a part of the 20 tons of coal per day reported by Mr. Kaufman, represented coal expended in keeping up banked fires, some steam used in running the feed pump and general losses of heat due to low fire of boilers. I can account for about 176,880 lbs. of steam per day as against 313,000, which was indicated by' his reported coal consumption. J11A& y

LOSS Ok POWER PUB TO LOW VACUUM.

I found conditions due to deficient cooling water worse than they had previously been. The amount of feed water during the ten days preceding my visit had averaged 2,886,800 lbs.,- being somewhat higher than our previous estimate of 2,661,592 lbs. per day,, which may have thrown some additional work on the condensers. The matter of loss of power and efficiency due to poor vacuum, and the m^tte^of a proper load for the various engines, may well be considered together.

I found the following conditions at the engines: mrr.TTTTi! tf\. ~ ROCK CRUSHER:

The steam gage read from 13? to 140 lbs. The vacuum gage from 20*" to 22". The load on this engine is variable, the range* being from. about 200 horse power upward to over 5?0. The indicator card shows some wire drawing of the steam and a con¬ siderable drop before the cut-off. Working at overload, the pressure at the end of the stroke is high, showing deficient expansion, the cut-off being about 5/7 of stroke. It does not appear to me that any additional power is needed here, but a more even load on the crusher would be desirable, and the output can

be increased by running an additional number of hours per day.

3

The engine cannot work at good economy, because of the fluctuating load.

I estimate the power lost here due to a vacuum averaging 21.7 inches as compared with a vacuum of '28 inches, is 65 horse power, practically constant at all loads. In order to appreciate the conditions under which this end the other engines are working, and the possibility of increasing their power output, I have summarized conditions for all the engines at various points of out-off in a table which follows later.

EHGIKB #2 — CHALK PLANT .

The steam gage read 140 lbs., the vacuum gage 19*".

The indicator cards show a cut-off at 57* of stroke, with a rather high pressure at the end of the stroke. It is evident that the engine is overloaded, but it cannot deliver the corresponding overload in power because of the low vacuum. I estimate the loss in indicated horse power, due to a vacuum of 19 inches as com¬ pared with 28 inches to be 101 horse power- This engine runs two tube mills, and its. power output at various points of cut-off and with 28 inches vacuum and 19 inches vacuum, are given in the later table referred to.

TinTftTHE — El HE PRIMPING,...

Steam gage read 144 lbs. The vacuum gage' 19* inches. The card shows a cut-off at 65* of stroke. The engineer says it usually runs at 50* of stroke, but this no doubt varies with the vacuum. As in the other engines, the pressure at the end of the stroke is high, showing poor expansion due to the late point of cut-off. The loss of power due to a vacuum of 19-25 as compared

lr ,4*

with 28 inches, amount!

a to 94 horse power.

EHGIKE H — COAL KLAITT.

This single cylinder engine cuts off at 5°$ of stroke, and the card shows a drop in pressure of nearly 20^ to the point of cut-off. The engine works against a hack pressure of 6 lhs.

(some times said to he 10 lhs). It is evident that the steam con¬ sumption per horse power is high. I estimate it at 3° l^s., hut the exhaust steam is used for drying coal; consequently, the economy cannot he considered had, although with lighter loading, or with present loading and a larger cylinder giving an earlier . point of cut-off, the steam consumption per horse power can he much improved. I estimate at present it is 30 lhs., and that it can he reduced to 25 lhs. There can he no increased power due to improved vacuum at this engine, and in fact unless the cylinder is increased, the load upon the engine should he reduced about 50 horse power.

BHGIHBB #5. 6, & 7:

The gages read, steam 131 lhs., vaouum 2 5i inches. The above vacuum as compared with 28 inches, shows a loss of 130 horse power for the three engines.

The vacuum in summer is said to range from 20 to 22 inches.

• Calling the average 21 inches, the loss of power under such con- ; ditions would amount to 259 horse power for the three engines.

• However, the loss on Oct. 13th as above estimated, should repre-

' sent about average conditions, and has been used by me hereafter, i The total loss of power in engines #1 to #7 inclusive,

jl due to low vacuum, therefore amounts to 389.4 horse power. It

i

5

mu at not be assumed, however, that this amount of power can he added effectively to the output hy improving condensation. The tables hereafter given will show the actual conditions under which the engines are working. Additional power cannot he well used at the crusher engine, as increased capacity there will he obtained ■by running increased number of hours per day. Also at Engines #2 and #3. The present output of the engine is the amount of power required to run the machinery connected up, and the additional power which could he produced hy improved condensation could not well he used effectively. In all these cases, (the same is practically true with Engines #5, 6 & 7.) improved condensation should he applied in order to produce the present power output with increased steam economy, and not to increase the load on the engines which are already badly overloaded.

The following table shows the output of each engine and its steam consumption per horse power at various points of cut¬ off. In each case, except #1, the latest point of cut-off is the one which applies to present conditions. In case of #1 engine, the load varies through all the different points of cut-off given in the table.

wnwniB OUTPUT AKP STEAK CONSUMPTION OCT. 13th ■_ Vacuum 28 ■' „ Vacuum as

Engine. Cut-off. I. H. P. Steam per. I. Z. T. StefT

2?$

33^

70 i

270

322

460

553

16.0

16.5

21.5

20.6 20.0 20.0

No. 1

20?

257

6

			Vacuum	as found.
		I. H. P.	Steam per H. P. Hr.	I. H. P.	Steam per H. P. Hr.
Ho. 2	33% 5°% 51%	895 955	16.0 17.5 17.5	534 794 854	18.5 19-5 19.5
Ho. 3	33% 50% 65%	63 1 89? 1030	16.0 17-5 18.0	541 801 936	18.5 19-5 20.0
Ho. 4	50 %	300	30.0	300	30.0
5. 6,7	2 5% 40%	E. H. P. 2610 3256	17.0 17.O	E. H. P. 2480 3126	18.0 18.0

From the foregoing table, X estimate the following saving in steam, which would he effected by a vacuum of 28 inches as compared with the vacuum actually found on Oct. 13th.

T.hs. of Steam per Day.

Engine Ho. 1 - " 40 ’,99 2

f _ 38', 448

A - 0

5, 6, 7 > - 2LMfL-

Total saving.... 168,584

The above assumes the power output of the several engines , to remain as at present. However, the additional amount of cool- .ing water requiredTf pumped~up to the present cooling reservoir, jt'Vill consume” 170~h^se power of electric power at the pump, in V addition to whats is novTrequired, but if an additional electric generating unit is not installed in the steam plant, this will be an added load on Engines #5, 6, & 7, which are already overloaded. For these conditions, therefore, it appears to me necessary to 'J install a steam driven pump to pump the hot water back to the I cooling reservoir. It will be better to make this of sufficient I capacity to pump all of the water now being pumped, together v

with

additional water, which require (285yhorse power. This measure^ will lighten the load of Engines 5, 6, & 7 hy about 11? horse \ power, and I believe is the only practicable way to provide for V pumping the cooling water- Such an engine will require not less than 20 lbs. of steam per horse power hour, or 136,800 lbs. per day. The lightening of the load on Engines #5, 6, & 7 will save 49,680 lbs. of steam per day, leaving the net additional require¬ ment 87,120 lbs. of steam per day, which must be deducted from the foregoing saving of 168,584 lbs., leaving the net saving 81,464 lbs. per day. YJith an evaporation of 7 lbs. of steam per pound of coal, this will save 11,638 lbs. of coal per day, or 5- 2 tons at j §5*50| or 028.60 per day, which will represent about all that it ; is practicable to save by improved condensation under the con¬ ditions which I have above assumed, namely, the use of the present Climax boilers to make up the amount of steam required over and j above that produced by the waste heat boilers, and the retention ; of the present engines, the whole working at a capacity of 5,100 bbls. of cement per day.

essary changes to produce

28 inches vacuum, cannot be accurately estimated until my surveys ; and investigations have been completed, but assuming it will cost -050,000., the saving above named, $28.60 per day, will re-pay the cost of the improvement in 1,75° days.

STEAM C01TBUHPTI01T OE PRESENT ENGINES Oct. 13th...

’ water measurements from (

1 of 2,886,800 lbs. per day. Estimated from coal consumption and

■boiler efficiency, the average for 1918 was 2,516,322 lbs. of steam per day. From my survey of actual conditions Oct. 13th, I esti¬ mate the power output of the engines and their steam consumption as per the following table:

OUTPUT AND STEAL' CONSUMPTION.

Estimated on Actual Conditions Oct. 13th:

EnKine .	I. H. P.	H. P. Htb. tier day.	Lbs. steam ner H. P. Hr.	Lbs. steam
No. 1	400	4,400	20.0	88,000
No. 2	854	20,496	19.5	399,672
No. 3	801	19 , 224	19.5	374,868
No. 4	300	7,200	30.0	216,000
Compress	;or 83 E. H. P.	2,000	18.0	36,000
#5. 6,7	3.256	78.144	18.0	1.406.592
All engines5694	131,464		2,521,132

Feed pumps 52,000

Heating, condensation, small auxiliaries 100,000.

Condensation in mains 30.880

2,704,012

The foregoing steam consumption is somewhat less than the average feed water used from Oct. 1st to 10th, but it is almost exactly a mean betv/een that estimate and the estimated boiler evaporation in 3)918. It will be observed also that the table given in my previous report was based upon the rated horse power of the engines, and did not take into account overload, average load, or the vacuum as actually recorded 00t. 13th. Nevertheless, the variation betv/een this and the previous estimate of the total steam consumption per day is not large, that estimate having been 2,661,592 lbs. The difference is in the distribution of the steam.

The foregoing table will be used hereafter in determining

how the waste heat hollers will work in connection with the present Climax boilers. The total consumption of steam being practically the same, all previous estimates as to saving in boiler installa¬ tion, hold good without change. I am advised however, that coal will actually cost next year $5 .JO per ton, which will increase all coal saving as given in my previous report by 10£i.

IUPROVElDiMT BY STAGES.

Following our conversation, 1 have given further con¬ sideration to the possibility of a more gradual improvement of the plant, talcing it step by step, and I shall now endeavor to point out what can and what cannot be done at each stage of the improvement.

There is but a small saving possible due to improved condensation, if the engines continue as they are, but I shall consider making this improvement at once, as it will better oper¬ ating conditions and will in any case be necessary for steam tur¬ bine operation.

1. Installation of waste heat boilers to be supplemented by a part of the Climax boilers, the power output to remain un¬ changed, and the cement output estimated at 5,100 bbls. per day.

2. Addition to stoker fired boilers, power output and cement output, as before.

3. Addition to engine capacity needed to make the operation of the plant at present capacity more reliable without increasing output.

4. Addition to a turbo-generator of 2,000 horse power, the present engines being continued in use and the output increased to

6,300'bbls. per day.

10

j>. Increase of turbo-generator capacity to 4,000 horse power, with present engines #1, 2, and 3 held as reserve, and the others continued in use.

ADDITION Of WASTE HEAT BOIUflRS OHLY.

The capacity of Mill 5,100 bbls. Mean effective horse power as at present:

The cost of this improvement will he $327, 5°0. The saving in coal will he that due to the generation of 1,44°, 000 lhs. of steam per day at 7 lhs. of steam per pound of coal equals 91.8 tons of coal at $5-50, or §5°4>90 per day.

The saving in labor I have estimated on the basis of continuing five Climax boilers under fire. Ordinarily, four boilers would be sufficient to produce the amount of steam needed over and above that produced in the waste heat boilers, but occasionally one or more roasters may go out of service, and it is necessary to provide for the taking up 'of the load promptly when this occurs. With the Climax boilers, this cannot well be done unless five boilers are kept under fire. At the present time we have 44 firemen, and ash handlers, in the boiler plant. After the waste heat boilers are installed, we shall need 28 men in the Climax boiler plant, and 14 men in the waste heat boiler plant,

\or a total of 42 men. There would, therefore, be a saving of two Wen, or 16 hours only, which at per hour, amounts to $8 .80

jJer day, making the total saving in coal and labor $5l3'70 per day.

_ .. The improvement of condensation, while it adds but little

to the saving, should be provided for for the reason that it will enable the engines to deliver their load under better conditions.

The cost and saving of the improvement up

this stage, will he

V/aBte heat boilers Condensation

$327,500.

50.000.

Saving per day. §513*70 28.60

§377,500. §542.30,

.e amount of steam being used

Total. . . ,

This is based upon the as at present. The plant will not v/orlc under conditions favorable to economy, for the reason that the full pressure cannot be main- f tained on the waste heat boilers as the entire pressure must come ''-A down to a point which can be safely carried by the five Climax

toilers retained in use, which will not exceed the present pressur< Furthermore, a high degree of super-heat cannot be used.

It will be noted that reduction in labor is small, practically only two men. I am advised that it is becoming in¬ creasingly difficult to obtain firemen at the plant. It is evi¬ dent that the firemen are of low grade, and are not interested in their work and not disposed to listen to complaints or suggestions for the betterment of the boiler service. Also the tendency of wages is constantly upward.

All of the engines are now working under conditions which make it extremely difficult to take down and overhaul any engine, or inspect the condition of cylinders, valves and piston rings, or to tighten up journals. They are and must be constantly operated at overload capacity.

These considerations of labor and of engine conditions •shave an important bearing upon the efficiency of the foregoing ;*stage of development of the plant, and they cannot very well be

i D;*

12

measured in terms of money, as they affect to a considerable degree the efficiency of the plant as a whole. It is unquestionably desirable to reduce the number of men in the boiler room, and also to lighten the load on the engines for other reasons than mere money saving in the power plant.

ADDITION 03? STOKER FIRED BOIKERS.

Por the reasons above stated, I consider this to be logically the next step. It will effect a much larger saving in labor, will enable us to raise the steam pressure to any point desired up to 200 lbs., and because of the elasticity of the stoker fired boilers and their ability to promptly take up and carry a large overload, they will work much better in conjunction with the waste heat boiler- Furthermore, this overload can be taken up without the addition of men to the boiler room force, which will be very small with the stoker fired boilers. The consumption of steam remaining as before, the coal consumption will be reduced owing to the fact that while the stoker fired boilers are working at overload, the evaporation will be increased from 7 lbs. to 8 lbs. of steam, representing a saving of l/7 of the cost of coal used in Climax boilers, or $72.13 per day.

The saving in labor will be represented by a reduction of the 28 men required for the five Climax boilers to a force of three men required by the stoker fired boilers, or 25 men, 8 hr-..

,:.j equals 200 hrs. @ 55(* equals $110. per day, making a total saving | in coal and labor of $182.13 per day. The cost of installation | will be $129,500.

.ft Steps 1 and 2, therefore, give us the following:

Is

13

Cost. Saving -per day.

V/aste heat boilers

Condensation

Stoker fired boilers

$327,500. 50,000. 129. 500.

-1,82,: 13 '^4 a* $724.43

Total . $507,000.

Thus far we have effected a saving in coal, but not in the amount of steam required, except the comparatively small amount saved by improved condensation, which is offset however, largely by the fact that we must operate the hot water pumps by steam, which leaves us on that account only a net saving of 81,464 lbs. of steam per day.

We have not increased our power output which is limited by engine conditions. We have improved by condensation, the work¬ ing conditions at the several engines, but if we attempt to take advantage of the increased amount of power which might be pro¬ duced thereby if we should continue to work our engines at heavy overload, we find that this power will be at points where it will not be effective. We do not need increased power at the crusher engine, for reasons already stated. Engines #2 and #3 also have a definite load, and the additional power which could be produced there cannot well be used, as it will not be sufficient to add other mills. This brings us to a consideration of the problem ho v/ to produce increased power with improved engine economy. Let us consider where this power will be needed. With the capacity of the mill remaining at 5,100 bbls. per day, I estimate that simply to improve working conditions, and make them more reliable, we should provide as follows:

14

50 horse power for reducing load on Engine #4,

400 horse power for reducing load on Engines #5, °, * 7,

170 horse power for driving the pump for returning hot water to the cooling tower,

200 horse power for general use in driving conveyors, elevators, and other handling about the plant

820 horse power additional in all.

If we wish to increase the capacity of the mill to 6,300 hhls. and to operate under proper load conditions at such increased capacity, we should add about the following:

850 horse power for two tube mills,

285 horse power for returning hot water to cooling tower,

50 horse power for reducing load on Engine //-4,

400 horse power for reducing load on Engines #5. 6, & 7,

200 horse power for general use about the plant

1785 horse power in all.

ADVANTAGE OE ELECTRIC DRIVE:

The above statement of the points at which the addition¬ al power will be required, and the amount of such power, indicate that it should be supplied by electric drive. It cannot be supplied by steam engines without adding a number of units which will work at relatively low economy and require additional attend¬ ance. I do not disagree with your point of view that electric power cannot be generated and distributed to points of use with less loss than that due. to engine friction and belting and shaft¬ ing losses, where conditions are such that the engine load can be thus applied to drive the necessary machinery, but if we assume a larger unit in a central station, such as a turbo generator ' which can produce power with a low consumption of steam per horse power hour, with transmission to motors at points of use, the economy of the whole will be materially greater than is possible

jwt rA-

1 ^IT

UtfWfc l?

with a direct steam drive. Incidentally, I will state also I do not rely so much, in making this statement, upon the pc bility of obtaining better steam economy in the turbo-generc than can be obtained in well designed Corliss compound engir working with super-heated steam, and a good vacuum, but the cost of the tirrbo-generato r unit will be very much less. II possible even at present relatively high prices, to purohasi such a unit at about gLj. per horse power, including turbim

purchase a Corliss engine of high duty i ftlJ.OO per horse power, and the cost of :

.generator, the discrepancy in cost is still greater* Indeed at

There is in addition to the actual power economy, another consideration which is of great importance in such a mill as ours, where the works are extended over considerable area and that is, the great flexibility afforded by electric distribution

.power requirements at any point promptly, and at low installatior •cost, by the installation of motors wherever they may be called for. This must result in very considerable economies- in oper- . ating the plant through enabling us to take advantage promptly of any possible economy in handling material, or in other opera- , tions about the mill. It will have immediate application in ; adjusting our cooling system, enabling us to add pumps where

17

The output in horse power hours per day is the same as that given in the table on page 8, v/ith the addition of 170 horse power for pumping hot water. The saving in steam amounts to 223,248 lbs . per day, which produced in the ’stoker fired boilers, will require 11. O? tons of coal at $5-50. The saving is therefore, §60.88 for coal. The above however, includes the saving due to improved condensation for which my previous estimates allowed §28.60 per day, leaving §32.28 saving due to the 2,000 horse power turbo -gen erato r .

X estimate the cost as follows:

18

fH Turbo-generator, 2,000 H. P. j.'-a Jet condenser and auxiliaries MS 2,000 H. P. of motors 3 Switchboard

J'.'l Power transmission, installation, etc.

$35,000.

7,500.

24,000.

7,500.

20.000.

Total.... $94,000.

Turbo-Generator 4,000 Horse Power.

If we install a turbo-generator of 4,000 horse power, we will not immediately procure the full economy due to such installation as it will give the best results at increased capac¬ ity of the mill. However, at present capacity, 5,100 bbls., we should run the turbo-generator full capacity, in order to make the best use of the steam from the waste heat boilers. Engines #1, 2 & 3, May be tahen out of operation and held in reserve. Engines #5, 6, & 7 will be run at a load which can be carried by two engines, thus permitting one engine to rest and giving time for inspection and overhauling. Condensation will be somewhat reduced .

STEAM COiTSUHPTIOH, TUKB0-GEI7ERAT0R 4.000 HORSE POWER.

Capacity of Mill 5,100 bhls.

Engine.	I. H. P.	H.P.Hrs. Daily.	Steam per H. P. Hr.	Lbs. Steam per day.
4 250	6,000	25	150,000
Compressc	)r 83	2,000	18	36,000
E. H. P. 5, 6, 7 1731	41,544	16	664,704
Turbo-Gen¬ erator